CX250C

CX250C LR
Tier 4
Crawler Excavator

SERVICE MANUAL

Printed in U.S.A. Part number 84402826

1st edition English
Copyright © 2011 CNH America LLC. All Rights Reserved.
Case is a registered trademark of CNH America LLC. August 2011
Racine Wisconsin 53404 U.S.A.
 List of special tools

Lower Roller Special Tool

CX250C

Co-
Order No. Jig name Remarks
de
1 Bushing removal jig
2 Bushing press-fit jig
3 Floating seal installation jig

84402826 - May 2011

1003-9
 List of special tools

Grease Cylinder Special Tool

CX250C

A Dust seal press-fit jig

B Removal jig

84402826 - May 2011

1003-10
 List of special tools

Center Joint Special Tool

CX250C
Axle removal jig

Removal jig (for O-ring and

1
V-ring)

1 Axle removal jig

M16 - M20 full threaded bolt
2
L = 370 - 420 mm
3 M16 - M20 female thread
Hexagon socket head bolt (5)
4
M8 x 25
Backing plate
Axle (1) outer diameter - about
5
5 mm
t = about 5 mm

Cover (7) installation dimen-

*1
sions

84402826 - May 2011

1003-11
 List of special tools

Swing Motor Special Tool

CX250C

Co-
Order No. Jig name Remarks
de
Tapered roller bearing/inner race
1
assembly jig
2 Oil seal assembly jig 1
3 Cylinder assembly jig
4 Brake piston assembly jig

84402826 - May 2011

1003-12
List of special tools

Co-
Order No. Jig name Remarks
de
5 Oil seal assembly jig 2
6 Pinion shaft assembly jig

84402826 - May 2011

1003-13
List of special tools

Co-
Order No. Jig name Remarks
de
7 Brake piston removal jig

84402826 - May 2011

1003-14
 List of special tools

Remote Control Valve Special Tool

CX250C

a Detailed diagram of jig main unit

b Joint installation state
c Detailed diagram of bushing

*1 SCM415N carburized *4 Hole *7 Bushing

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

Co-
Order No. Jig name Remarks
de
1 Joint disassembly jig
84402826 - May 2011
1003-15
 List of special tools

Center hole possible (D2 or

*1
less)

Co-
Order No. Jig name Remarks
de
2 Special jig 1 (for bushing removal)
3 Special jig 2 (for locking ring installation)

84402826 - May 2011

1003-16
 List of special tools

Gas Filling Special Tool

CX250C/CX350C/CX370C

Code Jig name Remarks

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

84402826 - May 2011

1003-17
 List of special tools

Hydraulic Circuit

Vacuum pump and power sup-

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

84402826 - May 2011

1003-18
 List of special tools

CASE SPECIAL TOOLS

Isuzu Engine Special Tools
4HK1X-6HK1X Tier 4 Isuzu Engine

Illustration Isuzu Reference CASE Tool Number Description

8-9439-6856-0 380001712 Oil seal setting tool kit

5-8840-2627-0 380001719 Oil seal Installer

5-8840-2623-0 380001720 Remover; Nozzle sleeve

5-8840-2624-0 380001721 Installer; Nozzle sleeve

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

5-8840-2360-0 380002574 Slinger puller

5-8840-2826-0 380002601 Fuel Injector Remover

5-8840-0019-0 380002602 Sliding Hammer

84402826 - May 2011

1003-19
 List of special tools

Illustration Isuzu Reference CASE Tool Number Description

5-8840-2222-0 380002604 Sealing cup Installer

5-8840-9061-0 380002611 Oil seal installer kit

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

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

5-8840-2815-0 380300015 Compression Gauge Adaptor

8–9439–6818–0 Common tool Crankshaft gear puller

84402826 - May 2011

1003-20
 List of special tools

Illustration Isuzu Reference CASE Tool Number Description

8–9439–6819–0 380002613 Crankshaft gear installer

5-8840–9018–0 380300022 Piston setting tool

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

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

5-8840-2621-0 Common Tool Remover; Valve spring

Digital multimeter with an input

Not Illustrated 5-8840-2691-0 Common Tool
impedance of 10MΩ

5-8840-2674-1 Not needed Scissors gear spring wrench

8-9439-6862-0 Not needed Pivot ASM

84402826 - May 2011

1003-21
 List of special tools

Attachment Special Tool (for Cylinder

Assembly)
Special Jigs Part Number List
• Select jigs for the cylinder head according to the rod diameter.
• Select jigs for the piston according to the cylinder bore.

CASE Tool
Description (applicable rod diameter in mm) Illustration
Number
KHV0511 Cylinder head assembly and disassembly jig (65)
KHV0512 Cylinder head assembly and disassembly jig (70)
KHV0513 Cylinder head assembly and disassembly jig (75)
KHV0514 Cylinder head assembly and disassembly jig (80)
KHV0515 Cylinder head assembly and disassembly jig (85)
KHV0516 Cylinder head assembly and disassembly jig (90)
KHV0517 Cylinder head assembly and disassembly jig (95)
KHV0518 Cylinder head assembly and disassembly jig (100)
KHV0519 Cylinder head assembly and disassembly jig (105)
KHV0520 Cylinder head assembly and disassembly jig (110)
KHV0521 Cylinder head assembly and disassembly jig (115)
KHV0522 Cylinder head assembly and disassembly jig (120)

CASE Tool
Description (applicable cylinder bore diameter in mm) Illustration
Number
KHV0526 Seal ring insertion and calibration jig (100)
KHV0527 Seal ring insertion and calibration jig (105)
KHV0528 Seal ring insertion and calibration jig (110)
KHV0529 Seal ring insertion and calibration jig (115)
KHV0530 Seal ring insertion and calibration jig (120)
KHV0531 Seal ring insertion and calibration jig (125)
KHV0532 Seal ring insertion and calibration jig (130)
KHV0533 Seal ring insertion and calibration jig (135)
KHV0534 Seal ring insertion and calibration jig (140)
KHV0535 Seal ring insertion and calibration jig (145)
KHV0536 Seal ring insertion and calibration jig (150)
KHV0537 Seal ring insertion and calibration jig (160)
KHV0539 Seal ring insertion and calibration jig (170)

84402826 - May 2011

1003-22
 List of special tools

CNH-EST DIAGNOSTIC TOOL (SCAN

TOOL)
The EST (Electronic Service Tool) system allows diag-
noses on machines and engines by detecting the oper-
ating parameters of electronic control components (con-
trol units, sensors etc.). It is also capable of reading fault
codes.
To use this tool, please refer to the book provided during
the CXC series training sessions.
Y-Cable 380060269 is required to connect the EST to the
controllers.

84402826 - May 2011

1003-23
List of special tools

84402826 - May 2011

1003-24
 Section

1004

FLUIDS AND LUBRICANTS

84402826 - May 2011

84402826 - May 2011
 CONTENTS

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

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

1004-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
1004-2 PRINTED IN FRANCE
 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.

84402826 - May 2011

1004-3
 FLUIDS AND LUBRICANTS
FUEL
The fuel must conform to Interim Tier 4/Stage 3B Ex-
haust Gas Control Regulations.
Use grade number 2-D (S15) fuel.
Using other types of fuel may lead to stalled engine out-
put or deterioration in fuel economy.
During cold weather (lower than -7℃), it is temporarily
acceptable to use a mixture of No. 1-D (S15) and No.
2-D (S15).
Consult the fuel supplier or the CASE dealer.
If the temperature drops below the fuel cloud point, out-
put deficiency or engine start problems may occur due
to wax crystals.
Conditions applicable to diesel fuel
The diesel fuel used must:
- be free from dust particles, even minute ones,
- have the proper viscosity,
- have a high cetane number,
- present great fluidity at low temperatures,
- have low sulphur content,
- have very little residual carbon.
RECOMMENDED CONDITIONS
THAT CAN BE APPLIED TO
DIESEL FUEL
- JIS (Japanese Industrial Standards): No. 2
- DIN (Deutsche Industrie Normen): DIN 51601
- SAE-J-313C: SAE (Society of Automotive Engineers)
based on No. 2-D (S15)
- BS (British Standards) based on BS/2869-1970: Class
A-1
- EN 590 (less than 10 ppm sulfur)
- Or fuel specified by the country using these standards
and this machine
84402826 - May 2011
1004-4
IMPORTANT:
EPA regulation ultra low sulfur fuel only.
IMPORTANT:
If a serious problem occurs when other fuels are used,
the warranty is invalidated.
Using a non-recommended fuel may lead to damage of
the fuel injection pump, injector, DPD, and other fuel
supply systems or to the engine.
CASE assumes no responsibility for these damages.
Note that the warranty will not be applied for these dam-
ages.
It is recommended that the following safety information
be considered in order to prevent damage to the engine
fuel supply system.
- Some fuel suppliers mix old engine oil and diesel fuel.
Makers of larger engine permit the use of this kind of
fuel.
However, do not use diesel fuel contaminated with en-
gine oil in customer's engines.
Not only will this fuel damage the engine, it may also
have a negative impact on the exhaust gas purification
function.
Before using diesel fuel, confirm with the supplier
whether the fuel complies with the above specifications.
IMPORTANT:
Consult the supplier or the CASE dealer regarding ap-
propriate use of fuel additives.
Do not use fuel oil or gasoline as these may damage the
engine.
IMPORTANT:
In order to prevent condensation during cold weather, fill
the fuel tank to full after the completing the day's work.
 Section

1005

Conversion Table

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Metric to U.S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
U.S to Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

1005-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
1005-2 PRINTED IN FRANCE
 Conversion Table

Metric to U.S
MULTIPLY BY TO OBTAIN
square meter 10.763 91 square foot
AREA:
hectare 2.471 05 acre
newton 3.596 942 ounce force
FORCE:
newton 2.224 809 pound force
millimeter 0.039 370 inch
LENGTH: meter 3.280 840 foot
kilometer 0.621 371 mile
MASS: kilogram 2.204 622 pound
MASS/AREA: kilogram/hectare 0.000 466 ton/acre
MASS/ENERGY: gr/kW/hr. 0.001 644 lbs/hp/hr.
MASS/VOLUME: kg/cubic meter 1.685 555 lb/cubic yd.
POWER: kilowatt 1.341 02 horsepower
kilopascal 0.145 038 lb/sq. inch
PRESSURE: bar 14.50385 lb/sq. inch
megapascal (MPA) 145.0385 psi
TEMPERATURE: degree C 1.8 x C +32 degree F
newton meter 8.850 748 lb/inch
TORQUE:
newton meter 0.737 562 lb/foot
VELOCITY: kilometer/hr 0.621 371 miles/hr.
cubic centimeter 0.061 024 cubic inch
cubic meter 35.314 66 cubic foot
cubic meter 1.307 950 cubic yd.
milliliter 0.033 814 ounce (US fluid)
VOLUME: quart (US liquid)
litre 1.056 814
litre 0.879 877 quart (Imperial)
litre 0.264 172 gallon (US liquid)
litre 0.219 969 gallon (Imperial)
litre/min. 0.264 172 gallon/min. (US liquid)
VOLUME/TIME:
litre/min 0.219 969 gallon/min. (Imperial)

84402826 - May 2011

1005-3
 Conversion Table

U.S to Metric
MULTIPLY BY TO OBTAIN
square foot 0.092 903 square meter
AREA:
acre 0.404 686 hectare
ounce force 0.278 014 newton
FORCE:
pound force 4.448 222 newton
inch 25.4 millimeter
LENGTH: foot 0.304 8 meter
mile 1.609 344 kilometer
pound 0.453 592 kilogram
MASS: gram
ounce 28.35
MASS/AREA: ton/acre 2241 702 kilogram/hectare
MASS/ENERGY: lbs/hp/hr. 608.277 4 gr/kW/hr.
MASS/VOLUME: lb/cubic yd. 0.593 276 kg/cubic meter
POWER: horsepower 0.745 700 kilowatt
lb/sq. inch 6.894 757 kilopascal
PRESSURE: lb/sq. inch 0.069 bar
psi lb/sq. inch 0.070 303 kg/sq. cm
psi 0.006 895 megapascal (Mpa)
TEMPERATURE: degree F 1.8 F - 32 degree C
lb/inch 0.112 985 newton meter
TORQUE:
lb/foot 1.355 818 newton meter
VELOCITY: miles/hr. 1.609 344 kilometer/hr
cubic inch 16.387 06 cubic centimeter
cubic foot 0.028 317 cubic meter
cubic yd. 0.764.555 cubic meter
ounce (US fluid) 29.573 53 milliliter
VOLUME: quart (US liquid) 0.946 353 litre
quart (Imperial) 1.136 523 litre
gallon (US) 3.785 412 litre
gallon (Imperial) 4.546 092 litre
VOLUME/TIME: gallon/min. 3.785 412 litre/min.

84402826 - May 2011

1005-4
Section

1900

Abbreviations

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

1900-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
1900-2 PRINTED IN FRANCE
 Abbreviations

Abbreviations
Abbreviation description
AC air conditioner
A/D analog/digital
ABDC after bottom dead center
AC alternating current
ACC accessory
ACG alternating current generator
ACT actuator
API american petroleum industry
ASM assembly
ATDC after top dead center
ATF automatic transmission fluid
drilled head B drilled head bolt
eye B eye bolt
full threaded B full threaded bolt
hexagon socket head B hexagon socket head bolt
high-strength B high-strength bolt
reamer B reamer bolt
B+ battery + terminal
BAT battery
BBDC before bottom dead center
BKT bracket
BRG bearing
BTDC before the top dead center
C/B circuit breaker
C/U control unit
CAL calibration
CAN a control unit communication method (control area network)
CFG config
CHK check
CKP crankshaft position
CMP camshaft position
CO carbon monoxide
CPU central processing unit
DC direct current
DI direct injection type
DIAG diagnosis
DLC data link connector
DMM digital multi–meter
DPD diesel particulate diffuser
DTC self-diagnosis code
ECM engine control module
ECT engine coolant temperature
ECU electronic control unit
EEPROM electrically erasable/programmable ROM
EGR exhaust gas recirculation
EMI electromagnetic interference
EMPS engine module programing system
ENG engine
EPF engine protection feature
EVRV electric vacuum regulating valve
EXH exhaust
F/B feedback
F/C fuel cut
F/L fusible link
FLW fusible link wire
FRT front
84402826 - May 2011
1900-3
 Abbreviations

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

84402826 - May 2011

1900-4
 Abbreviations

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

84402826 - May 2011

1900-5
Abbreviations

84402826 - May 2011

1900-6
 Section

2000

Removal and Installation of Engine Assembly

84402826 - May 2011

84402826 - May 2011
 CONTENTS

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

Installation of Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

2000-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
2000-2 PRINTED IN FRANCE
 Removal and Installation of Engine Assembly

WARNING Removal of Engine Assembly

• Keep away from fire.
• Be sure to release hydraulic pressure before
beginning work.
• The air conditioner circuit is filled with high-
pressure gas, so beware of the gas released
when loosening lines.
• Do not use open flames and do not allow
sparks near the battery.
1. Remove the counterweight.(For details, see "Re-
moval and Installation of Counterweight".)
2. Remove the pump.(For details, see "Removal and
Installation of Hydraulic Pump".)
3. Use a wrench （14 mm） to remove the bolts (1)
and (2), and then remove the fan shroud (3).

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.

Items to prepare
• Wrenches (7 mm, 8 mm, 10 mm, 12 mm, 13 mm, 14
mm, 17 mm, 36 mm)
• Box wrench (24 mm)
• Shackle (with the required lifting capacity) x 2
• Wire rope (with the required breaking load)
• Crane (with the required lifting capacity)
• Marking pen
• Caps
• Plugs
• Waste oil can
• Rag
• Cleaning fluid
• Wood plank

4. Use a wrench to remove the bolts (1), and then re-

move the fan guard (2).

84402826 - May 2011

2000-3
 Removal and Installation of Engine Assembly

5. Use a wrench (7 mm) to loosen the hose band (1) 8. Use a wrench (8 mm) to loosen the hose band (1)
on the radiator, and then remove the upper hose (2). on the inter cooler, and then remove the hose (2).
• Use caps to cover the line and hose to prevent the
entry of water, dust or dirt.

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

on the radiator, and then remove the lower hose (2).
• Use caps to cover the radiator and hoses to pre- 9. Remove the hose bands (1) in the 3 locations.
vent the entry of water, dust or dirt.
• Before removing the radiator hoses, completely
drain the coolant.

10. Prepare a waste oil can (1).

• Drain the engine oil before removing the engine
7. Use a wrench (12 mm) to loosen the line bolts (1) in oil hose.
2 locations, and then remove the 2 lines (2) and (3)
from the compressor.
• Always remove the low-pressure (suction side)
line (2) first.
• Attach caps or plugs to the compressor and lines
to prevent any entry of water, dust or dirt.

11. Use a wrench (36 mm) to remove the 2 engine oil

remote hoses (1).
• Mark the engine and hoses so that the connectors
match at the time of assembly.
• Attach caps or plugs to the engine and hoses to
prevent any entry of water, dust or dirt.
• Clean the engine and hoses by spraying them
with a parts cleaner to prevent scratches and pre-
3 Line (discharge side) vent dirt from accumulating on the connectors.

84402826 - May 2011

2000-4
 Removal and Installation of Engine Assembly

14. Use a wrench (14 mm) to remove the 1 nut (1), and
then remove the wiring (2) from the starter motor.

12. Use a wrench (17 mm) to remove the bolt (1), and
then remove the negative-side battery cable (2).
• When removing the terminal and harness, secure
them so that they do not interfere with the frame.
Also, cover with a rubber cap to protect against
sparks.
15. Remove the hose band (1), and then remove the
fuel hose (2).
• Attach caps or plugs to the engine and hose to
prevent any entry of water, dust or dirt.

13. Use a wrench (8 mm) to remove the 1 nut (1), and 16. Remove the hose band (1), and then remove the
then remove the wiring (2) from the starter motor. fuel hose (2).
• Attach caps or plugs to the engine and hose to
prevent any entry of water, dust or dirt.

84402826 - May 2011

2000-5
 Removal and Installation of Engine Assembly

17. Use a wrench (13 mm) to remove the 2 bolts (1), 20. Loosen the hose band (1), and then remove the
and then remove the connector bracket (2). heater hose (2).
• Attach caps or plugs to the engine and hose to
prevent any entry of water, dust or dirt.

18. Use a wrench (13 mm) to remove the hose band (1)
from the bracket, and then remove the connectors
(2).
21. Use a wrench (7 mm) to loosen the hose band (1),
• Wrap the removed connectors in plastic after tying and then remove the radiator hose (2).
them together.
• Use caps to cover the line and hose to prevent
any entry of water, dust or dirt.

19. Loosen the hose band (1), and then remove the
heater hose (2).
22. Use a wrench (7 mm) to loosen the hose band (1),
• Attach caps or plugs to the engine and hose to and then remove the air hose (2).
prevent any entry of water, dust or dirt.
• Use caps to cover the line and hose to prevent
any entry of water, dust or dirt.

84402826 - May 2011

2000-6
 Removal and Installation of Engine Assembly

23. Use a wrench (9.5 mm) to loosen the hose band (1), 26. Use a wrench (13 mm) to remove the bolt (1), and
and then remove the air hose (2). then remove the radiator hose clamp (2).
• Use caps to cover the line and hose to prevent
any entry of water, dust or dirt.

27. Install the 2 shackles (1), and then use the wire rope
(2) and crane to secure the engine.

24. Remove the connectors (1) from the alternator.

25. Use a wrench (10 mm) to remove the nut (1), and
then remove the wiring from the alternator (2).

84402826 - May 2011

2000-7
 Removal and Installation of Engine Assembly

28. Use a box wrench (24 mm) to remove the 4 bolts 29. Use the wire rope (1) and crane to lift the engine.
(1) from the mount. Thoroughly check that the location is safe before
lowering the engine on wood planks, etc.

84402826 - May 2011

2000-8
 Removal and Installation of Engine Assembly

Installation of Engine Assembly 2.
1. To install the engine, perform the reverse of the re- 3.
moval procedure.
After installing the engine, resupply coolant and en-
gine oil, perform fuel line air bleeding, and perform
filling for the air conditioner gas.
For details, see the individual explanations for each
procedure.
Run the engine at no-load idling and check for any
water or oil leaks.
Attach the hydraulic pump, covers, and counter-
weight.
For details, see the individual explanations for each
procedure.

84402826 - May 2011

2000-9
Removal and Installation of Engine Assembly

84402826 - May 2011

2000-10
 Section

2001

Removal and installation of the fuel cooler engine

inter-cooler radiator and oil cooler

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal and Installation of Fuel Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Removal of Fuel Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Fuel Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal and Installation of Engine Intercooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal of Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation of Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal and Installation of Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal of Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation of Radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal and Installation of Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removal of Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation of Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

2001-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
2001-2 PRINTED IN FRANCE
 Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
Removal and Installation of Fuel Removal of Fuel Cooler
Cooler 1. Mark the fuel cooler (5) and hoses (1) (2) so that the
connectors match at the time of assembly.
CAUTION
• Remove the fuel hose clamp (6).
• Be sure to stop the engine before beginning • Use pliers to loosen the hose bands (3) (4), and
work. then remove the hoses.
• As the fuel hose will be removed, strictly pro- • Fuel will spill out, so place a drip pan directly be-
hibit open flames. low the area.
• Install caps or plugs to the fuel cooler and hoses
Items to prepare to prevent any entry of water, dust or dirt.
• Tightening torque for bolt (1) installation: 25.0
• Wrenches (12 mm) N·m
• Screwdriver
• Pliers
• Marking pen
• Cap
• Plug
• Rag
• Cleaning fluid
• Drip pan

84402826 - May 2011

2001-3
 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),
and then remove the fuel cooler (2).
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
torque.
If the torque is not specified for a bolt or other part, see
the "Bolt Size and Torque Table".

84402826 - May 2011

2001-4
 Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
Removal and Installation of Engine Removal of Intercooler
Intercooler 1. Use a wrench (8 mm) or flathead screwdriver to
loosen the hose bands (1) in the 2 locations, and
CAUTION then remove the 2 hoses (2) (3).

• Be sure to stop the engine before beginning • Use caps to cover the intercooler and hoses to
work. prevent the entry of water, dust or dirt.
• As the fuel hose will be removed, strictly pro- Tightening torque for band (1) installation: 8.8 -
hibit open flames. 9.8 N·m

Items to prepare
• Wrenches (8 mm, 14 mm)
• Flathead screwdriver
• Cap
• Rag
• Cleaning fluid

2. Use a wrench (14 mm) to remove the 4 bolts (1),

and then remove the intercooler (2).
• Tightening torque for bolt (1) installation: 55.0
N·m

84402826 - May 2011

2001-5
 Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
Installation of Intercooler Removal and Installation of
To install, perform the reverse of the removal procedure. Radiator
Check for any air leaks.
When installing the bolts, tighten them to the specified WARNING
torque.
If the torque is not specified for a bolt or other part, see • Do not remove the radiator cap when the ra-
the "Bolt Size and Torque Table". 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.
• Do not stand or pass under the suspended
load.

Items to prepare
• Wrenches (7 mm, 8 mm, 13 mm, 14 mm, 19 mm)
• Box wrench (12 mm)
• Pliers
• Shackles (with the required lifting capacity) x 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.

84402826 - May 2011

2001-6
 Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
Removal of Radiator 4. Loosen the drain plug (1), and then drain the
coolant.
1. Use a wrench (19 mm) to remove the 3 bolts (1),
and then remove the under cover (2).

5. Use a wrench (13 mm) to remove the high-strength

bolt (1), plain washer (2), and seal retainer (3), and
2. Install the drain hose (1), and then prepare the drain then remove the cushion seal.
tank (2). Remove the 4 sems bolts (4), and then remove the
bracket.

3. To make it easier to drain the coolant, remove the

radiator cap (1). 6. Use a wrench (13 mm) to remove the 5 bolts (1),
and then remove the cover (2).

84402826 - May 2011

2001-7
 Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
7. Use a wrench (7 mm) to loosen the hose band (1), 9. Loosen the hose band (2), and then remove the
and then remove the upper hose (2) and lower hose hose (1) from the radiator cap.
(3) from the radiator.
• Install caps or plugs to the hoses to prevent any
• Use caps to cover the radiator and hoses to pre- entry of water, dust or dirt.
vent the entry of water, dust or dirt.
• Tightening torque for band (1) installation: 4.9 -
5.9 N·m

10. Use a wrench (14 mm) to remove the 3 bolts (1),

and then remove the brackets (2).

11. Use a wrench (14 mm) to remove the 2 bolts (1),

and then remove the fan guard (2).
8. Remove the drain plug (1), loosen the hose band
(2), and then remove the hose (3).

84402826 - May 2011

2001-8
 Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
12. Use a wrench (14 mm) to remove the 3 bolts (1), 15. Remove the 2 one-touch clips (1), and then remove
and then remove the brackets (2). the front anti-insect net (2).

13. Use a wrench (14 mm) to remove the 3 bolts (1), 16. Use a wrench (17 mm) to remove the 4 bolts (1),
and then remove the brackets (2). the 8 washers (2) and the 4 rubber cushions (3).

14. Use a box wrench (12 mm) to remove the 8 bolts

(2) from the fan shroud (1), and then move the fan
shroud (1) towards the engine.

84402826 - May 2011

2001-9
 Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
17. Install the 2 shackles (1) to the top of the radiator,
and then use the wire rope (2) and liftcrane to lift the
radiator.
Installation of Radiator
To install, perform the reverse of the removal procedure.
Tighten bolts being installed to the specified torque.
If the torque is not specified, see the "Bolt Size and
Torque Table".
Coolant capacity is 30.2 L.
Finally, check that the level of coolant is correct.

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

19. Thoroughly check that the location is safe before

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

84402826 - May 2011

2001-10
 Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
Removal and Installation of Oil Removal of Oil Cooler
Cooler • Drain the hydraulic oil from the hydraulic oil tank.
See "Draining Oil from Hydraulic Oil Tank" for details
WARNING of the procedure.

• Keep away from fire. 1. Use a wrench (19 mm) to remove the 3 bolts (1),
and then remove the under cover (2).
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.

Items to prepare
• Wrenches (13 mm, 17 mm, 19 mm)
• Hexagon wrench (10 mm)
• Pliers
• Screwdriver
• Eyebolts (M12 x 2) 2. Prepare the waste oil can (1).
• Shackles (with the required lifting capacity) x 2
• Wire rope (with the required breaking load)
• Liftcrane (with the required lifting capacity)
• Cap
• Waste oil can
• Rag
• Cleaning fluid
• Wood planks, etc.

3. Use a wrench (13 mm) to remove the 5 bolts (1),

and then remove the cover (2).

84402826 - May 2011

2001-11
 Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
4. Remove the 2 one-touch clips (1), and then remove 6. Use a wrench (14 mm) to remove the 3 bolts (1),
the anti-insect net (2). and then remove the brackets (2).

5. Use a hexagon wrench (10 mm) to remove the 2 7. Use a wrench (14 mm) to remove the 2 bolts (1),
upper hexagon socket head bolts (1) and 2 lower and then remove the fan guard (2).
bolts (1), and then use a wrench (8 mm) to loosen
the hose bands (2) and remove the lines (3) (4).
• Use caps to cover the oil cooler and lines to pre-
vent the entry of water, dust or dirt.

8. Use a wrench (14 mm) to remove the 3 bolts (1),

and then remove the brackets (2).

84402826 - May 2011

2001-12
 Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
9. Use a wrench (14 mm) to remove the 3 bolts (1), 11. Use a wrench (17 mm) to remove the 4 bolts (1).
and then remove the brackets (2).

10. Use a box wrench (12 mm) to remove the 8 bolts

(2) from the fan shroud (1), and then move the fan
shroud (1) towards the engine.

12. Install the 2 eyebolts (M12) (1) on the top of the oil
cooler.
• Fully tighten the eyebolts, and then loosen them
by a half turn.

84402826 - May 2011

2001-13
 Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
13. Install the 2 shackles (1) to the eyebolts, and then Installation of Oil Cooler
use the wire rope (2) and liftcrane to lift the oil cooler
main unit. 1. Use a liftcrane to lift the oil cooler (1) main unit.

14. Thoroughly check that the location is safe before

lowering the oil cooler on wood planks, etc.

84402826 - May 2011

2001-14
 Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
2. Mount the oil cooler (1), and then remove the shack- 3. Use a wrench (17 mm) to secure the oil cooler (1)
les (2), wire ropes (3), and eyebolts (4). with the 4 bolts (2).
• Bolt (2) tightening torque: 88.0 N·m

4. Use a box wrench (12 mm) to install the 8 bolts (2)

and install the fan shroud (1).
• Bolt (2) tightening torque: 25.0 N·m

84402826 - May 2011

2001-15
 Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
5. Use a wrench (14 mm) to install the 3 bolts (1) and 7. Use a wrench (14 mm) to install the 2 bolts (1) and
install the bracket (2). install the fan guard (2).

6. Use a wrench (14 mm) to install the 3 bolts (1) and 8. Use a wrench (14 mm) to install the 3 bolts (1) and
install the bracket (2). install the bracket (2).

84402826 - May 2011

2001-16
 Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
9. Set the O-rings (2) on the oil cooler (1) side and 10. Use a wrench (8 mm) to install the hose bands (1)
install the lines (3) (4) with 2 hexagon socket head and install the hoses (2).
bolts (5) each.
• The O-rings cannot be reused.Replace them with
new parts.

11. Install the anti-insect net (1) with the 2 one-touch

clips (2).

84402826 - May 2011

2001-17
 Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
12. Use a wrench (13 mm) to install the cover (1) with 13. Use a wrench (19 mm) to install the under cover (1)
the 5 bolts (2). with the 3 bolts (2).

Tighten bolts being installed to the specified torque.

If the torque is not specified, see the "Bolt Size and
Torque Table".

84402826 - May 2011

2001-18
 Section

2004

Removal and Installation of Turbo Charger

84402826 - May 2011

84402826 - May 2011
 CONTENTS

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

Turbocharger assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

2004-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
2004-2 PRINTED IN FRANCE
 Removal and Installation of Turbo Charger

WARNING Turbocharger assembly Removal

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

Items to prepare • After the coolant is discharged, make

sure to tighten the drain plug.
• Wrenches (8 mm, 10 mm, 13 mm, 14 mm, 17 mm)
• Cap 3. Turbocharger assembly Removal
• Plug
• Rag 1) Remove the air cleaner duct from the air
• Cleaning fluid cleaner assembly and the turbocharger as-
sembly.
2) Remove the air intake hose from the tur-
bocharger assembly and the intercooler.
3) Remove the exhaust pipe from the tur-
bocharger assembly.
4) Disengage the oil feed pipe from the tur-
bocharger assembly.
ANNOTATION:
• Remove the clip.

84402826 - May 2011

2004-3
 Removal and Installation of Turbo Charger

5) Disengage the oil return pipe from the tur- 7) Disengage the water feed pipe from the tur-
bocharger assembly. bocharger assembly.
ANNOTATION:
• Remove the clip.

1 Turbocharger assembly
2 Oil feed pipe
3 Oil return pipe

6) Disengage the water return pipe from the tur- 1 Water return pipe
bocharger assembly. 2 Water feed pipe

8) Remove the exhaust manifold stay from the

cylinder block and the turbocharger assembly.

1 Turbocharger assembly
2 Exhaust manifold
3 Exhaust manifold stay
84402826 - May 2011
2004-4
 Removal and Installation of Turbo Charger

9) Disengage the harness connector from the Turbocharger assembly

turbocharger assembly.
10) Remove the turbocharger assembly from the Installation
exhaust manifold.
1. Turbocharger assembly Installation
1) Temporarily tighten the turbocharger assem-
bly to the exhaust manifold.

1 Exhaust manifold
2 Turbocharger assembly

1 Exhaust manifold
2 Turbocharger assembly

2) Temporarily tighten the exhaust manifold stay

to the cylinder block and the turbocharger as-
sembly.

1 Turbocharger assembly
2 Exhaust manifold
3 Exhaust manifold stay

3) Securely tighten the turbocharger assembly to

the exhaust manifold.
Tightening torque： 52 N・m { 5.3 kgf・m /
38 lb・ft }

84402826 - May 2011

2004-5
 Removal and Installation of Turbo Charger

4) Securely tighten the exhaust manifold stay to 6) Connect the water return pipe to the tur-
the cylinder block and the turbocharger as- bocharger assembly.
sembly.
Tightening torque： 52 N・m { 5.3 kgf・m /
38 lb・ft } Nut
Tightening torque： 50 N・m { 5.1 kgf・m /
37 lb・ft } Bolt
ANNOTATION:
• Tightening order

5) Connect the water feed pipe to the tur-

bocharger assembly.

CAUTION
• Use new gaskets.

Tightening torque： 35 N・m { 3.5 kgf・m /

25 lb・ft } Eyebolt
Tightening torque： 14 N・m { 1.4 kgf・m /
1 Water return pipe
119 lb・in } Clip
2 Water feed pipe

Tightening torque： 35 N・m { 3.5 kgf・m /

25 lb・ft } Eyebolt
7) Connect the oil return pipe to the turbocharger
assembly.

CAUTION
• Use new gaskets.

Tightening torque： 9 N・m { 0.9 kgf・m / 78

lb・in }

84402826 - May 2011

2004-6
 Removal and Installation of Turbo Charger

8) Connect the oil feed pipe to the turbocharger 10) Install the air intake hose to the turbocharger
assembly. assembly and the intercooler.
11) Install the air cleaner duct to the air cleaner
CAUTION assembly and the turbocharger assembly.
12) Connect the harness connector to the tur-
・ Use new gaskets. bocharger assembly.
Tightening torque： 17 N・m { 1.7 kgf・m / 2. Coolant Filling
12 lb・ft } Eyebolt 1) Loosen the valve using a wrench.
Tightening torque： 24 N・m { 2.4 kgf・m / 2) Replenish the coolant with the radiator.
17 lb・ft } Clip
CAUTION
• Be careful not to let coolant over-
flow splash on the exhaust system
parts.
• Coolant overflow should be wiped
off.

3) Tighten the valve using a wrench.

CAUTION
• Use new gaskets.

Tightening torque： 28 N・m { 2.8 kgf・m /

20 lb・ft }
4) Replenish the coolant with the radiator.

1 Turbocharger assembly 1 Valve

2 Oil feed pipe 2 Gasket
3 Oil return pipe
3. Battery ground cable Connect
9) Install the exhaust pipe to the turbocharger 1) Connect the battery ground cable to the bat-
assembly. tery.

84402826 - May 2011

2004-7
Removal and Installation of Turbo Charger

84402826 - May 2011

2004-8
 Section

2005

Removal and Installation of EGR Valve

84402826 - May 2011

84402826 - May 2011
 CONTENTS

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

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

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

2005-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
2005-2 PRINTED IN FRANCE
 Removal and Installation of EGR Valve

EGR valve Removal 3) Remove the EGR pipe A from the EGR cooler
A and exhaust manifold.
1. Battery ground cable Disconnect
1) Disengage the battery ground cable from the
battery.
2. Coolant Drain
1) Drain the coolant from the radiator.

CAUTION
• After the coolant is discharged,
make sure to tighten the drain plug.

3. EGR cooler assembly Removal

1) Disengage the water rubber hose from the
EGR cooler assembly.

1 EGR cooler A
2 EGR pipe A
3 Exhaust manifold

4) Remove the EGR cooler A from the EGR pipe

B.
5) Remove the EGR pipe B from the EGR cooler
B.
6) Remove the EGR cooler B from the EGR pipe
C.
7) Remove the EGR pipe C from the EGR valve.

1 Water rubber hose

2) Remove the EGR heat protector from the

EGR pipe A.

1 EGR valve
2 EGR pipe C
3 EGR cooler B
4 EGR pipe B
5 EGR cooler A
1 EGR heat protector 6 EGR pipe D

84402826 - May 2011

2005-3
 Removal and Installation of EGR Valve

4. EGR valve Removal EGR valve Installation

1) Disengage the harness connector from the 1. EGR valve Installation
EGR valv.e
2) Remove the EGR valve from the EGR pipe D. 1) Install the EGR valve to the EGR pipe D.
Tightening torque： 24 N・m { 2.4 kgf・m /
17 lb・ft }

1 EGR cooler C
2 EGR pipe C
3 EGR valve 1 EGR cooler C
4 EGR pipe D 2 EGR pipe C
3 EGR valve
4 EGR pipe D

CAUTION
• Use new gaskets.

2) Connect the harness connector to the EGR

valve.
2. EGR cooler assembly Installation
1) Temporarily tighten the EGR pipe C to the
EGR valve.
2) Temporarily tighten the EGR cooler B to the
EGR pipe C.
3) Temporarily tighten the EGR pipe B to the
EGR cooler B.

84402826 - May 2011

2005-4
 Removal and Installation of EGR Valve

4) Temporarily tighten the EGR cooler A to the

EGR pipe B.

1 EGR valve
2 EGR pipe C
3 EGR cooler B
4 EGR pipe B
5 EGR cooler A
6 EGR pipe B

5) Temporarily tighten the EGR pipe A to the

EGR cooler A and the exhaust manifold.

6) Securely tighten the EGR pipe C to the EGR

valve.
Tightening torque： 24 N・m { 2.4 kgf・m /
17 lb・ft } No.1 in the diagram
7) Completely tighten the EGR pipe C to the en-
gine hanger bracket.
Tightening torque： 48 N・m { 4.9 kgf・m /
35 lb・ft } No.2 in the diagram
8) Securely tighten the EGR pipe B to the
bracket.
Tightening torque： 48 N・m { 4.9 kgf・m /
35 lb・ft } No.3 in the diagram
9) Securely tighten the EGR cooler B to the EGR
1 EGR cooler A pipe C.
2 EGR pipe A Tightening torque： 24 N・m { 2.4 kgf・m /
3 Exhaust manifold 17 lb・ft } No.4 in the diagram
10) Securely tighten the EGR pipe B to the EGR
ANNOTATION: cooler B.
Tightening torque： 24 N・m { 2.4 kgf・m /
• Complete tightening order of the EGR 17 lb・ft } No.5 in the diagram
cooler assembly 11) Securely tighten the EGR cooler A to the EGR
pipe B.
Tightening torque： 24 N・m { 2.4 kgf・m /
17 lb・ft } No.6 in the diagram
12) Securely tighten the EGR pipe A to the ex-
haust manifold.
Tightening torque： 28 N・m { 2.9 kgf・m /
21 lb・ft } No.7 in the diagram
13) Securely tighten the EGR pipe A to the EGR
cooler A.
Tightening torque： 28 N・m { 2.9 kgf・m /
21 lb・ft } No.8 in the diagram

84402826 - May 2011

2005-5
 Removal and Installation of EGR Valve

14) Install the EGR heat protector to the EGR pipe 1) Loosen the valve using a wrench.
A. 2) 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.

3) Tighten the valve using a wrench.

CAUTION
• Use new gaskets

Tightening torque： 28 N・m { 2.8 kgf・m /

20 lb・ft }
1 EGR heat protector 4) Replenish the coolant with the radiator.

15) Connect the water rubber hose to the EGR

cooler assembly.

1 Valve
2 Gasket

1 Water rubber hose 4. Battery ground cable Connect

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

84402826 - May 2011

2005-6
 Section

2006

Removal and Installation of Engine Hood

84402826 - May 2011

84402826 - May 2011
 CONTENTS

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

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

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

2006-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
2006-2 PRINTED IN FRANCE
 Removal and Installation of Engine Hood

CAUTION Removal of Engine Hood

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

Items to prepare
• Wrench (13 mm, 17 mm, 19 mm)
• Nylon sling (with the required breaking load)
• Liftcrane (with the required lifting capacity)

84402826 - May 2011

2006-3
 Removal and Installation of Engine Hood

2. Use the liftcrane and lift up the engine hood (2) until 4. Wrap the nylon sling (2) around the engine hood (1),
the damper (1) is completely extended and there is and then use the liftcrane to lift the engine hood (1).
no force on it.
Loosen the ring (3) of the damper’s head section,
and then remove the gas damper (1).

Installation of Engine Hood

3. After closing the engine hood (1), use a wrench (19
mm) to remove the 6 bolts (2) from the engine hood.
To install, perform the reverse of the removal procedure.
Tighten bolts being installed to the specified torque.
For bolts for which the torque is not specified, check
of the "About This Shop Manual Section • Tightening
Torque • Retightening Torque Table" in the explanation
in the materials.

84402826 - May 2011

2006-4
 Section

2007

Removal and Installation of Muffler

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

2007-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
2007-2 PRINTED IN FRANCE
 Removal and Installation of Muffler

WARNING Removal of Muffler

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

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

Items to prepare
• Wrench (10 mm)
• Wrench (13 mm)
• Wrench (14 mm)
• Cap
• Rag
• Cleaning fluid 2. Remove the connectors (1).

3. Use a wrench (10 mm) to loosen the bolt (1), and

then remove the cord clamp.

84402826 - May 2011

2007-3
 Removal and Installation of Muffler

4. Use a wrench (19 mm) to loosen the 4 bolts (1), and Installation of Muffler
then remove the muffler.
1. When installing the bolts, tighten them to the spec-
ified torque.
When the tightening torque is not specified for a bolt
or other part, see "Materials Explanation - Tighten-
ing Torque - Torque Table (one page)".
2. Place the DPD muffler (1) in the bracket, and install
the gasket (2), bolt (3), nut (4), and washers (5) on
the flanges. Move the DPD muffler over until the
DPD muffler flange touches the exhaust pipe (6)
flange surface, and then use a wrench (13 mm) to
temporarily tighten the flanges together.

CAUTION
• Use caution when handling the DPD muf-
fler (1), DPD pressure sensor (7), and
DPD thermo-sensors (8) (9) and do not
subject them to any impacts etc.
• Do not reuse these parts if they are
dropped or fall.

3. Use a wrench (19 mm) to tighten the 4 bolts (1) to

secure the muffler.

84402826 - May 2011

2007-4
 Removal and Installation of Muffler

4. Use a wrench (13 mm) to fully tighten the bolt (1), 6. Install the connectors (1).
nut (2), and washers (3) temporarily tightened in
Step 2.

7. After installation, run the engine at no-load idling

and check for any abnormalities.
5. Use a wrench (10 mm) to tighten the bolt (1) to in-
stall the cord clamp.

84402826 - May 2011

2007-5
Removal and Installation of Muffler

84402826 - May 2011

2007-6
 Section

2401

Primary specifications

84402826 - May 2011

84402826 - May 2011
 CONTENTS

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

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

2401-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
2401-2 PRINTED IN FRANCE
 Primary specifications

Primary specifications
1. Primary specifications
Engine main specifications

Item Engine model 4HK1X

Type Diesel/ 4-cycle /water cooling, inline 4 cylinder OHC
Shape of combustion chamber Direct injection type
Cylinder liner type Dry type
Cylinder bore x stroke 115 mm {4.53 in} x 125 mm {4.92 in}
Displacement 5.193 L ｛316.88 cu・in｝
Compression ratio 17.5
Compression pressure ： 3.23 MPa { 32.9 kgf/cm2 / 468 psi }
Idling rotation speed 800 r/min
Intake ： 0.4 mm { 0.016 in } While cool
valve clearance
Exhaust ： 0.4 mm { 0.016 in } While cool
Ignition method Compression ignition
Injection order 1,3,4,2
Lubricant system
Lubricating type Pressure type
Oil pump type Gear type
Lubrication oil amount ： 20 - 27 L { 5.2 - 7.1 US gal }
Oil filter type Full-flow / partial-flow united filter (cartridge type)
Oil cooling type Built-in type, water cooled
Cooling system
Cooling type Water cooling
Radiator type Corrugated fin (pressure type)
Water pump type Centrifugal, belt type
Thermostat type 2 wax type unit
： 82.0 °C { 180 °F } Without jiggle valve
Open valve temperature of the thermostat valve
： 85.0°C { 185 °F } With jiggle valve
Coolant container ： 14.5 L { 3.8 US gal }
fuel system
Injection nozzle type Electronic control common rail type
Governor type Electronic type
Timer type Electronic type
Multi-hole type
Injection nozzle type
7 holes, inner diameter D0.14 mm {0.0055 in}
Charging system
Generator type AC type
Output 24 V/50 A
Regulator type IC
Starting system
Starter type Reduction type
Output 24 V/5.0 kW
Preheat system type glow plug
Glow plug standard voltage/current 23 V/3.5 A

84402826 - May 2011

2401-3
 Primary specifications

Cleaning system main specifications

Item Specifications
water pump Centrifugal impeller method
Pulley ratio 0.950
thermostat Wax pellet type
： 85.0 °C { 185 °F } With jiggle valve
Open valve temperatur
： 82.0 °C { 180 °F } Without jiggle valve
： 100.0 °C { 212 °F } With jiggle valve
Full-open temperature
： 95.0 °C { 203 °F } Without jiggle valve

Electrical system main specifications

generator
Item Specifications
Isuzu parts number 8980921161
Nominal output 24 V/50 A
Rated rotation count 5,000 r/min
Regulator type IC type
Regulated voltage 27.5 V - 29.5　V
weight ： 9.5 kg { 20.9 lb }

starter
Type (Manufacturer) Nikko
voltage 24V
Rating Output 5 KW
Time 30 sec
Number of pinion teeth 13
Rotational direction (facing the pinion) Right
Weight (Approx.) ： 8.0 kg { 17.6 lb }
Current/voltage 85 A or less/24 V
No-load characteristics
Revolution speed 3,300 r/min or more
Current/voltage 400 A/18.5 V
Load characteristics Torque 28.4 N・m {2.9kgf・m} or more
Revolution speed 1,250 r/min or more
Current/voltage 1,400 A or less/9 V
Locking characteristics
Torque 88.2 N・m {9.0kgf・m} or more

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

84402826 - May 2011

2401-4
 Section

2415

Removal and Installation of Cylinder Head

84402826 - May 2011

84402826 - May 2011
 CONTENTS

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

Installation of Cylinder Head Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal and Installation of Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal of Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly of Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assembly of Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installation of Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

2415-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
2415-2 PRINTED IN FRANCE
 Removal and Installation of Cylinder Head

Cylinder head cover Removal Installation of Cylinder Head Cover

1. Cylinder head cover Removal 1. Cylinder head cover Installation
1) Disengage the oil level gauge guide tube from 1) Align the head cover gasket to the cylinder
the cylinder head cover. head cover.
2) Disengage the ventilation hose from the air 2) Install the cylinder head cover to the lower
breather. cover.
Tightening torque： 18 N・m { 1.8 kgf・m /
13 lb・ft }
ANNOTATION:
• Referring to the tightening order in the dia-
gram, temporarily tighten all bolts and then
completely tighten them.

1 Ventilation hose
2 Oil level gauge guide tube

3) Remove the cylinder head cover from the

lower cover.
4) Remove the head cover gasket from the cylin-
der head cover.

1 Cylinder head cover

2 Gasket
1 Cylinder head cover 3 Lower cover
2 Gasket
3) Connect the ventilation hose to the air
3 Lower cover breather.

84402826 - May 2011

2415-3
 Removal and Installation of Cylinder Head

4) Connect the oil level gauge guide tube to the Removal and Installation of
cylinder head cover.
Tightening torque： 19 N・m { 1.9 kgf・m / Cylinder Head
14 lb・ft }
Removal of Cylinder Head
1. Battery ground cable Disconnect
1) Disengage the battery ground cable from the
battery.
2. Coolant Drain
1) Drain the coolant from the radiator.

CAUTION
• After the coolant is discharged,
make sure to tighten the drain plug.

3. Engine harness Disconnect

1) Disengage the engine harness from the en-
1 Ventilation hose gine assembly.
2 Oil level gauge guide tube
ANNOTATION:
• Disconnect each connector.
4. Turbocharger assembly Removal
1) Remove the air cleaner duct from the air
cleaner assembly and the turbocharger as-
sembly.
2) Remove the air intake hose from the tur-
bocharger assembly and the intercooler.
3) Remove the exhaust pipe from the tur-
bocharger assembly.
4) Disengage the oil feed pipe from the tur-
bocharger assembly.
ANNOTATION:
• Remove the clip.
5) Remove the oil feed pipe from the oil port
cover.
ANNOTATION:
• Remove the clip.
6) Disengage the oil return pipe from the tur-
bocharger assembly.

84402826 - May 2011

2415-4
 Removal and Installation of Cylinder Head

7) Remove the oil return pipe from the cylinder 11) Remove the water feed pipe from the cylinder
block. block.
ANNOTATION:
• Remove the clip.

1 Turbocharger assembly
2 Oil feed pipe
3 Oil return pipe

8) Disengage the water return pipe from the tur- 1 Water return pipe
bocharger assembly. 2 Water feed pipe
9) Remove the water return pipe from the water
pump assembly.
10) Disengage the water feed pipe from the tur-
12) Remove the exhaust manifold stay from the
bocharger assembly.
cylinder block and the turbocharger assembly.
ANNOTATION:
• Remove the clip.

1 Turbocharger assembly
2 Exhaust manifold
3 Exhaust manifold stay
84402826 - May 2011
2415-5
 Removal and Installation of Cylinder Head

13) Disengage the harness connector from the 3) Remove the EGR pipe A from the EGR cooler
turbocharger assembly. A and exhaust manifold.
14) Remove the turbocharger assembly from the
exhaust manifold.

1 EGR cooler A
2 EGR pipe A
1 Exhaust manifold 3 Exhaust manifold
2 Turbocharger assembly
4) Remove the EGR cooler A from the EGR pipe
5. EGR cooler assembly Removal B.
5) Remove the EGR pipe B from the EGR cooler
1) Disengage the water rubber hose from the B.
EGR cooler assembly. 6) Remove the EGR cooler B from the EGR pipe
C.
7) Remove the EGR pipe C from the EGR valve.

1 Water rubber hose

1 EGR valve
2) Remove the EGR heat protector from the 2 EGR pipe C
EGR pipe A. 3 EGR cooler B
4 EGR pipe B
5 EGR cooler A
6 EGR pipe D

6. EGR valve Removal

1) Disengage the harness connector from the
EGR valve.

1 EGR heat protector

84402826 - May 2011
2415-6
 Removal and Installation of Cylinder Head

2) Remove the EGR valve from the EGR pipe D. 3) Disengage the radiator upper hose from the
water outlet pipe.
4) Remove the EGR cooler water pipe from the
engine assembly.
ANNOTATION:
• Remove the EGR cooler water feed pipe
and EGR cooler water return pipe.

1 EGR cooler C
2 EGR pipe C
3 EGR valve
4 EGR pipe D

7. EGR cooler water pipe Removal

1) Remove the fan guide stay from the fan guide
and the fan guide bracket.
2) Remove the fan guide bracket from the cylin-
der head assembly.

1 EGR cooler water feed pipe

2 EGR cooler water return pipe

1 Fan guide 8. Intake throttle valve Removal

2 Fan guide stay 1) Remove the air duct from the intake throttle
3 Fan guide bracket valve.

84402826 - May 2011

2415-7
 Removal and Installation of Cylinder Head

2) Disengage the harness connector from the in- 3) Disengage the harness connector from the
take throttle valve. EGR valve.
4) Disconnect the harness connector from the
ANNOTATION:
IMT sensor.
• Pull the lock operation portion to release the 5) Remove the harness clip from the inlet pipe.
lock.

1 Boost sensor
1 Lock operation section 2 IMT sensor
2 Lock release 3 EGR valve
3 Lock 4 Harness clip
5 Boost temperature sensor
3) Remove the intake throttle valve from the inlet
pipe. 6) Remove the inlet pipe from the case.

1 Boost temperature sensor 1 Case

2 Boost sensor 2 Gasket
3 Inlet pipe 3 Inlet pipe
4 Gasket
5 Intake throttle valve 10. Oil level gauge guide tube Removal
1) Remove the oil level gauge from the oil level
9. Inlet pipe Removal
gauge guide tube.
1) Disengage the harness connector from the 2) Disengage the oil level gauge guide tube from
boost sensor. the cylinder head cover.
2) Disconnect the harness connector from the 3) Disengage the oil level gauge guide tube from
boost temperature sensor. the case.

84402826 - May 2011

2415-8
 Removal and Installation of Cylinder Head

4) Remove the oil level gauge guide tube from

the cylinder block.

1 No.1 injection pipe

2 No.2 injection pipe
1 Cylinder head cover 3 No.3 injection pipe
2 Oil level gauge guide tube 4 No.4 injection pipe
3 Case 5 Fuel leak-off pipe
4 Cylinder block 6 Fuel pipe
7 Common rail assembly
11. Glow plug Removal
1) Remove the glow plug connector from the 13. Fuel pipe Removal
glow plug. 1) Remove the fuel pipe from the fuel supply
2) Remove the glow plug from the cylinder head pump and the common rail assembly.
assembly.
ANNOTATION:
• Remove the clip.
CAUTION
• Do not reuse the removed fuel pipe.

14. Fuel leak off pipe assembly Removal

1) Disengage the fuel leak-off pipe from the cylin-
der head assembly.
2) Remove the fuel leak-off pipe from the fuel
supply pump.
ANNOTATION:

12. Injection pipe Removal • Remove the eyebolt tightened together with
the fuel feed pipe.
1) Remove the clip from the bracket.
2) Remove the injection pipe from the injector 3) Disengage the fuel leak-off pipe from the com-
and the common rail assembly. mon rail assembly.

CAUTION
• Do not reuse the removed injection
pipe.
• Seal the common rail and injector to
prevent foreign material from enter-
ing.

84402826 - May 2011

2415-9
 Removal and Installation of Cylinder Head

4) Remove the fuel leak-off pipe from the case. 16. Cylinder head cover Removal
ANNOTATION: 1) Disengage the ventilation hose from the air
• Remove the clip. breather.
2) Remove the cylinder head cover from the
lower cover.
3) Remove the head cover gasket from the cylin-
der head cover.

1 Common rail assembly

2 Cylinder head assembly
3 Fuel leak-off pipe
4 Fuel supply pump
1 Cylinder head cover
15. Common rail assembly Removal 2 Gasket
3 Lower cover
1) Disengage the harness connector from the
fuel pressure sensor.
2) Remove the common rail assembly from the
inlet cover and the common rail bracket. 17. Lower cover Removal
3) Remove the common rail bracket from the oil 1) Remove the connector from the lower cover.
cooler assembly.
CAUTION
• Do not pull the wire, or pry the con-
nector with a screwdriver.

2) Disengage the injector harness from the injec-

tor.

CAUTION
• Be careful not to damage the injec-
tor side stud bolts.

3) Remove the injector harness from the cylinder

head assembly.
ANNOTATION:
1 Common rail assembly
• Remove the bracket tightening bolts and
2 Fuel pressure sensor then remove the injector harness together
3 Common rail bracket with the bracket.

84402826 - May 2011

2415-10
 Removal and Installation of Cylinder Head

4) Remove the lower cover from the cylinder

head assembly.

Special tool: sliding hammer (refer to

section 1003)

1 Lower cover
2 Connector

5) Remove the gasket from the lower cover.

6) Remove the rubber plug from the cylinder
head assembly.
18. Injector Removal
1) Remove the injector leak-off pipe from the in-
jector.
2) Remove the injector from the cylinder head
assembly.
ANNOTATION:
• When it is difficult to remove the injector, use
a special tool.

Special tool: fuel injector remover (refer 1 Sliding hammer

to section 1003) 2 Fuel injector remover
3 Injector

CAUTION
• Confirm that the sleeve is not pulled
out together when pulling out the
injector using a special tool.
• Store each ID code plate on the in-
jector head with the cylinder num-
ber tag attached to avoid a mix-up.
• Be extremely careful not to damage
the injector nozzle.

84402826 - May 2011

2415-11
 Removal and Installation of Cylinder Head

20. Camshaft Removal

1) Remove the camshaft bearing cap from the
cylinder head assembly.
2) Remove the camshaft bearing from the
camshaft bearing cap.
3) Remove the camshaft from the cylinder head.
4) Remove the camshaft bearing from the cylin-
der head assembly.
ANNOTATION:
• Temporarily assemble the removed caps
and bearings in the original position to avoid
a mix-up after the bearings have been in-
spected.
19. Rocker arm shaft Removal
1) Loosen the adjust screw using the wrench.
ANNOTATION:
• Loosen all valve clearance adjustment
screws.

21. Bridge Removal

1) Remove the bridge cap from the bridge.

CAUTION
• Be careful not to drop the bridge
2) Remove the rocker arm shaft from the cylinder cap into the engine.
head assembly.
2) Remove the bridge from the bridge guide.
ANNOTATION:
ANNOTATION:
• Evenly loosen the rocker arm shaft bracket
and the rocker arm assembly bracket tight- • After removing, organize to avoid a mix-up
ening bolts from both ends and remove with other installation locations.
them.

CAUTION
• Be careful not to remove the bolt
shown in the diagram.

1 Bridge cap
2 Bridge

22. Cylinder head assembly Removal

84402826 - May 2011

2415-12
 Removal and Installation of Cylinder Head

1) Remove the cylinder head assembly from the Disassembly of Cylinder Head
cylinder block.
1. Engine hanger bracket Removal
ANNOTATION:
1) Remove the front engine hanger bracket from
• Loosening order of the head bolts the cylinder head assembly.
2) Remove the rear engine hanger bracket from
the cylinder head assembly.

CAUTION
• Since the idle gear C protrudes
from the bottom surface of the
cylinder head, be careful not to
damage the gear.

1 Front engine hanger

2 Front engine hanger bracket
3 Rear engine hanger
4 Rear engine hanger bracket
1 Idle gear C
2. Inlet cover Removal
2) Remove the cylinder head gasket from the 1) Remove the case from the inlet cover.
cylinder block.
ANNOTATION:
CAUTION
• Remove it together with the EGR pipe D.
• Do not reuse the cylinder head gas-
ket. 2) Remove the inlet cover from the cylinder head
assembly.

84402826 - May 2011

2415-13
 Removal and Installation of Cylinder Head

3) Remove the exhaust manifold bracket from

the cylinder head assembly.

1 EGR pipe D
2 Case
3 Gasket 1 Distance tube
4 Inlet cover 2 Washer
3 Exhaust manifold bracket
CAUTION 4 Exhaust manifold bracket
5 Exhaust manifold
• Do not forget to remove the bolts in-
dicated by the arrow in the diagram. 4. Thermostat Removal
1) Remove the water outlet pipe from the cylin-
der head assembly.
2) Remove the thermostat from the cylinder
head assembly.
3) Remove the gasket from the thermostat.
5. Overheat switch Removal
1) Remove the overheat switch from the cylinder
head assembly.
6. Engine coolant temperature sensor Removal
1) Remove the engine coolant temperature sen-
sor from the cylinder head assembly.

3. Exhaust manifold Removal

1) Remove the exhaust manifold bracket from
the exhaust manifold.
2) Remove the exhaust manifold from the cylin-
der head assembly.

1 Overheat switch
2 Water temperature sensor

84402826 - May 2011

2415-14
 Removal and Installation of Cylinder Head

7. CMP sensor Removal 3) Remove the idle gear C from the cylinder head
assembly.
1) Remove the CMP sensor from the cylinder
head assembly.

1 Idle gear C
CAUTION 2 Idle gear shaft
• Be careful not to subject the sensor 9. Valve spring Removal
to shock.
1) 1. Press the valve spring using the special
8. Idle gear C Removal tool.

1) Press the idle gear C cover using the driver.

ANNOTATION:
• Lightly tap the outer perimeter of the cover
using a screwdriver and tilt the cover.
2) Remove the idle gear C cover from the cylin-
der head assembly using the pliers.

Special tool: valve spring replacer (refer

to section 1003)

Special tool: pivot ASM (refer to section

1003)

84402826 - May 2011

2415-15
 Removal and Installation of Cylinder Head

2) Remove the valve spring seat from the cylin-

der head assembly.
13. Valve guide Removal
1) Remove the valve guide from the cylinder
head assembly using the special tool.

2) Remove the split collar from the spring seat.

3) Remove the special tool from the cylinder
head assembly.
4) Remove the valve spring seat from the valve
spring.
5) Remove the valve spring from the cylinder
head assembly.
Special tool: valve guide replacer (refer
ANNOTATION: to section 1003)
• Store the removed valve springs according ANNOTATION:
to the cylinders.
• Tap the valve guides out from the bottom
10. Inlet valve Removal surface of the cylinder head.
1) Remove the inlet valve from the cylinder head
assembly.
ANNOTATION:
• Organize the removed valve according to
the cylinders.
11. Exhaust valve Removal
1) Remove the exhaust valve from the cylinder
head assembly.
ANNOTATION:
• Organize the removed valve according to
the cylinders.

14. Valve seat insert Removal

1) Heat the valve seat insert with the gas burner.
Heating temperature ： 700.0 - 800.0 °C {
1292 - 1472 °F }
： 2 section(s) Inner surface of the insert
ANNOTATION:
• Cool the valve seat insert naturally after
heating.
Specified time： 5 min Natural cool
2) Remove the valve seat insert from the cylinder
head assembly using the driver.

12. Valve stem oil seal Removal CAUTION

1) Remove the valve stem oil seal from the valve • Be careful not to damage the cylin-
guide using the pliers. der head.

CAUTION 15. Injector sleeve Removal

• Do not reuse the valve stem oil seal. 1) Remove the injector sleeve from the cylinder
head assembly using the special tool.
84402826 - May 2011
2415-16
 Removal and Installation of Cylinder Head

1) Install the nut to the bridge guide.

ANNOTATION:
• Electrically weld the nut to the top of the
bridge guide.
2) Remove the bridge guide from the cylinder
head assembly using the sliding hammer.

Special tool: nozzle sleeve remover (refer

to section 1003)
ANNOTATION:
• Tap the injector sleeve out from the bottom
surface of the cylinder head.

1 Nut

17. Oil seal Removal

1) Remove the oil seal from the cylinder head
assembly.
ANNOTATION:
• Attach a rod from the inner surface of the
cylinder head, and tap it to remove it to the
outer side.

1 Injector sleeve

CAUTION
• Be careful not to damage the bot-
tom surface of the cylinder head.
• Do not reuse the removed injector
sleeve.

16. Bridge guide Removal

84402826 - May 2011

2415-17
 Removal and Installation of Cylinder Head

Assembly of Cylinder Head 2. Bridge guide Installation

1. Oil seal Installation 1) Apply the engine oil to the bridge guide.
2) Install the bridge guide to the cylinder head
1) Install the oil seal to the cylinder head assem- assembly using the special tool.
bly.

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

CAUTION
• Be careful not to damage the lip
section of the oil seal.

Specified length： 122.0 to 123.0 mm {4.8031

to 4.8425 in} 1 in the diagram
Specified length： 37.5 mm {1.4764 in} 2 in
the diagram
3. Injector sleeve Installation
1) Install the O-ring to the injector sleeve.
2) Apply the engine oil to the O-ring.
3) Apply the cement to the injector sleeve.
ANNOTATION:
• Apply Loctite 620 to the tapered section of
the injector sleeve.

1 Cylinder head
2 Oil seal installer

84402826 - May 2011

2415-18
 Removal and Installation of Cylinder Head

4) Apply the engine oil to the cylinder head as- Special tool: nozzle sleeve setting tool
sembly. (refer to section 1003)
ANNOTATION:
• Apply engine oil to the injector sleeve con-
tact surface.

1 Punch bar
2 Ball
3 Guide sleeve
4 Injector sleeve
1 O-ring with white paint 5 Clamp
2 O-ring 6 Bolt
3 Loctite 620 application
4 Engine oil application
CAUTION
5) Install the injector sleeve to the cylinder head • Allow the cylinder head to float so
assembly using the special tool. that the ball comes out from the bot-
tom surface.

4. Valve seat insert Installation

1) Prepare the dolly block.
ANNOTATION:
• Prepare the one which has smaller outer
diameter than the valve seat insert.
2) Align the valve seat insert to the cylinder head.
3) Align the dolly block to the valve seat insert.

84402826 - May 2011

2415-19
 Removal and Installation of Cylinder Head

4) Install the valve seat insert to the cylinder Specified length： 17.0 - 17.9 mm {0.6693 -
head assembly using the press. 0.7047 in}

CAUTION
1 Dolly block • When replacing the valve guide, re-
2 Valve seat insert place it with the valve.
3 Press
6. Valve stem oil seal Installation
1) Install the valve spring seat to the cylinder
5. Valve guide Installation head assembly.
1) Apply the engine oil to the valve guide. 2) Apply the engine oil to the valve guide.
2) Install the valve guide to the cylinder head ANNOTATION:
assembly using the special tool.
• Apply engine oil to the outer circumference
of the valve guide.

CAUTION
• Use a new valve stem oil seal.

3) Install the valve stem oil seal to the valve

guide using the special tool.

Special tool: valve guide replacer (refer

to section 1003)
ANNOTATION:
• Tap the valve guides from the upper side of
the cylinder head.

Special tool: valve stem seal installer

(refer to section 1003)

84402826 - May 2011

2415-20
 List of special tools

Lower Roller Special Tool

CX250C

Co-
Order No. Jig name Remarks
de
1 Bushing removal jig
2 Bushing press-fit jig
3 Floating seal installation jig

84402826 - May 2011

1003-9
 List of special tools

Grease Cylinder Special Tool

CX250C

A Dust seal press-fit jig

B Removal jig

84402826 - May 2011

1003-10
 List of special tools

Center Joint Special Tool

CX250C
Axle removal jig

Removal jig (for O-ring and

1
V-ring)

1 Axle removal jig

M16 - M20 full threaded bolt
2
L = 370 - 420 mm
3 M16 - M20 female thread
Hexagon socket head bolt (5)
4
M8 x 25
Backing plate
Axle (1) outer diameter - about
5
5 mm
t = about 5 mm

Cover (7) installation dimen-

*1
sions

84402826 - May 2011

1003-11
 List of special tools

Swing Motor Special Tool

CX250C

Co-
Order No. Jig name Remarks
de
Tapered roller bearing/inner race
1
assembly jig
2 Oil seal assembly jig 1
3 Cylinder assembly jig
4 Brake piston assembly jig

84402826 - May 2011

1003-12
List of special tools

Co-
Order No. Jig name Remarks
de
5 Oil seal assembly jig 2
6 Pinion shaft assembly jig

84402826 - May 2011

1003-13
List of special tools

Co-
Order No. Jig name Remarks
de
7 Brake piston removal jig

84402826 - May 2011

1003-14
 List of special tools

Remote Control Valve Special Tool

CX250C

a Detailed diagram of jig main unit

b Joint installation state
c Detailed diagram of bushing

*1 SCM415N carburized *4 Hole *7 Bushing

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

Co-
Order No. Jig name Remarks
de
1 Joint disassembly jig
84402826 - May 2011
1003-15
 List of special tools

Center hole possible (D2 or

*1
less)

Co-
Order No. Jig name Remarks
de
2 Special jig 1 (for bushing removal)
3 Special jig 2 (for locking ring installation)

84402826 - May 2011

1003-16
 List of special tools

Gas Filling Special Tool

CX250C/CX350C/CX370C

Code Jig name Remarks

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

84402826 - May 2011

1003-17
 List of special tools

Hydraulic Circuit

Vacuum pump and power sup-

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

84402826 - May 2011

1003-18
 List of special tools

CASE SPECIAL TOOLS

Isuzu Engine Special Tools
4HK1X-6HK1X Tier 4 Isuzu Engine

Illustration Isuzu Reference CASE Tool Number Description

8-9439-6856-0 380001712 Oil seal setting tool kit

5-8840-2627-0 380001719 Oil seal Installer

5-8840-2623-0 380001720 Remover; Nozzle sleeve

5-8840-2624-0 380001721 Installer; Nozzle sleeve

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

5-8840-2360-0 380002574 Slinger puller

5-8840-2826-0 380002601 Fuel Injector Remover

5-8840-0019-0 380002602 Sliding Hammer

84402826 - May 2011

1003-19
 List of special tools

Illustration Isuzu Reference CASE Tool Number Description

5-8840-2222-0 380002604 Sealing cup Installer

5-8840-9061-0 380002611 Oil seal installer kit

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

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

5-8840-2815-0 380300015 Compression Gauge Adaptor

8–9439–6818–0 Common tool Crankshaft gear puller

84402826 - May 2011

1003-20
 List of special tools

Illustration Isuzu Reference CASE Tool Number Description

8–9439–6819–0 380002613 Crankshaft gear installer

5-8840–9018–0 380300022 Piston setting tool

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

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

5-8840-2621-0 Common Tool Remover; Valve spring

Digital multimeter with an input

Not Illustrated 5-8840-2691-0 Common Tool
impedance of 10MΩ

5-8840-2674-1 Not needed Scissors gear spring wrench

8-9439-6862-0 Not needed Pivot ASM

84402826 - May 2011

1003-21
 List of special tools

Attachment Special Tool (for Cylinder

Assembly)
Special Jigs Part Number List
• Select jigs for the cylinder head according to the rod diameter.
• Select jigs for the piston according to the cylinder bore.

CASE Tool
Description (applicable rod diameter in mm) Illustration
Number
KHV0511 Cylinder head assembly and disassembly jig (65)
KHV0512 Cylinder head assembly and disassembly jig (70)
KHV0513 Cylinder head assembly and disassembly jig (75)
KHV0514 Cylinder head assembly and disassembly jig (80)
KHV0515 Cylinder head assembly and disassembly jig (85)
KHV0516 Cylinder head assembly and disassembly jig (90)
KHV0517 Cylinder head assembly and disassembly jig (95)
KHV0518 Cylinder head assembly and disassembly jig (100)
KHV0519 Cylinder head assembly and disassembly jig (105)
KHV0520 Cylinder head assembly and disassembly jig (110)
KHV0521 Cylinder head assembly and disassembly jig (115)
KHV0522 Cylinder head assembly and disassembly jig (120)

CASE Tool
Description (applicable cylinder bore diameter in mm) Illustration
Number
KHV0526 Seal ring insertion and calibration jig (100)
KHV0527 Seal ring insertion and calibration jig (105)
KHV0528 Seal ring insertion and calibration jig (110)
KHV0529 Seal ring insertion and calibration jig (115)
KHV0530 Seal ring insertion and calibration jig (120)
KHV0531 Seal ring insertion and calibration jig (125)
KHV0532 Seal ring insertion and calibration jig (130)
KHV0533 Seal ring insertion and calibration jig (135)
KHV0534 Seal ring insertion and calibration jig (140)
KHV0535 Seal ring insertion and calibration jig (145)
KHV0536 Seal ring insertion and calibration jig (150)
KHV0537 Seal ring insertion and calibration jig (160)
KHV0539 Seal ring insertion and calibration jig (170)

84402826 - May 2011

1003-22
 List of special tools

CNH-EST DIAGNOSTIC TOOL (SCAN

TOOL)
The EST (Electronic Service Tool) system allows diag-
noses on machines and engines by detecting the oper-
ating parameters of electronic control components (con-
trol units, sensors etc.). It is also capable of reading fault
codes.
To use this tool, please refer to the book provided during
the CXC series training sessions.
Y-Cable 380060269 is required to connect the EST to the
controllers.

84402826 - May 2011

1003-23
List of special tools

84402826 - May 2011

1003-24
 Section

1004

FLUIDS AND LUBRICANTS

84402826 - May 2011

84402826 - May 2011
 CONTENTS

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

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

1004-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
1004-2 PRINTED IN FRANCE
 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.

84402826 - May 2011

1004-3
 FLUIDS AND LUBRICANTS
FUEL
The fuel must conform to Interim Tier 4/Stage 3B Ex-
haust Gas Control Regulations.
Use grade number 2-D (S15) fuel.
Using other types of fuel may lead to stalled engine out-
put or deterioration in fuel economy.
During cold weather (lower than -7℃), it is temporarily
acceptable to use a mixture of No. 1-D (S15) and No.
2-D (S15).
Consult the fuel supplier or the CASE dealer.
If the temperature drops below the fuel cloud point, out-
put deficiency or engine start problems may occur due
to wax crystals.
Conditions applicable to diesel fuel
The diesel fuel used must:
- be free from dust particles, even minute ones,
- have the proper viscosity,
- have a high cetane number,
- present great fluidity at low temperatures,
- have low sulphur content,
- have very little residual carbon.
RECOMMENDED CONDITIONS
THAT CAN BE APPLIED TO
DIESEL FUEL
- JIS (Japanese Industrial Standards): No. 2
- DIN (Deutsche Industrie Normen): DIN 51601
- SAE-J-313C: SAE (Society of Automotive Engineers)
based on No. 2-D (S15)
- BS (British Standards) based on BS/2869-1970: Class
A-1
- EN 590 (less than 10 ppm sulfur)
- Or fuel specified by the country using these standards
and this machine
84402826 - May 2011
1004-4
IMPORTANT:
EPA regulation ultra low sulfur fuel only.
IMPORTANT:
If a serious problem occurs when other fuels are used,
the warranty is invalidated.
Using a non-recommended fuel may lead to damage of
the fuel injection pump, injector, DPD, and other fuel
supply systems or to the engine.
CASE assumes no responsibility for these damages.
Note that the warranty will not be applied for these dam-
ages.
It is recommended that the following safety information
be considered in order to prevent damage to the engine
fuel supply system.
- Some fuel suppliers mix old engine oil and diesel fuel.
Makers of larger engine permit the use of this kind of
fuel.
However, do not use diesel fuel contaminated with en-
gine oil in customer's engines.
Not only will this fuel damage the engine, it may also
have a negative impact on the exhaust gas purification
function.
Before using diesel fuel, confirm with the supplier
whether the fuel complies with the above specifications.
IMPORTANT:
Consult the supplier or the CASE dealer regarding ap-
propriate use of fuel additives.
Do not use fuel oil or gasoline as these may damage the
engine.
IMPORTANT:
In order to prevent condensation during cold weather, fill
the fuel tank to full after the completing the day's work.
 Section

1005

Conversion Table

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Metric to U.S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
U.S to Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

1005-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
1005-2 PRINTED IN FRANCE
 Conversion Table

Metric to U.S
MULTIPLY BY TO OBTAIN
square meter 10.763 91 square foot
AREA:
hectare 2.471 05 acre
newton 3.596 942 ounce force
FORCE:
newton 2.224 809 pound force
millimeter 0.039 370 inch
LENGTH: meter 3.280 840 foot
kilometer 0.621 371 mile
MASS: kilogram 2.204 622 pound
MASS/AREA: kilogram/hectare 0.000 466 ton/acre
MASS/ENERGY: gr/kW/hr. 0.001 644 lbs/hp/hr.
MASS/VOLUME: kg/cubic meter 1.685 555 lb/cubic yd.
POWER: kilowatt 1.341 02 horsepower
kilopascal 0.145 038 lb/sq. inch
PRESSURE: bar 14.50385 lb/sq. inch
megapascal (MPA) 145.0385 psi
TEMPERATURE: degree C 1.8 x C +32 degree F
newton meter 8.850 748 lb/inch
TORQUE:
newton meter 0.737 562 lb/foot
VELOCITY: kilometer/hr 0.621 371 miles/hr.
cubic centimeter 0.061 024 cubic inch
cubic meter 35.314 66 cubic foot
cubic meter 1.307 950 cubic yd.
milliliter 0.033 814 ounce (US fluid)
VOLUME: quart (US liquid)
litre 1.056 814
litre 0.879 877 quart (Imperial)
litre 0.264 172 gallon (US liquid)
litre 0.219 969 gallon (Imperial)
litre/min. 0.264 172 gallon/min. (US liquid)
VOLUME/TIME:
litre/min 0.219 969 gallon/min. (Imperial)

84402826 - May 2011

1005-3
 Conversion Table

U.S to Metric
MULTIPLY BY TO OBTAIN
square foot 0.092 903 square meter
AREA:
acre 0.404 686 hectare
ounce force 0.278 014 newton
FORCE:
pound force 4.448 222 newton
inch 25.4 millimeter
LENGTH: foot 0.304 8 meter
mile 1.609 344 kilometer
pound 0.453 592 kilogram
MASS: gram
ounce 28.35
MASS/AREA: ton/acre 2241 702 kilogram/hectare
MASS/ENERGY: lbs/hp/hr. 608.277 4 gr/kW/hr.
MASS/VOLUME: lb/cubic yd. 0.593 276 kg/cubic meter
POWER: horsepower 0.745 700 kilowatt
lb/sq. inch 6.894 757 kilopascal
PRESSURE: lb/sq. inch 0.069 bar
psi lb/sq. inch 0.070 303 kg/sq. cm
psi 0.006 895 megapascal (Mpa)
TEMPERATURE: degree F 1.8 F - 32 degree C
lb/inch 0.112 985 newton meter
TORQUE:
lb/foot 1.355 818 newton meter
VELOCITY: miles/hr. 1.609 344 kilometer/hr
cubic inch 16.387 06 cubic centimeter
cubic foot 0.028 317 cubic meter
cubic yd. 0.764.555 cubic meter
ounce (US fluid) 29.573 53 milliliter
VOLUME: quart (US liquid) 0.946 353 litre
quart (Imperial) 1.136 523 litre
gallon (US) 3.785 412 litre
gallon (Imperial) 4.546 092 litre
VOLUME/TIME: gallon/min. 3.785 412 litre/min.

84402826 - May 2011

1005-4
Section

1900

Abbreviations

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

1900-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
1900-2 PRINTED IN FRANCE
 Abbreviations

Abbreviations
Abbreviation description
AC air conditioner
A/D analog/digital
ABDC after bottom dead center
AC alternating current
ACC accessory
ACG alternating current generator
ACT actuator
API american petroleum industry
ASM assembly
ATDC after top dead center
ATF automatic transmission fluid
drilled head B drilled head bolt
eye B eye bolt
full threaded B full threaded bolt
hexagon socket head B hexagon socket head bolt
high-strength B high-strength bolt
reamer B reamer bolt
B+ battery + terminal
BAT battery
BBDC before bottom dead center
BKT bracket
BRG bearing
BTDC before the top dead center
C/B circuit breaker
C/U control unit
CAL calibration
CAN a control unit communication method (control area network)
CFG config
CHK check
CKP crankshaft position
CMP camshaft position
CO carbon monoxide
CPU central processing unit
DC direct current
DI direct injection type
DIAG diagnosis
DLC data link connector
DMM digital multi–meter
DPD diesel particulate diffuser
DTC self-diagnosis code
ECM engine control module
ECT engine coolant temperature
ECU electronic control unit
EEPROM electrically erasable/programmable ROM
EGR exhaust gas recirculation
EMI electromagnetic interference
EMPS engine module programing system
ENG engine
EPF engine protection feature
EVRV electric vacuum regulating valve
EXH exhaust
F/B feedback
F/C fuel cut
F/L fusible link
FLW fusible link wire
FRT front
84402826 - May 2011
1900-3
 Abbreviations

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

84402826 - May 2011

1900-4
 Abbreviations

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

84402826 - May 2011

1900-5
Abbreviations

84402826 - May 2011

1900-6
 Section

2000

Removal and Installation of Engine Assembly

84402826 - May 2011

84402826 - May 2011
 CONTENTS

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

Installation of Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

2000-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
2000-2 PRINTED IN FRANCE
 Removal and Installation of Engine Assembly

WARNING Removal of Engine Assembly

• Keep away from fire.
• Be sure to release hydraulic pressure before
beginning work.
• The air conditioner circuit is filled with high-
pressure gas, so beware of the gas released
when loosening lines.
• Do not use open flames and do not allow
sparks near the battery.
1. Remove the counterweight.(For details, see "Re-
moval and Installation of Counterweight".)
2. Remove the pump.(For details, see "Removal and
Installation of Hydraulic Pump".)
3. Use a wrench （14 mm） to remove the bolts (1)
and (2), and then remove the fan shroud (3).

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.

Items to prepare
• Wrenches (7 mm, 8 mm, 10 mm, 12 mm, 13 mm, 14
mm, 17 mm, 36 mm)
• Box wrench (24 mm)
• Shackle (with the required lifting capacity) x 2
• Wire rope (with the required breaking load)
• Crane (with the required lifting capacity)
• Marking pen
• Caps
• Plugs
• Waste oil can
• Rag
• Cleaning fluid
• Wood plank

4. Use a wrench to remove the bolts (1), and then re-

move the fan guard (2).

84402826 - May 2011

2000-3
 Removal and Installation of Engine Assembly

5. Use a wrench (7 mm) to loosen the hose band (1) 8. Use a wrench (8 mm) to loosen the hose band (1)
on the radiator, and then remove the upper hose (2). on the inter cooler, and then remove the hose (2).
• Use caps to cover the line and hose to prevent the
entry of water, dust or dirt.

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

on the radiator, and then remove the lower hose (2).
• Use caps to cover the radiator and hoses to pre- 9. Remove the hose bands (1) in the 3 locations.
vent the entry of water, dust or dirt.
• Before removing the radiator hoses, completely
drain the coolant.

10. Prepare a waste oil can (1).

• Drain the engine oil before removing the engine
7. Use a wrench (12 mm) to loosen the line bolts (1) in oil hose.
2 locations, and then remove the 2 lines (2) and (3)
from the compressor.
• Always remove the low-pressure (suction side)
line (2) first.
• Attach caps or plugs to the compressor and lines
to prevent any entry of water, dust or dirt.

11. Use a wrench (36 mm) to remove the 2 engine oil

remote hoses (1).
• Mark the engine and hoses so that the connectors
match at the time of assembly.
• Attach caps or plugs to the engine and hoses to
prevent any entry of water, dust or dirt.
• Clean the engine and hoses by spraying them
with a parts cleaner to prevent scratches and pre-
3 Line (discharge side) vent dirt from accumulating on the connectors.

84402826 - May 2011

2000-4
 Removal and Installation of Engine Assembly

14. Use a wrench (14 mm) to remove the 1 nut (1), and
then remove the wiring (2) from the starter motor.

12. Use a wrench (17 mm) to remove the bolt (1), and
then remove the negative-side battery cable (2).
• When removing the terminal and harness, secure
them so that they do not interfere with the frame.
Also, cover with a rubber cap to protect against
sparks.
15. Remove the hose band (1), and then remove the
fuel hose (2).
• Attach caps or plugs to the engine and hose to
prevent any entry of water, dust or dirt.

13. Use a wrench (8 mm) to remove the 1 nut (1), and 16. Remove the hose band (1), and then remove the
then remove the wiring (2) from the starter motor. fuel hose (2).
• Attach caps or plugs to the engine and hose to
prevent any entry of water, dust or dirt.

84402826 - May 2011

2000-5
 Removal and Installation of Engine Assembly

17. Use a wrench (13 mm) to remove the 2 bolts (1), 20. Loosen the hose band (1), and then remove the
and then remove the connector bracket (2). heater hose (2).
• Attach caps or plugs to the engine and hose to
prevent any entry of water, dust or dirt.

18. Use a wrench (13 mm) to remove the hose band (1)
from the bracket, and then remove the connectors
(2).
21. Use a wrench (7 mm) to loosen the hose band (1),
• Wrap the removed connectors in plastic after tying and then remove the radiator hose (2).
them together.
• Use caps to cover the line and hose to prevent
any entry of water, dust or dirt.

19. Loosen the hose band (1), and then remove the
heater hose (2).
22. Use a wrench (7 mm) to loosen the hose band (1),
• Attach caps or plugs to the engine and hose to and then remove the air hose (2).
prevent any entry of water, dust or dirt.
• Use caps to cover the line and hose to prevent
any entry of water, dust or dirt.

84402826 - May 2011

2000-6
 Removal and Installation of Engine Assembly

23. Use a wrench (9.5 mm) to loosen the hose band (1), 26. Use a wrench (13 mm) to remove the bolt (1), and
and then remove the air hose (2). then remove the radiator hose clamp (2).
• Use caps to cover the line and hose to prevent
any entry of water, dust or dirt.

27. Install the 2 shackles (1), and then use the wire rope
(2) and crane to secure the engine.

24. Remove the connectors (1) from the alternator.

25. Use a wrench (10 mm) to remove the nut (1), and
then remove the wiring from the alternator (2).

84402826 - May 2011

2000-7
 Removal and Installation of Engine Assembly

28. Use a box wrench (24 mm) to remove the 4 bolts 29. Use the wire rope (1) and crane to lift the engine.
(1) from the mount. Thoroughly check that the location is safe before
lowering the engine on wood planks, etc.

84402826 - May 2011

2000-8
 Removal and Installation of Engine Assembly

Installation of Engine Assembly 2.
1. To install the engine, perform the reverse of the re- 3.
moval procedure.
After installing the engine, resupply coolant and en-
gine oil, perform fuel line air bleeding, and perform
filling for the air conditioner gas.
For details, see the individual explanations for each
procedure.
Run the engine at no-load idling and check for any
water or oil leaks.
Attach the hydraulic pump, covers, and counter-
weight.
For details, see the individual explanations for each
procedure.

84402826 - May 2011

2000-9
Removal and Installation of Engine Assembly

84402826 - May 2011

2000-10
 Section

2001

Removal and installation of the fuel cooler engine

inter-cooler radiator and oil cooler

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal and Installation of Fuel Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Removal of Fuel Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Fuel Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal and Installation of Engine Intercooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal of Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation of Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal and Installation of Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal of Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation of Radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal and Installation of Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removal of Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation of Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

2001-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
2001-2 PRINTED IN FRANCE
 Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
Removal and Installation of Fuel Removal of Fuel Cooler
Cooler 1. Mark the fuel cooler (5) and hoses (1) (2) so that the
connectors match at the time of assembly.
CAUTION
• Remove the fuel hose clamp (6).
• Be sure to stop the engine before beginning • Use pliers to loosen the hose bands (3) (4), and
work. then remove the hoses.
• As the fuel hose will be removed, strictly pro- • Fuel will spill out, so place a drip pan directly be-
hibit open flames. low the area.
• Install caps or plugs to the fuel cooler and hoses
Items to prepare to prevent any entry of water, dust or dirt.
• Tightening torque for bolt (1) installation: 25.0
• Wrenches (12 mm) N·m
• Screwdriver
• Pliers
• Marking pen
• Cap
• Plug
• Rag
• Cleaning fluid
• Drip pan

84402826 - May 2011

2001-3
 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),
and then remove the fuel cooler (2).
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
torque.
If the torque is not specified for a bolt or other part, see
the "Bolt Size and Torque Table".

84402826 - May 2011

2001-4
 Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
Removal and Installation of Engine Removal of Intercooler
Intercooler 1. Use a wrench (8 mm) or flathead screwdriver to
loosen the hose bands (1) in the 2 locations, and
CAUTION then remove the 2 hoses (2) (3).

• Be sure to stop the engine before beginning • Use caps to cover the intercooler and hoses to
work. prevent the entry of water, dust or dirt.
• As the fuel hose will be removed, strictly pro- Tightening torque for band (1) installation: 8.8 -
hibit open flames. 9.8 N·m

Items to prepare
• Wrenches (8 mm, 14 mm)
• Flathead screwdriver
• Cap
• Rag
• Cleaning fluid

2. Use a wrench (14 mm) to remove the 4 bolts (1),

and then remove the intercooler (2).
• Tightening torque for bolt (1) installation: 55.0
N·m

84402826 - May 2011

2001-5
 Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
Installation of Intercooler Removal and Installation of
To install, perform the reverse of the removal procedure. Radiator
Check for any air leaks.
When installing the bolts, tighten them to the specified WARNING
torque.
If the torque is not specified for a bolt or other part, see • Do not remove the radiator cap when the ra-
the "Bolt Size and Torque Table". 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.
• Do not stand or pass under the suspended
load.

Items to prepare
• Wrenches (7 mm, 8 mm, 13 mm, 14 mm, 19 mm)
• Box wrench (12 mm)
• Pliers
• Shackles (with the required lifting capacity) x 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.

84402826 - May 2011

2001-6
 Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
Removal of Radiator 4. Loosen the drain plug (1), and then drain the
coolant.
1. Use a wrench (19 mm) to remove the 3 bolts (1),
and then remove the under cover (2).

5. Use a wrench (13 mm) to remove the high-strength

bolt (1), plain washer (2), and seal retainer (3), and
2. Install the drain hose (1), and then prepare the drain then remove the cushion seal.
tank (2). Remove the 4 sems bolts (4), and then remove the
bracket.

3. To make it easier to drain the coolant, remove the

radiator cap (1). 6. Use a wrench (13 mm) to remove the 5 bolts (1),
and then remove the cover (2).

84402826 - May 2011

2001-7
 Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
7. Use a wrench (7 mm) to loosen the hose band (1), 9. Loosen the hose band (2), and then remove the
and then remove the upper hose (2) and lower hose hose (1) from the radiator cap.
(3) from the radiator.
• Install caps or plugs to the hoses to prevent any
• Use caps to cover the radiator and hoses to pre- entry of water, dust or dirt.
vent the entry of water, dust or dirt.
• Tightening torque for band (1) installation: 4.9 -
5.9 N·m

10. Use a wrench (14 mm) to remove the 3 bolts (1),

and then remove the brackets (2).

11. Use a wrench (14 mm) to remove the 2 bolts (1),

and then remove the fan guard (2).
8. Remove the drain plug (1), loosen the hose band
(2), and then remove the hose (3).

84402826 - May 2011

2001-8
 Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
12. Use a wrench (14 mm) to remove the 3 bolts (1), 15. Remove the 2 one-touch clips (1), and then remove
and then remove the brackets (2). the front anti-insect net (2).

13. Use a wrench (14 mm) to remove the 3 bolts (1), 16. Use a wrench (17 mm) to remove the 4 bolts (1),
and then remove the brackets (2). the 8 washers (2) and the 4 rubber cushions (3).

14. Use a box wrench (12 mm) to remove the 8 bolts

(2) from the fan shroud (1), and then move the fan
shroud (1) towards the engine.

84402826 - May 2011

2001-9
 Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
17. Install the 2 shackles (1) to the top of the radiator,
and then use the wire rope (2) and liftcrane to lift the
radiator.
Installation of Radiator
To install, perform the reverse of the removal procedure.
Tighten bolts being installed to the specified torque.
If the torque is not specified, see the "Bolt Size and
Torque Table".
Coolant capacity is 30.2 L.
Finally, check that the level of coolant is correct.

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

19. Thoroughly check that the location is safe before

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

84402826 - May 2011

2001-10
 Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
Removal and Installation of Oil Removal of Oil Cooler
Cooler • Drain the hydraulic oil from the hydraulic oil tank.
See "Draining Oil from Hydraulic Oil Tank" for details
WARNING of the procedure.

• Keep away from fire. 1. Use a wrench (19 mm) to remove the 3 bolts (1),
and then remove the under cover (2).
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.

Items to prepare
• Wrenches (13 mm, 17 mm, 19 mm)
• Hexagon wrench (10 mm)
• Pliers
• Screwdriver
• Eyebolts (M12 x 2) 2. Prepare the waste oil can (1).
• Shackles (with the required lifting capacity) x 2
• Wire rope (with the required breaking load)
• Liftcrane (with the required lifting capacity)
• Cap
• Waste oil can
• Rag
• Cleaning fluid
• Wood planks, etc.

3. Use a wrench (13 mm) to remove the 5 bolts (1),

and then remove the cover (2).

84402826 - May 2011

2001-11
 Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
4. Remove the 2 one-touch clips (1), and then remove 6. Use a wrench (14 mm) to remove the 3 bolts (1),
the anti-insect net (2). and then remove the brackets (2).

5. Use a hexagon wrench (10 mm) to remove the 2 7. Use a wrench (14 mm) to remove the 2 bolts (1),
upper hexagon socket head bolts (1) and 2 lower and then remove the fan guard (2).
bolts (1), and then use a wrench (8 mm) to loosen
the hose bands (2) and remove the lines (3) (4).
• Use caps to cover the oil cooler and lines to pre-
vent the entry of water, dust or dirt.

8. Use a wrench (14 mm) to remove the 3 bolts (1),

and then remove the brackets (2).

84402826 - May 2011

2001-12
 Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
9. Use a wrench (14 mm) to remove the 3 bolts (1), 11. Use a wrench (17 mm) to remove the 4 bolts (1).
and then remove the brackets (2).

10. Use a box wrench (12 mm) to remove the 8 bolts

(2) from the fan shroud (1), and then move the fan
shroud (1) towards the engine.

12. Install the 2 eyebolts (M12) (1) on the top of the oil
cooler.
• Fully tighten the eyebolts, and then loosen them
by a half turn.

84402826 - May 2011

2001-13
 Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
13. Install the 2 shackles (1) to the eyebolts, and then Installation of Oil Cooler
use the wire rope (2) and liftcrane to lift the oil cooler
main unit. 1. Use a liftcrane to lift the oil cooler (1) main unit.

14. Thoroughly check that the location is safe before

lowering the oil cooler on wood planks, etc.

84402826 - May 2011

2001-14
 Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
2. Mount the oil cooler (1), and then remove the shack- 3. Use a wrench (17 mm) to secure the oil cooler (1)
les (2), wire ropes (3), and eyebolts (4). with the 4 bolts (2).
• Bolt (2) tightening torque: 88.0 N·m

4. Use a box wrench (12 mm) to install the 8 bolts (2)

and install the fan shroud (1).
• Bolt (2) tightening torque: 25.0 N·m

84402826 - May 2011

2001-15
 Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
5. Use a wrench (14 mm) to install the 3 bolts (1) and 7. Use a wrench (14 mm) to install the 2 bolts (1) and
install the bracket (2). install the fan guard (2).

6. Use a wrench (14 mm) to install the 3 bolts (1) and 8. Use a wrench (14 mm) to install the 3 bolts (1) and
install the bracket (2). install the bracket (2).

84402826 - May 2011

2001-16
 Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
9. Set the O-rings (2) on the oil cooler (1) side and 10. Use a wrench (8 mm) to install the hose bands (1)
install the lines (3) (4) with 2 hexagon socket head and install the hoses (2).
bolts (5) each.
• The O-rings cannot be reused.Replace them with
new parts.

11. Install the anti-insect net (1) with the 2 one-touch

clips (2).

84402826 - May 2011

2001-17
 Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
12. Use a wrench (13 mm) to install the cover (1) with 13. Use a wrench (19 mm) to install the under cover (1)
the 5 bolts (2). with the 3 bolts (2).

Tighten bolts being installed to the specified torque.

If the torque is not specified, see the "Bolt Size and
Torque Table".

84402826 - May 2011

2001-18
 Section

2004

Removal and Installation of Turbo Charger

84402826 - May 2011

84402826 - May 2011
 CONTENTS

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

Turbocharger assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

2004-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
2004-2 PRINTED IN FRANCE
 Removal and Installation of Turbo Charger

WARNING Turbocharger assembly Removal

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

Items to prepare • After the coolant is discharged, make

sure to tighten the drain plug.
• Wrenches (8 mm, 10 mm, 13 mm, 14 mm, 17 mm)
• Cap 3. Turbocharger assembly Removal
• Plug
• Rag 1) Remove the air cleaner duct from the air
• Cleaning fluid cleaner assembly and the turbocharger as-
sembly.
2) Remove the air intake hose from the tur-
bocharger assembly and the intercooler.
3) Remove the exhaust pipe from the tur-
bocharger assembly.
4) Disengage the oil feed pipe from the tur-
bocharger assembly.
ANNOTATION:
• Remove the clip.

84402826 - May 2011

2004-3
 Removal and Installation of Turbo Charger

5) Disengage the oil return pipe from the tur- 7) Disengage the water feed pipe from the tur-
bocharger assembly. bocharger assembly.
ANNOTATION:
• Remove the clip.

1 Turbocharger assembly
2 Oil feed pipe
3 Oil return pipe

6) Disengage the water return pipe from the tur- 1 Water return pipe
bocharger assembly. 2 Water feed pipe

8) Remove the exhaust manifold stay from the

cylinder block and the turbocharger assembly.

1 Turbocharger assembly
2 Exhaust manifold
3 Exhaust manifold stay
84402826 - May 2011
2004-4
 Removal and Installation of Turbo Charger

9) Disengage the harness connector from the Turbocharger assembly

turbocharger assembly.
10) Remove the turbocharger assembly from the Installation
exhaust manifold.
1. Turbocharger assembly Installation
1) Temporarily tighten the turbocharger assem-
bly to the exhaust manifold.

1 Exhaust manifold
2 Turbocharger assembly

1 Exhaust manifold
2 Turbocharger assembly

2) Temporarily tighten the exhaust manifold stay

to the cylinder block and the turbocharger as-
sembly.

1 Turbocharger assembly
2 Exhaust manifold
3 Exhaust manifold stay

3) Securely tighten the turbocharger assembly to

the exhaust manifold.
Tightening torque： 52 N・m { 5.3 kgf・m /
38 lb・ft }

84402826 - May 2011

2004-5
 Removal and Installation of Turbo Charger

4) Securely tighten the exhaust manifold stay to 6) Connect the water return pipe to the tur-
the cylinder block and the turbocharger as- bocharger assembly.
sembly.
Tightening torque： 52 N・m { 5.3 kgf・m /
38 lb・ft } Nut
Tightening torque： 50 N・m { 5.1 kgf・m /
37 lb・ft } Bolt
ANNOTATION:
• Tightening order

5) Connect the water feed pipe to the tur-

bocharger assembly.

CAUTION
• Use new gaskets.

Tightening torque： 35 N・m { 3.5 kgf・m /

25 lb・ft } Eyebolt
Tightening torque： 14 N・m { 1.4 kgf・m /
1 Water return pipe
119 lb・in } Clip
2 Water feed pipe

Tightening torque： 35 N・m { 3.5 kgf・m /

25 lb・ft } Eyebolt
7) Connect the oil return pipe to the turbocharger
assembly.

CAUTION
• Use new gaskets.

Tightening torque： 9 N・m { 0.9 kgf・m / 78

lb・in }

84402826 - May 2011

2004-6
 Removal and Installation of Turbo Charger

8) Connect the oil feed pipe to the turbocharger 10) Install the air intake hose to the turbocharger
assembly. assembly and the intercooler.
11) Install the air cleaner duct to the air cleaner
CAUTION assembly and the turbocharger assembly.
12) Connect the harness connector to the tur-
・ Use new gaskets. bocharger assembly.
Tightening torque： 17 N・m { 1.7 kgf・m / 2. Coolant Filling
12 lb・ft } Eyebolt 1) Loosen the valve using a wrench.
Tightening torque： 24 N・m { 2.4 kgf・m / 2) Replenish the coolant with the radiator.
17 lb・ft } Clip
CAUTION
• Be careful not to let coolant over-
flow splash on the exhaust system
parts.
• Coolant overflow should be wiped
off.

3) Tighten the valve using a wrench.

CAUTION
• Use new gaskets.

Tightening torque： 28 N・m { 2.8 kgf・m /

20 lb・ft }
4) Replenish the coolant with the radiator.

1 Turbocharger assembly 1 Valve

2 Oil feed pipe 2 Gasket
3 Oil return pipe
3. Battery ground cable Connect
9) Install the exhaust pipe to the turbocharger 1) Connect the battery ground cable to the bat-
assembly. tery.

84402826 - May 2011

2004-7
Removal and Installation of Turbo Charger

84402826 - May 2011

2004-8
 Section

2005

Removal and Installation of EGR Valve

84402826 - May 2011

84402826 - May 2011
 CONTENTS

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

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

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

2005-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
2005-2 PRINTED IN FRANCE
 Removal and Installation of EGR Valve

EGR valve Removal 3) Remove the EGR pipe A from the EGR cooler
A and exhaust manifold.
1. Battery ground cable Disconnect
1) Disengage the battery ground cable from the
battery.
2. Coolant Drain
1) Drain the coolant from the radiator.

CAUTION
• After the coolant is discharged,
make sure to tighten the drain plug.

3. EGR cooler assembly Removal

1) Disengage the water rubber hose from the
EGR cooler assembly.

1 EGR cooler A
2 EGR pipe A
3 Exhaust manifold

4) Remove the EGR cooler A from the EGR pipe

B.
5) Remove the EGR pipe B from the EGR cooler
B.
6) Remove the EGR cooler B from the EGR pipe
C.
7) Remove the EGR pipe C from the EGR valve.

1 Water rubber hose

2) Remove the EGR heat protector from the

EGR pipe A.

1 EGR valve
2 EGR pipe C
3 EGR cooler B
4 EGR pipe B
5 EGR cooler A
1 EGR heat protector 6 EGR pipe D

84402826 - May 2011

2005-3
 Removal and Installation of EGR Valve

4. EGR valve Removal EGR valve Installation

1) Disengage the harness connector from the 1. EGR valve Installation
EGR valv.e
2) Remove the EGR valve from the EGR pipe D. 1) Install the EGR valve to the EGR pipe D.
Tightening torque： 24 N・m { 2.4 kgf・m /
17 lb・ft }

1 EGR cooler C
2 EGR pipe C
3 EGR valve 1 EGR cooler C
4 EGR pipe D 2 EGR pipe C
3 EGR valve
4 EGR pipe D

CAUTION
• Use new gaskets.

2) Connect the harness connector to the EGR

valve.
2. EGR cooler assembly Installation
1) Temporarily tighten the EGR pipe C to the
EGR valve.
2) Temporarily tighten the EGR cooler B to the
EGR pipe C.
3) Temporarily tighten the EGR pipe B to the
EGR cooler B.

84402826 - May 2011

2005-4
 Removal and Installation of EGR Valve

4) Temporarily tighten the EGR cooler A to the

EGR pipe B.

1 EGR valve
2 EGR pipe C
3 EGR cooler B
4 EGR pipe B
5 EGR cooler A
6 EGR pipe B

5) Temporarily tighten the EGR pipe A to the

EGR cooler A and the exhaust manifold.

6) Securely tighten the EGR pipe C to the EGR

valve.
Tightening torque： 24 N・m { 2.4 kgf・m /
17 lb・ft } No.1 in the diagram
7) Completely tighten the EGR pipe C to the en-
gine hanger bracket.
Tightening torque： 48 N・m { 4.9 kgf・m /
35 lb・ft } No.2 in the diagram
8) Securely tighten the EGR pipe B to the
bracket.
Tightening torque： 48 N・m { 4.9 kgf・m /
35 lb・ft } No.3 in the diagram
9) Securely tighten the EGR cooler B to the EGR
1 EGR cooler A pipe C.
2 EGR pipe A Tightening torque： 24 N・m { 2.4 kgf・m /
3 Exhaust manifold 17 lb・ft } No.4 in the diagram
10) Securely tighten the EGR pipe B to the EGR
ANNOTATION: cooler B.
Tightening torque： 24 N・m { 2.4 kgf・m /
• Complete tightening order of the EGR 17 lb・ft } No.5 in the diagram
cooler assembly 11) Securely tighten the EGR cooler A to the EGR
pipe B.
Tightening torque： 24 N・m { 2.4 kgf・m /
17 lb・ft } No.6 in the diagram
12) Securely tighten the EGR pipe A to the ex-
haust manifold.
Tightening torque： 28 N・m { 2.9 kgf・m /
21 lb・ft } No.7 in the diagram
13) Securely tighten the EGR pipe A to the EGR
cooler A.
Tightening torque： 28 N・m { 2.9 kgf・m /
21 lb・ft } No.8 in the diagram

84402826 - May 2011

2005-5
 Removal and Installation of EGR Valve

14) Install the EGR heat protector to the EGR pipe 1) Loosen the valve using a wrench.
A. 2) 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.

3) Tighten the valve using a wrench.

CAUTION
• Use new gaskets

Tightening torque： 28 N・m { 2.8 kgf・m /

20 lb・ft }
1 EGR heat protector 4) Replenish the coolant with the radiator.

15) Connect the water rubber hose to the EGR

cooler assembly.

1 Valve
2 Gasket

1 Water rubber hose 4. Battery ground cable Connect

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

84402826 - May 2011

2005-6
 Section

2006

Removal and Installation of Engine Hood

84402826 - May 2011

84402826 - May 2011
 CONTENTS

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

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

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

2006-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
2006-2 PRINTED IN FRANCE
 Removal and Installation of Engine Hood

CAUTION Removal of Engine Hood

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

Items to prepare
• Wrench (13 mm, 17 mm, 19 mm)
• Nylon sling (with the required breaking load)
• Liftcrane (with the required lifting capacity)

84402826 - May 2011

2006-3
 Removal and Installation of Engine Hood

2. Use the liftcrane and lift up the engine hood (2) until 4. Wrap the nylon sling (2) around the engine hood (1),
the damper (1) is completely extended and there is and then use the liftcrane to lift the engine hood (1).
no force on it.
Loosen the ring (3) of the damper’s head section,
and then remove the gas damper (1).

Installation of Engine Hood

3. After closing the engine hood (1), use a wrench (19
mm) to remove the 6 bolts (2) from the engine hood.
To install, perform the reverse of the removal procedure.
Tighten bolts being installed to the specified torque.
For bolts for which the torque is not specified, check
of the "About This Shop Manual Section • Tightening
Torque • Retightening Torque Table" in the explanation
in the materials.

84402826 - May 2011

2006-4
 Section

2007

Removal and Installation of Muffler

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

2007-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
2007-2 PRINTED IN FRANCE
 Removal and Installation of Muffler

WARNING Removal of Muffler

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

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

Items to prepare
• Wrench (10 mm)
• Wrench (13 mm)
• Wrench (14 mm)
• Cap
• Rag
• Cleaning fluid 2. Remove the connectors (1).

3. Use a wrench (10 mm) to loosen the bolt (1), and

then remove the cord clamp.

84402826 - May 2011

2007-3
 Removal and Installation of Muffler

4. Use a wrench (19 mm) to loosen the 4 bolts (1), and Installation of Muffler
then remove the muffler.
1. When installing the bolts, tighten them to the spec-
ified torque.
When the tightening torque is not specified for a bolt
or other part, see "Materials Explanation - Tighten-
ing Torque - Torque Table (one page)".
2. Place the DPD muffler (1) in the bracket, and install
the gasket (2), bolt (3), nut (4), and washers (5) on
the flanges. Move the DPD muffler over until the
DPD muffler flange touches the exhaust pipe (6)
flange surface, and then use a wrench (13 mm) to
temporarily tighten the flanges together.

CAUTION
• Use caution when handling the DPD muf-
fler (1), DPD pressure sensor (7), and
DPD thermo-sensors (8) (9) and do not
subject them to any impacts etc.
• Do not reuse these parts if they are
dropped or fall.

3. Use a wrench (19 mm) to tighten the 4 bolts (1) to

secure the muffler.

84402826 - May 2011

2007-4
 Removal and Installation of Muffler

4. Use a wrench (13 mm) to fully tighten the bolt (1), 6. Install the connectors (1).
nut (2), and washers (3) temporarily tightened in
Step 2.

7. After installation, run the engine at no-load idling

and check for any abnormalities.
5. Use a wrench (10 mm) to tighten the bolt (1) to in-
stall the cord clamp.

84402826 - May 2011

2007-5
Removal and Installation of Muffler

84402826 - May 2011

2007-6
 Section

2401

Primary specifications

84402826 - May 2011

84402826 - May 2011
 CONTENTS

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

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

2401-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
2401-2 PRINTED IN FRANCE
 Primary specifications

Primary specifications
1. Primary specifications
Engine main specifications

Item Engine model 4HK1X

Type Diesel/ 4-cycle /water cooling, inline 4 cylinder OHC
Shape of combustion chamber Direct injection type
Cylinder liner type Dry type
Cylinder bore x stroke 115 mm {4.53 in} x 125 mm {4.92 in}
Displacement 5.193 L ｛316.88 cu・in｝
Compression ratio 17.5
Compression pressure ： 3.23 MPa { 32.9 kgf/cm2 / 468 psi }
Idling rotation speed 800 r/min
Intake ： 0.4 mm { 0.016 in } While cool
valve clearance
Exhaust ： 0.4 mm { 0.016 in } While cool
Ignition method Compression ignition
Injection order 1,3,4,2
Lubricant system
Lubricating type Pressure type
Oil pump type Gear type
Lubrication oil amount ： 20 - 27 L { 5.2 - 7.1 US gal }
Oil filter type Full-flow / partial-flow united filter (cartridge type)
Oil cooling type Built-in type, water cooled
Cooling system
Cooling type Water cooling
Radiator type Corrugated fin (pressure type)
Water pump type Centrifugal, belt type
Thermostat type 2 wax type unit
： 82.0 °C { 180 °F } Without jiggle valve
Open valve temperature of the thermostat valve
： 85.0°C { 185 °F } With jiggle valve
Coolant container ： 14.5 L { 3.8 US gal }
fuel system
Injection nozzle type Electronic control common rail type
Governor type Electronic type
Timer type Electronic type
Multi-hole type
Injection nozzle type
7 holes, inner diameter D0.14 mm {0.0055 in}
Charging system
Generator type AC type
Output 24 V/50 A
Regulator type IC
Starting system
Starter type Reduction type
Output 24 V/5.0 kW
Preheat system type glow plug
Glow plug standard voltage/current 23 V/3.5 A

84402826 - May 2011

2401-3
 Primary specifications

Cleaning system main specifications

Item Specifications
water pump Centrifugal impeller method
Pulley ratio 0.950
thermostat Wax pellet type
： 85.0 °C { 185 °F } With jiggle valve
Open valve temperatur
： 82.0 °C { 180 °F } Without jiggle valve
： 100.0 °C { 212 °F } With jiggle valve
Full-open temperature
： 95.0 °C { 203 °F } Without jiggle valve

Electrical system main specifications

generator
Item Specifications
Isuzu parts number 8980921161
Nominal output 24 V/50 A
Rated rotation count 5,000 r/min
Regulator type IC type
Regulated voltage 27.5 V - 29.5　V
weight ： 9.5 kg { 20.9 lb }

starter
Type (Manufacturer) Nikko
voltage 24V
Rating Output 5 KW
Time 30 sec
Number of pinion teeth 13
Rotational direction (facing the pinion) Right
Weight (Approx.) ： 8.0 kg { 17.6 lb }
Current/voltage 85 A or less/24 V
No-load characteristics
Revolution speed 3,300 r/min or more
Current/voltage 400 A/18.5 V
Load characteristics Torque 28.4 N・m {2.9kgf・m} or more
Revolution speed 1,250 r/min or more
Current/voltage 1,400 A or less/9 V
Locking characteristics
Torque 88.2 N・m {9.0kgf・m} or more

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

84402826 - May 2011

2401-4
 Section

2415

Removal and Installation of Cylinder Head

84402826 - May 2011

84402826 - May 2011
 CONTENTS

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

Installation of Cylinder Head Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal and Installation of Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal of Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly of Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assembly of Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installation of Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

2415-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
2415-2 PRINTED IN FRANCE
 Removal and Installation of Cylinder Head

Cylinder head cover Removal Installation of Cylinder Head Cover

1. Cylinder head cover Removal 1. Cylinder head cover Installation
1) Disengage the oil level gauge guide tube from 1) Align the head cover gasket to the cylinder
the cylinder head cover. head cover.
2) Disengage the ventilation hose from the air 2) Install the cylinder head cover to the lower
breather. cover.
Tightening torque： 18 N・m { 1.8 kgf・m /
13 lb・ft }
ANNOTATION:
• Referring to the tightening order in the dia-
gram, temporarily tighten all bolts and then
completely tighten them.

1 Ventilation hose
2 Oil level gauge guide tube

3) Remove the cylinder head cover from the

lower cover.
4) Remove the head cover gasket from the cylin-
der head cover.

1 Cylinder head cover

2 Gasket
1 Cylinder head cover 3 Lower cover
2 Gasket
3) Connect the ventilation hose to the air
3 Lower cover breather.

84402826 - May 2011

2415-3
 Removal and Installation of Cylinder Head

4) Connect the oil level gauge guide tube to the Removal and Installation of
cylinder head cover.
Tightening torque： 19 N・m { 1.9 kgf・m / Cylinder Head
14 lb・ft }
Removal of Cylinder Head
1. Battery ground cable Disconnect
1) Disengage the battery ground cable from the
battery.
2. Coolant Drain
1) Drain the coolant from the radiator.

CAUTION
• After the coolant is discharged,
make sure to tighten the drain plug.

3. Engine harness Disconnect

1) Disengage the engine harness from the en-
1 Ventilation hose gine assembly.
2 Oil level gauge guide tube
ANNOTATION:
• Disconnect each connector.
4. Turbocharger assembly Removal
1) Remove the air cleaner duct from the air
cleaner assembly and the turbocharger as-
sembly.
2) Remove the air intake hose from the tur-
bocharger assembly and the intercooler.
3) Remove the exhaust pipe from the tur-
bocharger assembly.
4) Disengage the oil feed pipe from the tur-
bocharger assembly.
ANNOTATION:
• Remove the clip.
5) Remove the oil feed pipe from the oil port
cover.
ANNOTATION:
• Remove the clip.
6) Disengage the oil return pipe from the tur-
bocharger assembly.

84402826 - May 2011

2415-4
 Removal and Installation of Cylinder Head

7) Remove the oil return pipe from the cylinder 11) Remove the water feed pipe from the cylinder
block. block.
ANNOTATION:
• Remove the clip.

1 Turbocharger assembly
2 Oil feed pipe
3 Oil return pipe

8) Disengage the water return pipe from the tur- 1 Water return pipe
bocharger assembly. 2 Water feed pipe
9) Remove the water return pipe from the water
pump assembly.
10) Disengage the water feed pipe from the tur-
12) Remove the exhaust manifold stay from the
bocharger assembly.
cylinder block and the turbocharger assembly.
ANNOTATION:
• Remove the clip.

1 Turbocharger assembly
2 Exhaust manifold
3 Exhaust manifold stay
84402826 - May 2011
2415-5
 Removal and Installation of Cylinder Head

13) Disengage the harness connector from the 3) Remove the EGR pipe A from the EGR cooler
turbocharger assembly. A and exhaust manifold.
14) Remove the turbocharger assembly from the
exhaust manifold.

1 EGR cooler A
2 EGR pipe A
1 Exhaust manifold 3 Exhaust manifold
2 Turbocharger assembly
4) Remove the EGR cooler A from the EGR pipe
5. EGR cooler assembly Removal B.
5) Remove the EGR pipe B from the EGR cooler
1) Disengage the water rubber hose from the B.
EGR cooler assembly. 6) Remove the EGR cooler B from the EGR pipe
C.
7) Remove the EGR pipe C from the EGR valve.

1 Water rubber hose

1 EGR valve
2) Remove the EGR heat protector from the 2 EGR pipe C
EGR pipe A. 3 EGR cooler B
4 EGR pipe B
5 EGR cooler A
6 EGR pipe D

6. EGR valve Removal

1) Disengage the harness connector from the
EGR valve.

1 EGR heat protector

84402826 - May 2011
2415-6
 Removal and Installation of Cylinder Head

2) Remove the EGR valve from the EGR pipe D. 3) Disengage the radiator upper hose from the
water outlet pipe.
4) Remove the EGR cooler water pipe from the
engine assembly.
ANNOTATION:
• Remove the EGR cooler water feed pipe
and EGR cooler water return pipe.

1 EGR cooler C
2 EGR pipe C
3 EGR valve
4 EGR pipe D

7. EGR cooler water pipe Removal

1) Remove the fan guide stay from the fan guide
and the fan guide bracket.
2) Remove the fan guide bracket from the cylin-
der head assembly.

1 EGR cooler water feed pipe

2 EGR cooler water return pipe

1 Fan guide 8. Intake throttle valve Removal

2 Fan guide stay 1) Remove the air duct from the intake throttle
3 Fan guide bracket valve.

84402826 - May 2011

2415-7
 Removal and Installation of Cylinder Head

2) Disengage the harness connector from the in- 3) Disengage the harness connector from the
take throttle valve. EGR valve.
4) Disconnect the harness connector from the
ANNOTATION:
IMT sensor.
• Pull the lock operation portion to release the 5) Remove the harness clip from the inlet pipe.
lock.

1 Boost sensor
1 Lock operation section 2 IMT sensor
2 Lock release 3 EGR valve
3 Lock 4 Harness clip
5 Boost temperature sensor
3) Remove the intake throttle valve from the inlet
pipe. 6) Remove the inlet pipe from the case.

1 Boost temperature sensor 1 Case

2 Boost sensor 2 Gasket
3 Inlet pipe 3 Inlet pipe
4 Gasket
5 Intake throttle valve 10. Oil level gauge guide tube Removal
1) Remove the oil level gauge from the oil level
9. Inlet pipe Removal
gauge guide tube.
1) Disengage the harness connector from the 2) Disengage the oil level gauge guide tube from
boost sensor. the cylinder head cover.
2) Disconnect the harness connector from the 3) Disengage the oil level gauge guide tube from
boost temperature sensor. the case.

84402826 - May 2011

2415-8
 Removal and Installation of Cylinder Head

4) Remove the oil level gauge guide tube from

the cylinder block.

1 No.1 injection pipe

2 No.2 injection pipe
1 Cylinder head cover 3 No.3 injection pipe
2 Oil level gauge guide tube 4 No.4 injection pipe
3 Case 5 Fuel leak-off pipe
4 Cylinder block 6 Fuel pipe
7 Common rail assembly
11. Glow plug Removal
1) Remove the glow plug connector from the 13. Fuel pipe Removal
glow plug. 1) Remove the fuel pipe from the fuel supply
2) Remove the glow plug from the cylinder head pump and the common rail assembly.
assembly.
ANNOTATION:
• Remove the clip.
CAUTION
• Do not reuse the removed fuel pipe.

14. Fuel leak off pipe assembly Removal

1) Disengage the fuel leak-off pipe from the cylin-
der head assembly.
2) Remove the fuel leak-off pipe from the fuel
supply pump.
ANNOTATION:

12. Injection pipe Removal • Remove the eyebolt tightened together with
the fuel feed pipe.
1) Remove the clip from the bracket.
2) Remove the injection pipe from the injector 3) Disengage the fuel leak-off pipe from the com-
and the common rail assembly. mon rail assembly.

CAUTION
• Do not reuse the removed injection
pipe.
• Seal the common rail and injector to
prevent foreign material from enter-
ing.

84402826 - May 2011

2415-9
 Removal and Installation of Cylinder Head

4) Remove the fuel leak-off pipe from the case. 16. Cylinder head cover Removal
ANNOTATION: 1) Disengage the ventilation hose from the air
• Remove the clip. breather.
2) Remove the cylinder head cover from the
lower cover.
3) Remove the head cover gasket from the cylin-
der head cover.

1 Common rail assembly

2 Cylinder head assembly
3 Fuel leak-off pipe
4 Fuel supply pump
1 Cylinder head cover
15. Common rail assembly Removal 2 Gasket
3 Lower cover
1) Disengage the harness connector from the
fuel pressure sensor.
2) Remove the common rail assembly from the
inlet cover and the common rail bracket. 17. Lower cover Removal
3) Remove the common rail bracket from the oil 1) Remove the connector from the lower cover.
cooler assembly.
CAUTION
• Do not pull the wire, or pry the con-
nector with a screwdriver.

2) Disengage the injector harness from the injec-

tor.

CAUTION
• Be careful not to damage the injec-
tor side stud bolts.

3) Remove the injector harness from the cylinder

head assembly.
ANNOTATION:
1 Common rail assembly
• Remove the bracket tightening bolts and
2 Fuel pressure sensor then remove the injector harness together
3 Common rail bracket with the bracket.

84402826 - May 2011

2415-10
 Removal and Installation of Cylinder Head

4) Remove the lower cover from the cylinder

head assembly.

Special tool: sliding hammer (refer to

section 1003)

1 Lower cover
2 Connector

5) Remove the gasket from the lower cover.

6) Remove the rubber plug from the cylinder
head assembly.
18. Injector Removal
1) Remove the injector leak-off pipe from the in-
jector.
2) Remove the injector from the cylinder head
assembly.
ANNOTATION:
• When it is difficult to remove the injector, use
a special tool.

Special tool: fuel injector remover (refer 1 Sliding hammer

to section 1003) 2 Fuel injector remover
3 Injector

CAUTION
• Confirm that the sleeve is not pulled
out together when pulling out the
injector using a special tool.
• Store each ID code plate on the in-
jector head with the cylinder num-
ber tag attached to avoid a mix-up.
• Be extremely careful not to damage
the injector nozzle.

84402826 - May 2011

2415-11
 Removal and Installation of Cylinder Head

20. Camshaft Removal

1) Remove the camshaft bearing cap from the
cylinder head assembly.
2) Remove the camshaft bearing from the
camshaft bearing cap.
3) Remove the camshaft from the cylinder head.
4) Remove the camshaft bearing from the cylin-
der head assembly.
ANNOTATION:
• Temporarily assemble the removed caps
and bearings in the original position to avoid
a mix-up after the bearings have been in-
spected.
19. Rocker arm shaft Removal
1) Loosen the adjust screw using the wrench.
ANNOTATION:
• Loosen all valve clearance adjustment
screws.

21. Bridge Removal

1) Remove the bridge cap from the bridge.

CAUTION
• Be careful not to drop the bridge
2) Remove the rocker arm shaft from the cylinder cap into the engine.
head assembly.
2) Remove the bridge from the bridge guide.
ANNOTATION:
ANNOTATION:
• Evenly loosen the rocker arm shaft bracket
and the rocker arm assembly bracket tight- • After removing, organize to avoid a mix-up
ening bolts from both ends and remove with other installation locations.
them.

CAUTION
• Be careful not to remove the bolt
shown in the diagram.

1 Bridge cap
2 Bridge

22. Cylinder head assembly Removal

84402826 - May 2011

2415-12
 Removal and Installation of Cylinder Head

1) Remove the cylinder head assembly from the Disassembly of Cylinder Head
cylinder block.
1. Engine hanger bracket Removal
ANNOTATION:
1) Remove the front engine hanger bracket from
• Loosening order of the head bolts the cylinder head assembly.
2) Remove the rear engine hanger bracket from
the cylinder head assembly.

CAUTION
• Since the idle gear C protrudes
from the bottom surface of the
cylinder head, be careful not to
damage the gear.

1 Front engine hanger

2 Front engine hanger bracket
3 Rear engine hanger
4 Rear engine hanger bracket
1 Idle gear C
2. Inlet cover Removal
2) Remove the cylinder head gasket from the 1) Remove the case from the inlet cover.
cylinder block.
ANNOTATION:
CAUTION
• Remove it together with the EGR pipe D.
• Do not reuse the cylinder head gas-
ket. 2) Remove the inlet cover from the cylinder head
assembly.

84402826 - May 2011

2415-13
 Removal and Installation of Cylinder Head

3) Remove the exhaust manifold bracket from

the cylinder head assembly.

1 EGR pipe D
2 Case
3 Gasket 1 Distance tube
4 Inlet cover 2 Washer
3 Exhaust manifold bracket
CAUTION 4 Exhaust manifold bracket
5 Exhaust manifold
• Do not forget to remove the bolts in-
dicated by the arrow in the diagram. 4. Thermostat Removal
1) Remove the water outlet pipe from the cylin-
der head assembly.
2) Remove the thermostat from the cylinder
head assembly.
3) Remove the gasket from the thermostat.
5. Overheat switch Removal
1) Remove the overheat switch from the cylinder
head assembly.
6. Engine coolant temperature sensor Removal
1) Remove the engine coolant temperature sen-
sor from the cylinder head assembly.

3. Exhaust manifold Removal

1) Remove the exhaust manifold bracket from
the exhaust manifold.
2) Remove the exhaust manifold from the cylin-
der head assembly.

1 Overheat switch
2 Water temperature sensor

84402826 - May 2011

2415-14
 Removal and Installation of Cylinder Head

7. CMP sensor Removal 3) Remove the idle gear C from the cylinder head
assembly.
1) Remove the CMP sensor from the cylinder
head assembly.

1 Idle gear C
CAUTION 2 Idle gear shaft
• Be careful not to subject the sensor 9. Valve spring Removal
to shock.
1) 1. Press the valve spring using the special
8. Idle gear C Removal tool.

1) Press the idle gear C cover using the driver.

ANNOTATION:
• Lightly tap the outer perimeter of the cover
using a screwdriver and tilt the cover.
2) Remove the idle gear C cover from the cylin-
der head assembly using the pliers.

Special tool: valve spring replacer (refer

to section 1003)

Special tool: pivot ASM (refer to section

1003)

84402826 - May 2011

2415-15
 Removal and Installation of Cylinder Head

2) Remove the valve spring seat from the cylin-

der head assembly.
13. Valve guide Removal
1) Remove the valve guide from the cylinder
head assembly using the special tool.

2) Remove the split collar from the spring seat.

3) Remove the special tool from the cylinder
head assembly.
4) Remove the valve spring seat from the valve
spring.
5) Remove the valve spring from the cylinder
head assembly.
Special tool: valve guide replacer (refer
ANNOTATION: to section 1003)
• Store the removed valve springs according ANNOTATION:
to the cylinders.
• Tap the valve guides out from the bottom
10. Inlet valve Removal surface of the cylinder head.
1) Remove the inlet valve from the cylinder head
assembly.
ANNOTATION:
• Organize the removed valve according to
the cylinders.
11. Exhaust valve Removal
1) Remove the exhaust valve from the cylinder
head assembly.
ANNOTATION:
• Organize the removed valve according to
the cylinders.

14. Valve seat insert Removal

1) Heat the valve seat insert with the gas burner.
Heating temperature ： 700.0 - 800.0 °C {
1292 - 1472 °F }
： 2 section(s) Inner surface of the insert
ANNOTATION:
• Cool the valve seat insert naturally after
heating.
Specified time： 5 min Natural cool
2) Remove the valve seat insert from the cylinder
head assembly using the driver.

12. Valve stem oil seal Removal CAUTION

1) Remove the valve stem oil seal from the valve • Be careful not to damage the cylin-
guide using the pliers. der head.

CAUTION 15. Injector sleeve Removal

• Do not reuse the valve stem oil seal. 1) Remove the injector sleeve from the cylinder
head assembly using the special tool.
84402826 - May 2011
2415-16
 Removal and Installation of Cylinder Head

1) Install the nut to the bridge guide.

ANNOTATION:
• Electrically weld the nut to the top of the
bridge guide.
2) Remove the bridge guide from the cylinder
head assembly using the sliding hammer.

Special tool: nozzle sleeve remover (refer

to section 1003)
ANNOTATION:
• Tap the injector sleeve out from the bottom
surface of the cylinder head.

1 Nut

17. Oil seal Removal

1) Remove the oil seal from the cylinder head
assembly.
ANNOTATION:
• Attach a rod from the inner surface of the
cylinder head, and tap it to remove it to the
outer side.

1 Injector sleeve

CAUTION
• Be careful not to damage the bot-
tom surface of the cylinder head.
• Do not reuse the removed injector
sleeve.

16. Bridge guide Removal

84402826 - May 2011

2415-17
 Removal and Installation of Cylinder Head

Assembly of Cylinder Head 2. Bridge guide Installation

1. Oil seal Installation 1) Apply the engine oil to the bridge guide.
2) Install the bridge guide to the cylinder head
1) Install the oil seal to the cylinder head assem- assembly using the special tool.
bly.

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

CAUTION
• Be careful not to damage the lip
section of the oil seal.

Specified length： 122.0 to 123.0 mm {4.8031

to 4.8425 in} 1 in the diagram
Specified length： 37.5 mm {1.4764 in} 2 in
the diagram
3. Injector sleeve Installation
1) Install the O-ring to the injector sleeve.
2) Apply the engine oil to the O-ring.
3) Apply the cement to the injector sleeve.
ANNOTATION:
• Apply Loctite 620 to the tapered section of
the injector sleeve.

1 Cylinder head
2 Oil seal installer

84402826 - May 2011

2415-18
 Removal and Installation of Cylinder Head

4) Apply the engine oil to the cylinder head as- Special tool: nozzle sleeve setting tool
sembly. (refer to section 1003)
ANNOTATION:
• Apply engine oil to the injector sleeve con-
tact surface.

1 Punch bar
2 Ball
3 Guide sleeve
4 Injector sleeve
1 O-ring with white paint 5 Clamp
2 O-ring 6 Bolt
3 Loctite 620 application
4 Engine oil application
CAUTION
5) Install the injector sleeve to the cylinder head • Allow the cylinder head to float so
assembly using the special tool. that the ball comes out from the bot-
tom surface.

4. Valve seat insert Installation

1) Prepare the dolly block.
ANNOTATION:
• Prepare the one which has smaller outer
diameter than the valve seat insert.
2) Align the valve seat insert to the cylinder head.
3) Align the dolly block to the valve seat insert.

84402826 - May 2011

2415-19
 Removal and Installation of Cylinder Head

4) Install the valve seat insert to the cylinder Specified length： 17.0 - 17.9 mm {0.6693 -
head assembly using the press. 0.7047 in}

CAUTION
1 Dolly block • When replacing the valve guide, re-
2 Valve seat insert place it with the valve.
3 Press
6. Valve stem oil seal Installation
1) Install the valve spring seat to the cylinder
5. Valve guide Installation head assembly.
1) Apply the engine oil to the valve guide. 2) Apply the engine oil to the valve guide.
2) Install the valve guide to the cylinder head ANNOTATION:
assembly using the special tool.
• Apply engine oil to the outer circumference
of the valve guide.

CAUTION
• Use a new valve stem oil seal.

3) Install the valve stem oil seal to the valve

guide using the special tool.

Special tool: valve guide replacer (refer

to section 1003)
ANNOTATION:
• Tap the valve guides from the upper side of
the cylinder head.

Special tool: valve stem seal installer

(refer to section 1003)

84402826 - May 2011

2415-20
 Removal and Installation of Cylinder Head

CAUTION
• Inspect the valve stem oil seal for 1 Spring pitch (small)
deformation or cracks. 2 Identification paint
• Confirm that the garter spring has
not come loose.

7. Exhaust valve Installation 2) Install the valve spring to the cylinder head
assembly.
1) Apply the engine oil to the exhaust valve.
2) Install the exhaust valve to the cylinder head ANNOTATION:
assembly. • Turn the valve spring to face the identifica-
ANNOTATION: tion paint application area towards the cylin-
der head assembly.
• Confirm that there is an E-mark on the valve.
3) Install the spring seat to the valve spring.
8. Inlet valve Installation 4) Press the valve spring using the special tool.
1) Apply the engine oil to the inlet valve.
2) Install the inlet valve to the cylinder head as-
sembly.
ANNOTATION:
• Confirm that there is an I-mark on the valve.

Special tool: valve spring replacer (refer

to section 1003)

9. Valve spring Installation

1) Check the identification paint of the valve
spring.

Valve spring identification paint

Inlet Light blue
Exhaust White

Special tool: pivot ASM (refer to section

1003)
84402826 - May 2011
2415-21
 Removal and Installation of Cylinder Head

4) Securely tighten the idle gear C to the cylinder

head assembly
Tightening torque： 95 Nm {9.7 kgfm / 70 lbft}
5) Apply the cement to the idle gear C cover.
ANNOTATION:
• Apply Loctite 962T to the outer circumfer-
ence of the idle gear C cover.
6) Install the idle gear C cover to the cylinder
head assembly using the special tool.

5) Install the split collar to the spring seat.

ANNOTATION:
• Lightly tap the valve stem head to stabilize
the split collar.

CAUTION
• Confirm that the split collar is in the
valve stem groove.

10. Idle gear C Installation

Special tool: sealing cup installer (refer to
1) Apply the engine oil to the idle gear C. section 1003)
ANNOTATION:
• Apply to the sliding surface of the gear.
2) Apply the engine oil to the idle gear shaft.
ANNOTATION:
• Apply engine oil to the outer circumference
of the idle gear shaft.
3) Temporarily tighten the idle gear C to the cylin-
der head assembly.

CAUTION
• Confirm that the spigot of the idle
gear shaft is firmly installed to the
cylinder head assembly. Between the idle gear C cover
1 end surface and cylinder head
chamfered edge section

Specified length ： 1.5 - 2.5 mm {0.0591 -

0.0984 in}
11. CMP sensor Installation
1) Apply the engine oil to the O-ring.
2) Install the CMP sensor to the cylinder head
assembly.

CAUTION
• Be careful not to subject the sensor
to shock.

1 Idle gear C ANNOTATION:

2 Idle gear shaft • Tighten together with the clip.

84402826 - May 2011

2415-22
 Removal and Installation of Cylinder Head

Tightening torque ： 8 N ・ m {0.8 kgf ・ m / 1) Install the gasket to the thermostat.

69 lb ・ in}
CAUTION
• Use new gaskets.

2) Install the thermostat to the cylinder head as-

sembly

12. Overheat switch Installation

1) Install the overheat switch to the cylinder head
assembly.
ANNOTATION:
• Apply Loctite 572 to the threaded portion. 1 Thermostat
Tightening torque ： 29 N ・ m {3.0 kgf ・ m / 2 Cylinder head
22 lb ・ ft}
13. Engine coolant temperature sensor Installation CAUTION
1) Install the engine coolant temperature sensor • Be careful not to mistake the as-
to the cylinder head assembly. sembly position and direction.
ANNOTATION:
3) Install the water outlet pipe to the cylinder
• Apply Loctite 572 to the threaded portion. head assembly.
Tightening torque ： 25 N ・ m {2.5 kgf ・ m / Tightening torque： 25 N・m {2.5 kgf・m / 18
18 lb ・ ft} lb・ft}
15. Exhaust manifold Installation
1) Install the exhaust manifold bracket to the
cylinder head assembly.
Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft}
2) Install the gasket to the cylinder head assem-
bly.
ANNOTATION:
• Turn the protruding section of the gasket to-
wards the exhaust manifold and install.
3) Install the exhaust manifold to the cylinder
head assembly.
ANNOTATION:
1 Overheat switch • When assembling the washer, assemble the
2 Water temperature sensor distance nut section only.
Tightening torque： 34 N・m {3.5 kgf・m / 25
14. Thermostat Installation lb・ft}

84402826 - May 2011

2415-23
 Removal and Installation of Cylinder Head

4) Install the exhaust manifold bracket to the ex-

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

CAUTION
• Completely tighten the installation
bolt and nut when installing the
common rail assembly.
1 Distance tube
2 Washer 3) Install the case to the inlet cover.
3 Exhaust manifold bracket Tightening torque： 22 N・m {2.2 kgf・m / 16
4 Exhaust manifold bracket lb・ft}
5 Exhaust manifold ANNOTATION:
• Install it together with the EGR pipe D.
16. Inlet cover Installation
1) Apply the liquid gasket to the inlet cover.
ANNOTATION:
• Align with the inlet cover groove and apply
ThreeBond 1207.
Bead width： 3 - 6 mm {0.098 - 0.217 in}

CAUTION
• After applying liquid gasket, install
the inlet cover within 5 minutes.

2) Temporarily tighten the inlet cover to the cylin-

der head assembly.

CAUTION 1 EGR pipe D

2 Case
• Do not forget to install the bolts in-
dicated by the arrow in the diagram. 3 Gasket
4 Inlet cover

17. Engine hanger bracket Installation

1) Install the front engine hanger bracket to the
cylinder head assembly.
Tightening torque： 104 N・m {10.6 kgf・m
/ 77 lb・ ft} Front engine hanger bracket
Tightening torque： 48 N・m {4.9 kgf・m / 35
lb・ft}
Front engine hanger

84402826 - May 2011

2415-24
 Removal and Installation of Cylinder Head
2) Install the rear engine hanger bracket to the
cylinder head assembly.
Tightening torque： 104 N・m {10.6 kgf・m
/ 77 lb・ft} Rear engine hanger bracket
Tightening torque： 48 N・m {4.9 kgf・m / 35
lb・ft}
Rear engine hanger
1 Rear engine hanger
2 Front engine hanger bracket
3 Rear engine hanger
4 Rear engine hanger bracket
84402826 - May 2011
2415-25
Installation of Cylinder Head
1. Cylinder head assembly Installation
CAUTION
• Clean the aligning surface of the cylinder
head and cylinder block before installing
the cylinder head assembly.
• Be careful not to damage the cylinder
head and cylinder block while cleaning.
1) Apply the liquid gasket to the cylinder block.
ANNOTATION:
• Use ThreeBond 1207B.
Bead width： 3.0 mm {0.1181 in}
Bead height： 3.0 mm {0.1181 in}
CAUTION
• After applying liquid gasket, install
the cylinder head within 5 minutes.
2) Install the cylinder head gasket to the cylinder
block.
CAUTION
• Use a new cylinder head gasket.
3) Install the cylinder head assembly to the cylin-
der block.
CAUTION
• Be careful not to damage the cylin-
der head gasket.
ANNOTATION:
• Tightening order of the head bolts
 Removal and Installation of Cylinder Head

2) Install the bridge to the bridge guide.

CAUTION
• Confirm that the bridge moves
smoothly.

3) Apply the engine oil to the bridge cap.

4) Install the bridge cap to the bridge.

ANNOTATION:
• 1 to 18 in the diagram indicate the M14 bolts.
• 19 and 20 in the diagram indicate the M10
bolts.
4) Prepare the head bolt.
ANNOTATION:
• Apply molybdenum disulfide grease to the
seat surface and threaded portion of the CAUTION
M14 head bolts.
• Apply engine oil to the seat surface and • Be careful not to drop the bridge
threaded portion of the M10 head bolts. cap into the engine.
5) Tighten the head bolt using the torque wrench. 3. Camshaft Installation
Tightening torque： 157 N・m {16.0 kgf・m
/ 116 lb・ft} 1) Align 1st cylinder to the compression top dead
6) Tighten the head bolt using the torque wrench. center.
Tightening torque： 165 N・m {16.8 kgf・m
/ 122 lb・ft}
7) Tighten the head bolt using the special tool.

1 Front cover marking

0 degree marking on the crank-
Special tool: angle gauge (refer to section 2
shaft damper
1003)
Tightening angle： 55 ° M14 bolt
8) Tighten the head bolt using the torque wrench. 2) Apply the engine oil to the camshaft bearing.
Tightening torque： 38 N・m {3.9 kgf・m / 28 ANNOTATION:
lb・ft} M10 bolt
9) Tighten the head bolt using the torque wrench. • Apply engine oil to the sliding surface of the
Tightening torque： 167 N・m {17.0 kgf・m bearing.
/ 123 lb・ft} Check the tightening M14 bolt
CAUTION
2. Bridge Installation
• Apply engine oil after cleaning the
1) Apply the engine oil to the bridge. bearing installation sections of
the camshaft bearing and cylinder
head.

84402826 - May 2011

2415-26
 Removal and Installation of Cylinder Head

3) Install the camshaft bearing to the cylinder 8) Install the camshaft bearing cap to the cylinder
head assembly. head assembly.
4) Install the camshaft to the cylinder head as-
ANNOTATION:
sembly.
ANNOTATION: • Turn the camshaft bearing cap so that the
arrow mark on the top surface faces the en-
• Mesh together the idle gear C and the gine front side, and assemble in numerical
camshaft gear so that the alignment mark order.
on the camshaft gear matches the top sur-
Tightening torque： 28 N・m {2.8 kgf・m / 20
face of the cylinder head, and gently install
lb・ft} Apply engine oil
the camshaft.

5) Check alignment mark of the camshaft gear. 4. Rocker arm shaft Installation

CAUTION 1) Apply the engine oil to the bracket.

ANNOTATION:
• Confirm that the alignment mark is
not misaligned before installing the • Apply to each sliding surface.
camshaft bearing cap.
• If the alignment mark is not at 2) Apply the engine oil to the rocker arm.
the correct position, reinstall the ANNOTATION:
camshaft.
• Confirm that the adjust screw is fully loos-
6) Apply the engine oil to the camshaft bearing. ened.

ANNOTATION: 3) Temporarily tighten the bolt to the cylinder

head assembly.
• Apply engine oil to the sliding surface of the
bearing. ANNOTATION:
• Apply engine oil to the threaded portion of
CAUTION the bolts.
• Apply engine oil after cleaning the 4) Temporarily tighten the nut to the cylinder
bearing installation sections of the head assembly.
camshaft bearing and camshaft
bearing cap. ANNOTATION:
• Apply engine oil to the threaded portion of
7) Install the camshaft bearing to the camshaft the nuts.
bearing cap.
5) Securely tighten the rocker arm shaft to the
cylinder head assembly.
ANNOTATION:
• Hold the entire rocker arm shaft horizontally
and gradually tighten it.

Rocker arm shaft tightening torque

Parts Tightening torque
： 21 N・m {2.1 kgf・m / 15
No.1 Nut
lb・ft}
： 27 N・m {2.8 kgf・m / 20
No.2 Bolt
lb・ft}

84402826 - May 2011

2415-27
 Removal and Installation of Cylinder Head

Rocker arm shaft tightening torque CAUTION

Parts Tightening torque
： 56 N・m {5.7 kgf・m / 41 • Adjust the valve clearance while cool.
No.3 Bolt • Loosen all adjust screws before adjust-
lb・ft}
： 27 N・m {2.8 kgf・m / 20 ment.
No.4 Bolt
lb・ft}

1) Align 1st cylinder to the compression top dead

center.

1 Front cover marking

1 Nut 0 degree marking on the crank-
2 Bolt 2
shaft damper
3 Bolt
4 Bolt 2) Prepare the feeler gauge.
Thickness： 0.4 mm {0.0157 in} 2 pieces
5. Rocker arm shaft Adjustment
ANNOTATION:
ANNOTATION:
• Insert the thickness gauge between the
• Valve clearance adjustment rocker arm and bridge cap.

84402826 - May 2011

2415-28
 Removal and Installation of Cylinder Head

• Insert the thickness gauge between the Tightening torque： 22 N・m {2.2 kgf・m / 16
bridge and valve. lb・ft}
3) Turn the adjust screw.
ANNOTATION:
• When the movement of the thickness gauge
becomes stiff, secure the adjust screw nut
of the rocker arm.
Tightening torque： 22 N・m {2.2 kgf・m / 16
lb・ft}

Adjustment table
1 2 3 4
Cylinder No. I- E- I- I-
E- E- I- E-
N X N N X X N X
First cylinder compression
O O O O
top dead center
Fourth cylinder compres-
4) Turn the adjust screw. O O O
sion top dead center
ANNOTATION:
• With the thickness gauge inserted, lightly
tighten the adjust screw of the bridge. 6. Common rail assembly Installation
• Confirm that the leading end of the adjust 1) Temporarily tighten the common rail bracket
screw and valve shaft end have made con- to the oil cooler assembly.
tact and the movement of the thickness
gauge has become stiff. ANNOTATION:
• Check if the valve shaft end on the opposite
• The installation bolt and common rail as-
side is floating or touching at an angle.
sembly are tightened together.
• If it is floating or touching at an angle, slightly
loosen the bridge adjust screw and adjust 2) Align the common rail assembly to the inlet
the valve shaft ends on both sides to touch cover.
properly. 3) Temporarily tighten the nut to the common rail
assembly.
Valve bridge clearance ： less than 0.1 mm
{less than 0.0039 in} ANNOTATION:
ANNOTATION: • The stud bolts of the inlet cover are tight-
ened together.
• To prevent turning, fix the bridge adjust
screw with a flathead screwdriver, and 4) Temporarily tighten the bolt to the common rail
tighten the adjust screw nut. assembly.

84402826 - May 2011

2415-29
 Removal and Installation of Cylinder Head

5) Securely tighten the nut to the common rail 3) Temporarily tighten the fuel leak-off pipe to the
assembly. fuel supply pump.
Tightening torque： 22 N・m {2.2 kgf・m / 16
ANNOTATION:
lb・ft}
ANNOTATION: • Tighten the fuel feed pipe together.

• Refer to the tightening order in the diagram CAUTION

if the inlet cover is removed.
• Use new gaskets.

4) Securely tighten the fuel leak-off pipe to the

cylinder head assembly.
Tightening torque： 12 N・m {1.3 kgf・m /
109 lb・in}
5) Securely tighten the fuel leak-off pipe to the
common rail assembly.
Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft}
6) Securely tighten the fuel leak-off pipe to the
fuel supply pump.
Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft}
7) Install the clip to the fuel leak-off pipe.
6) Securely tighten the bolt to the common rail Tightening torque： 8 N・m {0.8 kgf・m / 69
assembly. lb・in}
Tightening torque： 19 N・m {1.9 kgf・m / 14
lb・ft}
7) Connect the harness connector to the fuel
pressure sensor.

1 Common rail assembly

2 Cylinder head assembly
3 Fuel leak-off pipe
4 Fuel supply pump

1 Common rail assembly

8. Fuel pipe Installation
2 Fuel pressure sensor
3 Common rail bracket 1) Install the fuel pipe to the fuel supply pump
and the common rail assembly.

CAUTION
7. Fuel leak off pipe assembly Installation
• Use new fuel pipes.
1) Temporarily tighten the fuel leak-off pipe to the
cylinder head assembly.
Tightening torque： 44 N・m {4.5 kgf・m / 33
CAUTION lb・ft}
2) Install the clip to the bracket.
• Use new gaskets. Tightening torque： 9 N・m {0.9 kgf・m / 78
lb・in}
2) Temporarily tighten the fuel leak-off pipe to the
9. Injector Installation
common rail assembly.

CAUTION
• Use new gaskets.
84402826 - May 2011
2415-30
 Removal and Installation of Cylinder Head

CAUTION 3) Install the clip to the bracket.

Tightening torque： 6 N・m {0.6 kgf・m / 52
• When reusing an injector, do not change lb・in}
the installation position.

1) Apply the engine oil to the bolt.

2) Temporarily tighten the injector to the cylinder
head assembly.

CAUTION
• Be extremely careful not to damage
the injector nozzle.

1 No.1 injection pipe

2 No.2 injection pipe
3 No.3 injection pipe
4 No.4 injection pipe
5 Fuel leak-off pipe
6 Fuel pipe
7 Common rail assembly

11. Lower cover Installation

1 Injector
1) Apply the liquid gasket to the rubber plug.
2 Installation bolt
ANNOTATION:
• Apply ThreeBond 1207B.
3) Temporarily tighten the injection pipe to the
injector.

CAUTION
• Use new injection pipes.

4) Temporarily tighten the injection pipe to the

common rail assembly.
5) Securely tighten the injector to the cylinder
head assembly.
Tightening torque： 30 N・m {3.1 kgf・m / 22
lb・ft}
6) Install the injector leak-off pipe to the injector.

CAUTION
• Use new gaskets.
1 Rubber plug
Tightening torque： 14 N・m {1.4 kgf・m / 2 Liquid gasket
126 lb・in}
10. Injection pipe Installation
CAUTION
1) Securely tighten the injection pipe to the injec-
tor. • After applying the liquid gasket, in-
Tightening torque： 30 N・m {3.0 kgf・m / 22 stall the lower cover within 5 min-
lb・ft} utes.
2) Securely tighten the injection pipe to the com-
mon rail assembly. 2) Install the rubber plug to the cylinder head
Tightening torque： 25 N・m {2.5 kgf・m / 18 assembly.
lb・ft} 3) Install the gasket to the lower cover.
84402826 - May 2011
2415-31
 Removal and Installation of Cylinder Head

4) Install the lower cover to the cylinder head 12. Glow plug Installation
assembly.
Tightening torque： 18 N・m {1.8 kgf・m / 13 1) Install the glow plug to the cylinder head as-
lb・ft} sembly.
5) Install the injector harness to the cylinder head Tightening torque： 20 N・m {2.0 kgf・m / 14
assembly. lb・ft}

ANNOTATION: CAUTION
• Tighten the bolts on the bracket and in- • Be careful not to exceed the speci-
stall the injector harness together with the fied torque when tightening.
bracket.
Tightening torque： 48 N・m {4.9 kgf・m / 35
lb・ft}

2) Install the glow plug connector to the glow

plug.
Tightening torque： 1 N・m {0.1 kgf・m / 11
lb・in}
1 Injector harness terminal
2 Injector harness bracket CAUTION
• Confirm that the glow plug connec-
6) Connect the injector harness to the injector. tor does not interfere with the sur-
Tightening torque： 2 N・m {0.2 kgf・m / 18 rounding parts.
lb・in}
13. Cylinder head cover Installation
CAUTION
1) Align the head cover gasket to the cylinder
• Be careful not to damage the injec- head cover.
tor side stud bolts. 2) Install the cylinder head cover to the lower
cover.
Tightening torque： 18 N・m {1.8 kgf・m / 13
lb・ft}
ANNOTATION:
• Referring to the tightening order in the dia-
gram, temporarily tighten all bolts and then
completely tighten them.

1 Lower cover
2 Connector

7) Install the connector to the lower cover.

Tightening torque： 2 N・m {0.2 kgf・m / 18
lb・in}

84402826 - May 2011

2415-32
 Removal and Installation of Cylinder Head

1) Install the inlet pipe to the case.

Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft}

CAUTION
• Use new gaskets.

1 Cylinder head cover

2 Gasket
3 Lower cover

3) Connect the ventilation hose to the air

breather.
14. Oil level gauge guide tube Installation 1 Case
1) Install the oil level gauge guide tube to the 2 Gasket
cylinder block. 3 Inlet pipe
2) Connect the oil level gauge guide tube to the
case. 2) Connect the harness connector to the IMT
Tightening torque： 19 N・m {1.9 kgf・m / 14 sensor.
lb・ft} 3) Connect the harness connector to the EGR
3) Connect the oil level gauge guide tube to the valve.
cylinder head cover. 4) Connect the harness connector to the boost
Tightening torque： 19 N・m {1.9 kgf・m / 14 temperature sensor.
lb・ft} 5) Connect the harness connector to the boost
4) Install the oil level gauge to the oil level gauge sensor.
guide tube. 6) Install the harness clip to the inlet pipe.

1 Boost sensor
1 Cylinder head cover
2 IMT sensor
2 Oil level gauge guide tube
3 EGR valve
3 Case
4 Harness clip
4 Cylinder block
5 Boost temperature sensor

15. Inlet pipe Installation 16. Intake throttle valve Installation

84402826 - May 2011

2415-33
 Removal and Installation of Cylinder Head

1) Install the intake throttle valve to the inlet pipe.

Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft}

1 Boost temperature sensor

2 Boost sensor
3 Inlet pipe
4 Gasket
5 Intake throttle valve

2) Install the air duct to the intake throttle valve.

3) Connect the harness connector to the intake
throttle valve.
ANNOTATION:
• After connecting the harness connector,
press in the lock operation portion to lock. 1 EGR cooler water feed pipe
2 EGR cooler water return pipe

1) Install the EGR cooler water pipe to the engine

assembly.
ANNOTATION:
• Install the EGR cooler water feed pipe and
EGR cooler water return pipe.
Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft} Clamp
2) Connect the radiator upper hose to the water
outlet pipe.
3) Install the fan guide bracket to the cylinder
head assembly.
Tightening torque： 50 N・m {5.1 kgf・m / 37
lb・ft}
1 Lock operation section Tightening torque ： 97 N ・ m {9.9 kgf ・ m}
2 Lock release The area where the spacer is used
3 Lock 4) Install the fan guide stay to the fan guide
bracket.
Tightening torque： 45 N・m {4.6 kgf・m / 33
17. EGR cooler water pipe Installation lb・ft}

84402826 - May 2011

2415-34
 Removal and Installation of Cylinder Head

5) Install the fan guide stay to the fan guide. 4) Temporarily tighten the EGR cooler A to the
Tightening torque： 45 N・m {4.6 kgf・m / 33 EGR pipe B.
lb・ft}

1 EGR valve
1 Fan guide stay 2 EGR pipe C
2 Fan guide 3 EGR cooler B
3 Fan guide bracket 4 EGR pipe B
4 Spacer 5 EGR cooler A
6 EGR pipe B
18. EGR valve Installation
5) Temporarily tighten the EGR pipe A to the
1) Install the EGR valve to the EGR pipe D. EGR cooler A and the exhaust manifold.
Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft}

CAUTION
• Use new gaskets.

19. EGR cooler assembly Installation

1) Temporarily tighten the EGR pipe C to the
EGR valve.
2) Temporarily tighten the EGR cooler B to the
EGR pipe C.
3) Temporarily tighten the EGR pipe B to the
EGR cooler B.

1 EGR cooler A
2 EGR pipe A
3 Exhaust manifold

ANNOTATION:
• Complete tightening order of the EGR
cooler assembly

84402826 - May 2011

2415-35
 Removal and Installation of Cylinder Head

14) Install the EGR heat protector to the EGR pipe

A.

1 EGR heat protector

15) Connect the water rubber hose to the EGR

cooler assembly.

6) Securely tighten the EGR pipe C to the EGR

valve.
Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft} No.1 in the diagram
7) Completely tighten the EGR pipe C to the en-
gine hanger bracket.
Tightening torque： 48 N・m {4.9 kgf・m / 35
lb・ft} No.2 in the diagram
8) Securely tighten the EGR pipe B to the 1 Water rubber hose
bracket.
Tightening torque： 48 N・m {4.9 kgf・m / 35 20. Turbocharger assembly Installation
lb・ft} No.3 in the diagram
9) Securely tighten the EGR cooler B to the EGR 1) Temporarily tighten the turbocharger assem-
pipe C. bly to the exhaust manifold.
Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft} No.4 in the diagram
10) Securely tighten the EGR pipe B to the EGR
cooler B.
Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft} No.5 in the diagram
11) Securely tighten the EGR cooler A to the EGR
pipe B.
Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft} No.6 in the diagram
12) Securely tighten the EGR pipe A to the ex-
haust manifold.
Tightening torque： 28 N・m {2.9 kgf・m / 21
lb・ft} No.7 in the diagram
13) Securely tighten the EGR pipe A to the EGR
cooler A.
Tightening torque： 28 N・m {2.9 kgf・m / 21 1 Exhaust manifold
lb・ft} No.8 in the diagram 2 Turbocharger assembly

84402826 - May 2011

2415-36
 Removal and Installation of Cylinder Head

2) Temporarily tighten the exhaust manifold stay 6) Connect the water feed pipe to the tur-
to the cylinder block and the turbocharger as- bocharger assembly.
sembly.
CAUTION
• Use new gaskets.

Tightening torque： 35 N・m {3.5 kgf・m / 25

lb・ft} Eyebolt
Tightening torque： 14 N・m {1.4 kgf・m /
119 lb・in} Clip
7) Install the water return pipe to the water pump
assembly.

CAUTION
• Use new gaskets.

Tightening torque： 35 N・m {3.5 kgf・m / 25

lb・ft} Eyebolt
1 Turbocharger assembly Tightening torque： 24 N・m {2.4 kgf・m / 17
2 Exhaust manifold lb・ft} Clip
3 Exhaust manifold stay 8) Connect the water return pipe to the tur-
bocharger assembly.
3) Securely tighten the turbocharger assembly to
the exhaust manifold.
Tightening torque： 52 N・m {5.3 kgf・m / 38
lb・ft}
4) Securely tighten the exhaust manifold stay to
the cylinder block and the turbocharger as-
sembly.
Tightening torque： 52 N・m {5.3 kgf・m / 38
lb・ft} Nut
Tightening torque： 50 N・m {5.1 kgf・m / 37
lb・ft} Bolt
ANNOTATION:
• Tightening order

5) Install the water feed pipe to the cylinder

block.

CAUTION
1 Water return pipe
• Use new gaskets.
2 Water feed pipe
Tightening torque： 41 N・m {4.2 kgf・m / 30
lb・ft} Eyebolt
Tightening torque： 24 N・m {2.4 kgf・m / 17 Tightening torque： 35 N・m {3.5 kgf・m / 25
lb・ft} Clip lb・ft} Eyebolt

84402826 - May 2011

2415-37
 Removal and Installation of Cylinder Head

9) Install the oil return pipe to the cylinder block. 12) Connect the oil feed pipe to the turbocharger
assembly.
CAUTION
CAUTION
• Use new gaskets.
• Use new gaskets.
Tightening torque： 22 N・m {2.2 kgf・m / 16
lb・ft} Tightening torque： 17 N・m {1.7 kgf・m / 12
10) Connect the oil return pipe to the turbocharger lb・ft} Eyebolt
assembly. Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft} Clip
CAUTION
• Use new gaskets.

Tightening torque： 9 N・m {0.9 kgf・m / 78

lb・in}
11) Install the oil feed pipe to the oil port cover.

CAUTION
• Use new gaskets.

Tightening torque： 17 N・m {1.7 kgf・m / 12

lb・ft} Eyebolt
Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft} Clip

1 Turbocharger assembly
2 Oil feed pipe
3 Oil return pipe

13) Install the exhaust pipe to the turbocharger

assembly.
14) Install the air intake hose to the turbocharger
assembly and the intercooler.
15) Install the air cleaner duct to the air cleaner
assembly and the turbocharger assembly.
16) Connect the harness connector to the tur-
bocharger assembly.
21. Engine harness Connect
1) Connect the engine harness to the engine as-
sembly.
ANNOTATION:
• Connect each connector.
22. Coolant Filling
1) Loosen the valve using a wrench.
84402826 - May 2011
2415-38
 Removal and Installation of Cylinder Head

2) Replenish the coolant with the radiator. 1 Priming pump

2 Plug
CAUTION 3 Drain plug
• Be careful not to let coolant over- 4 Case
flow splash on the exhaust system 5 Fuel filter element
parts.
• Coolant overflow should be wiped 1) Prepare the pan.
off. 2) Turn ON the starter switch.
3) Tighten the valve using a wrench. ANNOTATION:

CAUTION • This is for the models with an electromag-

netic pump.
• Use new gaskets. 3) Loosen the plug using the wrench.
4) Operate the priming pump.
Tightening torque： 28 N・m {2.8 kgf・m / 20 Number of times： 20 count(s) or more
lb・ft}
4) Replenish the coolant with the radiator. ANNOTATION:
• Confirm that fuel comes out from around the
plug.
5) Tighten the plug using the wrench.
6) Operate the priming pump.
Number of times： 10 count(s) or more
ANNOTATION:
• Wait for the specified time after operating
the priming pump.
Specified time： 1 min
7) Loosen the plug using the wrench.
ANNOTATION:
• Remove the air in the fuel filter.
8) Tighten the plug using the wrench.
1 Valve 9) Operate the priming pump.
2 Gasket Number of times： 10 count(s) or more
ANNOTATION:
23. Battery ground cable Connect • Wait for the specified time after operating
the priming pump.
1) Connect the battery ground cable to the bat-
tery. Specified time： 1 min
10) Loosen the plug using the wrench.
24. Fuel Air bleed
ANNOTATION:
CAUTION
• Remove the air in the fuel filter.
• To prevent engine failure, be sure to per- 11) Tighten the plug using the wrench.
form air removal after the installation or
12) Operate the priming pump.
removal of fuel system parts.
Number of times： 10 count(s) or more
ANNOTATION:
• Wait for the specified time after operating
the priming pump.
Specified time： 1 min
13) Loosen the plug using the wrench.
ANNOTATION:
• Remove the air in the fuel filter.

84402826 - May 2011

2415-39
 Removal and Installation of Cylinder Head

14) Tighten the plug using the wrench. Inspection

Tightening torque： 10 N・m {1.0 kgf・m / 89
lb・in} 1. Bridge cap Inspection
1) Measure the bridge cap using the dial gauge.
CAUTION
ANNOTATION:
• Remove the fuel around the plug
thoroughly after tightening. • Measure the contact surface of the bridge
cap and rocker arm.
15) Operate the priming pump. Limit: 0.1 mm {0.0039 in} Amount of wear on
Number of times the operation is Performed: the bridge cap
10 - 15 times
16) Start the engine. CAUTION
CAUTION • Replace the bridge cap if the mea-
sured value exceeds the limit value.
• Do not accelerate the engine revo- • Replace the bridge cap if it
lution right after staring. has an abnormal wear such as
band-shaped wear.
Idling: 5 s
ANNOTATION:
• Accelerate the engine revolution gradually.
Engine revolution hold: 3 min.
ANNOTATION:
• Accelerate the engine revolution to maxi-
mum.
• Lower the rotation.

2. Bridge Inspection
1) Inspect the bridge.
ANNOTATION:
• Confirm that the bridge moves smoothly.
2) Check the clearance of the bridge cap.
Specified value: 0.020 - 0.057 mm {0.0008 -
0.0022 in} Between the bridge and bridge cap
Limit: 0.1 mm {0.0039 in} Between the bridge
and bridge cap

1 Bridge
2 Bridge guide

3. Idle gear C Inspection

84402826 - May 2011
2415-40
 Removal and Installation of Cylinder Head

1) Measure the clearance using the feeler

gauge.
ANNOTATION:
• Measure the clearance in the axis direction
between the cylinder head and idle gear C.
Specified value: 0.090 - 0.145 mm {0.0035 -
0.0057 in}
Limit: 0.2 mm {0.0079 in}

2) Install the inlet valve to the valve guide.

3) Measure the valve guide clearance using the
dial gauge.
ANNOTATION:
• Valve guide clearance
Specified value: 0.039 - 0.071 mm {0.0015 -
0.0028 in}
Limit: 0.2 mm {0.0079 in}

1 Idle gear C

2) Measure the idle gear shaft using the vernier

caliper.
ANNOTATION:
• Outer diameter of the idle gear shaft
Specified value: 30.00 mm {1.1811 in} Diam-
eter
Limit: 29.85 mm {1.1752 in} Diameter
4. Inlet valve Inspection
1) Measure the inlet valve using the micrometer.
ANNOTATION: 1 Valve
The position 10 mm under the
• Outer diameter of the valve stem 2
valve guide head
Measurement part: 3 section(s) 3 Valve guide
Specified value: 8.00 mm {0.3150 in} Diame-
ter CAUTION
Limit: 7.88 mm {0.3102 in} Diameter
• Replace the inlet valve and valve
CAUTION guide if the measured value ex-
ceeds the limit value.
• Replace the inlet valve and valve
guide if the measured value is un- 4) Measure the inlet valve using the micrometer.
der the limit value.
ANNOTATION:
• Valve thickness
Specified value: 1.71 mm {0.0673 in}
Limit: 1.30 mm {0.0512 in}

84402826 - May 2011

2415-41
 Removal and Installation of Cylinder Head

6) Adjust the valve seat.

CAUTION
• Use a seat cutter suitable for the
valve seat angle and valve stem di-
ameter.

Valve seat angle: 30 °

External diameter of the valve stem: 8.0 mm
{0.3150 in} Diameter

CAUTION
• Replace the inlet valve and valve
guide if the measured value ex-
ceeds the limit value.

5) Inspect the inlet valve using the red lead

primer.
ANNOTATION:
• Inspect the contact surface of the inlet valve 7) Apply the compound to the valve seat.
and valve seat. 8) Install the inlet valve to the valve guide.
Specified value: 2.7 mm {0.1063 in} Contact 9) Adjust contact surface to standard value using
width the valve lapper.
Limit: 3.0 mm {0.1181 in} Contact width ANNOTATION:
CAUTION • Lightly tap the inlet valve on the valve seat
while turning it.
• If the measured value exceeds the
limit value, fix the contact surface
of the valve seat using a sheet cut-
ter.
• If the contact position is not in the
center of the valve seat, fix the con-
tact surface of the valve seat using
a sheet cutter.
• If the contact surface is not smooth,
fix the contact surface of the valve
seat using a sheet cutter.

CAUTION
• After fixing the valve, remove all
compounds.

84402826 - May 2011

2415-42
 Removal and Installation of Cylinder Head

10) Check the sinking amount of the inlet valve.

Specified value: 0.80 - 1.03 mm {0.0315 -
0.0406 in}
Limit: 2.3 mm {0.0906 in}

1 Valve
The position 10 mm under the
2
valve guide head
3 Valve guide
5. Exhaust valve Inspection
1) Measure the exhaust valve using the microm- CAUTION
eter.
• Replace the exhaust valve and
ANNOTATION: valve guide if the measured value
• Outer diameter of the valve stem exceeds the limit value.
Measurement part: 3 section(s) 4) Measure the exhaust valve using the microm-
Specified value: 8.00 mm {0.3150 in} Diame- eter.
ter
Limit: 7.88 mm {0.3102 in} Diameter ANNOTATION:

CAUTION • Valve thickness

Specified value: 1.75 mm {0.0689 in}
• Replace the exhaust valve and Limit: 1.30 mm {0.0512 in}
valve guide if the measured value
is under the limit value.

CAUTION
2) Install the exhaust valve to the valve guide. • Replace the exhaust valve and
3) Measure the valve guide clearance using the valve guide if the measured value
dial gauge. exceeds the limit value.
ANNOTATION:
5) Inspect the exhaust valve using the red lead
• Valve guide clearance primer.
Specified value: 0.064 - 0.096 mm {0.0025 - ANNOTATION:
0.0038 in}
Limit: 0.25 mm {0.0098 in} • Inspect the contact surface of the exhaust
valve and valve seat.
Specified value: 2.5 mm {0.0984 in} Contact
width
Limit: 3.0 mm {0.1181 in} Contact width
84402826 - May 2011
2415-43
 Removal and Installation of Cylinder Head

CAUTION
• If the measured value exceeds the
limit value, fix the contact surface
of the valve seat using a sheet cut-
ter.
• If the contact position is not in the
center of the valve seat, fix the con-
tact surface of the valve seat using
a sheet cutter.
• If the contact surface is not smooth,
fix the contact surface of the valve
seat using a sheet cutter.

CAUTION
• After fixing the valve, remove all
compounds.

10) Check the sinking amount of the exhaust

valve.
Specified value: 1.24 - 1.47 mm {0.0488 -
0.0579 in}
Limit: 2.8 mm {0.1102 in}

6) Adjust the valve seat.

CAUTION
• Use a seat cutter suitable for the
valve seat angle and valve stem di-
ameter.

Valve seat angle: 45 °

External diameter of the valve stem: 8.0 mm
{0.3150 in} Diameter

6. Cylinder head assembly Inspection

CAUTION
• Clean the each part of the cylinder head
assembly before inspecting.
• Be careful not to damage the cylinder
head while cleaning the cylinder head as-
sembly.

1) Inspect the cylinder head assembly.

ANNOTATION:
• Installation surface of the cylinder head gas-
7) Apply the compound to the valve seat. ket
8) Install the exhaust valve to the valve guide. • Combustion chamber
9) Adjust contact surface to standard value using • Exhaust port
the valve lapper. • Valve seat
ANNOTATION: • Glow plug hole

• Tap the exhaust valve on the valve seat CAUTION

while turning it.
• Replace the cylinder head if dam-
age such as a crack has been found
in the inspection.

84402826 - May 2011

2415-44
 Removal and Installation of Cylinder Head

ANNOTATION:
• Fix it if it is possible.
2) Perform dye penetrant check.
ANNOTATION:
• Check if there is a problem which cannot be
detected by visual inspection.
3) Align the simple straight ruler to the cylinder
head assembly.
4) Measure the clearance using the feeler
gauge.
ANNOTATION:
Measurement part: 6 section(s)
• Flatness of the bottom of the cylinder head
Specified value: less than 0.05 mm {less than
0.0020 in}
Limit: 0.2 mm {0.0079 in}

CAUTION
• Replace the cylinder head if the
measured value exceeds the limit
value.

5) Inspect the water leak using the water pres-

sure tester.
Specified pressure: 490.0 kPa {71 psi}
Specified time: 3 min
ANNOTATION:
Measurement part: 6 section(s) • Perform a hydraulic test with the injector
Limit: 0.2 mm {0.0079 in} holder installed.
ANNOTATION:
• Flatness of the installation surface of the ex-
haust manifold and inlet cover.

84402826 - May 2011

2415-45
Removal and Installation of Cylinder Head

84402826 - May 2011

2415-46
 Section

2425

Removal and Installation of Cylinder Block

84402826 - May 2011

84402826 - May 2011
 CONTENTS

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

Installation of Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

2425-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
2425-2 PRINTED IN FRANCE
 Removal and Installation of Cylinder Block

Removal of Cylinder Block 1) Remove the fan guide from the fan guide
bracket.
1. Battery ground cable Disconnect
1) Disengage the battery ground cable from the
battery.
2. Coolant Drain
1) Drain the coolant from the radiator.

CAUTION
• After the coolant is discharged,
make sure to tighten the drain plug.

3. Engine oil Drain

Remove the drain plug from the oil pan.
Drain the engine oil from the oil pan.
Install the drain plug to the oil pan.
tightening torque： 70 N・m { 7.1 kgf・m / 52 lb・
1 Bolt
ft }
4. Engine harness Disconnect 2 Washer
Disengage the engine harness from the engine as- 3 Rubber mount
sembly. 4 Rubber mountassembly.
5 Guide tube
CAUTION 6 Fan guide
• Disconnect each connector.

5. Cooling fan Removal 2) Remove the fan guide bracket from the engine
assembly.
1) Remove the cooling fan from the adapter.
7. Cooling fan belt Removal
1) Remove the cooling fan belt from the engine
assembly.

1 Cooling fan
2 Adapter

6. Fan guide Removal

1 Adjust bolt
2 Fixing bolt
3 Fixing bolt

8. Crankshaft pulley Removal

1) Remove the crankshaft pulley from the crank-
shaft.
2) Remove the crankshaft damper from the
crankshaft pulley.
9. Crankshaft front oil seal Removal
1) Remove the crankshaft front oil seal from the
crankshaft using the special tool.
84402826 - May 2011
2425-3
 Removal and Installation of Cylinder Block

tightened using a clip band to improve the

workability.
10. Water pump assembly Removal
1) Remove the adapter from the water pump as-
sembly.
2) Remove the spacer from the adapter.
3) Remove the fan pulley from the water pump
assembly.
4) Disengage the water hose from the water
pump assembly.
5) Disengage the water return pipe from the wa-
ter pump assembly.
6) Remove the water pump assembly from the
front cover.
Special tool: rear oil seal remover (refer
to section 1003)

1 Adapter
2 Spacer
1 Felt 3 Fan pulley
2 Slinger 4 Water pump assembly
3 Crankshaft front oil seal 5 Gasket

11. Front cover Removal

1) Remove the front cover from the cylinder
block.
12. Turbocharger assembly Removal
1) Remove the air cleaner duct from the air
cleaner assembly and the turbocharger as-
sembly.
2) Remove the air intake hose from the tur-
bocharger assembly and the intercooler.
3) Remove the exhaust pipe from the tur-
bocharger assembly.
4) Disengage the oil feed pipe from the tur-
bocharger assembly.
ANNOTATION:
CAUTION • Remove the clip.
• Be careful not to damage the oil 5) Remove the oil feed pipe from the oil port
seal press-fitting surface. cover.
ANNOTATION:
ANNOTATION:
• Remove the clip.
• Remove the slinger and oil seal together.
• If the slinger of the remover is easy to come 6) Disengage the oil return pipe from the tur-
off, the outer circumference of the jig can be bocharger assembly.

84402826 - May 2011

2425-4
 Removal and Installation of Cylinder Block

7) Remove the oil return pipe from the cylinder 11) Remove the water feed pipe from the cylinder
block. block.
ANNOTATION:
• Remove the clip.

1 Turbocharger assembly
2 Oil feed pipe
3 Oil return pipe

8) Disengage the water return pipe from the tur- 1 Water return pipe
bocharger assembly. 2 Water feed pipe
9) Remove the water return pipe from the water
pump assembly.
10) Disengage the water feed pipe from the tur-
12) Remove the exhaust manifold stay from the
bocharger assembly.
cylinder block and the turbocharger assembly.
ANNOTATION:
• Remove the clip.

1 Turbocharger assembly
2 Exhaust manifold
3 Exhaust manifold stay
84402826 - May 2011
2425-5
 Removal and Installation of Cylinder Block

13) Disengage the harness connector from the 3) Remove the EGR pipe A from the EGR cooler
turbocharger assembly. A and exhaust manifold.
14) Remove the turbocharger assembly from the
exhaust manifold.

1 EGR cooler A
2 EGR pipe A
1 Exhaust manifold 3 Exhaust manifold
2 Turbocharger assembly
4) Remove the EGR cooler A from the EGR pipe
13. EGR cooler assembly Removal B.
5) Remove the EGR pipe B from the EGR cooler
1) Disengage the water rubber hose from the B.
EGR cooler assembly. 6) Remove the EGR cooler B from the EGR pipe
C.
7) Remove the EGR pipe C from the EGR valve.

1 Water rubber hose

1 EGR valve
2) Remove the EGR heat protector from the 2 EGR pipe C
EGR pipe A. 3 EGR cooler B
4 EGR pipe B
5 EGR cooler A
6 EGR pipe D

14. EGR valve Removal

1) Disengage the harness connector from the
EGR valve.

1 EGR heat protector

84402826 - May 2011
2425-6
 Removal and Installation of Cylinder Block

2) Remove the EGR valve from the EGR pipe D. 2) Remove the EGR cooler water pipe from the
engine assembly.
ANNOTATION:
• Remove the EGR cooler water feed pipe
and EGR cooler water return pipe.

1 EGR cooler C
2 EGR pipe C
3 EGR valve
4 EGR pipe D

15. EGR cooler water pipe Removal

1) Disengage the radiator upper hose from the
water outlet pipe.

1 EGR cooler water feed pipe

2 EGR cooler water feed pipe

16. Intake throttle valve Removal

1) Remove the air duct from the intake throttle
valve.

84402826 - May 2011

2425-7
 Removal and Installation of Cylinder Block

2) Disengage the harness connector from the in- 3) Disengage the harness connector from the
take throttle valve. EGR valve.
4) Disconnect the harness connector from the
ANNOTATION:
IMT sensor.
• Pull the lock operation portion to release the 5) Remove the harness clip from the inlet pipe.
lock.

1 Boost sensor
1 Lock operation section 2 IMT sensor
2 Lock release 3 EGR valve
3 Lock 4 Harness clip
5 Boost temperature sensor
3) Remove the intake throttle valve from the inlet
pipe. 6) Remove the inlet pipe from the case.

1 Boost temperature sensor 1 Case

2 Boost sensor 2 Gasket
3 Inlet pipe 3 Inlet pipe
4 Gasket
5 Intake throttle valve 18. Oil level gauge guide tube Removal
1) Remove the oil level gauge from the oil level
17. Inlet pipe Removal
gauge guide tube.
1) Disengage the harness connector from the 2) Disengage the oil level gauge guide tube from
boost sensor. the cylinder head cover.
2) Disconnect the harness connector from the 3) Disengage the oil level gauge guide tube from
boost temperature sensor. the case.

84402826 - May 2011

2425-8
 Removal and Installation of Cylinder Block

4) Remove the oil level gauge guide tube from

the cylinder block.

1 No.1 injection pipe

2 No.2 injection pipe
1 Cylinder head cover 3 No.3 injection pipe
2 Oil level gauge guide tube 4 No.4 injection pipe
3 Case 5 Fuel leak-off pipe
4 Cylinder block 6 Fuel pipe
7 Common rail assembly
19. Glow plug Removal
1) Remove the glow plug connector from the 21. Fuel pipe Removal
glow plug. 1) Remove the fuel pipe from the fuel supply
2) Remove the glow plug from the cylinder head pump and the common rail assembly.
assembly.
ANNOTATION:
• Remove the clip.
CAUTION
• Do not reuse the removed fuel pipe.

22. Fuel leak off pipe assembly Removal

1) Disengage the fuel leak-off pipe from the cylin-
der head assembly.
2) Remove the fuel leak-off pipe from the fuel
supply pump.
ANNOTATION:

20. Injection pipe Removal • Remove the eyebolt tightened together with
the fuel feed pipe.
1) Remove the clip from the bracket.
2) Remove the injection pipe from the injector 3) Disengage the fuel leak-off pipe from the com-
and the common rail assembly. mon rail assembly.

CAUTION
• Do not reuse the removed injection
pipe.
• Seal the common rail and injector to
prevent foreign material from enter-
ing.

84402826 - May 2011

2425-9
 Removal and Installation of Cylinder Block

4) Remove the fuel leak-off pipe from the case. 24. Cylinder head cover Removal
ANNOTATION: 1) Disengage the ventilation hose from the air
• Remove the clip. breather.
2) Remove the cylinder head cover from the
lower cover.
3) Remove the head cover gasket from the cylin-
der head cover.

1 Common rail assembly

2 Cylinder head assembly
3 Fuel leak-off pipe
4 Fuel supply pump
1 Cylinder head cover
23. Common rail assembly Removal 2 Gasket
3 Lower cover
1) Disengage the harness connector from the
fuel pressure sensor.
2) Remove the common rail assembly from the
inlet cover and the common rail bracket. 25. Lower cover Removal
3) Remove the common rail bracket from the oil 1) Remove the connector from the lower cover.
cooler assembly.
CAUTION
• Do not pull the wire, or pry the con-
nector with a screwdriver.

2) Disengage the injector harness from the injec-

tor.

CAUTION
• Be careful not to damage the injec-
tor side stud bolts.

3) Remove the injector harness from the cylinder

head assembly.
ANNOTATION:
1 Common rail assembly
• Remove the bracket tightening bolts and
2 Fuel pressure sensor then remove the injector harness together
3 Common rail bracket with the bracket.

84402826 - May 2011

2425-10
 Removal and Installation of Cylinder Block

4) Remove the lower cover from the cylinder

head assembly.

Special tool: sliding hammer (refer to

section 1003)

1 Lower cover
2 Connector

5) Remove the gasket from the lower cover.

6) Remove the rubber plug from the cylinder
head assembly.
26. Injector Removal
1) Remove the injector leak-off pipe from the in-
jector.
2) Remove the injector from the cylinder head
assembly.
ANNOTATION:
• When it is difficult to remove the injector, use
a special tool.

Special tool: fuel injector remover (refer 1 Sliding hammer

to section 1003) 2 Fuel injector remover
3 Injector

CAUTION
• Confirm that the sleeve is not pulled
out together when pulling out the
injector using a special tool.
• Store each ID code plate on the in-
jector head with the cylinder num-
ber tag attached to avoid a mix-up.
• Be extremely careful not to damage
the injector nozzle.

84402826 - May 2011

2425-11
 Removal and Installation of Cylinder Block

1) Remove the camshaft bearing cap from the

cylinder head assembly.
2) Remove the camshaft bearing from the
camshaft bearing cap.
3) Remove the camshaft from the cylinder head.
4) Remove the camshaft bearing from the cylin-
der head assembly.
ANNOTATION:
• Temporarily assemble the removed caps
and bearings in the original position to avoid
a mix-up after the bearings have been in-
spected.

27. Rocker arm shaft Removal

1) Loosen the adjust screw using the wrench.
ANNOTATION:
• Loosen all valve clearance adjustment
screws.

29. Bridge Removal

1) Remove the bridge cap from the bridge.

CAUTION
• Be careful not to drop the bridge
cap into the engine.

2) Remove the rocker arm shaft from the cylinder 2) Remove the bridge from the bridge guide.
head assembly. ANNOTATION:
ANNOTATION:
• After removing, organize to avoid a mix-up
• Evenly loosen the rocker arm shaft bracket with other installation locations.
and the rocker arm assembly bracket tight-
ening bolts from both ends and remove
them.

CAUTION
• Be careful not to remove the bolt
shown in the diagram.

1 Bridge cap
2 Bridge

30. Cylinder head assembly Removal

1) Remove the cylinder head assembly from the
28. Camshaft Removal cylinder block.
84402826 - May 2011
2425-12
 Removal and Installation of Cylinder Block

ANNOTATION: 2) Remove the fuel supply pump from the cylin-

der block.
• Loosening order of the head bolts

CAUTION 1 Bolt
• Since the idle gear C protrudes
from the bottom surface of the 3) Remove the supply pump gear from the fuel
cylinder head, be careful not to supply pump using the puller.
damage the gear.

4) Remove the fuel supply pump from the supply

pump bracket.
1 Idle gear C
CAUTION

2) Remove the cylinder head gasket from the • Do not hold the pipe of the fuel sup-
cylinder block. ply pump.

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

31. Fuel supply pump Removal

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

1 Fuel supply pump

2 O-ring
3 Supply pump bracket
84402826 - May 2011
2425-13
 Removal and Installation of Cylinder Block

32. Starter assembly Removal • Gradually loosen the flywheel installation

bolts in the order shown in the diagram.
1) Disengage the earth cable from the starter as-
sembly.
2) Remove the starter assembly from the fly-
wheel housing.

CAUTION
• Fix the flywheel firmly so that it will
not rotate.
1 Oil pressure sensor
35. Crankshaft rear oil seal Removal
2 Oil port cover
3 Starter assembly 1) Remove the crankshaft rear oil seal from the
crankshaft using the special tool.

33. CKP sensor Removal

1) Disengage the harness connector from the
CKP sensor.
2) Remove the CKP sensor from the flywheel
housing.

CAUTION
• Be careful not to subject the sensor
to shock.

Special tool: rear oil seal remover (refer

to section 1003)

1 CKP sensor
2 Flywheel housing

34. Flywheel Removal

1 Felt
1) Remove the flywheel from the crankshaft. 2 Slinger
ANNOTATION: 3 Crankshaft rear oil seal

84402826 - May 2011

2425-14
 Removal and Installation of Cylinder Block

38. Flywheel housing Removal

1) Remove the cover from the flywheel housing.
2) Remove the flywheel housing from the cylin-
der block and the crankcase.

CAUTION
• Do not forget to remove the bolt
shown in the diagram.

CAUTION
• Be careful not to damage the oil
seal press fitting surface.

ANNOTATION:
• Remove the slinger and oil seal together.
• If the slinger of the remover is easy to come
off, the outer circumference of the jig can be
tightened using a clip band to improve the
workability.
1 Bolt
36. Oil pan Removal
1) Disengage the harness connector from the oil
level switch. 39. Idle gear Measurement
2) Remove the oil pan from the crankcase. 1) Align the dial gauge to the idle gear.
3) Remove the gasket from the oil pan.
ANNOTATION:
37. Oil strainer Removal
• Attach the dial gauge to the idle gear tooth
1) Remove the oil strainer from the crankcase. to be measured.
2) Remove the O-ring from the oil strainer.
2) Inspect the backlash.
ANNOTATION:
• Gently move the gear right and left to read
the inconsistency on the dial gauge.

CAUTION
• Measure the idle gear backlash be-
fore removing the idle gear A.

Specified value： 0.10 - 0.17 mm { 0.0039 -

0.0067 in }
Limit： 0.30 mm { 0.0118 in }

CAUTION

1 M10 bolt • Replace the idle gear if the mea-

2 M8 bolt sured value exceeds the limit value.

84402826 - May 2011

2425-15
 Removal and Installation of Cylinder Block

41. Oil pump assembly Removal

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

3) Measure the clearance using the feeler

gauge.
ANNOTATION:
• Measure the clearance between the idle 42. Idle gear B Removal
gear and the thrust collar.
1) Remove the idle gear B from the idle gear B
CAUTION shaft.
2) Remove the idle gear B shaft from the cylinder
• Measure the play of the idle gear in block.
the axis direction before removing
the idle gear B.

Specified value： 0.080 - 0.155 mm { 0.0031

- 0.0061 in }
Limit： 0.20 mm { 0.0079 in }

CAUTION
• Replace the idle gear if the mea-
sured value exceeds the limit value.

43. Piston Removal

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

40. Idle gear A Removal

1) Remove the idle gear A from the idle gear A
shaft.

84402826 - May 2011

2425-16
 Removal and Installation of Cylinder Block

2) Remove the connecting rod bearing cap from

the connecting rod.
ANNOTATION:
• Set the piston of the cylinder to be removed
to the bottom dead center.

CAUTION
• Replace the thrust bearing if the
measured value is not within the
range of the standard value.

3) Remove the connecting rod bearing from the 2) Remove the crankcase from the cylinder
connecting rod bearing cap. block.
ANNOTATION: ANNOTATION:
• Organize the removed bearings by the cylin- • Loosening order
ders using tags, etc.
4) Remove the piston from the cylinder block.
ANNOTATION:
• Pull out the piston and connecting rod to-
gether to the cylinder head side.

CAUTION
• Be careful not to damage the oil jet.

5) Remove the connecting rod bearing from the

connecting rod.
ANNOTATION:
• Organize the removed bearings by the cylin- ANNOTATION:
ders using tags, etc.
• Remove the crankcase using the replacer
44. Crankshaft Removal holes indicated by the arrow in the diagram.
1) Measure the clearance using the feeler ： 3 section(s) Replacer hole
gauge. 3) Remove the thrust bearing from the
ANNOTATION: crankcase.
4) Remove the crankshaft bearing from the
• Measure the crankshaft clearance in the crankcase.
axis direction at the bearing section no.7.
Specified value： 0.104 - 0.205 mm { 0.0041
- 0.0081 in }

84402826 - May 2011

2425-17
 Removal and Installation of Cylinder Block

5) Remove the crankshaft from the cylinder 46. Cylinder liner Removal
block.
1) Remove the cylinder liner from the cylinder
6) Remove the thrust bearing from the cylinder
block.
block.
7) Remove the crankshaft bearing from the cylin-
der block.
45. Piston oil jet Removal
1) Remove the piston oil jet from the cylinder
block.

CAUTION
• Do not tilt the cylinder liner when
storing.

84402826 - May 2011

2425-18
 Removal and Installation of Cylinder Block

Installation of Cylinder Block ： 118.001 ： 118.011

： 118.021
- 118.010 - 118.020
- 118.030
1. Cylinder liner Preparation Block inner
mm mm mm
diameter
{4.6457 - {4.6461 -
{4.6465 -
CAUTION 4.6461 in} 4.6464 in}
4.6468 in}
• When replacing the cylinder liner, select ： 118.001
the cylinder liner following the procedure - 118.010
Liner outer ： 117.991 - 118.000 mm
below. mm
diameter {4.6453 - 4.6457 in}
{4.6457 -
1) Check marking of the cylinder block. 4.6461 in}

ANNOTATION:
• A marking on a cylinder block indicates the 2. Cylinder liner Installation
cylinder block bore grade.
CAUTION
• Since the cylinder liner is thin, handle it
carefully.
• Do not tilt the cylinder liner when storing.

2) Check the grade of the cylinder liner.

1) Clean the cylinder block using the air.

2) Clean the cylinder liner using the air.
3) Install the cylinder liner to the cylinder block.
ANNOTATION:
• Install the cylinder liner on the cylinder block
vertically.

CAUTION
• Do not tap or apply excessive force
when inserting the liner.
1 Grade confirmation location

3) Select the cylinder liner.

Matching grades for cylinder block and liner outer

diameter
Marking on
1 2 3
the block
Liner outer
1X 3X
diameter

Cylinder block inner diameter, liner outer diameter

grade
Grade 1･1X 2･1X 3･3X

84402826 - May 2011

2425-19
 Removal and Installation of Cylinder Block

CAUTION
• After replacing the cylinder liner,
be sure to measure the protrusion
amount of the cylinder liner.

4) Measure the cylinder liner using the dial

gauge.
Specified value： 0.05 - 0.10 mm {0.0020 -
0.0039 in} Protrusion amount of cylinder liner
Limit： 0.03 mm {0.0012 in} less than
ANNOTATION:
• The limit value indicates the difference in the
protrusion amounts with the adjacent cylin- 4. Crankshaft bearing Preparation
der liner.
CAUTION
• When replacing the crankshaft bearing,
select the crankshaft bearing following
the procedure below.

1) Check marking of the crankcase.

ANNOTATION:
• The marking on the crankcase indicates the
inner diameter grade of the cylinder block
journal section.
• Grade indications are lined up as No.1, 2, 3,
4, 5 from the left when looking at the mark-
ing section from the front side.
3. Piston oil jet Installation
1) Install the piston oil jet to the cylinder block.

CAUTION
• Be careful not to deform or damage
the nozzle part of the piston oil jet.

Tightening torque： 21 N・m {2.1 kgf・m / 15

lb・ft}

2) Check the marking on the crankshaft.

ANNOTATION:
• The marking on the crankshaft indicates the
outer diameter grade of the journal section.
• Grade indications are lined up as No.1, 2, 3,
4, 5 from the left when looking at the mark-
ing section from the front side.

84402826 - May 2011

2425-20
 Removal and Installation of Cylinder Block

1 Upper bearing
2 Oil hole
3 Grade identification color
4 Oil groove
5 Lower bearing
6 Grade identification color

5. Crankshaft Installation
1) Install the crankshaft bearing to the cylinder
block.
ANNOTATION:
• Install a bearing with an oil hole on the cylin-
3) Select the crankshaft bearing. der block.
ANNOTATION: CAUTION
• Refer to the bearing selection table. • Make sure there is no grime or oil on
the cylinder block contact surface
for the crankshaft bearing.
Bearing selection table
Grade combination Oil clearance 2) Apply the grease to the thrust bearing.
Cylin- Crank
ANNOTATION:
der block journal 1, 2, 4, 5 3
grade grade • Apply a small amount of grease to the thrust
： 0.041 - ： 0.055 - bearing to prevent falling.
0.068 mm 0.082 mm
1 1 3) Install the thrust bearing to the cylinder block.
{0.0016 - {0.0022 -
0.0027 in} 0.0032 in} ANNOTATION:
： 0.039 -
0.065 mm
0.053 - 0.079 • Install the thrust bearing on the No.5 journal
1 2 mm {0.0021 - so that the oil groove faces the engine front.
{0.0015 -
0.0031 in}
0.0026 in}
： 0.043 - ： 0.057 -
0.070 mm 0.084 mm
2 1
{0.0017 - {0.0022 -
0.0028 in} 0.0033 in}
： 0.041 - ： 0.055 -
0.067 mm 0.081 mm
2 2
{0.0016 - {0.0022 -
0.0026 in} 0.0032 in}

CAUTION
• Be careful not to mistake the bear-
ing shape when installing the 4) Apply the engine oil to the crankshaft bearing.
crankshaft bearing. 5) Apply the engine oil to the crankshaft.
6) Put the crankshaft on the cylinder block.

84402826 - May 2011

2425-21
 Removal and Installation of Cylinder Block

7) Install the thrust bearing to the cylinder block.

ANNOTATION:
• Install the thrust bearing on the No.5 journal
so that the oil groove faces the engine rear.

1 2 - 3 mm
2 3 - 4 mm

8) Install the crankshaft bearing to the

crankcase. CAUTION

CAUTION • After applying the liquid gasket, in-

stall the crankcase within 5 min-
• Make sure there is no grime or oil on utes.
the crankcase contact surface for
the crankshaft bearing. 13) Put the crankcase on the cylinder block.

9) Apply the grease to the thrust bearing. CAUTION

ANNOTATION: • Be careful not to let the thrust bear-
ing fall.
• Apply a small amount of grease to the thrust
bearing to prevent falling. 14) Apply the disulfide molybdenum grease to the
10) Install the thrust bearing to the crankcase. bolt.
ANNOTATION: ANNOTATION:
• Install the thrust bearing on the No.5 journal • Apply to the threaded portion and seat sur-
so that the oil groove faces the engine rear. face on the M14 bolt for crankcase installa-
tion.

CAUTION
• Do not apply grease to the M10 bolt.

ANNOTATION:
• Tightening order

11) Apply the engine oil to the crankshaft bearing.

12) Apply the liquid gasket to the crankcase.
ANNOTATION:
• Apply ThreeBond 1207B to the crankcase
thoroughly so that there is no break in appli-
cation of the bead.

15) Tighten the bolt using the torque wrench.

Tightening torque： 54 N・m {5.5 kgf・m / 40
lb・ft} M14 bolt
84402826 - May 2011
2425-22
 Removal and Installation of Cylinder Block

16) Tighten the bolt using the torque wrench. 7) Install the special tool to the piston
Tightening torque： 132 N・m {13.5 kgf・m
/ 97 lb・ft} M14 bolt
17) Tighten the bolt using the special tool.

Special tool: piston setting tool (refer to

section 1003)
8) Align the piston to the cylinder block.
Special tool: angle gauge (refer to section
ANNOTATION:
1003)
Tightening angle： 30 ° M14 bolt • Turn the piston so that the front mark faces
18) Tighten the bolt using the torque wrench. the engine front.
Tightening torque： 37 N・m {3.8 kgf・m / 27
lb・ft} M10 bolt 9) Press the piston.
19) Tighten the bolt using the torque wrench.
CAUTION
Tightening torque： 142 N・m {14.5 kgf・m
/ 105 lb・ft} Check the tightening M14 bolt • To avoid damaging the oil jet, place
the crank pin on the cylinder on
CAUTION which the piston will be installed at
• Confirm that the crankshaft turns top dead center.
smoothly after tightening the bolts. • To avoid damaging the piston ring,
firmly attach the piston installer to
the cylinder block and push it.
6. Piston Installation
• Be careful not to damage the crank
1) Install the connecting rod bearing to the con- pin and cylinder liner.
necting rod. • Attach a stopper so that the liner
2) Apply the engine oil to the connecting rod does not protrude.
bearing.

CAUTION
• Apply engine oil only to the inter-
nal diameter of the connecting rod
bearing.

3) Apply the engine oil to the piston ring.

4) Apply the engine oil to the piston.
ANNOTATION:
• Thoroughly apply engine oil to the ring
grooves and piston side surface.
5) Adjust the piston ring.
ANNOTATION:
1 No.1 compression ring joint
• Shift each piston ring joint by the specified 2 No.2 compression ring joint
angle.
3 Oil ring joint
Specified angle： 90 ° 4 Front mark
6) Apply the engine oil to the cylinder liner.
10) Install the connecting rod bearing to the con-
necting rod bearing cap.

84402826 - May 2011

2425-23
 Removal and Installation of Cylinder Block

11) Apply the engine oil to the connecting rod CAUTION

bearing.
• Do not allow tightening tools to
CAUTION touch the oil jet.
• Confirm that the crankshaft turns
• Apply engine oil only to the inter-
nal diameter of the connecting rod smoothly after tightening the con-
necting rod bolt.
bearing.
14) Apply the disulfide molybdenum grease to the
12) Align the connecting rod bearing cap to the
bolt.
connecting rod.
ANNOTATION:
ANNOTATION:
• Apply to the threaded portion and seat sur-
• Confirm that the numbers on the connecting
face of the bolts for the connecting rod in-
rod bearing cap and the connecting rod are
stallation.
the same.
15) Tighten the bolt using the torque wrench.
Tightening torque： 39 N・m {4.0 kgf・m / 29
lb・ft}
16) Tighten the bolt using the special tool.

Front and back side discrimina-

1
tion boss
Grade mark of the large end Special tool: angle gauge (refer to section
2
hole diameter 1003)
3 Cylinder number Tightening angle： 60 °
17) Tighten the bolt using the special tool.
Tightening angle： 30 °
13) Install the connecting rod bearing cap to the 18) Tighten the bolt using the torque wrench.
connecting rod. Tightening torque： 98 N・m {10.0 kgf・m /
ANNOTATION: 72 lb・ft} Check the tightening

• Precautions when tightening the connecting

rod bolt

CAUTION
• Set each cylinder to the bottom
dead center while working.

7. Idle gear B Installation

1) Install the idle gear B shaft to the cylinder
block.
Tightening torque： 31 N・m {3.2 kgf・m / 23
lb・ft}

84402826 - May 2011

2425-24
 Removal and Installation of Cylinder Block

2) Apply the engine oil to the idle gear B shaft. 8. Oil pump assembly Installation
1) Install the oil pump to the cylinder block.

CAUTION
• Use new gaskets.

Tightening torque： 31 N・m {3.2 kgf・m / 23

lb・ft}
9. Idle gear A Installation
1) Align 1st cylinder to the compression top dead
center.
2) Apply the engine oil to the idle gear A.
3) Install the idle gear A shaft to the idle gear A.
4) Align the idle gear A to alignment mark.
3) Apply the engine oil to the idle gear B.
4) Install the idle gear B to the cylinder block. ANNOTATION:
Tightening torque： 110 N・m {11.2 kgf・m /
81 lb・ft} • Align the L mark on the crank gear with the
O mark on the idle gear A.
5) Apply the engine oil to the bolt.
ANNOTATION:
• Apply engine oil to the threaded portion and
seat surface on the idle gear A installation
bolt.

1 Idle gear B
2 Thrust collar
3 Bolt

CAUTION
• Confirm that the idle gear B turns
smoothly after installing.

84402826 - May 2011

2425-25
 Removal and Installation of Cylinder Block

6) Install the idle gear A to the cylinder block.

Tightening torque： 133 N・m {13.6 kgf・m
/ 98 lb・ft}

1 Idle gear C 4 PTO gear 7 Oil pump drive gear

2 Camshaft gear 5 PTO idle gear 8 Supply pump gear
3 Idle gear B 6 Crankshaft gear 9 Idle gear A

84402826 - May 2011

2425-26
 Removal and Installation of Cylinder Block

10. Flywheel housing Installation CAUTION

1) Clean the cylinder block using the scraper.
• Be careful not to forget to tighten
ANNOTATION: the bolt indicated in the diagram.
• Remove dust and oil from the flywheel hous-
ing installation area.
2) Apply the liquid gasket to the cylinder block.
ANNOTATION:
• Refer to the diagram and apply the Three-
Bond 1207B to the cylinder block.

1 Bolt

4) Apply engine oil to the PTO gear shaft.

5) Install the PTO idle gear shaft to the PTO idle
gear.
6) Install the PTO idle gear to the cylinder block.
Tightening torque： 134 N・m {13.7 kgf・m
/ 99 lb・ft}
CAUTION
• After applying the liquid gasket, in-
stall the flywheel housing within 5
minutes.

3) Install the flywheel housing to the cylinder

block.

Tightening torque
： 96 N・m {9.8 kgf・m
Flywheel housing side
/ 71 lb・ft}
： 38 N・m {3.9 kgf・m
Cylinder block side
/ 28 lb・ft}
Supply pump bracket ： 76 N・m {7.7 kgf・m
side / 56 lb・ft} 7) Install the O-ring to the cover.
8) Install the cover to the flywheel housing.
Tightening torque： 19 N・m {1.9 kgf・m / 14
ANNOTATION: lb・ft}
• Install the flywheel housing after aligning 11. Oil strainer Installation
with the knock pin position of the cylinder
block. 1) Install the O-ring to the oil strainer.

84402826 - May 2011

2425-27
 Removal and Installation of Cylinder Block

2) Install the oil strainer to the crankcase. 2) Install the gasket to the oil pan.
Tightening torque： 31 N・m {3.2 kgf・m / 23 3) Install the oil pan to the crankcase.
lb・ft} Tightening torque： 29 N・m {3.0 kgf・m / 22
lb・ft}
ANNOTATION:
• Tightening order

1 M10 bolt
2 M8 bolt
4) Connect the harness connector to the oil level
12. Oil pan Installation switch.
1) Apply the liquid gasket to the crankcase. 13. Crankshaft rear oil seal Installation
ANNOTATION: 1) Prepare the special tool.

• Apply ThreeBond 1207B to each joint of the

crankcase, flywheel housing and gear case.
Bead width： 3.0 mm {0.1181 in}

Special tool: oil seal installer (refer to

CAUTION
• After applying the liquid gasket, in-
stall the oil pan within 5 minutes.
section 1003)
ANNOTATION:
• Install the crankshaft rear oil seal and
slinger together.
• In order to install the crankshaft rear oil seal,
use the one(s) in the following table from
among the parts included in the kit.

84402826 - May 2011

2425-28
 Removal and Installation of Cylinder Block

8) Tighten the center bolt using the wrench.

ANNOTATION:
• Tighten the center bolt until the sleeve
touches the adapter.

Legend Parts number

1: Adapter 5-8840-2709-0
2: Adapter tightening bolts 5-8840-2714-0
3: Center bolt 5-8840-2713-0
4: Sleeve 5-8840-9063-0
5: Collar 5-8840-2710-0 9) Inspect the crankshaft rear oil seal.
6: Adapter ring 5-8840-2711-0
ANNOTATION:
7: Crankshaft rear oil seal -
• Measure the distance between the crank-
shaft head and the crankshaft rear oil seal.
2) Apply the engine oil to the crankshaft rear oil Specified value ： 7.2 - 7.8 mm {0.2835 -
seal. 0.3071 in}
CAUTION
• Apply only to the lip section of the
oil seal.

3) Install the crankshaft rear oil seal to the

adapter.
4) Install the adapter to the crankshaft.
5) Install the adapter ring to the sleeve.
6) Install the sleeve to the adapter.

1 Crankshaft
2 Crankshaft rear oil seal
3 Measurement location
4 Collar
5 Adapter ring
6 Sleeve
7 Adapter

14. Flywheel Installation

1) Apply the disulfide molybdenum grease to the
1 Sleeve bolt.
2 Adapter ring
ANNOTATION:
• Apply to the seat surface and threaded por-
7) Install the center bolt to the sleeve. tion on the flywheel installation bolts.

84402826 - May 2011

2425-29
 Removal and Installation of Cylinder Block

2) Install the flywheel to the crankshaft. • Tighten together with the clip.
CAUTION Tightening torque： 6 N・m {0.6 kgf・m / 52
lb・in}
• Pay attention to the knock pin posi- 2) Connect the harness connector to the CKP
tion of the crankshaft. sensor.

ANNOTATION:
• Tightening order

1 CKP sensor
2 Flywheel housing
3) Tighten the bolt using the torque wrench.
Tightening torque： 78 N・m {8.0 kgf・m / 58 16. Starter assembly Installation
lb・ft} 1) Install the starter assembly to the flywheel
4) Tighten the bolt using the special tool. housing.
Tightening torque： 106 N・m {10.8 kgf・m
/ 78 lb・ft}
2) Connect the earth cable to the starter assem-
bly.
Tightening torque： 51 N・m {5.1 kgf・m / 37
lb・ft}

Special tool: angle gauge (refer to section

1003)
Tightening angle： 120 °
15. CKP sensor Installation
1) Install the CKP sensor to the flywheel housing.

CAUTION 1 Oil pressure sensor

• Be careful not to subject the sensor 2 Oil port cover
to shock. 3 Starter assembly

ANNOTATION: 17. Fuel supply pump Installation

84402826 - May 2011

2425-30
 Removal and Installation of Cylinder Block

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

2) Install the fuel supply pump to the supply
pump bracket.
Tightening torque： 19 N・m {1.9 kgf・m / 14
lb・ft}

CAUTION
• Be careful not to let the O-ring get
twisted.

4) Align 1st cylinder to the compression top dead

center.

1 Fuel supply pump

2 O-ring
3 Supply pump bracket

3) Install the supply pump gear to the fuel supply

pump.
Tightening torque： 64 N・m {6.5 kgf・m / 47 1 Front cover marking
lb・ft} 0 degree marking on the crank-
2
shaft damper

5) Install the O-ring to the fuel supply pump.

6) Temporarily tighten the fuel supply pump to
the cylinder block.

1 Fuel supply pump

2 Supply pump gear
3 Nut

ANNOTATION:
1 Bolt
• After installing the supply pump gear, refer
to the diagram and make an alignment mark
on it. 7) Check alignment mark of the supply pump
gear.
ANNOTATION:
• Confirm that the alignment mark can be
seen through the plug hole on the left side
of the flywheel housing.
84402826 - May 2011
2425-31
 Removal and Installation of Cylinder Block

3) Install the O-ring to the front cover.

1 Plug hole
2 Alignment mark
1 O-ring
CAUTION
4) Install the front cover to the cylinder block.
• If the alignment mark could not be
confirmed, adjust the position of CAUTION
the supply pump gear.
• Pay attention to the knock pin posi-
8) Securely tighten the fuel supply pump to the tion of the cylinder block.
cylinder block.
Tightening torque： 50 N・m {5.1 kgf・m / 37 Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft} Nut lb・ft}
Tightening torque： 76 N・m {7.7 kgf・m / 56
lb・ft} Bolt 19. Water pump assembly Installation
9) Connect the harness connector to the fuel 1) Install the water pump assembly to the front
supply pump. cover.
18. Front cover Installation
CAUTION
1) Clean the cylinder block using the scraper.
2) Apply the liquid gasket to the front cover. • Use new gaskets.

ANNOTATION: Tightening torque： 52 N・m {5.3 kgf・m / 38

lb・ft} 1 bolt in the diagram
• Use ThreeBond 1207B.
Tightening torque： 24 N・m {2.4 kgf・m / 17
Bead width： 1.5 - 5.0 mm {0.0591 - 0.1969 lb・ft}
in}
Bead height： 0.3 - 1.5 mm {0.0118 - 0.0591
in}

CAUTION
• After applying the liquid gasket, in-
stall the front cover within 5 min-
utes.

1 Bolt
2 Stud bolt
3 Oil relief valve

2) Connect the water hose to the water pump

assembly.
84402826 - May 2011
2425-32
 Removal and Installation of Cylinder Block

3) Connect the water return pipe to the water

pump assembly.
Tightening torque： 35 N・m {3.6 kgf・m / 26
lb・ft}
4) Install the fan pulley to the water pump assem-
bly.
Tightening torque： 10 N・m {1.0 kgf・m / 87
lb・in}
5) Align the spacer to the adapter.
6) Install the adapter to the water pump assem-
bly.
Tightening torque： 45 N・m {4.6 kgf・m / 33
lb・ft}

Legend Parts number

1: Oil seal -
2: Adapter 5-8840-2705-0
3: Adapter ring 5-8840-2706-0
4: Adapter tightening bolt 5-8840-2714-0
5: Sleeve 5-8840-9062-0
6: Washer 5-8840-2707-0
7: Center bolt 5-8840-2713-0

2) Apply the engine oil to the crankshaft front oil

seal.

CAUTION
1 Adapter
2 Spacer • Apply only to the lip section of the
3 Fan pulley oil seal.
4 Water pump assembly
5 Gasket 3) Install the crankshaft front oil seal to the
adapter.
20. Crankshaft front oil seal Installation 4) Install the adapter to the crankshaft.
5) Install the adapter ring to the sleeve.
1) Prepare the special tool. 6) Install the sleeve to the adapter.

Special tool: oil seal installer (refer to

section 1003)
1 Crankshaft front oil seal
ANNOTATION: 2 Adapter ring
• Install the crankshaft front oil seal and 3 Sleeve
slinger together. 4 Washer
• In order to install the crankshaft front oil
seal, use the one(s) in the following table
from among the parts included in the kit. 7) Install the center bolt to the sleeve.

84402826 - May 2011

2425-33
 Removal and Installation of Cylinder Block

8) Tighten the center bolt using the wrench. 1) Install the crankshaft damper to the crankshaft
pulley.
ANNOTATION:
Tightening torque： 48 N・m {4.9 kgf・m / 35
• Tighten the center bolt until the sleeve lb・ft}
touches the adapter.
ANNOTATION:
• Tighten the bolts in a diagonal line order.

9) Inspect the crankshaft front oil seal.

ANNOTATION:
2) Install the crankshaft pulley to the crankshaft.
• Measure the distance between the crank-
shaft head and the crankshaft front oil seal. CAUTION
Specified value： 30.7 - 31.3 mm {1.2087 - • Pay attention to the knock pin posi-
1.2323 in} tion of the crankshaft.

Tightening torque： 200 N・m {20.4 kgf・m

/ 148 lb・ft} Apply engine oil on the threaded
area of bolt
ANNOTATION:
• Tightening order

Oil seal press-fitting measure-

1
ment
2 Front cover
3 Crankshaft front oil seal
4 Crankshaft

21. Crankshaft pulley Installation 22. Cylinder head assembly Installation

CAUTION
• Clean the aligning surface of the cylinder
head and cylinder block before installing
the cylinder head assembly.
• Be careful not to damage the cylinder
head and cylinder block while cleaning.

1) Apply the liquid gasket to the cylinder block.

ANNOTATION:
• Use ThreeBond 1207B.
Bead width： 3.0 mm {0.1181 in}
84402826 - May 2011
2425-34
 Removal and Installation of Cylinder Block

Bead height： 3.0 mm {0.1181 in} • Apply engine oil to the seat surface and
threaded portion of the M10 head bolts.
5) Tighten the head bolt using the torque wrench.
Tightening torque： 157 N・m {16.0 kgf・m
/ 116 lb・ft}
6) Tighten the head bolt using the torque wrench.
Tightening torque： 165 N・m {16.8 kgf・m
/ 122 lb・ft}
7) Tighten the head bolt using the special tool.

CAUTION
• After applying liquid gasket, install
the cylinder head within 5 minutes.

2) Install the cylinder head gasket to the cylinder

block.

CAUTION Special tool: angle gauge (refer to section

• Use a new cylinder head gasket. 1003)
Tightening angle： 55 ° M14 bolt
3) Install the cylinder head assembly to the cylin- 8) Tighten the head bolt using the torque wrench.
der block. Tightening torque： 38 N・m {3.9 kgf・m / 28
lb・ft} M10 bolt
CAUTION 9) Tighten the head bolt using the torque wrench.
Tightening torque： 167 N・m {17.0 kgf・m
• Be careful not to damage the cylin- / 123 lb・ft} Check the tightening M14 bolt
der head gasket.
23. Bridge Installation
ANNOTATION: 1) Apply the engine oil to the bridge.
• Tightening order of the head bolts 2) Install the bridge to the bridge guide.

CAUTION
• Confirm that the bridge moves
smoothly.

3) Apply the engine oil to the bridge cap.

4) Install the bridge cap to the bridge.

ANNOTATION:
• 1 - 18 in the diagram indicate the M14 bolts.
• 19 and 20 in the diagram indicate the M10
bolts.
4) Prepare the head bolt.
ANNOTATION:
CAUTION
• Apply molybdenum disulfide grease to the
seat surface and threaded portion of the • Be careful not to drop the bridge
M14 head bolts. cap into the engine.

84402826 - May 2011

2425-35
 Removal and Installation of Cylinder Block

24. Camshaft Installation 5) Check alignment mark of the camshaft gear.

1) Align 1st cylinder to the compression top dead CAUTION
center.
• Confirm that the alignment mark is
not misaligned before installing the
camshaft bearing cap.
• If the alignment mark is not at
the correct position, reinstall the
camshaft.

6) Apply the engine oil to the camshaft bearing.

ANNOTATION:
• Apply engine oil to the sliding surface of the
bearing.

CAUTION
• Apply engine oil after cleaning the
1 Front cover marking bearing installation sections of the
0 degree marking on the crank- camshaft bearing and camshaft
2 bearing cap.
shaft damper
7) Install the camshaft bearing to the camshaft
2) Apply the engine oil to the camshaft bearing. bearing cap.
ANNOTATION: 8) Install the camshaft bearing cap to the cylinder
head assembly.
• Apply engine oil to the sliding surface of the
bearing. ANNOTATION:

CAUTION • Turn the camshaft bearing cap so that the

arrow mark on the top surface faces the en-
• Apply engine oil after cleaning the gine front side, and assemble in numerical
bearing installation sections of order.
the camshaft bearing and cylinder
Tightening torque： 28 N・m {2.8 kgf・m / 20
head.
lb・ft} Apply engine oil
3) Install the camshaft bearing to the cylinder
head assembly.
4) Install the camshaft to the cylinder head as-
sembly.
ANNOTATION:
• Mesh together the idle gear C and the
camshaft gear so that the alignment mark
on the camshaft gear matches the top sur-
face of the cylinder head, and gently install
the camshaft.

25. Rocker arm shaft Installation

1) Apply the engine oil to the bracket.
ANNOTATION:
• Apply to each sliding surface.
2) Apply the engine oil to the rocker arm.
ANNOTATION:
• Confirm that the adjust screw is fully loos-
ened.

84402826 - May 2011

2425-36
 Removal and Installation of Cylinder Block

3) Temporarily tighten the bolt to the cylinder ANNOTATION:

head assembly.
• Valve clearance adjustment
ANNOTATION:
CAUTION
• Apply engine oil to the threaded portion of
the bolts. • Adjust the valve clearance while cool.
• Loosen all adjust screws before adjust-
4) Temporarily tighten the nut to the cylinder ment.
head assembly.
ANNOTATION:
• Apply engine oil to the threaded portion of
the nuts.
5) Securely tighten the rocker arm shaft to the
cylinder head assembly.
ANNOTATION:
• Hold the entire rocker arm shaft horizontally
and gradually tighten it.

Rocker arm shaft tightening torque

Parts Tightening torque
： 21 N・m {2.1 kgf・m / 15
No.1 Nut
lb・ft} 1) Align 1st cylinder to the compression top dead
： 27 N・m {2.8 kgf・m / 20 center.
No.2 Bolt
lb・ft}
： 56 N・m {5.7 kgf・m / 41
No.3 Bolt
lb・ft}
： 27 N・m {2.8 kgf・m / 20
No.4 Bolt
lb・ft}

1 Front cover marking

0 degree marking on the crank-
2
shaft damper

2) Prepare the feeler gauge.

Thickness： 0.4 mm {0.0157 in} 2 pieces
1 Nut
2 Bolt ANNOTATION:
3 Bolt • Insert the thickness gauge between the
4 Bolt rocker arm and bridge cap.
• Insert the thickness gauge between the
26. Rocker arm shaft Adjustment bridge and valve.

84402826 - May 2011

2425-37
 Removal and Installation of Cylinder Block

3) Turn the adjust screw. Adjustment table

1 2 3 4
ANNOTATION:
Cylinder No. E- E- E- E-
IN IN IN IN
• When the movement of the thickness gauge X X X X
becomes stiff, secure the adjust screw nut First cylinder compres-
of the rocker arm. O O O O
sion top dead center
Tightening torque： 22 N・m {2.2 kgf・m / 16 Fourth cylinder com-
lb・ft} pression top dead cen- O O O O
ter

27. Common rail assembly Installation

1) Temporarily tighten the common rail bracket
to the oil cooler assembly.
ANNOTATION:
• The installation bolt and common rail as-
sembly are tightened together.
2) Align the common rail assembly to the inlet
cover.
3) Temporarily tighten the nut to the common rail
assembly.
4) Turn the adjust screw. ANNOTATION:
ANNOTATION: • The stud bolts of the inlet cover are tight-
ened together.
• With the thickness gauge inserted, lightly
tighten the adjust screw of the bridge. 4) Temporarily tighten the bolt to the common rail
• Confirm that the leading end of the adjust assembly.
screw and valve shaft end have made con- 5) Securely tighten the nut to the common rail
tact and the movement of the thickness assembly.
gauge has become stiff. Tightening torque： 22 N・m {2.2 kgf・m / 16
• Check if the valve shaft end on the opposite lb・ft}
side is floating or touching at an angle.
ANNOTATION:
• If it is floating or touching at an angle, slightly
loosen the bridge adjust screw and adjust • Refer to the tightening order in the diagram
the valve shaft ends on both sides to touch if the inlet cover is removed.
properly.
Valve bridge clearance ： less than 0.1 mm
{less than 0.0039 in}
ANNOTATION:
• To prevent turning, fix the bridge adjust
screw with a flathead screwdriver, and
tighten the adjust screw nut.
Tightening torque： 22 N・m {2.2 kgf・m / 16
lb・ft}

6) Securely tighten the bolt to the common rail

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

84402826 - May 2011

2425-38
 Removal and Installation of Cylinder Block

7) Connect the harness connector to the fuel 5) Securely tighten the fuel leak-off pipe to the
pressure sensor. common rail assembly.
Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft}
6) Securely tighten the fuel leak-off pipe to the
fuel supply pump.
Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft}
7) Install the clip to the fuel leak-off pipe.
Tightening torque： 8 N・m {0.8 kgf・m / 69
lb・in}

1 Common rail assembly

2 Fuel pressure sensor
3 Common rail bracket

28. Fuel leak off pipe assembly Installation

1) Temporarily tighten the fuel leak-off pipe to the
cylinder head assembly.
1 Common rail assembly
CAUTION 2 Cylinder head assembly
3 Fuel leak-off pipe
• Use new gaskets.
4 Fuel supply pump
2) Temporarily tighten the fuel leak-off pipe to the
common rail assembly. 29. Fuel pipe Installation
1) Install the fuel pipe to the fuel supply pump
CAUTION and the common rail assembly.
• Use new gaskets. CAUTION
3) Temporarily tighten the fuel leak-off pipe to the • Use new fuel pipes.
fuel supply pump.
Tightening torque： 44 N・m {4.5 kgf・m / 33
ANNOTATION:
lb・ft}
• Tighten the fuel feed pipe together. 2) Install the clip to the bracket.
Tightening torque： 9 N・m {0.9 kgf・m / 78
CAUTION lb・in}
• Use new gaskets. 30. Injector Installation

4) Securely tighten the fuel leak-off pipe to the CAUTION

cylinder head assembly.
• When reusing an injector, do not change
Tightening torque： 12 N・m {1.3 kgf・m /
the installation position.
109 lb・in}

84402826 - May 2011

2425-39
 Removal and Installation of Cylinder Block

1) Apply the engine oil to the bolt. 3) Install the clip to the bracket.
2) Temporarily tighten the injector to the cylinder Tightening torque： 6 N・m {0.6 kgf・m / 52
head assembly. lb・in}

CAUTION
• Be extremely careful not to damage
the injector nozzle.

1 No.1 injection pipe

2 No.2 injection pipe
3 No.3 injection pipe
4 No.4 injection pipe
1 Injector 5 Fuel leak-off pipe
2 Installation bolt 6 Fuel pipe
7 Common rail assembly
3) Temporarily tighten the injection pipe to the
injector.

CAUTION 32. Lower cover Installation

1) Apply the liquid gasket to the rubber plug.
• Use new injection pipes.
ANNOTATION:
4) Temporarily tighten the injection pipe to the
common rail assembly. • Apply ThreeBond 1207B.
5) Securely tighten the injector to the cylinder
head assembly.
Tightening torque： 30 N・m {3.1 kgf・m / 22
lb・ft}
6) Install the injector leak-off pipe to the injector.

CAUTION
• Use new gaskets.

Tightening torque： 14 N・m {1.4 kgf・m /

126 lb・in}
31. Injection pipe Installation
1) Securely tighten the injection pipe to the injec-
tor.
Tightening torque： 30 N・m {3.0 kgf・m / 22
lb・ft} 1 Rubber plug
2) Securely tighten the injection pipe to the com- 2 Liquid gasket
mon rail assembly.
Tightening torque： 25 N・m {2.5 kgf・m / 18
lb・ft}
CAUTION
• After applying the liquid gasket, in-
stall the lower cover within 5 min-
utes.

2) Install the rubber plug to the cylinder head

assembly.
84402826 - May 2011
2425-40
 Removal and Installation of Cylinder Block

3) Install the gasket to the lower cover. 33. Glow plug Installation
4) Install the lower cover to the cylinder head
1) Install the glow plug to the cylinder head as-
assembly.
sembly.
Tightening torque： 18 N・m {1.8 kgf・m / 13
Tightening torque： 20 N・m {2.0 kgf・m / 14
lb・ft}
lb・ft}
5) Install the injector harness to the cylinder head
assembly. CAUTION
ANNOTATION:
• Be careful not to exceed the speci-
• Tighten the bolts on the bracket and in- fied torque when tightening.
stall the injector harness together with the
bracket.
Tightening torque： 48 N・m {4.9 kgf・m / 35
lb・ft}

2) Install the glow plug connector to the glow

plug.
Tightening torque： 1 N・m {0.1 kgf・m / 11
lb・in}

CAUTION
1 Injector harness terminal
2 Injector harness bracket • Confirm that the glow plug connec-
tor does not interfere with the sur-
rounding parts.
6) Connect the injector harness to the injector.
Tightening torque： 2 N・m {0.2 kgf・m / 18
34. Cylinder head cover Installation
lb・in}
1) Align the head cover gasket to the cylinder
CAUTION head cover.
2) Install the cylinder head cover to the lower
• Be careful not to damage the injec-
tor side stud bolts. cover.
Tightening torque： 18 N・m {1.8 kgf・m / 13
lb・ft}
ANNOTATION:
• Referring to the tightening order in the dia-
gram, temporarily tighten all bolts and then
completely tighten them.

1 Lower cover
2 Connector

7) Install the connector to the lower cover.

Tightening torque： 2 N・m {0.2 kgf・m / 18
lb・in}
84402826 - May 2011
2425-41
 Removal and Installation of Cylinder Block

1) Install the inlet pipe to the case.

Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft}

CAUTION
• Use new gaskets.

1 Cylinder head cover

2 Gasket
3 Lower cover

3) Connect the ventilation hose to the air

breather.
35. Oil level gauge guide tube Installation 1 Case
1) Install the oil level gauge guide tube to the 2 Gasket
cylinder block. 3 Inlet pipe
2) Connect the oil level gauge guide tube to the
case. 2) Connect the harness connector to the IMT
Tightening torque： 19 N・m {1.9 kgf・m / 14 sensor.
lb・ft} 3) Connect the harness connector to the EGR
3) Connect the oil level gauge guide tube to the valve.
cylinder head cover. 4) Connect the harness connector to the boost
Tightening torque： 19 N・m {1.9 kgf・m / 14 temperature sensor.
lb・ft} 5) Connect the harness connector to the boost
4) Install the oil level gauge to the oil level gauge sensor.
guide tube. 6) Install the harness clip to the inlet pipe.

1 Boost sensor
1 Cylinder head cover
2 IMT sensor
2 Oil level gauge guide tube
3 EGR valve
3 Case
4 Harness clip
4 Cylinder block
5 Boost temperature sensor

36. Inlet pipe Installation 37. Intake throttle valve Installation

84402826 - May 2011

2425-42
 Removal and Installation of Cylinder Block

1) Install the intake throttle valve to the inlet pipe.

Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft}

1 Boost temperature sensor

2 Boost sensor
3 Inlet pipe
4 Gasket
5 Intake throttle valve

2) Install the air duct to the intake throttle valve.

3) Connect the harness connector to the intake
throttle valve.
ANNOTATION:
• After connecting the harness connector,
press in the lock operation portion to lock. 1 EGR cooler water feed pipe
2 EGR cooler water return pipe

1) Install the EGR cooler water pipe to the engine

assembly.
ANNOTATION:
• Install the EGR cooler water feed pipe and
EGR cooler water return pipe.
Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft} Clamp
2) Connect the radiator upper hose to the water
outlet pipe.
3) Install the fan guide bracket to the cylinder
head assembly.
Tightening torque： 50 N・m {5.1 kgf・m / 37
lb・ft}
1 Lock operation section Tightening torque ： 97 N ・ m {9.9 kgf ・ m}
2 Lock release The area where the spacer is used
3 Lock 4) Install the fan guide stay to the fan guide
bracket.
Tightening torque： 45 N・m {4.6 kgf・m / 33
38. EGR cooler water pipe Installation lb・ft}

84402826 - May 2011

2425-43
 Removal and Installation of Cylinder Block

5) Install the fan guide stay to the fan guide. 40. EGR cooler assembly Installation
Tightening torque： 45 N・m {4.6 kgf・m / 33
1) Temporarily tighten the EGR pipe C to the
lb・ft}
EGR valve.
2) Temporarily tighten the EGR cooler B to the
EGR pipe C.
3) Temporarily tighten the EGR pipe B to the
EGR cooler B.
4) Temporarily tighten the EGR cooler A to the
EGR pipe B.

1 Fan guide stay

2 Fan guide
3 Fan guide bracket
4 Spacer

39. EGR valve Installation

1 EGR valve
1) Install the EGR valve to the EGR pipe D.
2 EGR pipe C
Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft} 3 EGR cooler B
4 EGR pipe B
5 EGR cooler A
6 EGR pipe B

5) Temporarily tighten the EGR pipe A to the

EGR cooler A and the exhaust manifold.

1 EGR cooler C
2 EGR pipe C
3 EGR valve
4 EGR pipe D

CAUTION 1 EGR cooler A

• Use new gaskets. 2 EGR pipe A
3 Exhaust manifold
2) Connect the harness connector to the EGR
valve. ANNOTATION:

84402826 - May 2011

2425-44
 Removal and Installation of Cylinder Block

• Complete tightening order of the EGR 14) Install the EGR heat protector to the EGR pipe
cooler assembly A.

1 EGR heat protector

15) Connect the water rubber hose to the EGR

cooler assembly.

6) Securely tighten the EGR pipe C to the EGR

valve.
Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft} No.1 in the diagram
7) Completely tighten the EGR pipe C to the en-
gine hanger bracket.
Tightening torque： 48 N・m {4.9 kgf・m / 35
lb・ft} No.2 in the diagram 1 Water rubber hose
8) Securely tighten the EGR pipe B to the
bracket.
Tightening torque： 48 N・m {4.9 kgf・m / 35 41. Turbocharger assembly Installation
lb・ft} No.3 in the diagram 1) Temporarily tighten the turbocharger assem-
9) Securely tighten the EGR cooler B to the EGR bly to the exhaust manifold.
pipe C.
Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft} No.4 in the diagram
10) Securely tighten the EGR pipe B to the EGR
cooler B.
Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft} No.5 in the diagram
11) Securely tighten the EGR cooler A to the EGR
pipe B.
Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft} No.6 in the diagram
12) Securely tighten the EGR pipe A to the ex-
haust manifold.
Tightening torque： 28 N・m {2.9 kgf・m / 21
lb・ft} No.7 in the diagram
13) Securely tighten the EGR pipe A to the EGR
cooler A.
Tightening torque： 28 N・m {2.9 kgf・m / 21 1 Exhaust manifold
lb・ft} No.8 in the diagram 2 Turbocharger assembly
84402826 - May 2011
2425-45
 Removal and Installation of Cylinder Block

2) Temporarily tighten the exhaust manifold stay 6) Connect the water feed pipe to the tur-
to the cylinder block and the turbocharger as- bocharger assembly.
sembly.
CAUTION
• Use new gaskets.

Tightening torque： 35 N・m {3.5 kgf・m / 25

lb・ft} Eyebolt
Tightening torque： 14 N・m {1.4 kgf・m /
119 lb・in} Clip
7) Install the water return pipe to the water pump
assembly.

CAUTION
• Use new gaskets.

Tightening torque： 35 N・m {3.5 kgf・m / 25

lb・ft} Eyebolt
1 Turbocharger assembly Tightening torque： 24 N・m {2.4 kgf・m / 17
2 Exhaust manifold lb・ft} Clip
3 Exhaust manifold stay 8) Connect the water return pipe to the tur-
bocharger assembly.
3) Securely tighten the turbocharger assembly to
the exhaust manifold.
Tightening torque： 52 N・m {5.3 kgf・m / 38
lb・ft}
4) Securely tighten the exhaust manifold stay to
the cylinder block and the turbocharger as-
sembly.
Tightening torque： 52 N・m {5.3 kgf・m / 38
lb・ft} Nut
Tightening torque： 50 N・m {5.1 kgf・m / 37
lb・ft} Bolt
ANNOTATION:
• Tightening order

5) Install the water feed pipe to the cylinder

block.

CAUTION
1 Water return pipe
• Use new gaskets.
2 Water feed pipe
Tightening torque： 41 N・m {4.2 kgf・m / 30
lb・ft} Eyebolt
Tightening torque： 24 N・m {2.4 kgf・m / 17 Tightening torque： 35 N・m {3.5 kgf・m / 25
lb・ft} Clip lb・ft} Eyebolt

84402826 - May 2011

2425-46
 Removal and Installation of Cylinder Block

9) Install the oil return pipe to the cylinder block. 12) Connect the oil feed pipe to the turbocharger
assembly.
CAUTION
CAUTION
• Use new gaskets.
• Use new gaskets.
Tightening torque： 22 N・m {2.2 kgf・m / 16
lb・ft} Tightening torque： 17 N・m {1.7 kgf・m / 12
10) Connect the oil return pipe to the turbocharger lb・ft} Eyebolt
assembly. Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft} Clip
CAUTION
• Use new gaskets.

Tightening torque： 9 N・m {0.9 kgf・m / 78

lb・in}
11) Install the oil feed pipe to the oil port cover.

CAUTION
• Use new gaskets.

Tightening torque： 17 N・m {1.7 kgf・m / 12

lb・ft} Eyebolt
Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft} Clip

1 Turbocharger assembly
2 Oil feed pipe
3 Oil return pipe

13) Install the exhaust pipe to the turbocharger

assembly.
14) Install the air intake hose to the turbocharger
assembly and the intercooler.
15) Install the air cleaner duct to the air cleaner
assembly and the turbocharger assembly.
16) Connect the harness connector to the tur-
bocharger assembly.
42. Cooling fan belt Installation
1) Install the cooling fan belt to the engine as-
sembly.
43. Cooling fan belt Adjustment

84402826 - May 2011

2425-47
 Removal and Installation of Cylinder Block

1) Press the cooling fan belt. 1) Install the fan guide bracket to the engine as-
sembly.
ANNOTATION:
Tightening torque： 40 N・m {4.1 kgf・m / 30
• Measure the amount of cooling fan belt flex lb・ft}
by pressing on the point indicated by the ar- 2) Install the fan guide to the fan guide bracket.
row in the diagram with the specified pres- Tightening torque： 30 N・m {3.1 kgf・m / 22
sure. lb・ft}
standard ： 98.0 N {10.0 kg / 22 lb}
Specified value ： 6.0 - 8.0 mm {0.2362 -
0.3150 in} Amount of flex

1 Bolt
2 Washer
3 Rubber mount
4 Rubber mount
1 Crankshaft pulley 5 Guide tube
2 Generator 6 Fan guide
3 Fan pulley
45. Cooling fan Installation
2) Adjust the cooling fan belt to standard value 1) Install the cooling fan to the adapter.
using the adjust bolt. Tightening torque： 52 N・m {5.3 kgf・m / 38
Tightening torque： 76 N・m {7.7 kgf・m / 56 lb・ft}
lb・ft} Nut of the adjust plate
Tightening torque： 127 N・m {12.9 kgf・m
/ 93 lb・ft} Bolt of the bracket side

1 Cooling fan
2 Adapter

46. Engine harness Connect

1 Adjust bolt
2 Adjust plate side nut 1) Connect the engine harness to the engine as-
3 Bracket side bolt sembly.
ANNOTATION:
44. Fan guide Installation • Connect each connector.

84402826 - May 2011

2425-48
 Removal and Installation of Cylinder Block

47. Engine oil Filling

1) Replenish the engine oil with the engine as-
sembly.

CAUTION
• Confirm the tightening of the oil pan
drain before adding engine oil.

48. Coolant Filling

1) Loosen the valve using a wrench.
2) Replenish the coolant with the radiator.

CAUTION
• Be careful not to let coolant over- 1 Priming pump
flow splash on the exhaust system
2 Plug
parts.
3 Drain plug
• Coolant overflow should be wiped
off. 4 Case
5 Fuel filter element
3) Tighten the valve using a wrench.
1) Prepare the pan.
CAUTION 2) Turn ON the starter switch.
• Use new gaskets. ANNOTATION:
Tightening torque： 28 N・m {2.8 kgf・m / 20 • This is for the models with an electromag-
lb・ft} netic pump.
4) Replenish the coolant with the radiator. 3) Loosen the plug using the wrench.
4) Operate the priming pump.
Number of times： 20 count(s) or more
ANNOTATION:
• Confirm that fuel comes out from around the
plug.
5) Tighten the plug using the wrench.
6) Operate the priming pump.
Number of times： 10 count(s) or more
ANNOTATION:
• Wait for the specified time after operating
the priming pump.
specified time： 1 min
1 Valve 7) Loosen the plug using the wrench.
2 Gasket ANNOTATION:
• Remove the air in the fuel filter.
49. Battery ground cable Connect
8) Tighten the plug using the wrench.
1) Connect the battery ground cable to the bat- 9) Operate the priming pump.
tery. Number of times： 10 count(s) or more
50. Fuel Air bleed ANNOTATION:
CAUTION • Wait for the specified time after operating
the priming pump.
• To prevent engine failure, be sure to per-
form air removal after the installation or specified time： 1 min
removal of fuel system parts. 10) Loosen the plug using the wrench.
ANNOTATION:
• Remove the air in the fuel filter.

84402826 - May 2011

2425-49
 Removal and Installation of Cylinder Block

11) Tighten the plug using the wrench. 15) Operate the priming pump.
12) Operate the priming pump. Number of times the operation is performed:
Number of times： 10 count(s) or more 10 - 15 times
16) Start the engine.
ANNOTATION:
• Wait for the specified time after operating CAUTION
the priming pump.
• Do not accelerate the engine revo-
specified time： 1 min lution right after staring.
13) Loosen the plug using the wrench.
Idling: 5 s
ANNOTATION:
ANNOTATION:
• Remove the air in the fuel filter.
• Accelerate the engine revolution gradually.
14) Tighten the plug using the wrench.
Tightening torque： 10 N・m {1.0 kgf・m / 89 Engine revolution hold: 3 min.
lb・in}
ANNOTATION:
CAUTION • Accelerate the engine revolution to maxi-
mum.
• Remove the fuel around the plug
thoroughly after tightening. • Lower the rotation.

84402826 - May 2011

2425-50
 Removal and Installation of Cylinder Block

Inspection 5) Remove the cylinder liner from the cylinder

block.
1. Cylinder block Inspection 6) Align the simple straight ruler to the cylinder
block.
CAUTION 7) Measure the clearance using the feeler
• Clean the each part of the cylinder block gauge.
before inspecting. ANNOTATION:
• Be careful not to damage the cylinder
block while cleaning. • Flatness of the cylinder block top surface
Measurement part: 6 section(s)
1) Inspect the cylinder block. Limit: 0.2 mm {0.0079 in}
CAUTION CAUTION
• Replace the cylinder block if dam- • Replace the cylinder block if the
age such as a crack has been found measured value exceeds the limit
in the inspection. value.

2) Perform dye penetrant check.

ANNOTATION:
• Check if there is a problem which cannot be
detected by visual inspection.

CAUTION
• Replace the cylinder block if dam-
age such as a crack has been found
in the inspection.

3) Inspect the water leak using the water pres-

sure tester.
ANNOTATION: 8) Inspect the oil jet.
• Check if there is a problem which cannot be ANNOTATION:
detected by visual inspection.
• Oil hole clogging
Specified pressure: 490 kPa {71 psi} • The fuel pipe deformation
Specified time: 3 min • Check valve operation
CAUTION Pen valve pressure of check valve: 160 kPa
{23.2 psi}
• Replace the cylinder block if dam-
age such as a crack has been found
in the inspection.

4) Measure the cylinder liner using the cylinder

gauge.
Measurement position: 15.0 - 20.0 mm
{0.5906 - 0.7874 in} From the cylinder block
top surface
Specified value: 115.021 - 115.050 mm
{4.5284 - 4.5295 in} Diameter
Limit: 115.20 mm {4.5354 in} Diameter

CAUTION
• Replace the cylinder block if the
measured value exceeds the limit
value.

84402826 - May 2011

2425-51
Removal and Installation of Cylinder Block

84402826 - May 2011

2425-52
 Section

2445

Lubrication System

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal and Installation of Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Removal of Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Oil Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal and Installation of Oil Level Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal of Oil Level Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation of Oil Level Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal and Installation of Oil Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal of Oil Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly of Oil Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Assembly of Oil Pump Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation of Oil Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Engine oil Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Removal and Installation of Oil Port Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Removal of Oil Port Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Installation of Oil Port Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

2445-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
2445-2 PRINTED IN FRANCE
 Lubrication System

Removal and Installation of Oil Installation of Oil Pan

Pan 1. Oil pan Installation
1) Apply the liquid gasket to the crankcase.
Removal of Oil Pan
ANNOTATION:
1. Battery ground cable Disconnect
• Apply ThreeBond 1207B to each joint of the
1) Disengage the battery ground cable from the crankcase, flywheel housing and gear case.
battery.
Bead width： 3.0 mm { 0.1181 in }
2. Engine oil Drain
1) Remove the drain plug from the oil pan.
2) Drain the engine oil from the oil pan.
3) Install the drain plug to the oil pan.
Tightening torque： 70 N・m {7.1 kgf・m / 52
lb・ft}
3. Oil pan Removal
1) Disengage the harness connector from the oil
level switch.
2) Remove the oil pan from the crankcase.
3) Remove the gasket from the oil pan.

CAUTION
• After applying the liquid gasket, in-
stall the oil pan within 5 minutes.

2) Install the gasket to the oil pan.

3) Install the oil pan to the crankcase.
Tightening torque： 29 N・m { 3.0 kgf・m /
22 lb・ft }
ANNOTATION:
• Tightening order

4) Connect the harness connector to the oil level

switch.
2. Engine oil Filling
1) Replenish the engine oil with the engine as-
sembly.

CAUTION
• Confirm the tightening of the oil pan
drain before adding engine oil.

84402826 - May 2011

2445-3
 Lubrication System

3. Battery ground cable Connect Removal and Installation of Oil

1) Connect the battery ground cable to the bat- Level Switch
tery.
Removal of Oil Level Switch
1. Engine oil Drain
1) Remove the drain plug from the oil pan.
2) Drain the engine oil from the oil pan.
3) Install the drain plug to the oil pan.
Tightening torque： 70 N・m { 7.1 kgf・m / 52 lb・
ft }
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 Spacer
2 Oil level switch
3 Spacer

84402826 - May 2011

2445-4
 Lubrication System

Installation of Oil Level Switch Removal and Installation of Oil

1. Oil level switch Installation Pump Assembly
1) Install the oil level switch to the oil pan.
Removal of Oil Pump Assembly
CAUTION 1. Battery ground cable Disconnect
• Use new O-rings. 1) Disengage the battery ground cable from the
battery.
Tightening torque： 10 N・m { 1.0 kgf・m /
87 lb・in } 2. Coolant Drain
2) Connect the harness connector to the oil level 1) Drain the coolant from the radiator.
switch.
CAUTION
• After the coolant is discharged,
make sure to tighten the drain plug.

3. Engine oil Drain

1) Remove the drain plug from the oil pan.
2) Drain the engine oil from the oil pan.
3) Install the drain plug to the oil pan.
Tightening torque: 70 N・m { 7.1 kgfEm / 52 lb・ft }
4. Engine harness Disconnect
1) Disengage the engine harness from the en-
gine assembly.
ANNOTATION:

1 Spacer • Disconnect each connector.

2 Oil level switch 5. Turbocharger assembly Removal
3 Spacer 1) Remove the air cleaner duct from the air
cleaner assembly and the turbocharger as-
2. Engine oil Filling sembly.
1) Replenish the engine oil with the engine as- 2) Remove the air intake hose from the tur-
sembly. bocharger assembly and the intercooler.
3) Remove the exhaust pipe from the tur-
CAUTION bocharger assembly.
4) Disengage the oil feed pipe from the tur-
• Confirm the tightening of the oil pan bocharger assembly.
drain before adding engine oil.
ANNOTATION:
• Remove the clip.
5) Remove the oil feed pipe from the oil port
cover.
ANNOTATION:
• Remove the clip.
6) Disengage the oil return pipe from the tur-
bocharger assembly.

84402826 - May 2011

2445-5
 Lubrication System

7) Remove the oil return pipe from the cylinder 11) Remove the water feed pipe from the cylinder
block. block.
ANNOTATION:
• Remove the clip.

1 Turbocharger assembly
2 Oil feed pipe
3 Oil return pipe

8) Disengage the water return pipe from the tur- 1 Water return pipe
bocharger assembly. 2 Water feed pipe
9) Remove the water return pipe from the water
pump assembly.
10) Disengage the water feed pipe from the tur-
12) Remove the exhaust manifold stay from the
bocharger assembly.
cylinder block and the turbocharger assembly.
ANNOTATION:
• Remove the clip.

1 Turbocharger assembly
2 Exhaust manifold
3 Exhaust manifold stay
84402826 - May 2011
2445-6
 Lubrication System

13) Disengage the harness connector from the 3) Remove the EGR pipe A from the EGR cooler
turbocharger assembly. A and exhaust manifold.
14) Remove the turbocharger assembly from the
exhaust manifold.

1 EGR cooler A
2 EGR pipe A
1 Exhaust manifold 3 Exhaust manifold
2 Turbocharger assembly
4) Remove the EGR cooler A from the EGR pipe
6. EGR cooler assembly Removal B.
5) Remove the EGR pipe B from the EGR cooler
1) Disengage the water rubber hose from the B.
EGR cooler assembly. 6) Remove the EGR cooler B from the EGR pipe
C.
7) Remove the EGR pipe C from the EGR valve.

1 Water rubber hose

1 EGR valve
2) Remove the EGR heat protector from the 2 EGR pipe C
EGR pipe A. 3 EGR cooler B
4 EGR pipe B
5 EGR cooler A
6 EGR pipe D

7. EGR valve Removal

1) Disengage the harness connector from the
EGR valve.

1 EGR heat protector

84402826 - May 2011
2445-7
 Lubrication System

2) Remove the EGR valve from the EGR pipe D. 3) Disengage the radiator upper hose from the
water outlet pipe.
4) Remove the EGR cooler water pipe from the
engine assembly.
ANNOTATION:
• Remove the EGR cooler water feed pipe
and EGR cooler water return pipe.

1 EGR cooler C
2 EGR pipe C
3 EGR valve
4 EGR pipe D

8. EGR cooler water pipe Removal

1) Remove the fan guide stay from the fan guide
and the fan guide bracket.
2) Remove the fan guide bracket from the cylin-
der head assembly.

1 EGR cooler water feed pipe

2 EGR cooler water return pipe

1 Fan guide 9. Intake throttle valve Removal

2 Fan guide stay 1) Remove the air duct from the intake throttle
3 Fan guide bracket valve.

84402826 - May 2011

2445-8
 Lubrication System

2) Disengage the harness connector from the in- 6) Remove the inlet pipe from the case.
take throttle valve.
3) Remove the intake throttle valve from the inlet
pipe.

1 Case
2 Gasket
3 Inlet pipe
1 Boost temperature sensor
2 Boost sensor
11. Oil level gauge guide tube Removal
3 Inlet pipe
4 Gasket 1) Remove the oil level gauge from the oil level
5 Intake throttle valve gauge guide tube.
2) Disengage the oil level gauge guide tube from
10. Inlet pipe Removal the cylinder head cover.
3) Disengage the oil level gauge guide tube from
1) Disengage the harness connector from the the case.
boost sensor. 4) Remove the oil level gauge guide tube from
2) Disconnect the harness connector from the the cylinder block.
boost temperature sensor.
3) Disengage the harness connector from the
EGR valve.
4) Disconnect the harness connector from the
IMT sensor.
5) Remove the harness clip from the inlet pipe.

1 Cylinder head cover

2 Oil level gauge guide tube
3 Case
4 Cylinder block

1 Boost sensor 12. Glow plug Removal

2 IMT sensor
1) Remove the glow plug connector from the
3 EGR valve glow plug.
4 Harness clip 2) Remove the glow plug from the cylinder head
5 Boost temperature sensor assembly.

84402826 - May 2011

2445-9
 Lubrication System

1) Disengage the fuel leak-off pipe from the cylin-

der head assembly.
2) Remove the fuel leak-off pipe from the fuel
supply pump.
ANNOTATION:
• Remove the eyebolt tightened together with
the fuel feed pipe.
3) Disengage the fuel leak-off pipe from the com-
mon rail assembly.
4) Remove the fuel leak-off pipe from the case.
ANNOTATION:
• Remove the clip.
13. Injection pipe Removal
1) Remove the clip from the bracket.
2) Remove the injection pipe from the injector
and the common rail assembly.

CAUTION
• Do not reuse the removed injection
pipe.
• Seal the common rail and injector to
prevent foreign material from enter-
ing.

1 Common rail assembly

2 Cylinder head assembly
3 Fuel leak-off pipe
4 Fuel supply pump

16. Common rail assembly Removal

1) Disengage the harness connector from the
fuel pressure sensor.
2) Remove the common rail assembly from the
inlet cover and the common rail bracket.
1 No.1 injection pipe 3) Remove the common rail bracket from the oil
2 No.2 injection pipe cooler assembly.
3 No.3 injection pipe
4 No.4 injection pipe
5 Fuel leak-off pipe
6 Fuel pipe
7 Common rail assembly

14. Fuel pipe Removal

1) Remove the fuel pipe from the fuel supply
pump and the common rail assembly.
ANNOTATION:
• Remove the clip.
CAUTION
• Do not reuse the removed fuel pipe. 1 Common rail assembly
2 Fuel pressure sensor
15. Fuel leak off pipe assembly Removal 3 Common rail bracket
84402826 - May 2011
2445-10
 Lubrication System

17. Cylinder head cover Removal 4) Remove the lower cover from the cylinder
head assembly.
1) Disengage the ventilation hose from the air
breather.
2) Remove the cylinder head cover from the
lower cover.
3) Remove the head cover gasket from the cylin-
der head cover.

1 Lower cover
2 Connector

5) Remove the gasket from the lower cover.

6) Remove the rubber plug from the cylinder
head assembly.
1 Cylinder head cover
2 Gasket 19. Injector Removal
3 Lower cover 1) Remove the injector leak-off pipe from the in-
jector.
2) Remove the injector from the cylinder head
18. Lower cover Removal assembly.
1) Remove the connector from the lower cover. ANNOTATION:
CAUTION • When it is difficult to remove the injector, use
a special tool.
• Do not pull the wire, or pry the con-
nector with a screwdriver.

2) Disengage the injector harness from the injec-

tor.

CAUTION
• Be careful not to damage the injec-
tor side stud bolts.

3) Remove the injector harness from the cylinder

head assembly.
ANNOTATION:
• Remove the bracket tightening bolts and
then remove the injector harness together Special tool: injector remover (refer to
with the bracket. section 1003)

84402826 - May 2011

2445-11
 Lubrication System

Special tool: sliding hammer (refer to 20. Rocker arm shaft Removal
section 1003)
1) Loosen the adjust screw using the wrench.
ANNOTATION:
• Loosen all valve clearance adjustment
screws.

2) Remove the rocker arm shaft from the cylinder

head assembly.
ANNOTATION:
• Evenly loosen the rocker arm shaft bracket
and the rocker arm assembly bracket tight-
ening bolts from both ends and remove
them.

CAUTION
• Be careful not to remove the bolt
shown in the diagram.
1 Sliding hammer
2 Fuel injector remover
3 Injector

CAUTION
• Confirm that the sleeve is not pulled
out together when pulling out the
injector using a special tool.
• Store each ID code plate on the in-
jector head with the cylinder num-
ber tag attached to avoid a mix-up.
• Be extremely careful not to damage
the injector nozzle.

84402826 - May 2011

2445-12
 Lubrication System

21. Camshaft Removal 23. Cylinder head assembly Removal

1) Remove the camshaft bearing cap from the 1) Remove the cylinder head assembly from the
cylinder head assembly. cylinder block.
2) Remove the camshaft bearing from the
ANNOTATION:
camshaft bearing cap.
3) Remove the camshaft from the cylinder head. • Loosening order of the head bolts
4) Remove the camshaft bearing from the cylin-
der head assembly.
ANNOTATION:
• Temporarily assemble the removed caps
and bearings in the original position to avoid
a mix-up after the bearings have been in-
spected.

CAUTION
• Since the idle gear C protrudes
from the bottom surface of the
cylinder head, be careful not to
damage the gear.

22. Bridge Removal

1) Remove the bridge cap from the bridge.

CAUTION
• Be careful not to drop the bridge
cap into the engine.

2) Remove the bridge from the bridge guide.

ANNOTATION:
• After removing, organize to avoid a mix-up
with other installation locations.

1 Idle gear C

2) Remove the cylinder head gasket from the

cylinder block.

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

24. Fuel supply pump Removal

1) Disengage the harness connector from the
fuel supply pump.
1 Bridge cap
2 Bridge

84402826 - May 2011

2445-13
 Lubrication System

2) Remove the fuel supply pump from the cylin- 25. Starter assembly Removal
der block.
1) Disengage the earth cable from the starter as-
sembly.
2) Remove the starter assembly from the fly-
wheel housing.

1 Bolt

3) Remove the supply pump gear from the fuel

supply pump using the puller. 1 Oil pressure sensor
2 Oil port cover
3 Starter assembly

26. CKP sensor Removal

1) Disengage the harness connector from the
CKP sensor.
2) Remove the CKP sensor from the flywheel
housing.

CAUTION
• Be careful not to subject the sensor
to shock.

4) Remove the fuel supply pump from the supply

pump bracket.

CAUTION
• Do not hold the pipe of the fuel sup-
ply pump.

1 CKP sensor
2 Flywheel housing

27. Flywheel Removal

1) Remove the flywheel from the crankshaft.
1 Fuel supply pump ANNOTATION:
2 O-ring • Gradually loosen the flywheel installation
3 Supply pump bracket bolts in the order shown in the diagram.
84402826 - May 2011
2445-14
 Lubrication System

CAUTION CAUTION
• Fix the flywheel firmly so that it will • Be careful not to damage the oil
not rotate. seal press-fitting surface.

28. Crankshaft rear oil seal Removal ANNOTATION:

1) Remove the crankshaft rear oil seal from the • Remove the slinger and oil seal together.
crankshaft using the special tool. • If the slinger of the remover is easy to come
off, the outer circumference of the jig can be
tightened using a clip band to improve the
workability.
29. Oil pan Removal
1) Disengage the harness connector from the oil
level switch.
2) Remove the oil pan from the crankcase.
3) Remove the gasket from the oil pan.
30. Flywheel housing Removal
1) Remove the cover from the flywheel housing.
2) Remove the flywheel housing from the cylin-
der block and the crankcase.

Special tool: rear oil seal remover (refer CAUTION

to section 1003)
• Do not forget to remove the bolt
shown in the diagram.

1 Felt
2 Slinger
3 Crankshaft rear oil seal 1 Bolt

31. Idle gear Measurement

84402826 - May 2011

2445-15
 Lubrication System

1) Align the dial gauge to the idle gear. Specified value: 0.080 - 0.155 mm { 0.0031 -
0.0061 in }
ANNOTATION:
Limit: 0.20 mm { 0.0079 in }
• Attach the dial gauge to the idle gear tooth
to be measured. CAUTION
2) Inspect the backlash. • Replace the idle gear if the mea-
sured value exceeds the limit value.
ANNOTATION:
• Gently move the gear right and left to read
the inconsistency on the dial gauge.

CAUTION
• Measure the idle gear backlash be-
fore removing the idle gear A.

Specified value: 0.10 - 0.17 mm { 0.0039 -

0.0067 in }
limit: 0.30 mm { 0.0118 in }

CAUTION
• Replace the idle gear if the mea-
sured value exceeds the limit value.
32. Idle gear A Removal
1) Remove the idle gear A from the idle gear A
shaft.
33. Oil pump assembly Removal
1) Remove the oil pump assembly from the cylin-
der block.

3) Measure the clearance using the feeler

gauge.
ANNOTATION:
• Measure the clearance between the idle
gear and the thrust collar.

CAUTION
• Measure the play of the idle gear in
the axis direction before removing
the idle gear B.

84402826 - May 2011

2445-16
 Lubrication System

Disassembly of Oil Pump Assembly Assembly of Oil Pump Assembly

1. Oil pump assembly Disassembly 1. Oil pump assembly Reassembly
1) Remove the driven gear from the body. 1) Install the ball to the body.
2) Install the spring to the body.
3) Install the cotter pin to the body.

2) Remove the cotter pin from the body.

3) Remove the spring from the body.
4) Remove the ball from the body.
1 Split pin

4) Apply the engine oil to the driven gear.

5) Install the driven gear to the body.

1 Split pin

84402826 - May 2011

2445-17
 Lubrication System

Installation of Oil Pump Assembly 2) Apply the engine oil to the idle gear A.
3) Install the idle gear A shaft to the idle gear A.
1. Oil pump assembly Installation 4) Align the idle gear A to alignment mark.
1) Install the oil pump to the cylinder block. ANNOTATION:
CAUTION • Align the L mark on the crank gear with the
O mark on the idle gear A.
• Use new gaskets.
5) Apply the engine oil to the bolt.
Tightening torque: 31 N・m {3.2 kgf・m / 23 ANNOTATION:
lb・ft}
• Apply engine oil to the threaded portion and
2. Idle gear A Installation seat surface on the idle gear A installation
1) Align 1st cylinder to the compression top dead bolt.
center.

84402826 - May 2011

2445-18
 Lubrication System

6) Install the idle gear A to the cylinder block.

Tightening torque: 133 N・m {13.6 kgf・m /
98 lb・ft}

1 Idle gear C 4 PTO gear 7 Oil pump drive gear

2 Camshaft gear 5 PTO idle gear 8 Supply pump gear
3 Idle gear B 6 Crankshaft gear 9 Idle gear A

84402826 - May 2011

2445-19
 Lubrication System

3. Flywheel housing Installation

1) Clean the cylinder block using the scraper.
ANNOTATION:
• Remove dust and oil from the flywheel hous-
ing installation area.
2) Apply the liquid gasket to the cylinder block.
ANNOTATION:
• Refer to the diagram and apply the Three-
Bond 1207B to the cylinder block.

1 Bolt

4) Apply engine oil to the PTO gear shaft.

5) Install the PTO idle gear shaft to the PTO idle
gear.
6) Install the PTO idle gear to the cylinder block.
Tightening torque: 134 N・m {13.7 kgf・m /
99 lb・ft}

CAUTION
• After applying the liquid gasket, in-
stall the flywheel housing within 5
minutes.

3) Install the flywheel housing to the cylinder

block

Tightening torque
: 96 N・m {9.8 kgf・ m / 7) Install the O-ring to the cover.
Flywheel housing side
71 lb・ft} 8) Install the cover to the flywheel housing.
: 38 N・m {3.9 kgf・ m / Tightening torque: 19 N・m {1.9 kgf・m / 14
Cylinder block side
28 lb・ft} lb・ft}
Supply pump bracket : 76 N・m {7.7 kgf・ m /
side 56 lb・ft} 4. Oil pan Installation
1) Apply the liquid gasket to the crankcase.
ANNOTATION:
ANNOTATION:
• Install the flywheel housing after aligning
with the knock pin position of the cylinder • Apply ThreeBond 1207B to each joint of the
block. crankcase, flywheel housing and gear case.

CAUTION Bead width: 3.0 mm {0.1181 in}

• Be careful not to forget to tighten

the bolt indicated in the diagram.

84402826 - May 2011

2445-20
 Lubrication System

ANNOTATION:
• Install the crankshaft rear oil seal and
slinger together.
• In order to install the crankshaft rear oil seal,
use the one(s) in the following table from
among the parts included in the kit.

CAUTION
• After applying the liquid gasket, in-
stall the oil pan within 5 minutes.

2) Install the gasket to the oil pan.

3) Install the oil pan to the crankcase.
Tightening torque: 29 N・m {3.0 kgf・m / 22
Legend Parts number
lb・ft}
1: Adapter 5-8840-2709-0
ANNOTATION: 2: Adapter tightening
5-8840-2714-0
bolts
• Tightening order
3: Center bolt 5-8840-2713-0
4: Sleeve 5-8840-9063-0
5: Collar 5-8840-2710-0
6: Adapter ring 5-8840-2711-0
7: Crankshaft rear oil -
seal

2) Apply the engine oil to the crankshaft rear oil

seal.

CAUTION
• Apply only to the lip section of the
oil seal.

4) Connect the harness connector to the oil level 3) Install the crankshaft rear oil seal to the
switch. adapter.
4) Install the adapter to the crankshaft.
5. Crankshaft rear oil seal Installation
5) Install the adapter ring to the sleeve.
1) Prepare the special tool. 6) Install the sleeve to the adapter.

Special tool: oil seal installer (refer to

section 1003) 1 Sleeve
2 Adapter ring
84402826 - May 2011
2445-21
 Lubrication System

7) Install the center bolt to the sleeve. 2) Install the flywheel to the crankshaft.
8) Tighten the center bolt using the wrench.
CAUTION
ANNOTATION:
• Pay attention to the knock pin posi-
• Tighten the center bolt until the sleeve tion of the crankshaft.
touches the adapter.
ANNOTATION:
• Tightening order

9) Inspect the crankshaft rear oil seal.

ANNOTATION:
• Measure the distance between the crank- 3) Tighten the bolt using the torque wrench.
shaft head and the crankshaft rear oil seal. Tightening torque: 78 N・m {8.0 kgf・m / 58
Specified value: 7.2 - 7.8 mm {0.2835 - 0.3071 lb・ft}
in} 4) Tighten the bolt using the special tool.

Special tool: angle gauge (refer to section

1 Crankshaft 1003)
2 Crankshaft rear oil seal Tightening angle: 120°
3 Measurement location 7. CKP sensor Installation
4 Collar
1) Install the CKP sensor to the flywheel housing.
5 Adapter ring
6 Sleeve CAUTION
7 Adapter
• Be careful not to subject the sensor
6. Flywheel Installation to shock.

1) Apply the disulfide molybdenum grease to the ANNOTATION:

bolt.
• Tighten together with the clip.
ANNOTATION:
Tightening torque: 6 N・m {0.6 kgf・m / 52
• Apply to the seat surface and threaded por- lb・in}
tion on the flywheel installation bolts.

84402826 - May 2011

2445-22
 Lubrication System

2) Connect the harness connector to the CKP 2) Install the fuel supply pump to the supply
sensor. pump bracket.
Tightening torque: 19 N・m {1.9 kgf・m / 14
lb・ft}

CAUTION
• Be careful not to let the O-ring get
twisted.

1 CKP sensor
2 Flywheel housing

8. Starter assembly Installation

1) Install the starter assembly to the flywheel
housing.
Tightening torque: 106 N・m {10.8 kgf・m / 1 Fuel supply pump
78 lb・ft} 2 O-ring
2) Connect the earth cable to the starter assem- 3 Supply pump bracket
bly.
Tightening torque: 51 N・m {5.1 kgf・m / 37 3) Install the supply pump gear to the fuel supply
lb・ft} pump.
Tightening torque: 64 N・m {6.5 kgf・m / 47
lb・ft}

1 Oil pressure sensor

2 Oil port cover
3 Starter assembly 1 Fuel supply pump
2 Supply pump gear
9. Fuel supply pump Installation 3 Nut

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

84402826 - May 2011

2445-23
 Lubrication System

• After installing the supply pump gear, refer 7) Check alignment mark of the supply pump
to the diagram and make an alignment mark gear.
on it.
ANNOTATION:
• Confirm that the alignment mark can be
seen through the plug hole on the left side
of the flywheel housing.

4) Align 1st cylinder to the compression top dead

center.

1 Plug hole
2 Alignment mark

CAUTION
• If the alignment mark could not be
confirmed, adjust the position of
the supply pump gear.

8) Securely tighten the fuel supply pump to the

1 Front cover marking cylinder block.
0 degree marking on the crank- Tightening torque: 50 N・m {5.1 kgf・m / 37
2
shaft damper lb・ft} Nut
Tightening torque: 76 N・m {7.7 kgf・m / 56
5) Install the O-ring to the fuel supply pump. lb・ft} Bolt
6) Temporarily tighten the fuel supply pump to 9) Connect the harness connector to the fuel
the cylinder block. supply pump.
10. Cylinder head assembly Installation

CAUTION
• Clean the aligning surface of the cylinder
head and cylinder block before installing
the cylinder head assembly.
• Be careful not to damage the cylinder
head and cylinder block while cleaning.

1) Apply the liquid gasket to the cylinder block.

ANNOTATION:
• Use ThreeBond 1207B.
Bead width: 3.0 mm {0.1181 in}
1 Bolt Bead height: 3.0 mm {0.1181 in}

84402826 - May 2011

2445-24
 Lubrication System

5) Tighten the head bolt using the torque wrench.

Tightening torque: 157 N・m {16.0 kgf・m /
116 lb・ft}
6) Tighten the head bolt using the torque wrench.
Tightening torque: 165 N・m {16.8 kgf・m /
122 lb・ft}
7) Tighten the head bolt using the special tool.

CAUTION
• After applying liquid gasket, install
the cylinder head within 5 minutes.

2) Install the cylinder head gasket to the cylinder

block.
Special tool: angle gauge (refer to section
CAUTION 1003)
Tightening angle: 55° M14 bolt
• Use a new cylinder head gasket.
8) Tighten the head bolt using the torque wrench.
Tightening torque: 38 N・m {3.9 kgf・m / 28
3) Install the cylinder head assembly to the cylin-
lb・ft} M10 bolt
der block.
9) Tighten the head bolt using the torque wrench.
CAUTION Tightening torque: 167 N・m {17.0 kgf・m /
123 lb・ft} Check the tightening M14 bolt
• Be careful not to damage the cylin-
der head gasket. 11. Bridge Installation
1) Apply the engine oil to the bridge.
2) Install the bridge to the bridge guide.

CAUTION
• Confirm that the bridge moves
smoothly.

3) Apply the engine oil to the bridge cap.

4) Install the bridge cap to the bridge.

ANNOTATION:
• Tightening order of the head bolts
ANNOTATION:
• 1 to 18 in the diagram indicate the M14 bolts.
• 19 and 20 in the diagram indicate the M10
bolts.
4) Prepare the head bolt.
ANNOTATION: CAUTION
• Apply molybdenum disulfide grease to the • Be careful not to drop the bridge
seat surface and threaded portion of the cap into the engine.
M14 head bolts.
• Apply engine oil to the seat surface and 12. Camshaft Installation
threaded portion of the M10 head bolts.
84402826 - May 2011
2445-25
 Lubrication System

1) Align 1st cylinder to the compression top dead CAUTION

center.
• Confirm that the alignment mark is
not misaligned before installing the
camshaft bearing cap.
• If the alignment mark is not at
the correct position, reinstall the
camshaft.

6) Apply the engine oil to the camshaft bearing.

ANNOTATION:
• Apply engine oil to the sliding surface of the
bearing.

CAUTION
• Apply engine oil after cleaning the
1 Front cover marking bearing installation sections of the
0 degree marking on the crank- camshaft bearing and camshaft
2 bearing cap.
shaft damper

2) Apply the engine oil to the camshaft bearing. 7) Install the camshaft bearing to the camshaft
bearing cap.
ANNOTATION: 8) Install the camshaft bearing cap to the cylinder
• Apply engine oil to the sliding surface of the head assembly.
bearing. ANNOTATION:
CAUTION • Turn the camshaft bearing cap so that the
arrow mark on the top surface faces the en-
• Apply engine oil after cleaning the gine front side, and assemble in numerical
bearing installation sections of
order.
the camshaft bearing and cylinder
head. Tightening torque: 28 N・m {2.8 kgf・m / 20
lb・ft} Apply engine oil
3) Install the camshaft bearing to the cylinder
head assembly.
4) Install the camshaft to the cylinder head as-
sembly.
ANNOTATION:
• Mesh together the idle gear C and the
camshaft gear so that the alignment mark
on the camshaft gear matches the top sur-
face of the cylinder head, and gently install
the camshaft.

13. Rocker arm shaft Installation

1) Apply the engine oil to the bracket.
ANNOTATION:
• Apply to each sliding surface.
2) Apply the engine oil to the rocker arm.
ANNOTATION:
• Confirm that the adjust screw is fully loos-
5) Check alignment mark of the camshaft gear. ened.

84402826 - May 2011

2445-26
 Lubrication System

3) Temporarily tighten the bolt to the cylinder

head assembly.
ANNOTATION:
• Apply engine oil to the threaded portion of
the bolts.
4) Temporarily tighten the nut to the cylinder
head assembly.
ANNOTATION:
• Apply engine oil to the threaded portion of
the nuts.
5) Securely tighten the rocker arm shaft to the
cylinder head assembly.
1) Align 1st cylinder to the compression top dead
ANNOTATION: center.
• Hold the entire rocker arm shaft horizontally
and gradually tighten it.

Rocker arm shaft tightening torque

Parts Tightening torque
: 21 N・m {2.1 kgf・m / 15 lb・
No.1 Nut
ft}
: 27 N・m {2.8 kgf・m / 20 lb・
No.2 Bolt
ft}
: 56 N・m {5.7 kgf・m / 41 lb・
No.3 Bolt
ft}
: 27 N・m {2.8 kgf・m / 20 lb・
No.4 Bolt
ft}

1 Front cover marking

0 degree marking on the crank-
2
shaft damper

2) Prepare the feeler gauge.

thickness: 0.4 mm {0.0157 in} 2 pieces
ANNOTATION:
• Insert the thickness gauge between the
rocker arm and bridge cap.
• Insert the thickness gauge between the
bridge and valve.
3) Turn the adjust screw.
1 Nut ANNOTATION:
2 Bolt
• When the movement of the thickness gauge
3 Bolt becomes stiff, secure the adjust screw nut
4 Bolt of the rocker arm.
Tightening torque: 22 N・m {2.2 kgf・m / 16
14. Rocker arm shaft Adjustment lb・ft}
4) Turn the adjust screw.
ANNOTATION:
ANNOTATION:
• Valve clearance adjustment
• With the thickness gauge inserted, lightly
CAUTION tighten the adjust screw of the bridge.
• Confirm that the leading end of the adjust
• Adjust the valve clearance while cool.
screw and valve shaft end have made con-
• Loosen all adjust screws before adjust-
tact and the movement of the thickness
ment.
gauge has become stiff.
84402826 - May 2011
2445-27
 Lubrication System

• Check if the valve shaft end on the opposite 5) Securely tighten the nut to the common rail
side is floating or touching at an angle. assembly.
• If it is floating or touching at an angle, slightly Tightening torque: 22 N・m {2.2 kgf・m / 16
loosen the bridge adjust screw and adjust lb・ft}
the valve shaft ends on both sides to touch
ANNOTATION:
properly.
Valve bridge clearance: less than 0.1 mm • Refer to the tightening order in the diagram
if the inlet cover is removed.
{less than 0.0039 in}
ANNOTATION:
• To prevent turning, fix the bridge adjust
screw with a flathead screwdriver, and
tighten the adjust screw nut.
Tightening torque: 22 N・m {2.2 kgf・m / 16
lb・ft}

6) Securely tighten the bolt to the common rail

assembly.
Tightening torque: 19 N・m {1.9 kgf・m / 14
lb・ft}
7) Connect the harness connector to the fuel
pressure
the inlet cover is removed.

Adjustment table
Cylinder No. 1 2 3 4
E- E- E- E-
IN IN IN IN
X X X X
First cylinder compres-
O O O O
sion top dead center
Fourth cylinder com-
pression top dead cen- O O O O
ter

15. Common rail assembly Installation

1) Temporarily tighten the common rail bracket
to the oil cooler assembly.
1 Common rail assembly
ANNOTATION: 2 Fuel pressure sensor
• The installation bolt and common rail as- 3 Common rail bracket
sembly are tightened together.
2) Align the common rail assembly to the inlet 16. Fuel leak off pipe assembly Installation
cover.
3) Temporarily tighten the nut to the common rail 1) Temporarily tighten the fuel leak-off pipe to the
assembly. cylinder head assembly.
ANNOTATION: CAUTION
• The stud bolts of the inlet cover are tight- • Use new gaskets.
ened together.
4) Temporarily tighten the bolt to the common rail 2) Temporarily tighten the fuel leak-off pipe to the
assembly. common rail assembly.

CAUTION
• Use new gaskets.
84402826 - May 2011
2445-28
 Lubrication System

3) Temporarily tighten the fuel leak-off pipe to the 18. Injector Installation
fuel supply pump.
CAUTION
ANNOTATION:
• When reusing an injector, do not change
• Tighten the fuel feed pipe together. the installation position.
CAUTION
1) Apply the engine oil to the bolt.
• Use new gaskets. 2) Temporarily tighten the injector to the cylinder
head assembly.
4) Securely tighten the fuel leak-off pipe to the
cylinder head assembly. CAUTION
Tightening torque: 12 N・m {1.3 kgf・m / 109
• Be extremely careful not to damage
lb・in} the injector nozzle.
5) Securely tighten the fuel leak-off pipe to the
common rail assembly.
Tightening torque: 24 N・m {2.4 kgf・m / 17
lb・ft}
6) Securely tighten the fuel leak-off pipe to the
fuel supply pump.
Tightening torque: 24 N・m {2.4 kgf・m / 17
lb・ft}
7) Install the clip to the fuel leak-off pipe.
Tightening torque: 8 N・m {0.8 kgf・m / 69
lb・in}

1 Injector
2 Installation bolt

3) Temporarily tighten the injection pipe to the

injector.
4) Temporarily tighten the injection pipe to the
common rail assembly.
5) Securely tighten the injector to the cylinder
head assembly.
Tightening torque: 30 N・m {3.1 kgf・m / 22
1 Common rail assembly lb・ft}
2 Cylinder head assembly 6) Install the injector leak-off pipe to the injector.
3 Fuel leak-off pipe
4 Fuel supply pump CAUTION
• Use new gaskets.
17. Fuel pipe Installation
Tightening torque: 14 N・m {1.4 kgf・m / 126
1) Install the fuel pipe to the fuel supply pump
lb・in}
and the common rail assembly.
19. Injection pipe Installation
CAUTION
1) Securely tighten the injection pipe to the injec-
• Use new fuel pipes. tor.
Tightening torque: 30 N・m {3.0 kgf・m / 22
Tightening torque: 44 N・m {4.5 kgf・m / 33 lb・ft}
lb・ft} 2) Securely tighten the injection pipe to the com-
2) Install the clip to the bracket. mon rail assembly.
Tightening torque: 9 N・m {0.9 kgf・m / 78 Tightening torque: 25 N・m {2.5 kgf・m / 18
lb・in} lb・ft}

84402826 - May 2011

2445-29
 Lubrication System

3) Install the clip to the bracket. 4) Install the lower cover to the cylinder head
Tightening torque: 6 N・m {0.6 kgf・m / 52 assembly.
lb・in} Tightening torque: 18 N・m {1.8 kgf・m / 13
lb・ft}
5) Install the injector harness to the cylinder head
assembly.
ANNOTATION:
• Tighten the bolts on the bracket and in-
stall the injector harness together with the
bracket.
Tightening torque: 48 N・m {4.9 kgf・m / 35
lb・ft}

1 No.1 injection pipe

2 No.2 injection pipe
3 No.3 injection pipe
4 No.4 injection pipe
5 Fuel leak-off pipe
6 Fuel pipe
7 Common rail assembly

20. Lower cover Installation

1 Injector harness terminal
1) Apply the liquid gasket to the rubber plug. 2 Injector harness bracket
ANNOTATION:
• Apply ThreeBond 1207B. 6) Connect the injector harness to the injector.
Tightening torque: 2 N・m {0.2 kgf・m / 18
lb・in}

CAUTION
• Be careful not to damage the injec-
tor side stud bolts.

1 Rubber plug
2 Liquid gasket

CAUTION
• After applying the liquid gasket, in- 1 Lower cover
stall the lower cover within 5 min- 2 Connector
utes.

2) Install the rubber plug to the cylinder head Install the connector to the lower cover.
assembly. Tightening torque: 2 N・m {0.2 kgf・m / 18
3) Install the gasket to the lower cover. lb・in}
84402826 - May 2011
2445-30
 Lubrication System

21. Glow plug Installation

1) Install the glow plug to the cylinder head as-
sembly.
Tightening torque: 20 N・m {2.0 kgf・m / 14
lb・ft}

CAUTION
• Be careful not to exceed the speci-
fied torque when tightening.

1 Cylinder head cover

2 Gasket
3 Lower cover

3) Connect the ventilation hose to the air

breather.

2) Install the glow plug connector to the glow 23. Oil level gauge guide tube Installation
plug. 1) Install the oil level gauge guide tube to the
Tightening torque: 1 N・m {0.1 kgf・m / 11 cylinder block.
lb・in} 2) Connect the oil level gauge guide tube to the
case.
CAUTION Tightening torque: 19 N・m {1.9 kgf・m / 14
• Confirm that the glow plug connec- lb・ft}
tor does not interfere with the sur- 3) Connect the oil level gauge guide tube to the
rounding parts. cylinder head cover.
Tightening torque: 19 N・m {1.9 kgf・m / 14
22. Cylinder head cover Installation lb・ft}
4) Install the oil level gauge to the oil level gauge
1) Align the head cover gasket to the cylinder guide tube.
head cover.
2) Install the cylinder head cover to the lower
cover.
Tightening torque: 18 N・m {1.8 kgf・m / 13
lb・ft}
ANNOTATION:
• Referring to the tightening order in the dia-
gram, temporarily tighten all bolts and then
completely tighten them.

1 Cylinder head cover

2 Oil level gauge guide tube
3 Case
4 Cylinder block

24. Inlet pipe Installation

84402826 - May 2011

2445-31
 Lubrication System

1) Install the inlet pipe to the case. 25. Intake throttle valve Installation
Tightening torque: 24 N・m {2.4 kgf・m / 17
1) Install the intake throttle valve to the inlet pipe.
lb・ft}
Tightening torque: 24 N・m {2.4 kgf・m / 17
CAUTION lb・ft}

• Use new gaskets.

1 Boost temperature sensor

2 Boost sensor
1 Case 3 Inlet pipe
2 Gasket 4 Gasket
3 Inlet pipe 5 Intake throttle valve

2) Connect the harness connector to the IMT

sensor. 2) Install the air duct to the intake throttle valve.
3) Connect the harness connector to the EGR 3) Connect the harness connector to the intake
valve. throttle valve.
4) Connect the harness connector to the boost ANNOTATION:
temperature sensor.
5) Connect the harness connector to the boost • After connecting the harness connector,
sensor. press in the lock operation portion to lock.
6) Install the harness clip to the inlet pipe.

1 Boost sensor 1 Lock operation section

2 IMT sensor 2 Lock release
3 EGR valve 3 Lock
4 Harness clip
5 Boost temperature sensor 26. EGR cooler water pipe Installation

84402826 - May 2011

2445-32
 Lubrication System

5) Install the fan guide stay to the fan guide.

Tightening torque: 45 N・m {4.6 kgf・m / 33
lb・ft}

1 Fan guide stay

2 Fan guide
3 Fan guide bracket
4 Spacer

27. EGR valve Installation

1) Install the EGR valve to the EGR pipe D.
Tightening torque: 24 N・m {2.4 kgf・m / 17
lb・ft}

1 EGR cooler water feed pipe

2 EGR cooler water return pipe

1) Install the EGR cooler water pipe to the engine

assembly.
ANNOTATION:
• Install the EGR cooler water feed pipe and
EGR cooler water return pipe.
Tightening torque: 24 N・m {2.4 kgf・m / 17
lb・ft} Clamp
2) Connect the radiator upper hose to the water
outlet pipe.
3) Install the fan guide bracket to the cylinder 1 EGR cooler C
head assembly. 2 EGR pipe C
Tightening torque: 50 N・m {5.1 kgf・m / 37 3 EGR valve
lb・ft} 4 EGR pipe D
Tightening torque: 97 N・m {9.9 kgf・m} The
area where the spacer is used
4) Install the fan guide stay to the fan guide CAUTION
bracket. • Use new gaskets.
Tightening torque: 45 N・m {4.6 kgf・m / 33
lb・ft} 2) Connect the harness connector to the EGR
valve.
28. EGR cooler assembly Installation
1) Temporarily tighten the EGR pipe C to the
EGR valve.
2) Temporarily tighten the EGR cooler B to the
EGR pipe C.
3) Temporarily tighten the EGR pipe B to the
EGR cooler B.
84402826 - May 2011
2445-33
 Lubrication System

4) Temporarily tighten the EGR cooler A to the

EGR pipe B.

1 EGR valve
2 EGR pipe C
3 EGR cooler B
4 EGR pipe B
5 EGR cooler A
6 EGR pipe B

5) Temporarily tighten the EGR pipe A to the

EGR cooler A and the exhaust manifold.

6) Securely tighten the EGR pipe C to the EGR

valve.
Tightening torque: 24 N・m {2.4 kgf・m / 17
lb・ft} No.1 in the diagram
7) Completely tighten the EGR pipe C to the en-
gine hanger bracket.
Tightening torque: 48 N・m {4.9 kgf・m / 35
lb・ft} No.2 in the diagram
8) Securely tighten the EGR pipe B to the
bracket.
Tightening torque: 48 N・m {4.9 kgf・m / 35
lb・ft} No.3 in the diagram
9) Securely tighten the EGR cooler B to the EGR
1 EGR cooler A pipe
2 EGR pipe A C.
3 Exhaust manifold Tightening torque: 24 N・m {2.4 kgf・m / 17
lb・ft} No.4 in the diagram
ANNOTATION: 10) Securely tighten the EGR pipe B to the EGR
cooler
• Complete tightening order of the EGR B.
cooler assembly Tightening torque: 24 N・m {2.4 kgf・m / 17
lb・ft} No.5 in the diagram
11) Securely tighten the EGR cooler A to the EGR
pipe
B.
Tightening torque: 24 N・m {2.4 kgf・m / 17
lb・ft} No.6 in the diagram
12) Securely tighten the EGR pipe A to the ex-
haust manifold.
Tightening torque: 28 N・m {2.9 kgf・m / 21
lb・ft} No.7 in the diagram

84402826 - May 2011

2445-34
 Lubrication System

13) Securely tighten the EGR pipe A to the EGR 1) Temporarily tighten the turbocharger assem-
cooler bly to the exhaust manifold.
A.
Tightening torque: 28 N・m {2.9 kgf・m / 21
lb・ft} No.8 in the diagram
14) Install the EGR heat protector to the EGR pipe
A.

1 Exhaust manifold
2 Turbocharger assembly

2) Temporarily tighten the exhaust manifold stay

to the cylinder block and the turbocharger as-
1 EGR heat protector sembly.

15) Connect the water rubber hose to the EGR

cooler assembly.

1 Turbocharger assembly
2 Exhaust manifold
3 Exhaust manifold stay

1 Water rubber hose 3) Securely tighten the turbocharger assembly to

the exhaust manifold.
Tightening torque: 52 N・m {5.3 kgf・m / 38
29. Turbocharger assembly Installation lb・ft}

84402826 - May 2011

2445-35
 Lubrication System

4) Securely tighten the exhaust manifold stay to 8) Connect the water return pipe to the tur-
the cylinder block and the turbocharger as- bocharger assembly.
sembly.
Tightening torque: 52 N・m {5.3 kgf・m / 38
lb・ft} Nut
Tightening torque: 50 N・m {5.1 kgf・m / 37
lb・ft} Bolt
ANNOTATION:
• Tightening order

5) Install the water feed pipe to the cylinder

block.

CAUTION
• Use new gaskets.

Tightening torque: 41 N・m {4.2 kgf・m / 30

lb・ft} Eyebolt
Tightening torque: 24 N・m {2.4 kgf・m / 17
lb・ft} Clip 1 Water return pipe
6) Connect the water feed pipe to the tur- 2 Water feed pipe
bocharger assembly.
Tightening torque: 35 N・m {3.5 kgf・m / 25
CAUTION lb・ft} Eyebolt
9) Install the oil return pipe to the cylinder block.
• Use new gaskets.
CAUTION
Tightening torque: 35 N・m {3.5 kgf・m / 25
lb・ft} Eyebolt • Use new gaskets.
Tightening torque: 14 N・m {1.4 kgf・m / 119
lb・in} Clip Tightening torque: 22 N・m {2.2 kgf・m / 16
7) Install the water return pipe to the water pump lb・ft}
assembly. 10) Connect the oil return pipe to the turbocharger
assembly.
CAUTION
CAUTION
• Use new gaskets.
• Use new gaskets.
Tightening torque: 35 N・m {3.5 kgf・m / 25
lb・ft} Eyebolt Tightening torque: 9 N・m {0.9 kgf・m / 78
Tightening torque: 24 N・m {2.4 kgf・m / 17 lb・in}
lb・ft} Clip 11) Install the oil feed pipe to the oil port cover.

CAUTION
• Use new gaskets.

Tightening torque: 17 N・m {1.7 kgf・m / 12

lb・ft} Eyebolt
Tightening torque: 24 N・m {2.4 kgf・m / 17
lb・ft} Clip
84402826 - May 2011
2445-36
 Lubrication System

12) Connect the oil feed pipe to the turbocharger 31. Engine oil Filling
assembly.
1) Replenish the engine oil with the engine as-
CAUTION sembly.

• Use new gaskets. CAUTION

Tightening torque: 17 N・m {1.7 kgf・m / 12
lb・ft} Eyebolt
Tightening torque: 24 N・m {2.4 kgf・m / 17
lb・ft} Clip
• Confirm the tightening of the oil pan
drain before adding engine oil.
32. Coolant Filling
1) Loosen the valve using a wrench.
2) 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.

3) Tighten the valve using a wrench.

CAUTION
• Use new gaskets.

Tightening torque: 28 N・m {2.8 kgf・m / 20

lb・ft}
4) Replenish the coolant with the radiator.

1 Turbocharger assembly
2 Oil feed pipe
3 Oil return pipe

13) Install the exhaust pipe to the turbocharger 1 Valve

assembly. 2 Gasket
14) Install the air intake hose to the turbocharger
assembly and the intercooler.
15) Install the air cleaner duct to the air cleaner 33. Battery ground cable Connect
assembly and the turbocharger assembly.
16) Connect the harness connector to the tur- 1) Connect the battery ground cable to the bat-
bocharger assembly. tery.

30. Engine harness Connect 34. Fuel Air bleed

1) Connect the engine harness to the engine as- CAUTION

sembly.
• To prevent engine failure, be sure to per-
ANNOTATION: form air removal after the installation or
removal of fuel system parts.
• Connect each connector.

84402826 - May 2011

2445-37
 Lubrication System

9) Operate the priming pump.

Number of times: 10 count(s) or more
ANNOTATION:
• Wait for the specified time after operating
the priming pump.
Specified time: 1 min
10) Loosen the plug using the wrench.
ANNOTATION:
• Remove the air in the fuel filter.
11) Tighten the plug using the wrench.
12) Operate the priming pump.
Number of times: 10 count(s) or more
1 Priming pump ANNOTATION:
2 Plug
3 Drain plug • Wait for the specified time after operating
the priming pump.
4 Case
5 Fuel filter element specified time: 1 min
13) Loosen the plug using the wrench.
1) Prepare the pan. ANNOTATION:
2) Turn ON the starter switch.
• Remove the air in the fuel filter.
ANNOTATION:
14) Tighten the plug using the wrench.
• This is for the models with an electromag- Tightening torque: 10 N・m {1.0 kgf・m / 89
netic pump. lb・in}
3) Loosen the plug using the wrench.
CAUTION
4) Operate the priming pump.
Number of times: 20 count(s) or more • Remove the fuel around the plug
ANNOTATION: 　after tightening.
thoroughly　

• Confirm that fuel comes out from around the 15) Operate the priming pump.
plug. Number of times the operation is performed:
5) Tighten the plug using the wrench. 10 - 15 times
6) Operate the priming pump. 16) Start the engine.
Number of times: 10 count(s) or more CAUTION
ANNOTATION:
• Do not accelerate the engine revo-
• Wait for the specified time after operating lution right after staring.
the priming pump.
Idling: 5 s
Specified time: 1 min
7) Loosen the plug using the wrench. ANNOTATION:
ANNOTATION: • Accelerate the engine revolution gradually.
• Remove the air in the fuel filter. Engine revolution hold: 3 min.
8) Tighten the plug using the wrench. ANNOTATION:
• Accelerate the engine revolution to maxi-
mum.
• Lower the rotation.

84402826 - May 2011

2445-38
 Lubrication System

Inspection 4) Measure the cylinder block using the gauge.

1. Oil pump assembly Inspection ANNOTATION:
1) Measure the clearance using the feeler • Measure the bush inner diameter of the
gauge. cylinder block.
ANNOTATION:
• The clearance between the inner wall of the
body and each gear tooth tip.
Specified value: 0.125 - 0.220 mm {0.0049 -
0.0087 in}
Limit: 0.30 mm {0.0118 in}

5) Calculate the clearance from the measured

value.
ANNOTATION:
• The difference between the shaft outer di-
ameter and the bush inner diameter is the
clearance.
Specified value: 0.04 - 0.07 mm {0.0016 -
CAUTION 0.0028 in}
• Replace the gear if the measured Limit: 0.20 mm {0.0079 in}
value exceeds the limit value.
CAUTION
2) Measure the shaft using the micrometer. • Replace the gear if the clearance
exceeds the limit value.
ANNOTATION:
• Driven gear shaft outer diameter 6) Inspect the ball.
7) Inspect the spring.
Specified value: 15.989 - 16.000 mm {0.6295
- 0.6299 in}
Limit: 15.900 mm {0.6260 in}
3) Measure the body using the gauge.
ANNOTATION:
• Measure the bush inner diameter of the
body.

1 Ball
2 Spring

84402826 - May 2011

2445-39
 Lubrication System

Engine oil Inspection Removal and Installation of Oil

1. Engine oil Inspection Port Cover
CAUTION Removal of Oil Port Cover
• The engine should be in a horizontal po- 1. Oil pressure sensor Removal
sition.
• Wait at least 5 minutes before starting the 1) Disconnect the harness connector from the oil
engine and after stopping the engine. pressure sensor.
2) Remove the oil pressure sensor from the oil
1) Remove the oil level gauge from the oil level port cover.
gauge guide tube.
ANNOTATION:
• Wipe off the engine oil remaining on the oil
level gauge.
2) Install the oil level gauge to the oil level gauge
guide tube.
3) Remove the oil level gauge from the oil level
gauge guide tube.
4) Inspect the engine oil.
ANNOTATION:
• Check the engine oil remaining on the oil
level gauge to inspect the engine oil level.
1 Oil pressure sensor
2 Oil port cover
3 Starter assembly

2. Oil port cover Removal

1) Disengage the oil feed pipe from the oil port
cover.
2) Remove the oil port cover from the cylinder
block.
3) Remove the O-ring from the oil port cover.

1 Upper limit
2 Lower limit

ANNOTATION:
• If the oil level is under the lower limit, add
engine oil.
• Replace the engine oil if engine oil is dirty.

1 O-ring
2 O-ring

84402826 - May 2011

2445-40
 Lubrication System

Installation of Oil Port Cover 3) Connect the oil feed pipe to the oil port cover.
1. Oil port cover Installation CAUTION
1) Install the O-ring to the oil port cover. • Use new gaskets.

Tightening torque： 17 N・m { 1.7 kgf・m /

12 lb・ft } Eyebolt
2. Oil pressure sensor Installation
1) Install the oil pressure sensor to the oil port
cover.
Tightening torque： 41 N・m { 4.2 kgf・m /
30 lb・ft }

CAUTION
• Use new gaskets.

2) Connect the harness connector to the oil pres-

sure sensor.
1 O-ring
2 O-ring

2) Install the oil port cover to the cylinder block.

Tightening torque： 48 N・m { 4.9 kgf・m /
35 lb・ft }

1 Oil pressure sensor

2 Oil port cover
3 Starter assembly

1 Bolt - short
2 Bolt - long

84402826 - May 2011

2445-41
Lubrication System

84402826 - May 2011

2445-42
Section

2455

Cooling System

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal and Installation of Water Pump Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Removal of Water Pump Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Water Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal and Installation of Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removal of Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation of Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspection of Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspection of Cooling Fan Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal and Installation of Overheat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removal of Overheat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation of Overheat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

2455-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
2455-2 PRINTED IN FRANCE
 Cooling System

Removal and Installation of Water 2) Remove the fan guide bracket from the engine
assembly.
Pump Assembly
5. Cooling fan belt Removal
Removal of Water Pump Assembly 1) Remove the cooling fan belt from the engine
1. Battery ground cable Disconnect assembly.

1) Disengage the battery ground cable from the

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

CAUTION
• After the coolant is discharged,
make sure to tighten the drain plug.

3. Cooling fan Removal

1) Remove the cooling fan from the adapter

1 Adjuster bolt
2 Fixing bolt
3 Fixing bolt

6. Water pump assembly Removal

1) Remove the adapter from the water pump as-
sembly.
2) Remove the spacer from the adapter.
3) Remove the fan pulley from the water pump
assembly.
4) Disengage the water hose from the water
pump assembly.
5) Disengage the water return pipe from the wa-
1 Cooling fan ter pump assembly.
2 Adapter 6) Remove the water pump assembly from the
front cover.
4. Fan guide Removal
1) Remove the fan guide from the fan guide
bracket.

1 Adapter
2 Spacer
3 Fan pulley
4 Water pump assembly
1 Bolt
5 Gasket
2 Washer
3 Rubber mount
4 Rubber mount
5 Guide tube
6 Fan guide
84402826 - May 2011
2455-3
 Cooling System

Installation of Water Pump Assembly 6) Install the adapter to the water pump assem-
bly.
1. Water pump assembly Installation Tightening torque： 45 N・m {4.6 kgf・m / 33
1) Install the water pump assembly to the front lb・ft}
cover.

CAUTION
• Use new gaskets.

Tightening torque： 52 N・m {5.3 kgf・m / 38

lb・ft} 1 bolt in the diagram
Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft}

1 Adapter
2 Spacer
3 Fan pulley
4 Water pump assembly
5 Gasket

2. Cooling fan belt Installation

1 Bolt 1) Install the cooling fan belt to the engine as-
2 Stud bolt sembly.
3 Oil relief valve 3. Cooling fan belt Adjustment

2) Connect the water hose to the water pump 1) Press the cooling fan belt.
assembly. ANNOTATION:
3) Connect the water return pipe to the water
pump assembly. • Measure the amount of cooling fan belt flex
Tightening torque： 35 N・m {3.6 kgf・m / 26 by pressing on the point indicated by the ar-
lb・ft} row in the diagram with the specified pres-
4) Install the fan pulley to the water pump assem- sure.
bly. Standard： 98.0 N {10.0 kg / 22 lb}
Tightening torque： 10 N・m {1.0 kgf・m / 87 Specified value ： 6.0 - 8.0 mm {0.2362 -
lb・in} 0.3150 in}
5) Align the spacer to the adapter. Amount of flex

1 Crankshaft pulley
2 Generator
3 Fan pulley
84402826 - May 2011
2455-4
 Cooling System

2) Adjust the cooling fan belt to standard value 5. Cooling fan Installation
using the adjust bolt.
1) Install the cooling fan to the adapter.
Tightening torque： 76 N・m {7.7 kgf・m / 56
Tightening torque： 52 N・m {5.3 kgf・m / 38
lb・ft}
lb・ft}
Nut of the adjust plate
Tightening torque： 127 N・m {12.9 kgf・m
/ 93 lb・ft} Bolt of the bracket side

1 Cooling fan
2 Adapter
1 Adjust bolt
2 Adjust plate side nut
3 Bracket side bolt
6. Coolant Filling
4. Fan guide Installation 1) Loosen the valve using a wrench.
2) Replenish the coolant with the radiator.
1) Install the fan guide bracket to the engine as-
sembly. CAUTION
Tightening torque： 40 N・m {4.1 kgf・m / 30
lb・ft} • Be careful not to let coolant over-
2) Install the fan guide to the fan guide bracket. flow splash on the exhaust system
Tightening torque： 30 N・m {3.1 kgf・m / 22 parts.
lb・ft} • Coolant overflow should be wiped
off.

3) Tighten the valve using a wrench.

CAUTION
• Use new gaskets.

Tightening torque： 28 N・m {2.8 kgf・m / 20

lb・ft}
4) Replenish the coolant with the radiator.

1 Bolt
2 Washer
3 Rubber mount
4 Rubber mount
5 Guide tube
6 Fan guide

1 Valve
2 Gasket
84402826 - May 2011
2455-5
 Cooling System

7. Battery ground cable Connect Inspection

1) Connect the battery ground cable to the bat- 1. Water pump assembly Inspection
tery.
1) Inspect the water pump assembly.
ANNOTATION:
• Cracks and damage on the water pump
body
• Cracks and corrosion on the impeller
• Water leak from the seal unit
CAUTION
• If any abnormality is found in the
inspection, replace the water pump
assembly.

2) Inspect the bearing unit.

ANNOTATION:
• Rotate the fan while pushing the fan center
to the radius direction and inspect for any
significant looseness or abnormal sounds.

CAUTION
• If any abnormality is found in the
inspection, replace the water pump
assembly.

84402826 - May 2011

2455-6
 Cooling System

Removal and Installation of Installation of Thermostat

Thermostat 1. Thermostat Installation
1) Install the gasket to the thermostat.
Removal of Thermostat
1. Battery ground cable Disconnect CAUTION

1) Disengage the battery ground cable from the • Use new gaskets.
battery.
2) Install the thermostat to the cylinder head as-
2. Coolant Drain sembly.
1) Drain the coolant from the radiator.

CAUTION
• After the coolant is discharged,
make sure to tighten the drain plug.

3. Thermostat Removal
1) Disengage the radiator upper hose from the
water outlet pipe.
2) Remove the water outlet pipe from the cylin-
der head assembly.
3) Remove the thermostat from the cylinder
head assembly.
4) Remove the gasket from the thermostat.
1 Thermostat
2 Cylinder head

CAUTION
• Be careful not to mistake the as-
sembly position and direction.

3) Install the water outlet pipe to the cylinder

head assembly.
Tightening torque： 25 N・m {2.5 kgf・m / 18
lb・ft}
4) Connect the radiator upper hose to the water
outlet pipe.
2. Coolant Filling
1) Loosen the valve using a wrench.
2) 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.

3) Tighten the valve using a wrench.

CAUTION
• Use new gaskets.

Tightening torque： 28 N・m {2.8 kgf・m / 20

lb・ft}

84402826 - May 2011

2455-7
 Cooling System

4) Replenish the coolant with the radiator. CAUTION

• Do not heat the thermostat directly.

4) Measure the water temperature using the

thermometer.
ANNOTATION:
• Measure open valve temperature of the
thermostat.
Valve opening temperature： 80 - 84 °C {176
- 183 °F}
Temperature when fully open： 90 °C {194 °F}
Lift amount： 8.0 mm {0.3150 in}

1 Valve
2 Gasket

3. Battery ground cable Connect

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

Inspection
1. Thermostat Inspection
1) Inspect the thermostat.
ANNOTATION:
• Inspect the pellet, spring, shaft, jiggle valve,
and crimped sections for damage. 1 Piece of wood
2 Stirring rod

Inspection of Coolant
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.

CAUTION
1 Jiggle valve
• Be sure to use long life coolant which is
2) Prepare the container. specified or recommended by Isuzu.
• Using at an unspecified concentration
ANNOTATION: may result in freezing due to decreased
• Put water and the thermostat into a heatable antifreezing performance.
container. • Use a coolant concentration appropriate
for the usage environment.
3) Raise the water temperature.
ANNOTATION: ANNOTATION:
• In order to equalize the water temperature • Before using, dilute the specified long life coolant
in the container, stir well. to the specified concentration with soft tap water.

84402826 - May 2011

2455-8
 Cooling System

LLC 4) Measure the temperature using the ther-

con- mometer.
Area where the equipment is used
centra- Engine coolant temperature： 0 - 50 °C {32 -
tion 122 °F}While in inspection
General area; Area where the lowest 5) Calculate the concentration from the mea-
： 30 ％ sured value.
temperature is higher than (-12) degrees.
Cold area; Area where the lowest tem-
： 50 ％
perature is (-30) degrees.
Area where temperature drop to (-30) de-
： 55 ％
grees.

1) Inspect the radiator reverse tank.

ANNOTATION:
• If coolant level is MIN or less, add it until it
reaches MAX. Specific
gravity
CAUTION
• When adding coolant, use coolant
appropriate for the usage environ-
ment.

Volume of coolant ： 30.2 L {7.978 US gal}

Engine only
2) Inspect the water leak using the radiator cap
tester. LLC temperature (°C)
Inspection pressure： 100.0 kPa {14.505 psi
/ 2 kgf/cm2} ANNOTATION:
ANNOTATION:
• Measuring the coolant concentration using
• Inspection locations a coolant scope is also possible.
• Radiator assembly
• Water pump assembly
• Radiator hose
• Heater hose
3) Measure the specific gravity using the hy-
drometer.
Engine coolant temperature： 0 - 50 °C {32 -
122 °F}While in inspection
ANNOTATION:
• Use a container that is deeper than the
length of the hydrometer.

1 Radiator
2 Hydrometer
84402826 - May 2011
2455-9
 Cooling System

Inspection of Cooling Fan Belt 2) Adjust the cooling fan belt to standard
value using the adjust bolt.
1. Cooling fan belt Inspection Tightening torque： 76 N・m {7.7 kgf・
1) Inspect the cooling fan belt. m / 56 lb・ft} Nut of the adjust plate
Tightening torque ： 127 N ・ m {12.9
ANNOTATION: kgf・m / 93 lb・ft} Bolt of the bracket
side
• Inspect for wear or damage.
2) Cooling fan belt Adjustment
1) Press the cooling fan belt.
ANNOTATION:
• Measure the amount of cooling fan
belt flex by pressing on the point indi-
cated by the arrow in the diagram with
the specified pressure.
Standard： 98.0 N {10.0 kg / 22 lb}
Specified value： 6.0 - 8.0 mm {0.2362
- 0.3150 in} Amount of flex

1 Adjust bolt
2 Adjust plate side nut
3 Bracket side bolt

1 Crankshaft pulley
2 Generator
3 Fan pulley

84402826 - May 2011

2455-10
 Cooling System

Removal and Installation of Installation of Overheat Switch

Overheat Switch 1. Overheat switch Installation
1) Install the overheat switch to the cylinder head
Removal of Overheat Switch assembly.
1. Overheat switch Removal ANNOTATION:
1) Disconnect the harness connector from the • Apply Loctite 572 to the threaded portion.
overheat switch.
2) Remove the overheat switch from the cylinder Tightening torque： 29 N・m { 3.0 kgf・m /
head assembly. 22 lb・ft }
2. Connect the harness connector to the overheat
switch.

1 Overheat switch
2 Water temperature sensor
1 Overheat switch
2 Water temperature sensor

84402826 - May 2011

2455-11
Cooling System

84402826 - May 2011

2455-12
 Section

2465

Removal and Installation of Exhaust Manifold

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

2465-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
2465-2 PRINTED IN FRANCE
 Removal and Installation of Exhaust Manifold

Removal of Exhaust Manifold 5) Disengage the oil return pipe from the tur-
bocharger assembly.
1. Coolant Drain
1) Drain the coolant from the radiator.

CAUTION
• After the coolant is discharged,
make sure to tighten the drain plug.

2. Battery ground cable Disconnect

1) Disengage the battery ground cable from the
battery.
3. Turbocharger assembly Removal
1) Remove the air cleaner duct from the air
cleaner assembly and the turbocharger as-
sembly.
2) Remove the air intake hose from the tur-
bocharger assembly and the intercooler.
3) Remove the exhaust pipe from the tur-
bocharger assembly.
4) Disengage the oil feed pipe from the tur-
bocharger assembly.
ANNOTATION:
• Remove the clip.

1 Turbocharger assembly
2 Oil feed pipe
3 Oil return pipe

6) Disengage the water return pipe from the tur-

bocharger assembly.

84402826 - May 2011

2465-3
 Removal and Installation of Exhaust Manifold

7) Disengage the water feed pipe from the tur- 9) Disengage the harness connector from the
bocharger assembly. turbocharger assembly.
10) Remove the turbocharger assembly from the
ANNOTATION:
exhaust manifold.
• Remove the clip.

1 Exhaust manifold
2 Turbocharger assembly

4. EGR cooler assembly Removal

1) Disengage the water rubber hose from the
EGR cooler assembly.

1 Water return pipe

2 Water feed pipe

8) Remove the exhaust manifold stay from the

cylinder block and the turbocharger assembly. 1 Water rubber hose

2) Remove the EGR heat protector from the

EGR pipe A.

1 Turbocharger assembly
2 Exhaust manifold
3 Exhaust manifold stay 1 EGR heat protector

84402826 - May 2011

2465-4
 Removal and Installation of Exhaust Manifold

3) Remove the EGR pipe A from the EGR cooler 3) Remove the exhaust manifold bracket from
A and exhaust manifold. the cylinder head assembly.

1 EGR cooler A 1 Distance tube

2 EGR pipe A 2 Washer
3 Exhaust manifold 3 Exhaust manifold bracket
4 Exhaust manifold bracket
4) Remove the EGR cooler A from the EGR pipe 5 Exhaust manifold
B.
5) Remove the EGR pipe B from the EGR cooler
B.
6) Remove the EGR cooler B from the EGR pipe
C.
7) Remove the EGR pipe C from the EGR valve.

1 EGR valve
2 EGR pipe C
3 EGR cooler B
4 EGR pipe B
5 EGR cooler A
6 EGR pipe D

5. Exhaust manifold Removal

1) Remove the exhaust manifold bracket from
the exhaust manifold.
2) Remove the exhaust manifold from the cylin-
der head assembly.

84402826 - May 2011

2465-5
 Removal and Installation of Exhaust Manifold

Installation of Exhaust Manifold 2) Temporarily tighten the EGR cooler B to the

EGR pipe C.
1. Exhaust manifold Installation 3) Temporarily tighten the EGR pipe B to the
1) Install the exhaust manifold bracket to the EGR cooler B.
cylinder head assembly. 4) Temporarily tighten the EGR cooler A to the
Tightening torque： 24 N・m {2.4 kgf・m / 17 EGR pipe B.
lb・ft}
2) Install the gasket to the cylinder head assem-
bly.
ANNOTATION:
• Turn the protruding section of the gasket to-
wards the exhaust manifold and install.
3) Install the exhaust manifold to the cylinder
head assembly.
ANNOTATION:
• When assembling the washer, assemble the
distance nut section only.
Tightening torque： 34 N・m {3.5 kgf・m / 25
lb・ft} 1 EGR valve
4) Install the exhaust manifold bracket to the ex- 2 EGR pipe C
haust manifold. 3 EGR cooler B
Tightening torque： 50 N・m {5.1 kgf・m / 37
4 EGR pipe B
lb・ft}
5 EGR cooler A
6 EGR pipe B

5) Temporarily tighten the EGR pipe A to the

EGR cooler A and the exhaust manifold.

1 Distance tube
2 Washer
3 Exhaust manifold bracket
4 Exhaust manifold bracket
5 Exhaust manifold 1 EGR cooler A
2 EGR pipe A
2. EGR cooler assembly Installation 3 Exhaust manifold
1) Temporarily tighten the EGR pipe C to the
EGR valve. ANNOTATION:

84402826 - May 2011

2465-6
 Removal and Installation of Exhaust Manifold

• Complete tightening order of the EGR 14) Install the EGR heat protector to the EGR pipe
cooler assembly A.

1 EGR heat protector

15) Connect the water rubber hose to the EGR

cooler assembly.

6) Securely tighten the EGR pipe C to the EGR

valve.
Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft} No.1 in the diagram
7) Completely tighten the EGR pipe C to the en-
gine hanger bracket.
Tightening torque： 48 N・m {4.9 kgf・m / 35
lb・ft} No.2 in the diagram 1 Water rubber hose
8) Securely tighten the EGR pipe B to the
bracket.
Tightening torque： 48 N・m {4.9 kgf・m / 35 3. Turbocharger assembly Installation
lb・ft} No.3 in the diagram 1) Temporarily tighten the turbocharger assem-
9) Securely tighten the EGR cooler B to the EGR bly to the exhaust manifold.
pipe C.
Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft} No.4 in the diagram
10) Securely tighten the EGR pipe B to the EGR
cooler B.
Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft} No.5 in the diagram
11) Securely tighten the EGR cooler A to the EGR
pipe B.
Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft} No.6 in the diagram
12) Securely tighten the EGR pipe A to the ex-
haust manifold.
Tightening torque： 28 N・m {2.9 kgf・m / 21
lb・ft} No.7 in the diagram
13) Securely tighten the EGR pipe A to the EGR
cooler A.
Tightening torque： 28 N・m {2.9 kgf・m / 21 1 Exhaust manifold
lb・ft} No.8 in the diagram 2 Turbocharger assembly
84402826 - May 2011
2465-7
 Removal and Installation of Exhaust Manifold

2) Temporarily tighten the exhaust manifold stay 5) Connect the water feed pipe to the tur-
to the cylinder block and the turbocharger as- bocharger assembly.
sembly.
ANNOTATION:
• Use new gaskets.
Tightening torque： 14 N・m {1.4 kgf・m /
119 lb・in} Clip
6) Connect the water return pipe to the tur-
bocharger assembly.

1 Turbocharger assembly
2 Exhaust manifold
3 Exhaust manifold stay

3) Securely tighten the turbocharger assembly to

the exhaust manifold.
Tightening torque： 52 N・m {5.3 kgf・m / 38
lb・ft}
4) Securely tighten the exhaust manifold stay to
the cylinder block and the turbocharger as-
sembly.
Tightening torque： 52 N・m {5.3 kgf・m / 38
lb・ft} Nut
Tightening torque： 50 N・m {5.1 kgf・m / 37
lb・ft} Bolt
ANNOTATION:
• Tightening order

1 Water return pipe

2 Water feed pipe

Tightening torque： 35 N・m {3.5 kgf・m / 25

lb・ft} Eyebolt
7) Connect the oil return pipe to the turbocharger
assembly.

CAUTION
• Use new gaskets.

Tightening torque： 9 N・m {0.9 kgf・m / 78

lb・in}

84402826 - May 2011

2465-8
 Removal and Installation of Exhaust Manifold

8) Connect the oil feed pipe to the turbocharger 10) Install the air intake hose to the turbocharger
assembly. assembly and the intercooler.
11) Install the air cleaner duct to the air cleaner
CAUTION assembly and the turbocharger assembly.
12) Connect the harness connector to the tur-
• Use new gaskets. bocharger assembly.
Tightening torque： 17 N・m {1.7 kgf・m / 12 4. Battery ground cable Connect
lb・ft} Eyebolt
1) Connect the battery ground cable to the bat-
Tightening torque： 24 N・m {2.4 kgf・m / 17
tery.
lb・ft} Clip
5. Coolant Filling
1) Loosen the valve using a wrench.
2) 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.

3) Tighten the valve using a wrench.

CAUTION
• Use new gaskets.

Tightening torque： 28 N・m {2.8 kgf・m / 20

lb・ft}
4) Replenish the coolant with the radiator.

1 Turbocharger assembly
2 Oil feed pipe
3 Oil return pipe

9) Install the exhaust pipe to the turbocharger 1 Valve

assembly. 2 Gasket

84402826 - May 2011

2465-9
 Removal and Installation of Exhaust Manifold

Inspection
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
Specified value： 0.3 mm {0.0118 in}
Limit： 0.5 mm {0.0197 in}

CAUTION
• Replace the exhaust manifold if flatness
is above the limit value.

84402826 - May 2011

2465-10
 Section

2470

Disassembly, Removal and Installation of DPD Assembly

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Disassembly of DPD Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Assembly of DPD Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

2470-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
2470-2 PRINTED IN FRANCE
 Disassembly, Removal and Installation of DPD Assembly

Disassembly of DPD Assembly 2) Disengage the harness connector from the

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

DPD differential pressure sen-

1
sor

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-
ture sensor which has been subjected to
shock such as being dropped.
1 Screw
4. Exhaust gas temperature sensor Removal
2. Exhaust differential pressure sensor Removal 1) Disengage the harness connector from the
exhaust gas temperature sensor.
CAUTION
ANNOTATION:
• Before performing work, be sure to
check the DPD differential pressure sen- • To prevent incorrect assembling, make an
alignment mark on the connector before dis-
sor precautions.
connecting.
1) Disengage the differential pressure hose from 2) Remove the exhaust gas temperature sensor
the exhaust differential pressure sensor. from the DPD assembly.

84402826 - May 2011

2470-3
 Disassembly, Removal and Installation of DPD Assembly

4) Remove the differential pressure pipe from

the DPD assembly.

1 Bracket
2 Differential pressure pipe

5) Remove the oxidation catalyst assembly from

the filter assembly.
6) Remove the filter assembly from the exhaust
silencer assembly.

Exhaust gas temperature sen-

1
sor 1
Exhaust gas temperature sen-
2
sor 2

5. DPD assembly Disassembly

1) Remove the bracket from the DPD assembly.
2) Loosen the differential pressure pipe using the
wrench. 1 Oxidation catalyst assembly
3) Remove the clip from the differential pressure 2 Filter assembly
pipe. 3 Exhaust silencer assembly

84402826 - May 2011

2470-4
 Disassembly, Removal and Installation of DPD Assembly

Assembly of DPD Assembly 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： 10 N・m { 1.0 kgf・m /
• Do not reuse gaskets, bolts, and nuts. 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： 35 N・m { 3.6 kgf・m /
26 lb・ft } Pipe sleeve nut
ANNOTATION: 9) Install the bracket to the DPD assembly.
Tightening torque： 25 N・m { 2.5 kgf・m /
• Tighten together with the bracket. 18 lb・ft }
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： 29 N・m { 3.0 kgf・m /
21 lb・ft }
4) Securely tighten the oxidation catalyst assem-
bly to the filter assembly.
Tightening torque： 29 N・m { 3.0 kgf・m / 1 Bracket
21 lb・ft }
2 Differential pressure pipe

2. Exhaust gas temperature sensor Installation

1 Oxidation catalyst assembly
2 Filter assembly
3 Exhaust silencer assembly
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 Temperature
Stainless Grade: anti-seize lubricant,
manufactured by Bostik in the United
states.
• Replace the oxidation catalyst assembly
if damage has been found in the sensor
installation section of the oxidation cata-
lyst assembly.

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: anti-seize ANNOTATION:
lubricant, manufactured by Bostik
in the United states. • Exhaust gas temperature sensor identifica-
tion
84402826 - May 2011
2470-5
 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 DPD differen-
M12 x 1.25 Light gray tial pressure sensor.
ture sensor 2
• Do not reuse a DPD differential pressure
2) Securely tighten the exhaust gas temperature sensor which has been subjected to
sensor to the DPD assembly. shock such as being dropped.
Tightening torque： 30 N・m { 3.1 kgf・m / • Install or remove the DPD differen-
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 DPD differential pressure
CAUTION sensor.
• Replace the DPD differential pressure
• Be careful not to twist the harness. sensor if the 4 screws installed on the
DPD differential pressure sensor have
been loosened.

1 Screw

4. Exhaust differential pressure sensor Installation

CAUTION
• Before performing work, be sure to
check the DPD differential pressure sen-
sor precautions.

1) Install the exhaust differential pressure sensor

to the DPD assembly.
2) Connect the harness connector to the exhaust
differential pressure sensor.
Exhaust gas temperature sen- 3) Connect the differential pressure hose to the
1
sor 1 exhaust differential pressure sensor.
Exhaust gas temperature sen-
2 CAUTION
sor 2

ANNOTATION: • Be careful not to mistake the connecting

position of the differential pressure hose.
• Start the engine after assembling each part, • Since the differential pressure sensor
and check for gas leaks from each joint and may malfunction if exhaust gas leaks
for vibration. from the joint sections, confirm that
there is no exhaust gas leakage after the
3. Exhaust differential pressure sensor Safety Infor-
engine starts.
mation

84402826 - May 2011

2470-6
Disassembly, Removal and Installation of 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.

DPD differential pressure sen-

1
sor

1 Filter
2 Filter case

2) Oxidation catalyst assembly Inspection

1) Inspect the oxidation catalyst assembly.
ANNOTATION:
• Inspect the catalyst section for ero-
sion, damage, or clogging.
3) Filter assembly Cleaning

CAUTION
• Clean the filter when clogged be-
cause gradual accumulation or
firm, sticky calcination occurs on
the filter since ashes are non-
flammable unlike particle materials
(PM).
• When cleaning, use a DPD ash
removal device which blows com-
pressed air instantaneously.
• For further details on the cleaning
procedure, check the DPD ash re-
moval device handling manual.

ANNOTATION:
• Attach the filter on the DPD ash removal
device.

84402826 - May 2011

2470-7
Disassembly, Removal and Installation of DPD Assembly

CAUTION
• Confirm that there is no air leakage
on the pipe connections by check-
ing the pressure gauge attached
to the pressure reducing valve to
avoid supplying air pressure to the
air tank over the limit value.

Limit： 0.5 MPa { 72.5 psi }

ANNOTATION:
• Operate the mechanical valve for 3 seconds
to clean the filter by backwashing.
• Repeat the 2 operations above 3 times or
ANNOTATION: more.
• Add air pressure of the specified pressure to
the air tank until it increases to the specified CAUTION
pressure, and then stop adding. • While cleaning, ashes may gush
Specified pressure： 0.4 MPa { 58.0 psi } from the air removal filter with
backwashing noise, so be sure to
wear protective equipments such
as a protective mask, protective
glasses, earplugs, etc. and keep
your face and hands away.

84402826 - May 2011

2470-8
 Section

3001

Removal and Installation of Fuel Tank

84402826 - May 2011

84402826 - May 2011
 CONTENTS

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

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

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

3001-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
3001-2 PRINTED IN FRANCE
 Removal and Installation of Fuel Tank

WARNING 2. Drain out all the fuel from the fuel tank into a drum
can.
• Keep away from fire.

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.

Items to prepare
• Wrenches (19 mm, 24 mm)
• Eyebolts (M12 x 4)
• Shackle (with the required lifting capacity) x 4 3. Use a wrench (19 mm) to remove the 8 bolts (1),
• Wire ropes (with the required breaking load) and then remove the top cover (2).
• Liftcrane (with the required lifting capacity)
• Caps
• Plugs
• Drum can (for draining fuel)
• Rag
• Cleaning fluid
• Wood planks

Removal of Fuel Tank

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

4. Use a wrench (19 mm) to remove the 2 bolts (2)

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

84402826 - May 2011

3001-3
 Removal and Installation of Fuel Tank

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

7. Use a wrench (19 mm) to remove the 5 bolts (1),

and then remove the under cover (2).
Tightening torque for bolt installation: 63.7 - 73.5
N・m

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

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

84402826 - May 2011

3001-4
 Removal and Installation of Fuel Tank

11. Use a wrench (19 mm) to remove the 4 bolts (1),

and then remove the side covers (tank) (2).

9. Remove the connector (1).

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

tank.
• Fully tighten the eyebolts, and then loosen them
by a half turn.

10. Use a wrench (19 mm) to remove the 5 bolts (1),

and then remove the under cover (2).
• Depending on the machine, there may be height
adjustment shims between the tank and the
frame. Do not lose them.
Also, mark or write down the locations where they
are and how many.
Tightening torque for bolt installation: 232.4 - 276.0
N・m

84402826 - May 2011

3001-5
 Removal and Installation of Fuel Tank

13. Connect the 4 shackles (1) to the eyebolts, then use
the wire ropes (2) and liftcrane to lift.
Thoroughly check that the location is safe before
lowering the fuel tank (3) on wood planks.
Installation of fuel tank
To install, perform the reverse of the removal procedure.
Tighten bolts being installed to the specified torque.
For bolts for which the torque is not specified, check of
the "Section 1002E• Tightening Torque • Retightening
Torque Table".
Finally, carefully check for any fuel leaks.

84402826 - May 2011

3001-6
 Section

3004A

Removal and Installation of Fuel Supply Pump

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of Fuel Supply Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Fuel Supply Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

3004A-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
3004A-2 PRINTED IN FRANCE
 Removal and Installation of Fuel Supply Pump

Removal of Fuel Supply Pump 1) Disengage the harness connector from the
fuel supply pump.
1. Battery ground cable Disconnect 2) Remove the fuel supply pump from the cylin-
1) Disengage the battery ground cable from the der block.
battery.
2. Engine harness Disconnect
1) Disengage the engine harness from the en-
gine assembly.
ANNOTATION:
• Disconnect each connector.
3. Fuel pipe Removal
1) Remove the fuel pipe from the fuel supply
pump and the common rail assembly.
ANNOTATION:
• Remove the clip.
1 Bolt
CAUTION
• Do not reuse the removed fuel pipe. 3) Remove the supply pump gear from the fuel
supply pump using the puller.
4. Fuel leak off pipe assembly Removal
1) Disengage the fuel leak-off pipe from the cylin-
der head assembly.
2) Remove the fuel leak-off pipe from the fuel
supply pump.
ANNOTATION:
• Remove the eyebolt tightened together with
the fuel feed pipe.
3) Disengage the fuel leak-off pipe from the com-
mon rail assembly.
4) Remove the fuel leak-off pipe from the case.
ANNOTATION:
4) Remove the fuel supply pump from the supply
• Remove the clip. pump bracket.

CAUTION
• Do not hold the pipe of the fuel sup-
ply pump.

1 Common rail assembly

2 Cylinder head assembly
3 Fuel leak-off pipe
4 Fuel supply pump
1 Fuel supply pump
2 O-ring
5. Fuel supply pump Removal 3 Supply pump bracket
84402826 - May 2011
3004A-3
 Removal and Installation of Fuel Supply Pump

Installation of Fuel Supply Pump

1. Fuel supply pump Installation
1) Install the O-ring to the fuel supply pump.
2) Install the fuel supply pump to the supply
pump bracket.
Tightening torque： 19 N・m {1.9 kgf・m / 14
lb・ft}

CAUTION
• Be careful not to let the O-ring get
twisted.

4) Align 1st cylinder to the compression top dead

center.

1 Fuel supply pump

2 O-ring
3 Supply pump bracket 1 Front cover marking
0 degree marking on the crank-
2
shaft damper
3) Install the supply pump gear to the fuel supply
pump.
Tightening torque： 64 N・m {6.5 kgf・m / 47 5) Install the O-ring to the fuel supply pump.
lb・ft} 6) Temporarily tighten the fuel supply pump to
the　cylinder block.

1 Fuel supply pump 1 Bolt

2 Supply pump gear
3 Nut 7) Check alignment mark of the supply pump
gear.
ANNOTATION: ANNOTATION:
• After installing the supply pump gear, refer • Confirm that the alignment mark can be
to the diagram and make an alignment mark seen through the plug hole on the left side
on it. of the flywheel housing.
84402826 - May 2011
3004A-4
 Removal and Installation of Fuel Supply Pump

5) Securely tighten the fuel leak-off pipe to the

common rail assembly.
Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft}
6) Securely tighten the fuel leak-off pipe to the
fuel supply pump.
Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft}
7) Install the clip to the fuel leak-off pipe.
Tightening torque： 8 N・m {0.8 kgf・m / 69
lb・in}

1 Plug hole
2 Alignment mark

CAUTION
• If the alignment mark could not be
confirmed, adjust the position of
the supply pump gear.

8) Securely tighten the fuel supply pump to the

cylinder block.
Tightening torque： 50 N・m {5.1 kgf・m / 37 1 Common rail assembly
lb・ft} Nut
2 Cylinder head assembly
Tightening torque： 76 N・m {7.7 kgf・m / 56
lb・ft} Bolt 3 Fuel leak-off pipe
9) Connect the harness connector to the fuel 4 Fuel supply pump
supply pump.
2. Fuel leak off pipe assembly Installation 3. Fuel pipe Installation
1) Temporarily tighten the fuel leak-off pipe to the 1) Install the fuel pipe to the fuel supply pump
cylinder head assembly. and the common rail assembly.

CAUTION CAUTION
• Use new gaskets. • Use new fuel pipes.

2) Temporarily tighten the fuel leak-off pipe to the Tightening torque： 44 N・m {4.5 kgf・m / 33
common rail assembly. lb・ft}
2) Install the clip to the bracket.
CAUTION Tightening torque： 9 N・m {0.9 kgf・m / 78
lb・in}
• Use new gaskets.
4. Engine harness Connect
3) Temporarily tighten the fuel leak-off pipe to the 1) Connect the engine harness to the engine as-
fuel supply pump. sembly.
ANNOTATION: ANNOTATION:
• Tighten the fuel feed pipe together. • Connect each connector.
CAUTION 5. Battery ground cable Connect
• Use new gaskets. 1) Connect the battery ground cable to the bat-
tery.
4) Securely tighten the fuel leak-off pipe to the
6. Fuel Air bleed
cylinder head assembly.
Tightening torque： 12 N・m {1.3 kgf・m / CAUTION
109 lb・in}
• To prevent engine failure, be sure to per-
form air removal after the installation or
removal of fuel system parts.

84402826 - May 2011

3004A-5
 Removal and Installation of Fuel Supply Pump

9) Operate the priming pump.

Number of times： 10 count(s) or more
ANNOTATION:
• Wait for the specified time after operating
the priming pump.
Specified time： 1 min
10) Loosen the plug using the wrench.
ANNOTATION:
• Remove the air in the fuel filter.
11) Tighten the plug using the wrench.
12) Operate the priming pump.
Number of times： 10 count(s) or more
1 Priming pump ANNOTATION:
2 Plug
3 Drain plug • Wait for the specified time after operating
the priming pump.
4 Case
5 Fuel filter element Specified time： 1 min
13) Loosen the plug using the wrench.
1) Prepare the pan. ANNOTATION:
2) Turn ON the starter switch.
• Remove the air in the fuel filter.
ANNOTATION:
14) Tighten the plug using the wrench.
• This is for the models with an electromag- Tightening torque： 10 N・m {1.0 kgf・m / 89
netic pump. lb・in}
3) Loosen the plug using the wrench.
CAUTION
4) Operate the priming pump.
Number of times： 20 count(s) or more • Remove the fuel around the plug
ANNOTATION: thoroughly after tightening.

• Confirm that fuel comes out from around the 15) Operate the priming pump.
plug. Number of times the operation is Performed:
5) Tighten the plug using the wrench. 10 - 15 times
6) Operate the priming pump. 16) Start the engine.
Number of times： 10 count(s) or more CAUTION
ANNOTATION:
• Do not accelerate the engine revo-
• Wait for the specified time after operating lution right after staring.
the priming pump.
Idling: 5 s
Specified time： 1 min
7) Loosen the plug using the wrench. ANNOTATION:
ANNOTATION: • Accelerate the engine revolution gradually.
• Remove the air in the fuel filter. Engine revolution hold: 3 min.
8) Tighten the plug using the wrench. ANNOTATION:
• Accelerate the engine revolution to maxi-
mum.
• Lower the rotation.

84402826 - May 2011

3004A-6
 Section

3004B

Removal and Installation of Common Rail Assembly

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of Common Rail Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Common Rail Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

3004B-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
3004B-2 PRINTED IN FRANCE
 Removal and Installation of Common Rail Assembly

Removal of Common Rail 3) Remove the intake throttle valve from the inlet
pipe.
Assembly
1. Battery ground cable Disconnect
1) Disengage the battery ground cable from the
battery.
2. Engine harness Disconnect
1) Disengage the engine harness from the en-
gine assembly.
ANNOTATION:
• Disconnect each connector.
3. Intake throttle valve Removal
1) Remove the air duct from the intake throttle
valve.
2) Disengage the harness connector from the in- 1 Boost temperature sensor
take throttle valve. 2 Boost sensor
3 Inlet pipe
ANNOTATION: 4 Gasket
• Pull the lock operation portion to release the 5 Intake throttle valve
lock.
4. Inlet pipe Removal
1) Disengage the harness connector from the
boost sensor.
2) Disconnect the harness connector from the
boost temperature sensor.
3) Disengage the harness connector from the
EGR valve.
4) Disconnect the harness connector from the
IMT sensor.
5) Remove the harness clip from the inlet pipe.

1 Lock operation section

2 Lock release
3 Lock

1 Boost sensor
2 IMT sensor
3 EGR valve
4 Harness clip
5 Boost temperature sensor

84402826 - May 2011

3004B-3
 Removal and Installation of Common Rail Assembly

6) Remove the inlet pipe from the case. 2) Remove the injection pipe from the injector
and the common rail assembly.

CAUTION
• Do not reuse the removed injection
pipe.
• Seal the common rail and injector to
prevent foreign material from enter-
ing.

1 Case
2 Gasket
3 Inlet pipe

5. Oil level gauge guide tube Removal

1) Remove the oil level gauge from the oil level
gauge guide tube.
2) Disengage the oil level gauge guide tube from
the cylinder head cover. 1 No.1 injection pipe
3) Disengage the oil level gauge guide tube from 2 No.2 injection pipe
the case. 3 No.3 injection pipe
4) Remove the oil level gauge guide tube from 4 No.4 injection pipe
the cylinder block. 5 Fuel leak-off pipe
6 Fuel pipe
7 Common rail assembly

7. Fuel pipe Removal

1) Remove the fuel pipe from the fuel supply
pump and the common rail assembly.
ANNOTATION:
• Remove the clip.
CAUTION
• Do not reuse the removed fuel pipe.

8. Fuel leak off pipe assembly Removal

1 Cylinder head cover 1) Disengage the fuel leak-off pipe from the cylin-
2 Oil level gauge guide tube der head assembly.
3 Case 2) Remove the fuel leak-off pipe from the fuel
4 Cylinder block supply pump.
ANNOTATION:
6. Injection pipe Removal
• Remove the eyebolt tightened together with
1) Remove the clip from the bracket. the fuel feed pipe.

84402826 - May 2011

3004B-4
 Removal and Installation of Common Rail Assembly

3) Disengage the fuel leak-off pipe from the com- Installation of Common Rail
mon rail assembly.
4) Remove the fuel leak-off pipe from the case. Assembly
ANNOTATION: 1. Common rail assembly Installation
• Remove the clip. 1) Temporarily tighten the common rail bracket
to the oil cooler assembly.
ANNOTATION:
• The installation bolt and common rail as-
sembly are tightened together.
2) Align the common rail assembly to the inlet
cover.
3) Align the common rail assembly to the com-
mon rail bracket.
4) Temporarily tighten the nut to the common rail
assembly.
ANNOTATION:
• The stud bolts of the inlet cover are tight-
ened together.
1 Common rail assembly 5) Temporarily tighten the bolt to the common rail
2 Cylinder head assembly assembly.
3 Fuel leak-off pipe 6) Securely tighten the nut to the common rail
4 Fuel supply pump assembly.
Tightening torque： 22 N・m {2.2 kgf・m / 16
9. Common rail assembly Removal lb・ft}
1) Disengage the harness connector from the ANNOTATION:
fuel pressure sensor.
• Refer to the tightening order in the diagram
2) Remove the common rail assembly from the
if the inlet cover is removed.
inlet cover and the common rail bracket.
3) Remove the common rail bracket from the oil
cooler assembly.

7) Securely tighten the bolt to the common rail

assembly.
Tightening torque： 19 N・m {1.9 kgf・m / 14
lb・ft}
1 Common rail assembly
2 Fuel pressure sensor
3 Common rail bracket

84402826 - May 2011

3004B-5
 Removal and Installation of Common Rail Assembly

8) Connect the harness connector to the fuel 7) Install the clip to the fuel leak-off pipe.
pressure sensor. Tightening torque： 8 N・m {0.8 kgf・m / 69
lb・in}

1 Common rail assembly 1 Common rail assembly

2 Fuel pressure sensor 2 Cylinder head assembly
3 Common rail bracket 3 Fuel leak-off pipe
4 Fuel supply pump

3. Fuel pipe Installation

2. Fuel leak off pipe assembly Installation
1) Install the fuel pipe to the fuel supply pump
1) Temporarily tighten the fuel leak-off pipe to the
and the common rail assembly.
cylinder head assembly.
CAUTION
CAUTION
• Use new fuel pipes.
• Use new gaskets.
Tightening torque： 44 N・m {4.5 kgf・m / 33
2) Temporarily tighten the fuel leak-off pipe to the
lb・ft}
common rail assembly.
2) Install the clip to the bracket.
CAUTION Tightening torque： 9 N・m {0.9 kgf・m / 78
lb・in}
• Use new gaskets.
4. Injection pipe Installation
3) Temporarily tighten the fuel leak-off pipe to the CAUTION
fuel supply pump.
• Use new injection pipes.
ANNOTATION:
• Tighten the fuel feed pipe together. 1) Apply the engine oil to the injector sleeve.

CAUTION ANNOTATION:

• Use new gaskets. • Apply to the injection pipe sleeve on the in-
jector side.
4) Securely tighten the fuel leak-off pipe to the 2) Temporarily tighten the injection pipe to the
cylinder head assembly. injector.
Tightening torque： 12 N・m {1.3 kgf・m / 3) Temporarily tighten the injection pipe to the
109 lb・in} common rail assembly.
5) Securely tighten the fuel leak-off pipe to the 4) Securely tighten the injection pipe to the injec-
common rail assembly. tor.
Tightening torque： 24 N・m {2.4 kgf・m / 17 Tightening torque： 30 N・m {3.0 kgf・m / 22
lb・ft} lb・ft}
6) Securely tighten the fuel leak-off pipe to the 5) Securely tighten the injection pipe to the com-
fuel supply pump. mon rail assembly.
Tightening torque： 24 N・m {2.4 kgf・m / 17 Tightening torque： 25 N・m {2.5 kgf・m / 18
lb・ft} lb・ft}

84402826 - May 2011

3004B-6
 Removal and Installation of Common Rail Assembly

6) Install the clip to the bracket. 6. Inlet pipe Installation

Tightening torque： 6 N・m {0.6 kgf・m / 52
1) Install the inlet pipe to the case.
lb・in}
Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft}

CAUTION
• Use new gaskets.

1 No.1 injection pipe

2 No.2 injection pipe
3 No.3 injection pipe
4 No.4 injection pipe
5 Fuel leak-off pipe
6 Fuel pipe 1 Case
7 Common rail assembly 2 Gasket
3 Inlet pipe

5. Oil level gauge guide tube Installation

2) Connect the harness connector to the IMT
1) Install the oil level gauge guide tube to the sensor.
cylinder block. 3) Connect the harness connector to the EGR
2) Connect the oil level gauge guide tube to the valve.
case. 4) Connect the harness connector to the boost
Tightening torque： 19 N・m {1.9 kgf・m / 14 temperature sensor.
lb・ft} 5) Connect the harness connector to the boost
3) Connect the oil level gauge guide tube to the sensor.
cylinder head cover. 6) Install the harness clip to the inlet pipe.
Tightening torque： 19 N・m {1.9 kgf・m / 14
lb・ft}
4) Install the oil level gauge to the oil level gauge
guide tube.

1 Boost sensor
2 IMT sensor
3 EGR valve
4 Harness clip
1 Cylinder head cover 5 Boost temperature sensor
2 Oil level gauge guide tube
3 Case
4 Cylinder block 7. Intake throttle valve Installation
84402826 - May 2011
3004B-7
 Removal and Installation of Common Rail Assembly

1) Install the intake throttle valve to the inlet pipe. CAUTION

Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft} • To prevent engine failure, be sure to per-
form air removal after the installation or
removal of fuel system parts.

1 Boost temperature sensor

2 Boost sensor
3 Inlet pipe
4 Gasket 1 Priming pump
5 Intake throttle valve 2 Plug
3 Drain plug
2) Install the air duct to the intake throttle valve. 4 Case
3) Connect the harness connector to the intake 5 Fuel filter element
throttle valve.
ANNOTATION: 1) Prepare the pan.
• After connecting the harness connector, 2) Turn ON the starter switch.
press in the lock operation portion to lock. ANNOTATION:
• This is for the models with an electromag-
netic pump.
3) Loosen the plug using the wrench.
4) Operate the priming pump.
Number of times： 20 count(s) or more
ANNOTATION:
• Confirm that fuel comes out from around the
plug.
5) Tighten the plug using the wrench.
6) Operate the priming pump.
Number of times： 10 count(s) or more
ANNOTATION:
1 Lock operation section • Wait for the specified time after operating
2 Lock release the priming pump.
3 Lock Specified time： 1 min
7) Loosen the plug using the wrench.
8. Engine harness Connect
ANNOTATION:
1) Connect the engine harness to the engine as-
sembly. • Remove the air in the fuel filter.

ANNOTATION: 8) Tighten the plug using the wrench.

9) Operate the priming pump.
• Connect each connector. Number of times： 10 count(s) or more
9. Battery ground cable Connect ANNOTATION:
1) Connect the battery ground cable to the bat- • Wait for the specified time after operating
tery. the priming pump.
10. Fuel Air bleed Specified time： 1 min
84402826 - May 2011
3004B-8
 Removal and Installation of Common Rail Assembly

10) Loosen the plug using the wrench. 15) Operate the priming pump.
Number of times the operation is Performed:
ANNOTATION:
10 - 15 times
• Remove the air in the fuel filter. 16) Start the engine.
11) Tighten the plug using the wrench. CAUTION
12) Operate the priming pump.
Number of times： 10 count(s) or more • Do not accelerate the engine revo-
lution right after staring.
ANNOTATION:
• Wait for the specified time after operating Idling: 5 s
the priming pump. ANNOTATION:
Specified time： 1 min
• Accelerate the engine revolution gradually.
13) Loosen the plug using the wrench.
Engine revolution hold: 3 min.
ANNOTATION:
ANNOTATION:
• Remove the air in the fuel filter.
• Accelerate the engine revolution to maxi-
14) Tighten the plug using the wrench. mum.
Tightening torque： 10 N・m {1.0 kgf・m / 89
• Lower the rotation.
lb・in}

CAUTION
• Remove the fuel around the plug
thoroughly after tightening.

84402826 - May 2011

3004B-9
Removal and Installation of Common Rail Assembly

84402826 - May 2011

3004B-10
 Section

3005

Removal and Installation of Injector

84402826 - May 2011

84402826 - May 2011
 CONTENTS

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

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

3005-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
3005-2 PRINTED IN FRANCE
 Removal and Installation of Injector

Removal of Injector 3) Remove the intake throttle valve from the inlet
pipe.
1. Battery ground cable Disconnect
1) Disengage the battery ground cable from the
battery.
2. Engine harness Disconnect
1) Disengage the engine harness from the en-
gine assembly.
ANNOTATION:
• Disconnect each connector.
3. Intake throttle valve Removal
1) Remove the air duct from the intake throttle
valve.
2) Disengage the harness connector from the in-
takethrottle valve. 1 Boost temperature sensor
ANNOTATION: 2 Boost sensor
3 Inlet pipe
• Pull the lock operation portion to release the 4 Gasket
lock.
5 Intake throttle valve

4. Inlet pipe Removal

1) Disengage the harness connector from the
boost sensor.
2) Disconnect the harness connector from the
boost temperature sensor.
3) Disengage the harness connector from the
EGR valve.
4) Disconnect the harness connector from the
IMT sensor.
5) Remove the harness clip from the inlet pipe.

1 Lock operation section

2 Lock release
3 Lock

1 Boost sensor
2 IMT sensor
3 EGR valve
4 Harness clip
5 Boost temperature sensor

84402826 - May 2011

3005-3
 Removal and Installation of Injector

6) Remove the inlet pipe from the case.

1 No.1 injection pipe

1 Case 2 No.2 injection pipe
2 Gasket 3 No.3 injection pipe
3 Inlet pipe 4 No.4 injection pipe
5 Fuel leak-off pipe
6 Fuel pipe
5. Oil level gauge guide tube Removal
7 Common rail assembly
1) Remove the oil level gauge from the oil level
gauge guide tube. 7. Cylinder head cover Removal
2) Disengage the oil level gauge guide tube from
the cylinder head cover. 1) Disengage the ventilation hose from the air
3) Disengage the oil level gauge guide tube from breather.
the case. 2) Remove the cylinder head cover from the
4) Remove the oil level gauge guide tube from lower cover.
the cylinder block. 3) Remove the head cover gasket from the cylin-
der head cover.

1 Cylinder head cover

2 Oil level gauge guide tube 1 Cylinder head cover
3 2 Gasket
Case
3 Lower cover
4 Cylinder block

8. Lower cover Removal

6. Injection pipe Removal
1) Remove the connector from the lower cover.
1) Remove the clip from the bracket.
2) Remove the injection pipe from the injector CAUTION
and the common rail assembly.
• Do not pull the wire, or pry the con-
CAUTION nector with a screwdriver.
• Do not reuse the removed injection
pipe.
• Seal the common rail and injector to
prevent foreign material from enter-
ing.

84402826 - May 2011

3005-4
 Removal and Installation of Injector

2) Disengage the injector harness from the injec- Special tool: fuel injector remover (refer
tor. to section 1003)

CAUTION
• Be careful not to damage the injec-
tor side stud bolts.

3) Remove the injector harness from the cylinder

head assembly.
ANNOTATION:
• Remove the bracket tightening bolts and
then remove the injector harness together
with the bracket.
4) Remove the lower cover from the cylinder
head assembly.
Special tool: sliding hammer (refer to
section 1003)

1 Lower cover
2 Connector

5) Remove the gasket from the lower cover.

6) Remove the rubber plug from the cylinder
head assembly.
9. Injector Removal
1) Remove the injector leak-off pipe from the in-
jector.
2) Remove the injector from the cylinder head
assembly.
ANNOTATION:
• When it is difficult to remove the injector, use
a special tool.

1 Sliding hammer
2 Fuel injector remover
3 Injector

84402826 - May 2011

3005-5
 Removal and Installation of Injector

CAUTION 3) Temporarily tighten the injection pipe to the

injector.
• Confirm that the sleeve is not pulled
out together when pulling out the CAUTION
injector using a special tool.
• Use new injection pipes.
• Store each ID code plate on the in-
jector head with the cylinder num-
ber tag attached to avoid a mix-up. 4) Temporarily tighten the injection pipe to the
common rail assembly.
• Be extremely careful not to damage
the injector nozzle. 5) Securely tighten the injector to the cylinder
head assembly.
Tightening torque： 30 N・m {3.1 kgf・m / 22
lb・ft}
6) Install the injector leak-off pipe to the injector.

CAUTION
• Use new gaskets.

Tightening torque： 14 N・m {1.4 kgf・m /

126 lb・in}
2. Injection pipe Installation
1) Securely tighten the injection pipe to the injec-
tor.
Tightening torque： 30 N・m {3.0 kgf・m / 22
lb・ft}
2) Securely tighten the injection pipe to the com-
mon rail assembly.
Tightening torque： 25 N・m {2.5 kgf・m / 18
Installation of Injector lb・ft}
1. Injector Installation 3) Install the clip to the bracket.
Tightening torque： 6 N・m {0.6 kgf・m / 52
CAUTION lb・in}

• When reusing an injector, do not change

the installation position.

1) Apply the engine oil to the bolt.

2) Temporarily tighten the injector to the cylinder
head assembly.

CAUTION
• Be extremely careful not to damage
the injector nozzle.

1 No.1 injection pipe

2 No.2 injection pipe
3 No.3 injection pipe
4 No.4 injection pipe
5 Fuel leak-off pipe
6 Fuel pipe
7 Common rail assembly

3. Lower cover Installation

1) Apply the liquid gasket to the rubber plug.
1 Injector ANNOTATION:
2 Installation bolt • Apply ThreeBond 1207B.

84402826 - May 2011

3005-6
 Removal and Installation of Injector

6) Connect the injector harness to the injector.

Tightening torque： 2 N・m {0.2 kgf・m / 18
lb・in}

CAUTION
• Be careful not to damage the injec-
tor side stud bolts.

1 Rubber plug
2 Liquid gasket

CAUTION
• After applying the liquid gasket, in-
stall the lower cover within 5 min-
utes.

2) Install the rubber plug to the cylinder head 1 Lower cover

assembly. 2 Connector
3) Install the gasket to the lower cover.
4) Install the lower cover to the cylinder head
assembly. 7) Install the connector to the lower cover.
Tightening torque： 18 N・m {1.8 kgf・m / 13 Tightening torque： 2 N・m {0.2 kgf・m / 18
lb・ft} lb・in}
5) Install the injector harness to the cylinder head 4. Cylinder head cover Installation
assembly.
1) Align the head cover gasket to the cylinder
ANNOTATION: head cover.
• Tighten the bolts on the bracket and in- 2) Install the cylinder head cover to the lower
stall the injector harness together with the cover.
bracket. Tightening torque： 18 N・m {1.8 kgf・m / 13
lb・ft}
Tightening torque： 48 N・m {4.9 kgf・m / 35
lb・ft} ANNOTATION:
• Referring to the tightening order in the dia-
gram, temporarily tighten all bolts and then
completely tighten them.

1 Injector harness terminal

2 Injector harness bracket

84402826 - May 2011

3005-7
 Removal and Installation of Injector

1) Install the inlet pipe to the case.

Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft}

CAUTION
• Use new gaskets.

1 Cylinder head cover

2 Gasket
3 Lower cover

3) Connect the ventilation hose to the air

breather.
5. Oil level gauge guide tube Installation 1 Case
1) Install the oil level gauge guide tube to the 2 Gasket
cylinder block. 3 Inlet pipe
2) Connect the oil level gauge guide tube to the
case. 2) Connect the harness connector to the IMT
Tightening torque： 19 N・m {1.9 kgf・m / 14 sensor.
lb・ft} 3) Connect the harness connector to the EGR
3) Connect the oil level gauge guide tube to the valve.
cylinder head cover. 4) Connect the harness connector to the boost
Tightening torque： 19 N・m {1.9 kgf・m / 14 temperature sensor.
lb・ft} 5) Connect the harness connector to the boost
4) Install the oil level gauge to the oil level gauge sensor.
guide tube. 6) Install the harness clip to the inlet pipe.

1 Boost sensor
1 Cylinder head cover
2 IMT sensor
2 Oil level gauge guide tube
3 EGR valve
3 Case
4 Harness clip
4 Cylinder block
5 Boost temperature sensor

6. Inlet pipe Installation 7. Intake throttle valve Installation

84402826 - May 2011

3005-8
 Removal and Installation of Injector

1) Install the intake throttle valve to the inlet pipe. CAUTION

Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft} • To prevent engine failure, be sure to per-
form air removal after the installation or
removal of fuel system parts.

1 Boost temperature sensor

2 Boost sensor
3 Inlet pipe
4 Gasket 1 Priming pump
5 Intake throttle valve 2 Plug
3 Drain plug
2) Install the air duct to the intake throttle valve. 4 Case
3) Connect the harness connector to the intake 5 Fuel filter element
throttle valve.
ANNOTATION: 1) Prepare the pan.
• After connecting the harness connector, 2) Turn ON the starter switch.
press in the lock operation portion to lock. ANNOTATION:
• This is for the models with an electromag-
netic pump.
3) Loosen the plug using the wrench.
4) Operate the priming pump.
Number of times： 20 count(s) or more
ANNOTATION:
• Confirm that fuel comes out from around the
plug.
5) Tighten the plug using the wrench.
6) Operate the priming pump.
Number of times： 10 count(s) or more
ANNOTATION:
1 Lock operation section • Wait for the specified time after operating
2 Lock release the priming pump.
3 Lock Specified time： 1 min
7) Loosen the plug using the wrench.
8. Engine harness Connect
ANNOTATION:
1) Connect the engine harness to the engine as-
sembly. • Remove the air in the fuel filter.

ANNOTATION: 8) Tighten the plug using the wrench.

9) Operate the priming pump.
• Connect each connector. Number of times： 10 count(s) or more
9. Battery ground cable Connect ANNOTATION:
1) Connect the battery ground cable to the bat- • Wait for the specified time after operating
tery. the priming pump.
10. Fuel Air bleed Specified time： 1 min
84402826 - May 2011
3005-9
 Removal and Installation of Injector

10) Loosen the plug using the wrench. 15) Operate the priming pump.
Number of times the operation is Performed:
ANNOTATION:
10 - 15 times
• Remove the air in the fuel filter. 16) Start the engine.
11) Tighten the plug using the wrench. CAUTION
12) Operate the priming pump.
Number of times： 10 count(s) or more • Do not accelerate the engine revo-
lution right after staring.
ANNOTATION:
• Wait for the specified time after operating Idling: 5 s
the priming pump. ANNOTATION:
Specified time： 1 min
• Accelerate the engine revolution gradually.
13) Loosen the plug using the wrench.
Engine revolution hold: 3 min.
ANNOTATION:
ANNOTATION:
• Remove the air in the fuel filter.
• Accelerate the engine revolution to maxi-
14) Tighten the plug using the wrench. mum.
Tightening torque： 10 N・m {1.0 kgf・m / 89
• Lower the rotation.
lb・in}

CAUTION
• Remove the fuel around the plug
thoroughly after tightening.

84402826 - May 2011

3005-10
 Section

4001A

Electrical and Engine Basic Functions

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Monitor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Coolant Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Oil Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Monitor Display Dimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Eco Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DPD Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Diagnostic Trouble Code Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fuel Economy Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Neutral Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine Start/Stop Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Preheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Idling Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Auto Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
One-touch Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Auto Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Quick Warm-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Idling Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Idle up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Travel Speed Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Swing Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Static Horsepower Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Working Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Radio Mute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Engine Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Travel Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Back/Side View Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Swing Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Overload Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Operability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Swing Speed Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Pressure Boost Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Free Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Energy saving / Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Pump Standby Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Swing Relief Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Stroke Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Boom Down Energy Save. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Auto Energy Save . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Overload Reduction Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
End Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Breaker Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Crusher Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

4001A-1 PRINTED IN FRANCE
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Anti-theft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Enabling the anti-theft function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Immobilizer Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Feed Pump Automatic Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Coolant Level Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Hydraulic Oil Filter Clog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Air Filter Clog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Fuel Filter Clog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
DPD Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Automatic Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Manual Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Forced Manual Regeneration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Hydraulic Assist Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

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

Monitor Control
Fuel Gauge
Summary
The fuel level is displayed as one of 9 levels, 0-8.
When the fuel level reaches Level 1, a warning is is-
sued.
If the sensor breaks down, the level becomes 0.
(When the sensor is normal, the Levels 1-8 are dis-
played.)
Configuration

• The table below shows the correspondence be-

tween the fuel sensor % and the bar graph level.

Lever angle [%] Bar graph level

100 8
83 7
67 6
50 5
33 4
17 3
1 2
0 1

* Currently, the above settings are common to all

models.

*1 Monitor
*2 Computer B
*3 Computer A
• Refueling warning: When the gauge falls to Level
*4 Overhead 1, the "LOW FUEL" message is displayed on the
*5 Fuel sensor monitor and the buzzer sounds for 5 sec..
*6 Reserve (1 hour of work) • Monitor display: The following processing is used to
*7 Fuel tank prevent the monitor gauge from fluctuating due to
fluctuation of the fuel surface.
Sensor angle measurement period = 1 sec.
Operation explanation Gauge update period = 5 sec.
Gauge update judgment = Average of sensor angle
• Computer A reads out the resistance of the fuel level for past 20 sec. (20 times)
sensor installed in the fuel tank and communicates • Gauge display: For the work screen, an arc is dis-
it to the monitor. played at the center of the screen.
On the camera screen, displayed vertically on the
right edge of the screen.
Resistance [Ω] Fuel sensor [%]
• Trouble mode: If trouble occurs in the fuel level sen-
10 100 sor, the fuel gauge itself is not displayed.
38 50 If an abnormality occurs in monitor communication,
80 0 the display will not update.
84402826 - May 2011
4001A-3
 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
84402826 - May 2011
4001A-4
 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
84402826 - May 2011
4001A-5
 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.

84402826 - May 2011

4001A-6
 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.

84402826 - May 2011

4001A-7
 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.

84402826 - May 2011

4001A-8
 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.

84402826 - May 2011

4001A-9
 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.

84402826 - May 2011

4001A-10
 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.

84402826 - May 2011

4001A-11
 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

84402826 - May 2011

4001A-12
 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.

84402826 - May 2011

4001A-13
 Electrical and Engine Basic Functions

Throttle
Purpose
Indicates the target engine speed.

1 Monitor 3 Throttle volume 5 Engine

2 Computer A 4 ECM

a Icon

Operation explanation
1. Turn the key ON.
2. The target engine speed is calculated based on the throttle VOL voltage signal.
3. An icon that indicates the work mode is displayed on the monitor.

84402826 - May 2011

4001A-14
 Electrical and Engine Basic Functions

Idling Start
Purpose
When the engine starts, the engine speed starts in low idle regardless of the throttle volume position.(Warm-up
operation, engine protection)

1 Throttle volume 4 Pressure sensor (upper) 7 Pressure sensor (option 1)

2 Computer A 5 Pressure sensor (swing) 8 Pressure sensor (option 2)
3 One-touch idle switch 6 Pressure sensor (travel)

Operation explanation
1. Idling start operation condition
Because idling start is a warm-up operation, it operates when the engine is started.
2. Idling start end conditions
The operation ends under the following conditions.
1) When an operation lever is operated.(When one of the following pressure sensors is turned ON: upper,
swing, travel, option 1, or option 2)
2) When the throttle volume is operated.
3) When the one-touch idle switch is pressed.

84402826 - May 2011

4001A-15
 Electrical and Engine Basic Functions

Auto Idle
Purpose
Automatically put the engine into an idling state (1200 min-1) when the machine is not being operated. (Energy
saving)

1 Monitor display 5 One-touch idle switch 9 Pressure sensor (upper)

2 Computer A 6 Throttle volume 10 Pressure sensor (swing)
3 Engine 7 Pressure sensor (option 1) 11 Pressure sensor (travel)
4 ECM 8 Pressure sensor (option 2)

Operation explanation
1. Operation conditions for auto idle
Operation starts when all the conditions below are satisfied.
1) The auto idle mode switch is pressed, turning the auto idle mode ON.
2) An operating lever is not operated for a continuous period of 5 sec. (The upper, swing, travel, option 1,
and option 2 pressure sensor are OFF for a continuous period of 5 sec.)
2. End conditions for auto idle
Operation ends under the following conditions.
1) An operation lever is operated during auto idle. (The upper, swing, travel, option 1, or option 2 pressure
sensor is ON.)
2) The throttle volume is operated.
3) The one-touch idle switch is pressed.

84402826 - May 2011

4001A-16
 Electrical and Engine Basic Functions

One-touch Idle
Purpose
Reduces the engine speed when the one-touch idle switch is pressed. (Energy saving)

1 Monitor display 5 One-touch idle switch 9 Pressure sensor (upper)

2 Computer A 6 Throttle volume 10 Pressure sensor (swing)
3 Engine 7 Pressure sensor (option 1) 11 Pressure sensor (travel)
4 ECM 8 Pressure sensor (option 2)

Operation explanation
1. Operation conditions for one-touch idle
When the one-touch idle switch is pressed.
2. End conditions for one-touch idle
When the one-touch idle switch is pressed once more after the one-touch idle switch is pressed and the engine
has gone into low idle.

84402826 - May 2011

4001A-17
 Electrical and Engine Basic Functions

Auto Warm Up
Purpose
Incrementally raises the engine speed if the coolant temperature is low when the engine starts.
1. Operation conditions for auto warm up
Auto warm up operates if the coolant temperature is less than 50°C when the engine starts.
2. Summary
The engine speed increases incrementally as shown in the diagram.
1) Low idle; 5 min.
2) 1200 min-1; 3 min.
3) 1500 min-1; 3 min.
4) SP mode; 3 min.

a 5 min. d 3 min. g 1200 min-1

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).

84402826 - May 2011

4001A-18
 Electrical and Engine Basic Functions

Quick Warm-up
Summary
When the engine starts up, if the outside air temperature is low, a hydraulic load is put on to warm up the engine.
Configuration

*1 Key switch *6 Computer A *11 Option pressure switch

Pump flow proportional valve
*2 *7 ECM *12 2nd option pressure switch
(on hydraulic pump)
*3 Boom 2 proportional valve *8 Upper pressure sensor *13 Coolant temperature sensor
*4 Color monitor *9 Swing pressure sensor *14 Suction air temperature sensor
*5 Computer B *10 Travel pressure sensor

Operation explanation
1. When the following conditions are all detected, quick warm-up starts.
• The engine must be starting up.
• The engine must not be warming up (Step 1: low idle 5 minutes).
• The machine must not be operating (upper, swing, travel, option 1, or option 2).
• The outside air temperature must be -15°C.
• The coolant temperature must be between 0 and 80°C.
• There must not be any sensor abnormality (P1, upper, swing, travel, option (1 or 2), coolant temperature,
outside air temperature.
• DPD regeneration must not be underway.
2. This control can be disabled with the Setup/Parameters screen.
3. When the engine starts, the speed incrementally increases according to the diagram below if the coolant tem-
perature is < 50°C. (If the coolant temperature is 50°C, a normal idling start occurs.)
4. When the quick warm-up starts, the system sets the pump flow proportional valve to the minimum flow (Current
740 mA).
5. After 1 sec., the system sets the boom 2 proportional valve current to 540 mA.
An icon that indicates the start of quick warm-up is displayed on the monitor for 2 sec..
84402826 - May 2011
4001A-19
 Electrical and Engine Basic Functions

6. After 1 sec., if the system detects event (a) below for 20 sec. or longer, it raises the boom 2 proportional valve
target current at a pace of 2 mA/20 sec..
When event (b) is detected, the system sets the boom 2 proportional valve target current to 540 mA.
Also, if no event is detected, the system holds the boom 2 proportional valve target current in its current state.
(a) P1 pressure < 10 MPa
(b) P1 pressure > 15 MPa
7. If the system does not detect either of the above two conditions, it ends or stops quick warm-up.

84402826 - May 2011

4001A-20
 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.

84402826 - May 2011

4001A-21
 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.

84402826 - May 2011

4001A-22
 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.

84402826 - May 2011

4001A-23
 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)

84402826 - May 2011

4001A-24
 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.

84402826 - May 2011

4001A-25
 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.

84402826 - May 2011

4001A-26
 Electrical and Engine Basic Functions

Radio Mute
Purpose
Enables the radio volume to be turned ON or OFF with a one-touch operation.

Operation explanation
1. Each time the radio mute switch (1) is pressed, the radio volume is switched between ON Û OFF.
2. When the key is switched ON, the radio always starts with mute off (normal radio volume).

84402826 - May 2011

4001A-27
 Electrical and Engine Basic Functions

Safety
Engine Emergency Stop
Purpose
Stops the engine in an emergency.

1 Computer A 3 Engine emergency stop switch

2 Engine 4 ECM

Operation explanation
1. If an emergency occurs while the engine is running, press the emergency stop switch.
2. When the ECM and computer A detect that the emergency stop switch is ON, the engine is stopped.
* To restart, make sure that the emergency stop switch is OFF, and then start cranking the engine.

84402826 - May 2011

4001A-28
 Electrical and Engine Basic Functions

Travel Alarm
Purpose
The travel alarm sounds when a travel operation is performed.(Safety function)

1 Computer A
2 Travel pressure sensor
3 Travel alarm

84402826 - May 2011

4001A-29
 Electrical and Engine Basic Functions

1. Operation conditions for travel alarm

The operation starts under the following conditions.
1) When a travel operation is being performed.(Travel pressure sensor ON)
2. End conditions for travel alarm
The operation ends under the following conditions.
1) When the travel operation is stopped.
2) When 10 sec. or longer elapses while a travel operation is being performed.

a Travel alarm
b Pressure sensor (travel)
c 10 sec.

84402826 - May 2011

4001A-30
 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.

84402826 - May 2011

4001A-31
 Electrical and Engine Basic Functions

Swing Lock
Purpose
Turns the swing brake ON.

1 Monitor 4 Horn volume select switch 7 Swing brake

2 Working light switch 5 Computer A
3 Auto idle switch 6 Swing brake solenoid

Operation explanation
1. Operation conditions for swing lock
1) Hold down the horn volume select switch, working light switch and auto idle switch at the same time for
3 sec.
* When the swing lock is ON and the key is OFF.Then, when the key is turned ON again, the swing lock stays
ON.
* When the swing lock and free swing are both ON, the swing lock is prioritized.
* When the swing lock is ON, the swing lock icon is displayed on the monitor.
* Even when an attachment operation or swing operation is performed while swing is ON, swing lock ON is
prioritized.(Be careful because if the swing operation is performed in this condition, the swing brake plate will
be dragged.)
2. End conditions for swing lock
1) While the swing lock is ON, hold down the horn volume select switch, working light switch and auto idle
switch at the same time for 3 sec.

84402826 - May 2011

4001A-32
 Electrical and Engine Basic Functions

Overload Warning
Summary
Overload warning device for lifting work with shovel
If the bottom pressure of the boom cylinder exceeds the stipulated pressure, it is judged that there is a danger of
the machine falling over and the monitor buzzer sounds (overload warning).
Configuration

*1 Overload switch *3 Computer B *5 Overload pressure sensor

*2 Color monitor *4 Computer A

Operation explanation
1. When the overload switch is turned ON, the buzzer sound starts and stops according to the conditions below.
When the overload switch is OFF, the buzzer does not sound.
1) Overload warning start: The boom bottom pressure is greater than or equal to the set pressure continu-
ously for 1 sec.
2) Overload warning stop: The boom bottom pressure is less than or equal to the set pressure -2 MPa
continuously for 1 sec.
2. The alarm pattern is a 1-second cycle - ON for 0.5 sec. and OFF for 0.5 sec.

*1 Overload switch *3 Monitor buzzer

*2 Boom bottom pressure *4 Set pressure

3. Display: The warning is only given with the monitor buzzer.

The lamps etc. do not illuminate.
84402826 - May 2011
4001A-33
 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

2 Throttle volume
3 Pressure sensor (travel)
4 Pressure switch (option 1)
P1 flow control proportional
6 Pressure sensor (N2) 10
valve
7 Pressure sensor (P1)
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).

84402826 - May 2011

4001A-34
 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

84402826 - May 2011

4001A-35
 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.

84402826 - May 2011

4001A-36
 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.

84402826 - May 2011

4001A-37
 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
84402826 - May 2011
4001A-38
 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.

84402826 - May 2011

4001A-39
 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)

b Boom (2) e Travel (left) h Bucket
c Swing f Arm (2) i Travel (right)

Operation explanation
1. Operation conditions for swing relief cut
The operation starts when all the conditions below are satisfied.
Oil temperature is 30°C or higher
1) When a swing operation is performed. (Swing pressure sensor ON)
2) Within 1 sec. after start of swing
3) When travel or option operations are not being performed.(Travel and option pressure sensors OFF)
2. Swing relief cut end conditions
1) When a swing operation is not being performed.(Swing pressure sensor OFF)
2) When a travel or option operation is performed.(Travel or option pressure sensor ON)

84402826 - May 2011

4001A-40
 Electrical and Engine Basic Functions

Stroke Control
Summary
In order to improve fuel efficiency, the pump pressure is lowered by reducing the orifice loss.
A 3-stack proportional valve is used for control.
Arm 2 control
1. In normal operations, flow volume loss is reduced by suppressing the spool opening for Arm 2.
2. In the second half of leveling work, the spool opening is opened to reduce P2-arm bottom pressure loss and to
give priority to the arm for flow volume, thus suppressing flow volume loss.
Configuration
• The larger the proportional valve output current, the more the secondary pressure output is suppressed.

*1 P2 pressure sensor *4 Computer B *7 Arm-in pressure sensor

Arm-in reverse proportional
*2 Travel pressure sensor *5 *8 Bucket-close pressure sensor
valve
*3 Computer A *6 Boom-up pressure sensor

Operation explanation
1. The operator operates the shovel.
2. When the system detects the events below, it judges that this is the start of leveling.
• When any of the following conditions is established the instant that arm-in operation becomes full
• Boom-up lever operation is at half lever.
• The boom-up and bucket-close levers are operated at the same time.
3. When the system judges leveling to be starting, it releases the restriction on Arm 2.
4. If the events below occur when the system does not judge leveling to be starting, it releases the restriction
on Arm 2. When that is not the case, it restricts Arm 2.
• Boom-up lever operation is at half lever.
5. The operator stops arm-in full operation or travels.
6. The system restricts Arm 2.
* When Arm 2 is released from the restricted state, it is released gradually as a measure against shock from
the restriction release.
Boom 2 control
In leveling work, the boom spool is pressed back to reduce P1-arm bottom pressure loss and to allow more flow to
the arm and bucket.
Configuration
• When the output current is raised, the force pushing back the spool is increased.

84402826 - May 2011

4001A-41
 Electrical and Engine Basic Functions

*1 Boom-up proportional valve *4 Computer B *7 Bucket-close pressure sensor

*2 Travel pressure sensor *5 Boom-up pressure sensor
*3 Computer A *6 Arm-in pressure sensor

Operation
1. The operator operates the shovel.
2. When the system detects the events below, it judges that this is the start of leveling.
• When any of the following conditions is established the instant that arm-in operation becomes full
• The boom-up lever operation is at half lever.
• The boom-up and bucket-close levers are operated at the same time.
3. If the system detects any of the events below when the system judges leveling to be starting, it issues the
Boom-2-down proportional valve instruction.
• The boom-up lever operation is at half lever.
• During bucket-close operation
4. When the system does not judge leveling to be starting, it does not issue the Boom-2-down proportional valve
instruction.
5. The operator stops arm-in full operation or travels.
6. The system stops the Boom-2-down proportional valve instruction.
* When the Boom-2-down proportional valve instruction changes, as a measure against vibration, the Boom-
2-down proportional valve command current value is lowered gradually (for both ON→OFF and OFF→ON).
Bucket control
Mostly in the second half of leveling and when collecting dirt and sand during digging, the spool opening is opened
so that a larger volume can flow.
Configuration
The larger the output current, the more the secondary pressure output is suppressed.

Bucket-close reverse propor-

*1 Travel pressure sensor *4 *7 Bucket-close pressure sensor
tional valve
*2 Computer A *5 Boom-up pressure sensor
*3 Computer B *6 Arm-in pressure sensor
84402826 - May 2011
4001A-42
 Electrical and Engine Basic Functions

Operation explanation
1. The operator operates the shovel.
2. If any of the events below occurs, the system outputs current restricting the bucket secondary pressure.
• Not arm-in full operation
• The boom-up operation is not at half lever.
• During travel

84402826 - May 2011

4001A-43
 Electrical and Engine Basic Functions

Boom Down Energy Save

Purpose
Reduces the engine speed during swinging (except during lift swinging).

1 Computer A 4 Pressure sensor (P1) 7 Pressure sensor (swing)

2 ECM 5 Pressure sensor (P2) 8 Pressure sensor (upper)
3 Engine 6 Pressure sensor (N2) 9 Throttle volume

a Engine speed control

Operation explanation
1. Operation conditions for boom down energy save
The operation starts when all the conditions below are satisfied.
1) When the work mode is H mode or lower.
2) When the boom down and swing operation is performed.Or when the swing operation is performed.
2. End conditions for boom down energy save
The operation ends when all the conditions below are satisfied.
1) When the work mode is SP mode.
2) When an operation other than boom down and swing is performed.Or when an operation other than swing
is performed.
* When control is established at the same time as auto energy save, the control that reduces the engine speed the
most is prioritized.

84402826 - May 2011

4001A-44
 Electrical and Engine Basic Functions

Auto Energy Save

Purpose
Reduces the engine speed when machine operations are not being performed.(Energy saving)

1 Computer A 4 Pressure sensor (P1) 7 Pressure sensor (swing)

2 ECM 5 Pressure sensor (P2) 8 Pressure sensor (upper)
3 Engine 6 Pressure sensor (N2)

a Engine speed control

Operation explanation
1. Operation conditions for auto energy save.
1) When a machine operation is not being performed.
2. End conditions for auto energy save.
1) When a machine operation is performed.
* When control is established at the same time as boom down energy save, the control that reduces the engine
speed the most is prioritized.

84402826 - May 2011

4001A-45
 Electrical and Engine Basic Functions

Overload Reduction Control

Purpose
Prevents reductions in the engine speed by detecting sharp attachment operations and sharp loads during opera-
tion. (Lowers the pump milli-amp and prevents reductions in the engine speed.)
Operation explanation
1. Operation conditions for transient load reduction control
The milli-amp of the pump horsepower proportional valve is temporarily reduced under the following conditions.
1) When a sharp attachment operation is performed. (Judged from the upper pressure sensor pressure
boost state.)
2) When there is a sharp load during operation. (Judged from the main pressure boost state of the P1 or
P2 pressure sensor.)
2. End conditions for transient load reduction control
The milli-amp of the pump horsepower proportional valve is restored under the following conditions.
1) When a sharp attachment operation is not being performed. (Judged from the upper pressure sensor
pressure boost state.)
2) When there is no sharp load during operation. (Judged from the main pressure boost state of the P1 or
P2 pressure sensor.)

84402826 - May 2011

4001A-46
 Electrical and Engine Basic Functions

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.

84402826 - May 2011

4001A-47
 Electrical and Engine Basic Functions

Maintenance
Anti-theft
Enabling the anti-theft function
With the key OFF, connect the anti-theft knob terminal.
When the male and female knob terminals are connected on the cab main harness in the rear cover, the anti-theft
function is enabled.
The factory setting is for these knob terminals to be disconnected.
Anti-theft setting knob Connect VG (purple / green) and BG (black / green)

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.

84402826 - May 2011

4001A-48
 Electrical and Engine Basic Functions

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.

84402826 - May 2011

4001A-49
 Electrical and Engine Basic Functions

Feed Pump Automatic Stop

Summary
The feed pump power supply is controlled and when the fuel tank is full (Level 8), the fuel feed is automatically
stopped.
Configuration

*1 Monitor *3 FUEL PUMP STOP RL *5 BUZZER

*2 FUEL PUMP RL *4 FUEL PUMP

Operation explanation
The fuel pump rocker switch has three positions: Manual, OFF, and Auto.
• Auto mode
The switch is the toggle type. When it comes ON, the fuel feed starts.
When the fuel tank angle sensor reaches the full level (Level 8), the monitor relay is driven and the feed pump
power is switched OFF.
In place of that, the relay buzzes the buzzer to announce that the automatic feed has ended.
To silence the buzzer, the rocker switch must be switched to OFF or Manual.
• Manual mode
The switch is the momentary type. The feed pump only drives fuel feed while the switch is pressed.

84402826 - May 2011

4001A-50
 Electrical and Engine Basic Functions

Coolant Level Drop

Summary
If the engine coolant level drops, the low coolant level warning is issued.
Configuration

*1 Reserve tank *3 Computer A *5 Monitor

*2 Coolant level switch *4 Computer B *6 Buzzer

Operation
1. The radiator reserve tank level switch is detected and an warning is issued.
• SW ON: 0.33 - 0.53 L
2. When the monitor receives the level drop signal, it carries out the following operation.
• Message: "LOW COOLANT" is displayed.
Even after the coolant level is restored to normal, the "LOW COOLANT" message remains displayed while
the key is ON.
• Diagnostic Trouble Code: "7423" is displayed.
Even after the coolant level is restored to normal, the "LOW COOLANT" message remains displayed while
the key is ON.
• Monitor buzzer: The buzzer sounds at the same time that the message is displayed and the buzzer automat-
ically stops after 5 sec.
3. When 3 sec. have passed after the coolant level switch was detected going OFF, the low coolant level alarm
stops, the "LOW COOLANT" message goes off, and the buzzer stops.

84402826 - May 2011

4001A-51
 Electrical and Engine Basic Functions

Hydraulic Oil Filter Clog

Summary
If the hydraulic oil filter clogs, a warning is issued.
Configuration

*1 Monitor *4 Breaker mode switch *7 Hydraulic oil tank

Breaker/crusher (1st option)
*2 Computer B *5 *8 1st option pressure switch
pedal
*3 Computer A *6 Hydraulic oil filter clog switch

Operation explanation
If clogging occurs in the return filter inside the hydraulic tank, a message is displayed on the monitor giving the
diagnostic trouble code and the warning buzzer sounds. (For breaker, multi-purpose machines only)
1. Configuration: When the clog detection pressure switch goes open, Computer A detects the clog and sends a
command to the monitor.
2. Clog detection: Starts 10 sec. after the engine starts.
When the clog switch contact opens, Computer A detects this.
If the contact point is ON continuously for 1 sec., the return filter is judged to be clogged.
However, detection does not occur in the following cases.
• During breaker operation: Because pulsation is severe (In other words, no warning is issued while the breaker
is operating.)
• When the oil temperature is less than 30°C: Because the hydraulic oil viscosity is high and accurate detection
is not possible.
• When the clog detection switch is broken: For details, see the sections below.
3. Warning: When the monitor receives the filter clog command, it carries out the following operation.
• Message: "RETURN FILTER" is displayed.
Even after the coolant level is restored to normal, the "LOW COOLANT" message remains displayed while
the key is ON.
• Diagnostic Trouble Code: "7423" is displayed.
Even after the coolant level is restored to normal, the "LOW COOLANT" message remains displayed while
the key is ON.
84402826 - May 2011
4001A-52
 Electrical and Engine Basic Functions

• Monitor buzzer: The buzzer sounds at the same time that the message is displayed and the buzzer automat-
ically stops after 5 sec.
4. Clog switch trouble detection: Before engine starting, the contact point of the clog detection switch should be
closed (B contact point).
However, if the circuit is open (continuously for 1 sec.), it is judged that the clog detection switch is disconnected,
the "Electrical system abnormality" message and diagnostic trouble code "7063" are displayed, and the buzzer
sounds for 5 sec..
5. Time chart:

*1 1st option pressure switch *3 Message trouble card

*2 Hydraulic oil filter clog switch *4 Monitor buzzer

84402826 - May 2011

4001A-53
 Electrical and Engine Basic Functions

Air Filter Clog

Summary
If clogging occurs in the air cleaner filter, a message is displayed on the monitor giving the diagnostic trouble code
and the warning buzzer sounds.
Configuration

*1 Color monitor *3 Computer A *5 Barometric pressure

*2 Computer B *4 Clog sensor *6 Air cleaner

Operation explanation
1. When the clog detection pressure switch comes ON, Computer A detects the clog and sends a command to
the monitor via Computer B
2. Clog detection starts 10 sec. after the engine starts.
3. When the clog switch comes ON, Computer A detects this.
If the contact point is ON continuously for 1 sec., the return filter is judged to be clogged.
4. When the monitor receives the filter clog command, it carries out the following operations.
• Message: "AIR FILTER" is displayed.
Even after the coolant level is restored to normal, the "LOW COOLANT" message remains displayed while
the key is ON.
• Diagnostic Trouble Code: "7424" is displayed.
Even after the coolant level is restored to normal, the "LOW COOLANT" message remains displayed while
the key is ON.
• Monitor buzzer: The buzzer sounds at the same time that the message is displayed and the buzzer automat-
ically stops after 5 sec.

84402826 - May 2011

4001A-54
 Electrical and Engine Basic Functions

Fuel Filter Clog

Summary
If the fuel filter clogs, a warning is issued.
There are 2 types of clogs: Stage 1 and Stage 2.
Configuration

*1 Color monitor *3 Computer B *5 ECM

*2 Buzzer *4 Computer A *6 Fuel filter clog sensor

Operation explanation
1. Turn the key ON.
• Control is performed by Computer A and is displayed on the monitor via Computer B.
2. When the system detects the following, it issues the fuel filter clog warning.
• The fuel filter clog signal from the ECM is ON continuously for 5 sec. or longer.
• The clog is judged by the ECM and only the results are sent to the computer via the CAN.
• The signal is sent with values of 0-2.

Signal numeric value Meaning Sensor pressure Error code

0 No clog
1 Clog stage 1 -30 kPa max. 7426
2 Clog stage 2 -40 kPa max. 7427

3. A message is displayed and the buzzer sounds.

• The "FUEL FILTER CLOG" warning message is displayed on the monitor.
• The buzzer sounds.
4. Engine protection
When a 2nd stage clog (40 kPa max.) occurs, the engine speed is fixed to 1700 min-1.

84402826 - May 2011

4001A-55
 Electrical and Engine Basic Functions

DPD Regeneration
Purpose
The DPD (Diesel Particle Diffuser) is a device that purifies particulate matter (PM) from exhaust gases.
Particulate matter is collected in the DPD filter, and when a certain amount has accumulated, that particulate matter
is automatically combusted to regenerate the filter.
During normal work, the amount of PM accumulated is displayed on the DPD gauge.
Configuration

*1 ECM *5 DPD SW *9 DPD Prerss sensor

*2 CONT_A *6 Water Temp. sensor *10 Pump Flow P-S/V
*3 CONT_B *7 DPD(CT) Temp. sensor *11 Boom2 P-S/V
*4 MONITOR *8 DPD(FT) Temp. sensor *12 Lever lock S/V

Operation explanation
There are the following 4 regeneration methods.
• Automatic regeneration: The filter is automatically regenerated during machine operation.
The machine can work normally.
• Manual regeneration: If automatic regeneration is incomplete or the amount of accumulated PM is large, the filter
is regenerated with a switch.
The machine cannot operate.
• Forced manual regeneration: During automatic regeneration, it is possible to interrupt automatic regeneration and
switch to manual regeneration.
• Slow regeneration: When manual regeneration is interrupted for a prolonged period, it is necessary to combust
the PM slower than normal.
The diagnostic trouble code is displayed and service engineer operation is required. The machine cannot operate.
1. Switch the key ON and operate.
The system displays the current amount of PM accumulated on the DPD bar graph.
The PM accumulated on the filter continually self-combusts due to high-temperature exhaust gases during
engine operation.

84402826 - May 2011

4001A-56
 Electrical and Engine Basic Functions

2. When the work was at low load, because the exhaust gas temperature is low, the PM does not self combust
but accumulates.
When the DPD differential pressure is high or every 8 hours, the ECM forces up the exhaust gas temperature
to combust the accumulated PM. (See Automatic Regeneration.)
3. Normally, the above continuous regeneration and automatic regeneration keep the accumulated amount of PM
from going above a certain amount, but if the operating conditions are such that the accumulated amount of
PM becomes excessive, in order to avoid the risk of damage to the DPD assembly due to excessive tempera-
ture rise during regeneration, the ECM prohibits automatic regeneration and requests the operator to perform
manual regeneration.
The operator receives this request and starts regeneration. (See Manual Regeneration.)
4. While automatic regeneration is stopped, the operator can execute manual regeneration at any time with switch
operation. (See Forced Manual Regeneration.)
5. If the operator ignores the manual regeneration request and continues to work, this causes (excess PM collec-
tion) and the ECM issues the diagnostic trouble code.
When this point is reached, regeneration by the operator is no longer possible and special regeneration using
service tools has become necessary. (See Slow Regeneration.)
6. If any of the following troubles occurs during regeneration, the hydraulic pressure load is stopped.
Excess PM collection
When the accumulated amount of PM exceeds the limit and the excess PM collected state is reached, the system
behaves as follows.
• Ends the hydraulic pressure assist load.
• Lights the red lamp.
• Lights up the DPD gauge all red.
• Displays the "CHECK ENGINE" message.
Slow regeneration
Regeneration through a process that raises the temperature slower than for normal regeneration.

84402826 - May 2011

4001A-57
 Electrical and Engine Basic Functions

Automatic Regeneration
Summary
The filter is automatically regenerated during machine operation. The machine can work normally.
The ECM determines the amount of PM accumulated from the difference in pressure before and after the DPD filter.
When a certain amount has accumulated, the ECM regenerates the filter automatically.
Also, if the operating time since the last regeneration reaches a certain level, the ECM automatically regenerates
the filter.
Configuration

*1 ECM *5 DPD SW *9 DPD Prerss sensor

*2 CONT_A *6 Water Temp. sensor *10 Pump Flow P-S/V
*3 CONT_B *7 DPD(CT) Temp. sensor *11 Boom2 P-S/V
*4 MONITOR *8 DPD(FT) Temp. sensor *12 Lever lock S/V

Operation explanation
1. Conditions for the start of automatic regeneration: When the automatic regeneration request comes from the
ECM, if the following conditions are met, automatic regeneration is started.
• Engine is starting
• The engine coolant temperature is at least 70°C but less than 100°C.
• The difference in pressure before and after the DPD filter has been stable for a certain period of time.
• The gate bar limit switch is ON (hydraulic operation is enabled).
• There is no sensor or DPD related abnormality.
2. Start of automatic regeneration: If the conditions above are met, the computer starts the following control.
• Lights the DPD green lamp.
• Sets off the buzzer for 2 sec..
• Switches the DPD gauge from accumulated amount display to regeneration progress display.
• Displays the "AUTO DPD RE-GEN" and "CAUTION! HOT EXHAUST" messages alternating.
• Computer A drives the DPD relay and sends the DPD regeneration signal to the ECM.
• Stops the auto idle/idle stop control.
3. Stopping automatic regeneration: When the operations below are performed, the ECM regeneration prohibition
signal is sent and automatic regeneration is stopped.
84402826 - May 2011
4001A-58
 Electrical and Engine Basic Functions

While automatic regeneration is stopped, the DPD green lamp goes out.
Displays the "PUSH DPD SWITCH TO ACTIVATE" message.
Switches the DPD gauge from regeneration progress display to accumulated amount display.
Starts the auto idle/idle stop control.
To restart regeneration, after the cause of the stoppage has been eliminated, press the DPD switch.
• If the gate bar limit switch comes OFF (hydraulic operation is disabled), regeneration is stopped.
• During automatic regeneration, if the monitor's DPD switch is pressed, regeneration is stopped.
• If the exhaust gas temperature reaches 400°C or higher, regeneration is stopped.
4. Ending automatic regeneration: The computer receives the automatic regeneration end signal from the ECM
and ends the control.
• Puts out the DPD green lamp.
• Switches the DPD gauge from regeneration progress display to accumulated amount display.
• Puts out the "AUTO DPD RE-GEN" and "CAUTION! HOT EXHAUST" messages.
• Starts the auto idle/idle stop control.

84402826 - May 2011

4001A-59
 Electrical and Engine Basic Functions

Manual Regeneration
Summary
If automatic regeneration is incomplete or the amount of accumulated PM is large, the ECM requests manual re-
generation.
The machine cannot be operated during manual regeneration.
The computer controls the regeneration assist load.
Configuration

*1 ECM *5 DPD SW *9 DPD Prerss sensor

*2 CONT_A *6 Water Temp. sensor *10 Pump Flow P-S/V
*3 CONT_B *7 DPD(CT) Temp. sensor *11 Boom2 P-S/V
*4 MONITOR *8 DPD(FT) Temp. sensor *12 Lever lock S/V

Operation explanation
1. Requesting manual regeneration: When the manual regeneration request comes from the ECM to the com-
puter, it displays the following items on the monitor.
• Flashes the DPD amber lamp (2-second cycle at first, high-speed 0.6-second cycle afterward)
• Displays the "PUSH DPD SWITCH TO ACTIVATE" message.
2. Manual regeneration start conditions: When the following conditions are all met and the DPD switch is pressed,
the computer sets the engine speed to 1000 min-1 and starts manual regeneration.
• The gate bar limit switch is OFF (hydraulic operation is disabled).
• The engine coolant temperature is at least 70°C but less than 100°C.
• There is no sensor or DPD related abnormality.
• When released, automatically goes to 1000 min-1.
3. Start of manual regeneration: If the conditions above are met, Computer A starts the following control.
• Lights the DPD amber lamp.
• Sets off the buzzer for 2 sec..
• Switches the DPD gauge from accumulated amount display to regeneration progress display.
• Displays the "AUTO DPD RE-GEN" and "CAUTION! HOT EXHAUST" messages alternating.
• Computer A drives the DPD relay and sends the DPD regeneration signal to the ECM.
84402826 - May 2011
4001A-60
 Electrical and Engine Basic Functions

• Stops the auto idle/idle stop control.

• Starts the hydraulic pressure assist load control (in order to raise the exhaust gas temperature).
4. Stopping manual regeneration: When the operations below are performed, the ECM regeneration prohibition
signal is sent and manual regeneration is stopped.
While regeneration is stopped, the DPD amber lamp flashes.
Displays the "PUSH DPD SWITCH TO ACTIVATE" message.
Switches the DPD gauge from regeneration progress display to accumulated amount display.
Starts the auto idle/idle stop control.
To restart regeneration, after the cause of the stoppage has been eliminated, press the DPD switch.
• If the gate bar limit switch comes ON (hydraulic operation enabled), regeneration is stopped.
• During automatic regeneration, if the monitor's DPD switch is pressed, regeneration is stopped.
• If the exhaust gas temperature reaches 400°C or higher, regeneration is stopped.
• If the hydraulic pressure assist proportional valve breaks down during regeneration
• If the throttle is operated
5. Ending manual regeneration: The computer receives the manual regeneration end signal from the ECM and
ends the control.
• Puts out the DPD amber lamp.
• Switches the DPD gauge from regeneration progress display to accumulated amount display.
• Puts out the "AUTO DPD RE-GEN" and "CAUTION! HOT EXHAUST" messages.
• Starts the auto idle/idle stop control.
6. Regeneration hydraulic pressure load assist: During manual regeneration, puts a load on the pump in order to
raise the exhaust gas temperature.
• Computer A set the pump flow proportional valve to the minimum flow at 740 mA.
• After 1 sec., Computer A sets the boom 2 proportional valve to 600 mA for the maximum load.
• After 1 sec., Computer A sets the pump flow proportional valve to 600 mA.
• After 30 sec., Computer A controls the pump flow proportional valve so that the DPD exhaust gas temperature
(before DOC) is constant at 270°C. (Lowers it gradually 50 mA/second. update period 15 sec., update width
5 mA)

84402826 - May 2011

4001A-61
 Electrical and Engine Basic Functions

Forced Manual Regeneration

Summary
During automatic regeneration, it is possible to interrupt automatic regeneration and switch to manual regeneration.
This can only be executed while automatic regeneration is stopped.
Configuration

*1 ECM *5 DPD SW *9 DPD Prerss sensor

*2 CONT_A *6 Water Temp. sensor *10 Pump Flow P-S/V
*3 CONT_B *7 DPD(CT) Temp. sensor *11 Boom2 P-S/V
*4 MONITOR *8 DPD(FT) Temp. sensor *12 Lever lock S/V

Operation explanation
1. With automatic regeneration stopped and with the gate bar open, if the DPD switch is held down for 3 sec.,
Computer A sends the forced manual regeneration start request signal to the ECM via the DPD relay.
2. When the ECM receives the forced manual regeneration start request signal, the following is displayed on the
monitor.
• Lights up the amber lamp for 3 sec..
3. If the system meets the following conditions, the ECM judges that manual regeneration is necessary, puts out
the amber lamp, and returns to the automatic regeneration stopped state.
• If the state of it being impossible to complete automatic regeneration has continued or longer than 8 hours
• If the ECM judges that manual regeneration is not necessary
4. If the ECM judges that manual regeneration is necessary, the system receives the manual regeneration request
signal from the ECM, and waits for the manual regeneration switch to be pressed.
• After 10 sec., it flashes the amber lamp (2-second cycle).
Displays the "PUSH DPD SWITCH TO ACTIVATE" message on the monitor.
• The operator presses the DPD switch during this time.
• If the operator does not press the DPD switch at least 10 sec., the ECM puts out the amber lamp and returns
to the automatic regeneration stopped state.
(From here on is the same process as from 2 in manual regeneration.)
5. Lowers the engine speed to 1000 min-1 and starts manual regeneration.
84402826 - May 2011
4001A-62
 Electrical and Engine Basic Functions

6. Start of manual regeneration: If the conditions above are met, the computer starts the following control.
• Lights the DPD amber lamp.
• Sets off the buzzer for 2 sec..
• Switches the DPD gauge from accumulated amount display to regeneration progress display.
• Displays the "AUTO DPD RE-GEN" and "CAUTION! HOT EXHAUST" messages alternating.
• Computer A drives the DPD relay and sends the DPD regeneration signal to the ECM.
• Stops the auto idle/idle stop control.
• Starts the hydraulic pressure assist load control (in order to raise the exhaust gas temperature).
7. Stopping manual regeneration: When the operations below are performed, the ECM regeneration prohibition
signal is sent and manual regeneration is stopped.
While regeneration is stopped, the DPD amber lamp flashes.
Displays the "PUSH DPD SWITCH TO ACTIVATE" message.
Switches the DPD gauge from regeneration progress display to accumulated amount display.
Starts the auto idle/idle stop control.
To restart regeneration, after the cause of the stoppage has been eliminated, press the DPD switch.
• If the gate bar limit switch comes ON (hydraulic operation enabled), regeneration is stopped.
• During automatic regeneration, if the monitor's DPD switch is pressed, regeneration is stopped.
• If the exhaust gas temperature reaches 400°C or higher, regeneration is stopped.
• If the hydraulic pressure assist proportional valve breaks down during regeneration
• If the throttle is operated
8. Ending manual regeneration: The computer receives the manual regeneration end signal from the ECM and
ends the control.
• Puts out the DPD amber lamp.
• Switches the DPD gauge from regeneration progress display to accumulated amount display.
• Puts out the "AUTO DPD RE-GEN" and "CAUTION! HOT EXHAUST" messages.
• Starts the auto idle/idle stop control.
9. Regeneration hydraulic pressure load assist: During manual regeneration, puts a load on the pump in order to
raise the exhaust gas temperature.
• The computer set the pump flow proportional valve to the minimum flow at 740 mA.
• After 1 sec., the computer sets the boom 2 proportional valve to 600 mA for the maximum load.
• After 1 sec., the computer sets the pump flow proportional valve to 600 mA.
• After 30 sec., the computer controls the pump flow proportional valve so that the DPD exhaust gas temper-
ature (before DOC) is constant at 270°C. (Lowers it gradually 50 mA/second. update period 15 sec., update
width 5 mA)

84402826 - May 2011

4001A-63
 Electrical and Engine Basic Functions

Hydraulic Assist Load

Summary
During DPD manual regeneration, hydraulic load is added to raise the exhaust gas temperature.
Operation explanation
1. When regeneration starts, the system sets the pump flow proportional value to the minimum flow (Current 740
mA).
2. After 1 sec., the system sets the boom 2 proportional valve to the maximum load (Current 600 mA).
3. After 1 sec., the system sets the current for pump flow proportional valve to 600 mA. (*1)
4. After 30 sec., the system controls the pump flow proportional valve so that the DPD exhaust gas temperature
(before DOC) is constant at 270°C. (*2) (*3)
• Lowers it gradually 50 mA/sec..
• Current update width: 5 mA, update period 15 sec.
• If the DPD exhaust gas temperature (before DOC) exceeds 400°C, addition of the hydraulic load is stopped.
When the temperature falls below 250°C, the addition of the hydraulic load resumes after 1 sec..

84402826 - May 2011

4001A-64
Section

4001B

Service Support

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Service Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Screen Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Screen Display List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHECK Screen List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
MACHINE STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FAULT HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
WORK HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ENGINE HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
HYDRAULIC HISTORY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
PART NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SETUP Screen List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
MACHINE SELECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Model Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Throttle Volume Default Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Password Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Adjusting the Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Option Flow Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Screen Brightness Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

4001B-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
4001B-2 PRINTED IN FRANCE
 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

84402826 - May 2011

4001B-3
 Service Support

CHECK Screen List MACHINE STATUS

In CHECK mode, in addition to the machine status (milli- 1. Engine and pump
amp, oil pressures, temperatures, etc.), it is possible to
check sensor and switch input/output states, as well as
the angle, load ratio and work radius, etc. at the applied
machine (liftcrane specifications machine, lifting magnet
machine).

ENGINE SPEED min-1 Engine speed

ENGINE LOAD
% Engine load ratio
RATIO
Pump 1; Discharge
P1 PRESS. MPa
pressure
Pump 2; Discharge
1 Section P2 PRESS. MPa
pressure
Pump 1; Negative
N1 PRESS. MPa
control pressure
For the CHECK mode section types and their contents, Pump 2; Negative
see the separate sheet. N2 PRESS. MPa
control pressure
Horsepower control
P.SOL;PUMP-
By pressing and on the monitor, mA proportional valve;
POWER
MACHINE STATUS, FAULT HISTORY, etc. can be Actual milli-amp
selected. Flow milli-amp pro-
Detailed data for the selected item can be seen by press- P.SOL;PUMP-
mA portional valve; Ac-
FLOW
tual milli-amp
SOL;POWER-
on/off Power save solenoid
ing . SAVE

84402826 - May 2011

4001B-4
 Service Support

2. Temperature and pressure 4. Pressure and solenoid

BOOST PRESS. kPa Boost pressure BOOM-UP PILOT Boom-up pilot pres-
MPa
BAROMETRIC PRESS. sure
kPa Barometric pressure ARM-CLOSE PI-
PRESS. MPa Arm-in pilot pressure
BOOST TEMP. °C Boost temperature LOT PRESS.
Suction air tempera- BUCKET-CLOSE Bucket-close pilot
AIR INLET TEMP. °C MPa
ture PILOT PRESS. pressure
FUEL TEMP. °C Fuel temperature P.SOL;BOOM-
mA Boom-down solenoid
MANIFOLD IN- DOWN
°C Manifold temperature P.SOL;BOOM-UP mA Boom-up solenoid
NER TEMP.
COOLANT TEMP. °C Coolant temperature P.SOL;ARM-
mA Arm-in solenoid
HYD.OIL TEMP. °C Oil temperature CLOSE
P.SOL;BUCKET- Bucket-close sole-
mA
3. Pressure and solenoid CLOSE noid
P.SOL;OFFSET-
mA Offset left solenoid
LEFT
SOL;BUCKET Bucket-open sole-
on/off
OPEN noid

UPPER PILOT
MPa Upper pilot pressure
PRESS.
SWING PILOT
MPa Swing pilot pressure
PRESS.
TRAVEL PILOT
MPa Travel pilot pressure
PRESS.
OPT.LINE
on/off 1st option operation
PRESS SW.
2ND OPT.LINE
on/off 2nd option operation
PRESS SW.
TRAVEL ALARM
on/off Travel alarm
OUT.
POWER SAVE
on/off Power save solenoid
SOL.
SWING BRAKE
on/off Swing brake solenoid
SOL.
FREE SWING
on/off Free swing solenoid
SOL.
84402826 - May 2011
4001B-5
 Service Support

5. Pressure and solenoid 6. Engine

PILOT SW. on/off Pilot switch

Pump 1; Discharge ENGINE OIL
P1 PRESS. MPa kPa Engine oil pressure
pressure PRESS
Pump 2; Discharge COOLANT LLC reserve tank
P2 PRESS. MPa on/off
pressure LEVEL SW. level switch
Pump 1; Negative Air cleaner clog
N1 PRESS. MPa AIR FILTER SW. on/off
control pressure switch
Pump 2; Negative BATTERY VOLT-
N2 PRESS. MPa V Battery voltage
control pressure AGE
P.SOL;OPT.LINE BATTERY Alternator power
mA Option line solenoid on/off
RELIEF CHARGE generation
SOL;OPTION 2 pumps flow sole- IDLE SHUT Idling stop relay out-
on/off on/off
2SPEED noid DOWN OUT put
SOL;OPTION SE- Option selection so- 2SPEED TRAVEL Travel 2nd speed so-
on/off
LECT lenoid SOL lenoid output
SOL;POWER FAN REVERS- Option switchover
on/off Power boost solenoid
BOOST ING SOL solenoid output

84402826 - May 2011

4001B-6
 Service Support

7. Fuel 8. Engine

FUEL DENSITY ENGINE SPEED min-1 Engine speed

g/cm3 Fuel density
(RAW) ENGINE LOAD
FUEL DENSITY % Engine load ratio
g/cm3 Fuel density RATIO
(15℃) DPD DPD exhaust gas dif-
FUEL TEMP. (IN- kPa
℃ Fuel temperature DIFF.PRESS. ferential pressure
NER TANK) EXHAUST TEMP. Exhaust gas temper-
FUEL SENSOR ℃
% Fuel sensor (DOC) ature (DOC)
POSITION EXHAUST TEMP. Exhaust gas temper-
REFUEL AUTO- Fuel supply auto- ℃
on/off (DPD) ature (DPD)
STOP OUT matic stop P.SOL;RE-
HYD.OIL FILTER Hydraulic oil filter mA
on/off GEN.ASSIST
SW. switch Flow milli-amp pro-
LOCK STATUS1 - - P.SOL;PUMP-
mA portional valve; Ac-
LOCK STATUS2 - - FLOW
tual milli-amp
Pump 1; Discharge
P1 PRESS. MPa
pressure
Pump 1; Negative
N1 PRESS. MPa
control pressure

84402826 - May 2011

4001B-7
 Service Support

9. Engine 11. Safety distances

ENGINE TAR- BOOM ANGLE deg Boom angle

min-1 Engine target speed
GET SPEED OFFSET ANGLE deg Offset angle
ENGINE SPEED min-1 Engine speed ARM ANGLE deg Arm angle
ENGINE LOAD P.SOL;BOOM-UP % Boom-up solenoid
% Engine load ratio
RATIO P.SOL;OFFSET-
% Offset solenoid
FUEL INJEC- LEFT
% Fuel injection ratio
TION LIMIT P.SOL;ARM-
mA Arm-in solenoid
COMMON RAIL Common rail pres- CLOSE
MPa
PRESS. sure SAFETY DIS- Safety distance
m
C.RAIL Common rail differ- TANCE(TOP) (side)
MPa
DIFF.PRESS. ential pressure SAFETY DIS- Safety distance
m
SUPPLY- TANCE(SIDE) (front)
Supply pump pres-
PUMP(IN) kPa
sure (IN)
PRESS 12. Hanging load
TARGET FUEL Target fuel injection
mm3/st
INJECTION quantity
FUEL FLOW L/h

10. Work radius and height

BOOM BOTTOM Boom bottom pres-

MPa
PRESS. sure
BOOM ROD
MPa Boom rod pressure
PRESS.
WORKING RA- m Work radius
BOOM ANGLE deg Boom angle DIUS
OFFSET ANGLE deg Offset angle LIFTING LOAD kg Hanging load
ARM ANGLE deg Arm angle RATED LOAD kg Rated load
WORKING RA- TOTAL MOMENT kg.m Total moment
m Work radius Attachment indepen-
DIUS ATT.MOMENT kg.m
LIFTING HEIGHT m Work height dent moment
HEIGHT LIMIT m Hanging limit height
LIFTING LOAD kg Hanging load
RATED LOAD kg Rated load
WARNING
on/off Liftcrane buzzer
BUZZER OUT
84402826 - May 2011
4001B-8
 Service Support

13. GPS information FAULT HISTORY

1. With FAULT HISTORY, the contents for the trouble
currently occurring and a log of trouble that has oc-
curred in the past can be checked.

To switch to a page from 1 to 15, press the monitor

switch while the MACHINE STATUS screen

is displayed and select the desired page.
1 Displayed/Not displayed
2 Occurrence count
3 Initial occurrence time
4 Final occurrence time

• Diagnostic trouble codes that occur display in

"DTC-1" - "DTC-4".
•
The cursor is moved with the and
switches. (The cursor moves between "DTC-1"
and "DTC-4".)
• The information for the diagnostic trouble code for
the location under the cursor is displayed with the
items from "STATUS" to "LAST HOUR".
• Up to 30 diagnostic trouble codes can be dis-
played.
To switch to a page from 1 to 6, press the monitor

switch while the FAULT HISTORY screen

is displayed and select the desired page.

84402826 - May 2011

4001B-9
 Service Support

WORK HISTORY 2. Work mode

Operation times for mechanical parts, electrical parts,
etc., and operation counts for switches can be displayed.

SP-MODE OPERA- SP mode operation

hour
1. Machine main unit TION TIME time
H-MODE OPERA- H mode operation
hour
TION TIME time
A-MODE OPERA- A mode operation
hour
TION TIME time
- - -
POWER-BOOST Boosted pressure
hour
TIME time
AUTO IDLE TIME hour Auto idle time
ONE-TOUCH-IDLE
hour One-touch idle time
TIME

3. End attachment

KEY-ON TIME hour Key ON time

Engine operation
ENGINE-RUN TIME hour
time
OPERATION TIME hour Operation time
UPPER OPERA-
hour Upper operation time
TION TIME
SWING OPERATION
hour Swing operation time
TIME
TRAVEL OPERA-
hour Travel operation time
TION TIME
INDEPENDENT Independent travel
hour
TRAVEL TIME operation time
Lo-SPEED TRAVEL 1st speed travel oper-
hour
TIME ation time
Hi-SPEED TRAVEL 2nd speed travel op- BREAKER OPERATION Breaker operation
hour hour
TIME eration time TIME time
CRUSHER OPERA- Crusher operation
hour
TION TIME time
OPT.1 PUMP OPERA- 1st option opera-
hour
TION TIME tion time
OPT.2 PUMP OPERA- 2nd option opera-
hour
TION TIME tion time
2ND OPT. OPERATION 2 pumps flow op-
hour
TIME eration time
CRANE OPERATION Liftcrane opera-
hour
TIME tion time
MAGNET OPERATION Lifting magnet op-
hour
TIME eration time
84402826 - May 2011
4001B-10
 Service Support

4. Electrical part 6. Air conditioner

KEY-ON COUNT hour Key ON count A/C OPERATION AC power supply

hour
TIME ON time
ENGINE-START
hour Engine ON count A/C BLOWER-Lo AC blower Lo set-
COUNT hour
TIME ting time
IDLE SHUT Front window open
hour A/C BLOWER-M1 AC blower M1 set-
DOWN COUNT count hour
TIME ting time
WINDOW OPEN
hour Door open count A/C BLOWER-M2 AC blower M2 set-
TIME hour
TIME ting time
WINDOW OPEN
10 times Idle stop time A/C BLOWER-M3 AC blower M3 set-
COUNT hour
TIME ting time
DOOR OPEN Front window open
hour A/C BLOWER-M4 AC blower M4 set-
TIME time hour
TIME ting time
DOOR OPEN
10 times Door open time A/C BLOWER-Hi AC blower Hi set-
COUNT hour
TIME ting time
MAG.CLUTCH RE- Electromagnetic
5. Electrical part hour
LAY ON TIME clutch ON time
CLUTCH RELAY ON Electromagnetic
10 times
COUNT clutch ON count

WIPER-INT. OPER-
hour Wiper (INT) time
ATION TIME
WIPER-CNT. OPER-
hour Wiper (CNT) time
ATION TIME
WASHER OPERA- Washer operation
hour
TION TIME time
WORKING LAMP Working light ON
hour
ON TIME time
RADIO MUTE TIME hour Radio mute time
DISPLAY-MODE1 No camera screen
hour
TIME selection time
DISPLAY-MODE2 Camera screen dis-
hour
TIME play 1 selection time
DISPLAY-MODE3 Camera screen dis-
hour
TIME play 2 selection time
84402826 - May 2011
4001B-11
 Service Support

7. Air conditioner ENGINE HISTORY

The engine speed, coolant temperature, fuel tempera-
ture, and suction air temperature distributions, etc. can
be displayed.

Maximum cooling op-

COOL-MAX TIME hour
eration time
T1 TARGET TEMP T1 Target tempera-
hour
＜ T2 TIME ture T ＜ T2 time 1. Actual speed distribution
T2 TARGET TEMP T2 Target tempera-
hour
＜ T3 TIME ture T ＜ T3 time
T3 TARGET TEMP T3 Target tempera-
hour
＜ T4 TIME ture T ＜ T4 time
Maximum heating
HOT-MAX TIME hour
operation time
RECIRC.AIR MAX- Maximum inside air
℃
TEMP. temperature
RECIRC.AIR MIN- Minimum inside air
℃
TEMP. temperature
INTAKE AIR MAX- Maximum outside air
℃
TEMP. temperature
INTAKE AIR MIN- Minimum outside air
℃
TEMP. temperature

To switch to a page from 1 to 7, press the monitor switch ROTATION ＜ R1 hour S 1025
R1 REV. SPEED ＜
hour 1025 S ＜ 1225
R2
while the WORK HISTORY screen is displayed R2 REV. SPEED ＜
hour 1225 S ＜ 1425
and select the desired page. R3
R3 REV. SPEED ＜
hour 1425 S ＜ 1625
R4
R4 REV. SPEED ＜
hour 1625 S ＜ 1825
R5
R5 REV. SPEED ＜
hour 1825 S ＜ 2025
R6
R6 REV. SPEED hour 2025 S

84402826 - May 2011

4001B-12
 Service Support

2. Water temperature distribution 4. Suction air temperature distribution

TEMP. ＜ T1 hour T ＜ 77 TEMP. ＜ T1 hour T ＜ -20

T1 TEMP. ＜ T2 hour 77 T ＜ 82 T1 TEMP. ＜ T2 hour -20 T ＜ 0
T2 TEMP. ＜ T3 hour 82 T ＜ 97 T2 TEMP. ＜ T3 hour 0 T ＜ 15
T3 TEMP. ＜ T4 hour 97 T ＜ 100 T3 TEMP. ＜ T4 hour 15 T ＜ 30
T4 TEMP. ＜ T5 hour 100 T ＜ 103 T4 TEMP. ＜ T5 hour 30 T ＜ 45
T5 TEMP. ＜ T6 hour 103 T ＜ 105 T5 TEMP. ＜ T6 hour 45 T ＜ 60
T6 TEMP. hour 105 T T6 TEMP. hour 60 T
- - - - - -
Maximum temper- Maximum temper-
TEMP. MAX ℃ TEMP. MAX ℃
ature ature

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

84402826 - May 2011

4001B-13
 Service Support

6. Suction air temperature distribution 8. Boost pressure distribution

PRESS. ＜ P1 hour P ＜ 100

P1 PRESS. ＜ P2 hour 100 P ＜ 140 PRESS. ＜ P1 hour P＜0
P2 PRESS. ＜ P3 hour 140 P ＜ 180 P1 PRESS. ＜ P2 hour 0 P ＜ 150
P3 PRESS. ＜ P4 hour 180 P ＜ 220 P2 PRESS. ＜ P3 hour 150 P ＜ 300
P4 PRESS. ＜ P5 hour 220 P ＜ 260 P3 PRESS. ＜ P4 hour 300 P＜450
P5 PRESS. ＜ P6 hour 260 P ＜ 300 P4 PRESS. ＜ P5 hour 450 P ＜ 600
P6 PRESS. hour 300 P P5 PRESS. ＜ P6 hour 600 P ＜ 750
Maximum pres- P6 PRESS. hour 750 P
PRESS. MAX kPa
sure Maximum pres-
Minimum pres- PRESS. MAX kPa
PRESS. MIN kPa sure
sure Minimum pres-
PRESS. MIN kPa
sure
7. Oil pressure distribution

9. Load ratio distribution

PRESS. ＜ P1 hour P＜0

P1 PRESS. ＜ P2 hour 0 P ＜ 150
P2 PRESS. ＜ P3 hour 150 P ＜ 300
P3 PRESS. ＜ P4 hour 300 P ＜ 450
P4 PRESS. ＜ P5 hour 450 P ＜ 600 RATIO ＜ R1 hour R＜ 30
P5 PRESS. ＜ P6 hour 600 P ＜ 750 R1 RATIO ＜ R2 hour 30 R ＜ 40
P6 PRESS. hour 750 P R2 RATIO ＜ R3 hour 40 R ＜ 50
Maximum pres- R3 RATIO ＜ R4 hour 50 R ＜ 60
PRESS. MAX kPa R4 RATIO ＜ R5 hour 60 R ＜ 70
sure
Minimum pres- R5 RATIO ＜ R6 hour 70 R ＜ 80
PRESS. MIN kPa
sure R6 RATIO hour 80 R

84402826 - May 2011

4001B-14
 Service Support

10. SP mode load ratio distribution 12. Fuel density distribution

DENSITY ＜ D1 hour D＜ D1
RATIO ＜ R1 hour R ＜ 30 D1 DENSITY ＜ D2 hour D1 D ＜ D2
R1 RATIO ＜ R2 hour 30 R ＜ 40 D2 DENSITY ＜ D3 hour D2 D ＜ D3
R2 RATIO ＜ R3 hour 40 R ＜ 50 D3 DENSITY ＜ D4 hour D3 D ＜ D4
R3 RATIO ＜ R4 hour 50 R＜60 D4 DENSITY ＜ D5 hour D4 D ＜ D5
R4 RATIO ＜ R5 hour 60 R ＜ 70 D5 DENSITY ＜ D6 hour D5 D ＜ D6
R5 RATIO ＜ R6 hour 70 R ＜ 80 D6 DENSITY hour D6 D
R6 RATIO hour 80 R
13. DOC temperature distribution

11. H mode load ratio distribution

TEMP. ＜ T1 hour T ＜ 200

T1 TEMP. ＜ T2 hour 200 T ＜ 300
T2 TEMP. ＜ T3 hour 300 T ＜ 400
RATIO ＜ R1 hour R ＜ 30 T3 TEMP. ＜ T4 hour 400 T ＜ 500
R1 RATIO ＜ R2 hour 30 R ＜ 40 T4 TEMP. ＜ T5 hour 500 T ＜ 600
R2 RATIO ＜ R3 hour 40 R ＜ 50 T5 TEMP. ＜ T6 hour 600 T ＜ 700
R3 RATIO ＜ R4 hour 50 R ＜ 60 T6 TEMP. hour 700 T
R4 RATIO ＜ R5 hour 60 R ＜ 70 - - -
R5 RATIO ＜ R6 hour 70 R ＜ 80 Maximum temper-
TEMP. MAX ℃
R6 RATIO hour 80 R ature

84402826 - May 2011

4001B-15
 Service Support

14. DPD temperature distribution 16. Hot shutdown

TEMP. ＜ T1 hour T ＜ 200 ITEM-1 - -

T1 TEMP. ＜ T2 hour 200 T ＜ 300 ITEM-2 - -
T2 TEMP. ＜ T3 hour 300 T ＜ 400 ITEM-3 - -
T3 TEMP. ＜ T4 hour 400 T ＜ 500 ITEM-4 - -
T4 TEMP. ＜ T5 hour 500 T ＜ 600 ITEM-5 - -
T5 TEMP. ＜ T6 hour 600 T ＜ 700 ITEM-6 - -
T6 TEMP. hour 700 T ITEM-7 - -
- - - ITEM-8 - -
Maximum temper- ITEM-9 - -
TEMP. MAX ℃
ature

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

84402826 - May 2011

4001B-16
 Service Support

18. DPD regeneration count HYDRAULIC HISTORY

The P1 and P2 pilot pressure can be displayed.

ITEM-1 - -
ITEM-2 - - 1. P1 pressure
ITEM-3 - -
ITEM-4 - -
ITEM-5 - -
ITEM-6 - -
ITEM-7 - -
ITEM-8 - -
ITEM-9 - -

To switch to a page from 1 to 18, press the monitor switch

while the ENGINE HISTORY screen is displayed

and select the desired page.

PRESS. ＜ P1 hour P＜ 10
P1 PRESS. ＜ P2 hour 10 P＜ 15
P2 PRESS. ＜ P3 hour 15 P＜ 20
P3 PRESS. ＜ P4 hour 20 P＜ 25
P4 PRESS. ＜ P5 hour 25 P＜ 30
P5 PRESS. ＜ P6 hour 30 P＜ 35
P6 PRESS. hour 35 P

84402826 - May 2011

4001B-17
 Service Support

2. P2 pressure 4. N2 pressure

PRESS. ＜ P1 hour P ＜ 10 PRESS. ＜ P1 hour P＜ 1.0

P1 PRESS. ＜ P2 hour 10 P ＜ 15 P1 PRESS. ＜ P2 hour 1.0 P＜ 1.5
P2 PRESS. ＜ P3 hour 15 P ＜ 20 P2 PRESS. ＜ P3 hour 1.5 P＜ 2.0
P3 PRESS. ＜ P4 hour 20 P ＜ 25 P3 PRESS. ＜ P4 hour 2.0 P＜ 2.5
P4 PRESS. ＜ P5 hour 25 P ＜ 30 P4 PRESS. ＜ P5 hour 2.5 P＜ 3.0
P5 PRESS. ＜ P6 hour 30 P ＜ 35 P5 PRESS. ＜ P6 hour 3.0 P＜ 3.5
P6 PRESS. hour 35 P P6 PRESS. hour 3.5 P

3. N1 pressure 5. P1 + P2 pressure

PRESS. ＜ P1 hour P＜ 1.0 PRESS. ＜ P1 hour P＜ 20

P1 PRESS. ＜ P2 hour 1.0 P＜ 1.5 P1 PRESS. ＜ P2 hour 20 P＜ 30
P2 PRESS. ＜ P3 hour 1.5 P＜ 2.0 P2 PRESS. ＜ P3 hour 30 P＜ 40
P3 PRESS. ＜ P4 hour 2.0 P＜ 2.5 P3 PRESS. ＜ P4 hour 40 P＜ 50
P4 PRESS. ＜ P5 hour 2.5 P＜ 3.0 P4 PRESS. ＜ P5 hour 50 P＜ 60
P5 PRESS. ＜ P6 hour 3.0 P＜ 3.5 P5 PRESS. ＜ P6 hour 60 P＜ 70
P6 PRESS. hour 3.5 P P6 PRESS. hour 70 P

84402826 - May 2011

4001B-18
 Service Support

6. Operation count 7. Oil temperature distribution

UPPER PILOT Upper operation

1000 times TEMP. ＜ T1 hour T ＜ 45
PRESS count
SWING PILOT Swing operation T1 TEMP. ＜ T2 hour 45 T ＜ 60
1000 times T2 TEMP. ＜ T3 hour 60 T ＜ 80
PRESS count
TRAVEL PILOT Travel operation T3 TEMP. ＜ T4 hour 80 T ＜ 88
1000 times
PRESS count T4 TEMP. ＜ T5 hour 88 T ＜ 95
ARM-CLOSE PI- Arm-in operation T5 TEMP. ＜ T6 hour 95 T ＜ 98
1000 times
LOT PRESS. count T6 TEMP. hour 98 T
OPT.LINE 1st option opera- - - -
1000 times
PRESS SW. tion count Maximum tempera-
TEMP. MAX ℃
2ND OPT.LINE 2nd option opera- ture
1000 times
PRESS SW. tion count
POWER BOOST Pressure boost
1000 times
SOL. operation count To switch to a page from 1 to 7, press the monitor switch
SWING BRAKE Swing operation
1000 times
SOL. count
POWER-SAVE Power save oper- while the HYDRAULIC HISTORY screen is dis-
1000 times
TIME ation count played and select the desired page.

84402826 - May 2011

4001B-19
 Service Support

PART NUMBER SETUP Screen List

The software version for computers A, B, C can be dis- The model selection, work mode speed, etc. can be
played. changed.

By pressing "Wiper switch" (5) and "Auto idling switch"

(6) on the monitor, MACHINE SELECT, PARAMETERS,
etc. can be selected.
Detailed data for the selected item can be seen by press-
ing "Working light switch" (4).

84402826 - May 2011

4001B-20
 Service Support

MACHINE SELECT PARAMETERS

Machine data information, etc. are registered. The work mode speed and pump milli-amps can be set.
1. Engine

MACHINE
Fix the selection.
TERRITORY ITEM-1 min-1 Auto idling speed
ITEM-2 ms*100 Auto idle time
0 JAPAN Transient load minimum milli-
ITEM-3 mA
1 NA amp (normally 50 mA)
2 - Semi-transient load minimum
ITEM-4 mA
3 EU milli-amp
4 IHI Eco gauge update period (nor-
ITEM-5 ms*100
5 TURK mally 1000 ms)
6 CHINA
2. Work mode milli-amp
BRAND

0 SUMITOMO
1 LBX
2 CASE
3 IHI

LANGUAGE

0 Japanese
1 English
2 Thai
3 Chinese
4 German ITEM-1 mA SP mode milli-amp (Hi)
5 French ITEM-2 mA SP mode milli-amp (Low)
6 Italian ITEM-3 mA H mode milli-amp (Hi)
7 Spanish ITEM-4 mA H mode milli-amp (Low)
8 Portuguese ITEM-5 mA A mode milli-amp (Hi)
9 Dutch ITEM-6 mA A mode milli-amp (Low)
10 Danish ITEM-7 mA Minimum milli-amp
11 Norwegian
12 Swedish
13 Finnish
14 Turkish
15 Arabic
16 Malay
17 Indonesian
18 Russian
19 Canadian French
20 Pictographs only
84402826 - May 2011
4001B-21
 Service Support

3. Work mode engine speed 5.

ITEM-1 min-1 SP mode speed ITEM-1 - -

ITEM-2 min-1 H mode speed ITEM-2 - -
ITEM-3 min-1 A mode speed ITEM-3 - -
ITEM-4 min-1 Idling speed ITEM-4 - -
ITEM-5 - -
4. Energy save ITEM-6 - -
ITEM-7 - -
ITEM-8 - -
ITEM-9 - -

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-6 - -
ITEM-7 mA Speed limit milli-amp

84402826 - May 2011

4001B-22
 Service Support

Setting
Model Select
Summary
The model information is input to set the control parameters specific to the model.
Configuration
• Screen

Operation explanation
Move up and down to move the cursor, left and right to select a model, set the throttle to H mode, and decide with
the menu switch.
• · Reset by holding down the left and right. (The display changes to "?" for all items.)
* From Ver. 1.8.6
Without a reset, only the LANGUAGE and UNIT can be changed.
Other changes always require a complete reset.
Setting items, values and details
Select "SET UP" on the service screen and input the following items.
The setting item values and setting details are given below.
Explanation of item

Pag-
Item name Explanation Remarks
e
MACHINE Model
TERRITORY Destination
BRAND Brand
LANGUAGE Language
1 UNIT Unit 0: {MPa, °C}, 1: {psi, °F}, 2: {kgf/cm2, °C}
-
-
-
-
-
-
OVERLOAD WARNING Load warning
Interference preven-
ANTI INTERFERENCE Not currently supported
tion
ATT. TYPE Attachment type Used for interference prevention·crane·overload warning
2
OPTION LINE Option Line
GENERATOR Lifting magnet Not currently supported
-
-
-

84402826 - May 2011

4001B-23
 Service Support

Pag-
Item name Explanation Remarks
e
-
Currently not supported; used for Computer ST trouble diag-
REMOTE SUPPORT Remote Support
nosis
Fuel abnormality Currently not supported; used for density sensor trouble di-
FMS
warning agnosis
3 RESERVE 1 Free Swing
RESERVE 2 Reserve 2 Not currently supported
RESERVE 3 Reserve 3 Not currently supported
-
-
-

Explanation of number
1. Model (Machine)
Omitted
2. Destination (Territory)

Value Details Remarks

0 JAPAN
Travel alarm continuous buzzing function ON (Cannot be set
1 NA
OFF)
2 - (Skipped number)
3 EU
4 IHI
5 TURK
6 CHINA

3. Brand

Value Details Remarks

Background color = blue, Sumitomo logo displayed after model
0 SUMITOMO
selection completed
Background color = black, LBX logo displayed after model se-
1 LBX
lection completed
Background color = black, CASE logo displayed after model se-
2 CASE
lection completed
3 IHI Not currently supported, background color = ?

84402826 - May 2011

4001B-24
 Service Support

4. Language
• Can be changed with "LANGUAGE" on the menu screen.

Value Details Remarks

0 Japanese
1 English
2 Thai Not currently supported
3 Chinese
4 German
5 French
6 Italian
7 Spanish
8 Portuguese
9 Dutch
10 Danish
11 Norwegian
12 Swedish
13 Finnish
14 Turkish
15 Arabic
16 Malay Not currently supported
17 Indonesian Not currently supported
18 Russian
19 Canadian French
20 Pictographs only

5. Unit

Value Details Remarks

0 Domestic, Europe (SI units) (MPa, °C)
1 North America (psi, °F)
2 Weight unit system (kgf/cm2, °C)

6. Load warning (OVERLOAD WARNING)

Value Details Remarks

0 None
1 Liftcrane Not currently supported
2 Overload warning
3 Overload warning (rod pressure correction) Not currently supported

7. Interference prevention (ANTI INTERFERENCE)

Value Details Remarks

0 None Not currently supported
1 Yes Not currently supported

8. Attachment type (ATT. TYPE)

Value Details Remarks

0 STD
1 HD
2 Ultra-long
84402826 - May 2011
4001B-25
 Service Support

9. Option line

Value Details Remarks

None (Option adjustment screen cannot be
0
displayed)
1 Breaker
2 Double-acting no 2nd speed
3 Double-acting with 2nd speed
4 W/O multi-purpose pressure adjustment
5 W/ Multi-purpose pressure adjustment

10. Lifting magnet (Generator)

Value Details Remarks

0 None Not currently supported
1 Yes Not currently supported

11. Remote Support

Value Details Remarks

0 None Not currently supported
1 Yes Not currently supported

12. Fuel abnormality warning (FMS)

Value Details Remarks

0 None Not currently supported
1 Yes Not currently supported

13. Free swing (Reserve 1)

Value Details Remarks

0 None
1 Yes

84402826 - May 2011

4001B-26
 Service Support

Throttle Volume Default Setting

Summary
Corrects the throttle volume installation error.
Configuration

*1 Throttle volume *3 Computer B *5 ECM

*2 Color monitor *4 Computer A *6 ENG

Operation explanation
1. Switch the key ON and select (Select Model). (See Select Model.)
2. Set all the model selection items and set the throttle volume to H mode, then finalize the selections.
3. The system performs the initial adjustment of the throttle volume. (*1)
• The adjustment results are retained in memory even after the key is switched OFF.

84402826 - May 2011

4001B-27
 Service Support

Password Setting
Summary
Set the anti-theft password.
Configuration
• Monitor: Connected to Computer B
• Anti-theft setting knob: On the cab main harness
Operation explanation
1. With the key OFF, connect the anti-theft setting knob.
2. After connecting the knob, when you switch ON the key, the system displays the password setting screen.
3. After setting the 4-digit password, if you switch the key ON→OFF→ON→OFF, the system switches ON the
anti-theft function.
• All the key switching operations should be done within 2 sec.
4. When the anti-theft function comes ON, the monitor sets off the buzzer and the key icon is displayed.
* See Anti-theft (password type).

84402826 - May 2011

4001B-28
 Service Support

Adjusting the Clock *1 Color monitor

Summary
This adjusts the clock displayed on the monitor. Operation explanation

• For details on the clock, see the clock section.
Configuration
1. When the key is turned ON, --:-- is displayed on
the monitor.
2. The operator can set the time with "CLOCK AD-
JUST" on the menu screen.
Move left and right to move the cursor, up and
down to change the time, and decide with the
menu switch.
3. The system displays the time on the monitor.
• Since the clock data is stored in the monitor, the
time is retained even if Computer B is replaced.
When the monitor is replaced, it is necessary to
set the clock again.

84402826 - May 2011

4001B-29
 Service Support

Parameter Settings
* The following covers software Version 1.8.7.
Summary
Control parameters can be changed using the monitor.
For example, the time until auto idle is started or the current and speed for work mode can be set.
The items up to the 3rd page of the setting screen can overwrite the parameters changed with the key OFF.
Configuration
The diagram below shows the items that can be checked with each page of the setting screen.

Pag-
Item name Unit Explanation Remarks
e
Lo-IDLE ENGINE SPEED min-1 Low idle engine speed
AUTO IDLE TIME sec Auto idle time
AUTO IDLE ENGINE
min-1 Auto idling speed
SPEED
IDLE SHUT DOWN TIME min Idle shut-down time 10 minutes max.
AUTO POWER BOOST Y/N Auto pressure boost function
Milli-amp for pump horsepower control
1 PUMP POWER AT START mA proportional valve (mA); when ATT op-
erations start
Milli-amp for pump horsepower control
PUMP POWER DOWN mA proportional valve (mA); negative offset
amount
Flow control (breaker mode) with en-
REV. LIMIT AT BREAKER Y/N Not currently supported
gine speed
Can only be changed for 20
ENABLE POWER SAVE Y/N Power save function
tons - 29 tons.
Cannot be switched OFF on
ENABLE TRAVEL ALARM Y/N Travel alarm function
North American models
TRV. ALARM-ON TIME sec Travel alarm sounding time Range = 1..30, Step = 1
Previous travel speed data hold func-
MEMORIZE TRV. SPEED Y/N
tion
ENABLE EPF Y/N EPF Yes/No
2 OVERLOAD PRESS. MPa Overload set pressure
MAINTENANCE MES-
Y/N Service due message
SAGE
FORCED DIM. BY W.LAMP Y/N working light linked dimming
AUTO CLOCK ADJUST Y/N For automatic adjustment Not currently supported
TIME DIFFERENCE WITH -
hour Not currently supported
UTC
ITEM-1 Y/N Eco gauge display
ITEM-2 - -
ITEM-3 - -
ITEM-4 - -
3 ITEM-5 - -
ITEM-6 - -
ITEM-7 - -
ITEM-8 - -
ITEM-9 - -

84402826 - May 2011

4001B-30
 Service Support

Pag-
Item name Unit Explanation Remarks
e
Milli-amp for pump horsepower control
ITEM-1 mA
proportional valve (SP_Hi)
Milli-amp for pump horsepower control
ITEM-2 mA
proportional valve (SP_Low)
Milli-amp for pump horsepower control
ITEM-3 mA
proportional valve (H_Hi)
Milli-amp for pump horsepower control
ITEM-4 mA
proportional valve (H_Low)
4
Milli-amp for pump horsepower control
ITEM-5 mA
proportional valve (A_Hi)
Milli-amp for pump horsepower control
ITEM-6 mA
proportional valve (A_Low)
Milli-amp for pump horsepower control
ITEM-7 mA
proportional valve (Min)
ITEM-8 - -
ITEM-9 - -
ITEM-1 Y/N Quick warm-up control ON/OFF
ITEM-2 - Development parameter
ITEM-3 - Development parameter
ITEM-4 - Development parameter
5 ITEM-5 - Development parameter
ITEM-6 - Development parameter
ITEM-7 - Development parameter
ITEM-8 - Development parameter
ITEM-9 - Development parameter
ITEM-1 min-1 Engine speed (SP)
ITEM-2 min-1 Engine speed (H)
ITEM-3 min-1 Engine speed (A)
ITEM-4 - -
6 ITEM-5 - -
ITEM-6 - -
ITEM-7 - -
ITEM-8 - -
ITEM-9 - -

Operation explanation
1. Select an item with the cursor, then input the number with ←→.
2. Decide the selection with the menu switch, then press the menu switch again to leave the screen.

84402826 - May 2011

4001B-31
 Service Support
Option Flow Pressure Setting
Summary
Sets the option line flow / pressure.
Sets the breaker/crusher maximum flow and maxi-
mum pressure.
After making the setting, follow the procedure and cor-
rect so that the pressure becomes the set pressure.
Configuration
• The 1st option, 2nd option pressure switch: Con-
nected to Computer A
Used during pressure adjustment to judge whether
or not operation is independent breaker (crusher)
operation.
• Bucket-close, arm-in, boom-up pressure sensor:
Connected to Computer B and sent to Computer A
via the CAN.
Used during pressure adjustment to judge whether
or not operation is independent breaker (crusher)
operation.
• Oil temperature sensor: Connected to Computer A
Used to judge whether or not the temperature per-
mits pressure adjustment.
• Engine speed sensor: Connected to the ECM and
recognized by Computer A via the CAN.
Used to judge whether or not the speed permits
pressure adjustment.
• P1 pressure sensor: Connected to Computer A
Used to judge whether pressure is being relieved
according to the set pressure.
• Option line switching solenoid: Connected to and
controlled by Computer A.
When this solenoid is ON, it switches to the breaker
circuit and at the same time that the relief pressure
reaches the breaker setting, the return hydraulic oil
falls directly into the tank through the filter.
• Pump flow proportional valve: Connected to and
controlled by Computer A.
So that the preset maximum flow is not exceeded in
breaker/crusher mode.
• Option relief pressure proportional valve: Con-
nected to Computer B
The target command current value is sent from Com-
puter A via CAN communication.
• 2 pumps flow solenoid: Connected to and controlled
by Computer A.
When this solenoid is ON, if a backup operation is
carried out, 2 pumps flow.
2 pumps will not flow if a backup operation is not
carried out even if this solenoid is ON.
• With the X2, the 2 pumps flow switch was installed
on the console as a rocker switch, but with X3, this
was eliminated.
Instead, this is decided beforehand with the option
line setting screen.
• Option line setting screen items: consists of follow-
ing five items
1. Attachment selection,
2. Breaker No. (or Crusher No.)
3. Maximum flow setting
84402826 - May 2011
4001B-32
4. Maximum pressure setting
5. Pressure adjustment
For Item 1), when a multi-purpose circuit is set with
model selection, the maximum pressure settings
and pressure adjustment items in 4) and 5) are only
displayed when pressure adjustment is set with the
model selection.
• Message displayed on the option line setting screen:
There is one message display area at the top of the
screen and one at the bottom of the screen.
"PRESSURE ADJUSTING INCOMPLETE" or "AD-
JUST PRESSURE" is displayed in the top message
display area.
"BREAKER OPERATION REQUIRED/CRUSHER
OPERATION REQUIRED", "SET IN SP-MODE",
"INCREASE ENGINE RPM", "INCREASE OIL
TEMP.", "ADJUSTING PRESSURE", "PRESSURE
ADJUSTING. COMPLETE", PRESSURE ADJUST-
ING INCOMPLETE", or "CHECK FLOW RATE" is
displayed in the bottom message display area.
Operation explanation
1. The operator enters the option line setting screen
from the menu.
The system cuts away option line switching sole-
noid, pump flow
proportional valve, option relief pressure propor-
tional valve, 2 pumps flow from normal controls
and sets to setting mode.
• There are two ways to enter the option line set-
ting screen.
One is from the menu screen.
The other is by holding down the ATT select
switch for one second.
When the former method is used, the ATT
when one enters the option line setting screen
is Breaker 1. (However, if a double-acting cir-
cuit is selected with the model selection, it is
Crusher 1.)
When the latter method is used, the display
moves to the currently selected ATT and a
switch guide is displayed on the monitor. (Nor-
mally, this is from Breaker 1. (However, if
double-acting circuit is selected with the model
selection, it is from Crusher 1).)
 Service Support
2. The operator selects the breaker or the crusher
from the "Attachment selection". (When
multi-purpose circuit is selected with model se-
lection: For a breaker or crusher, "Attachment
selection" is not displayed and the selection can-
not be changed.)
For a breaker, the system sets the item immedi-
ately below to "Breaker No." and for a crusher,
"Crusher No.".
At the same time, the system switches the option
line switching solenoid to ON for a breaker or OFF
for a crusher.
3. The operator selects a number from 1 to 5 with
the "Breaker No. (or Crusher No.)" item.
The system displays the maximum flow and max-
imum pressure corresponding to that number
in the two items immediately below "SET MAX
FLOW" and "SET MAX PRESSURE".
• The factory setting is that the maximum flow and
maximum pressure setting are only for Breaker
1 and Crusher 1.
(* The pressure is not adjusted, so for pressure
adjustment model setting, the icon does not ap-
pear even if the ATT select switch is pressed.
The icon appears for the model setting only with
flow setting.)
Other breakers, 2-5, and crushers, 2-5, are not
set.
When an breaker or crusher is selected that has
not been set, four hyphens (---) are displayed for
the "SET MAX FLOW" and "SET MAX PRES-
SURE".
• If the maximum flow and maximum pressure
have not yet been set, that breaker or crusher
cannot be selected with a work screen.
To put it the other way, everything set here can
be selected with a work screen.
Since the X3 has only one ATT selection switch,
when the flow volume is set here for all the
breakers or crushers, care is required because
selecting the target ATT requires pressing the
switch a number of times.
* When items that had been set are reset, the
reset items can no longer be selected.
4. The operator sets the maximum flow from the
"SET MAX FLOW" item and sets the maximum
pressure from the "SET MAX PRESSURE" item.
• As selection options for the maximum flow, the
system has available 20 levels for the flow vol-
ume, 10 for without 2 pumps flow and 10 for with
2 pumps flow.
• However, the maximum flow depends on the
model. Even though 20 levels are displayed
for all models, the flow volumes for the levels
depend on the model. (See (Number table) flow
adjustment levels below.)
• When the flow volume is set, if a stand-alone
option operation is executed, the flow propor-
tional valve command current value is output
to achieve that flow volume. (Breaker mode or
crusher mode processing is executed.)
• The range in which the maximum pressure can
be set depends on the model, but for all models,
84402826 - May 2011
4001B-33
the settings are made in increments of 0.5 MPa.
(See (Number table) pressure adjustment range
below.)
• No maximum pressure can be set that exceeds
the relief valve pressure setting range.
• When an item that had been set is reset, four
hyphens (---) are displayed for either the "SET
MAX FLOW" or the "SET MAX PRESSURE"
and when you exit the options adjustment
screen, the information that had been set is
reset.
• If the pressure adjustment is not selected with
the model selection, the option flow setting ends
after just setting the maximum flow.
• When multi-purpose circuit is selected with
model selection, when the flow volume for 2
pumps flow is set with breaker mode, "CHECK
FLOW RATE" is displayed on the monitor.
Once that flow volume is decided, the "CHECK
FLOW RATE" display goes out.
5. When the operator has changed the maximum
flow or maximum pressure, the system redoes the
option relief pressure proportional valve adjust-
ment again.
The system displays "ADJUST PRESSURE" on
the monitor.
6. The operator checks that the work mode is SP
and that the oil temperature is 30°C minimum and
operates the breaker (crusher).
The system displays "ADJUSTING PRESSURE"
on the monitor.
At the same time, the "PRESSURE SETTING"
and "CURRENT PRESSURE" items are dis-
played.
• When the operator stops the operation, the dis-
play returns to "BREAKER OPERATION RE-
QUIRED".
• When the work mode is not SP, "SET IN
SP-MODE" is displayed instead of "ADJUST-
ING PRESSURE".
• During one-touch idle or while the engine is
stopped, "INCREASE ENGINE RPM" is dis-
played instead of "ADJUSTING PRESSURE".
• When the operator operates in SP mode, if the
oil temperature is less than 30°C, "INCREASE
OIL TEMP." is displayed instead of "ADJUST-
ING PRESSURE".
At the same time, the "TARGET OIL TEMP." and
"CURRENT OIL TEMP." items are displayed.
• During adjustment, if any operation other than
breaker (crusher) operation is done, the sys-
tem stops the adjustment, displays "BREAKER
OPERATING REQUIRED" on the monitor, and
waits for operation of the breaker (crusher) in-
dependently.
7. The operator continues operating the breaker
(crusher).
The system waits for the pressure to stabilize for
2 sec., then starts the adjustment.
The system continues to compare the actual P1
pressure and the target set pressure and when
the difference between them is no more than 0.5
 Service Support
MPa (*) continuously for at least 5 sec., it judges
the adjustment to be complete.
The system displays "PRESSURE ADJUSTING.
COMPLETE" on the monitor and puts out the
"PRESSURE ADJUSTING INCOMPLETE" dis-
play.
• During adjustment, the system updates the op-
tion relief pressure proportional valve current
every 500 ms in increments of 5 mA.
• If the pedal continues to be held down even after
the setting value is finalized, the setting value is
updated every 5 sec..
• If the pressure adjustment does not end within
30 sec., "PRESSURE ADJUSTING INCOM-
PLETE" is displayed on the monitor.
8. When the operator presses the menu switch to
exit the option line setting screen, the system
stores the settings into memory.
• If the setting screen was entered from the menu
screen, the display returns to the menu screen.
If the setting screen was entered from the
main screen by holding down the ATT select
switch for 1 sec., the display returns to the main
screen.
84402826 - May 2011
4001B-34
Screen Brightness Setting
<Summary>
Decides the brightness of the backlight through oper-
ation that is linked to the working light and solar radi-
ation sensor.
<Operation explanation>
The screen brightness can be selected on the menu
screen.
Dimming setting can be changed on the service
screen.
1. Working Light OFF: Normal (with key ON),
"Brightness (day)" setting
2. Working Light ON: The monitor brightness is re-
duced and the display changes automatically to
the "Brightness (night)" setting.
3. Brightness settings: "Brightness (day)" and
"Brightness (night)" can be set on the menu
screen.
4. Dimming by solar radiation sensor: When the
working light-linked dimming is set OFF on the
menu screen, the dimming level is adjusted au-
tomatically to the ambient brightness by the solar
radiation sensor.
 Section

4001C

Function, Structure, Operation

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Function, Structure, Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

4001C-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
4001C-2 PRINTED IN FRANCE
 Function, Structure, Operation

Function, Structure, Operation

1. Engine number

1 Engine number stamping

84402826 - May 2011

4001C-3
 Function, Structure, Operation

2. Function, Structure, Operation

1) Engine structural diagram

84402826 - May 2011

4001C-4
 Function, Structure, Operation

2) Description of functions and operations

Engine electronic control
The control provided by the control unit applies to the range from injection to air intake and exhaust in-
cluding fuel injection amount, injection timing, air intake restriction, EGR and idling speed.
Cylinder block
The cylinder block is made of cast iron, and it has the equal center distance for each bore and a high
rigidity, and the center of the crankshaft matches the center of the block.
The bearing cap has the ladder frame structure, and is tightened using the plastic region rotational angle
tightening method.
Cylinder liner
The cylinder liner is selected in accordance with the inner diameter of the cylinder block bore, and its
identification number is stamped on the left side of the cylinder.
Piston
The piston is a strut cast autothermatic piston made of aluminum alloy, and the combustion chamber is
the round re-entrant type.
Cylinder head
The cylinder head is made of cast iron, and has four valves per each cylinder.
The angle tightening method has been adopted to the cylinder head bolt to further improve its reliability
and durability.
Crankshaft
The tufftrided steel is being used, and the grade of each journal diameter is engraved on the No.1 balance
weight.
EGR system
The EGR system is controlled by the engine control module (ECM) according to various data including
the water temperature, engine RPM, and engine load to recirculate the exhaust gas for purification.
The primary components are the EGR valve, EGR cooler, and various sensors.
Connecting rod cap bolt
The angle tightening method has been adopted to the connecting rod cap bolt to further improve its reli-
ability and durability.
Common rail type electronic control injection system
The common rail type electronic control injection system consists of the supply pump that sets the target
pressure of high-pressure fuel to supply the fuel, the common rail that measures the high-pressure fuel
and the fuel injector that injects the fuel in the form of a fine mist.

84402826 - May 2011

4001C-5
 Function, Structure, Operation

Each of these are controlled by the ECM based on various signals to control the injection timing and
injection amount in accordance with the working condition.
Fuel injector
The fuel injector has adopted the 7-hole nozzle, and adjusts the fuel injection amount and injection timing
by opening or closing the electromagnetic valve on the injector head portion.
The ECM corrects variation in the fuel injection amount from fuel injector to fuel injector in accordance
with the ID code data in the memory.
When adjusting the fuel injector, the ID code date must be recorded in the ECM.
Fuel filter with sedimenter
The fuel filter with sedimenter removes the water by using the difference in the relative density between
diesel oil and water, and notifies the operator through the indicator when it becomes full of water.
Preheat system
The preheat system consists of the ECM, glow relay, glow plug and glow indicator light.
The preheat system is activated when the engine coolant temperature is low to help engine start.
Lubricating system
It uses and oil filter with a full-flow bypass, and cools down the pistons using the water-cooled oil cooler
and the oil jet.
DPD
An integrated DPD oxidation catalyst is installed for reducing exhaust gas.

84402826 - May 2011

4001C-6
 Function, Structure, Operation

3) Fuel system
Fuel system diagram

1 Electromagnetic pump 4 Fuel injector 7 Fuel return pipe

2 Fuel filter 5 Supply pump 8 Pre-fuel filter
3 Common rail 6 Fuel tank

CAUTION
• Since the high-precision fuel system has been adopted, take care to prevent any foreign
matter from entering the fuel system.

84402826 - May 2011

4001C-7
 Function, Structure, Operation

Common rail

1 Pressure sensor
2 Pressure limiter

84402826 - May 2011

4001C-8
 Function, Structure, Operation

Fuel supply pump

1 Fuel temperature sensor 4 Camshaft key 7 Joint bolt

2 Suction control valve 5 Camshaft nut
3 High pressure pipe 6 Union

CAUTION
• There is a gauze filter assembled inside the union of the fuel supply pump, but the union
should not be removed to prevent any foreign matter from entering.

84402826 - May 2011

4001C-9
Function, Structure, Operation

1 Union
2 Gauze filter
3 Supply pump
4 Strainer
5 Joint bolt

84402826 - May 2011

4001C-10
 Function, Structure, Operation

Injector

1 ID plate
2 Terminal stud
3 Injector drive section
4 Injector assembly
5 Gasket
6 O-ring
Leak-off pipe installation sec-
7
tion

84402826 - May 2011

4001C-11
 Function, Structure, Operation

Fuel filter

1 Priming pump
2 Plug
3 Case
4 Drain plug

84402826 - May 2011

4001C-12
 Function, Structure, Operation

4) Cooling system
The coolant system is the forced-circulation system, and its main components are the water pump, thermo-
stat and radiator.

1 Water jacket 7 Cooling fan 13 Thermostat, 2 units

2 Drain plug 8 Radiator cap 14 Water temperature sensor
3 Oil cooler 9 Heater core 15 Bypass route
4 Water pump 10 Radiator reserve tank 16 Turbocharger
5 Drain cock 11 Air removal plug 17 EGR cooler
6 Radiator 12 Water outlet pipe

Water pump
The water pump is a centrifugal impeller type pump and is driven by the engine fan belt.

84402826 - May 2011

4001C-13
Function, Structure, Operation

1 Fan guide 3 Impeller

2 Bearing 4 Seal unit

84402826 - May 2011

4001C-14
 Function, Structure, Operation

Thermostat
The thermostat is the wax pellet type, and consists of 2 units.
One unit is the bottom bypass type and its initial open valve temperature is 82°C {185 °F}, and the other
unit is the inline type and its initial open valve temperature is 85°C {185 °F}.
The structure allows the water temperature to be fine adjusted, and it is assembled inside the thermostat
housing unit.

1 Jiggle valve 3 Valve 5 Piston

Stamp mark (initial open
2 4 Gasket
valve temperature)

84402826 - May 2011

4001C-15
 Function, Structure, Operation

5) Lubrication system
A full-flow bypass integrated filter element, water cooling oil cooler, and piston coolant oil jet are adopted
for the lubrication system.

*1 Delivery Valve *9 Oil Cooler *17 Conn-rod Bearing

*2 Oil Port *10 Thermo Valve *18 Oiling jet
*3 Full Flow Oil Filter *11 Oil gallery *19 Oil pump
*4 Oil pressure switch *12 Valve Mechanism *20 Strainer
*5 Oil Pressure Indicator Lamp *13 Crankshaft Bearing *21 Flywheel P.T.O
*6 Fuse *14 Crank Valve *22 Turbochager
*7 Starter Switch *15 Relief Valve *23 Engine Oil Pan
*8 Battery *16 Gear Train

Oil pump structural diagram

84402826 - May 2011

4001C-16
 Function, Structure, Operation

1 Driven gear assembly 4 Oil pump drive gear 7 Driven gear assembly
2 Oil pump body 5 Oil pump body 8 Oil pump drive gear
3 Drive gear assembly 6 Drive gear assembly

84402826 - May 2011

4001C-17
 Function, Structure, Operation

6) Induction system Turbocharger structural diagram

1 Connector 4 Turbine housing 7 Coolant outlet

2 Rod 5 Exhaust adapter 8 Oil outlet
3 Oil inlet 6 Coolant inlet 9 Compressor housing

84402826 - May 2011

4001C-18
 Function, Structure, Operation

7) Exhaust system

1 DPD assembly 3 Exhaust temperature sensor 2

DPD differential pressure sen-
2 Exhaust temperature sensor 1 4
sor

84402826 - May 2011

4001C-19
 Function, Structure, Operation

8) Emission control device

EGR
The EGR system recirculates a part of the exhaust gas to the intake manifold, and the generation of NOx
is suppressed.
By controlling the EGR system, high operability and exhaust gas reduction are both achieved.
The control current from the ECM activate the solenoid to control the EGR valve lift amount.
The EGR position sensor detects the actual valve lift amount and the data is used for precise control of
the EGR amount.
The EGR operates when the engine RPM, engine coolant temperature, intake temperature, and atmo-
spheric pressure satisfy certain criteria.
Thereafter, the valve opening angle is calculated according to the engine RPM and the desired fuel injec-
tion amount.
The calculated valve opening angle is used to determine the motor drive duty and the valve is driven
accordingly.
The intake throttle valve closes when the EGR operates to ensure an appropriate internal pressure of the
intake manifold.

84402826 - May 2011

4001C-20
 Function, Structure, Operation

*1 Intake throttle position sensor *7 Engine speed *13 Exhaust

*2 EGR valve *8 Engine load *14 Intake throttle valve
*3 EGR position sensor *9 Outlet port of coolant *15 Boost temperature sensor
*4 ECM *10 Inlet port of coolant *16 Boost sensor
*5 IAT/MAF sensor *11 EGR cooler
*6 Intake air *12 IMT sensor

84402826 - May 2011

4001C-21
 Function, Structure, Operation

9) Electrical system
Charging system
The main components of the charging system are the battery, generator, and battery discharge indicator
light circuit.
Generator is a self-rectifier type with a regulator built in.
Generator
The generator is the brushless type.
The main components are the rotor, stator, rectifier assembly, front bracket, rear bracket, IC regulator,
bearing, pulley, etc.
The moving parts are the rotor and pulley.
The field coil is fixed to the rear bracket.
6 main diodes and 2 additional diodes are used to change the three-phase alternating current generated
in the stator coil to a direct current.
3 out of the 6 main diodes are referred to as positive diode, and the rest is referred to as negative diode.
In addition, 3 small diodes that are referred to as trio-diode are used to supply the field current.
This generator has 3 terminals of B terminal (direct current output terminal), L terminal and R terminal.
Since the L terminal is connected to the field coil, it works as an input terminal together with the R terminal
until the generator starts generating power.
Also, it functions as an output terminal. (current capacity is 1 A)
When the L terminal voltage reaches the battery voltage, the charge light turns off.
Since the both bearings are sealed, periodic lubrications are not required.
The IC regulator cannot be disassembled, so it should be handled as an assembly.

1 Rectifier 5 Pulley 9 Regulator

2 Field coil 6 Front bracket 10 Bearing
3 Stator 7 Rotor
4 Bearing 8 Rear bracket

84402826 - May 2011

4001C-22
 Function, Structure, Operation

Starter system
The starter is 5 kW and uses a reduction type.
Gear housing and armature end bearing housing are made of aluminum.
Brush assembly is an replaceable type.
Starter circuit is started using a battery.
The battery cable is connected to a large terminal on the starter.
The wiring is connected from the terminal to the engine control switch and the starter relay.
Starter
The starter is an outer gearing mesh method reduction starter adopting the magnetic shift type.
When the starter switch is turned ON, the plunger is drawn in, the contact point of the magnetic switch
closes and the armature rotates.
At the same time, the pinion is pushed to the front via the shift lever to mesh with the ring gear.
When the ring gear rotates, the crankshaft is turned to start the engine.
After the engine is started, the plunger returns, the pinion separates from the ring gear, and the armature
stops rotating when the starter switch is turned OFF.
When the engine rotation becomes faster than the pinion, the pinion is caused to turn in reverse, but the
pinion just idles due to the one-way clutch function, so the armature is not driven.

1 Lever assembly 4 Armature 7 Clutch

2 Magnetic switch assembly 5 Brush holder 8 Pinion
3 Yoke 6 Internal gear

Preheat system
The preheat system has adopted the QOS system glow plug type.
Also, the energization control is performed by the ECM.

84402826 - May 2011

4001C-23
 Function, Structure, Operation

10) Engine control system

Engine control system overview and implementation
The engine control system is an electronic control system that controls the engine to be always in the
optimal combustion state according to the driving condition, and consists of the electronic control fuel
injection system, EGR, and idling control.
Also, besides controlling the engine, the engine control system has the QOS system, engine RPM sig-
nal output, self-diagnosing function, and CAN communication SAE J1939/21 and SAE J1939/11 system
control functions.
System control schematic
The specifications vary depending on the actual unit, so refer to the manual of the actual unit.

84402826 - May 2011

4001C-24
 Function, Structure, Operation

Correction
Engine coolant temperature
correction
Barometric Pressure
a Fuel temperture boost pres-
sure correction
Correction between sylinders
Q-key correction
QR correction

Accelerator position sensor in- SCV opening time determina-

*1 *8 *15 SCV
put tion
Injector coil energizing time
*2 Boost sensor input *9 *16 Supply pump
Timing determination
*3 CKP sensor input *10 CAN communication *17 Fuel tank
*4 CMP sensor input *11 Machine control unit *18 Injector coil
*5 Engine control module (ECM) *12 Water temperture sensor input *19 Injector
*6 Basic fuel injection amount *13 Common rail pressure sensor
*7 Correction *14 Common rail

84402826 - May 2011

4001C-25
 Function, Structure, Operation

Fuel injection correction

The ECM calculates the basic injection amount based on the signals from the accelerator position sensor,
boost sensor, crankshaft position sensor, camshaft position sensor, etc.
At this time, the open or close timing of the SCV and the energizing time of the injector are controlled
based on the conditions such as the common rail pressure and engine coolant temperature to make
optimal corrections to the injection timing and injection amount.
About initial Q correction
ECM implements the initial Q correction when the initial Q correction is under the specified engine rotation
during engine start.
Also, ECM cannot implement the initial about initial Q correction and cannot start the engine because it
does not recognize the engine rotation when it is under the engine rpm the system can recognize.

Engine speed (r/min)

*1 Idle speed
Starting Q specified engine
*2
speed
*3 Minimum firing engine speed
System realization engine
*4
speed

84402826 - May 2011

4001C-26
 Function, Structure, Operation

About high altitude correction

ECM calculates the current altitude using signals from the atmospheric pressure sensor.
According to the conditions such as the current altitude, the fuel amount is corrected properly.

Fuel flow limit (mm3/st)

Barometric pressure kPa (psi)

*1 Highland

84402826 - May 2011

4001C-27
 Function, Structure, Operation

Control during overheat

To protect the engine, restriction on fuel flow is started when the engine coolant temperature exceeds 100
°C {212 °F}.
When the engine coolant temperature increases further, the fuel flow is also restricted further.
When the temperature reaches 110 °C {230 °F}, 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 actual unit manufacturer.
The actual unit is designed to issue an alarm from 105 °C {221 °F}.
By reducing the load applied to the actual unit 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

84402826 - May 2011

4001C-28
 Function, Structure, Operation

Engine emergency stop function

The ECM is designed to make an emergency engine stop when an input from the engine stop switch,
decrease in the engine oil pressure, increase in the engine coolant temperature or overrun occurs.
As for emergency stop made due to decrease in the engine oil pressure, increase in the engine coolant
temperature or overrun, the control is performed when the corresponding function is added to the calibra-
tion of the ECM.
Input from engine stop switch
The engine stops when the battery voltage is applied to the ECM terminal No.121.

*1 Engine stop switch

*2 Starter switch (ON)

84402826 - May 2011

4001C-29
 Function, Structure, Operation

Decrease in engine oil pressure

When the engine oil pressure drops to 100 kPa {1.02 kgf/ cm2 / 14 psi} or lower, an alarm for engine oil
pressure decrease is issued and the engine is stopped.
Increase in engine coolant temperature
When the engine coolant temperature increases to 105°C {221 °F} or higher, an alarm for engine coolant
temperature increase is issued and the engine is stopped.
Overrun
When the engine RPM reaches to the specified value, an alarm for overrun is issued and the engine is
stopped.
It varies depending on the actual unit manufacturer.
I/O Table

Sensor input Injection control output

• CKP sensor • Suction control valve
• CMP sensor • TWV (injector)
• Water temperature sensor
• Fuel temperature sensor Actuator control output
• IAT sensor
• IMT sensor • EGR DC motor
• Fuel pressure sensor • Intake throttle motor
• Boost temperature sensor
• Barometric pressure sensor Relay, lamp control output
• Accelerator position senser
• EGR position sensor • Glow relay
• Intake throttle position sensor • Starter cut relay
• DPD differential pressure sensor • ECM main relay
• Exhaust temperature sensor • Hour meter relay
(1: in front of filter, 2: in front of oxidation catalyst) • Diagnosis lamp
• Boost sensor • Glow lamp
• Oil pressure sensor ECM • Engine hydraulic lamp
• MAF sensor • Boost temperature sensor pilot
• Fuel sensor lamp
• Overheat lamp
• Engine overrun lamp
Switch input
• DPD regenerate lamp
• Starter switch (ON/start) • Fuel temperature lamp
• Diagmostic swich • Fuel filter pressure lamp
• Idling control selector switch • DPD lamp
• Idling control switch (UP/Down)
• Mode map switch 0
• Mode map switch 1
• Mode map switch 2 Communication
• Reguration mode switch
• Load advance switch • Speed signal
• SCV switch • Diagnostic scan tool
• Memory clear switch • CAN (ECU on machine side)
• Engine stop switch
• DPD switch

84402826 - May 2011

4001C-30
 Function, Structure, Operation

Electronic control fuel injection system

This is the system in which the ECM obtains information such as the engine RPM and engine load and
sends the electrical signals based on the information to the supply pump, injectors, etc.to properly control
the fuel injection amount and injection timing for each cylinder.
Injection amount control
To make the injection amount optimal, the fuel injection amount is controlled by regulating the injector
based on mainly the signals from the engine RPM and accelerator opening angle or the instructed rotation
from the control unit in the actual unit.

・Boost Press.
a ・Coolant Temp,
・Barometric Press.

Maximum Fuel Injection Fuel Injection Quantity Cor-

*1 Accelerator Pedal Position *4 *7
Quantity rection
Injector ON Time Determi-
*2 Engine Speed *5 Reduction Rate *8
nation
Cylinder by Cylinder Correc-
*3 Basic Fuel Injection Quantity *6 Final Fuel Injection Quantity *9
tion

84402826 - May 2011

4001C-31
 Function, Structure, Operation

Injection pressure control

The injection pressure is controlled by regulating the fuel pressure inside the common rail.
The proper pressure inside the common rail is controlled by calculating from the engine RPM, fuel injection
amount, etc., and the appropriate amount of the fuel is discharged by regulating the supply pump to be
force-fed to the common rail.
Injection timing control
This control is performed by calculating the proper fuel injection timing mainly from the engine RPM or
injection amount in substitution for the timer function to regulate the injector.
Injection rate control
To improve combustion inside the cylinder, only a small amount of the fuel is injected first to be ignited,
and then the second injection is performed when ignition is made.
This control for injection timing and injection amount is performed through regulating the injector.
Maximum fuel injection amount
The maximum fuel injection amount is the amount of fuel injection calculated by adjustment of initial in-
jection amount under certain water temperature, limitation of maximum injection amount for the boost
p ressure, and control of injection amount for the high altitude due to the atmospheric pressure.
Inter-cylinder correction
It is not used for this engine.
System schematic

Each sensor
a Accelerator, Boost, Water
temperature, etc.

*1 Electromagnetic pump *5 Fuel pressure sensor *9 CMP sensor

*2 Fuel filter *6 Common rail *10 CKP sensor
*3 Pre fuel filter *7 Pressure limiter *11 ECM
*4 Supply pump *8 Injctor *12 Fuel tank

84402826 - May 2011

4001C-32
 Function, Structure, Operation

Fuel system
The fuel is supplied to the supply pump from the fuel tank, and then it is boosted by the pump before
supplied to the common rail.
At this time, the fuel amount to be supplied to the common rail is controlled by regulating the suction
control valve based on the signal from the ECM.

1 Electromagnetic pump 4 Fuel injector 7 Fuel return pipe

2 Fuel filter 5 Supply pump 8 Pre-fuel filter
3 Common rail 6 Fuel tank

Fuel filter clog warning function and engine RPM restriction function
When the clogged fuel filter is kept used, the ECM detects DTC P0093, and the output restriction is im-
plemented.
The first stage
In order to notify a filter clogging before DTC P0093 is detected, the first stage alarm is issued when the
output value from the fuel filter pressure sensor falls below the specified threshold value.
The alarm stops when the output value exceeds the threshold value.
The second stage
The second stage alarm is issued when the output value from the fuel filter pressure sensor falls below
the threshold value even after the first stage alarm occurs.
The second stage alarm remains as issued until the starter switch is turned OFF.
At the same time as the second stage alarm is issued, the target engine RPM is reduced gradually at a
constant rate.
When the output value from the sensor exceeds the specified threshold value, reduction of the restricted
engine RPM is stopped, and the regulation is continued maintaining the restricted engine RPM at that
time.
When the output value from the sensor falls below the threshold value again, the restricted engine RPM
is reduced further.
When the starter switch is turned OFF and then turned back ON, the restriction is once cancelled.

84402826 - May 2011

4001C-33
Function, Structure, Operation

1 Supply pump
2 Warning light
3 Monitor
4 Monitor, CAN communication
5 Fuel tank
6 Pre-filter
7 Electromagnetic pump
8 Fuel filter pressure sensor
9 Main filter

1 First stage
2 Second stage

*1 Lamp
*2 Starter SW
*3 Engine Speed (r/min)
84402826 - May 2011
4001C-34
 Function, Structure, Operation

Removing air from fuel system

Place an appropriate pan under the air removal plug.
Turn the starter switch ON, and activate the electromagnetic pump.
Loose the air removal plug of the fuel filter sufficiently, and operate the priming pump 20 times or more
until the fuel comes out from near the plug.
Tighten the plug, and operate the priming pump 10 times or more until the fuel permeates.
Wait for approx.
1 minute, and then loosen the plug to remove the air in the fuel filter.
This should be repeated at least 3 times until no air comes out from the plug.
Securely tighten each plug, and wipe off the fuel spilled around.
Operate the priming pump 10 - 15 times until the fuel permeates and then is fed to the engine.

a On the machine with electro-

magnetic pump

*1 Pre fuel filter

*2 Electromagnetic pump
*3 Fuel filter
*4 Supply pump
*5 Fuel tank

84402826 - May 2011

4001C-35
 Function, Structure, Operation

EGR
The EGR system recirculates a part of the exhaust gas to the intake manifold, and by mixing in inert gas
to the intake air, the combustion temperature is lowered and the generation of NOx is suppressed.
The EGR amount is controlled by opening and closing the EGR valve provided between the exhaust
manifold and intake manifold.
The EGR amount is determined from the engine RPM and engine load ratio and the EGR valve is operated
to control the EGR amount.
By installing the EGR cooler on the path of the EGR gas, high-temperature gas is cooled by the EGR
cooler and then mixed with fresh air to further lower the burning temperature in order to reduce NOx
amount.
Further, the EGR system is also equipped with a check valve to prevent the EGR from flowing in the
opposite direction to increase the EGR amount.
EGR control
The ECM controls the EGR valve lift amount by operating the motor according to the engine status such
as the engine RPM and engine load.
The valve lift amount is detected by the EGR position sensor.
Darker portions in the diagram represent large valve lift amounts and the darkest portion represents the
lift amount of nearly 100 ％.

Accelerator position

Engine speed

*1 No idle EGR

84402826 - May 2011

4001C-36
 Function, Structure, Operation

EGR system schematic diagram

*1 Intake thottle position sensor *7 Engine speed *13 Exhaust

*2 EGR valve *8 Engine load *14 Intake throttle valve
*3 EGR position sensor *9 Outlet port of coolant *15 Boost temperature sensor
*4 ECM *10 Inlet port of coolant *16 Boost sensor
*5 IAT/MAF sensor *11 EGR cooler
*6 Intake air *12 IMT sensor

84402826 - May 2011

4001C-37
 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 using an appropriate silencer.
For some OEMs which 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 Wiht EGR

84402826 - May 2011

4001C-38
 Function, Structure, Operation

Turbocharger control
The turbocharger is a system that provides efficient supercharge to archive the turbo effect by overcoming
the turbo’s weakness of low exhaust energy during low engine revolution.
The turbocharger optimizes the turbine revolution by varying the nozzle opening angle within the turbine
housing to adjust the turbo inlet area according to the revolution and load of the engine and control the
supercharging pressure.
The ECM sends the target nozzle opening angle based on the information from each sensor to the turbo
control unit through CAN communication to control the boost pressure properly in accordance with the
engine load requirements.
The turbo control unit drives the turbo actuator based on the information received from the ECM and
controls the nozzle vane through the control rod.
The turbo actuator has a position sensor installed.
The turbo control unit performs feedback control based on the information from the position sensor, etc.
The actual nozzle opening angle is determined at this time, and the nozzle vane opening angle is optimally
adjusted through the nozzle control rod.

*1 Turbine wheel
*2 Nozzle
*3 Turbo actuator
*4 Exhaust gas inlet
*5 Control rod
*6 Exhaust gas outlet

*1 Engine control module (ECM) *5 CAN-H *9 Turbo motor

*2 ECM *6 CAN-L *10 Turbo position sensor
*3 POWER *7 Turbo control unit
*4 GND *8 Turbo actuator

84402826 - May 2011

4001C-39
 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 operates the nozzle control rod through the operation plate.

a The gap is narrow

b The gap is wide

*1 At low engine RPM *3 Nozzle vane *5 Turbo actuator

*25 At high engine RPM *4 Nozzle control rod *6 Unison ring

84402826 - May 2011

4001C-40
 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 in-
struction RPM instruction given through mode map switch control, RPM instruction and change instruc-
tion given by APS
Increase and decrease instruction for each rotation given by the 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.

H, S, L and B of the mode map switch change as follows depending on the APS input.

84402826 - May 2011

4001C-41
 Function, Structure, Operation

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.

84402826 - May 2011

4001C-42
 Function, Structure, Operation

CAN communication
When CAN controller does not exist on the actual unit side

*1 Diagnostic scan tool

*2 MCX
*3 ECM
*4 LCD
*5 TCM
*6 Shift Control

When CAN controller exists on the actual unit side

*1 Diagnostic scan tool

*2 MCX
*3 ECM
*4 TCM
*5 Shift Control

84402826 - May 2011

4001C-43
 Function, Structure, Operation

Mode map switch control

*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

Outer switch
Operation mode Control
MAP0 MAP1 MAP2
OFF OFF OFF
H OFF ON ON Basic operations
ON ON ON
S ON OFF OFF Maximum rotation count control #1
L OFF ON OFF Maximum rotation count control #2
I OFF OFF ON Constant rotation operation #1
B ON ON OFF Maximum rotation count control #3
LM ON OFF ON Constant rotation operation #2

84402826 - May 2011

4001C-44
 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

H, S, L, and B modes (irrigation pump)

*1 Idle speed
*2 Max. speed

84402826 - May 2011

4001C-45
 Function, Structure, Operation

Accelerator position switch

By operating the accelerator position switch, the output voltage changes between 1 V and 4 V.
Voltages between 0.2 V and 1.05 V are recognized as 1 V.
When the voltage is lowered below 0.2 V or raised above 1.05 V, an error is detected.
In addition, if the ECM terminals 85 and 86 are not at the same potential, DTC P2138 is detected.

Accelerator pedal position sen-

*1
sor

Accelerator position switch, with APS learning control If the APS learning control is available, for example,
when the ignition cycle ends with the accelerator position as 2 V (1), the accelerator position learning
causes the 2 V status to be recognized as the opening angle 0 ％ and the control range is set to 2 V to 4
V (2).

84402826 - May 2011

4001C-46
 Function, Structure, Operation

Regulation mode switch

When an input from the regulation mode switch is present, the engine RPM changes as follows.

*1 Regulation mode switch

Idling control
By operating the idling control change switch during the warm-up operation, the minimum idling RPM can
be adjusted.
In addition, by operating the idling control change switch, the minimum idling RPM can be automatically
set to the optimum value in accordance with the engine coolant temperature.
ANNOTATION:
• The specifications vary depending on the actual unit, so availability of functions also differ.
Idling control change switch
By operating the idling control change switch, the idling control functions can be switched.
The idling control switch
By operating idling control switch, the idling RPM can be adjusted.
ANNOTATION:
• As for the installation positions of the idling control change switch and idling control switch, refer to the
manual of the actual unit.
The engine RPM upper limit varies depending on the engine model, actual unit specifications and en-
gine warming-up condition.

84402826 - May 2011

4001C-47
 Function, Structure, Operation

Up
While the Up side of the switch is pressed, the engine RPM is increased and the idling RPM can be raised.
Down
While the Down side of the switches is pressed, the engine RPM is decreased and the idling RPM can
be lowered.
However, the engine RPM cannot be decreased below the minimum idling RPM.
Control during starter switch OFF state
There are 2 types of controls provided when the starter switch is turned OFF after the idling control switch
is operated, and either one of them is performed depending on the specification.
The engine RPM adjusted by the idling control switch is recorded in the ECM, and the next operation is
performed with the engine RPM at the time when the starter switch is turned OFF.
The engine RPM adjusted by the idling control switch is not recorded in the ECM, and the next operation
is performed with the default engine RPM.
As for confirmation and questions regarding the specifications, contact an Isuzu service related person.
Idle manual control

*1 Starter switch *3 Idle down switch

*2 Idle up switch *4 Engine speed

84402826 - May 2011

4001C-48
 Function, Structure, Operation

Engine RPM output to tachometer

The ECM outputs the engine rpm pulse to the tachometer as a tachometer output.
The tachometer displays the engine RPM based on the engine RPM pulse sent from the ECM.

a Output from machine control

unit by machine

*1 CKP sensor *4 CAN communication *7 Tachometer

*2 Engine speed *5 Control unit on machine side
*3 Engine control module (ECM) *6 Tachometor output

84402826 - May 2011

4001C-49
 Function, Structure, Operation

Preheat control
QOS system
The ECM determines the glow time according to the engine coolant temperature, and activates the glow
relay and the QOC indicator light..
The QOS system is a system to facilitate engine start in a low temperature as well as reducing the
amount of white smoke and noise generated immediately after engine start.
When the starter switch is turned ON, the ECM detects the temperature of the engine coolant based
on the signal sent from the water temperature sensor to change the glow time, so the engine can be
always started under the optimum conditions.
Also, the after-glow function can stabilize the idling immediately after engine start.

a LCD or Lamp

*1 Starter switch (ON) *4 QOS indicator lamp *7 Glow plug

*2 Battery *5 (ECM)
*3 Glow relay *6 Water temperature sensor

84402826 - May 2011

4001C-50
 Function, Structure, Operation

DPD
DPD uses the oxidation catalyst to clean NOx and HC, and uses a dedicated filter to collect PM emitted
from the engine.
When PM has accumulated on the filter, the filter regeneration is performed.
The ECM detects the accumulation status of PM from the DPD differential pressure sensor or mileage.
When the accumulated amount of PM or mileage has reached a certain value, automatic regeneration
of the filter is performed.
During regeneration, the filter is heated up to burn the accumulated PM.
To adjust the burning temperature to the optimum value, the ECM detects the exhaust temperature
using the the exhaust temperature sensor and control fuel injection to raise the temperature to burn the
accumulated PM.
When regeneration has started, it must complete within a certain period of time.
After regeneration has completed, the purification status of the filter can be determined by checking the
exhaust differential pressure.
When excessive amount of accumulated PM has been detected, regeneration is not performed because
burning cannot be controlled, but the check engine warning light is turned ON instead.

1 Engine 5 ECM 9 Oxidation catalyst

Exhaust gas temperature sen-
2 MAF sensor 6 DPD switch 10
sor
DPD differential pressure sen-
3 Air cleaner 7 Silencer 11
sor
4 Various sensors 8 Filter

84402826 - May 2011

4001C-51
 Function, Structure, Operation

ECM
About ECM function
The ECM constantly monitors the information sent from various sensors, and controls the each system
of the powertrain.
The ECM performs the diagnostic functions of the system, detects operational problems of the system,
warns the operator via the monitor, and records the DTC.
The DTC identifies the area where the problem has occurred to assist the repair operation performed
by the technician.
The ECM outputs voltages (e.g., 5 V) to supply power to various sensors and switches.
The ECM controls the output circuit by controlling the ground or power supply circuit via one of the
devices.
ANNOTATION:
• As for the ECM installation position, refer to the manual of the actual unit.

ECM and components

The ECM is designed to maintain regulation levels of exhaust gases while obtaining excellent fuel effi-
ciency.
The ECM monitors various engine functions via the sensors such as the crankshaft position sensor.
ECM voltage
The ECM applies the standard voltage to various switches and sensors.
The ECM is able to apply voltage in such a way because the ECM resistance value is very high.
The voltage that is actually applied to the circuit is low.
Therefore, the test light may not illuminate even if it is connected to the circuit.
The voltmeter that is normally used at maintenance factories may not display a correct reading because
its input impedance is too low.
An accurate voltage reading can be obtained by using a digital multimeter with an input impedance of
10MΩ (for example, 5-8840-2691-0).
Electrically Erasable Programmable Read Only Memory, EEPROM
EEPROM contains various programs and calibration information necessary for the ECM to control the
power train operations.
If abnormalities are found with the EEPROM, replace the ECM.
The program and calibration information for the ECM power train control includes the engine type, en-
gine number, ECM part number, DTC, inter-cylinder correction learning value, QR, Q tune, and EGR
correction learning value.
Notes on ECM maintenance
The ECM has been designed to withstand the regular current consumption associated with the actual
unit operation.
Make sure that the circuit does not overload.
When performing tests for an open circuit or short circuit, do not ground or apply voltage to the circuit
of the ECM, unless otherwise instructed.
When performing these circuit tests, make sure to use the digital multimeter 5-8840-2691-0.
ANNOTATION:
• Use the ECM which has the part No. corresponding to the actual unit.
When performing welding work on the actual unit, start the work after disconnecting the negative
terminal of the battery.

84402826 - May 2011

4001C-52
 Function, Structure, Operation

Turning OFF of the ECM power supply

In approximately 10 seconds after turning the starter switch to OFF, the internal power supply of the ECM
is not turned to OFF.
When it is necessary to turn OFF the ECM power supply, e.g., when clearing the memory, it is required
to wait for 10 seconds or longer after turning the starter switch OFF.

*1 Starter switch ON
*2 Starter switch OFF

84402826 - May 2011

4001C-53
 Function, Structure, Operation

Engine components location diagram

Locations, shapes and existence or nonexistence of components vary depending on the specifications of
the actual unit.

1 Overheat switch 6 IMT sensor 11 Fuel pressure sensor

2 Water temperature sensor 7 Boost temperature sensor 12 EGR valve
3 Glow plug 8 Fuel temperature sensor 13 CMP sensor
4 Injector 9 Suction control valve 14 Oil level switch
5 Boost sensor 10 Oil pressure sensor 15 CKP sensor

84402826 - May 2011

4001C-54
 Function, Structure, Operation

Supply pump
The supply pump highly pressurizes the fuel using the engine torque, and force-feeds the fuel to the
common rail.
Also, the suction control valve, fuel temperature sensor, feed pump, etc, are installed on the supply pump.

1 Suction control valve

2 Fuel temperature sensor
3 Feed pump

84402826 - May 2011

4001C-55
 Function, Structure, Operation

Suction control valve

The suction control valve is installed on the supply pump portion, and controls the fuel force-feed to the
common rail.
The ECM controls the fuel discharge amount by regulating the energizing time to the suction control valve.

1 Suction control valve

84402826 - May 2011

4001C-56
 Function, Structure, Operation

Fuel temperature sensor

The fuel temperature sensor is installed on the supply pump, and the thermistor changes the resistance
value according to the temperature change.
The resistance value becomes lower when the fuel temperature is high, and it becomes higher when the
fuel temperature is low.
The ECM applies 5 V to the fuel temperature sensor through the pull-up resistor, and it calculates the fuel
temperature from changes in the voltage and uses it for controlling the supply pump, etc.
The voltage becomes lower when the resistance is lower, and it becomes higher when the resistance is
higher.
ANNOTATION:
• Do not replace the fuel temperature sensor.
When an abnormality is found, replace the supply pump assembly.

Common rail
The common rail receives the fuel from the supply pump, retains the fuel pressure and distributes the fuel
to each cylinder.
The fuel pressure sensor and the pressure limiter are installed on the common rail.

1 Pressure limiter
2 Fuel pressure sensor
3 Common rail

84402826 - May 2011

4001C-57
 Function, Structure, Operation

Pressure limiter
The pressure limiter is activated when the pressure in the common rail becomes abnormally high to re-
lease the pressure inside the common rail.

1 Pressure limiter

Fuel pressure sensor

The fuel pressure sensor is installed on the common rail, and detects the fuel pressure inside the common
rail to convert into the voltage signal and sends it to the ECM.
The voltage becomes higher when the pressure is higher, and it becomes lower when the pressure is
lower.
The ECM calculates the actual fuel pressure from the voltage signal sent from the sensor, and uses it to
control the fuel injection, etc.

1 Fuel pressure sensor

Injector
The injector is installed on the cylinder head portion, and is controlled by the ECM to perform fuel injection.
The ECM internally boosts the voltage for driving the injector to apply it to the injector, and uses it for fuel
injection amount control and injection timing control by regulating the energizing time of the injector.

84402826 - May 2011

4001C-58
 Function, Structure, Operation

Water temperature sensor

Water temperature sensor is installed on the engine block, and the thermistor changes the resistance
value according to the temperature change.
The resistance value becomes smaller when the engine coolant temperature is high, and the value be-
comes larger when the engine coolant temperature is low.
The ECM applies 5 V to the water temperature sensor through the pull-up resistor, and calculates the
engine coolant temperature from changes in the voltage.
This value is used in various control mechanisms, such as for fuel injection control.
The voltage becomes higher when the resistance is higher, and it becomes lower when the resistance is
lower.

Overheat switch
The overheat switch is installed on the water outlet pipe, and is turned ON when the engine coolant
temperature exceeds 105°C {221 °F}.

84402826 - May 2011

4001C-59
 Function, Structure, Operation

Crankshaft position sensor

The crankshaft position sensor is installed on the flywheel housing and the CKP signal is generated every
time when the protruding section of the flywheel passes the sensor.
The ECM determines the cylinder and specifies the crank angle using the CMP signal input from the
camshaft position sensor, and uses the information for the fuel injection control and calculation of the
engine RPM.
While this control is usually performed using the CKP signal, the CMP signal is used instead when the
crankshaft position sensor is faulty.

Camshaft position sensor

The camshaft position sensor is installed behind the cylinder head, and generates a CMP signal when
the camshaft cam passes by it.
The ECM determines the cylinder and specifies the crank angle using the CMP signal input from the
camshaft position sensor, and uses the information for the fuel injection control and calculation of the
engine RPM.
While this control is usually performed using the CKP signal, the CMP signal is used instead when the
crankshaft position sensor is faulty.

1 Camshaft gear
2 Rotational direction
3 CMP sensor

84402826 - May 2011

4001C-60
 Function, Structure, Operation

Oil pressure sensor

The oil pressure sensor is installed near the starter motor of the cylinder block, and it detects the pressure
of the engine oil to convert into the voltage signal and send it to the ECM.
The voltage becomes higher when the pressure is higher, and it becomes lower when the pressure is
lower.

Accelerator position sensor

The accelerator position sensor is installed on the console panel of the actual unit to supply the voltage
signal which varies in accordance with the accelerator volume angle to the ECM.
The ECM calculates the accelerator pedal position from the voltage signal, and uses it for fuel injection
control and many other controls.
ANNOTATION:
• As for the installation position of the accelerator position sensor, refer to the manual of the actual unit.
Atmospheric pressure sensor
The atmospheric pressure sensor is installed on the actual unit side, and it replaces the atmospheric
pressure with the voltage signal.
The ECM calculates the atmospheric pressure from the voltage signal, and uses the atmospheric pres-
sure to correct the fuel injection amount.
ANNOTATION:
• As for the installation position of the atmospheric pressure sensor, refer to the manual of the actual unit.

84402826 - May 2011

4001C-61
 Function, Structure, Operation

EGR position sensor

This sensor is installed inside the EGR valve to detect the EGR valve lift amount.
ANNOTATION:
• Do not disassemble the EGR position sensor.
When an abnormality is found, replace the EGR valve assembly.

Boost sensor
The boost sensor detects the boost using the pressure hose between the boost sensor and intake pipe
to convert into the voltage signal and sends it to the ECM.
The voltage becomes higher when the pressure is higher, and it becomes lower when the pressure is
lower.
The ECM calculates the boost from the voltage signal sent from the sensor, and uses it to control the fuel
injection, etc.

84402826 - May 2011

4001C-62
 Function, Structure, Operation

The boost temperature sensor

The boost temperature sensor is installed to the EGR valve upstream side of the intake manifold.
The sensor is the thermistor type, and the resistance value inside the sensor changes in accordance with
the change in the temperature.

Fuel filter pressure sensor

The fuel filter pressure sensor is installed on the fuel filter, and converts the negative pressure in the fuel
filter into the voltage signal.
The ECM calculates the negative pressure in the fuel filter based on the voltage signal to determine clog-
ging in the fuel filter.

84402826 - May 2011

4001C-63
 Function, Structure, Operation

Intake air temparture and mass air flow sensors

Intake air temperature sensor
The intake air temperature sensor is installed on the duct between the air cleaner and turbocharger.
The intake air temperature sensor is variable resistance inside the mass air flow sensor to measure the
temperature of air taken into the engine.
When the intake air temparture sensor is cold, the resistance of the sensor is high.
When the air temperature rises, the resistance of the sensor becomes low.
For high sensor resistance, the ECM detects a high voltage of the signal circuit.
For low sensor resistance, the ECM detects a low voltage of the signal circuit.
Mass air flow sensor
The mass air flow sensor measures the amount of air taken into the engine, and it is installed on the duct
between the air cleaner and turbocharger.
The mass air flow sensor consists of the mass air flow sensor and intake air temperature sensor to mea-
sure some of air flowing in the duct.
A small amount of air taken into the engine indicates deceleration or idle RPM.
A large amount of air indicates acceleration or high load.

Intake throttle valve

The intake throttle valve is installed on the inlet of the inlet manifold.
The ECM controls the opening angle of the intake throttle valve according to the condition of engine
operation.
The motor inside the intake throttle valve is controlled based on the duty ratio signals sent from the ECM.
The opening angle of the intake throttle valve is adjusted when the duty ratio is changing from 0 ％ to the
appropriate ratio.
The valve closes when the du％ty signal increases, and the valve opens when the duty signal decreases.
The opening angle of the intake throttle valve is detected by the position sensor.
The position sensor outputs the signal representing the intake throttle valve opening angle.
The ECM detects a low signal voltage when the opening angle is small or the valve is at the closed
position.
Also, the ECM detects a high signal voltage when the opening angle is large.

84402826 - May 2011

4001C-64
 Function, Structure, Operation

DPD differential pressure sensor

The DPD differential pressure sensor is installed near DPD.
DPD differential pressure sensor varies the signal voltage according to changes of the exhaust gas dif-
ferential pressure between in front and rear of DPD filter.
The ECM detects a lower signal voltage when the differential pressure is small due to a small amount of
accumulated PM.
The ECM detects a higher signal voltage when the differential pressure is large due to a large amount of
accumulated PM.
The ECM uses this voltage signal for controlling DPD regeneration and determining purification after re-
generation.
It also uses the signal voltage to detect filter failures such as a too low differential pressure.

Exhaust gas temperature sensor

The exhaust gas temperature sensors are the variable resistors that are installed at 2 locations on the
DPD housing, and one is installed in front of the DPD oxidation catalyst, and the other is installed in front
of the filter.
The exhaust gas temperature sensor 1 that is located in front of the filter measures the temperature of the
exhaust gas before entering the DPD filter, and the exhaust gas temperature sensor 2 that is located in
front of the oxidation catalyst measures the temperature of the exhaust gas before entering the oxidation
catalyst.
When the exhaust gas temperature sensor is cold, the resistance of the sensor is high.
When the exhaust temperature rises, the resistance of the sensor decreases.
The ECM detects a high voltage in the signal circuit when the sensor resistance is high.
Also, the ECM detects a low voltage in the signal circuit when the sensor resistance is low.
The ECM uses this voltage signal for temperature control during the DPD regeneration.

84402826 - May 2011

4001C-65
 Function, Structure, Operation

IMT sensor
The IMT sensor is a variable resistance installed on the intake manifold to measure the intake temperature
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.

Turbo actuator
The turbo actuator is installed on the turbocharger.
The ECM communicates with the turbo control unit based on the engine load, etc., and the turbo control
unit controls the turbo actuator.
The nozzle control of the turbocharger is activated by the operation of the motor built into to the turbo
actuator to control the variable nozzle.
The ECM performs control that changes the boost pressure by adjusting the variable nozzle opening
angle in accordance with the load requirement for the engine.

*1 Turbine wheel
*2 Nozzle
*3 Turbo actuator
*4 Exhasut gas inlet
*5 Control rod
*6 Exhasut gas outlet

84402826 - May 2011

4001C-66
 Function, Structure, Operation

Turbo control unit

The turbo control unit is installed on the actual unit.
The ECM communicates with the turbo control unit based on the engine load, etc., and the turbo control
unit performs control by operating the motor built into the the turbo actuator.
Also, it receives the signal from the position sensor built into the turbo actuator, and provides the ECM
with feedback on the turbocharger operation amount through communication with the ECM.

*1 Connector lock position

Monitor
By turning ON the diagnostic switch, the DTC is indicated by blinking.
ANNOTATION:
• As for the installation position of the monitor, refer to the manual of the actual unit.
DLC
DLC is the connector for communication and connection between the trouble diagnosis scanning tool and
various controllers.
ANNOTATION:
• As for the DLC installation position, refer to the manual of the actual unit.

84402826 - May 2011

4001C-67
 Function, Structure, Operation

Diagnostic switch
The diagnostic switch shorts the DLC terminal No.1 and No.4 or No.5 and flashes the monitor to indicate
the DTC.
ANNOTATION:
• As for the installation position and shape of the diagnostic switch, refer to the manual of the actual unit.
Memory clear switch
This is used when clearing the recorded DTCs in the ECM by operating the diagnostic switch and the
memory clear switch.
ANNOTATION:
• As for the installation position of the memory clear switch, refer to the manual of the actual unit.
Mode change switch (0, 1, 2)
The operation can be performed at the engine RPM specified for each mode by switching the mode
change switch.
ANNOTATION:
• As for the installation position of the mode change switch, refer to the manual of the actual unit.

1 Starter switch
2 Engine stop switch
3 Fuel meter
4 Memory clear switch
5 Mode switch
6 Water temperature gauge
7 Oil temperature gauge
8 Hour meter

84402826 - May 2011

4001C-68
 Function, Structure, Operation

ECM power distribution diagram

Some sensors may not be connected to the ECM depending on the specifications of the actual unit.
Since some sensors may perform input/output with the ECM depending on the CAN communication, con-
firm the specifications of the actual unit.

84402826 - May 2011

4001C-69
Function, Structure, Operation

84402826 - May 2011

4001C-70
 Function, Structure, Operation

Accelerator pedal position sen-

*1 *18 Memory clear switch *35 Power ground
sor
*2 BARO sensor *19 diagnosis switch *36 Power ground
DPD differential pressure sen-
*3 *20 MAF sensor *37 Power ground
sor
*4 fuel filter pressure sensor *21 IAT sensor *38 Power ground
Exhaust temperature sensor 1
*5 *22 CKP sensor *39 diagnosis lamp
(in front of filter)
*6 Exhaust temperature sensor 2 *23 Fuel pressure sensor *40 Oil pressure lamp
*7 Engine stop switch *24 Starter switch (ON) *41 Glow plug lamp
*8 Idling selector switch *25 Starter switch (START) *42 Boost temperature lamp
*9 Idle up switch *26 Main relay *43 Over heat lamp
*10 Idle down switch *27 Starter switch *44 Engine over run lamp
*11 Mode map switch 0 *28 Battery *45 DPD regemerate lamp
*12 Mode map switch 1 *29 Dropping resistor *46 Fuel temperature lamp
*13 Mode map switch 2 *30 Case ground *47 Fuel filter pressure lamp
*14 Reguration mode switch *31 Signal ground *48 DPD lamp
*15 Load advance switch *32 Signal ground *49 Glow relay
*16 DPD regeneration switch *33 Power ground *50 Glow plug
*17 SCV switch *34 Power ground *51 ECM

84402826 - May 2011

4001C-71
Function, Structure, Operation

84402826 - May 2011

4001C-72
 Function, Structure, Operation

*1 Boost sensor *10 Starter cut relay *19 Intake thrttle motor
*2 EGR position sensor *11 Hour meter relay *20 Fuel injector 1 (Cylinder #1)
*3 Intake throttle position sensor *12 Starter *21 Fuel injector 1 (Cylinder #3)
*4 Fuel temperature sensor *13 Tacho meter *22 Fuel injector 1 (Cylinder #2)
*5 CMP sensor *14 TOOL *23 Fuel injector 1 (Cylinder #5)
*6 Boost temperature sensor *15 OEM unit *24 Fuel injector 1 (Cylinder #6)
*7 Oil pressure sensor *16 Terminator *25 Fuel injector 1 (Cylinder #4)
*8 Water temperature sensor *17 Turbo unit *26 Suction control valve
*9 IMT sensor *18 EGR DC motor *27 ECM

84402826 - May 2011

4001C-73
 Function, Structure, Operation

ECM pin assignment

60 pin connector

Pin No. Pin name Connection

1 OP-COM1A Injector power supply 1, First cylinder
2 OP-COM1B Injector power supply 1, Fourth cylinder
3 - -
4 - -
5 OM-EBM3 EGR valve DC servomotor power input W
6 SP-5V4 Boost sensor power supply
7 SP-5V8 -
8 IA-MAT IMT sensor signal
9 IA-THL Fuel temperature sensor signal
10 IA-THBST Boost temperature sensor signal
11 IA-PFUEL Fuel pressure sensor signal
12 IA-OILPRESS Oil pressure sensor signal
13 IA-MAP Boost sensor signal
14 IA-IDMPOS Intake throttle position sensor signal
15 OP-SCVHI SCV-HI drive
16 OP-COM2A Injector power supply 2, Third cylinder
17 OP-COM2B Injector power supply 2, Second cylinder
18 - -
19 - -
20 OM-EBM2 EGR valve DC servomotor power input V
21 SP-5V5 Crankshaft position sensor, fuel pressure sensor power supply
22 SP-5V6 Camshaft position sensor power supply
23 SP-5V7 Oil pressure sensor power supply
24 - -
25 IA-THW Water temperature sensor signal
Boost sensor, EGR position sensor, intake throttle position sensor, fuel temperature sensor
26 SG-5VRT4
GND

84402826 - May 2011

4001C-74
 Function, Structure, Operation

Pin No. Pin name Connection

27 - -
28 SG-SLD5 Crankshaft position sensor shield
29 IA-OPLO -
30 OP-SCVHI SCV-HI drive
31 OS-INJ1 Injector 1, First cylinder
32 - -
33 OS-INJ4 Injector 4, Second cylinder
34 - -
35 OM-EBM1 EGR valve DC servomotor power input U
36 - -
37 - -
38 - -
39 - -
40 SG-5VRT7 Oil pressure sensor, water temperature sensor GND
41 SG-5VRT5 Intake air temperature sensor, crankshaft position sensor, fuel pressure sensor GND
42 SG-5VRT6 Camshaft position sensor, boost temperature sensor GND
43 SG-SLD6 Camshaft position sensor GND
44 - -
45 IA-SCVLO SCV-LO drive
46 OS-INJ3 Injector 3, Fourth cylinder
47 - -
48 OS-INJ2 Injector 2, Third cylinder
49 OM-IDM1 Intake throttle motor, +
50 OM-IDM2 Intake throttle motor, -
51 - -
52 IS-EBMPOS1 EGR position sensor signal U
53 IS-EBMPOS2 EGR position sensor signal V
54 IS-EBMPOS3 EGR position sensor signal W
55 SG-5VRT8 IMT sensor GND
56 IF-CAM Camshaft position sensor signal
57 IF-CRANK Crankshaft position sensor signal
58 SG-SLD8 Fuel pressure sensor shield
59 - -
60 IA-SCVLO SCV-LO drive

84402826 - May 2011

4001C-75
 Function, Structure, Operation

94 pin connector

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
66 PG-POWER GND
67 PS-+B Power supply
68 SP-5V1 Accelerator position sensor power supply
69 SP-5V2 Atmospheric pressure sensor power supply
70 SP-5V3 DPD differential pressure sensor, fuel filter pressure sensor power supply
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 Intake air temperature sensor signal
82 IA-MAF Mass air flow sensor signal
83 IA-FIPRESS Fuel filter pressure sensor signal
84 IA-EXHP DPD differential pressure sensor signal
85 IA-ACCEL1 Accelerator pedal position sensor 1 signal
86 IA-ACCEL2 Accelerator pedal position sensor 2 signal
87 IA-BARO Atmospheric pressure sensor signal
88 CC-ISOCAN-L ISO CAN-Low
89 PS-+B Power supply
90 SG-5VRT1 Accelerator position sensor GND
91 - -
92 - -
93 - -
94 - -
(CC- -
95
BOOTTX)
96 (MOD1) -
97 PG-SIGN GND
98 - -
99 IS-SCVSW SCV switch signal
100 IS-START Starter switch start signal
101 IS-LOAD Load advance switch signal
102 IS-REG Regulation mode switch signal
103 IS-SWLO1 -
104 IS-IDLMNL Idling control change selector 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 supply
DPD differential pressure sensor, fuel filter pressure sensor, exhaust gas temperature sen-
112 SG-5VRT3
sor 1, exhaust gas temperature sensor 2 GND

84402826 - May 2011

4001C-76
 Function, Structure, Operation

Pin No. Pin name Connection

113 SG-12VRT Mass air flow sensor GND
114 OS-MAINR ECM main relay
115 SG-SLD1 Accelerator position sensor shield
116 - -
117 SP-12V Mass air flow sensor power supply
118 - -
119 PG-SIGN GND
120 - -
121 IS-ENGSTP Engine stop switch signal
122 IS-DPDREG DPD switch
123 OS-OVRL Engine overrun light
124 OS-OILPL Engine oil pressure light
125 OS-BOOSTL Boost temperature sensor pilot light
126 OS-OVHL Overheat light
127 OS-OPL1 -
128 OF-TACHO Tachometer
129 OS-DPDREG DPD regeneration light
130 OS-DIAGL Diagnosis light
131 OS-EGRTL -
132 CC-CAN-L CAN-Low
133 PS-+B Power supply
134 IS-IGKEY Starter switch ON signal
135 SG-5VRT2 Atmospheric 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 rne白r relay
151
152 OS-STARTR Starter cut relay
153 OS-GLOWR glow relay
154 CC-CAN-H CAN-High

84402826 - May 2011

4001C-77
Function, Structure, Operation

84402826 - May 2011

4001C-78
Section

4001E

Symptom

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Frequent DPD regeneration by manual regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Long DPD regeneration time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine start failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine stalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Engine hunting, rough idling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Excessive white smoke in the exhaust gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Excessive black smoke in the exhaust gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Abnormal noise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Large fuel consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Large oil consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Insufficient engine output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

4001E-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
4001E-2 PRINTED IN FRANCE
 Symptom

Frequent DPD regeneration by manual regeneration

1. DPD system manual regeneration frequently Description of Symptom
The manual regeneration is frequently requested by blinking the DPD manual regeneration lamp or indicating
Press DPD switch.
Or, it is requested more frequently than before.
{Automatic regeneration cannot be performed frequently}
ANNOTATION:
• Depending on the manufacturer of the actual unit, the indication may not be shown.
2. DPD system manual regeneration frequently Diagnostics
• Preliminary inspection
Inspect the fuel quality.
Inspect the engine oil level and quality.
Inspect whether the hourmeter operates correctly.
If excessive amount of black smoke is observed, inspect the black smoke.
Inspect the inside of the DPD filter for excessive ash deposits.
Check the scan tool data list.
Check the service technical report.
Confirm the ECM carry part number.
Check the operator's operating habits and conditions.
Recommend the owner to voluntarily carry out regeneration as necessary.
Check whether the idling time is too long under the normal operation conditions.
Check whether operation is frequently performed at low speed under the normal operation conditions.
Check whether long downhill driving is performed under the normal operation conditions.
Check whether the idling time is too long in DPD regeneration.
Check whether operation is frequently performed at low speed in DPD regeneration.
Check whether PTO is activated frequently and for long period of time in DPD regeneration.
Check whether the engine operating time is short in DPD regeneration.
Check whether accelerator is switched frequently between ON and OFF in DPD regeneration.
• Inspection of the sensor
Inspect the hose and pipe of the DPD differential pressure sensor for incorrect piping or if they came off.
{The hose of the DPD differential pressure sensor has a specified installation direction}
• Inspect the hose and pipe of the DPD differential pressure sensor for clogging, collapsing, or twisting.
Inspect the DPD differential pressure sensor for incorrect installation.
Inspect the DPD differential pressure sensor for damage.
Inspect the DPD differential pressure sensor for contamination and foreign materials which interfere with its
inlet.
Check the DPD differential pressure sensor for abnormalities and operation delay with the scan tool data display
exhaust differential pressure.
Check the exhaust temperature sensor at various temperatures, and inspect for the possibility of sensor ab-
normalities.
Check the mass air flow sensor for abnormalities and operation delay with the scan tool data display MAF.
Check the boost pressure and atmospheric pressure when the starter switch is ON and the engine is not started.
It is normal if both data displays are within 7.0kPa {0.07 kgf/cm2 / 1.0 psi}.
• Inspection of the air intake system
Inspect the air cleaner and air intake duct for clogging, holes, and leakage.
Inspect whether a condition exists where the flow in the turbocharger inlet duct is restricted.
Inspect the intake throttle valve for anchoring.
Inspect the inside of the intake manifold for clogging or air leaks.
Inspect the air intake system for modification.
Inspect the mass air flow sensor for contamination and damage.
Inspect the turbocharger turbine wheel, shaft, or compressor wheel for wear and damage.
• Inspection of the exhaust system
Inspect for any condition that restricts the flow of the exhaust system.
Inspect for absence or damage of the exhaust system gasket.
Inspect for exhaust gas leakage from the exhaust pipe, gasket, DPD, exhaust temperature sensor, and DPD
differential pressure sensor's hose and pipe.
Inspect the exhaust system for modification.
Inspect the inside of the DPD filter for excessive ash deposits.
Inspect the DPD filter for damages, cracks, melt and excessive deposits.
Inspect the oxidation catalyst for damages, cracks, melt and excessive deposits.
If any excessive white smoke is observed in the regeneration process, the oxidation catalyst may be deterio-
rated or damaged.
84402826 - May 2011
4001E-3
 Symptom

Long DPD regeneration time

1. DPD system regeneration long time Description of Symptom
The regeneration requires more time than expected.
Or, it takes longer than before.
2. DPD system regeneration long time Diagnostics
• Preliminary inspection
Inspect the fuel quality.
Check the scan tool data list.
Check the service technical report.
Check whether DPD regeneration and engine warm up control are mixed up.
Check the operator's operating habits and conditions.
Check whether the manual regeneration is started when the engine is cold in DPD regeneration.
Check whether the idling time is too long in DPD regeneration.
Check whether operation is frequently performed at low speed in DPD regeneration.
Check whether the engine operating time is short in DPD regeneration.
Check whether accelerator is switched frequently between ON and OFF in DPD regeneration.
Check whether the temperature in the work environment is excessively high in DPD regeneration.
• Inspection of the sensor
Inspect the hose and pipe of the DPD differential pressure sensor for incorrect piping or if they came off.
{The hose of the DPD differential pressure sensor has a specified installation direction}
Inspect the hose and pipe of the DPD differential pressure sensor for clogging, collapsing, or twisting.
Inspect the DPD differential pressure sensor for incorrect installation.
Inspect the DPD differential pressure sensor for damage.
Inspect the DPD differential pressure sensor for contamination and foreign materials which interfere with its
inlet.
Check the DPD differential pressure sensor for abnormalities and operation delay with the scan tool data display
exhaust differential pressure.
Check the exhaust gas temperature sensor at various temperatures, and inspect for the possibility of sensor
abnormalities.
• Inspection of the cooling system
Inspect the engine coolant level.
Inspect the engine coolant leakage.
Inspect the cooling fan belt slip.
Inspect the operation of the cooling fan clutch.
Inspect the operation of the thermostat.
Inspect the operation of the water pump.
Inspect the radiator for clogging.
Inspect whether the cooling amount of the cooling system is not low due to modification.
• Inspection of the air intake system
Inspect the air cleaner, air intake duct, and intercooler for clogging, holes, or leakage.
Inspect whether a condition exists where the flow in the turbocharger inlet duct is restricted.
Inspect the intake throttle valve for anchoring.
Inspect the inside of the intake manifold for clogging or air leaks.
Inspect the air intake system for modification.
Inspect the mass air flow sensor for contamination and damage.
Inspect the turbocharger turbine wheel, shaft, or compressor wheel for wear and damage.
• Inspection of the exhaust system
Inspect for any condition that restricts the flow of the exhaust system.
Inspect for absence or damage of the exhaust system gasket.
Inspect for exhaust gas leakage from the exhaust pipe, gasket, DPD, exhaust gas temperature sensor, and
DPD differential pressure sensor's hose and pipe.
Inspect the exhaust system for modification.
Inspect the inside of the DPD filter for excessive ash deposits.
Inspect the DPD filter for damages, cracks, melt and excessive deposits.
Inspect the oxidation catalyst for damages, cracks, melt and excessive deposits.
If any excessive white smoke is observed in the regeneration process, the oxidation catalyst may be deterio-
rated or damaged.
• Other inspections
Inspect for possible factors of overheat.

84402826 - May 2011

4001E-4
 Symptom

Engine start failure

1. Engine start failure Description of Symptom
The cranking revolution is low.
The cranking revolution is normal, but the engine does not start.
The engine starts but cannot maintain its revolution stably or does not reach normal revolution speeds.
2. Engine start failure Diagnostics
• Preliminary inspection
Before using this section, perform the functional inspection and OBD system check to check all of the following.
Check whether the actual unit has a significant load.
The ECM and monitor are operating correctly.
DTC check.
The scan tool data is within the normal operating range.
Check the condition of the actual unit, and locate the appropriate symptom.
Check with the customers whether they are using the specified engine oil and fuel.
• Visual inspection
Careful visual inspection is required for several symptom procedures.
This can lead to fixing a problem without further inspections, and can save valuable time.
The inspection includes the following.
Whether there is grime or clogging of the fuel filter.
Whether there is an improper connection of connectors.
Particularly for the crankshaft position sensor and camshaft position sensor.
Whether the battery terminal voltage has dropped.
Proper wiring connections, tightening, and disconnection
Whether the power of any commercial accessories is being taken divergingly from the ECM power.
Whether the ECM ground is free of dirt, etc. and securely installed in the correct location Proper connections,
cracks, and twists in the pipes and hoses related to fuel, air, and oil.
Extensively check for any leaks or blockage.
Whether the layout of the fuel filter, pre-filter, and electromagnetic pump has a structure in which air accumu-
lates easily.
Check whether they are arranged to prevent air accumulation as Isuzu genuine pre-filters do not have any
plugs for air removal.
Also check whether the inlet and outlet of the electromagnetic pump have an appropriate layout.
Fix layouts which have the electromagnetic pump inlet on the upper side or have an outlet toward the motion
direction of the actual unit.
Whether there are any fuel leaks, pipe damage, or dents in the fuel system.
Abnormalities of the air intake system parts
Abnormalities of the exhaust system parts

84402826 - May 2011

4001E-5
 Symptom

*1 Pre fuel filter

*2 Electromagnetic pump
*3 Fuel filter

• Diagnostic aids
Fuel system abnormalities such as fuel running out, fuel freezing, mixture of air into the fuel piping, filter abnor-
malities, piping abnormalities, fuel quality, fuel tank, etc.
Air intake system abnormalities such as filter clogging, air intake piping abnormalities, etc.
Use of low-viscosity fuel such as kerosene causes wear on the supply pump plunger and may result in the
discharge abnormalities and cause start failure.
In such cases, replacement of the supply pump is required.
When a start failure has occurred, check with the customer about the fuel used.
If low-viscosity fuel such as kerosene has been used, instruct the customer not to use low-viscosity fuel because
the malfunction recurs even after replacing the supply pump.
A mixed oil biofuel containing long-term storage fuel and organic substances is easily oxidizable.
An oxidized fuel causes wear on the camshaft related parts in the supply pump and may result in start failure
due to discharge abnormalities.
In such cases, replacement of the supply pump is required.
Since the replacement of the supply pump due to the use of mixed oil biofuel containing long-term storage
fuel and organic substances is at the customer’s expense, instruct the customer not to use mixed oil biofuel
containing long-term storage fuel and organic substances.
When using fuel with a high water content, add the larger sedimenter to the pre-fuel filter to prevent water from
entering into the fuel system.
Abnormalities of the supply pump, non-pressure fuel supply
The ECM determination of the supply pump non-pressure fuel supply DTC will not be detected unless a con-
dition continues for 3 seconds or more in which the engine revolution speed is 900 r/min and the absolute
pressure is below 15 MPa {153 kgf/cm2 / 2175 psi}.
Therefore, the DTC will not be detected when the engine does not start with non-pressure fuel supply due to
the supply pump abnormalities.
ANNOTATION:
• Since the crankshaft position sensor abnormalities will not be diagnosed unless cranking is performed 14
revolutions or more, crank for more than 14 seconds at 60 r/min or more.
84402826 - May 2011
4001E-6
 Symptom

For crankshaft position sensor errors at low engine revolution speed, the crankshaft position sensor DTC
may not be detected.
For intermittent failure, increase the engine revolution speed to No Load Max and check if the crankshaft
position sensor related DTC is detected.

Engine speed (r/min)

P0093 Judgment required en-

*1
gine speed
*2 Minimum fining engine speed
System realization engine
*3
speed

Absolute pressure

Engine speed (r/min)

*1 Non-criteria range
*2 P0093 Criteria range
*3 Range in P0093 is established

Abnormalities of the common rail such as the flow damper, operation of the pressure limiter, or inside sealing
degradation Abnormalities of the injector, no fuel injection
System down due to failure Engine body abnormalities such as seizure, insufficient compression pressure, and
other mechanical failures, etc.
ACG failure Failure related to the actual unit equipment such as the oil pressure pump, etc.
Effect of the post-installed accessories such as wireless devices and lights, etc.
ECM failure Inspect the connector for connection failures and the harness for abnormalities such as abrasions,
bending, etc.
Inspect to see if the wires inside the harness are separate and have not caused a short circuit with other circuits.
Perform inspections for functional diagnosis, and confirm the operation, control of each part, etc.
84402826 - May 2011
4001E-7
 Symptom

Repair if abnormalities are found.

84402826 - May 2011

4001E-8
 Symptom

Engine stalling
1. Engine stalling Description of Symptom
Engine cranks but takes a long time to start.
The engine ultimately operates, or starts but stops soon.
2. Engine stalling Diagnostics
• Preliminary inspection
Before using this section, perform the functional inspection and OBD system check to check all of the following.
Check whether the actual unit has a significant load.
The ECM and monitor are operating correctly.
Since the crankshaft position sensor abnormalities will not be diagnosed with cranking less than 14 revolutions,
crank for more than 14 seconds at 60 r/min or more.
DTC check.
For crankshaft position sensor errors at low engine revolution speed, the crankshaft position sensor DTC may
not be detected.
For intermittent failure, increase the engine revolution speed to No Load Max and check if the crankshaft po-
sition sensor related DTC is detected.
The scan tool data is within the normal operating range.
Check the condition of the actual unit, and locate the appropriate symptom.
Check with the customers whether they are using the specified engine oil and fuel.
Check whether fuel is contained.
• Visual inspection
Careful visual inspection is required for several symptom procedures.
This can lead to fixing a problem without further inspections, and can save valuable time.
The inspection includes the following.
Whether there is an improper connection of connectors.
Particularly for the crankshaft position sensor and camshaft position sensor.
Proper wiring connections, tightening, and disconnection
Whether the power of any commercial accessories is being taken divergingly from the ECM power.
Whether the ECM ground is free of dirt, etc. and securely installed in the correct location.
Proper connections, cracks, and twists in the pipes and hoses related to fuel, air, and oil.
Extensively check for any leaks or blockage.
Whether there are any fuel leaks, pipe damage, or dents in the fuel system.
Whether the layout of the fuel filter, pre-filter, and electromagnetic pump has a structure in which air accumu-
lates easily.
Check whether they are arranged to prevent air accumulation as Isuzu genuine pre-filters do not have any
plugs for air removal.
Also check whether the inlet and outlet of the electromagnetic pump have an appropriate layout.
Fix layouts which have the electromagnetic pump inlet on the upper side or have an outlet toward the motion
direction of the actual unit.
Abnormalities of the air intake system parts
Abnormalities of the exhaust system parts

84402826 - May 2011

4001E-9
 Symptom

*1 Pre fuel filter

*2 Electromagnetic pump
*3 Fuel filter

• Diagnostic aids
Fuel system abnormalities such as fuel running out, fuel freezing, mixture of air into the fuel piping, filter abnor-
malities, piping abnormalities, fuel quality, fuel tank, etc.
Air intake system abnormalities such as filter clogging and air intake piping abnormalities, etc.
Abnormalities of the supply pump, non-pressure fuel supply
The ECM determination of the supply pump non-pressure fuel supply DTC will not be detected unless a con-
dition continues for 3 seconds or more in which the engine revolution speed is 900 r/min and the absolute
pressure is below 15 MPa {153 kgf/cm2 / 2175 psi}.
Therefore, the DTC will not be detected when the engine does not start with non-pressure fuel supply due to
supply pump abnormalities.

84402826 - May 2011

4001E-10
 Symptom

Engine speed (r/min)

P0093 Judgment required en-

*1
gine speed
*2 Minimum fining engine speed
System realization engine
*3
speed

Absolute pressure

Engine speed (r/min)

*1 Non-criteria range
*2 P0093 Criteria range
*3 Range in P0093 is established

Abnormalities of the common rail such as the flow damper, operation of the pressure limiter, or inside sealing
degradation
Abnormalities of the injector, no fuel injection
System down due to failure
Engine body abnormalities such as seizure, insufficient compression pressure, and other mechanical failures,
etc.
ACG failure
Failure related to the actual unit equipment such as the oil pressure pump, etc.
Effect of the post-installed accessories such as wireless devices and lights, etc.
ECM failure
Inspect the connector for connection failures and the harness for abnormalities such as abrasions, bending,
etc.
Inspect to see if the wires inside the harness are separate and have not caused a short circuit with other circuits.
Perform inspections for functional diagnosis, and confirm the operation, control of each part, etc.
Repair if abnormalities are found.
84402826 - May 2011
4001E-11
 Symptom

Engine hunting, rough idling

1. Engine hunching, rough idling Description of Symptom
The engine has variable engine idling, or has change in idling revolution speed.
In a severe case, the engine or the actual unit may vibrate.
In either case, the engine stall may occur if the symptom gets worse.
2. Engine hunching, rough idling Diagnostics
• Preliminary inspection
Before using this section, perform the functional inspection and OBD system check to check all of the following.
The ECM and monitor are operating correctly.
DTC check.
The scan tool data is within the normal operating range.
Check the condition of the actual unit, and locate the appropriate symptom.
Check with the customers whether they are using the specified engine oil and fuel.
• Visual inspection
Careful visual inspection is required for several symptom procedures.
This can lead to fixing a problem without further inspections, and can save valuable time.
The inspection includes the following.
Whether there is an improper connection of connectors.
Whether the battery terminal voltage has dropped.
Proper wiring connections, tightening, and disconnection
Whether the power of any commercial accessories is being taken divergingly from the ECM power.
Whether the ECM ground is free of dirt, etc. and securely installed in the correct location.
Proper connections, cracks, and twists in the pipes and hoses related to fuel, air, and oil.
Extensively check for any leaks or blockage.
Whether there are any fuel leaks, pipe damage, or dents in the fuel system.
Whether the layout of the fuel filter, pre-filter, and electromagnetic pump has a structure in which air accumu-
lates easily.
Check whether they are arranged to prevent air accumulation as Isuzu genuine pre-filters do not have any
plugs for air removal.
Also check whether the inlet and outlet of the electromagnetic pump have an appropriate layout.
Fix layouts which have the electromagnetic pump inlet on the upper side or have an outlet toward the motion
direction of the actual unit.
Whether there are any fuel leaks, pipe damage, or dents in the fuel system.
Abnormalities of the air intake system parts
Abnormalities of the exhaust system parts

84402826 - May 2011

4001E-12
 Symptom

*1 Pre fuel filter

*2 Electromagnetic pump
*3 Fuel filter

• Diagnostic aids
Fuel system abnormalities such as fuel running out, fuel freezing, mixture of air into the fuel piping, filter abnor-
malities, piping abnormalities, fuel quality, fuel tank, etc.
Air intake system abnormalities such as filter clogging, air intake piping abnormalities, etc.
Abnormalities of the supply pump, non-pressure fuel supply
Switch input circuit system abnormalities Abnormalities of the sensor input circuit system such as the acceler-
ator position sensor, harness, and water temperature sensor
Accelerator position sensor system abnormalities
Engine body abnormalities such as seizure, insufficient compression pressure, and other mechanical failures,
etc.
Failure related to the actual unit equipment such as the oil pressure pump, etc.
Effect of the post-installed accessories such as wireless devices and lights, etc.
Inspect the connector for connection failures and the harness for abnormalities such as abrasions, bending,
etc.
Inspect that the wires inside the harness are separate and have not caused a short circuit with other circuits.
Perform inspections for functional diagnosis, and confirm the operation, control of each part, etc.
Repair if abnormalities are found.

84402826 - May 2011

4001E-13
 Symptom

Excessive white smoke in the exhaust gas

1. Excessive white smoke in the exhaust gas Description of Symptom
Excessive white smoke when driving.
2. Excessive white smoke in the exhaust gas Diagnostics
• Preliminary inspection
Before using this section, perform the functional inspection and OBD system check to check all of the following.
The ECM and monitor are operating correctly.
DTC check.
The scan tool data is within the normal operating range.
Check the condition of the actual unit, and locate the appropriate symptom.
Check with the customers whether they are using the specified engine oil and fuel.
• Visual inspection
Careful visual inspection is required for several symptom procedures.
This can lead to fixing a problem without further inspections, and can save valuable time.
The inspection includes the following.
Whether there is an improper connection of injector connectors.
Proper wiring connections, tightening, and disconnection
Whether the power of any commercial accessories is being taken divergingly from the ECM power.
Whether the ECM ground is free of dirt, etc. and securely installed in the correct location.
Proper connections, cracks, and twists in the pipes and hoses related to fuel, air, and oil.
Extensively check for any leaks or blockage.
Whether there are any fuel leaks, pipe damage, or dents in the fuel system.
Abnormalities of the air intake system parts
Abnormalities of the exhaust system parts
• Diagnostic aids
Fuel quality when using a product with a low cetane number or a product other than those specified
Use of low-viscosity fuel such as kerosene may result in abnormal wear on the seat area of the injector and
cause abnormal spray and white smoke.
In such cases, replacement of the injector is required.
Since the replacement of the injector due to the use of low-viscosity fuel such as kerosene is at the customer's
expense, instruct the customer not to use low-viscosity fuel such as kerosene.
Idling for a long time
Failure of the water temperature sensor, fuel temperature sensor, intake air temperature sensor, boost sensor
failure, or air pressure sensor
Engine body failure such as insufficient compression pressure, piston related failure, turbocharger failure, and
raised oil or sucked down oil, etc.
ECM failure

84402826 - May 2011

4001E-14
 Symptom

Excessive black smoke in the exhaust gas

1. Excessive black smoke in the exhaust gas Description of Symptom
Excessive black smoke when driving.
2. Excessive black smoke in the exhaust gas Diagnostics
ANNOTATION:
• Preliminary inspection
Before using this section, perform the functional inspection and OBD system check to check all of the following.
The ECM and monitor are operating correctly.
DTC check.
The scan tool data is within the normal operating range.
Check the condition of the actual unit, and locate the appropriate symptom.
Check with the customers whether they are using the specified engine oil and fuel.
ANNOTATION:
• Visual inspection
Careful visual inspection is required for several symptom procedures.
This can lead to fixing a problem without further inspections, and can save valuable time.
The inspection includes the following.
Whether there is grime or clogging in the air cleaner element.
Proper wiring connections, tightening, and disconnection
Whether the power of any commercial accessories is being taken divergingly from the ECM power.
Whether the ECM ground is free of dirt, etc. and securely installed in the correct location.
Proper connections, cracks, and twists in the pipes and hoses related to fuel, air, and oil.
Extensively check for any leaks or blockage.
Whether there are any fuel leaks, pipe damage, or dents in the fue lsystem.
Abnormalities of the air intake system parts
Abnormalities of the exhaust system parts
ANNOTATION:
• Diagnostic aids
Fuel quality when using a product other than those specified, etc.
Air intake system abnormalities such as filter clogging, air intake piping abnormalities, etc.
Abnormalities of the EGR control system
Abnormalities of the exhaust system such as exhaust pipe abnormalities, etc.
Water temperature sensor malfunction
Boost sensor failure
Engine body failure such as insufficient compression
pressure, piston related failure, turbocharger failure, and raised oil, etc.

84402826 - May 2011

4001E-15
 Symptom

Abnormal noise
1. Abnormal noise Description of Symptom
Engine combustion noise is abnormal.
2. Abnormal noise Diagnostics
• Preliminary inspection
Before using this section, perform the functional inspection and OBD system check to check all of the following.
Refer to the actual unit manual and inspect the abnormal noise.
The ECM and monitor are operating correctly.
DTC check.
The scan tool data is within the normal operating range.
Check the condition of the actual unit, and locate the appropriate symptom.
Check with the customers whether they are using the specified engine oil and fuel.
• Visual inspection
Careful visual inspection is required for several symptom procedures.
This can lead to fixing a problem without further inspections, and can save valuable time.
The inspection includes the following.
Proper wiring connections, tightening, and disconnection
Whether the ECM ground is free of dirt, etc. and securely installed in the correct location.
Proper connections, cracks, and twists in the pipes and hoses related to fuel, air, and oil.
Extensively check for any leaks or blockage.
Whether there are any fuel leaks, pipe damage, or dents in the fuel system.
Abnormalities of the air intake system parts
Abnormalities of the exhaust system parts
• Diagnostic aids
Fuel system abnormalities such as fuel running out, fuel freezing, mixture of air into the fuel piping, filter abnor-
malities, piping abnormalities, fuel quality, fuel tank, etc.
Air intake system abnormalities such as EGR valve abnormalities, etc.
Abnormalities of the injector, no fuel injection
Engine body abnormalities such as seizure, insufficient compression pressure, and other mechanical failures,
etc.
Failure related to the actual unit equipment such as the oil pressure pump, etc.
ECM failure Inspect the connector for connection failures and the harness for abnormalities such as abrasions,
bending, etc.
Inspect that the wires inside the harness are separate and have not caused a short circuit with other circuits.
Perform inspections for functional diagnosis, and confirm the operation, control of each part, etc.
Repair if abnormalities are found.

84402826 - May 2011

4001E-16
 Symptom

Large fuel consumption

1. Large fuel consumption Description of Symptom
Fuel consumption is significantly larger than indicated in the actual unit manual.
2. Large fuel consumption Diagnostics
• Preliminary inspection
Before using this section, perform the functional inspection and OBD system check to check all of the following.
Since the fuel consumption varies widely depending on the handling of the actual unit, check the reference fuel
consumption (A) of the actual unit manufacturer.
Reference fuel consumption (L {qts}/hour)
Check the actual fuel consumption (B).
Actual fuel consumption (L {qts}/hour)
If B is greater than A, refer to the actual unit manual and check the setting of the unit.
Check whether the actual unit does not have a significant load.
Refer to the inspections and maintenance list in the operation manual and perform the inspection based on the
operation time of the actual unit.
Refer to the actual unit manual to inspect an actual unit whose operation time exceeds 3,000 hours.
The ECM and monitor are operating correctly.
DTC check.
Check the condition of the actual unit, and locate the appropriate symptom.
Check with the customers whether they are using the specified engine oil and fuel.
Check whether engine oil change or periodical maintenance for the air cleaner filter or fuel filter, etc. has been
performed.
• Visual inspection
Careful visual inspection is required for several symptom procedures.
This can lead to fixing a problem without further inspections, and can save valuable time.
The inspection includes the following.
Proper wiring connections, tightening, and disconnection
Whether the ECM ground is free of dirt, etc. and securely installed in the correct location.
Proper connections, cracks, and twists in the pipes and hoses related to fuel, air, and oil.
Extensively check for any leaks or blockage.
Whether there are any fuel leaks, pipe damage, or dents in the fuel system.
Abnormalities of the air intake system parts
Abnormalities of the exhaust system parts
• Diagnostic aids
Fuel system abnormalities such as fuel running out, fuel freezing, mixture of air into the fuel piping, filter abnor-
malities, piping abnormalities, fuel quality, fuel tank, etc.
Air intake system abnormalities such as EGR valve abnormalities, etc.
Abnormalities of the injector such as excessive fuel injection
Engine body abnormalities such as seizure, insufficient compression pressure, and other mechanical failures,
etc.
Failure related to the actual unit equipment such as the oil pressure pump, etc.
ECM failure Inspect the connector for connection failures and the harness for abnormalities such as abrasions,
bending, etc.
Inspect that the wires inside the harness are separate and have not caused a short circuit with other circuits.
Perform inspections for functional diagnosis, and confirm the operation, control of each part, etc.
Repair if abnormalities are found.
For the inspection locations of the engine air intake and exhaust system
Inspect the air intake and exhaust system for abnormalities such as clogging, collapsing and damage.
Other than the inspection locations of the engine body, inspect the air cleaner, intercooler, and muffler.

84402826 - May 2011

4001E-17
 Symptom

1 EGR valve 4 To the intercooler

2 From the intercooler 5 Exhaust pipe
3 From the air cleaner 6 EGR cooler

84402826 - May 2011

4001E-18
 Symptom

Large oil consumption

1. Large oil consumption Description of Symptom
The oil consumption amount described in the manual of the actual unit is significantly exceeded.
2. Large oil consumption Diagnostics
• Preliminary inspection
Before using this section, perform the functional inspection and OBD system check to check all of the following.
Since the oil consumption varies widely by handling of the actual unit, check the reference oil consumption (A)
of the actual unit manufacturer.
Reference oil consumption/hour
Reference oil consumption per engine: 4　L {4.2 qts}/100 hours Check the actual oil consumption (B).
Actual oil consumption/hour
Refer to the inspections and maintenance list in the operation manual and perform the inspection based on the
operation time of the actual unit.
Refer to the actual unit manual to inspect an actual unit whose operation time exceeds 3,000 hours.
The ECM and monitor are operating correctly.
DTC check.
Check the condition of the actual unit, and locate the appropriate symptom.
Check with the customers whether they are using the specified engine oil and fuel.
• Visual inspection
Careful visual inspection is required for several symptom procedures.
This can lead to fixing a problem without further inspections, and can save valuable time.
The inspection includes the following.
Whether bluish white smoke continuously comes out.
Whether blow-by gas comes out excessively.
Whether oil is mixed into the coolant.
Proper connections, cracks, and twists in the pipes and hoses related to oil.
Extensively check for any leaks or blockage.
Whether there is any fuel leak, pipe damage, or dents in the lubricant system.
Abnormalities of the air intake system parts such as the turbocharger inspection
• Diagnostic aids
Air intake system abnormalities such as sucked down oil or raised oil and excessive blow-by gas
Engine body abnormalities such as oil combustion and excessive blow-by gas
Perform inspections for functional diagnosis, and confirm the operation, control of each part,etc.
Repair if abnormalities are found.

84402826 - May 2011

4001E-19
 Symptom

Insufficient engine output

1. Insufficient engine output Description of Symptom
The engine output is lower than expected, the output does not change when the accelerator lever (throttle lever)
is lifted up, the operation is not effective.
2. Insufficient engine output Diagnostics
• Preliminary inspection
Before using this section, perform the functional inspection, OBD system check to confirm the following all
items.
The ECM and the monitor are operating properly.
DTC check.
The scan tool data is within the normal operating range.
Check the actual unit condition, and locate the corresponding symptom.
Check with the customer if the customer is using the specified engine oil and fuel.
For insufficient output, various causes can be suspected, so thoroughly investigate the relationship between
the engine and the actual unit side.
Check what kind of operations cause insufficient output.
If hesitation or lug-down is included in the symptoms of insufficient output, it is related to the control on the
actual unit side, so contact the manufacturer of the actual unit.
If a trouble diagnosis scan tool is available, the engine output at the rated point can be easily verified by check-
ing the boost at the rated point.
• Visual inspection
Careful visual inspection is required for several symptom procedures.
This can lead to fixing a problem without further inspections, and can save valuable time.
The inspection includes the following.
Whether there is grime or clogging in the air cleaner element.
Proper wiring connections, tightening, and disconnection
Whether the power of any commercial accessories is being taken divergingly from the ECM power.
Whether the ECM ground is free of dirt, etc. and securely installed in the correct location.
Proper connections, cracks, and twists in the pipes and hoses related to fuel, air, and oil.
Extensively check for any leaks or blockage.
Whether there are any fuel leaks, pipe damage, or dents in the fuel system.
Increased resistance due to grime, clogging, or air intake piping collapsing particularly in the air cleaner element
among the air intake system parts
Abnormalities of the exhaust system parts
• Diagnostic aids
Fuel system abnormalities such as running out of fuel, fuel freezing, air intrusion in the fuel pipe, filter abnor-
mality, pipe abnormality, fuel quality, and fuel tank
Air intake system abnormalities such as filter clogging and air intake pipe abnormality
Exhaust system abnormalities such as exhaust pipe abnormality
Abnormalities of the sensor input circuit system including the accelerator position sensor and the harness
Abnormalities of the switch input circuit system
Engine unit abnormalities including other mechanical failures such as compression pressure, valve clearance,
turbocharger, supply pump, injector, and common rail
Failures related to actual unit side equipment such as hydraulic pump
Influence of the post-mounted electrical components such as wireless devices and lights
Inspect for connector improper connections, harness abnormalities such as abrasions and bends, and short
circuits with other circuits due to wire split inside harness.
Also, perform inspections for functional diagnosis, and check the operation and control of each part.
Make repairs if any abnormality is found.
Output reduction due to fuel flow restriction imposed upon overheat
Insufficient output due to fuel flow restriction during operation at high altitude
• Control when overheating
To protect the engine, restriction on fuel flow is started when the engine coolant temperature exceeds 100 °C
(212 °F).
When the engine coolant temperature increases further, the fuel flow is also restricted further.
When the temperature is near 120 °C (248 °F), the fuel flow is restricted to a certain level.
The setting varies depending on the actual unit manufacturer.
The actual unit is designed to issue an alarm from 105 °C (221 °F).
By reducing the load applied to the actual unit upon alarm issuance, it is possible to avoid the operation condi-
tion with fuel flow restriction.

84402826 - May 2011

4001E-20
 Symptom

Fuel flow

Engine coolant temperature

*1 Warning indication
*2 DTC set

• High altitude correction

The ECM calculates the current altitude in accordance with the signal from the atmospheric pressure sensor.
Depending on the conditions of altitude, etc. at this time, the SCV opening and closing timing and injector
energizing time are controlled and the fuel flow is corrected to be optimum.

Fuel flow limit (mm3/st)

Barometric pressure kPa (psi)

*1 Highland

84402826 - May 2011

4001E-21
 Symptom

84402826 - May 2011

4001E-22
 Section

4001F

Functional Inspection

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Inspection of the monitor warning light blinking circuit system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Inspection of the scan tool (Electronic Service Tool) power circuit system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection of the starter circuit system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Compression pressure inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Inspection of the starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspection of the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspection of the air intake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspection of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspection of the EGR control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspection of the glow control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Functional inspection of the DPD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
OBD system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Inspection of the monitor warning light illumination circuit system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

4001F-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
4001F-2 PRINTED IN FRANCE
 Functional Inspection

Inspection of the monitor warning Inspection of the scan tool

light blinking circuit system (Electronic Service Tool) power
1. Inspection of the monitor warning light blinking cir- circuit system
cuit system Description of Function
The monitor is supplied with power supply voltage 1. Inspection of the scan tool power circuit system De-
via the starter switch and shows an abnormality dis- scription of Function
play due to a signal from the ECM. The ECM and other ECU communicate with the
The ECM makes the monitor show an abnormality trouble diagnosis scan tool via the DLC.
display during a lamp check when the starter switch The power voltage of the trouble diagnosis scan tool
is ON and when the DTC is set. is supplied by the battery or AC power.
It also blinks the monitor depending on the detected
CAUTION
DTC when the body ground terminal and diagnostic
switch terminal of the DLC are shorted. • Draw power for the trouble diagnosis
A monitor circuit is incorporated inside the ECM and scan tool from the battery or AC power.
monitors operation of the warning light. • The power supply voltage is the same as
2. Inspection of the monitor warning light blinking cir- the battery voltage of the actual unit.
cuit system Inspection
Inspection if the monitor continues showing an ab- 2. Inspection of the scan tool power circuit system In-
normality display and does not flash when the diag- spection
nostic switch is switched ON Inspection when the trouble diagnosis scan tool
1) Perform the OBD system check. does not power on
2) Turn OFF the starter switch. 1) Inspect the battery voltage of the actual unit
3) Connect the DMM between the DLC diagnos- using the DMM.
tic switch terminal and GND. Standard value: 18V
4) Turn ON the starter switch. 2) Charge or replace the battery if it is below the
5) Confirm that the voltage displayed on the standard value.
DMM exceeds the standard value. 3) Check that the battery cable of the trouble di-
Standard： 18 V agnosis scan tool does not have a defective
6) Inspect the diagnostic switch circuit between connection.
the ECM and DLC using the DMM if it is under 4) Repair the connection if a problem is discov-
the standard value. ered.
• No open circuit or high resistance should be 5) Check that the battery cable of the trouble di-
found. agnosis scan tool does not have an open or
Standard value: 100 Ω or less short circuit.
• No short circuit with GND should be found. 6) Request repair of the battery cable if a prob-
Standard value: 10 MΩ or more lem is discovered.

7) Repair if a problem is discovered.

8) Turn OFF the starter switch.
9) Confirm that there is continuity between the
DLC body ground and GND.
10) Turn ON the starter switch.
11) Short the DTC.
ANNOTATION:
• Short the No.4 terminal and No.12 terminal.
12) Check if the monitor is blinking.
ANNOTATION:
• If it does not blink, inspect the monitor blink-
ing circuit system.
13) Replace the ECM.
Removal of ECM
Installation of ECM
14) After replacing the ECM, perform EGR learn-
ing.
15) Turn ON the starter switch.
16) Short the body ground terminal and diagnostic
switch terminal of the DLC.
17) Check if the monitor is blinking.
18) Perform the OBD system check.

84402826 - May 2011

4001F-3
 Functional Inspection

Inspection of the starter circuit 8) Inspect the starter relay.

system • Connect the battery between the coil side
terminals and check the continuity between
1. Inspection of the starter circuit system Description the switch side terminals.
of Function Standard value: 100Ω or less
The starter relay on the ECM is turned to ON when
the starter switch moves to the START position. 9) Replace the relay if a problem is discovered.
When the starter relay is turned to ON, the starter 10) Inspect the starter switch start signal circuit.
operates to start the engine. • No open circuits or high resistance should
2. Inspection of the starter circuit system Inspection be found between the starter switch and
Inspection when the starter does not operate ECM.
1) Turn the emergency stop switch to OFF. Standard value: 100 Ω or less
• No short circuits with the GND should be
ANNOTATION: found between the starter switch and ECM.
Standard value: 10 MΩ or more
• If the actual unit does not have an emer-
gency stop switch setting, do not perform 11) Repair the circuit if a problem is discovered.
this operation. 12) Inspect the starter circuit.
2) Check the DTC. • No open circuit should be found between
the starter switch and starter cut relay.
ANNOTATION:
• No open circuit should be found between
• If the DTC P0117, P0340, P0341, P0615, the starter cut relay and starter relay.
P0651, or P1625 is detected, inspect the • No open circuit should be found between
corresponding DTC. the starter relay and GND.
• No open circuit should be found between
3) Turn OFF the starter switch. the starter relay and starter.
4) Remove the starter cut relay.
5) Inspect the starter cut relay. 13) Repair the circuit if a problem is discovered.
14) Inspect the starter.
• Check the continuity between the switch Inspection of the starter
side terminals. 15) Replace the starter if a problem is discovered.
Standard value: 100 Ω or less 16) Replace the ECM.
6) Replace the relay if a problem is discovered. Removal of ECM
7) Remove the starter relay. Installation of ECM
17) After replacing the ECM, perform EGR learn-
ing.

84402826 - May 2011

4001F-4
 Functional Inspection

Compression pressure inspection

1. Engine compression pressure inspection Inspection
ANNOTATION:
• Warm-up the engine.
1) Remove the glow plug from the cylinder head
assembly.
ANNOTATION:
• Remove all glow plugs.
2) Remove the injector harness connector from
the lower cover.
SST: compression gauge (refer to section
1003)

1 Injector harness connector

3) Install the special tool to the cylinder head as-

sembly.
ANNOTATION:
• Insert the compression gauge adapter into
the installation hole of the glow plug to install
the compression gauge.

1 Compression gauge
2 Compression gauge adapter

ANNOTATION:
SST: compression gauge adapter (refer to • Measure the compression pressure.
section 1003) • Rotate the starter, and read the indication
of the compression pressure when the com-
pression gauge needle stabilizes at approx-
imately 200 min-1 { 200 rpm }.
• Measure the compression pressure of all
cylinders.
Specified value： 2840.0 - 3240.0 kPa { 28.96
- 33.04 kgf/cm2 / 412 - 470 psi }
Limit： 1960.0 kPa { 19.99 kgf/cm2 / 284 psi }
84402826 - May 2011
4001F-5
 Functional Inspection

Difference between each cylinder：294.0 kPa 1) Turn the emergency stop switch to OFF.
{ 3.00 kgf/ cm2 / 43 psi }
ANNOTATION:
CAUTION • If the actual unit does not have an emer-
gency stop switch setting, do not perform
• Note that air will burst out through
the glow plug hole during rotation. this operation.
2) Inspect the overheat switch circuit.
ANNOTATION:
ANNOTATION:
• When the starter switch is turned to ON with • If the actual unit does not have a overheat
the injector harness connector removed, the switch setting, do not perform this operation.
ECM determines a malfunction and records
a DTC, so make sure the DTC has been 3) Repair the circuit if a problem is discovered.
cleared after the inspection is completed. 4) Check the DTC.
ANNOTATION:
Inspection of the starting system
• If the DTC is detected, inspect the corre-
1. Starting system check Description of Function sponding DTC.
This diagnosis chart is an organized approach to
identifying a condition that causes the status for 5) Check the SCV F/B display using a trouble
when an engine does not start. diagnosis scan tool while cranking the engine.
The appropriate system diagnosis can be per- Standard： 900 mA
formed with this diagnostic chart. 6) Repair the SCVLO drive circuit if it is below
the standard value.
• The battery should be fully charged when per- 7) Remove the harness connector from the SCV.
forming this diagnosis. 8) Crank the engine.
• The battery cable should be securely connected
when performing this diagnosis. ANNOTATION:
• The rotation speed during cranking should be nor- • If the engine starts, diagnose the DTC
mal when performing this diagnosis. P0090.
• The appropriate fuel should be sufficiently sup-
plied when performing this diagnosis. 9) Inspect the fuel system if the engine does not
• No fuel leaks should be found when performing start.
this diagnosis. 10) Inspect the engine coolant temperature sen-
• No air should be mixed into the fuel when perform- sor.
ing this diagnosis. 11) Inspect the fuel pressure sensor.
• The air cleaner element should be clean when 12) Inspect the EGR position sensor.
performing this diagnosis. 13) Inspect the injector.
• The fuel filter should be clean when performing 14) Inspect the engine mechanical timing.
this diagnosis. 15) Inspect the installation status of the flywheel.
16) Inspect the air intake system.
2. Starting system check Inspection 17) Inspect the exhaust piping for collapsing,
Inspection when the starter operates and cranks but damage, and exhaust leakage.
the engine does not start 18) Repair or replace the part found to have a
problem.

84402826 - May 2011

4001F-6
 Functional Inspection

Inspection of the fuel system Inspection of the air intake system

1. Fuel system check Description of Function 1. Air intake system check Description of Function
The fuel system is composed of the fuel filter, supply
pump, common rail, and injector, and each of them CAUTION
connects with the fuel pipe.
2. Fuel system check Inspection • If the air intake system part is installed by
the actual unit manufacturer, refer to the
Inspection when there is a possibility that there is
manual of the actual unit.
an abnormality in the fuel system
1) Inspect the quality of fuel. The air intake system is comprised of the air
Appropriate fuel should be used. cleaner, air intake piping, turbocharger, etc.
2) Check the amount of fuel. The intake air is supplied to the engine through the
Sufficient amount should be supplied. air cleaner and intake manifold.
3) Perform the fuel discharge inspection for the 2. Air intake system check Inspection
supply pump. Inspection when there is a possibility that there is
Fuel discharge inspection an abnormality in the air intake system
The fuel discharge should be normal and no
air should be mixed. 1) Inspect the air cleaner.
4) Confirm that the genuine fuel filter, pre filter, • No excessive contamination or clogging
and filters other than for the electromagnetic should be found.
pump are added to the fuel piping of the actual
unit. 2) Clean or replace if a problem is discovered.
3) Inspect the air intake piping.
ANNOTATION:
• No collapsing, damage, or air leakage
• A problem such as the detection of the DTC should be found.
P0093 may occur as the resistance of fuel • There are no distorted or improper piping ar-
increases due to the added filter. rangements which may lead to an increase
5) Remove it if the filter is added. in the air intake resistance.
6) Inspect the main fuel filter, pre-fuel filter, and • The lead valve should have no damage.
electromagnetic pump filter. 4) Repair or replace if a problem is discovered.
5) Inspect the turbocharger.
• No excessive contamination or clogging
should be found. • The turbine axis should have no abnormal
• No air should be mixed in. looseness.
7) Clean or replace if a problem is discovered. • There are no oil leaks.
8) Inspect the fuel pipe. 6) Repair or replace if a problem is discovered.
No damage, clogging, or improper connec-
tions should be found.
9) Repair or replace if a problem is discovered.
10) Inspect the fuel tank.
• No dust should be mixed in.
• The fuel supply pipe should have no mis-
alignment or damage.
• The tank should have no collapsing or dam-
age.
• The fuel pipe should not be arranged incor-
rectly.
• The fuel filler should have no clogging.
• No water should be mixed into the tank.
11) Repair or replace the fuel tank if a problem is
discovered.
12) Remove air.

84402826 - May 2011

4001F-7
 Functional Inspection

Inspection of the exhaust system Inspection of the EGR control

1. Exhaust system check Description of Function system
The exhaust system is comprised of the exhaust
pipe, tail pipe, etc. 1. EGR control system check Description of Function
2. Exhaust system check Inspection The ECM controls the EGR valve based on the en-
Inspection when there is a possibility that there is gine revolution speed, engine coolant temperature,
an abnormality in the exhaust system intake air temperature, fuel injection amount, and
atmospheric pressure.
1) Inspect the exhaust pipe and tail pipe. The EGR valve is driven by the EGR motor, and the
EGR valve opening is detected by the EGR position
• No collapsing, damage, or exhaust leakage sensor.
should be found.
2. EGR control system check Inspection
2) Repair or replace if a problem is discovered. Inspection when there is a possibility that there is
3) Repair the actual unit. an abnormality in the locations relating to the EGR.
1) Check the DTC.
ANNOTATION:
• If the DTC is detected, inspect the corre-
sponding DTC.
2) Start the engine and warm it up until the
coolant temperature exceeds the standard
value.
Specified value： 70 °C { 158 °F }
3) Check the EGR position display using a trou-
ble diagnosis scan tool.
Specified value： (-3) - 3％
4) Perform the actuator test EGR control using a
trouble diagnosis scan tool if the EGR position
display is outside the standard value.
5) Execute an Up and Down command to the
EGR valve and check the EGR position dis-
play.
Specified value： (-3) - 3％
6) Inspect the EGR piping if the EGR position
display is outside the standard value.
No damage or gas leaks should be found.
7) Repair or replace if a problem is discovered.
8) Start the engine and warm it up until the
coolant temperature exceeds the standard
value.
Specified value： 70 °C { 158 °F }
9) Check the EGR position display using a trou-
ble diagnosis scan tool.
Specified value： (-3) - 3％
10) Replace the EGR valve if the EGR position
display is outside the standard value.
EGR valve Removal
EGR valve Installation
11) When replacing the EGR valve, perform EGR
learning to the ECM.

84402826 - May 2011

4001F-8
 Functional Inspection

Inspection of the glow control 8) Replace the relay if a problem is discovered.

9) Remove all glow plugs.
system 10) Measure the resistance between the glow
plug terminal and GND using the DMM.
1. Glow control system check Description of Function
Standard： 6 Ω At room temperature
CAUTION ANNOTATION:
• The starter ECM control specification • If it is outside the standard value, inspect the
and safety relay specification are the corresponding glow plug.
same for the QOS circuit.
11) Replace the glow plug if a problem is discov-
The QOS system is comprised of the ECM, glow ered.
relay, glow plug, and QOS indicator light. 12) Connect the DMM to the glow plug connector
When the starter switch is turned to ON under low and GND.
engine coolant temperature, the ECM determines 13) Turn ON the starter switch.
the glow time according to the engine coolant tem- 14) Perform the actuator test glow plug relay using
perature, and starts the glow relay and QOS indica- a trouble diagnosis scan tool.
tor light. ANNOTATION:
The ECM will turn to OFF the glow relay and QOS
indicator light after a certain period of time. • Turn the command to OFF and check the
2. Glow control system check Inspection voltage value of the DMM.
Inspection when there is a possibility that there is Standard： 0 V
an abnormality in the locations relating to the QOS 15) Inspect the circuit if it is outside the standard
system control value.
1) Perform the OBD system check. ANNOTATION:
2) Check the DTC.
• No short circuit to battery or ignition power
ANNOTATION: supply should be found between the glow
• If the DTC P0117, P0118, P0380, or P0381 relay and glow plug.
is detected, inspect the corresponding DTC. 16) Repair or replace the circuit if a problem is
3) Turn ON the starter switch. discovered.
4) Check the operation of the QOS indicator 17) Perform the actuator test glow plug relay using
light. a trouble diagnosis scan tool.

ANNOTATION: ANNOTATION:

• If the QOS does not operate, the QOS in- • Turn the command to ON and check the
dicator light will illuminate when the starter voltage value of the DMM.
switch is turned to ON by the light check Standard： 18 V
function. 18) Inspect the circuit if it is below the standard
• The QOS indicator light turns off within 10 value.
seconds.
• No fuse should be blown.
5) Inspect the circuit if the QOS indicator light • No open circuit should be found between
does not illuminate or turn off. the fuse and glow relay.
• No fuse should be blown. • No open circuit should be found between
• No open circuit should be found between the glow relay and glow plug.
the fuse and QOS indicator light. • No open circuit should be found between
• No open circuit or short circuit should be the glow relay and ECM.
found between the QOS indicator light and 19) Repair or replace the circuit if a problem is
ECM. discovered.
• The QOS indicator light should not have a 20) Replace the ECM.
burned-out bulb. Removal of ECM
6) Repair or replace the circuit if a problem is Installation of ECM
discovered. 21) After replacing the ECM, perform EGR learn-
7) Inspect the glow relay. ing.

84402826 - May 2011

4001F-9
 Functional Inspection

Functional inspection of the DPD 11) Inspect the exhaust differential pressure sen-
sor.
1. DPD control system check Description of Function
The ECM detects the condition of PM accumula- • Damage on the DPD differential pressure
tions from the DPD differential pressure sensor. sensor
The DPD differential pressure sensor changes the • Foreign matter or contamination which inter-
signal voltage in accordance with changes in the feres with the DPD differential pressure sen-
exhaust gas pressure difference between the front sor inlet
and the rear of the DPD filter. • Wrong detection or slow response for the
When the DPD differential pressure sensor reaches DPD differential pressure sensor
to a certain amount of PM accumulation, or a certain 12) Inspect the exhaust system.
period of operating hours, DPD automatic regener- 13) Inspect the air intake system.
ation starts. 14) Start the engine and maintain idling for 30 sec-
If the automatic regeneration cannot be completed onds.
due to working, the DPD manual regeneration indi- 15) Confirm that the DPD manual regeneration in-
cator light in the monitor panel blinks to prompt the dicator light blinks.
driver to perform manual regeneration.
When regeneration has once started, it must be ANNOTATION:
completed within a certain period of time. • If it is not blinking, use the trouble diagno-
After completion of DPD regeneration, purification sis scan tool to confirm DPD accumulation
status of the filter is determined based on the ex- status and DPD time status and applicable
haust differential pressure. area based on the DPD status table.
When the ECM detects excessive amount of PM ac-
cumulation, it becomes so hot that it is eroded dur- • Compare DPD accumulation status and
ing regeneration process and cannot control com- DPD time status and use the DPD status ta-
bustion; therefore, DPD regeneration is not allowed ble to determine DPD regeneration process
to start. status.
2. DPD control system check Inspection • To use the DPD status table, confirm the
Inspection for determining the failure location in the data display values on the trouble diagnosis
DPD system scan tool and readings in the DPD status
table.
1) Perform the inspection of the engine control
system.
2) Turn the starter switch ON for 30 seconds.
3) Check that the monitor panel functions nor-
mally.
• DPD automatic regeneration indicator light
illuminates in green
• DPD manual regeneration indicator light il-
luminates in orange DPD Ac-
cumula-
ANNOTATION:
tion Sta-
• If it does not illuminate, inspect the circuit of tus
the DPD indicator light.
• Not all are displayed depending on actual
unit manufacturers.
4) Turn the starter switch OFF for 30 seconds.
5) Inspect the amount of engine oil.
6) Connect the trouble diagnosis scan tool to the
DTC.
7) Start the engine. DPD Distance Status
8) Display the scan tool data DPD regeneration
switch using a trouble diagnosis scan tool. Range
9) Check if the data displayed on the DPD regen- A Normal range
eration switch of the trouble diagnosis scan DPD amber lamp binks but
tool is turned to ON or OFF when changing B manual regeneration is possi-
each switch. ble.
ANNOTATION: Exhaust differential pressure is
C excessive high range and man-
• If the ON or OFF operation does not link, ual regeneration is inhibited.
inspect the DPD switch and harness. Time status is abnormal range
10) Inspect the installation condition of the DPD D and manual regeneration is in-
differential pressure sensor. hibited.

84402826 - May 2011

4001F-10
 Functional Inspection
ANNOTATION:
• The area where 2 status values meets will
point to either A, B, C, or D.
16) Operate the trouble diagnosis scan tool.
ANNOTATION:
• Use a trouble diagnosis scan tool to reset
the DPD status.
• If it is range A or B, perform the DPD forced
regeneration test with the trouble diagnosis
scan tool.
• If it is range C or D, perform the DPD forced
slow regeneration test with the trouble diag-
nosis scan tool.
ANNOTATION:
• After the DPD forced slow regeneration is
completed, replace the engine oil.
17) Check the DTC detection with the trouble di-
agnosis scan tool if the regeneration does not
start.
ANNOTATION:
• If no DTC is detected, confirm data display
related to DPD regeneration control.
18) Inspect the corresponding DTC if the regener-
ation is not completed and the scan tool dis-
plays an error message.
ANNOTATION:
• If no error message has been displayed, in-
spect the DPD filter for damage, cracks, or
melting.
• If no error message has been displayed, in-
spect the oxidation catalyst for degradation,
damage, cracks, melting, or excessive sed-
iment.
84402826 - May 2011
4001F-11
• If no error message has been displayed, in-
spect for the cause of overheating.
• If no error message has been displayed, in-
spect for a problem in the fuel system.
19) Confirm that the data display of exhaust tem-
perature 1 is below the standard value using a
trouble diagnosis scan tool if the regeneration
completed.
Specified value： 130 °C { 266 °F }
ANNOTATION:
• If it is the standard value or greater, idle the
engine until it reaches the standard value or
lower.
20) Accelerate the engine revolution to maximum
revolution speed without load.
21) Check the data display of the exhaust differen-
tial pressure when the data display of exhaust
temperature 1 reaches the standard value.
Specified value： 150 °C { 302 °F }
22) Check the exhaust differential pressure data
display using a trouble diagnosis scan tool.
Specified pressure ： 0.5 - 1.8 kPa { 0.01 -
0.02 kgf/ cm2 / 0.07 - 0.26 psi }
ANNOTATION:
• If it is the standard value or lower, perform
ash removal.
• If it is the standard value or greater, inspect
for the abnormalities in the DPD differential
pressure sensor system.
23) Replace the ECM if any problem can be seen
through the inspections above.
ECM Removal
ECM Installation
24) Set the injector ID code on the ECM.
25) Perform the unit difference learning of the fuel
supply pump to the ECM.
 Functional Inspection

OBD system check 4) Check if the monitor is blinking.

1. OBD system check ANNOTATION:

OBD system check Description of Function
The OBD system check is a systematic method for
checking problems caused by functional failures in
the engine control system, and is also the starting
point for all diagnoses for driveability complaints.
By correctly using this diagnostic step, it is possible
to reduce the time for diagnosis and prevent the
replacement of parts that are not defective.
ANNOTATION:
• Points to remember regarding the OBD system
check
• If there are no complaints on driveability, do not
perform these diagnostic steps unless otherwise
instructed in other sections.
• Check the service technical report before starting
the diagnosis.
• Do not delete the DTCs unless it is instructed in a
diagnostic step.
• If a malfunction is found in the engine starting sys-
tem, inspect the starting system.
• The battery should be fully charged.
• The battery cable should be normal and securely
connected.
• The GND of the ECM should be securely con-
nected in the correct position.
• The harness connector of the ECM should be
clean and correctly connected.
2. OBD system check Inspection
Inspection for determining the failure location in the
OBD system
1) Turn ON the starter switch.
2) Check the abnormality display of the monitor.
ANNOTATION:
• If the actual unit does not have a monitor
setting, do not perform this operation.
• If the monitor is off, an abnormality display is
performed for the monitor illumination circuit
system.
3) Short the DTC.
ANNOTATION:
• Short the No.4 terminal and No.12 terminal.
• If the actual unit does not have a monitor
setting, do not perform this operation.
• If the actual unit does not have a monitor
setting, do not perform this operation.
• If the monitor is not blinking, inspect the
monitor blinking circuit system.
5) Use the trouble diagnosis scan tool to confirm
the DTCs of the ECU that has communication
established.
Loss of communication with the trouble diag-
nosis scan tool occurs due to the abnormali-
ties in the communication circuit of ECM and
the trouble diagnosis scan tool.
6) Start the engine.
ANNOTATION:
• If the starter does not operate, inspect the
starter circuit system.
• If the engine does not start, check the DTC.
• If the DTC is detected, inspect the corre-
sponding DTC.
• If no DTC has been detected, inspect the
starting system.
7) Check the engine stalling for problems.
8) Check the engine hunching and rough idling
for problems.
9) Check if there are problems with insufficient
engine output, blowup failure, or engine hesi-
tation.
10) Check for problems with sudden stopping.
11) Check for problems with sudden change.
12) Check for problems with insufficient output or
blowup failure.
13) Check for problems with engine hesitation or
acceleration failure.
14) Check for problems with dark smoke.
15) Check for problems with white smoke.
16) Check for problems with the idling revolution
speed maladjustment.
17) Check for problems with the idling revolution
speed not decreasing.
18) Check for problems with frequent DPD regen-
eration by the manual regeneration.
19) Check for problems with long DPD regenera-
tion time.

84402826 - May 2011

4001F-12
 Functional Inspection

Inspection of the monitor warning Inspection if the monitor does not show an abnor-
mality display when the starter switch is switched
light illumination circuit system ON
1. Inspection of the monitor warning light illumination 1) Perform the OBD system check.
circuit system Description of Function 2) Inspect the monitor bulb.
The monitor is supplied with power supply voltage 3) Replace the valve if a problem is discovered.
via the starter switch and shows an abnormality dis- 4) Inspect the monitor circuit.
play due to a signal from the ECM.
The ECM makes the monitor show an abnormality • No open circuit or high resistance should be
display during a lamp check when the starter switch found between the fuse and monitor.
is ON and when the DTC is set. • No open circuit or high resistance should be
It also blinks the monitor depending on the detected found between the monitor and ECM.
DTC when the body ground terminal and diagnostic 5) Repair the circuit if a problem is discovered.
switch terminal of the DLC are shorted. 6) Replace the ECM.
A monitor circuit is incorporated inside the ECM and Removal of ECM
monitors operation of the light. Installation of ECM
2. Inspection of the monitor warning light illumination 7) After replacing the ECM, perform EGR learn-
circuit system Inspection ing.

84402826 - May 2011

4001F-13
Functional Inspection

84402826 - May 2011

4001F-14
 Section

4001G

Maintenance precautions

84402826 - May 2011

84402826 - May 2011
CONTENTS

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

4001G-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
4001G-2 PRINTED IN FRANCE
 Maintenance precautions
1. Maintenance precautions
1) Precautions on maintenance
To prevent the engine from being damaged
and to ensure the reliability of engine perfor-
mance, be careful of the following points when
performing maintenance works.
When placing the engine on the ground, make
sure that the bearing surface of the oil pan
does not directly contact the ground.
Use an appropriate wood frame, etc. to sup-
port the engine at the engine foot portion and
the flywheel housing portion.
There is only a small gap between the oil pan
and oil pump strainer, so be careful not to
damage the oil pan and oil strainer.
• While the air duct or air cleaner is removed,
cover the open section of the intake to pre-
vent foreign matters from entering the cylin-
der.
If a foreign matter enters the cylinder, it may
seriously damage the cylinder when the en-
gine starts.
• When maintaining the engine, be sure to
disconnect the negative battery cable.
Failure to do this may cause the harness or
electrical components to be damaged.
If energizing is required for inspection, be
careful not to cause a short.
• Before assembly, apply the engine oil to the
slide contact surface of the engine.
This work ensures appropriate lubrication
when first starting the engine.
• When the valve train component, piston,
piston ring, connecting rod, connecting rod
bearing, and/or crankshaft journal bearing
are removed, line them up in the correct or-
der so that their original positions are clear.
• When installing, install it in the same posi-
tion as when it was removed.
• When assembling the engine, replace the
gasket, oil seal, and O-ring with new ones.
• For a component with the liquid gasket ap-
plied, carefully remove the old liquid gasket
and clean the component so that no oil, wa-
ter, and/or dust remain.
Thereafter, apply the specified liquid gasket
to each component before assembly.
• Assemble components with the liquid gas-
ket applied within 5 minutes of applying the
liquid gasket.
If 5 minutes have passed, remove the old
liquid gasket and apply liquid gasket again.
84402826 - May 2011
4001G-3
• When assembling or installing a compo-
nent, make sure to tighten them at the
specified torque to ensure secure installa-
tion.
Important precautions for handling this en-
gine
The holes and gaps in the fuel system in-
cluding inside the injector where the fuel
passes through are manufactured with high
precision.
Therefore, these are extremely sensitive to
any foreign matter, and may be severely
damaged due to foreign matter accidentally
intruded.
For this reason, extreme care must be taken
to prevent any foreign matter from entering.
When performing maintenance on the fuel
system, take extreme care to prevent any
foreign matter from entering the system.
• Before starting maintenance, clean the fuel
line and its surroundings.
• Be sure to wash your hands before starting
maintenance.
Do not put on cotton work gloves.
• When the fuel hose or fuel pipe is removed,
cover the opening with a plastic bag and fix
it with a piece of tape.
WARNING
When the high-pressure piping of
the fuel system is removed, be sure
to replace it with a new one.
If it is reused, the sealing surface
may be damaged to cause fuel leak-
age.
• When replacing the fuel hose and/or fuel
pipe, do not unpack new components be-
fore starting installation.
• When the fuel pipe, injection pipe, fuel injec-
tor, fuel supply pump, and/or common rail
are removed, seal each opening immedi-
ately.
• Store the eyebolt and gasket in a clean parts
box with a cover so that foreign matter does
not attach to them.
• Fuel leakage may cause a fire.
Therefore, be sure to wipe spilled fuel af-
ter completing the maintenance work and
confirm that there is no fuel leakage before
starting the engine.
 Maintenance precautions
2) Cautions on electronic system
Using circuit test tools
Unless specifically instructed in the diag-
nostic procedure, do not use a test light
when diagnosing the powertrain electronic
system.
When a probe connector is required in the
diagnostic procedure, use the connector
test adapter kit.
SST: connector test adapter kit (refer to
section 1003)
Commercial electronic equipment
Commercial electronic equipment refers
to commercially available electronic equip-
ment attached to the unit after it has been
shipped from the factory.
Be careful, as such accessories are not
taken into particular consideration at the
machine design stage.
Commercial electronic equipment may
cause malfunctions in the electronic control
system, even if the equipment is properly
attached.
This includes equipment not connected to
the electronic system of the machine, such
as mobile telephones and radios.
Therefore, when diagnosing power train
problems, confirm whether such commer-
cial electronic equipment is attached first
and then remove them from the machine if
such equipment is attached.
If the problem has not been resolved after
removing the equipment, perform the diag-
nosis using the regular procedure.
CAUTION
• Make sure that commercial elec-
tronic equipment is connected to
a circuit that is not involved with
the circuits of the electronic con-
trol system for both power and
ground.
Welding operation for the actual unit
When performing welding to the actual unit,
make sure to disconnect the battery in prior
to the operation.
84402826 - May 2011
4001G-4
Current that occurred during welding may
lead to failure and/or damage to the elec-
tronic control system.
Damage caused by electrostatic discharge
As the electronic components used in the
electronic control system are designed to
operate at extremely low voltages, they
can be easily damaged by electrostatic
discharge, and some types of electronic
components can be damaged by static
electricity of 100 V or less, which cannot be
felt by a person.
Note that a voltage of 4000 V is required for
a person to be able to detect electrostatic
discharge.
There are various ways a person can build
up an electrostatic charge.
The most common way to build up an elec-
trostatic charge is through methods based
on friction or induction.
An example of when a person builds an
electrostatic charge by friction is when
he/she slides across the seat of the ma-
chine.
A person wearing insulated shoes can
build an electrostatic charge by induction
if he/she momentarily touches the ground
while standing near a highly charged object.
A charge of the same polarity flows out, and
with a highly opposing polarity, that person
becomes charged.
As static electricity causes damage, be
cautious when handling or testing electronic
components.
CAUTION
• To prevent damage due to electro-
static discharge, do not touch the
connector pins of the ECM or the
electronic components soldered
onto the circuit board of the ECM.
• To prevent damage due to elec-
trostatic discharge, do not open
the packaging of a replacement
part until installation preparation
for the replacement part is com-
pleted.
• To prevent damage due to electro-
static discharge, connect the part
packaging to a properly working
ground connection of the actual
unit before removing the part
from its packaging.
• To prevent damage due to electro-
static discharge, when handling a
part while sliding across the seat,
sitting down from a standing po-
sition, or walking a certain dis-
tance, touch a properly working
ground connection before attach-
ing the part.
 Maintenance precautions

Fuel injection system 3) Programming

Fuel piping
WARNING
The high pressure pipe and injector
pipe in the fuel system should not
be reused.
When it is once removed, make
sure to replace it with new one.
The pressure limiter or fuel pressure sensor
should not be replaced individually.
When a failure is found, the common rail
assembly and all fuel pipes should be re-
placed.
Programming guideline
When the ECM or injector has been re-
placed, the EST cannot be used to write
injector data into the ECM - it can either
be done with the Isuzu EIDSS or the en-
gine service monitor on the machine. Doug
Reinhardt wrote up the procedure in his
service training document, XC Engine Ser-
vice Monitor. Need clarification from Isuzu
on use of the EIDSS.
As for the programming method, refer to the
instruction manual of the trouble diagnosis
scan tool.
Prior confirmation item for programming
When performing programming, check the
ECM part No. as necessary.
When performing programming, check the
engine type as necessary.
When performing programming, check the
engine No. as necessary.
When performing programming, check the
injector ID code as necessary.
Items require programming
When the ECM has been replaced, perform
programming.
When the engine has been replaced, per-
form programming.
When the injector has been replaced, per-
form programming.

1 Injector pipe
2 Fuel pressure sensor
3 Pressure limiter
4 Common rail

84402826 - May 2011

4001G-5
Maintenance precautions

84402826 - May 2011

4001G-6
 Section

4004

Removal and Installation of Starter Motor

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

4004-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
4004-2 PRINTED IN FRANCE
 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)
• Rag
• Cleaning fluid

2. Use a wrench (19 mm) to remove the 4 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).

84402826 - May 2011

4004-3
 Removal and Installation of Starter Motor

4. Use a wrench (14 mm) to remove the bolt (7), and
then remove the wiring (8).
Installation of Starter Motor
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

84402826 - May 2011

4004-4
 Section

4005

Removal and Installation of Alternator

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

4005-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
4005-2 PRINTED IN FRANCE
 Removal and Installation of Alternator

Job code 55301AA10 Removal of Alternator

1. Remove the fan belt.
WARNING (For details, see "Fan Belt Replacement".)
2. Use a wrench (17 mm) to remove the bolt (1), and
• Do not use open flames and do not allow then remove the battery cable (2) on the negative
sparks near the battery.
side.

CAUTION • When removing the terminal and harness, secure

them so that they do not interfere with the frame.
• Be sure to stop the engine before beginning Also, cover with a rubber cap to protect against
work. sparks.

Items to prepare
• Wrenches (10 mm, 17 mm, 22 mm)
• Rag
• Cleaning fluid

3. Remove the connector (3).

4. Use a wrench (10 mm) to remove the bolt (4), and

then remove the wiring (5).

84402826 - May 2011

4005-3
 Removal and Installation of Alternator

5. Use a wrench (8 mm) to remove the nut (6), then Installation of Alternator
remove the wiring (5).
To install, perform the reverse of the removal procedure.
Adjust the fan belt according to the "Fan Belt Installa-
tion" tension adjustment procedures in "Fan Belt Re-
placement".

6. Use a wrench (22 mm) to remove the bolt (7), and

then remove the alternator (8).
Tightening torque for bolt installation: 127.0 N·m

84402826 - May 2011

4005-4
 Section

4008

Preheating System

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal and Installation of Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Removal of Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Glow plug Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

4008-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
4008-2 PRINTED IN FRANCE
 Preheating System

Removal and Installation of Glow Installation of Glow Plug

Plug 1. Glow plug Installation
1) Install the glow plug to the cylinder head as-
Removal of Glow Plug sembly.
1. Battery ground cable Disconnect Tightening torque： 20 N・m { 2.0 kgf・m /
14 lb・ft }
1) Disengage the battery ground cable from the
battery. CAUTION
2. Glow plug Removal • Be careful not to exceed the speci-
fied torque when tightening.
1) Remove the glow plug connector from the
glow plug.
2) Remove the glow plug from the cylinder head
assembly.

2) Install the glow plug connector to the glow

plug.
Tightening torque： 1 N・m { 0.1 kgf・m / 11
lb・in }

CAUTION
• Confirm that the glow plug connec-
tor does not interfere with the sur-
rounding parts.

2. Battery ground cable Connect

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

84402826 - May 2011

4008-3
 Preheating System

Glow plug Inspection

1. Glow plug Inspection
1) Measure the resistance using the circuit
tester.
Resistance： under 5.00 Ω

CAUTION
• Replace the glow plug if the mea-
sured value is not within the range
of standard value.
• Use a set of 4 glow plugs from the
same manufacturer.

84402826 - May 2011

4008-4
 Section

4020A

Electrical Equipment Layout Diagram

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Main Unit Center Section Layout Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Main Unit Left Side Layout Diagram (radiator chamber) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine Section Layout Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Main Unit Right Side Layout Diagram (pump chamber) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cab Layout Diagram 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cab Layout Diagram 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Layout Around Operator Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Stand Alone Parts Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

4020A-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
4020A-2 PRINTED IN FRANCE
 Electrical Equipment Layout Diagram

Main Unit Center Section Layout Diagram

1 Arm pressure sensor 4 Suction air sensor 7 Bucket pressure sensor

2 N1 pressure sensor 5 Upper pressure sensor
3 Boom pressure sensor 6 Travel pressure sensor

84402826 - May 2011

4020A-3
 Electrical Equipment Layout Diagram

Main Unit Left Side Layout Diagram (radiator chamber)

84402826 - May 2011

4020A-4
 Electrical Equipment Layout Diagram

1 Air cleaner sensor 6 Fusible link (IGN) 65 A 11 Battery relay

2 Air cleaner 7 Fuse: +B 50 A 12 Battery
3 Shuttle valve 8 Fuse: ST 50 A 13 Receiver dryer sensor
4 Swing pilot pressure sensor 9 Fuse: Computer 20 A 14 Washer motor
5 Glow relay 10 Starter relay

84402826 - May 2011

4020A-5
 Electrical Equipment Layout Diagram

Engine Section Layout Diagram

84402826 - May 2011

4020A-6
 Electrical Equipment Layout Diagram

Engine coolant temperature

1 6 Boost temperature sensor 11 Cam position sensor
sensor
2 Boost pressure sensor 7 Starter motor 12 Crank position sensor
Engine hydraulic pressure sen-
3 Overheat switch 8 13 Intake manifold sensor
sor
4 Common rail pressure sensor 9 Suction control valve
5 EGR valve 10 Fuel temperature sensor

84402826 - May 2011

4020A-7
Electrical Equipment Layout Diagram

84402826 - May 2011

4020A-8
 Electrical Equipment Layout Diagram

1 Sensor hose DPD FT 3 Pressure sensor DPD 5 Thermo-sensor DPD CT

2 Sensor hose DPD RR 4 Thermo-sensor DPD FT 6 MAF sensor

84402826 - May 2011

4020A-9
 Electrical Equipment Layout Diagram

Main Unit Right Side Layout Diagram (pump chamber)

84402826 - May 2011

4020A-10
 Electrical Equipment Layout Diagram

Horsepower control propor-

1 Magnetic fuel pump 6 Lever lock 11
tional valve
2 P1 pressure sensor 7 Swing brake 12 Oil temperature sensor
3 P2 pressure sensor 8 2-stage relief 13 N2 pressure sensor
4 5 stack solenoid valve 9 2-stage travel
Actual milli-amp for flow control
5 Power save 10
proportional valve

84402826 - May 2011

4020A-11
 Electrical Equipment Layout Diagram

Cab Layout Diagram 1

84402826 - May 2011

4020A-12
 Electrical Equipment Layout Diagram

1 Air conditioner sunlight sensor 6 Rocker switch 11 Air conditioner control panel
2 Monitor display 7 Wiper motor 12 Engine emergency stop switch
3 Knob 8 Radio 13 Rocker switch
4 Cigar lighter 9 Throttle volume 14 Gate lock limit switch
5 Wiper controller 10 Key cylinder

84402826 - May 2011

4020A-13
 Electrical Equipment Layout Diagram

Cab Layout Diagram 2

84402826 - May 2011

4020A-14
 Electrical Equipment Layout Diagram

1 Computer B 3 ECM (engine control module) 5 Relay

2 Computer A 4 Fuse box

No. Name No. Name No. Name

CN. A9 ECM relay CN. A14 Neutral start relay CN. A19 Beacon relay
CN. A10 DPF relay CN. A15 Key ON relay CN. A20 Room lamp relay
CN.A11 Battery relay CN. A16 Horn relay CN. A21 Right speaker relay
CN. A12 Idle stop relay CN. A17 Boom, house light relay CN. A22 Left speaker relay
CN. A13 Starter cut relay CN.A18 Cab top light relay

No. Name No. Name

F1 Key switch 15 A F11 Wiper, washer 15 A
F2 ECM (engine control module) 20 A F12 Travel alarm, signal lamp 10 A
F3 GPS computer 15 A F13 Cigar lighter, seat suspension 10 A
F4 Backup (radio, room lamp) 10 A F14 DC converter 10 A
F5 Gate lock lever 10 A F15 Air conditioner unit 5A
F6 Solenoid 10 A F16 Air conditioner blower motor 15 A
F7 Horn 10 A F17 Air conditioner compressor 5A
F8 Cab top light 15 A F18 Option power supply 10 A
F9 Boom, house light 15 A F19 Feed pump 15 A
F10 Option power supply 15 A F20 Option line solenoid 10 A

84402826 - May 2011

4020A-15
 Electrical Equipment Layout Diagram

Layout Around Operator Seat

84402826 - May 2011

4020A-16
 Electrical Equipment Layout Diagram

Air conditioner
1 Cup holder 5 Throttle volume 9
control panel
Engine emer-
2 Starter switch 6 Tilt lever right 10
gency stop switch
Rocker switch
3 7 Tilt lever left 11 Gate lever
space
4 Radio 8 Ashtray

84402826 - May 2011

4020A-17
 Electrical Equipment Layout Diagram

Stand Alone Parts Diagram

Name Shape Circuit Remarks

Specification;
For +24 VDC
Battery relay
Sumitomo part
No.; KHR1241

Specification;
5.0 kW -24 V
Starter motor
Isuzu part No.;
898070-3211

Specification;
50 A -24 V
Alternator
Isuzu part No.;
898092-1161

Model;
130E41R
Battery
Sumitomo part
No.; KHR3944

Sumitomo part
Washer motor No.; KHR2261
(tank + motor)

84402826 - May 2011

4020A-18
 Electrical Equipment Layout Diagram

Name Shape Circuit Remarks

Specification;
Fusible link 65 A
(fuse box) Sumitomo part
No.; KHR1592

Specification;
Fusible link 50 A
(safety relay) Sumitomo part
No.; KHR3850

Model; 7224-
Fuse 8511 (20 A)
(computer) 7224-8512 (15
A)

Model;
RA30Y2
Throttle vol-
30SKB1KΩK
ume
Sumitomo part
No.; KHR2751

Specification;
24 VDC
Starter switch Sumitomo
part No.;
KHR20050

84402826 - May 2011

4020A-19
 Electrical Equipment Layout Diagram

Name Shape Circuit Remarks

Sumitomo
Fuel level sen-
part No.;
sor
KHR10670

Specification;
24 VDC
Charge fuel
Sumitomo
pump
part No.;
KHH11880

Sumitomo
Reserve tank
part No.;
limit switch
KHH10840

Sumitomo
Vacuum sen-
part No.;
sor
KHH10330

84402826 - May 2011

4020A-20
 Electrical Equipment Layout Diagram

Name Shape Circuit Remarks

Isuzu part No.;

Glow plug
894390-7776

EGR valve ac-

EGR motor cessory
EGR position EGR valve
sensor Isuzu part No.;
898170-5910

Common rail
Common rail accessory
pressure sen- Common rail
sor Isuzu part No.;
898027-4560

Cam angle Isuzu part No.;

sensor 898019-0240

Crank angle Isuzu part No.;

sensor 897606-9430

84402826 - May 2011

4020A-21
 Electrical Equipment Layout Diagram

Name Shape Circuit Remarks

Oil pressure Isuzu part No.;

sensor 898027-4560

Boost pressure Isuzu part No.;

sensor 180220-0140

Boost temper- Isuzu part No.;

ature sensor 81246-8300

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

Supply pump
accessory
Suction control
Supply pump
valve
Isuzu part No.;
897306-0448

84402826 - May 2011

4020A-22
 Electrical Equipment Layout Diagram

Name Shape Circuit Remarks

Isuzu part No.;

Injector
898151-8560

Suction air Isuzu part No.;

temperature 897601-9670
and flow sen- Sumitomo
sor part No.;
(MAF sensor) KHH13270

Engine coolant
Isuzu part No.;
temperature
897363-9360
sensor

Isuzu part No.;

Barometric
897217-7780
pressure sen-
Sumitomo part
sor
No.; KHH0536

Sumitomo
Computer A part No.;
KHR29000

84402826 - May 2011

4020A-23
 Electrical Equipment Layout Diagram

Name Shape Circuit Remarks

Specification;
24 VDC
Relay
Sumitomo part
No.; KHR3802

DC-DC con- Sumitomo part

verter No.; KHR2447

Alarm Sumitomo part

(feed pump) No.; KHR4024

Sumitomo
Feed pump part No.;
KHR12840

Sumitomo
Feed pump
part No.;
switch
KHR12900

84402826 - May 2011

4020A-24
 Electrical Equipment Layout Diagram

Name Shape Circuit Remarks

Specification;
Lamp
24 V 70 W
(front right
Sumitomo part
housing)
No.; KHR2475

Specification;
Lamp 24 V 70 W
(boom) Sumitomo part
No.; KHR0957

Specification;
24 V 70 W
Lamp
Sumitomo
(cab top)
part No.;
KHR16240

Speaker Sumitomo part

(right) (left) No.; KHR3366

Model;
SD107023
Monitor display Sumitomo
part No.;
KHR23591

84402826 - May 2011

4020A-25
 Electrical Equipment Layout Diagram

Name Shape Circuit Remarks

Specification;
Pressure sen- 50.0 MPa
sor Sumitomo
(P1) (P2) part No.;
KHR10290

Pressure sen-
sor Specification;
(N1) (N2) 5.0 MPa
(swing) (upper) Sumitomo
(travel) (arm in) part No.;
(bucket close) KHR26940
(boom up)

Specification;
Pressure
0.49 MPa
switch
Sumitomo
(option) (2nd
part No.;
option)
KHR21490

Pressure Sumitomo
switch part No.;
(filter) KHR14470

Sumitomo
5 stack sole-
part No.;
noid valve
KHJ14520

84402826 - May 2011

4020A-26
 Electrical Equipment Layout Diagram

Name Shape Circuit Remarks

2 stack sole-
Sumitomo
noid valve
part No.;
(knob switch
KHJ14780
type)

2 stack sole- Sumitomo

noid valve part No.;
(pedal type) KHJ14000

P1 flow control Sumitomo

proportional part No.;
valve TIP0002128

Horsepower
Sumitomo part
control propor-
No.; LJ00684
tional valve

84402826 - May 2011

4020A-27
 Electrical Equipment Layout Diagram

Name Shape Circuit Remarks

Model; KAB
555
KAB seat Sumitomo
part No.;
KHN13560

Hydraulic oil
Sumitomo part
temperature
No.; KHR2433
sensor

Model; With 4
Knob; Right switches
(with one- Sumitomo
touch switch) part No.;
KHJ24640

Model; With 4
Knob; Left
switches
(with horn
Sumitomo
switch and ra-
part No.;
dio mute)
KHJ24630

Sumitomo part
No.; KHR3852
Travel alarm Basic fre-
quency; 2560
Hz

84402826 - May 2011

4020A-28
 Electrical Equipment Layout Diagram

Name Shape Circuit Remarks

Sumitomo
part No.;
KHR21430
Horn (low)
Basic fre-
quency; 350
Hz

Sumitomo
part No.;
KHR21440
Horn (high)
Basic fre-
quency; 415
Hz

Sumitomo
Wiring Sys-
tems part No.;
Diode 6098-0017,
6098-0061
Sumitomo part
No.; KHP1796

Sumitomo
Lever lock limit
part No.;
switch
KHR14930

84402826 - May 2011

4020A-29
 Electrical Equipment Layout Diagram

Name Shape Circuit Remarks

Specification;
Lamp 24 V, 10 W
(room lamp) Sumitomo part
No.; KHN2714

Specification;
Accessory 12 VDC
socket Sumitomo part
No.; KHR2501

Specification;
24 VDC
Cigar lighter 24
Sumitomo
V
part No.;
KHR11210

Air conditioner Sumitomo part

unit No.; KHR2716

84402826 - May 2011

4020A-30
 Electrical Equipment Layout Diagram

Name Shape Circuit Remarks

Limit switch
Sumitomo part
(front window)
No.; KHR2950
(door)

Wiper con- Sumitomo part

troller No.; KHN3392

Sumitomo
Wiper motor part No.;
KHN25780

Sumitomo
Solar radiation
part No.;
sensor
KHR10540

Sumitomo
Receiver dryer
part No.;
(switch)
KHR13590

84402826 - May 2011

4020A-31
 Electrical Equipment Layout Diagram

Name Shape Circuit Remarks

Air conditioner
compressor Sumitomo part
(magnetic No.; KHR3197
clutch)

Motor actuator
Sumitomo
(air mix)
part No.;
(mode) (inside/
KHR27530
outside air)

Sumitomo
EVA sensor part No.;
KHR27650

Interior tem- Sumitomo

perature sen- part No.;
sor KHR27490

Relay
Sumitomo part
(compressor)
No.; KHR2836
(blower OFF)

84402826 - May 2011

4020A-32
 Electrical Equipment Layout Diagram

Name Shape Circuit Remarks

Sumitomo
Blower motor part No.;
KHR27850

Sumitomo
Blower amp part No.;
KHR27840

Sumitomo
Air conditioner
part No.;
switch panel
KHR27250

Engine emer- Sumitomo

gency stop part No.;
switch KHR28530

Sumitomo
Beacon switch part No.;
KHR15480

84402826 - May 2011

4020A-33
 Electrical Equipment Layout Diagram

Name Shape Circuit Remarks

Sumitomo
Glow relay part No.;
KHH13260

Sumitomo
Horn volume
part No.;
select switch
KHR28540

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)

84402826 - May 2011

4020A-34
 Electrical Equipment Layout Diagram

Name Shape Circuit Remarks

Isuzu part No.;

DPD tempera- 898004-3300
ture sensor Sumitomo
(Isuzu) (CT) part No.;
KHH13360

Isuzu part No.;

DPD tempera- 898004-3290
ture sensor Sumitomo
(Isuzu) (FT) part No.;
KHH13350

Isuzu part No.;

Turbo com- 898133-1241
puter Sumitomo
(Isuzu) part No.;
KBH13650

EGR manifold Isuzu part No.;

temperature -
sensor Sumitomo part
(Isuzu) No.; -

Sumitomo part
VGS TURBO
No.; -

84402826 - May 2011

4020A-35
Electrical Equipment Layout Diagram

84402826 - May 2011

4020A-36
 Section

4020B

Connection Connector Pin Layout

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Computer A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

4020B-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
4020B-2 PRINTED IN FRANCE
 Connection Connector Pin Layout

Computer A

84402826 - May 2011

4020B-3
 Connection Connector Pin Layout

Monitor

84402826 - May 2011

4020B-4
 Section

4020C

Sequence Circuit Diagram

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Code table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Overall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Computer A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Computer B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Lever Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Working lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Other . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electrical Symbol List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

4020C-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
4020C-2 PRINTED IN FRANCE
 Sequence Circuit Diagram

Code table

FRONT WINDOW LIMIT

A1 COMPUTER H8 CCD CAMERA S54
SWITCH
RESERVE TANK LOW
A2 ENGINE CONTROLLER K2 RELAY-GLOW PLUG S55
SWITCH
A4 WIPER CONTROLLER K3 RELAY-HORN S61 REFUEL PUMP SWITCH
A6 BLOWER CONTROLLER K5 RELAY-ROTARY LIGHT S62 AIR CLEANER SENSOR
RELAY-AIR CONDITIONER
A13 CONTROLLER B K6 S70 HORN VOLUME SWITCH
CONDENSER FAN
PRESSURE SWITCH FILTER
A14 TURBO CONTROLLER K7 RELAY BATTERY S71 INDICATOR (BREAKER OP-
TION)
RELAY-WORKING LIGHT
COOLANT TEMPERATURE
B1 K10 (UPPERSTRUCTURE / AT- S85 BEACON (EU)
SENSOR
TACHMENT)
HYDRAULIC OIL TEMPERA- RELAY-WORKING LIGHT DC-DC (24V-12V) CON-
B2 K11 U1
TURE SENSOR (CAB) VERTER
FUEL TEMPERATURE SEN- ROTARY LIGHT CONNEC-
B3 K17 BLOWER OFF RELAY X2
SOR TOR
OPTIONAL POWER CON-
B5 EVAPORATOR SENSOR K30 REFUEL PUMP RELAY X3
NECTOR
ENGINE OIL PRESSURE ENGINE TEST POINT CON-
B21 K31 REFUEL PUMP STOP RELAY X4
SWITCH NECTOR
SWING PILOT PRESSURE CONTROLLER TEST POINT
B22 K34 RELAY STARTER CUT X5
SWITCH CONNECTOR
UPPER PILOT PRESSURE CAB SEAT COMPRESSOR
B26 K35 RELAY ROOM LAMP X6
SENSOR MOTOR CONNECTOR
TRAVEL PILOT PRESSURE ANTI-THEFT SYSTEM CON-
B27 K36 RELAY SPEAKER LEFT X9
SENSOR NECTOR
SECOND OPTION PILOT CIR-
B28 K37 RELAY SPEAKER RIGHT X15 ACCESSORY SOCKET
CUIT 1 PRESSURE SWITCH
PUMP PRESSURE SENSOR
B40 K63 RELAY ECM X23 CLEAR MEMORY 1
(NEGA-CONT. P2)
PUMP PRESSURE SENSOR
B42 K64 RELAY KEY ON X24 CLEAR MEMORY 2
(P1)
PUMP PRESSURE SENSOR
B43 K65 RELAY BATTERY RL X25 TO CONTROLLER C
(NEGA-CONT. P1)
PUMP PRESSURE SENSOR
B44 K66 RELAY IDLE STOP X26 EST CONECTOR B
(P2) (BLUE BAND)
OVERLOAD INDICATOR
B45 K67 RELAY DPF X27 TO GPS UNIT
PRESSURE SWITCH
B47 BOOST PRESSURE SENSOR K68 RELAY NEUTRAL START X32 TO DRM
AMBIENT AIR (BAROMET-
B48 K69 RELAY STARTER X33 FOR CRANE
RIC) PRESSURE SENSOR
CRANKSHAFT POSITION
B49 M1 STARTER MOTOR X34 FOR FAN REVERSE
SENSOR
BOOST TEMPERATURE 12V OUTPUT(FOR RADIO
B51 M3 WIPER MOTOR X36
SENSOR EU)
COMMON RAIL PRESSURE PILOT PRESSURE SOLE-
B52 M4 WASHER MOTOR Y2
SENSOR NOID VALVE (BLUE BAND)
SWING BRAKE SOLENOID
B61 SUNLOAD SENSOR M5 MOTOR (AIR CHANGING) Y3
VALVE (WHITE BAND)
AIR VENT DIRECTION CON- 2 STAGE TRAVEL SOLENOID
B82 REFUEL PUMP STOP ALARM M6 Y4
TROL MOTOR VALVE (RED BAND)
PRESS. SENSOR (PILOT MOTOR ACTUATOR (AIR POWER-UP SOLENOID
B83 M7 Y5
ARM CLOSE) MIX) VALVE (YELLOW BAND)
PRESS. SENSOR (PILOT POWER SAVE SOLENOID
B84 M8 BLOWER MOTOR Y6
BUCKET CLOSE) VALVE (GREEN BAND)
PRESS. SENSOR (PILOT MAIN PUMP POWER PRO-
B85 M14 FUEL FEED PUMP MOTOR Y7
BOOM UP) PORTIONAL SOLENOID
84402826 - May 2011
4020C-3
 Sequence Circuit Diagram

AIR CONDITIONER MAGNET

B86 EGR INTAKE TEMP. SENSOR M20 ELECTRIC FUEL PUMP Y8
CLUTCH
OPTION 2 SPEED SOLENOID
B87 CAM ANG(MRE) SENSOR M23 VGS TURBO Y9
VALVE (BLUE TAPE)
INTAKE THROTTLE DC-MO- MAIN PUMP FLOW PROPOR-
B88 FUEL FILTER SENSOR M24 Y11
TOR TIONAL SOLENOID
EXHAUST GAS RECIRCULA- FREE SWING SOLENOID
B89 EXSHAUST PRESS. SENSOR M25 Y18
TION VALVE VALVE (NA)
EXSHAUST TEMP. SEN- OPT.1 KNOB (R) -R SOLE-
B90 P1 INSTRUMENT PANEL Y23
SOR(CNT) NOID VALVE (BLUE TAPE)
EXSHAUST TEMP. SEN- SWITCH PANEL (LEFT- OPT.1 KNOB (R) -L SOLE-
B91 P2 Y24
SOR(FNT) HAND) NOID VALVE (RED TAPE)
SWITCH PANEL (RIGHT- OPT.2 KNOB (L) -R SOLE-
B92 HORN LOW (LEFT) P3 Y25
HAND) NOID VALVE (BLUE TAPE)
AIR CONDITIONER SWITCH OPT.2 KNOB (L) -L SOLENOID
B93 HORN HIGH (RIGHT) P6 Y26
PANEL VALVE (RED TAPE)
PRESS. SWITCH (1ST OP- OPTION SELECT SOLENOID
B94 P15 RADIO SET (NA) Y27
TION) VALVE (RED TAPE)
AIR INTAKE SENSOR MASS SUCTION CONTROL VALVE
B95 R1 GLOW PLUG Y35
& TEMP (SCV)
WORKING LIGHT (UPPER- BOOM UP PROPORTIONAL
E1 R3 THROTTLE VOLUME Y59
STRUCTURE) SOLENOID VALVE (NO TAPE)
ARM CLOSE PROPOTIONAL
WORKING LIGHT (ATTACH- THERMISTOR INNER TEM-
E2 R4 Y60 SOLENOID VALVE (RED
MENT) PERATURE
TAPE)
BUCKET CLOSE PROPO-
E3 WORKING LIGHT (CAB) R5 FUEL SENSOR Y61 TIONAL SOLENOID VALVE
(BLUE TAPE)
OPTION PRESS. PROPOR-
E4 CAB LIGHT R7 RESISTOR (MAF) Y62
TIONAL SOLENOID VALVE
E51 CIGAR LIGHTER S1 KEY SWITCH Y63 INJ1 (#1)
ENGINE EMERGENCY STOP
E52 AIR CONDITIONER S9 Y64 INJ2 (#3)
SWITCH
G1 BATTERY S13 OVERLOAD SWITCH (EU) Y65 INJ3 (#4)
FREE SWING (NA) ; OP-
G2 ALTERNATOR S22 Y66 INJ4 (#2)
TIONAL (EU)
HYDRAULIC FUNCTION
OPTION SELECT SOLENOID
H2 TRAVEL ALARM S51 CANCELLATION LEVER Y67
VALVE (BLUE TAPE)
SWITCH
AIR CONDITIONING COM- OPTION 2SPEED SOLENOID
H4 SPEAKER RIGHT S52 Y68
PRESSOR CLUTCH SWITCH VALVE (RED TAPE)
H5 SPEAKER LEFT S53 DOOR LIMIT SWITCH

84402826 - May 2011

4020C-4
 Sequence Circuit Diagram

Overall

84402826 - May 2011

4020C-5
Sequence Circuit Diagram

84402826 - May 2011

4020C-6
 Sequence Circuit Diagram

Block diagram
Computer A

84402826 - May 2011

4020C-7
 Sequence Circuit Diagram

Computer B

84402826 - May 2011

4020C-8
 Sequence Circuit Diagram

ECM

84402826 - May 2011

4020C-9
 Sequence Circuit Diagram

Monitor

84402826 - May 2011

4020C-10
 Sequence Circuit Diagram

Air Conditioner

84402826 - May 2011

4020C-11
 Sequence Circuit Diagram

Lever Lock

Horn

Working lights

84402826 - May 2011

4020C-12
 Sequence Circuit Diagram

Option

84402826 - May 2011

4020C-13
 Sequence Circuit Diagram

Other

84402826 - May 2011

4020C-14
 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

84402826 - May 2011

4020C-15
 Sequence Circuit Diagram

Symbol Name Symbol Name

Relay contact "b" contact Speaker

Solenoid valve Lamp

84402826 - May 2011

4020C-16
 Section

4021

Engine-side DTC List

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Engine-side DTC List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

4021-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
4021-2 PRINTED IN FRANCE
 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
84402826 - May 2011
4021-3
 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

84402826 - May 2011

4021-4
 Section

4022

Main Unit-side DTC List

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Main Unit-side DTC List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

4022-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
4022-2 PRINTED IN FRANCE
 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
84402826 - May 2011
4022-3
 Main Unit-side DTC List

DTC Trouble mode

7605 ECM Mismatch
7606 EEPROM Data Abnormality
7607 Computer C Communication Abnormality

84402826 - May 2011

4022-4
 Section

4023B

Introduction to the trouble diagnosis

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Introduction to the trouble diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

4023B-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
4023B-2 PRINTED IN FRANCE
 Introduction to the trouble diagnosis

Introduction to the trouble diagnosis

1. Introduction to the trouble diagnosis
1) About trouble diagnosis
The following trouble diagnosis procedure is extremely important to resolve problems of all electric/elec-
tronic systems.
Neglecting to implement these steps may result in requiring unnecessary repairs.
Read and understand the procedure carefully and proceed with the trouble diagnosis.
Also, use available functions and the trouble diagnosis scan tool to perform the trouble diagnosis and sys-
tem check.
2) Trouble diagnosis procedure
Checking complaints from customer
• Use the check sheet to organize the trouble situation.
Performing preliminary inspection
• Perform overall visual inspection.
• Check the past maintenance history.
• Detect any abnormality such as abnormal noise, smell, etc.
• Collect the failure trouble DTC information to provide effective repair.
• Inspect for an abnormality by comparing to the standard value.
Inspect the service information
• Check the market service bulletin.
Perform inspection for the displayed code.
• Inspect the item shown by DTC.
Perform an inspection for problems according to symptoms
• Check the item that is not displayed in the DTC.
NOTE
System trouble diagnosis type
The system diagnosis method is a standardized method applied for repairing all electric/electronic systems.
Failures in electric/electronic systems often occur in the following steps unlike common actual unit failures.
Initial stage of failure
The failure occurs sporadically and for a short time, often times the driver does not notice it.
At this stage, the customer's complaint is unclear, and the malfunction cannot be reproduced.
However, the ECM may have recorded the failure.
Past malfunction, past failures
Middle stage of failure
The failure occurs sporadically and for a short time, but may occur repeatedly at intervals, and occurs under
specific conditions.
The customer complaint is clear, but the failure conditions are unclear.
Therefore, the person performing the diagnosis can reproduce the failure by understanding its conditions.
Intermittent failures, intermittent
Stage where failure is realistic
The occurrence of the failure is set, and the customer complaint is real and clear.
Therefore, the person performing the diagnosis can reproduce the failure.
However, there may sometimes be more than 2 causes for the failure.
Current malfunction, Current failures

84402826 - May 2011

4023B-3
 Introduction to the trouble diagnosis

3) Diagnosis
Fully understand the description given by the customer using the Engine Control System Check Sheet.
ANNOTATION:
• When questioning, do not ask randomly but focus on the system that is inferred to be defective based on
the malfunction phenomenon.
Determine failure information accurately.
Have concrete understanding based on 5W1H.
Low air temperature, at start or on a steady basis, near the engine parts, metallic sound, etc.
Check points
• Failure symptoms
• Month and Date, Time, Frequency of occurrence
• Road conditions
• Working conditions, Operation conditions, Weather
• Feeling of symptom
Engine control system check sheet
When receiving the actual unit from the customer at the service factory, the failure symptoms and the data
on occurrence of failure must be confirmed with the customer based on the engine control check sheet.
• Failure symptoms may not be able to be reproduced at the service factory.
• The customer's complaint may not always be a malfunction.
• Notification of incorrect malfunction conditions to the person in charge of repairs may result in unneces-
sary man-hours for repairs.
• The check sheet assists actual unit diagnosis, repair, and repair confirmation at the vehicle servicing
station.

1 Failure symptoms
Failure frequency・failure con-
2
ditions

84402826 - May 2011

4023B-4
Introduction to the trouble diagnosis

84402826 - May 2011

4023B-5
 Introduction to the trouble diagnosis

4) Preparatory check
Visual inspection of engine room
When implementing the diagnostic procedures, carefully make a visual inspection of the engine room.
This inspection can often lead to solving a problem without taking extra steps.
• Visually inspect all air hoses for punched holes, cuts, disconnections, and appropriate piping.
• Visually inspect the hoses that are difficult to see behind other components.
• For every harness in the engine room, visually inspect that all harnesses are properly connected.
Inspect that there are no burned or worn areas, that the harnesses are properly fastened and that they
are not in contact with sharp edges or the hot exhaust manifold or pipes.
Checking the machine maintenance status
If the maintenance of the actual machine is not performed correctly, the monitor may illuminate.
Restricted oil filters, fuel filters, and crankcase deposits due to lack of oil changes or improper oil viscosity
can trigger actual unit faults that were not previously monitored prior to OBD.
Poor vehicle maintenance cannot be classified as a non-machine failure, but since the sensitivity of OBD
system checks is high, actual unit maintenance schedules must be further closely followed.
Non-OEM parts
All the OBD system checks are adjusted to operate with the genuine parts.
Therefore, when a commercially sold sensor or switch, etc. is installed, a wrong diagnosis is made, and
the monitor comes on.
Accordingly, if general commercially-available sensors or switches are installed, this will cause mistakes in
diagnosis and the monitor to show an abnormality display.
If a commercially-available electronic device such as a mobile phone, stereo or anti-theft device is inappro-
priately installed, an EMI may be emitted to the control system.
As the result, false sensor information is generated causing the monitor to come on.
When conducting a trouble diagnoses, either turn OFF the power for all commercially sold parts or remove
them, and then check the failure again.
NOTE
Related system failure
Many OBD system checks go into the backup operation mode based on the instruction from the ECM which
is given when the ECM detects a failure in the related systems or components.
When the backup operation mode is activated, the output is reduced to protect the actual unit.

84402826 - May 2011

4023B-6
 Introduction to the trouble diagnosis

5) Trouble diagnosis
Basic knowledge of tools required
ANNOTATION:
• When performing the diagnostic procedure, lack of basic knowledge regarding this powertrain could result
in an incorrect diagnosis or damage to the powertrain components.
Do not attempt to diagnose a problem related to the powertrain without having the basic knowledge.
A basic understanding of hand tools, such as the trouble diagnosis scan tools, is required to utilize the
service manual effectively.
About the diagnostic test performed on the actual unit
Past failures
• The diagnostic tests of the previous ignition cycle have been completed.
• The diagnostic tests of the current ignition cycle have passed.
• Problems identified in the diagnostic tests currently do not exist.
Current failures
• The diagnostic tests of the previous ignition cycle have been completed.
• Problems identified in the diagnostic tests currently exist.
• Problems exist in the current ignition cycle.
Glossary
DTC
Every time the starter switch is turned ON, the ECM performs the self-test on most of the wiring and com-
ponents, records any detected system failure in the memory of the ECM, and performs the backup control,
depending on the DTC.
Also, abnormalities that affect travel will cause the monitor to show an abnormality display to inform the
operator.
Ignition cycle
Because the actual unit activates with a method to satisfy a predetermined diagnosis standard, an ignition
cycle is defined as turning the starter switch ON, running, then turning the starter switch OFF.
Monitor
In general, the monitor shows an abnormality display when a malfunction occurs in electronic control such
as the ECM and a DTC is detected.
DLC
The equipment for communicating with the control unit is the Data Link Connector (DLC).
The DLC is also provided to establish a connection with the scan tool.
Identification of recorded
DTC Reading the serial data
ANNOTATION:
• The installation position of the DLC and existence or nonexistence of the DLC vary depending on the
actual unit, so refer to the manual of the actual unit.
ECM OFF
Turn the ECM off starter switch off and the ECM power supply completely tops in approximately 10 seconds
to disable the ECM.
General diagnostic operations of the components monitor
To run the engine normally, a general diagnosis of the components is required.
Input components
Inspect the input components to see whether an open in the circuit or outside range value exists.
Crankshaft position sensor
Camshaft position sensor
Water temperature sensor
Boost sensor
Fuel pressure sensor
Accelerator position sensor
Output components
The output components are inspected to diagnose whether responses to commands from the control unit
are appropriate.
Inspect whether the circuits have disconnections and whether their values are within the range.
Suction control valve
Light, Relay control
Magnetic valve
Monitor

84402826 - May 2011

4023B-7
 Introduction to the trouble diagnosis

6) DTC reading procedure

Reading DTC with monitor
Current and past DTCs recorded in the ECM can be displayed by connecting the diagnostic switch and
blinking the monitor.
• Switch the starter switch ON and check that the monitor shows an abnormality display.
• Turn the starter switch ON, but the engine off.
• Connect the diagnostic switch.
For an actual unit with no diagnostic switch, short the DLC No. 1 and No. 4 or No. 5.
• Read the blinking count of the monitor.
• The DTC determines the failure contents from the diagnostic trouble code list.
If the trouble diagnostic scan tool is connected, the diagnostic codes can be read by operating the trouble
diagnostic scan tool.
ANNOTATION:
• As for the installation position of the monitor, refer to the manual of the actual unit.
Display code when no DTC is recorded
Code 1 (indicating the start of code display) continues to be displayed.
Display when a DTC is recorded
The recorded trouble codes are displayed 3 times.
If more than 2 or more trouble codes have been recorded, the DTCs will be output in ascending order with
each DTC being displayed three times.
After displaying all codes, the codes will be displayed again starting with the smallest code number.
This display continues while the diagnosis connector is connected.

a At code "23"
b At code "413"

*1 ON *3 Tens digit *5 Hundreds digit

*2 Goes off *4 Units digit

84402826 - May 2011

4023B-8
 Introduction to the trouble diagnosis

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

The current and past DTCs are both displayed while the engine is being stopped.
While the engine is in operation, the light is turned on only when a current DTC exists.
Using the trouble display monitor to read the DTC
When a DTC occurs, the DTC can be displayed on the trouble display monitor of the actual unit.
Using the scan tool to read the DTC
The DTC can be read using the trouble diagnosis scan tool.
ANNOTATION:
• For the work procedure, refer to the manual of the trouble diagnosis scan tool.
When the DTC is recorded
Perform repairs accurately according to the specified DTC chart.
If no DTC is available
Select the symptom from "Diagnosis By Symptom".
Complete the repair according to the diagnostic procedure.
It is also possible to perform the inspection by referring to the functional diagnosis.
When the appropriate symptom is not found;
Investigate the complaint in detail.
Create a diagnosis plan.
Utilize the schematics and operation principles.
When repair history for similar cases are available, request technical assistance.
Combine technical knowledge and effective utilization of available service information.
Intermittent
A failure condition that does not necessarily always appear is referred to as intermittent.
Check the DTC information and the data display.
Verify the symptoms and conditions reported by the customer.
Use a check sheet or other method to check the circuit or electronic system components.
When no trouble is detected
This status indicates that the actual unit is determined as operating properly.
The condition reported by the customer may be normal.
Check the customer complaint by comparing to other actual unit that is operating properly.
However, depending on the condition, it may be an intermittent.
Before returning the actual unit, check the complaint under the conditions given by the customer.
Investigate the complaint again.
If the complaint cannot be adequately detected or confirmed , it is necessary to perform the diagnosis again
to verify the complaint.
As stated above in "Intermittent", the complaint may be an intermittent or normal condition.
Repair and confirm.
Perform the repair when the cause has been confirmed.
Confirm that the operation is performed properly, and that the symptom has been corrected.
This includes the confirmation test performed on the actual unit or other methods to confirm that the com-
plaint has been resolved.
Confirm by testing under the conditions given by the customer.
When a DTC is diagnosed, confirm that the failure has been repaired by reproducing the condition that
appeared when the DTC was set while checking the scan tool data.

84402826 - May 2011

4023B-9
 Introduction to the trouble diagnosis

7) Check after repair

Check repair on actual unit
When an repair has been performed for the electronic control system, it is necessary to check that the repair
is accurate after repairing the actual unit.
If this confirmation is not done thoroughly, the monitor may show an abnormality display again or operability
problems may occur when the actual machine is handed over to the customer.
It is especially necessary to recreate customer complaint conditions and confirm repair for intermittent prob-
lems.
About confirmation of the actual unit repairs
It is effective to use the OBD system check for confirming actual unit repairs.
After the repair is completed, the person who have performed the actual unit diagnosis shall review either
the DTC that was diagnosed or scan tool data, or both, and record it.
Clear the DTC.
Run the actual unit based on the scan tool data.
Check the DTC status information of the specified DTC that was diagnosed until the diagnosis test related
to that DTC is implemented by the control unit.
The implementation of these steps is extremely important when checking the repair status with the OBD
system check.
Neglecting to implement these steps may result in unnecessary repairs.

84402826 - May 2011

4023B-10
 Introduction to the trouble diagnosis

8) Final check item list

Item Item Objective Method

Clear the previous DTCs.
Keep the engine idling to warm up,
Confirm the DTC display after the re-
1 DTC check then perform a racing run to increase
pair.
the engine rpm to No Load Max to se-
cure the test conditions.
Check whether the idling rotation
Idling speed speed is constant under the no load
To check whether the idling control is
2 check after warm- condition after engine is warmed up.
operating normally.
ing up the engine If a problem is detected, refer to Idling
Unstable in Diagnosis by Symptom.
Monitor the scan tool data list, and
Check the engine control, communica- check the values using a typical value
Confirm the scan
3 tion status error and abnormality under sheet.
tool data list
the standard condition. Confirm the typical values of the scan
tool data list.
After warming up the engine, confirm
that the cranking time is 5 seconds or
Re-startability To check whether the starting control is
4 less when restarting the vehicle, and
check normal.
that the engine revolution is stable after
starting.
Check whether turning the electromag-
netic transmitter such as a transceiver
When electromagnetic transmitters ON and OFF causes the idling engine
Check powerful
such as a transceiver have been added rpm to change.
5 electromagnetic
to the vehicle, confirm that no interfer- If a problem is found, let the customer
transmitters
ing waves are being emitted. know that the installation position and
output of the electromagnetic transmit-
ter need to be changed.

Supplementary information regarding the check for powerful electromagnetic transmitters

If you discover a problem in this item, convey it to the customer as necessary.
• Install the antenna to the a place distant from the electronic control system of the actual unit such as the
control units and sensors.
• Install the antenna cord at least 20 cm away from the electronic systems of the actual unit, such as the
control units and sensors.
• Do not wire other cables together with antenna.
Also, locate the antenna cord as far away from other wiring as possible.
• Make sure to attach retrofitted equipment in accordance with their respective installation manuals.
• Do not install high-output mobile communication devices.
CAUTION
• Follow the steps when performing the OBD system checks to confirm the repair.
Failure to follow these steps may result in performing unnecessary repair works.
• Review the scan tool data relating to the DTC that was diagnosed and make a record.
• Clear the DTC.
• Operate the actual unit while checking the related scan tool data.

84402826 - May 2011

4023B-11
 Introduction to the trouble diagnosis

9) DTC clearing method

Clearing DTC
If an error occurs in the system and the DTC is recorded in the ECU, 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 connected, you can delete codes by performing turning off of the trouble
diagnosis scan tool.
Erasure by ECM
A DTC recorded in the ECM is erased if the same DTC has not been satisfied for 40 consecutive ignition
cycles.
About trouble diagnosis scan tool
This tool is effective for diagnosing electrical failures in engine control units and performing system checks.
If you connect the SAE 16/19 adapter to the DLC installed in the unit, it performs communication with the
control units of the machine, and enables various diagnoses and tests to be performed.
Functions of the trouble diagnosis scan tool.
Data display
Snapshot
Programming
Actuator test

CAUTION
• When conditions such as the running state of the actual unit or the engine, water tempera-
ture, switches and gear position are not met, or when a DTC has been detected, each test
may possibly not operate.

ECM reflash
The ECM can be updated by overwriting its control program using the most recent control data issued every
3 months.
Normal reflash
The ECM is reflashed by automatically searching for the ECM part number compatible with the part number
currently reflashed.
Forced reflash
The ECM is reflashed by specifying an arbitrary ECM part number.
In this case, a password dedicated for forced reflash is necessary.
Campaign reflash The ECM is reflashed by selecting the part number during a campaign carried out by the
manufacturer.
Rewriting injector QR code
The injector QR code that is required when replacing the injector can be rewritten.
This allows fuel compensation to be performed on each injector to optimize the engine condition.
Engine replacement mode
This should be used when changing back to the old ECM part number which requires hardware changes
such as addition of actual unit wiring is performed along with engine replacement, etc.
ECM replacement
When replacing the ECM within the same model, the data can be updated from the current ECM to a trouble
diagnosis scan tool and then downloaded it from the trouble diagnosis scan tool to the new ECM after
replacement.
Factory shipment settings
Based on the engine serial number, data such as ECM injector QR code can be downloaded to ECM.
Actuator test
The injector test, fuel injection test, rail pressure test, glow plug test, and EGR control test are performed
to inspect the operation and function of each target component.

CAUTION
• When conditions such as the running state of the actual unit or the engine, water tempera-
ture, switches and gear position are not met, or when a DTC has been detected, each test
may possibly not operate.

Links with the HTML manual display

DTC to display the manual along with the failure diagnosis procedure.
Reading saved data
Read in the saved snapshot data to display reproduction.

84402826 - May 2011

4023B-12
 Introduction to the trouble diagnosis

CAUTION
• When using the trouble diagnosis scan tool, refer to the separate instruction manual for the
trouble diagnosis scan tool.

10) Reference data value

84402826 - May 2011

4023B-13
Introduction to the trouble diagnosis

84402826 - May 2011

4023B-14
 Section

4023D

Engine Control System

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal and Installation of Suction Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Removal of Suction Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Suction Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal and Installation of Fuel filter pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuel filter pressure sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuel filter pressure sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal and Installation of Engine coolant temperature sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine coolant temperature sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine coolant temperature sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine coolant temperature sensor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removal and Installation of CKP sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CKP sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CKP sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CKP sensor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal and Installation of CMP sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CMP sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CMP sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CMP sensor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal and Installation of Oil pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Oil pressure sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Oil pressure sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Oil pressure sensor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removal and Installation of Boost sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Boost sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Boost sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal and Installation of Boost temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Boost temperature sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Boost temperature sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Removal and Installation of IMT sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
IMT sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
IMT sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal and Installation of Exhaust differential pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Exhaust differential pressure sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Exhaust differential pressure sensor Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Exhaust differential pressure sensor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Removal and Installation of Exhaust gas temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DPD temperature sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DPD temperature sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Exhaust gas temperature sensor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

4023D-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
4023D-2 PRINTED IN FRANCE
 Engine Control System

Removal and Installation of 2) Remove the suction control valve from the fuel
supply pump.
Suction Control Valve
Removal of Suction Control Valve
1. Battery ground cable Disconnect
1) Disengage the battery ground cable from the
battery.
2. Suction control valve Removal

CAUTION
• Before removing the suction control
valve, clean the surrounding area.

1 Relief valve
2 Union
3 Fuel temperature sensor
4 Suction control valve

3. Remove the O-ring from the fuel supply pump.

1) Disengage the harness connector from the

suction control valve.

1 O-ring

84402826 - May 2011

4023D-3
 Engine Control System

Installation of Suction Control Valve 2. Battery ground cable Connect

1. Suction control valve Installation 1) Connect the battery ground cable to the bat-
tery.
1) Install the O-ring to the fuel supply pump.
3. Fuel Air bleed

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

1 O-ring

2) Apply the engine oil to the O-ring.

3) Temporarily tighten the suction control valve
to the fuel supply pump.
ANNOTATION:
1 Priming pump
• Temporarily tighten by hand until it adheres 2 Plug
the supply pump. 3 Drain plug
CAUTION 4 Case
5 Fuel filter element
• Be careful not to allow the O-ring to
caught in. 1) Prepare the pan.
2) Turn ON the starter switch.
4) Securely tighten the suction control valve to
ANNOTATION:
the fuel supply pump.
Tightening torque： 9 N・m { 0.9 kgf・m / 79 • This is for the models with an electromag-
lb・in } netic pump.
5) Connect the harness connector to the suction
control valve. 3) Loosen the plug using the wrench.
4) Operate the priming pump.
Number of times： 20 count(s) or more
ANNOTATION:
• Confirm that fuel comes out from around the
plug.
5) Tighten the plug using the wrench.
6) Operate the priming pump.
Number of times： 10 count(s) or more
ANNOTATION:
• Wait for the specified time after operating
the priming pump.
Specified time： 1 min
7) Loosen the plug using the wrench.
1 Relief valve ANNOTATION:
2 Union
3 Fuel temperature sensor • Remove the air in the fuel filter.
4 Suction control valve 8) Tighten the plug using the wrench.

84402826 - May 2011

4023D-4
 Engine Control System

9) Operate the priming pump. Removal and Installation of Fuel

Number of times： 10 count(s) or more
filter pressure
ANNOTATION:
• Wait for the specified time after operating Fuel filter pressure sensor Removal
the priming pump. 1. Fuel filter pressure sensor Removal
Specified time： 1 min 1) Disengage the harness connector from the
10) Loosen the plug using the wrench. fuel filter pressure sensor.
ANNOTATION: 2) Remove the fuel filter pressure sensor from
the fuel filter.
• Remove the air in the fuel filter.
11) Tighten the plug using the wrench.
12) Operate the priming pump.
Number of times： 10 count(s) or more
ANNOTATION:
• Wait for the specified time after operating
the priming pump.
Specified time： 1 min
13) Loosen the plug using the wrench.
ANNOTATION:
• Remove the air in the fuel filter.
14) Tighten the plug using the wrench.
Tightening torque： 10 N・m { 1.0 kgf・m / 1 Fuel filter pressure sensor
89 lb・in }

CAUTION
• Remove the fuel around the plug
thoroughly after tightening.

15) Operate the priming pump.

Number of times the operation is performed:
10 - 15 times
16) Start the engine.

CAUTION
• Do not accelerate the engine revo-
lution right after staring.

Idling: 5 s
ANNOTATION:
• Accelerate the engine revolution gradually.
Engine revolution hold: 3 min.
ANNOTATION:
• Accelerate the engine revolution to maxi-
mum.
• Lower the rotation.S

84402826 - May 2011

4023D-5
 Engine Control System

Fuel filter pressure sensor Installation Removal and Installation of Engine

1. Fuel filter pressure sensor Installation coolant temperature sensor
1) Install the fuel filter pressure sensor to the fuel
filter. Engine coolant temperature sensor
Removal
CAUTION
1. Engine coolant temperature sensor Removal
• After cleaning the threaded portion
of the fuel filter body, install it. 1) Disengage the harness connector from the
engine coolant temperature sensor.
Tightening torque： 12 N・m { 1.2 kgf・m / 2) Remove the engine coolant temperature sen-
108 lb・in } sor from the cylinder head assembly.
2) Connect the harness connector to the fuel fil-
ter pressure sensor.

1 Overheat switch
2 Water temperature sensor
1 Fuel filter pressure sensor

3) Start the engine.

ANNOTATION:
• Check that there is no fuel leaks.
• Confirm that DTC has not yet been de-
tected.

84402826 - May 2011

4023D-6
 Engine Control System

Engine coolant temperature sensor Engine coolant temperature sensor

Installation Inspection
1. Engine coolant temperature sensor Installation 1. Engine coolant temperature sensor Inspection
1) Install the engine coolant temperature sensor 1) Inspect the engine coolant temperature sen-
to the cylinder head assembly. sor using the circuit tester.
ANNOTATION: ANNOTATION:
• Apply Loctite 572 to the threaded portion. • Confirm that the resistance value according
to water temperature matches the thermis-
Tightening torque： 25 N・m { 2.5 kgf・m /
tor characteristics.
18 lb・ft }

1 Overheat switch GND terminal for engine con-

1
trol
2 Water temperature sensor
Signal terminal for engine con-
2
trol
2) Connect the harness connector to the engine 3 Signal terminal for meters
coolant temperature sensor.

Resistance (kΩ）

Temperature °C (°F)

84402826 - May 2011

4023D-7
 Engine Control System

Removal and Installation of CKP CKP sensor Installation

sensor 1. CKP sensor Installation
1) Install the CKP sensor to the flywheel housing.
CKP sensor Removal
1. Battery ground cable Disconnect CAUTION

1) Disengage the battery ground cable from the • Be careful not to subject the sensor
battery. to shock.

2. CKP sensor Removal ANNOTATION:

1) Disengage the harness connector from the • Tighten together with the clip.
CKP sensor.
2) Remove the CKP sensor from the flywheel Tightening torque： 6 N・m { 0.6 kgf・m / 52
housing. lb・in }
2) Connect the harness connector to the CKP
CAUTION sensor.

• Be careful not to subject the sensor

to shock.

1 CKP sensor
2 Flywheel housing

2. Battery ground cable Connect

1 CKP sensor
2 Flywheel housing 1) Connect the battery ground cable to the bat-
tery.

CKP sensor Inspection

1. Inspect the CKP sensor.
ANNOTATION:
• Condition of the sensor installation
• Grime on the sensor and connector

84402826 - May 2011

4023D-8
 Engine Control System

Removal and Installation of CMP CMP sensor Installation

sensor 1. CMP sensor Installation
1) Apply the engine oil to the O-ring.
CMP sensor Removal 2) Install the CMP sensor to the cylinder head
1. Battery ground cable Disconnect assembly.

1) Disengage the battery ground cable from the CAUTION

battery.
• Be careful not to subject the sensor
2. CMP sensor Removal to shock.
1) Disengage the harness connector from the
CMP sensor. ANNOTATION:
2) Remove the CMP sensor from the cylinder • Tighten together with the clip.
head assembly.
Tightening torque： 8 N・m { 0.8 kgf・m / 69
lb・in }
3) Connect the harness connector to the CMP
sensor.

CAUTION
• Be careful not to subject the sensor
to shock. 2. Battery ground cable Connect
1) Connect the battery ground cable to the bat-
tery.

CMP sensor Inspection

1. Inspect the CMP sensor.
ANNOTATION:
• Condition of the sensor installation
• Grime on the sensor and connector

84402826 - May 2011

4023D-9
 Engine Control System

Removal and Installation of Oil Oil pressure sensor Installation

pressure sensor 1. Oil pressure sensor Installation
1) Install the oil pressure sensor to the oil port
Oil pressure sensor Removal cover.
1. Oil pressure sensor Removal Tightening torque： 41 N・m { 4.2 kgf・m /
30 lb・ft }
1) Disconnect the harness connector from the oil
pressure sensor. CAUTION
2) Remove the oil pressure sensor from the oil
port cover. • Use new gaskets.

2) Connect the harness connector to the oil pres-

sure sensor.

1 Oil pressure sensor

2 Oil port cover
3 Starter assembly 1 Oil pressure sensor
2 Oil port cover
3 Starter assembly

84402826 - May 2011

4023D-10
 Engine Control System

Oil pressure sensor Inspection Removal and Installation of Boost

1. Oil pressure sensor Inspection sensor
1) Turn OFF the starter switch.
2) Disconnect the harness connector from the oil Boost sensor Removal
pressure sensor. 1. Battery ground cable Disconnect
3) Inspect the continuity using the circuit tester.
1) Disengage the battery ground cable from the
battery.
2. Boost sensor Removal
1) Disengage the harness connector from the
boost sensor.
2) Remove the boost sensor from the inlet pipe.

CAUTION
• Replace the oil pressure sensor if
there is no continuity.

4) Turn ON the starter switch.

5) Inspect the circuit using the jumper wire.
1 Boost sensor
2 IMT sensor
3 EGR valve
4 Harness clip
5 Boost temperature sensor

6) Check lighting of the warning light.

ANNOTATION:
• If the warning light does not illuminate, in-
spect the circuit between the meter and the
oil pressure.

84402826 - May 2011

4023D-11
 Engine Control System

Boost sensor Installation Removal and Installation of Boost

1. Boost sensor Installation temperature sensor
1) Install the boost sensor to the inlet pipe.
Tightening torque： 2 N・m { 0.2 kgf・m / 18 Boost temperature sensor Removal
lb・in } 1. Boost temperature sensor Removal
1) Disconnect the harness connector from the
boost temperature sensor.
2) Remove the boost temperature sensor from
the inlet pipe.

1 Boost sensor
2 IMT sensor
3 EGR valve
4 Harness clip
5 Boost temperature sensor
1 Boost sensor
2) Connect the harness connector to the boost 2 IMT sensor
sensor. 3 EGR valve
4 Harness clip
2. Battery ground cable Connect 5 Boost temperature sensor
1) Connect the battery ground cable to the bat-
tery.
3. Boost sensor Inspection
1) Inspect the boost sensor.
ANNOTATION:
• Stains on the unit
• Damage on the unit
• Malfunction of the terminal
CAUTION
• Do not clean the sensor unit since
damage may be caused inside the
sensor.

84402826 - May 2011

4023D-12
 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 pipe. IMT sensor Removal
Tightening torque： 13 N・m { 1.3 kgf・m / 1. IMT sensor Removal
113 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 bracket.

1 Boost sensor 1 Boost sensor

2 IMT sensor 2 IMT sensor
3 EGR valve 3 EGR valve
4 Harness clip 4 Harness clip
5 Boost temperature sensor 5 Boost temperature sensor

84402826 - May 2011

4023D-13
 Engine Control System

IMT sensor Installation Removal and Installation of

1. IMT sensor Installation Exhaust differential pressure
1) Install the IMT sensor to the bracket. 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. Exhaust differential pressure sensor Safety Infor-
mation

CAUTION
• Do not use a tool which causes vibra-
tions such as an impact wrench when in-
stalling and removing the DPD differen-
tial pressure sensor.
• Do not reuse a DPD differential pressure
sensor which has been subjected to
shock such as being dropped.
• Install or remove the DPD differen-
tial pressure sensor together with the
bracket.
• Be sure not to loosen the 4 screws in-
1 Boost sensor stalled on the DPD differential pressure
2 IMT sensor sensor.
3 EGR valve • Replace the DPD differential pressure
4 Harness clip sensor if the 4 screws installed on the
5 Boost temperature sensor DPD differential pressure sensor have
been loosened.

1 Screw

2. Exhaust differential pressure sensor Removal

CAUTION
• Before performing work, be sure to
check the DPD differential pressure sen-
sor precautions.

1) Disengage the differential pressure hose from

the exhaust differential pressure sensor.
2) Disengage the harness connector from the
exhaust differential pressure sensor.

84402826 - May 2011

4023D-14
 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
Information
• Remove the DPD differential pres-
sure 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 DPD differen-
tial pressure sensor.
• Do not reuse a DPD differential pressure
sensor which has been subjected to
shock such as being dropped.
• Install or remove the DPD differen-
tial pressure sensor together with the
bracket.
• Be sure not to loosen the 4 screws in-
stalled on the DPD differential pressure
sensor.
• Replace the DPD differential pressure
sensor if the 4 screws installed on the
DPD differential
DPD differential pressure sen- • pressure sensor have been loosened.
1
sor

1 Screw

2. Exhaust differential pressure sensor Installation

CAUTION
• Before performing work, be sure to
check the DPD differential pressure sen-
sor 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.

84402826 - May 2011

4023D-15
 Engine Control System

CAUTION Exhaust differential pressure sensor

Inspection
• 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.
CAUTION
• Perform 0-point correction when replacing
the DPD differential pressure sensor.
• Perform 0-point correction when the DPD dif-
ferential pressure sensor is at room temper-
ature.
• 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.

CAUTION
• Do not start the engine.

starter switch ON time： 40 s or more

3. Turn OFF the starter switch.
starter switch OFF time： 15 s or more

DPD differential pressure sen-

1
sor

84402826 - May 2011

4023D-16
 Engine Control System
Removal and Installation of
Exhaust gas temperature sensor
DPD temperature sensor Removal
1. 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-
ture sensor which has been subjected to
shock such as being dropped.
2. Exhaust gas temperature sensor Removal
1) Disengage the harness connector from the
exhaust gas temperature sensor.
ANNOTATION:
• To prevent incorrect assembling, make an
alignment mark on the connector before dis-
connecting.
2) Remove the exhaust gas temperature sensor
from the DPD assembly.
Exhaust gas temperature sen-
1 tightening torque： 30 N・m {3.1 kgf・m / 22
sor 1
Exhaust gas temperature sen-
2
sor 2
84402826 - May 2011
4023D-17
DPD temperature sensor Installation
1. 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 Temperature
Stainless Grade: anti-seize lubricant,
manufactured by Bostik in the United
states.
• Replace the oxidation catalyst assembly
if damage has been found in the sensor
installation section of the oxidation cata-
lyst assembly.
1) Temporarily tighten the exhaust gas tempera-
ture sensor to the DPD assembly.
CAUTION
• To avoid damaging the sensor in-
stallation sections due to sensor
incorrect assembly, tighten it by
hand.
ANNOTATION:
• Exhaust gas temperature sensor identifica-
tion
Screw Connector
Sensor type
size color
Exhaust gas tempera- M12 x
Dark gray
ture sensor 1 1.75
Exhaust gas tempera- M12 x
Light gray
ture sensor 2 1.25
2) Securely tighten the exhaust gas temperature
sensor to the DPD assembly.
lb・ft}
3) Connect the harness connector to the exhaust
gas temperature sensor.
CAUTION
• Be careful not to twist the harness.
 Engine Control System

Exhaust gas temperature sensor

Inspection
1. Exhaust gas temperature sensor Inspection
1) Measure the resistance using the circuit
tester.
ANNOTATION:
• The reference values for the sensor
characteristics are indicated in the diagram.

temperature Resistance value

： 1000.0 °C ： 115.00 - 127.00 Ω
： 950.0 °C ： 130.00 - 143.00 Ω
Exhaust gas temperature sen- ： 900.0 °C ： 147.00 - 163.00 Ω
1
sor 1 ： 850.0 °C ： 167.00 - 187.00 Ω
Exhaust gas temperature sen- ： 800.0 °C ： 192.00 - 219.00 Ω
2
sor 2 ： 750.0 °C ： 226.00 - 258.00 Ω
： 700.0 °C ： 267.00 - 309.00 Ω
ANNOTATION: ： 650.0 °C ： 333.00 - 360.00 Ω
• Start the engine after assembling each part, ： 600.0 °C ： 406.00 - 442.00 Ω
and check for gas leaks from each joint and ： 550.0 °C ： 504.00 - 552.00 Ω
for vibration. ： 500.0 °C ： 640.00 - 709.00 Ω
： 450.0 °C ： 835.00 - 937.00 Ω
： 400.0 °C ： 1130.00 - 1280.00 Ω
： 350.0 °C ： 1590.00 - 1850.00 Ω
： 300.0 °C ： 2360.00 - 2830.00 Ω
： 200.0 °C ： 6230.00 - 7830.00 Ω
： 150.0 °C ： 11900.00 - 16300.00 Ω
： 100.0 °C ： 27600.00 - 41200.00 Ω
： 50.0 °C ： 82000.00 - 137000.00 Ω

84402826 - May 2011

4023D-18
 Section

4023G

Engine-side Trouble

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Engine-side Trouble. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DTC U0001 (Flash Code 84) CAN-Bus Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DTC P0016 (Flash Code 16) Crankshaft Position - Camshaft Position Correlation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DTC P0045 (Flash Code 33) Turbocharger Boost Control Solenoid Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DTC U0073 (Flash Code 84) Control Module Communication Bus Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DTC P0087 (Flash Code 225) Fuel Rail/System Pressure - Too Low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DTC P0088 (Flash Code 118) Fuel Rail/System Pressure - Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DTC P0089 (Flash Code 151)Fuel Pressure Regulator Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DTC P0091 (Flash Code 247) Fuel Pressure Regulator Control Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DTC P0092 (Flash Code 247) Fuel Pressure Regulator Control Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DTC P0093 (Flash Code 227) Fuel System Leak Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DTC U0101 (Flash Code 85) Lost Communication with TCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DTC P0102 (Flash Code 91) Mass Air Flow Circuit Low Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DTC P0103 (Flash Code 91) Mass Air Flow Circuit High Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DTC U0110 (Flash Code 87) Lost Communication with VNT System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DTC P0112 (Flash Code 22) Intake Air Temperature Sensor Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DTC P0113 (Flash Code 22) Intake Air Temperature Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DTC P0117 (Flash Code 23) Engine Coolant Temperature Sensor Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DTC P0118 (Flash Code 23) Engine Coolant Temperature Sensor Circuit High. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DTC P0122 (Flash Code 43) Throttle Position Sensor Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DTC P0123 (Flash Code 43) Throttle Position Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
DTC P0182 (Flash Code 211) Fuel Temperature Sensor Circuit Low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
DTC P0183 (Flash Code 211) Fuel Temperature Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
DTC P0192 (Flash Code 245) Fuel Rail Pressure Sensor Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
DTC P0193 (Flash Code 245) Fuel Rail Pressure Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
DTC P0201 (Flash Code 271) Injector Circuit - Cylinder 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DTC P0202 (Flash Code 272) Injector Circuit - Cylinder 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
DTC P0203 (Flash Code 273) Injector Circuit - Cylinder 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
DTC P0204 (Flash Code 274) Injector Circuit - Cylinder 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
DTC P0237 (Flash Code 32) Turbo Charger Boost Sensor Circuit Low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
DTC P0238 (Flash Code 32) Turbo Charger Boost Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
DTC P0336 (Flash Code 15) Crankshaft Position Sensor Circuit Range/Performance. . . . . . . . . . . . . . . . . . . . . . . 33
DTC P0340 (Flash Code 14) Camshaft Position Sensor Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
DTC P0404 (Flash Code 45) Exhaust Gas Recirculation Control Circuit Range/Performance . . . . . . . . . . . . . . . . 34
DTC P0409 (Flash Code 44) Exhaust Gas Recirculation Sensor Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
DTC P0426 (Flash Code 143) Catalyst Temperature Sensor Circuit Range/Performance Sensor 1 . . . . . . . . . . . 36
DTC P0427 (Flash Code 48) Catalyst Temperature Sensor Circuit Low Sensor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . 37
DTC P0428 (Flash Code 48) Catalyst Temperature Sensor Circuit High Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 37
DTC P0522 (Flash Code 294) Oil Pressure Sensor Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
DTC P0523 (Flash Code 294) Oil Pressure Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
DTC P0560 (Flash Code 155) System Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
DTC P0563 (Flash Code 35) System Voltage High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
DTC P0601 (Flash Code 53) Internal Control Module Memory Check Sum Error . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
DTC P0602 (Flash Code 154) Control Module Programming Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
DTC P0604 (Flash Code 153) Internal Control Module Random Access Memory (RAM) Error . . . . . . . . . . . . . . . 43
DTC P0606 (Flash Code 51) ECM/PCM Processor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

4023G-1 PRINTED IN FRANCE
DTC P0638 (Flash Code 61) Throttle Actuator Control Range/Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
DTC P0641 (Flash Code 55) Sensor Reference Voltage 1 Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
DTC P0651 (Flash Code 56) Sensor Reference Voltage 2 Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
DTC P0685 (Flash Code 416) ECM/PCM Power Relay Control Circuit/Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
DTC P0687 (Flash Code 416) ECM/PCM Power Relay Control Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
DTC P0697 (Flash Code 57) Sensor Reference Voltage 3 Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
DTC P1093 (Flash Code 227) Fuel Rail Pressure (FRP) Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
DTC P1112 (Flash Code 295) Boost Temperature Sensor Circuit Low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
DTC P1113 (Flash Code 295) Boost Temperature Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
DTC P1261 (Flash Code 34) Injector Positive Voltage Control Circuit Group 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
DTC P1262 (Flash Code 34) Injector Positive Voltage Control Circuit Group 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
DTC P1293 (Flash Code 211) Fuel Pressure Sensor Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
DTC P1294 (Flash Code 211) Fuel Pressure Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
DTC P1404 (Flash Code 45) Exhaust Gas Recirculation (EGR) Closed Position Performance . . . . . . . . . . . . . . . 56
DTC P1455 (Flash Code 132) PM Over Accumulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
DTC P1471 (Flash Code 149) DPD Insufficient Regeneration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
DTC P1621 (Flash Code 54) Control Module Long Term Memory Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
DTC P1655 (Flash Code 57) Sensor Reference Voltage Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
DTC P1669 (Flash Code 75) DPD Lamp Control Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
DTC P2146 (Flash Code 158) Fuel Injector Group 1 Supply Voltage Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
DTC P2149 (Flash Code 159) Fuel Injector Group 2 Supply Voltage Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
DTC P2228 (Flash Code 71) Barometric Pressure Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
DTC P2229 (Flash Code 71) Barometric Pressure Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
DTC P2452 (Flash Code 142) DPD Differential Pressure Sensor Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
DTC P2453 (Flash Code 141) DPD Differential Pressure Sensor Circuit Range/Performance . . . . . . . . . . . . . . . . 67
DTC P2454 (Flash Code 47) DPD Differential Pressure Sensor Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
DTC P2455 (Flash Code 47) DPD Differential Pressure Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
DTC P2458 (Flash Code 139) DPD Regeneration Duration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
DTC P042B (Flash Code 145) Catalyst Temperature Sensor Circuit Range/Performance Sensor 2 . . . . . . . . . . . 70
DTC P042C (Flash Code 49) Catalyst Temperature Sensor Circuit Low Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 71
DTC P042D (Flash Code 49) Catalyst Temperature Sensor Circuit High Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 71
DTC P060B (Flash Code 36) Internal Control Module A/D Processing Performance . . . . . . . . . . . . . . . . . . . . . . . . 72
DTC P242F (Flash Code 131) DPD Restriction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

4023G-2 PRINTED IN FRANCE
 Engine-side Trouble

Engine-side Trouble
DTC U0001 (Flash Code 84) DTC P0016 (Flash Code 16)
CAN-Bus Malfunction Crankshaft Position - Camshaft
1. DTC U0001 Diagnostics Position Correlation
1) Turn OFF the starter switch. 1. DTC P0016 Priority DTC
2) Disconnect the harness connector from the DTC P0335
ECM. DTC P0336
3) Measure the resistance between the CAN- DTC P0340
High side terminal and CAN-Low side termi- 2. DTC P0016 Diagnostics
nal.
1) Inspect the CKP sensor.
ANNOTATION: Refer to "1.Engine 1B.Mechanical(4HK1X)
CKP sensor Inspection".
• Measure the resistance between the termi- 2) If a problem is discovered, replace the crank-
nals of the ECM harness connector.
shaft position sensor.
Resistance： about 120.0 Ω Refer to "1.Engine 1B.Mechanical(4HK1X)
4) If it is outside the standard range, inspect CKP sensor Removal".
the CANLow circuit and CAN-High circuit be- Refer to "1.Engine 1B.Mechanical(4HK1X)
tween the ECM and the control unit of the ac- CKP sensor Installation".
tual unit. 3) Inspect the CMP sensor.
Refer to "1.Engine 1B.Mechanical(4HK1X)
• There should be no short to the battery or CMP sensor Inspection".
ignition power supply. 4) If a problem is discovered, replace the
• There should be no open circuit or high re- camshaft position sensor.
sistance. Refer to "1.Engine 1B.Mechanical(4HK1X)
• There should be no short to GND. CMP sensor Removal".
5) If a problem is discovered, repair the CAN Refer to "1.Engine 1B.Mechanical(4HK1X)
circuit. CMP sensor Installation".
6) If the CAN circuit is normal, replace the control 5) Inspect the flywheel.
unit of the actual unit.
• The sensor rotor should not be damaged.
7) Connect the harness connector to the ECM.
• The ring gear should be installed correctly.
8) Disconnect the harness connector from the
control unit of the actual unit. 6) If a problem is discovered, repair the flywheel.
9) Measure the resistance between the CAN- 7) Inspect the camshaft gear.
High side terminal and CAN-Low side termi-
nal. • The camshaft gear should not be damaged
• The camshaft gear should be installed cor-
ANNOTATION: rectly.
• Measure the resistance between the termi- 8) If a problem is discovered, repair the camshaft
nals of the ECM harness connector. gear.
Resistance： about 120.0 Ω 3. DTC P0016 Confirm Resolution
10) If it is outside the standard range, replace the
1) Clear the DTC using the trouble diagnosis
ECM.
scan tool.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
2) Turn the starter switch OFF for 30 seconds or
Removal".
longer.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
3) Start the engine.
Installation".
11) Set the injector ID code on the ECM. ANNOTATION:
12) Perform the unit difference learning of the fuel
supply pump to the ECM. • When the engine does not start, crank the
engine for 10 seconds.
2. DTC U0001 Confirm Resolution
4) Perform a test-run.
1) Clear the DTC using the trouble diagnosis 5) Use the trouble diagnosis scan tool to confirm
scan tool. that a DTC has not been detected.
2) Turn the starter switch OFF for 30 seconds or
longer.
3) Start the engine.
4) Perform a test-run.
5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.

84402826 - May 2011

4023G-3
 Engine-side Trouble

DTC P0045 (Flash Code 33) 14) If the voltage is outside the standard range,
inspect the position sensor power supply cir-
Turbocharger Boost Control cuit between the turbo actuator and the turbo
Solenoid Circuit control unit.
• There should be no open circuit or high re-
1. DTC P0045 Priority DTC
sistance.
DTC P0563
• There should be no short to the battery
2. DTC P0045 Diagnostics
power supply or ignition power supply cir-
1) Turn OFF the starter switch. cuit.
2) Inspect the turbocharger assembly. • There should be no short to GND.
Refer to "1.Engine 1F.Induction(4HK1X) Tur-
15) If a problem is discovered, repair the position
bocharger assembly Inspection".
sensor power supply circuit.
3) If a problem is discovered, replace the tur-
16) If the circuit is normal, inspect to the turbo
bocharger assembly.
control unit harness connector for a contact
Refer to "1.Engine 1F.Induction(4HK1X) Tur-
failure.
bocharger assembly Removal".
17) If a problem is discovered, repair the harness
Refer to "1.Engine 1F.Induction(4HK1X) Tur-
connector.
bocharger assembly Installation".
18) If the harness connector is normal, replace the
4) Disconnect the harness connector from the
turbo control unit.
turbo actuator.
19) If the voltage is within the standard range,
5) Connect the test light between the motor op-
measure the voltage between the position
eration terminal and GND of the turbo actuator
sensor signal terminal of the turbo actuator
harness connector.
harness connector and GND.
6) Turn ON the starter switch.
7) Check if the test light does not come on or ANNOTATION:
remains on.
• Measurement of voltage value should be
ANNOTATION: taken on each terminal.
• The inspection with a test light should be Voltage： 4.0 - 6.0 V
performed on each terminal. 20) If the voltage is outside the standard range,
• When it is normal, the test light comes on inspect the position sensor signal circuit be-
after the key switch is turned ON, and then tween the turbo actuator and the turbo control
goes out after a few seconds. unit.
8) If the test light does not come on or remains • There should be no open circuit or high re-
on, inspect the motor operation circuit be- sistance.
tween the turbo • There should be no short to the battery
actuator and turbo control unit. power supply or ignition power supply cir-
cuit.
• There should be no open circuit or high re-
• There should be no short to GND.
sistance.
• There should be no short to the battery 21) If a problem is discovered, repair the position
power supply or ignition power supply cir- sensor signal circuit.
cuit. 22) If the circuit is normal, inspect to the turbo
• There should be no short to GND. control unit harness connector for a contact
failure.
9) If a problem is discovered, repair the motor
23) If a problem is discovered, repair the harness
operation circuit.
connector.
10) If the test light operates properly, inspect to
24) If the harness connector is normal, replace the
see if a short with other circuit exists in the
turbo control unit.
motor operation circuit between the turbo ac-
25) If the voltage is within the standard range, in-
tuator and turbo control unit.
spect to see if there is a short circuit with the
11) If a problem is discovered, repair the motor
position sensor.
operation circuit.
12) Turn ON the starter switch.
13) Measure the voltage between the position
sensor power supply terminal and GND of the
turbo actuator harness connector.
Voltage： 8.0 - 11.0 V

84402826 - May 2011

4023G-4
 Engine-side Trouble

DTC U0073 (Flash Code 84) 12) Replace the ECM if the resistance value is
within the range of standard value.
Control Module Communication Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Bus Off Removal".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
1. DTC U0073 Diagnostics Installation".
13) Set the injector ID code on the ECM.
1) Turn OFF the starter switch. 14) Perform the unit difference learning of the fuel
2) Measure the resistance between the termi- supply pump to the ECM.
nals of the termination resistor harness con- 15) Turn OFF the starter switch.
nector. 16) Connect the harness connector to the ECM.
ANNOTATION: 17) Turn ON the starter switch.
18) Measure the voltage between the CAN-High
• Make a measurement from the back with the terminal and GND of the termination resistor
harness connector connected. harness connector.
• Confirm that the parallel resistance of the 19) Measure the voltage between the CAN-Low
120 Ω resistor in the termination resistor and terminal and GND of the termination resistor
that of the 120 Ω resistor in the ECM are harness connector.
both 60Ω. Roltage： 1.5 - 3.5 V
Resistance： 50.0 - 70.0 Ω 20) If the voltage is outside the standard range,
3) Disconnect the harness connector from termi- replace the ECM.
nation resistor if the resistance value is out- Refer to "1.Engine 1J.Electrical(4HK1X) ECM
side the standard range. Removal".
4) Measure the resistance of the termination re- Refer to "1.Engine 1J.Electrical(4HK1X) ECM
sistor. Installation".
Resistance： 110.0 - 130.0 Ω 21) Set the injector ID code on the ECM.
5) If the resistance value is outside the standard 22) Perform the unit difference learning of the fuel
range, replace the termination resistor. supply pump to the ECM.
6) Connect the harness connector to the termi- 23) Turn OFF the starter switch.
nation resistor . 24) Connect the harness connector to the control
7) Disconnect the harness connector from the unit of the actual unit.
control unit of the actual unit. 25) Turn ON the starter switch.
8) Measure the resistance between the termi- 26) Measure the voltage between the CAN-High
nals of the termination resistor harness con- terminal and GND of the termination resistor
nector. harness connector.
27) Measure the voltage between the CAN-Low
ANNOTATION: terminal and GND of the termination resistor
• Make a measurement from the back with the harness connector.
harness connector connected. Voltage： 1.5 - 3.5 V
28) If the voltage is outside the standard range,
Resistance： 50.0 - 70.0 Ω replace the control unit of the actual unit.
9) If the resistance value is within the standard 29) If the voltage is within the standard range, re-
range, replace the control unit of the actual place the termination resistor.
unit.
10) Disconnect the harness connector from the 2. DTC U0073 Confirm Resolution
ECM. 1) Use the trouble diagnosis scan tool to clear
11) Measure the resistance between the termi- the DTC.
nals of the termination resistor harness con- 2) Turn the starter switch OFF for 30 seconds.
nector. 3) Start the engine.
ANNOTATION: 4) Perform a test-run.
5) Use the trouble diagnosis scan tool to check
• Make a measurement from the back with the if a DTC has been detected.
harness connector connected.
Resistance： 110.0 - 130.0 Ω

84402826 - May 2011

4023G-5
 Engine-side Trouble

DTC P0087 (Flash Code 225) Fuel 15) If the harness connector and each circuit are
normal, replace the fuel pressure sensor.
Rail/System Pressure - Too Low Refer to "1.Engine 1C.Fuel System(4HK1X)
Common rail assembly Removal".
1. DTC P0087 Priority DTC
Refer to "1.Engine 1C.Fuel System(4HK1X)
DTC P0088
Common rail assembly Installation".
DTC P0089
DTC P0091 ANNOTATION:
DTC P0092
DTC P0192 • Do not replace the fuel pressure sensor sep-
DTC P0193 arately. When a problem is found, replace
DTC P0201 the common rail assembly.
DTC P0202 16) If the fuel rail pressure sensor display is within
DTC P0203 the standard range, start the engine.
DTC P0204 17) Perform the injector stop test with the trouble
DTC P2146 diagnosis scan tool.
DTC P2149 18) Command each injector OFF, and confirm that
2. DTC P0087 Diagnostics the engine RPM changes on each injector.
1) Start the engine. 19) If any injector does not change the engine
2) Rev the engine a few times in neutral while RPM when OFF is instructed, replace the rel-
checking for a DTC with the trouble diagnosis evant injector.
scan tool. Refer to "1.Engine 1C.Fuel System(4HK1X)
3) Check to see if the DTC P0087 is detected. Injector Removal".
4) If the DTC P0087 is not detected, replace the Refer to "1.Engine 1C.Fuel System(4HK1X)
fuel filter element. Injector Installation".
20) When the injector has been replaced, set the
ANNOTATION: injector ID code on the ECM.
21) Inspect to see if there is clogging with the fuel
• An intermittent problem due to foreign mat- system between the fuel tank and the fuel sup-
ter in the fuel is suspected.
ply pump.
Refer to "1.Engine 1C.Fuel System(4HK1X) 22) If a problem is discovered, repair the clogging
Fuel filter element Removal". of the fuel system.
Refer to "1.Engine 1C.Fuel System(4HK1X) 23) Inspect the fuel hose between the fuel tank
Fuel filter element Installation". and the fuel supply pump for a cut and crack.
5) Turn OFF the starter switch. 24) If a problem is discovered, replace the fuel
6) Wait for the specified period of time until the hose.
fuel pressure is released from the common
ANNOTATION:
rail.
Specified time： 2 min • The fuel hose between the fuel tank and the
7) Turn ON the starter switch. fuel supply pump becomes negative pres-
8) Check the fuel rail pressure sensor display sure state when the engine is running.
with the trouble diagnosis scan tool. • When the fuel hose is not connected se-
Voltage： 0.9 - 1.0 V curely, the air can enter.
9) If the fuel rail pressure sensor display is out- • When the engine RPM or the engine load
side the standard range, inspect the fuel pres- increases while the air has intruded in the
sure sensor harness connector for a contact fuel system, fluctuation in the common rail
failure. pressure is caused, and DTC P0087 may
10) If a problem is discovered, repair the harness be detected.
connector.
11) Inspect the ECM harness connector for a con- 25) Check that an appropriate clamp is used be-
tact failure. tween the fuel tank and the fuel supply pump.
12) If a problem is discovered, repair the harness 26) If a problem is discovered, replace the clamp.
connector. 27) Operate the priming pump until the handle be-
13) Inspect each circuit for high resistance. comes heavy.
14) Repair the circuit if a problem is discovered. ANNOTATION:
• When a leak exists in the fuel system be-
tween the priming pump and the fuel sup-
ply pump, the pressing weight of the priming
pump does not become heavy.
28) Start the engine.
29) Inspect the high-pressure side of the fuel sys-
tem and check for fuel leak between the fuel
supply pump and common rail.

84402826 - May 2011

4023G-6
 Engine-side Trouble

ANNOTATION: 39) If a problem is discovered, repair the fuel sys-

tem.
• The fuel may leak to the bottom section of 40) Inspect the fuel tank bent hose.
the cylinder head cover from the high pres- 41) If a problem is discovered, repair the bent
sure hose inlet. hose.
• The engine oil level increases when the fuel 42) Check to see if there is any foreign matter in
leaks to the bottom portion of the cylinder the fuel tank or any foreign matter which can
head cover. cause fuel clogging.
• Inspect for fuel leaks into the engine oil. 43) If a problem is discovered, repair it.
30) If fuel leak if found, fix the problem. 44) Replace the fuel filter element.
31) Turn OFF the starter switch. Refer to "1.Engine 1C.Fuel System(4HK1X)
32) Remove the fuel hose on the fuel supply pump Fuel filter element Removal".
side from the fuel filter. Refer to "1.Engine 1C.Fuel System(4HK1X)
Fuel filter element Installation".
ANNOTATION: 45) If the negative pressure is at or below the stan-
• Use a pan to catch the fuel from the re- dard value, pinch the fuel hose at a position as
moved fuel hose. close as possible to the fuel tank, so that the
• Clean the pressure gauge and connection fuel does not flow.
hose before connecting to the fuel pipe. ANNOTATION:
• The fuel supply pump may be damaged due
to foreign matter that has entered in the con- • The fuel pipe can be disconnected and
nection hose. clogged with a plug.
33) Connect the pressure gauge between the fuel 46) Start the engine and use the idling control
filter and the removed fuel hose. switch to increase the RPM to the highest
level.
ANNOTATION: 47) Check the pressure gauge.
• Confirm that the fuel system is connected Specified value ： 27.0 kPa {203 mmHg / 8
securely. inHg}
34) Remove the air using the priming pump, and ANNOTATION:
crank the engine for the specified period of • When the pressure gauge is likely to indi-
time or shorter. cate a value exceeding the standard value
Specified time： 5 s during inspection, release the fuel being
ANNOTATION: blocked.
• Air mixture is checked with the negative
• Repeat this until the engine starts. pressure amount while the fuel flow is being
35) Leave the engine idling for the specified pe- blocked.
riod of time or longer. 48) If the standard negative pressure cannot be
specified time： 1 min generated, inspect to see if there is a cut or
36) While keeping the engine rotating at the spec- crack with the fuel hose.
ified engine RPM for the specified period of 49) If a problem is discovered, replace the fuel
time, check the pressure gauge. hose.
specified time： 1 min 50) Inspect to see if appropriate clamp is used.
rotational speed： 2500 min-1 {2500 r/min} 51) If a problem is discovered, replace the clamp
37) Check if the pressure gauge shows a negative with an appropriate one.
pressure value at or above the standard value 52) Turn OFF the starter switch.
during inspection. 53) Inspect the suction control valve harness con-
Specified value ： 17.0 kPa {128 mmHg / 5 nector for a contact failure.
inHg} 54) If a problem is discovered, repair the harness
ANNOTATION: connector.
55) Inspect the ECM harness connector for a con-
• Fuel clogging is checked with the negative tact failure.
pressure amount in the fuel system. 56) If a problem is discovered, repair the harness
38) If the negative pressure is at or above the connector.
standard value, inspect to see if there is dam- 57) Inspect each circuit for high resistance.
age or twisting with the fuel system between 58) Repair the circuit if a problem is discovered.
the fuel supply pump and the fuel tank.

84402826 - May 2011

4023G-7
 Engine-side Trouble

59) If the suction control valve harness connector DTC P0088 (Flash Code 118) Fuel
and the ECM harness connector are normal
and there is no high resistance in each circuit, Rail/System Pressure - Too High
replace the fuel supply pump and the fuel filter
1. DTC P0088 Priority DTC
element.
DTC P0089
Refer to "1.Engine 1C.Fuel System(4HK1X)
DTC P0091
Fuel supply pump Removal".
DTC P0092
Refer to "1.Engine 1C.Fuel System(4HK1X)
DTC P0192
Fuel supply pump Installation".
DTC P0193
Refer to "1.Engine 1C.Fuel System(4HK1X)
DTC P0201
Fuel filter element Removal".
DTC P0202
Refer to "1.Engine 1C.Fuel System(4HK1X)
DTC P0203
Fuel filter element Installation".
DTC P0204
ANNOTATION: DTC P2146
DTC P2149
• When replacing the fuel supply pump, it is 2. DTC P0088 Diagnostics
required to also replace the fuel filter ele-
ment at the same time. 1) Start the engine.
2) Rev the engine a few times in neutral while
60) Perform the unit difference learning of the fuel checking the actual fuel rail pressure display
supply pump to the ECM. with the trouble diagnosis scan tool.
3. DTC P0087 Confirm Resolution 3) Check the actual fuel rail pressure display with
the trouble diagnosis scan tool.
1) Clear the DTC using the trouble diagnosis Standard value ：(-5) - 5 MPa
scan tool. 4) If it is at or below the standard value, replace
2) Turn the starter switch OFF for 30 seconds or the fuel filter element.
longer.
3) Start the engine. ANNOTATION:
4) Perform a test-run.
• An intermittent problem due to foreign mat-
5) Use the trouble diagnosis scan tool to confirm ter in the fuel is suspected.
that a DTC has not been detected.
Refer to "1.Engine 1C.Fuel System(4HK1X)
Fuel filter element Removal".
Refer to "1.Engine 1C.Fuel System(4HK1X)
Fuel filter element Installation".
5) Turn OFF the starter switch.
6) Wait for the specified period of time until the
fuel pressure is released from the common
rail.
Specified time： 2 min
7) Turn ON the starter switch.
8) Check the fuel rail pressure sensor display
with the trouble diagnosis scan tool.
Voltage： 0.9 - 1.0 V
9) If the fuel rail pressure sensor display is out-
side the standard range, inspect the fuel pres-
sure sensor harness connector for a contact
failure.
10) If a problem is discovered, repair the harness
connector.
11) Inspect the ECM harness connector for a con-
tact failure.
12) If a problem is discovered, repair the harness
connector.
13) Inspect each circuit for high resistance.
14) If a problem is discovered, repair the circuit.

84402826 - May 2011

4023G-8
 Engine-side Trouble
15) If the harness connector and each circuit are
normal, replace the fuel pressure sensor.
Refer to "1.Engine 1C.Fuel System(4HK1X)
Common rail assembly Removal".
Refer to "1.Engine 1C.Fuel System(4HK1X)
Common rail assembly Installation".
ANNOTATION:
• Do not replace the fuel pressure sensor sep-
arately.
When a problem is found, replace the com-
mon rail assembly.
16) Start the engine.
17) Perform the injector stop test with the trouble
diagnosis scan tool.
18) Command each injector OFF, and confirm that
the engine RPM changes on each injector.
19) If any injector does not change the engine
RPM when OFF is instructed, replace the rel-
evant injector.
Refer to "1.Engine 1C.Fuel System(4HK1X)
Injector Removal".
Refer to "1.Engine 1C.Fuel System(4HK1X)
Injector Installation".
20) When the injector has been replaced, set the
injector ID code on the ECM.
21) Inspect to see if there is clogging with the fuel
system between the fuel tank and the fuel sup-
ply pump.
22) If a problem is discovered, repair the clogging
of the fuel system.
23) Inspect the fuel hose between the fuel tank
and the fuel supply pump for a cut and crack.
24) If a problem is discovered, replace the fuel
hose.
ANNOTATION:
• The fuel hose between the fuel tank and the
fuel supply pump becomes negative pres-
sure state when the engine is running.
• When the fuel hose is not connected se-
curely, the air can enter.
• When the engine RPM or the engine load
increases while the air has intruded in the
fuel system, fluctuation in the common rail
pressure is caused, and DTC P0088 may
be detected.
25) Check that an appropriate clamp is used be-
tween the fuel tank and the fuel supply pump.
26) If a problem is discovered, replace the clamp.
27) Operate the priming pump until the handle be-
comes heavy.
ANNOTATION:
• When a leak exists in the fuel system be-
tween the priming pump and the fuel sup-
ply pump, the pressing weight of the priming
pump does not become heavy.
28) Start the engine.
29) Inspect the high-pressure side of the fuel sys-
tem and check for fuel leak between the fuel
supply pump and common rail.
84402826 - May 2011
4023G-9
ANNOTATION:
• The fuel may leak to the bottom section of
the cylinder head cover from the high pres-
sure hose inlet.
• The engine oil level increases when the fuel
leaks to the bottom portion of the cylinder
head cover.
• Inspect for fuel leaks into the engine oil.
30) If fuel leak if found, fix the problem.
31) Turn OFF the starter switch.
32) Remove the fuel hose on the fuel supply pump
side from the fuel filter.
ANNOTATION:
• Use a pan to catch the fuel from the re-
moved fuel hose.
• Clean the pressure gauge and connection
hose before connecting to the fuel pipe.
• The fuel supply pump may be damaged due
to foreign matter that has entered in the con-
nection hose.
33) Connect the pressure gauge between the fuel
filter and the removed fuel hose.
ANNOTATION:
• Confirm that the fuel system is connected
securely.
34) Remove the air using the priming pump, and
crank the engine for the specified period of
time or shorter.
specified time： 5 s
ANNOTATION:
• Repeat this until the engine starts.
35) Leave the engine idling for the specified pe-
riod of time or longer.
specified time： 1 min
36) While keeping the engine rotating at the spec-
ified engine RPM for the specified period of
time, check the pressure gauge.
Specified time： 1 min
Rotational speed： 2500 min-1 {2500 r/min}
37) Check if the pressure gauge shows a negative
pressure value at or above the standard value
during inspection.
specified value ： 17.0 kPa {128 mmHg / 5
inHg}
ANNOTATION:
• Fuel clogging is checked with the negative
pressure amount in the fuel system.
38) If the negative pressure is at or above the
standard value, inspect to see if there is dam-
age or twisting with the fuel system between
the fuel supply pump and the fuel tank.
39) If a problem is discovered, repair the fuel sys-
tem.
40) Inspect the fuel tank bent hose.
41) If a problem is discovered, repair the bent
hose.
 Engine-side Trouble
42) Check to see if there is any foreign matter in
the fuel tank or any foreign matter which can
cause fuel clogging.
43) If a problem is discovered, repair it.
44) Replace the fuel filter element.
Refer to "1.Engine 1C.Fuel System(4HK1X)
Fuel filter element Removal".
Refer to "1.Engine 1C.Fuel System(4HK1X)
Fuel filter element Installation".
45) If the negative pressure is at or below the stan-
dard value, pinch the fuel hose at a position as
close as possible to the fuel tank, so that the
fuel does not flow.
ANNOTATION:
• The fuel pipe can be disconnected and
clogged with a plug.
46) Start the engine and use the idling control
switch to increase the RPM to the highest
level.
47) Check the pressure gauge.
Specified value ： 27.0 kPa {203 mmHg / 8
inHg}
ANNOTATION:
• When the pressure gauge is likely to indi-
cate a value exceeding the standard value
during inspection, release the fuel being
blocked.
• Air mixture is checked with the negative
pressure amount while the fuel flow is being
blocked.
48) If the standard negative pressure cannot be
generated, inspect to see if there is a cut or
crack with the fuel hose.
49) If a problem is discovered, replace the fuel
hose.
50) Inspect to see if appropriate clamp is used.
51) If a problem is discovered, replace the clamp
with an appropriate one.
52) Turn OFF the starter switch.
84402826 - May 2011
4023G-10
53) Inspect the suction control valve harness con-
nector for a contact failure.
54) If a problem is discovered, repair the harness
connector.
55) Inspect the ECM harness connector for a con-
tact failure.
56) If a problem is discovered, repair the harness
connector.
57) Inspect each circuit for high resistance.
58) Repair the circuit if a problem is discovered.
59) If the suction control valve harness connector
and the ECM harness connector are normal
and there is no high resistance in each circuit,
replace the fuel supply pump and the fuel filter
element.
Refer to "1.Engine 1C.Fuel System(4HK1X)
Fuel supply pump Removal".
Refer to "1.Engine 1C.Fuel System(4HK1X)
Fuel supply pump Installation".
Refer to "1.Engine 1C.Fuel System(4HK1X)
Fuel filter element Removal".
Refer to "1.Engine 1C.Fuel System(4HK1X)
Fuel filter element Installation".
ANNOTATION:
• When replacing the fuel supply pump, it is
required to also replace the fuel filter ele-
ment at the same time.
60) Perform the unit difference learning of the fuel
supply pump to the ECM.
3. DTC P0088 Confirm Resolution
1) Clear the DTC using the trouble diagnosis
scan tool.
2) Turn the starter switch OFF for 30 seconds or
longer.
3) Start the engine.
4) Perform a test-run.
5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.
 Engine-side Trouble

DTC P0089 (Flash Code 151)Fuel 13) If a problem is discovered, repair the harness
connector.
Pressure Regulator Performance 14) Inspect each circuit for high resistance.
15) Repair the circuit if a problem is discovered.
1. DTC P0089 Priority DTC
16) Turn the starter switch OFF for 30 seconds or
DTC P0091
longer.
DTC P0092
17) Start the engine.
DTC P0192
18) Rev the engine a few times in neutral while
DTC P0193
checking the actual fuel rail pressure display
DTC P0201
with the trouble diagnosis scan tool.
DTC P0202
19) Use the trouble diagnosis scan tool to check
DTC P0203
if the actual fuel rail pressure display shows a
DTC P0204
value within the standard range at a sufficient
DTC P2146
rate.
DTC P2149
Standard values: (-5) - 5 MPa
2. DTC P0089 Diagnostics
ANNOTATION:
1) Wait for the specified period of time until the
fuel pressure is released from the common • If possible, compare with other actual unit
rail. equipped with the same model engine.
Specified time： 2 min
2) Check the fuel rail pressure sensor display 20) If it is within the standard range, replace the
with the trouble diagnosis scan tool. fuel filter element.
Coltage： 0.9 - 1.0 V Refer to "1.Engine 1C.Fuel System(4HK1X)
3) If the fuel rail pressure sensor display is out- Fuel filter element Removal".
side the standard range, inspect the fuel pres- Refer to "1.Engine 1C.Fuel System(4HK1X)
sure sensor harness connector for a contact Fuel filter element Installation".
failure. 21) If it is outside the standard range, replace the
4) If a problem is discovered, repair the harness fuel supply pump and the fuel filter element.
connector. Refer to "1.Engine 1C.Fuel System(4HK1X)
5) Inspect the ECM harness connector for a con- Fuel supply pump Removal".
tact failure. Refer to "1.Engine 1C.Fuel System(4HK1X)
6) If a problem is discovered, repair the harness Fuel supply pump Installation".
connector. Refer to "1.Engine 1C.Fuel System(4HK1X)
7) Inspect each circuit for high resistance. Fuel filter element Removal".
8) Repair the circuit if a problem is discovered. Refer to "1.Engine 1C.Fuel System(4HK1X)
9) If the harness connector and each circuit are Fuel filter element Installation".
normal, replace the fuel pressure sensor. ANNOTATION:
Refer to "1.Engine 1C.Fuel System(4HK1X)
Common rail assembly Removal". • When replacing the fuel supply pump, it is
Refer to "1.Engine 1C.Fuel System(4HK1X) required to also replace the fuel filter ele-
Common rail assembly Installation". ment at the same time.

ANNOTATION: 22) Perform the unit difference learning of the fuel

supply pump to the ECM.
• Do not replace the fuel pressure sensor sep-
arately. 3. DTC P0089 Confirm Resolution
When a problem is found, replace the com- 1) Clear the DTC using the trouble diagnosis
mon rail assembly. scan tool.
10) Inspect the suction control valve harness con- 2) Turn the starter switch OFF for 30 seconds or
nector for a contact failure. longer.
11) If a problem is discovered, repair the harness 3) Start the engine.
connector. 4) Perform a test-run.
12) Inspect the ECM harness connector for a con- 5) Use the trouble diagnosis scan tool to confirm
tact failure. that a DTC has not been detected.

84402826 - May 2011

4023G-11
 Engine-side Trouble

DTC P0091 (Flash Code 247) Fuel 12) If a problem is discovered, repair the High side
circuit.
Pressure Regulator Control Circuit 13) Turn the starter switch OFF for 30 seconds or
Low 14)
longer.
Connect the test light between the suction
1. DTC P0091 Diagnostics control valve Low side circuit and battery
power supply.
1) Check the rail pressure regulator feedback 15) Turn ON the starter switch.
current display with the trouble diagnosis scan 16) Check if the test light comes on and then goes
tool. off.
Current： 300 - 900 mA 17) If it does not turn off, inspect the Low side
2) If it is at or above the standard value, inspect circuit between the ECM and suction control
to see if there is a short circuit to the battery valve.
or ignition power supply with the High side cir-
cuit between the ECM and the suction control • There should be no open circuit or high re-
valve. sistance.
• There should be no short to the battery or
ANNOTATION: ignition power supply.
• When the High side circuit is shorted to the 18) If a problem is discovered, repair the Low side
voltage, the engine stalls and does not start. circuit.
3) If a problem is discovered, repair the High side 19) Inspect the suction control valve harness con-
circuit. nector for a contact failure.
4) If it is within the standard range, inspect to 20) If a problem is discovered, repair the harness
see if there is a short circuit to the GND with connector.
the Low side circuit between the ECM and the 21) If the harness connector is normal, replace the
suction control valve. suction control valve.
Refer to "1.Engine 1C.Fuel System(4HK1X)
ANNOTATION: Suction control valve Removal".
• When the Low side circuit is shorted to Refer to "1.Engine 1C.Fuel System(4HK1X)
GND, DTC P0091 may not be detected. Suction control valve Installation".
• When the Low side circuit is shorted to 22) Inspect the ECM harness connector for a con-
GND, the engine stalls and does not start. tact failure.
23) If a problem is discovered, repair the harness
5) If a problem is discovered, repair the Low side connector.
circuit. 24) If the harness connector is normal, replace the
6) Turn the starter switch OFF for 30 seconds or ECM.
longer. Refer to "1.Engine 1J.Electrical(4HK1X) ECM
7) Disconnect the harness connector from the Removal".
suction control valve. Refer to "1.Engine 1J.Electrical(4HK1X) ECM
8) Connect the test light between the suction Installation".
control valve High side circuit and a normal 25) Set the injector ID code on the ECM.
GND. 26) Perform the unit difference learning of the fuel
9) Turn ON the starter switch. supply pump to the ECM.
10) Check if the test light comes on and then goes
off. 2. DTC P0091 Confirm Resolution
11) If it does not turn off, inspect the High side cir- 1) Clear the DTC using the trouble diagnosis
cuit between the ECM and the suction control scan tool.
valve. 2) Turn the starter switch OFF for 30 seconds or
• There should be no open circuit or high re- longer.
sistance. 3) Start the engine.
• There should be no short to GND. 4) Perform a test-run.
• There should be no short to the LOW side 5) Use the trouble diagnosis scan tool to confirm
circuit. that a DTC has not been detected.

84402826 - May 2011

4023G-12
 Engine-side Trouble

DTC P0092 (Flash Code 247) Fuel 12) If a problem is discovered, repair the High side
circuit.
Pressure Regulator Control Circuit 13) Turn the starter switch OFF for 30 seconds or
High 14)
longer.
Connect the test light between the suction
1. DTC P0092 Diagnostics control valve Low side circuit and battery
power supply.
1) Check the rail pressure regulator feedback 15) Turn ON the starter switch.
current display with the trouble diagnosis scan 16) Check if the test light comes on and then goes
tool. off.
Current： 300 - 900 mA 17) If it does not turn off, inspect the Low side
2) If it is at or above the standard value, inspect circuit between the ECM and suction control
to see if there is a short circuit to the battery valve.
or ignition power supply with the High side cir-
cuit between the ECM and the suction control • There should be no open circuit or high re-
valve. sistance.
• There should be no short to the battery or
ANNOTATION: ignition power supply.
• When the High side circuit is shorted to the 18) If a problem is discovered, repair the Low side
voltage, the engine stalls and does not start. circuit.
3) If a problem is discovered, repair the High side 19) Inspect the suction control valve harness con-
circuit. nector for a contact failure.
4) If it is within the standard range, inspect to 20) If a problem is discovered, repair the harness
see if there is a short circuit to the GND with connector.
the Low side circuit between the ECM and the 21) If the harness connector is normal, replace the
suction control valve. suction control valve.
Refer to "1.Engine 1C.Fuel System(4HK1X)
ANNOTATION: Suction control valve Removal".
• When the Low side circuit is shorted to Refer to "1.Engine 1C.Fuel System(4HK1X)
GND, DTC P0092 may not be detected. Suction control valve Installation".
• When the Low side circuit is shorted to 22) Inspect the ECM harness connector for a con-
GND, the engine stalls and does not start. tact failure.
23) If a problem is discovered, repair the harness
5) If a problem is discovered, repair the Low side connector.
circuit. 24) If the harness connector is normal, replace the
6) Turn the starter switch OFF for 30 seconds or ECM.
longer. Refer to "1.Engine 1J.Electrical(4HK1X) ECM
7) Disconnect the harness connector from the Removal".
suction control valve. Refer to "1.Engine 1J.Electrical(4HK1X) ECM
8) Connect the test light between the suction Installation".
control valve High side circuit and a normal 25) Set the injector ID code on the ECM.
GND. 26) Perform the unit difference learning of the fuel
9) Turn ON the starter switch. supply pump to the ECM.
10) Check if the test light comes on and then goes
off. 2. DTC P0092 Confirm Resolution
11) If it does not turn off, inspect the High side cir- 1) Clear the DTC using the trouble diagnosis
cuit between the ECM and the suction control scan tool.
valve. 2) Turn the starter switch OFF for 30 seconds or
• There should be no open circuit or high re- longer.
sistance. 3) Start the engine.
• There should be no short to GND. 4) Perform a test-run.
• There should be no short to the LOW side 5) Use the trouble diagnosis scan tool to confirm
circuit. that a DTC has not been detected.

84402826 - May 2011

4023G-13
 Engine-side Trouble

DTC P0093 (Flash Code 227) Fuel 6) If fuel leak is found, replace the corresponding
injector.
System Leak Detected Refer to "1.Engine 1C.Fuel System(4HK1X)
Injector Removal".
1. DTC P0093 Priority DTC
Refer to "1.Engine 1C.Fuel System(4HK1X)
DTC P0087
Injector Installation".
DTC P0091
7) When the injector has been replaced, set the
DTC P0092
injector ID code on the ECM.
DTC P0192
8) Turn OFF the starter switch.
DTC P0193
9) Wait for the specified period of time until the
DTC P0201
fuel pressure is released from the common
DTC P0202
rail.
DTC P0203
Specified time： 2 min
DTC P0204
10) Turn ON the starter switch.
DTC P2146
11) Check the fuel rail pressure sensor display
DTC P2149
with the trouble diagnosis scan tool.
2. DTC P0093 Diagnostics
Voltage： 0.9 - 1.0 V
1) Inspect for fuel leaks on the high-pressure 12) If the fuel rail pressure sensor display is out-
side between the fuel supply pump and injec- side the standard range, inspect the fuel pres-
tor. sure sensor harness connector for a contact
failure.
• There should be no fuel leakage from the 13) If a problem is discovered, repair the harness
fuel supply pump. connector.
• There should be no fuel leakage from the 14) Inspect the ECM harness connector for a con-
common rail. tact failure.
• There should be no fuel leakage from the 15) If a problem is discovered, repair the harness
pressure limiter valve. connector.
• There should be no fuel leakage from the 16) Inspect each circuit for high resistance.
fuel pressure sensor. 17) Repair the circuit if a problem is discovered.
• There should be no fuel leakage from the 18) If the harness connector and each circuit are
fuel pipe between the fuel supply pump and normal, replace the fuel pressure sensor.
common rail. Refer to "1.Engine 1C.Fuel System(4HK1X)
• There should be no fuel leakage from the Common rail assembly Removal".
fuel pipe between the common rail and in- Refer to "1.Engine 1C.Fuel System(4HK1X)
jector. Common rail assembly Installation".
• There should be no fuel leakage from the
sleeve nut of the fuel pipe. ANNOTATION:
2) If fuel leak if found, fix the problem. • Do not replace the fuel pressure sensor sep-
arately.
ANNOTATION: When a problem is found, replace the com-
• The fuel may leak to the bottom section of mon rail assembly.
the cylinder head cover from the high pres-
sure pipe inlet. 19) If the fuel rail pressure sensor display is within
the standard range, start the engine.
• The engine oil level increases when the fuel
leaks to the bottom portion of the cylinder 20) Perform the injector stop test with the trouble
head cover. diagnosis scan tool.
21) Command each injector OFF, and confirm that
• Inspect for fuel leaks into the engine oil.
the engine RPM changes on each injector.
• Remove and inspect the high pressure pipe
joint connected to the injector for a fuel leak- 22) If any injector does not change the engine
age from the sleeve nut. RPM when OFF is instructed, replace the rel-
evant injector.
• When foreign matter has been attached,
replace the injector and the high pressure Refer to "1.Engine 1C.Fuel System(4HK1X)
pipe. Injector Removal".
Refer to "1.Engine 1C.Fuel System(4HK1X)
3) Remove each glow plug from the cylinder Injector Installation".
head assembly. 23) When the injector has been replaced, set the
Refer to "1.Engine 1B.Mechanical(4HK1X) injector ID code on the ECM.
Cylinder head assembly Removal". 24) Inspect to see if there is clogging with the fuel
4) Inspect for fuel leaks into the combustion system between the fuel tank and the fuel sup-
chamber. ply pump.
5) Inspect to see if there is a cylinder from which 25) If a problem is discovered, repair clogging.
fuel leaks into the combustion chamber. 26) Inspect to see if there is cut or crack with the
fuel hose in the fuel system between the fuel
tank and the fuel supply pump.

84402826 - May 2011

4023G-14
 Engine-side Trouble
27) If a problem is discovered, replace the fuel
hose.
ANNOTATION:
• The fuel hose between the fuel tank and
the supply pump becomes negative pres-
sure state when the engine is running.
• When the fuel hose is not connected se-
curely, the air can enter.
• When the engine RPM or the engine load
increases while the air has intruded in the
fuel system, fluctuation in the common rail
pressure is caused, and DTC P0093 may
be detected.
28) Check that an appropriate clamp is used be-
tween the fuel tank and the fuel supply pump.
29) If a problem is discovered, replace the clamp
with an appropriate one.
30) Operate the priming pump until the handle be-
comes heavy.
ANNOTATION:
• When a leak exists in the fuel system be-
tween the priming pump and the fuel sup-
ply pump, the pressing weight of the priming
pump does not become heavy.
31) Start the engine.
32) Inspect the high-pressure side of the fuel sys-
tem and check for fuel leak between the fuel
supply pump and common rail.
ANNOTATION:
• The fuel may leak to the bottom section of
the cylinder head cover from the high pres-
sure hose inlet.
• The engine oil level increases when the fuel
leaks to the bottom portion of the cylinder
head cover.
• Inspect for fuel leaks into the engine oil.
33) If fuel leak if found, fix the problem.
34) Turn OFF the starter switch.
35) Remove the fuel hose on the fuel supply pump
side from the fuel filter.
ANNOTATION:
• Use a pan to catch the fuel from the re-
moved fuel hose.
• Clean the pressure gauge and connection
hose before connecting to the fuel pipe.
• The fuel supply pump may be damaged due
to foreign matter that has entered in the con-
nection hose.
36) Connect the pressure gauge between the fuel
filter and the removed fuel hose.
ANNOTATION:
• Confirm that the fuel system is connected
securely.
84402826 - May 2011
4023G-15
37) Remove the air using the priming pump, and
crank the engine for the specified period of
time or shorter.
Specified time： 5 s
ANNOTATION:
• Repeat this until the engine starts.
38) Leave the engine idling for the specified pe-
riod of time or longer.
Specified time： 1 min
39) While keeping the engine rotating at the spec-
ified engine RPM for the specified period of
time, check the pressure gauge.
Specified time： 1 min
Rotational speed： 2500 min-1 {2500 r/min}
40) Check if the pressure gauge shows a negative
pressure value at or above the standard value
during inspection.
Specified value ： 17.0 kPa {128 mmHg / 5
inHg}
ANNOTATION:
• Fuel clogging is checked with the negative
pressure amount in the fuel system.
41) If the negative pressure is at or above the
standard value, inspect to see if there is dam-
age or twisting with the fuel system between
the fuel supply pump and the fuel tank.
42) If a problem is discovered, repair the fuel sys-
tem.
43) Inspect the fuel tank bent hose.
44) If a problem is discovered, repair the bent
hose.
45) Check to see if there is any foreign matter in
the fuel tank or any foreign matter which can
cause fuel clogging.
46) If a problem is discovered, repair it.
47) Replace the fuel filter element.
Refer to "1.Engine 1C.Fuel System(4HK1X)
Fuel filter element Removal".
Refer to "1.Engine 1C.Fuel System(4HK1X)
Fuel filter element Installation".
48) If the negative pressure is at or below the stan-
dard value, pinch the fuel hose at a position as
close as possible to the fuel tank, so that the
fuel does not flow.
ANNOTATION:
• The fuel pipe can be disconnected and
clogged with a plug.
49) Start the engine and use the idling control
switch to increase the RPM to the highest
level.
50) Check the pressure gauge.
Specified value ： 27.0 kPa {203 mmHg / 8
inHg}
ANNOTATION:
• When the pressure gauge is likely to indi-
cate a value exceeding the standard value
during inspection, release the fuel being
blocked.
 Engine-side Trouble

• Air mixture is checked with the negative DTC U0101 (Flash Code 85) Lost
pressure amount while the fuel flow is being
blocked. Communication with TCM
51) If the standard negative pressure cannot be 1. DTC U0101 Diagnostics
generated, inspect to see if there is a cut or
1) Inspect the CAN-Low circuit and CAN-High
crack with the fuel hose.
circuit between the ECM and the control unit
52) If a problem is discovered, replace the fuel
of the actual unit.
hose.
53) Inspect to see if appropriate clamp is used. • There should be no short to the battery or
54) If a problem is discovered, replace the clamp ignition power supply.
with an appropriate one. • There should be no open circuit or high re-
55) Turn OFF the starter switch. sistance.
56) Inspect the suction control valve harness con- • There should be no short to GND.
nector for a contact failure.
57) If a problem is discovered, repair the harness 2) If a problem is discovered, repair the CAN
connector. circuit.
58) Inspect the ECM harness connector for a con- 3) If the CAN circuit is normal, connect all har-
tact failure. nesses.
59) If a problem is discovered, repair the harness 4) Clear the DTC using the trouble diagnosis
connector. scan tool.
60) Inspect each circuit for high resistance. 5) Turn the starter switch OFF for 30 seconds or
61) Repair the circuit if a problem is discovered. longer.
62) If the suction control valve harness connector 6) Perform a test-run.
and the ECM harness connector are normal 7) Check the DTC.
and there is no high resistance in each circuit, 8) If a DTC has been detected, replace the con-
replace the fuel supply pump and the fuel filter trol unit of the actual unit.
element. 9) Connect all harnesses.
Refer to "1.Engine 1C.Fuel System(4HK1X) 10) Clear the DTC using the trouble diagnosis
Fuel supply pump Removal". scan tool.
Refer to "1.Engine 1C.Fuel System(4HK1X) 11) Turn the starter switch OFF for 30 seconds or
Fuel supply pump Installation". longer.
Refer to "1.Engine 1C.Fuel System(4HK1X) 12) Perform a test-run.
Fuel filter element Removal". 13) Check the DTC.
Refer to "1.Engine 1C.Fuel System(4HK1X) 14) If a DTC has been detected, replace the ECM.
Fuel filter element Installation". Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Removal".
ANNOTATION: Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Installation".
• When replacing the fuel supply pump, it is 15) Set the injector ID code on the ECM.
required to also replace the fuel filter ele-
16) Perform the unit difference learning of the fuel
ment at the same time.
supply pump to the ECM.
63) Perform the unit difference learning of the fuel
2. DTC U0101 Confirm Resolution
supply pump to the ECM.
1) Clear the DTC using the trouble diagnosis
3. DTC P0093 Confirm Resolution
scan tool.
1) Clear the DTC using the trouble diagnosis 2) Turn the starter switch OFF for 30 seconds or
scan tool. longer.
2) Turn the starter switch OFF for 30 seconds or 3) Start the engine.
longer. 4) Perform a test-run.
3) Start the engine. 5) Use the trouble diagnosis scan tool to confirm
4) Perform a test-run. that a DTC has not been detected.
5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.

84402826 - May 2011

4023G-16
 Engine-side Trouble

DTC P0102 (Flash Code 91) Mass DTC P0103 (Flash Code 91) Mass
Air Flow Circuit Low Input Air Flow Circuit High Input
1. DTC P0102 Priority DTC 1. DTC P0103 Priority DTC
DTC P0560 DTC P0560
2. DTC P0102 Diagnostics 2. DTC P0103 Diagnostics
1) Turn OFF the starter switch. 1) Turn OFF the starter switch.
2) Disconnect the harness connector from the 2) Disconnect the harness connector from the
mass air flow sensor. mass air flow sensor.
3) Inspect to see if there is an open circuit or high 3) Check the mass air flow sensor display with
resistance in the 12 V power supply circuit be- the trouble diagnosis scan tool.
tween the ECM and the mass air flow sensor. Voltage： 0.1 V
4) If a problem is discovered, repair the 12 V 4) If it is at or above the standard value, inspect
power supply circuit. the signal circuit between the ECM and the
5) Connect the test cable with fuse between the mass air flow sensor.
12 V power supply circuit and the signal circuit
of the mass air flow sensor harness connector. • There should be no short to the battery or
6) Check the mass air flow sensor display with ignition power supply.
the trouble diagnosis scan tool. • There should be no short to the 12 V or 5 V
Voltage： 4.9 V power supply.
7) If it is at or above the standard value, inspect 5) If a problem is discovered, repair the Signal
to see if there is a contact failure with the mass circuit.
air flow sensor harness connector. 6) Inspect to see if there is an open circuit or
8) If a problem is discovered, repair the harness high resistance in the GND circuit between the
connector. ECM and the mass air flow sensor.
9) If the harness connector is normal, replace the 7) If a problem is discovered, repair the GND
mass air flow sensor. circuit.
10) Inspect the signal circuit between the ECM 8) Inspect the mass air flow sensor harness con-
and the mass air flow sensor. nector for a contact failure.
9) If a problem is discovered, repair the harness
• There should be no open circuit or high re-
connector.
sistance.
10) If the harness connector is normal, replace the
• There should be no short to GND.
mass air flow sensor.
11) If a problem is discovered, repair the Signal 11) Inspect the ECM harness connector for a con-
circuit. tact failure.
12) Inspect the ECM harness connector for a con- 12) If a problem is discovered, repair the harness
tact failure. connector.
13) If a problem is discovered, repair the harness 13) If the harness connector is normal, replace the
connector. ECM.
14) If the harness connector is normal, replace the Refer to "1.Engine 1J.Electrical(4HK1X) ECM
ECM. Removal".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Removal". Installation".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM 14) Set the injector ID code on the ECM.
Installation". 15) Perform the unit difference learning of the fuel
15) Set the injector ID code on the ECM. supply pump to the ECM.
16) Perform the unit difference learning of the fuel
3. DTC P0103 Confirm Resolution
supply pump to the ECM.
1) Clear the DTC using the trouble diagnosis
3. DTC P0102 Confirm Resolution
scan tool.
1) Clear the DTC using the trouble diagnosis 2) Turn the starter switch OFF for 30 seconds or
scan tool. longer.
2) Turn the starter switch OFF for 30 seconds or 3) Start the engine.
longer. 4) Perform a test-run.
3) Start the engine. 5) Use the trouble diagnosis scan tool to confirm
4) Perform a test-run. that a DTC has not been detected.
5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.

84402826 - May 2011

4023G-17
 Engine-side Trouble

DTC U0110 (Flash Code 87) Lost DTC P0112 (Flash Code 22)
Communication with VNT System Intake Air Temperature Sensor
1. DTC U0110 Priority DTC Circuit Low
DTC P0045
DTC U0001 1. DTC P0112 Priority DTC
2. DTC U0110 Diagnostics DTC P0641
2. DTC P0112 Diagnostics
1) Turn OFF the starter switch.
2) Remove the harness connector from the turbo 1) Turn OFF the starter switch.
control unit. 2) Disconnect the harness connector from the
3) Turn ON the starter switch. intake air temperature sensor.
4) Measure the voltage between the CAN-High 3) Check the intake air temperature sensor dis-
circuit and GND of the turbo control unit har- play with the trouble diagnosis scan tool.
ness connector. Voltage： 4.5 V
5) Measure the voltage between the CAN-High 4) If it is at or above the standard value, replace
circuit and GND of the turbo control unit har- the intake air temperature sensor.
ness connector. 5) Inspect to see if there is a short circuit to the
Voltage： 1.5 - 3.5 V GND with the signal circuit between the ECM
6) If it is outside the standard range, inspect to and the intake air temperature sensor.
see if there is an open circuit or high resis- 6) If a problem is discovered, repair the signal
tance with the CAN-High circuit between the circuit.
turbo control unit and the ECM. 7) Turn OFF the starter switch.
7) If a problem is discovered, repair the CAN- 8) Disconnect the harness connector from the
High circuit. ECM.
8) Inspect to see if there is an open circuit or high 9) Inspect the ECM harness connector for a con-
resistance with the CAN-Low circuit between tact failure.
the turbo control unit and the ECM. 10) If a problem is discovered, repair the harness
9) If a problem is discovered, repair the CAN- connector.
Low circuit. 11) If the harness connector is normal, replace the
10) Inspect the turbo control unit harness connec- ECM.
tor for a contact failure. Refer to "1.Engine 1J.Electrical(4HK1) ECM
11) If a problem is discovered, repair the harness Removal".
connector. Refer to "1.Engine 1J.Electrical(4HK1) ECM
12) Replace the turbo control unit. Installation".
12) Set the injector ID code on the ECM.
3. DTC U0110 Confirm Resolution 13) Perform the unit difference learning of the fuel
supply pump to the ECM.
1) Clear the DTC using the trouble diagnosis
scan tool. 3. DTC P0112 Confirm Resolution
2) Turn the starter switch OFF for 30 seconds or
longer. 1) Clear the DTC using the trouble diagnosis
3) Start the engine. scan tool.
4) Perform a test-run. 2) Turn the starter switch OFF for 30 seconds or
5) Use the trouble diagnosis scan tool to confirm longer.
that a DTC has not been detected. 3) Start the engine.
4) Perform a test-run.
5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.

84402826 - May 2011

4023G-18
 Engine-side Trouble

DTC P0113 (Flash Code 22) 15) Check the intake air temperature sensor dis-
play with the trouble diagnosis scan tool.
Intake Air Temperature Sensor Voltage： 0.1 V
Circuit High 16) If it is at or below the standard value, inspect
to see if there is an open circuit or high resis-
1. DTC P0113 Priority DTC tance with the GND circuit between the ECM
DTC P0641 and the intake air temperature sensor.
2. DTC P0113 Diagnostics
ANNOTATION:
1) Turn OFF the starter switch.
• The intake air temperature sensor shares
2) Disconnect the harness connector from the
the GND circuit with other sensors.
intake air temperature sensor.
• The DTC set on a sensor which shares this
3) Turn ON the starter switch.
circuit may be detected.
4) Measure the voltage between the intake air
temperature sensor signal circuit and a nor- 17) If a problem is discovered, repair the GND
mal GND. circuit.
Voltage： 5.5 V 18) Inspect to see if there is an open circuit or
5) If it is at or above the standard value, inspect high resistance in the signal circuit between
the signal circuit between the ECM and the the ECM and the intake air temperature sen-
intake air temperature sensor. sor.
19) If a problem is discovered, repair the signal
• There should be no short to the battery or circuit.
ignition power supply
20) Inspect the ECM harness connector for a con-
• There should be no short to the 12 V power tact failure.
supply.
21) If a problem is discovered, repair the harness
6) If a problem is discovered, repair the signal connector.
circuit. 22) If the harness connector is normal, replace the
7) Connect the test cable with fuse between the ECM.
intake air temperature sensor signal circuit Refer to "1.Engine 1J.Electrical(4HK1X) ECM
and the GND circuit. Removal".
8) Check the intake air temperature sensor dis- Refer to "1.Engine 1J.Electrical(4HK1X) ECM
play with the trouble diagnosis scan tool. Installation".
Voltage： 0.1 V 23) Set the injector ID code on the ECM.
9) If it is at or below the standard value, inspect to 24) Perform the unit difference learning of the fuel
see if there is a short circuit to the 5 V power supply pump to the ECM.
supply circuit with the signal circuit between
3. DTC P0113 Confirm Resolution
the ECM and the intake air temperature sen-
sor. 1) Clear the DTC using the trouble diagnosis
10) If a problem is discovered, repair the signal scan tool.
circuit. 2) Turn the starter switch OFF for 30 seconds or
11) Inspect the intake air temperature sensor har- longer.
ness connector for a contact failure. 3) Start the engine.
12) If a problem is discovered, repair the harness 4) Perform a test-run.
connector. 5) Use the trouble diagnosis scan tool to confirm
13) If the harness connector is normal, replace the that a DTC has not been detected.
intake air temperature sensor.
14) Connect the test cable with fuse between the
intake air temperature sensor signal circuit
and a normal GND.

84402826 - May 2011

4023G-19
 Engine-side Trouble

DTC P0117 (Flash Code 23) DTC P0118 (Flash Code 23)
Engine Coolant Temperature Engine Coolant Temperature
Sensor Circuit Low Sensor Circuit High
1. DTC P0117 Priority DTC 1. DTC P0118 Priority DTC
DTC P0697 DTC P0697
2. DTC P0117 Diagnostics 2. DTC P0118 Diagnostics
1) Turn OFF the starter switch. 1) Turn OFF the starter switch.
2) Disconnect the harness connector from the 2) Disconnect the harness connector from the
water temperature sensor. water temperature sensor.
3) Check the coolant temperature sensor display 3) Turn ON the starter switch.
with the trouble diagnosis scan tool. 4) Measure the voltage between the water tem-
Voltage： 4.5 V perature sensor signal circuit and normal
4) If it is at or above the standard value, replace GND.
the water temperature sensor. Voltage： 5.5 V
Refer to "1.Engine 1D.Cooling(4HK1X) En- 5) If it is at or above the standard value, inspect
gine coolant temperature sensor Removal". to see if there is a short circuit to the battery
Refer to "1.Engine 1D.Cooling(4HK1X) En- or ignition power supply with the signal circuit
gine coolant temperature sensor Installation". between the ECM and the water temperature
5) Inspect to see if there is a short circuit to the sensor.
GND with the signal circuit between the ECM 6) If a problem is discovered, repair the signal
and water temperature sensor. circuit.
6) If a problem is discovered, repair the signal 7) Connect the test cable with fuse between the
circuit. water temperature sensor signal Circuit and
7) Inspect the ECM harness connector for a con- GND circuit.
tact failure. 8) Check the coolant temperature sensor display
8) If a problem is discovered, repair the harness with the trouble diagnosis scan tool.
connector. Voltage： 0.1 V
9) If the harness connector is normal, replace the 9) If it is at or below the standard value, inspect to
ECM. see if there is a short circuit to the 5 V power
Refer to "1.Engine 1J.Electrical(4HK1X) ECM supply circuit with the signal circuit between
Removal". the ECM and the water temperature sensor.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM 10) If a problem is discovered, repair the signal
Installation". circuit.
10) Set the injector ID code on the ECM. 11) Inspect to see if there is a contact failure with
11) Perform the unit difference learning of the fuel the water temperature sensor harness con-
supply pump to the ECM. nector.
12) If a problem is discovered, repair the harness
3. DTC P0117 Confirm Resolution connector.
1) Clear the DTC using the trouble diagnosis 13) If the harness connector is normal, replace the
scan tool. water temperature sensor.
2) Turn the starter switch OFF for 30 seconds or Refer to "1.Engine 1D.Cooling(4HK1X) En-
longer. gine coolant temperature sensor Removal".
3) Start the engine. Refer to "1.Engine 1D.Cooling(4HK1X) En-
4) Perform a test-run. gine coolant temperature sensor Installation".
5) Use the trouble diagnosis scan tool to confirm 14) Connect the test cable with fuse between the
that a DTC has not been detected. water temperature sensor signal circuit and
normal GND.
15) Check the coolant temperature sensor display
with the trouble diagnosis scan tool.
Voltage： 0.1 V
16) If it is at or below the standard value, inspect
to see if there is an open circuit or high resis-
tance with the water temperature sensor GND
circuit.
ANNOTATION:
• The water temperature sensor shares the
GND circuit with other sensors.
• The DTC set on a sensor which shares this
circuit may be detected.
17) If a problem is discovered, repair the GND
circuit.
84402826 - May 2011
4023G-20
 Engine-side Trouble

18) Inspect to see if there is a breakage or high re- DTC P0122 (Flash Code 43)
sistance in the signal circuit of the water tem-
perature sensor. Throttle Position Sensor Circuit
19) If a problem is discovered, repair the signal
circuit.
Low
20) Inspect the ECM harness connector for a con- 1. DTC P0122 Priority DTC
tact failure. DTC P1655
21) If a problem is discovered, repair the harness 2. DTC P0122 Diagnostics
connector.
22) If the harness connector is normal, replace the 1) Turn OFF the starter switch.
ECM. 2) Disconnect the harness connector from the
Refer to "1.Engine 1J.Electrical(4HK1X) ECM intake throttle valve.
Removal". 3) Turn ON the starter switch.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM 4) Measure the voltage between the intake throt-
Installation". tle position sensor 5 V power supply circuit
23) Set the injector ID code on the ECM. and a normal GND.
24) Perform the unit difference learning of the fuel Voltage： 4.9 V
supply pump to the ECM. 5) If it is at or below the standard value, inspect
to see if there is an open circuit or high re-
3. DTC P0118 Confirm Resolution sistance with the 5 V power supply circuit be-
tween the ECM and the intake throttle position
1) Clear the DTC using the trouble diagnosis
sensor.
scan tool.
2) Turn the starter switch OFF for 30 seconds or ANNOTATION:
longer.
3) Start the engine. • The intake throttle position sensor shares
4) Perform a test-run. the 5 V power supply circuit with other sen-
5) Use the trouble diagnosis scan tool to confirm sors.
that a DTC has not been detected. • The DTC set on a sensor which shares this
circuit may be detected.
6) If a problem is discovered, repair the 5 V
power supply circuit.
7) Connect the test cable with fuse between the
intake throttle position sensor 5 V power sup-
ply circuit and the signal circuit.
8) Check the intake throttle position sensor dis-
play with the trouble diagnosis scan tool.
Voltage： 4.9 V
9) If it is at or above the standard value, inspect
to see if there is a contact failure with the in-
take throttle valve harness connector.
10) If a problem is discovered, repair the harness
connector.
11) If the harness connector is normal, replace the
intake throttle valve.
Refer to "1.Engine 1B.Mechanical(4HK1X) In-
take throttle valve Removal".
Refer to "1.Engine 1B.Mechanical(4HK1X) In-
take throttle valve Installation".
12) Inspect the signal circuit between the ECM
and intake throttle position sensor.
• There should be no open circuit or high re-
sistance.
• There should be no short to GND.
13) If a problem is discovered, repair the signal
circuit.
14) Inspect the ECM harness connector for a con-
tact failure.
15) If a problem is discovered, repair the harness
connector.

84402826 - May 2011

4023G-21
 Engine-side Trouble

16) If the harness connector is normal, replace the DTC P0123 (Flash Code 43)
ECM.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM Throttle Position Sensor Circuit
Removal".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
High
Installation". 1. DTC P0123 Priority DTC
17) Set the injector ID code on the ECM. DTC P1655
18) Perform the unit difference learning of the fuel 2. DTC P0123 Diagnostics
supply pump to the ECM.
1) Turn OFF the starter switch.
3. DTC P0122 Confirm Resolution 2) Disconnect the harness connector from the
intake throttle valve.
1) Clear the DTC using the trouble diagnosis
3) Check the intake throttle position sensor dis-
scan tool.
play with the trouble diagnosis scan tool.
2) Turn the starter switch OFF for 30 seconds or
Voltage： 0.1 V
longer.
4) If it is at or above the standard value, inspect
3) Start the engine.
the signal circuit between the ECM and the
4) Perform a test-run.
intake throttle position sensor.
5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected. • There should be no short to the battery or
ignition power supply.
• There should be no short to the 5 V power
supply.
5) If a problem is discovered, repair the signal
circuit.
6) Inspect the intake throttle valve harness con-
nector for a contact failure.
7) If a problem is discovered, repair the harness
connector.
8) If the harness connector is normal, replace the
intake throttle valve.
Refer to "1.Engine 1B.Mechanical(4HK1X) In-
take throttle valve Removal".
Refer to "1.Engine 1B.Mechanical(4HK1X) In-
take throttle valve Installation".
9) Inspect to see if there is an open circuit or
high resistance in the GND circuit between the
ECM and the intake throttle position sensor.
ANNOTATION:
• The intake throttle position sensor shares
the GND circuit with other sensors.
• The DTC set on a sensor which shares this
circuit may be detected.
10) If a problem is discovered, repair the GND
circuit.
11) Check the ECM harness connector for a con-
tact failure.
12) If a problem is discovered, repair the harness
connector.
13) If the harness connector is normal, replace the
ECM.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Removal".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Installation".
14) Set the injector ID code on the ECM.
15) Perform the unit difference learning of the fuel
supply pump to the ECM.
3. DTC P0123 Confirm Resolution
1) Clear the DTC using the trouble diagnosis
scan tool.

84402826 - May 2011

4023G-22
 Engine-side Trouble

2) Turn the starter switch OFF for 30 seconds or DTC P0182 (Flash Code 211) Fuel
longer.
3) Start the engine. Temperature Sensor Circuit Low
4) Perform a test-run.
1. DTC P0182 Priority DTC
5) Use the trouble diagnosis scan tool to confirm
DTC P1655
that a DTC has not been detected.
2. DTC P0182 Diagnostics
1) Turn OFF the starter switch.
2) Disconnect the harness connector from the
fuel temperature sensor.
3) Check the fuel temperature sensor display
with the trouble diagnosis scan tool.
Voltage： 4.5 V
4) If it is at or above the standard value, replace
the fuel temperature sensor.
Refer to "1.Engine 1C.Fuel System(4HK1X)
Fuel supply pump Removal".
Refer to "1.Engine 1C.Fuel System(4HK1X)
Fuel supply pump Installation".
ANNOTATION:
• Do not replace the fuel temperature sensor
separately.
If a problem is found, replace the fuel supply
pump.
5) Inspect to see if there is a short circuit to the
GND with the signal circuit between the ECM
and fuel temperature sensor.
6) If a problem is discovered, repair the signal
circuit.
7) Inspect the ECM harness connector for a con-
tact failure.
8) If a problem is discovered, repair the harness
connector.
9) If the harness connector is normal, replace the
ECM.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Removal".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Installation".
10) Set the injector ID code on the ECM.
11) Perform the unit difference learning of the fuel
supply pump to the ECM.
3. DTC P0182 Confirm Resolution
1) Clear the DTC using the trouble diagnosis
scan tool.
2) Turn the starter switch OFF for 30 seconds or
longer.
3) Start the engine.
4) Perform a test-run.
5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.

84402826 - May 2011

4023G-23
 Engine-side Trouble

DTC P0183 (Flash Code 211) Fuel 14) Connect the test cable with fuse between the
fuel temperature sensor signal circuit and nor-
Temperature Sensor Circuit High mal GND.
15) Check the fuel temperature sensor display
1. DTC P0183 Priority DTC
with the trouble diagnosis scan tool.
DTC P1655
Voltage： 0.1 V
2. DTC P0183 Diagnostics
16) If it is at or below the standard value, inspect
1) Turn OFF the starter switch. to see if there is an open circuit or high resis-
2) Disconnect the harness connector from the tance with the GND circuit between the ECM
fuel temperature sensor. and fuel temperature sensor.
3) Turn ON the starter switch.
ANNOTATION:
4) Measure the voltage between the fuel temper-
ature sensor signal circuit and normal GND. • The fuel temperature sensor shares the
Voltage： 5.5 V GND circuit with other sensors.
5) If it is at or above the standard value, inspect • The DTC set on a sensor which shares this
to see if there is a short circuit to the battery circuit may be detected.
or ignition power supply with the signal circuit
between the ECM and the fuel temperature 17) If a problem is discovered, repair the GND
sensor. circuit.
6) If a problem is discovered, repair the signal 18) Inspect to see if there is an open circuit or
circuit. high resistance in the signal circuit between
7) Connect the test cable with fuse between the ECM and the fuel temperature sensor.
the fuel temperature sensor signal circuit and 19) If a problem is discovered, repair the signal
GND circuit. circuit.
8) Check the fuel temperature sensor display 20) Inspect the ECM harness connector for a con-
with the trouble diagnosis scan tool. tact failure.
Voltage： 0.1 V 21) If a problem is discovered, repair the harness
9) If it is at or below the standard value, inspect to connector.
see if there is a short circuit to the 5 V power 22) If the harness connector is normal, replace the
supply circuit with the signal circuit between ECM.
the ECM and the fuel temperature sensor. Refer to "1.Engine 1J.Electrical(4HK1X) ECM
10) If a problem is discovered, repair the signal Removal".
circuit. Refer to "1.Engine 1J.Electrical(4HK1X) ECM
11) Inspect to see if there is a contact failure with Installation".
the fuel temperature sensor harness connec- 23) Set the injector ID code on the ECM.
tor. 24) Perform the unit difference learning of the fuel
12) If a problem is discovered, repair the harness supply pump to the ECM.
connector. 3. DTC P0183 Confirm Resolution
13) If the harness connector is normal, replace the
fuel temperature sensor. 1) Clear the DTC using the trouble diagnosis
Refer to "1.Engine 1C.Fuel System(4HK1X) scan tool.
Fuel supply pump Removal". 2) Turn the starter switch OFF for 30 seconds or
Refer to "1.Engine 1C.Fuel System(4HK1X) longer.
Fuel supply pump Installation". 3) Start the engine.
4) Perform a test-run.
ANNOTATION:
ANNOTATION:
• Do not replace the fuel temperature sensor
separately. • Run the engine for 3 minutes or longer.
If a problem is found, replace the fuel supply 5) Use the trouble diagnosis scan tool to confirm
pump. that a DTC has not been detected.

84402826 - May 2011

4023G-24
 Engine-side Trouble

DTC P0192 (Flash Code 245) Fuel 10) Inspect to see if there is an open circuit or high
resistance with the 5 V power supply circuit
Rail Pressure Sensor Circuit Low between the ECM and fuel pressure sensor.
1. DTC P0192 Priority DTC ANNOTATION:
DTC P0641
2. DTC P0192 Diagnostics • The fuel pressure sensor shares the 5 V
power supply circuit with other sensors.
1) Turn OFF the starter switch. • The DTC set on a sensor which shares this
2) Disconnect the harness connector from the circuit may be detected.
fuel pressure sensor.
3) Check the fuel rail pressure sensor display 11) If a problem is discovered, repair the 5 V
with the trouble diagnosis scan tool. power supply circuit.
Voltage： 4.5 V 12) Inspect the ECM harness connector for a con-
4) If it is at or below the standard value, inspect to tact failure.
see if there is a short circuit to the GND with 13) If a problem is discovered, repair the harness
the signal circuit between the ECM and the connector.
fuel pressure sensor. 14) If the harness connector is normal, replace the
5) If a problem is discovered, repair the signal ECM.
circuit. Refer to "1.Engine 1J.Electrical(4HK1X) ECM
6) Measure the voltage between the fuel pres- Removal".
sure sensor 5 V power supply circuit and nor- Refer to "1.Engine 1J.Electrical(4HK1X) ECM
mal GND. Installation".
Voltage： 4.5 V 15) Set the injector ID code on the ECM.
7) If it is at or above the standard value, inspect 16) Perform the unit difference learning of the fuel
to see if there is a contact failure with the fuel supply pump to the ECM.
pressure sensor harness connector. 3. DTC P0192 Confirm Resolution
8) If a problem is discovered, repair the harness
connector. 1) Clear the DTC using the trouble diagnosis
9) If the harness connector is normal, replace the scan tool.
fuel pressure sensor. 2) Turn the starter switch OFF for 30 seconds or
Refer to "1.Engine 1C.Fuel System(4HK1X) longer.
Common rail assembly Removal". 3) Start the engine.
Refer to "1.Engine 1C.Fuel System(4HK1X) 4) Perform a test-run.
Common rail assembly Installation". 5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.
ANNOTATION:
• Do not replace the fuel pressure sensor sep-
arately.
When a problem is found, replace the com-
mon rail assembly.

84402826 - May 2011

4023G-25
 Engine-side Trouble

DTC P0193 (Flash Code 245) Fuel 15) Inspect to see if there is an open circuit or
high resistance in the GND circuit between the
Rail Pressure Sensor Circuit High ECM and the fuel pressure sensor.
1. DTC P0193 Priority DTC ANNOTATION:
DTC P0641
2. DTC P0193 Diagnostics • The fuel pressure sensor shares the GND
circuit with other sensors.
1) Turn OFF the starter switch. • The DTC set on a sensor which shares this
2) Disconnect the harness connector from the circuit may be detected.
fuel pressure sensor.
3) Turn ON the starter switch. 16) If a problem is discovered, repair the GND
4) Measure the voltage between the fuel pres- circuit.
sure sensor signal circuit and normal GND. 17) Inspect to see if there is an open circuit or
Voltage： 5.5 V high resistance in the signal circuit between
5) If it is at or above the standard value, inspect the ECM and the fuel pressure sensor.
to see if there is a short circuit to the battery 18) If a problem is discovered, repair the signal
or ignition power supply with the signal circuit circuit.
between the ECM and the fuel pressure sen- 19) Inspect the ECM harness connector for a con-
sor. tact failure.
6) If a problem is discovered, repair the signal 20) If a problem is discovered, repair the harness
circuit. connector.
7) Measure the voltage between the fuel pres- 21) If the harness connector is normal, replace the
sure sensor signal circuit and normal GND. ECM.
Voltage： 4.5 V Refer to "1.Engine 1J.Electrical(4HK1X) ECM
8) If it is at or above the standard value, inspect Removal".
to see if there is a short circuit to the 5 V power Refer to "1.Engine 1J.Electrical(4HK1X) ECM
supply circuit with the signal circuit between Installation".
the ECM and the fuel pressure sensor. 22) Set the injector ID code on the ECM.
9) If a problem is discovered, repair the signal 23) Perform the unit difference learning of the fuel
circuit. supply pump to the ECM.
10) Connect the test cable with fuse between the 3. DTC P0193 Confirm Resolution
fuel pressure sensor signal circuit and GND
circuit. 1) Clear the DTC using the trouble diagnosis
11) Check the fuel rail pressure sensor display scan tool.
with the trouble diagnosis scan tool. 2) Turn the starter switch OFF for 30 seconds or
Voltage： 0.1 V longer.
12) If it is at or below the standard value, inspect 3) Start the engine.
to see if there is a contact failure with the fuel 4) Perform a test-run.
pressure sensor harness connector. 5) Use the trouble diagnosis scan tool to confirm
13) If a problem is discovered, repair the harness that a DTC has not been detected.
connector.
14) If the harness connector is normal, replace the
fuel pressure sensor.
Refer to "1.Engine 1C.Fuel System(4HK1X)
Common rail assembly Removal".
Refer to "1.Engine 1C.Fuel System(4HK1X)
Common rail assembly Installation".
ANNOTATION:
• Do not replace the fuel pressure sensor sep-
arately.
When a problem is found, replace the com-
mon rail assembly.

84402826 - May 2011

4023G-26
 Engine-side Trouble

DTC P0201 (Flash Code 271) 18) Inspect to see if any foreign matter is attached
to the injector terminal.
Injector Circuit - Cylinder 1 19) If any foreign matter is attached to the injector
terminal, remove it.
1. DTC P0201 Diagnostics
20) Inspect the injector harness intermediate har-
1) Turn OFF the starter switch. ness connector for a contact failure.
2) Disconnect the harness connector from the 21) If a problem is discovered, repair the interme-
cylinder head injector intermediate harness diate harness connector.
connector. 22) Inspect the first cylinder injector circuit be-
3) Turn ON the starter switch. tween the injector and injector harness inter-
4) Measure the voltage between the first cylin- mediate connector.
der injector charge voltage circuit and normal
GND. • There should be no open circuit or high re-
sistance.
Voltage： 1.0 V
5) If it is at or above the standard value, inspect • There should be no short between the cir-
cuits.
to see if there is a short circuit to the common
power supply 1 charge voltage circuit with the 23) If a problem is discovered, repair the injector
control circuit between the ECM and the injec- circuit.
tor harness intermediate connector. 24) If the first cylinder injector circuit between the
6) If a problem is discovered, repair the control injector and the injector intermediate connec-
circuit. tor is normal, replace the first cylinder injector.
7) Measure the voltage between the solenoid Refer to "1.Engine 1C.Fuel System(4HK1X)
control circuit of the first cylinder injector and Injector Removal".
normal GND. Refer to "1.Engine 1C.Fuel System(4HK1X)
Voltage： 16.0 V Injector Installation".
8) If it is at or above the standard value, inspect 25) When the injector has been replaced, set the
to see if there is a short circuit to the battery injector ID code on the ECM.
or ignition power supply with the control circuit 26) Disconnect the harness connector from the
between the ECM and the injector harness ECM.
intermediate connector. 27) Inspect the ECM harness connector for a con-
9) If a problem is discovered, repair the control tact failure.
circuit. 28) If a problem is discovered, repair the harness
10) Measure the voltage between the solenoid connector.
control circuit of the first cylinder injector and 29) If the harness connector is normal, replace the
normal GND. ECM.
Voltage： 12.0 V Refer to "1.Engine 1J.Electrical(4HK1X) ECM
11) If it is at or below the standard value, inspect Removal".
to see if there is an open circuit or high resis- Refer to "1.Engine 1J.Electrical(4HK1X) ECM
tance with the control circuit between the ECM Installation".
and injector harness intermediate connector. 30) Set the injector ID code on the ECM.
12) If a problem is discovered, repair the control 31) Perform the unit difference learning of the fuel
circuit. supply pump to the ECM.
13) Inspect the injector harness intermediate con-
nector for a contact failure. 2. DTC P0201 Confirm Resolution
14) If a problem is discovered, repair the injector 1) Clear the DTC using the trouble diagnosis
harness intermediate connector. scan tool.
15) Remove the cylinder head cover. 2) Turn the starter switch OFF for 30 seconds or
Refer to "1.Engine 1B.Mechanical(4HK1X) longer.
Cylinder head cover Removal". 3) Start the engine.
16) Inspect the injector harness tightening nut for 4) Perform a test-run.
looseness. 5) Use the trouble diagnosis scan tool to confirm
17) If the injector harness tightening nut is loose, that a DTC has not been detected.
tighten it.

84402826 - May 2011

4023G-27
 Engine-side Trouble

DTC P0202 (Flash Code 272) 18) Inspect to see if any foreign matter is attached
to the injector terminal.
Injector Circuit - Cylinder 2 19) If any foreign matter is attached to the injector
terminal, remove it.
1. DTC P0202 Diagnostics
20) Inspect the injector harness intermediate har-
1) Turn OFF the starter switch. ness connector for a contact failure.
2) Disconnect the harness connector from the 21) If a problem is discovered, repair the interme-
cylinder head injector intermediate harness diate harness connector.
connector. 22) Inspect the second cylinder injector circuit be-
3) Turn ON the starter switch. tween the injector and injector harness inter-
4) Measure the voltage between the second mediate connector.
cylinder injector charge voltage circuit and
normal GND. • There should be no open circuit or high re-
sistance.
Voltage： 1.0 V
5) If it is at or above the standard value, inspect • There should be no short between the cir-
cuits.
to see if there is a short circuit to the common
power supply 2 charge voltage circuit with the 23) If a problem is discovered, repair the injector
control circuit between the ECM and the injec- circuit.
tor harness intermediate connector. 24) If the second cylinder injector circuit between
6) If a problem is discovered, repair the control the injector and the injector intermediate con-
circuit. nector is normal, replace the second cylinder
7) Measure the voltage between the solenoid injector.
control circuit of the second cylinder injector Refer to "1.Engine 1C.Fuel System(4HK1X)
and normal GND. Injector Removal".
Voltage： 16.0 V Refer to "1.Engine 1C.Fuel System(4HK1X)
8) If it is at or above the standard value, inspect Injector Installation".
to see if there is a short circuit to the battery 25) When the injector has been replaced, set the
or ignition power supply with the control circuit injector ID code on the ECM.
between the ECM and the injector harness 26) Disconnect the harness connector from the
intermediate connector. ECM.
9) If a problem is discovered, repair the control 27) Inspect the ECM harness connector for a con-
circuit. tact failure.
10) Measure the voltage between the solenoid 28) If a problem is discovered, repair the harness
control circuit of the second cylinder injector connector.
and normal GND. 29) If the harness connector is normal, replace the
Voltage： 12.0 V ECM.
11) If it is at or below the standard value, inspect Refer to "1.Engine 1J.Electrical(4HK1X) ECM
to see if there is an open circuit or high resis- Removal".
tance with the control circuit between the ECM Refer to "1.Engine 1J.Electrical(4HK1X) ECM
and injector harness intermediate connector. Installation".
12) If a problem is discovered, repair the control 30) Set the injector ID code on the ECM.
circuit. 31) Perform the unit difference learning of the fuel
13) Inspect the injector harness intermediate con- supply pump to the ECM.
nector for a contact failure.
14) If a problem is discovered, repair the injector 2. DTC P0202 Confirm Resolution
harness intermediate connector. 1) Clear the DTC using the trouble diagnosis
15) Remove the cylinder head cover. scan tool.
Refer to "1.Engine 1B.Mechanical(4HK1X) 2) Turn the starter switch OFF for 30 seconds or
Cylinder head cover Removal". longer.
16) Inspect the injector harness tightening nut for 3) Start the engine.
looseness. 4) Perform a test-run.
17) If the injector harness tightening nut is loose, 5) Use the trouble diagnosis scan tool to confirm
tighten it. that a DTC has not been detected.

84402826 - May 2011

4023G-28
 Engine-side Trouble

DTC P0203 (Flash Code 273) 18) Inspect to see if any foreign matter is attached
to the injector terminal.
Injector Circuit - Cylinder 3 19) If any foreign matter is attached to the injector
terminal, remove it.
1. DTC P0203 Diagnostics
20) Inspect the injector harness intermediate har-
1) Turn OFF the starter switch. ness connector for a contact failure.
2) Disconnect the harness connector from the 21) If a problem is discovered, repair the interme-
cylinder head injector intermediate harness diate harness connector.
connector. 22) Inspect the third cylinder injector circuit be-
3) Turn ON the starter switch. tween the injector and injector harness inter-
4) Measure the voltage between the third cylin- mediate connector.
der injector charge voltage circuit and normal
GND. • There should be no open circuit or high re-
sistance.
Voltage： 1.0 V
5) If it is at or above the standard value, inspect • There should be no short between the cir-
cuits.
to see if there is a short circuit to the common
power supply 2 charge voltage circuit with the 23) If a problem is discovered, repair the injector
control circuit between the ECM and the injec- circuit.
tor harness intermediate connector. 24) If the third cylinder injector circuit between the
6) If a problem is discovered, repair the control injector and the injector intermediate connec-
circuit. tor is normal, replace the third cylinder injec-
7) Measure the voltage between the solenoid tor.
control circuit of the third cylinder injector and Refer to "1.Engine 1C.Fuel System(4HK1X)
normal GND. Injector Removal".
Voltage： 16.0 V Refer to "1.Engine 1C.Fuel System(4HK1X)
8) If it is at or above the standard value, inspect Injector Installation".
to see if there is a short circuit to the battery 25) When the injector has been replaced, set the
or ignition power supply with the control circuit injector ID code on the ECM.
between the ECM and the injector harness 26) Disconnect the harness connector from the
intermediate connector. ECM.
9) If a problem is discovered, repair the control 27) Inspect the ECM harness connector for a con-
circuit. tact failure.
10) Measure the voltage between the solenoid 28) If a problem is discovered, repair the harness
control circuit of the third cylinder injector and connector.
normal GND. 29) If the harness connector is normal, replace the
Voltage： 12.0 V ECM.
11) If it is at or below the standard value, inspect Refer to "1.Engine 1J.Electrical(4HK1X) ECM
to see if there is an open circuit or high resis- Removal".
tance with the control circuit between the ECM Refer to "1.Engine 1J.Electrical(4HK1X) ECM
and injector harness intermediate connector. Installation".
12) If a problem is discovered, repair the control 30) Set the injector ID code on the ECM.
circuit. 31) Perform the unit difference learning of the fuel
13) Inspect the injector harness intermediate con- supply pump to the ECM.
nector for a contact failure.
14) If a problem is discovered, repair the injector 2. DTC P0203 Confirm Resolution
harness intermediate connector. 1) Clear the DTC using the trouble diagnosis
15) Remove the cylinder head cover. scan tool.
Refer to "1.Engine 1B.Mechanical(4HK1X) 2) Turn the starter switch OFF for 30 seconds or
Cylinder head cover Removal". longer.
16) Inspect the injector harness tightening nut for 3) Start the engine.
looseness. 4) Perform a test-run.
17) If the injector harness tightening nut is loose, 5) Use the trouble diagnosis scan tool to confirm
tighten it. that a DTC has not been detected.

84402826 - May 2011

4023G-29
 Engine-side Trouble

DTC P0204 (Flash Code 274) 18) Inspect to see if any foreign matter is attached
to the injector terminal.
Injector Circuit - Cylinder 4 19) If any foreign matter is attached to the injector
terminal, remove it.
1. DTC P0204 Diagnostics
20) Inspect the injector harness intermediate har-
1) Turn OFF the starter switch. ness connector for a contact failure.
2) Disconnect the harness connector from the 21) If a problem is discovered, repair the interme-
cylinder head injector intermediate harness diate harness connector.
connector. 22) Inspect the fourth cylinder injector circuit be-
3) Turn ON the starter switch. tween the injector and injector harness inter-
4) Measure the voltage between the fourth cylin- mediate connector.
der injector charge voltage circuit and normal
GND. • There should be no open circuit or high re-
sistance.
Voltage： 1.0 V
5) If it is at or above the standard value, inspect • There should be no short between the cir-
cuits.
to see if there is a short circuit to the common
power supply 1 charge voltage circuit with the 23) If a problem is discovered, repair the injector
control circuit between the ECM and the injec- circuit.
tor harness intermediate connector. 24) If the fourth cylinder injector circuit between
6) If a problem is discovered, repair the control the injector and the injector intermediate con-
circuit. nector is normal, replace the fourth cylinder
7) Measure the voltage between the solenoid injector.
control circuit of the fourth cylinder injector Refer to "1.Engine 1C.Fuel System(4HK1X)
and normal GND. Injector Removal".
Voltage： 16.0 V Refer to "1.Engine 1C.Fuel System(4HK1X)
8) If it is at or above the standard value, inspect Injector Installation".
to see if there is a short circuit to the battery 25) When the injector has been replaced, set the
or ignition power supply with the control circuit injector ID code on the ECM.
between the ECM and the injector harness 26) Disconnect the harness connector from the
intermediate connector. ECM.
9) If a problem is discovered, repair the control 27) Inspect the ECM harness connector for a con-
circuit. tact failure.
10) Measure the voltage between the solenoid 28) If a problem is discovered, repair the harness
control circuit of the third cylinder injector and connector.
normal GND. 29) If the harness connector is normal, replace the
Voltage： 12.0 V ECM.
11) If it is at or below the standard value, inspect Refer to "1.Engine 1J.Electrical(4HK1X) ECM
to see if there is an open circuit or high resis- Removal".
tance with the control circuit between the ECM Refer to "1.Engine 1J.Electrical(4HK1X) ECM
and injector harness intermediate connector. Installation".
12) If a problem is discovered, repair the control 30) Set the injector ID code on the ECM.
circuit. 31) Perform the unit difference learning of the fuel
13) Inspect the injector harness intermediate con- supply pump to the ECM.
nector for a contact failure.
14) If a problem is discovered, repair the injector 2. DTC P0204 Confirm Resolution
harness intermediate connector. 1) Clear the DTC using the trouble diagnosis
15) Remove the cylinder head cover. scan tool.
Refer to "1.Engine 1B.Mechanical(4HK1X) 2) Turn the starter switch OFF for 30 seconds or
Cylinder head cover Removal". longer.
16) Inspect the injector harness tightening nut for 3) Start the engine.
looseness. 4) Perform a test-run.
17) If the injector harness tightening nut is loose, 5) Use the trouble diagnosis scan tool to confirm
tighten it. that a DTC has not been detected.

84402826 - May 2011

4023G-30
 Engine-side Trouble

DTC P0237 (Flash Code 32) Turbo 11) If the harness connector is normal, replace the
boost sensor.
Charger Boost Sensor Circuit Low Refer to "1.Engine 1F.Induction(4HK1X)
Boost sensor Removal".
1. DTC P0237 Priority DTC
Refer to "1.Engine 1F.Induction(4HK1X)
DTC P1655
Boost sensor Installation".
2. DTC P0237 Diagnostics
12) Inspect the signal circuit between the ECM
1) Turn OFF the starter switch. and the boost sensor.
2) Disconnect the harness connector from the
boost sensor. • There should be no open circuit or high re-
sistance.
3) Turn ON the starter switch.
4) Measure the voltage between the 5 V power • There should be no short to GND.
supply circuit of the boost sensor harness con- 13) If a problem is discovered, repair the signal
nector and a normal GND. circuit.
Voltage： 4.5 V 14) Inspect the ECM harness connector for a con-
5) If it is at or below the standard value, inspect tact failure.
to see if there is an open circuit or high re- 15) If a problem is discovered, repair the harness
sistance with the 5 V power supply circuit be- connector.
tween the ECM and the boost sensor. 16) If the harness connector is normal, replace the
ECM.
ANNOTATION:
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
• The boost sensor shares the 5 V power sup- Removal".
ply circuit with other sensors. Refer to "1.Engine 1J.Electrical(4HK1X) ECM
• The DTC set on a sensor which shares this Installation".
circuit may be detected. 17) Set the injector ID code on the ECM.
18) Perform the unit difference learning of the fuel
6) If a problem is discovered, repair the 5 V supply pump to the ECM.
power supply circuit.
7) Connect the test cable with fuse between the 3. DTC P0237 Confirm Resolution
5 V power supply circuit and the signal circuit
1) Clear the DTC using the trouble diagnosis
of the boost sensor harness connector.
scan tool.
8) Check the boost pressure sensor display with
2) Turn the starter switch OFF for 30 seconds or
the trouble diagnosis scan tool.
longer.
Voltage： 4.5 V
3) Start the engine.
9) If it is at or above the standard value, inspect
4) Perform a test-run.
to see if there is a contact failure with the boost
5) Use the trouble diagnosis scan tool to confirm
sensor harness connector.
that a DTC has not been detected.
10) If a problem is discovered, repair the harness
connector.

84402826 - May 2011

4023G-31
 Engine-side Trouble

DTC P0238 (Flash Code 32) Turbo 8) Inspect the boost sensor harness connector
for a contact failure.
Charger Boost Sensor Circuit High 9) If a problem is discovered, repair the harness
connector.
1. DTC P0238 Priority DTC
10) If the harness connector is normal, replace the
DTC P1655
boost sensor.
2. DTC P0238 Diagnostics
Refer to "1.Engine 1F.Induction(4HK1X)
1) Turn OFF the starter switch. Boost sensor Removal".
2) Disconnect the harness connector from the Refer to "1.Engine 1F.Induction(4HK1X)
boost sensor. Boost sensor Installation".
3) Check the boost pressure sensor display with 11) Inspect the ECM harness connector for a con-
the trouble diagnosis scan tool. tact failure.
Voltage： 0.1 V 12) If a problem is discovered, repair the harness
4) If it is at or above the standard value, inspect connector.
the signal circuit between the ECM and the 13) If the harness connector is normal, replace the
boost sensor. ECM.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
• There should be no short to the battery or Removal".
ignition power supply. Refer to "1.Engine 1J.Electrical(4HK1X) ECM
• There should be no short to the 5 V power Installation".
supply. 14) Set the injector ID code on the ECM.
5) If a problem is discovered, repair the signal 15) Perform the unit difference learning of the fuel
circuit. supply pump to the ECM.
6) Inspect to see if there is an open circuit or 3. DTC P0238 Confirm Resolution
high resistance in the GND circuit between the
ECM and the boost sensor. 1) Clear the DTC using the trouble diagnosis
scan tool.
ANNOTATION: 2) Turn the starter switch OFF for 30 seconds or
• The boost sensor shares the GND circuit longer.
with other sensors. 3) Start the engine.
4) Perform a test-run.
• The DTC set on a sensor which shares this 5) Use the trouble diagnosis scan tool to confirm
circuit may be detected. that a DTC has not been detected.
7) If a problem is discovered, repair the GND
circuit.

84402826 - May 2011

4023G-32
 Engine-side Trouble

DTC P0336 (Flash Code 15) DTC P0340 (Flash Code 14)
Crankshaft Position Sensor Circuit Camshaft Position Sensor Circuit
Range/Performance 1. DTC P0340 Priority DTC
DTC P0601
1. DTC P0336 Priority DTC DTC P0651
DTC P0335 2. DTC P0340 Diagnostics
DTC P0340
DTC P0641 1) Turn OFF the starter switch.
2. DTC P0336 Diagnostics 2) Disconnect the harness connector from the
camshaft position sensor.
1) Inspect the crankshaft position sensor circuit. 3) Turn ON the starter switch.
• There should be enough clearing from the 4) Measure the voltage between the 5 V
wiring or component of the fuel injection power supply circuit and normal GND of the
unit. camshaft position sensor harness connector.
• There should be enough clearing from addi- voltage： 4.5 V
tionally installed electronic components. 5) If it is at or below the standard value, inspect
• There should be enough clearing from the to see if there is an open circuit or high re-
solenoids and relays. sistance with the 5 V power supply circuit be-
tween the ECM and the camshaft position
2) If a problem is discovered, repair the crank- sensor.
shaft position sensor circuit. 6) If a problem is discovered, repair the 5 V
3) Turn OFF the starter switch. power supply circuit.
4) Disconnect the harness connector from the 7) Measure the voltage between the signal cir-
ECM. cuit and normal GND of the camshaft position
5) Inspect the ECM harness connector for a con- sensor harness connector.
tact failure. voltage： 5.5 V
6) If a problem is discovered, repair the harness 8) If it is at or above the standard value, inspect
connector. to see if there is a short circuit to the battery
7) Disconnect the harness connector from the or ignition power supply with the signal circuit
crankshaft position sensor. between the ECM and the camshaft position
8) Inspect the crankshaft position sensor har- sensor.
ness connector for a contact failure. 9) If a problem is discovered, repair the signal
9) If a problem is discovered, repair the harness circuit.
connector. 10) Measure the voltage between the signal cir-
10) Inspect the CKP sensor. cuit of the camshaft position sensor harness
Refer to "1.Engine 1B.Mechanical(4HK1X) connector and a
CKP sensor Inspection". normal GND again.
11) If a problem is discovered, replace the crank- voltage： 4.5 V
shaft position sensor. 11) If it is at or below the standard value, inspect
Refer to "1.Engine 1B.Mechanical(4HK1X) the signal circuit between the ECM and the
CKP sensor Removal". camshaft position sensor.
Refer to "1.Engine 1B.Mechanical(4HK1X)
CKP sensor Installation". • There should be no open circuit or high re-
sistance.
3. DTC P0336 Confirm Resolution • There should be no short to GND.
1) Clear the DTC using the trouble diagnosis 12) If a problem is discovered, repair the signal
scan tool. circuit.
2) Turn the starter switch OFF for 30 seconds or 13) Connect the test light between the signal cir-
longer. cuit and normal GND of the camshaft position
3) Start the engine. sensor harness connector.
4) Perform a test-run. 14) Measure the voltage between the probe of the
5) Use the trouble diagnosis scan tool to confirm test light and a normal GND.
that a DTC has not been detected. voltage： 4.5 V
15) If it is at or above the standard value, inspect
to see if there is a short circuit to the 5 V power
supply circuit with the signal circuit between
the ECM and the camshaft position sensor.
16) If a problem is discovered, repair the signal
circuit.
17) Measure the voltage between the 5 V power
supply circuit and GND circuit of the camshaft
position sensor harness connector.
voltage： 4.5 V

84402826 - May 2011

4023G-33
 Engine-side Trouble

18) If it is at or above the standard value, inspect DTC P0404 (Flash Code 45)
to see if there is a contact failure with the
camshaft position sensor harness connector. Exhaust Gas Recirculation Control
19) If a problem is discovered, repair the harness
connector.
Circuit Range/Performance
20) If the harness connector is normal, inspect the 1. DTC P0404 Priority DTC
camshaft position sensor. DTC P0409
Refer to "1.Engine 1B.Mechanical(4HK1X) 2. DTC P0404 Diagnostics
CMP sensor Inspection".
21) If a problem is discovered, replace the 1) Remove the EGR valve assembly from the
camshaft position sensor. engine.
Refer to "1.Engine 1B.Mechanical(4HK1X) Refer to "1.Engine 1H.Aux. Emission Control
CMP sensor Removal". Devices(4HK1X) EGR valve Removal".
Refer to "1.Engine 1B.Mechanical(4HK1X) 2) Inspect the EGR valve.
CMP sensor Installation". • There should be nothing to limit flow inside
22) Inspect the camshaft gear. the EGR valve.
• The camshaft gear should not be damaged • There should be no excessive accumulates
• The camshaft gear should be installed cor- inside the EGR valve.
rectly. • There should be no bending with the valve
shaft or valve itself inside the EGR valve.
23) If a problem is discovered, repair the camshaft
gear. 3) Turn OFF the starter switch.
24) Inspect the GND circuit between the ECM and 4) Disconnect the harness connector from the
the camshaft position sensor for an open cir- EGR valve.
cuit and high resistance. 5) Inspect the EGR valve harness connector for
a contact failure.
ANNOTATION: 6) If a problem is discovered, repair the harness
connector.
• The camshaft position sensor shares the
7) Disconnect the harness connector from the
GND circuit with other sensors.
ECM.
• The DTC set on a sensor which shares this
8) Inspect the ECM harness connector for a con-
circuit may be detected.
tact failure.
25) If a problem is discovered, repair the GND 9) If a problem is discovered, repair the harness
circuit. connector.
26) Inspect the ECM harness connector for a con- 10) Inspect to see if there is an open circuit or high
tact failure. resistance in the EGR control circuit.
27) If a problem is discovered, repair the harness 11) If a problem is discovered, repair the EGR
connector. control circuit.
28) If the harness connector is normal, replace the 12) Inspect the EGR solenoid circuit between the
ECM. ECM and EGR valve.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Removal". • There should be no short to GND.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM • There should be no short to the battery or
ignition power supply circuit.
Installation".
29) Set the injector ID code on the ECM. • There should be no short between the cir-
cuits.
30) Perform the unit difference learning of the fuel
supply pump to the ECM. • There should be no short to EGR position
sensor circuit.
3. DTC P0340 Confirm Resolution
13) If a problem is discovered, repair the EGR
1) Clear the DTC using the trouble diagnosis solenoid circuit.
scan tool. 14) If the EGR solenoid circuit is normal, replace
2) Turn the starter switch OFF for 30 seconds or the EGR valve.
longer. Refer to "1.Engine 1H.Aux. Emission Control
3) Start the engine. Devices(4HK1X) EGR valve Removal".
4) Perform a test-run. Refer to "1.Engine 1H.Aux. Emission Control
5) Use the trouble diagnosis scan tool to confirm Devices(4HK1X) EGR valve Installation".
that a DTC has not been detected. 15) Restore the actual unit.
16) Turn ON the starter switch.
17) Clear the DTC using the trouble diagnosis
scan tool.
18) Turn the starter switch OFF for 30 seconds or
longer.
19) Start the engine.
20) Perform a test-run.

84402826 - May 2011

4023G-34
 Engine-side Trouble

21) Check the DTC using the trouble diagnosis DTC P0409 (Flash Code 44)
scan tool.
22) If the DTC P0404 has been detected, replace Exhaust Gas Recirculation Sensor
the ECM.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Circuit
Removal". 1. DTC P0409 Priority DTC
Refer to "1.Engine 1J.Electrical(4HK1X) ECM DTC P1655
Installation". 2. DTC P0409 Diagnostics
23) Set the injector ID code on the ECM.
24) Perform the unit difference learning of the fuel 1) Turn OFF the starter switch.
supply pump to the ECM. 2) Disconnect the harness connector from the
EGR valve.
3. DTC P0404 Confirm Resolution 3) Turn ON the starter switch.
4) Use the trouble diagnosis scan tool to check
1) Clear the DTC using the trouble diagnosis
if any of the EGR position 1, EGR position 2,
scan tool.
and EGR position 3 shows ON.
2) Turn the starter switch OFF for 30 seconds or
5) If there is a data display showing ON, inspect
longer.
the signal circuit between the ECM and EGR
3) Start the engine.
valve of the EGR showing ON.
4) Perform a test-run.
5) Use the trouble diagnosis scan tool to confirm • There should be no short to the battery or
that a DTC has not been detected. ignition power supply.
• There should be no short to the 5 V power
supply.
6) If a problem is discovered, repair the signal
circuit.
7) Measure the voltage between the EGR posi-
tion sensor 5 V power supply circuit and a nor-
mal GND.
Voltage： 4.5 V
8) If it is at or below the standard value, inspect
to see if there is an open circuit or high re-
sistance with the 5 V power supply circuit be-
tween the ECM and the EGR position sensor.
ANNOTATION:
• The EGR position sensor shares the 5 V
power supply circuit with other sensors.
• The DTC set on a sensor which shares this
circuit may be detected.
9) If a problem is discovered, repair the 5 V
power supply circuit.
10) Measure the voltage between the EGR posi-
tion sensor 5 V power supply circuit and the
GND circuit.
voltage： 4.5 V
11) If it is at or below the standard value, inspect
to see if there is an open circuit or high resis-
tance with the GND circuit between the ECM
and EGR position sensor.
ANNOTATION:
• The EGR position sensor shares the GND
circuit with other sensors.
• The DTC set on a sensor which shares this
circuit may be detected.
12) If a problem is discovered, repair the GND
circuit.
13) While momentarily disconnecting the test ca-
ble with fuse from the EGR position sensor
1 signal circuit and 5 V power supply circuit,
check the EGR position 1 display with the
trouble diagnosis scan tool.

84402826 - May 2011

4023G-35
 Engine-side Trouble

14) While momentarily disconnecting the test ca- DTC P0426 (Flash Code 143)
ble with fuse from the EGR position sensor
2 signal circuit and 5 V power supply circuit, Catalyst Temperature Sensor
check the EGR position 2 display with the
trouble diagnosis scan tool.
Circuit Range/Performance
15) While momentarily disconnecting the test ca- Sensor 1
ble with fuse from the EGR position sensor
3 signal circuit and 5 V power supply circuit, 1. DTC P0426 Priority DTC
check the EGR position 3 display with the DTC P0093
trouble diagnosis scan tool. DTC P0427
16) Check to see if there is a data display which DTC P1093
does not display ON when the EGR position 2. DTC P0426 Diagnostics
sensor signal circuit and 5 V power supply 1) Inspect the exhaust gas temperature sensor
circuit are shorted. 1.
17) If there is a data display which does not dis- Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
play ON, inspect the EGR position sensor cir- haust gas temperature sensor Inspection".
cuit which does not display ON. 2) If a problem is discovered, replace the ex-
• There should be no open circuit or high re- haust gas temperature sensor 1.
sistance between ECM and EGR position Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
sensor. haust gas temperature sensor Removal".
• There should be no short to GND between Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
ECM and EGR position sensor. haust gas temperature sensor Installation".
3) Inspect the DPD filter for a damage.
18) If a problem is discovered, repair the EGR Refer to "1.Engine 1G.Exhaust(4HK1X) DPD
position sensor circuit. assembly Inspection".
19) Inspect the EGR valve harness connector for 4) If a problem is discovered, replace the DPD
a contact failure. filter.
20) If a problem is discovered, repair the harness Refer to "1.Engine 1G.Exhaust(4HK1X) DPD
connector. assembly Disassembly".
21) In the EGR solenoid circuit between the ECM Refer to "1.Engine 1G.Exhaust(4HK1X) DPD
and EGR valve, inspect to see if there is a assembly Reassembly".
short circuit with the EGR position sensor. 5) Perform the DPD regeneration data reset with
22) If a problem is discovered, repair the EGR the trouble diagnosis scan tool.
solenoid circuit.
23) If the EGR solenoid circuit is normal, replace 3. DTC P0426 Confirm Resolution
the EGR valve. 1) Clear the DTC using the trouble diagnosis
Refer to "1.Engine 1H.Aux. Emission Control scan tool.
Devices(4HK1X) EGR valve Removal". 2) Turn the starter switch OFF for 30 seconds or
Refer to "1.Engine 1H.Aux. Emission Control longer.
Devices(4HK1X) EGR valve Installation". 3) Start the engine.
24) Inspect the ECM harness connector for a con- 4) Perform a test-run.
tact failure. 5) Use the trouble diagnosis scan tool to confirm
25) If a problem is discovered, repair the harness that a DTC has not been detected.
connector.
26) If the harness connector is normal, replace the
ECM.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Removal".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Installation".
27) Set the injector ID code on the ECM.
28) Perform the unit difference learning of the fuel
supply pump to the ECM.
3. DTC P0409 Confirm Resolution
1) Clear the DTC using the trouble diagnosis
scan tool.
2) Turn the starter switch OFF for 30 seconds or
longer.
3) Start the engine.
4) Perform a test-run.
5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.

84402826 - May 2011

4023G-36
 Engine-side Trouble

DTC P0427 (Flash Code 48) DTC P0428 (Flash Code 48)
Catalyst Temperature Sensor Catalyst Temperature Sensor
Circuit Low Sensor 1 Circuit High Sensor 1
1. DTC P0427 Priority DTC 1. DTC P0428 Priority DTC
DTC P0697 DTC P0697
2. DTC P0427 Diagnostics 2. DTC P0428 Diagnostics
1) Turn OFF the starter switch. 1) Turn OFF the starter switch.
2) Disconnect the harness connector from the 2) Disconnect the harness connector from the
exhaust gas temperature sensor 1. exhaust gas temperature sensor 1.
3) Check the exhaust temperature sensor (be- 3) Turn ON the starter switch.
fore the filter) display with the trouble diagno- 4) Measure the voltage between the exhaust gas
sis scan tool. temperature sensor 1 signal circuit and nor-
Voltage： 4.5 V mal GND.
4) If it is at or above the standard value, replace Voltage： 5.5 V
the exhaust gas temperature sensor 1. 5) If it is at or above the standard value, inspect
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex- to see if there is a short circuit to the battery
haust gas temperature sensor Removal". or ignition power supply with the signal circuit
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex- between the ECM and the exhaust gas tem-
haust gas temperature sensor Installation". perature sensor 1.
5) Inspect to see if there is a short circuit to the 6) If a problem is discovered, repair the signal
GND with the signal circuit between the ECM circuit.
and the exhaust gas temperature sensor 1. 7) Connect the test cable with fuse between the
6) If a problem is discovered, repair the signal exhaust gas temperature sensor 1 signal cir-
circuit. cuit and GND circuit.
7) Inspect the ECM harness connector for a con- 8) Check the exhaust temperature sensor (be-
tact failure. fore the filter) display with the trouble diagno-
8) If a problem is discovered, repair the harness sis scan tool.
connector. Voltage： 0.1 V
9) If the harness connector is normal, replace the 9) If it is at or below the standard value, inspect to
ECM. see if there is a short circuit to the 5 V power
Refer to "1.Engine 1J.Electrical(4HK1X) ECM supply circuit with the signal circuit between
Removal". the ECM and the exhaust gas temperature
Refer to "1.Engine 1J.Electrical(4HK1X) ECM sensor 1.
Installation". 10) If a problem is discovered, repair the signal
10) Set the injector ID code on the ECM. circuit.
11) Perform the unit difference learning of the fuel 11) Inspect to see if there is a contact failure with
supply pump to the ECM. the exhaust gas temperature sensor 1 har-
ness connector.
3. DTC P0427 Confirm Resolution 12) If a problem is discovered, repair the harness
1) Clear the DTC using the trouble diagnosis connector.
scan tool. 13) If the harness connector is normal, replace the
2) Turn the starter switch OFF for 30 seconds or exhaust gas temperature sensor 1.
longer. Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
3) Start the engine. haust gas temperature sensor Removal".
4) Perform a test-run. Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
5) Use the trouble diagnosis scan tool to confirm haust gas temperature sensor Installation".
that a DTC has not been detected. 14) Connect the test cable with fuse between the
exhaust gas temperature sensor 1 signal cir-
cuit and normal GND.
15) Check the exhaust temperature sensor (be-
fore the filter) display with the trouble diagno-
sis scan tool.
Voltage： 0.1 V
16) If it is at or above the standard value, inspect
to see if there is an open circuit or high resis-
tance with the signal circuit between the ECM
and the exhaust gas temperature sensor 1.
17) If a problem is discovered, repair the signal
circuit.
18) Inspect to see if there is an open circuit or
high resistance in the GND circuit between the

84402826 - May 2011

4023G-37
 Engine-side Trouble

ECM and the exhaust gas temperature sensor DTC P0522 (Flash Code 294) Oil
1.
Pressure Sensor Circuit Low
ANNOTATION:
1. DTC P0522 Priority DTC
• The exhaust gas temperature sensor 1 DTC P0697
shares the GND circuit with other sensors. 2. DTC P0522 Diagnostics
• The DTC may be detected on a sensor
which shares this circuit. 1) Turn OFF the starter switch.
2) Disconnect the harness connector from the oil
19) If a problem is discovered, repair the GND pressure sensor.
circuit. 3) Turn ON the starter switch.
20) Inspect the ECM harness connector for a con- 4) Measure the voltage between the 5 V power
tact failure. supply circuit and normal GND of the oil pres-
21) If a problem is discovered, repair the harness sure sensor harness connector.
connector. Voltage： 4.5 V
22) If the harness connector is normal, replace the 5) If it is at or below the standard value, inspect
ECM. to see if there is an open circuit or high re-
Refer to "1.Engine 1J.Electrical(4HK1X) ECM sistance with the 5 V power supply circuit be-
Removal". tween the ECM and the oil pressure sensor.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM 6) If a problem is discovered, repair the 5 V
Installation". power supply circuit.
23) Set the injector ID code on the ECM. 7) Connect the test cable with fuse between the
24) Perform the unit difference learning of the fuel 5 V power supply circuit and signal circuit of
supply pump to the ECM. the oil pressure sensor harness connector.
3. DTC P0428 Confirm Resolution 8) Check the oil pressure sensor display with the
trouble diagnosis scan tool.
1) Clear the DTC using the trouble diagnosis Voltage： 4.5 V
scan tool. 9) If it is at or above the standard value, inspect
2) Turn the starter switch OFF for 30 seconds or to see if there is a contact failure with the oil
longer. pressure sensor harness connector.
3) Start the engine and warm it up until the 10) If a problem is discovered, repair the harness
coolant temperature exceeds the standard connector.
value. 11) If the harness connector is normal, replace the
Specified value： 70 °C {158 °F} oil pressure sensor.
4) Repeatedly rev the engine in neutral to in- Refer to "1.Engine 1E.Lubrication(4HK1X) Oil
crease the engine rpm while checking the ex- pressure sensor Removal".
haust temperature sensor (in front of the filter) Refer to "1.Engine 1E.Lubrication(4HK1X) Oil
display with the trouble diagnosis scan tool. pressure sensor Installation".
5) Use the trouble diagnosis scan tool to confirm 12) Inspect the signal circuit between the ECM
that the exhaust temperature sensor (before and the oil pressure sensor.
the filter) display does not exceed the stan-
dard value. • There should be no open circuit or high re-
Voltage： 4.8 V sistance.
6) Use the trouble diagnosis scan tool to confirm • There should be no short to GND.
that a DTC has not been detected. 13) If a problem is discovered, repair the signal
circuit.
14) Inspect the ECM harness connector for a con-
tact failure.
15) If a problem is discovered, repair the harness
connector.
16) If the harness connector is normal, replace the
ECM.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Removal".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Installation".
17) Set the injector ID code on the ECM.
18) Perform the unit difference learning of the fuel
supply pump to the ECM.
3. DTC P0522 Confirm Resolution
1) Clear the DTC using the trouble diagnosis
scan tool.
2) Turn the starter switch OFF for 30 seconds or
longer.
84402826 - May 2011
4023G-38
 Engine-side Trouble

3) Start the engine. DTC P0523 (Flash Code 294) Oil

4) Perform a test-run.
5) Use the trouble diagnosis scan tool to confirm Pressure Sensor Circuit High
that a DTC has not been detected.
1. DTC P0523 Priority DTC
DTC P0697
2. DTC P0523 Diagnostics
1) Turn OFF the starter switch.
2) Disconnect the harness connector from the oil
pressure sensor.
3) Check the oil pressure sensor display with the
trouble diagnosis scan tool.
Voltage： 0.1 V
4) If it is at or above the standard value, inspect
the signal circuit between the ECM and the oil
pressure
sensor.
• There should be no short to the battery or
ignition power supply.
• There should be no short to the 5 V power
supply.
5) If a problem is discovered, repair the signal
circuit.
6) Inspect to see if there is an open circuit or
high resistance in the GND circuit between the
ECM and the oil pressure sensor.
ANNOTATION:
• The oil pressure sensor shares the GND cir-
cuit with other sensors.
• The DTC set on a sensor which shares this
circuit may be detected.
7) If a problem is discovered, repair the GND
circuit.
8) Inspect the oil pressure sensor harness con-
nector for a contact failure.
9) If a problem is discovered, repair the harness
connector.
10) If the harness connector is normal, replace the
oil pressure sensor.
Refer to "1.Engine 1E.Lubrication(4HK1X) Oil
pressure sensor Removal".
Refer to "1.Engine 1E.Lubrication(4HK1X) Oil
pressure sensor Installation".
11) Inspect the ECM harness connector for a con-
tact failure.
12) If a problem is discovered, repair the harness
connector.
13) If the harness connector is normal, replace the
ECM.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Removal".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Installation".
14) Set the injector ID code on the ECM.
15) Perform the unit difference learning of the fuel
supply pump to the ECM.
3. DTC P0523 Confirm Resolution
1) Clear the DTC using the trouble diagnosis
scan tool.
2) Turn the starter switch OFF for 30 seconds or
longer.

84402826 - May 2011

4023G-39
 Engine-side Trouble

3) Start the engine. DTC P0560 (Flash Code 155)

4) Perform a test-run.
5) Use the trouble diagnosis scan tool to confirm System Voltage
that a DTC has not been detected.
1. DTC P0560 Diagnostics
1) Turn OFF the starter switch.
2) Disconnect the harness connector from the
mass air flow sensor.
3) Use the trouble diagnosis scan tool to check
if a DTC is detected.
4) If a DTC has not been detected, inspect the
mass air flow sensor harness connector for a
contact failure.
5) If a problem is discovered, repair the harness
connector.
6) If the harness connector is normal, replace the
mass air flow sensor.
7) Turn OFF the starter switch.
8) Leave the mass air flow sensor harness con-
nector disconnected.
9) Disconnect the harness connector from the
dropping register.
10) Use the trouble diagnosis scan tool to check
if a DTC is detected.
11) If a DTC has been detected, inspect the volt-
age supply circuit between the ECM and drop-
ping register.
• There should be no short to GND.
• There should be no short to the battery or
ignition power supply.
12) If a problem is discovered, repair the voltage
supply circuit.
13) If the voltage supply circuit is normal, inspect
the 12 V power supply circuit between the
ECM and the mass air flow sensor.
• There should be no short to GND.
• There should be no short to the battery or
ignition power supply.
14) If a problem is discovered, repair the 12 V
power supply circuit.
15) Check the resistance value of the dropping
register.
Resistance： 45.0 - 55.0 Ω
16) If the resistance value is outside the standard
range, replace the dropping register.
17) Turn ON the starter switch.
18) Measure the voltage between the ignition
power supply circuit of the dropping register
and a normal GND.
Voltage： 18.0 V
19) If it is at or below the standard value, inspect
the fuse.
20) If the fuse is faulty, replace the fuse.
21) If it is at or below the standard value, repair
an open circuit or high resistance in the igni-
tion power supply circuit between the fuse and
dropping register.
22) Measure the voltage between the voltage sup-
ply circuit of the dropping register and a nor-
mal GND.
Voltage： 13.0 V

84402826 - May 2011

4023G-40
 Engine-side Trouble

23) If it is at or above the standard value, inspect DTC P0563 (Flash Code 35)
to see if there is a contact failure with the drop-
ping register harness connector. System Voltage High
24) If a problem is discovered, repair the harness
1. DTC P0563 Diagnostics
connector.
25) Inspect to see if there is an open circuit or 1) Check if the battery charger has been recently
high resistance in the voltage supply circuit connected to the battery.
between the ECM and the dropping register. 2) Start the engine, and idle it.
26) If a problem is discovered, repair the voltage 3) Check the ignition voltage display with the
supply circuit. trouble diagnosis scan tool.
27) Inspect the ECM harness connector for a con- Voltage： 32.0 V
tact failure. 4) If it is at or above the standard value, inspect
28) If a problem is discovered, repair the harness the charging system.
connector. Refer to "1.Engine 1J.Electrical(4HK1X) Gen-
29) If the harness connector is normal, replace the erator Reassembly".
ECM. 5) If a problem is discovered, repair the charging
Refer to "1.Engine 1J.Electrical(4HK1X) ECM system.
Removal". 6) If the charging system is normal, replace the
Refer to "1.Engine 1J.Electrical(4HK1X) ECM ECM.
Installation". Refer to "1.Engine 1J.Electrical(4HK1X) ECM
30) Set the injector ID code on the ECM. Removal".
31) Perform the unit difference learning of the fuel Refer to "1.Engine 1J.Electrical(4HK1X) ECM
supply pump to the ECM. Installation".
7) Set the injector ID code on the ECM.
2. DTC P0560 Confirm Resolution
8) Perform the unit difference learning of the fuel
1) Clear the DTC using the trouble diagnosis supply pump to the ECM.
scan tool.
2. DTC P0563 Confirm Resolution
2) Turn the starter switch OFF for 30 seconds or
longer. 1) Clear the DTC using the trouble diagnosis
3) Start the engine. scan tool.
4) Perform a test-run. 2) Turn the starter switch OFF for 30 seconds or
5) Use the trouble diagnosis scan tool to confirm longer.
that a DTC has not been detected. 3) Start the engine, and idle it.
4) Check the ignition voltage display with the
trouble diagnosis scan tool, and confirm that
the value does not exceed the standard value.
voltage： 32.0 V
5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.

84402826 - May 2011

4023G-41
 Engine-side Trouble

DTC P0601 (Flash Code 53) DTC P0602 (Flash Code 154)
Internal Control Module Memory Control Module Programming
Check Sum Error Error
1. DTC P0601 Diagnostics 1. DTC P0602 Diagnostics
1) Replace the ECM. 1) Confirm that the connecting sections of all
Refer to "1.Engine 1J.Electrical(4HK1X) ECM tools are securely connected.
Removal". 2) Confirm that the programming device is oper-
Refer to "1.Engine 1J.Electrical(4HK1X) ECM ating normally.
Installation". 3) Use the trouble diagnosis scan tool to confirm
2) Set the injector ID code on the ECM. that the correct injector ID code has been en-
3) Perform the unit difference learning of the fuel tered to the ECM.
supply pump to the ECM.
ANNOTATION:
2. DTC P0601 Confirm Resolution
• When the injector ID code has been cor-
1) Clear the DTC using the trouble diagnosis rectly input, clear the DTC using the trouble
scan tool. diagnosis scan tool.
2) Turn the starter switch OFF for 30 seconds or
4) Turn the starter switch OFF for 30 seconds or
longer.
3) Start the engine. longer.
5) Turn ON the starter switch.
4) Perform a test-run.
5) Use the trouble diagnosis scan tool to confirm 6) Use the trouble diagnosis scan tool to check
that a DTC has not been detected. if a DTC has been detected.
7) If a DTC has been detected, replace the ECM.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Removal".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Installation".
8) Set the injector ID code on the ECM.
9) Perform the unit difference learning of the fuel
supply pump to the ECM.
2. DTC P0602 Confirm Resolution
1) Clear the DTC using the trouble diagnosis
scan tool.
2) Turn the starter switch OFF for 30 seconds or
longer.
3) Start the engine.
4) Perform a test-run.
5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.

84402826 - May 2011

4023G-42
 Engine-side Trouble

DTC P0604 (Flash Code 153) DTC P0606 (Flash Code 51)
Internal Control Module Random ECM/PCM Processor
Access Memory (RAM) Error 1. DTC P0606 Diagnostics
1. DTC P0604 Diagnostics 1) Replace the ECM.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
1) Replace the ECM. Removal".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Removal". Installation".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM 2) Set the injector ID code on the ECM.
Installation". 3) Perform the unit difference learning of the fuel
2) Set the injector ID code on the ECM. supply pump to the ECM.
3) Perform the unit difference learning of the fuel
supply pump to the ECM. 2. DTC P0606 Confirm Resolution
2. DTC P0604 Confirm Resolution 1) Clear the DTC using the trouble diagnosis
scan tool.
1) Clear the DTC using the trouble diagnosis 2) Turn the starter switch OFF for 30 seconds or
scan tool. longer.
2) Turn the starter switch OFF for 30 seconds or 3) Start the engine.
longer. 4) Perform a test-run.
3) Start the engine. 5) Use the trouble diagnosis scan tool to confirm
4) Perform a test-run. that a DTC has not been detected.
5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.

84402826 - May 2011

4023G-43
 Engine-side Trouble

DTC P0638 (Flash Code 14) If a problem is discovered, repair the solenoid
circuit.
61) Throttle Actuator Control 15) If the solenoid circuit is normal, replace the
Range/Performance intake throttle valve.
Refer to "1.Engine 1B.Mechanical(4HK1X) In-
1. DTC P0638 Priority DTC take throttle valve Removal".
DTC P0122 Refer to "1.Engine 1B.Mechanical(4HK1X) In-
DTC P0123 take throttle valve Installation".
2. DTC P0638 Diagnostics 16) Restore the actual unit.
17) Turn ON the starter switch.
1) Remove the air intake hose from the intake 18) Turn the starter switch OFF for 30 seconds or
throttle valve. longer.
Refer to "1.Engine 1B.Mechanical(4HK1X) In-
take throttle valve Removal". ANNOTATION:
2) Inspect the intake throttle valve.
• The starter switch must be once turned ON
• The intake throttle valve flow should not be and then turned OFF before clearing the
limited. DTC.
• There should be no excessive deposit inside 19) Clear the DTC using the trouble diagnosis
the throttle bore of the intake throttle valve.
scan tool.
• There should be no bending with the butter- 20) Turn the starter switch OFF for 30 seconds or
fly valve of the intake throttle valve.
longer.
• The intake throttle valve should not be 21) Start the engine.
locked.
22) Use the trouble diagnosis scan tool to check
3) If a problem is discovered, replace the intake if a DTC has been detected.
throttle valve. 23) If a DTC has been detected, replace the ECM.
Refer to "1.Engine 1B.Mechanical(4HK1X) In- Refer to "1.Engine 1J.Electrical(4HK1X) ECM
take throttle valve Removal". Removal".
Refer to "1.Engine 1B.Mechanical(4HK1X) In- Refer to "1.Engine 1J.Electrical(4HK1X) ECM
take throttle valve Installation". Installation".
4) Turn OFF the starter switch. 24) Set the injector ID code on the ECM.
5) Disconnect the harness connector from the 25) Perform the unit difference learning of the fuel
intake throttle valve. supply pump to the ECM.
6) Inspect the intake throttle valve harness con-
3. DTC P0638 Confirm Resolution
nector for a contact failure.
7) If a problem is discovered, repair the harness 1) Turn ON the starter switch.
connector. 2) Turn the starter switch OFF for 30 seconds or
8) Disconnect the harness connector from the longer.
ECM.
9) Inspect the ECM harness connector for a con- ANNOTATION:
tact failure. • The starter switch must be once turned ON
10) If a problem is discovered, repair the harness and then turned OFF before clearing the
connector. DTC.
11) Inspect the intake throttle valve circuit for high
resistance. 3) Clear the DTC using the trouble diagnosis
12) Repair the circuit if a problem is discovered. scan tool.
13) Inspect the solenoid circuit between the ECM 4) Turn the starter switch OFF for 30 seconds or
and the intake throttle valve. longer.
5) Start the engine.
• There should be no short to GND. 6) Perform a test-run with the intake throttle so-
• There should be no short to the battery or lenoid drive duty of 20 ％ or above.
ignition power supply. 7) Use the trouble diagnosis scan tool to confirm
• There should be no short between the sole- that a DTC has not been detected.
noid circuits.
• There should be no short to intake throttle
position sensor circuit.

84402826 - May 2011

4023G-44
 Engine-side Trouble

DTC P0641 (Flash Code 55) 18) If it is at or below the standard value, turn the
starter switch OFF.
Sensor Reference Voltage 1 19) Disconnect the harness connector from the
Circuit 20)
fuel pressure sensor.
Turn ON the starter switch.
1. DTC P0641 Diagnostics 21) Measure the voltage between the accelerator
position sensor 5 V power supply circuit and
1) Turn OFF the starter switch. GND of the accelerator position sensor har-
2) Disconnect the harness connector from the ness connector.
accelerator position sensor. Voltage： 4.5 V
3) Turn ON the starter switch. 22) If it is at or above the standard value, replace
4) Measure the voltage between the accelerator the fuel pressure sensor.
position sensor 5 V power supply circuit and Refer to "1.Engine 1C.Fuel System(4HK1X)
GND of the accelerator position sensor har- Common rail assembly Removal".
ness connector. Refer to "1.Engine 1C.Fuel System(4HK1X)
Voltage： 5.5 V Common rail assembly Installation".
5) If it is at or above the standard value, inspect
to see if there is a short circuit to the battery or ANNOTATION:
ignition power supply with the accelerator po-
• Do not replace the fuel pressure sensor sep-
sition sensor 5 V power supply circuit between
arately.
the ECM and the accelerator position sensor.
When a problem is found, replace the com-
6) If a problem is discovered, repair the acceler-
mon rail assembly.
ator position sensor 5 V power supply circuit.
7) Inspect to see if there is a short circuit to the 23) If it is at or below the standard value, inspect
battery or ignition power supply with the crank- to see if there is a short circuit to the GND with
shaft position sensor 5 V power supply circuit the accelerator position sensor 5 V power sup-
between the ECM and the crankshaft position ply circuit between the ECM and the acceler-
sensor. ator position sensor.
8) If a problem is discovered, repair the crank- 24) If a problem is discovered, repair the acceler-
shaft position sensor 5 V power supply circuit ator position sensor 5 V power supply circuit.
between the ECM and the crankshaft position 25) Inspect to see if there is a short circuit to the
sensor. GND with the crankshaft position sensor 5 V
9) Inspect to see if there is a short circuit to the power supply circuit between the ECM and the
battery or ignition power supply with the fuel crankshaft position sensor.
pressure sensor 5 V power supply circuit be- 26) If a problem is discovered, repair the crank-
tween the ECM and the fuel pressure sensor. shaft position sensor 5 V power supply circuit.
10) If a problem is discovered, repair the fuel pres- 27) Inspect to see if there is a short circuit to the
sure sensor 5 V power supply circuit. GND with the fuel pressure sensor 5 V power
11) If it is at or below the standard value, measure supply circuit between the ECM and the fuel
the voltage between the 5 V power supply cir- pressure sensor.
cuit and GND of the accelerator position sen- 28) If a problem is discovered, repair the fuel pres-
sor harness connector. sure sensor 5 V power supply circuit.
Voltage： 4.5 V 29) Replace the ECM.
12) If it is at or above the standard value, replace Refer to "1.Engine 1J.Electrical(4HK1X) ECM
the throttle accelerator switch assembly. Removal".
13) If it is at or below the standard value, turn the Refer to "1.Engine 1J.Electrical(4HK1X) ECM
starter switch OFF. Installation".
14) Disconnect the harness connector from the 30) Set the injector ID code on the ECM.
crankshaft position sensor. 31) Perform the unit difference learning of the fuel
15) Turn ON the starter switch. supply pump to the ECM.
16) Measure the voltage between the accelerator
position sensor 5 V power supply circuit and 2. DTC P0641 Confirm Resolution
GND of the accelerator position sensor har- 1) Clear the DTC using the trouble diagnosis
ness connector. scan tool.
Voltage： 4.5 V 2) Turn the starter switch OFF for 30 seconds or
17) If it is at or above the standard value, replace longer.
the crankshaft position sensor. 3) Start the engine.
Refer to "1.Engine 1B.Mechanical(4HK1X) 4) Perform a test-run.
CKP sensor Removal". 5) Use the trouble diagnosis scan tool to confirm
Refer to "1.Engine 1B.Mechanical(4HK1X) that a DTC has not been detected.
CKP sensor Installation".

84402826 - May 2011

4023G-45
 Engine-side Trouble

DTC P0651 (Flash Code 56) 12) Disconnect the harness connector from the
atmospheric pressure sensor.
Sensor Reference Voltage 2 13) Turn ON the starter switch.
Circuit 14) Measure the voltage between the camshaft
position sensor 5 V power supply circuit and
1. DTC P0651 Diagnostics GND of the camshaft position sensor harness
connector.
1) Turn OFF the starter switch. Voltage： 4.5 V
2) Disconnect the harness connector from the 15) If it is at or above the standard value, replace
camshaft position sensor. the atmospheric pressure sensor.
3) Turn ON the starter switch. 16) If it is at or below the standard value, inspect
4) Measure the voltage between the camshaft to see if there is a short circuit to the GND with
position sensor 5 V power supply circuit and the camshaft position sensor 5 V power sup-
GND of the camshaft position sensor harness ply circuit between the ECM and the camshaft
connector. position sensor.
Voltage： 5.5 V 17) If a problem is discovered, repair the camshaft
5) If it is at or above the standard value, inspect position sensor 5 V power supply circuit.
to see if there is a short circuit to the battery or 18) Inspect to see if there is a short circuit to the
ignition power supply with the camshaft posi- GND with the atmospheric pressure sensor 5
tion sensor 5 V power supply circuit between V power supply circuit between the ECM and
the ECM and the camshaft position sensor. the atmospheric pressure sensor.
6) If a problem is discovered, repair the camshaft 19) If a problem is discovered, repair the atmo-
position sensor 5 V power supply circuit. spheric pressure sensor 5 V power supply cir-
7) Inspect to see if there is a short circuit to the cuit.
battery or ignition power supply with the atmo- 20) Replace the ECM.
spheric pressure sensor 5 V power supply cir- Refer to "1.Engine 1J.Electrical(4HK1X) ECM
cuit between the ECM and atmospheric pres- Removal".
sure sensor. Refer to "1.Engine 1J.Electrical(4HK1X) ECM
8) If a problem is discovered, repair the atmo- Installation".
spheric pressure sensor 5 V power supply cir- 21) Set the injector ID code on the ECM.
cuit. 22) Perform the unit difference learning of the fuel
9) If it is at or below the standard value, mea- supply pump to the ECM.
sure the voltage between the camshaft posi-
tion sensor 5 V power supply circuit and GND 2. DTC P0651 Confirm Resolution
of the camshaft position sensor harness con-
1) Clear the DTC using the trouble diagnosis
nector.
scan tool.
Voltage： 4.5 V
2) Turn the starter switch OFF for 30 seconds or
10) If it is at or above the standard value, replace
longer.
the camshaft position sensor.
3) Start the engine.
Refer to "1.Engine 1B.Mechanical(4HK1X)
4) Perform a test-run.
CMP sensor Removal".
5) Use the trouble diagnosis scan tool to confirm
Refer to "1.Engine 1B.Mechanical(4HK1X)
that a DTC has not been detected.
CMP sensor Installation".
11) If it is at or below the standard value, turn the
starter switch OFF.

84402826 - May 2011

4023G-46
 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 Diagnostics 1. DTC P0687 Diagnostics
1) Turn the starter switch OFF for 30 seconds or 1) Turn OFF the starter switch.
longer. 2) Remove the main relay.
2) Replace the main relay with a glow relay or 3) Turn ON the starter switch.
normal relay. 4) Use the trouble diagnosis scan tool to see if
3) Turn ON the starter switch. DTC P0685 is detected.
4) Use the trouble diagnosis scan tool to check 5) If the DTC P0685 is not detected, repair the
if a DTC is detected. short circuit to the battery power supply of the
5) If a DTC has not been detected, replace the power supply circuit between the ECM and
main relay. main relay.
6) Inspect the body grounding terminal for a con- 6) Turn the starter switch OFF for 30 seconds or
tact failure. longer.
7) If a problem is discovered, repair the terminal. 7) Replace the main relay with a glow relay or
8) Inspect the slow blow fuse. normal relay.
9) If a problem is discovered, replace the slow 8) Turn ON the starter switch.
blow fuse. 9) Use the trouble diagnosis scan tool to check
if DTC P0687 has been detected.
ANNOTATION:
10) If the DTC P0687 is not detected, replace the
• When the fuse is blown again, repair the main relay.
cause of slow-blow fuse meltdown.
2. DTC P0687 Confirm Resolution
10) Turn OFF the starter switch.
1) Clear the DTC using the trouble diagnosis
11) Disconnect the harness connector from the
scan tool.
ECM.
2) Turn the starter switch OFF for 30 seconds or
12) Inspect the ECM harness connector for a con-
longer.
tact failure.
3) Turn ON the starter switch.
13) If a problem is discovered, repair the harness
4) Use the trouble diagnosis scan tool to confirm
connector.
that a DTC has not been detected.
14) If the harness connector is normal, replace the
ECM.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Removal".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Installation".
15) Set the injector ID code on the ECM.
16) Perform the unit difference learning of the fuel
supply pump to the ECM.
2. DTC P0685 Confirm Resolution
1) Clear the DTC using the trouble diagnosis
scan tool.
2) Turn the starter switch OFF for 30 seconds or
longer.
3) Turn ON the starter switch.
4) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.

84402826 - May 2011

4023G-47
 Engine-side Trouble
DTC P0697 (Flash Code 57)
Sensor Reference Voltage 3
Circuit
1. DTC P0697 Diagnostics
1) Turn OFF the starter switch.
2) Disconnect the harness connector from the
DPD differential pressure sensor.
3) Turn ON the starter switch.
4) Measure the voltage between the DPD differ-
ential pressure sensor 5 V power supply cir-
cuit and GND of the DPD differential pressure
sensor harness connector.
Voltage： 5.5 V
5) If it is at or above the standard value, inspect
to see if there is a short circuit to the battery or
ignition power supply with the DPD differential
pressure sensor 5 V power supply circuit be-
tween the ECM and the DPD differential pres-
sure sensor.
6) If a problem is discovered, repair the DPD
differential pressure sensor 5 V power supply
circuit.
7) Inspect to see if there is a short circuit to the
battery or ignition power supply with the oil
pressure sensor 5 V power supply circuit be-
tween the ECM and oil pressure sensor.
8) If a problem is discovered, repair the oil pres-
sure sensor 5 V power supply circuit.
9) Inspect to see if there is a short circuit to the
battery or ignition power supply with the fuel
filter pressure sensor 5 V power supply circuit
between the ECM and the fuel filter pressure
sensor.
10) If a problem is discovered, repair the fuel filter
pressure sensor 5 V power supply circuit.
11) If it is at or below the standard value, mea-
sure the voltage between the DPD differential
pressure sensor 5 V power supply circuit and
GND of the DPD differential pressure sensor
harness connector.
Voltage： 4.5 V
12) If it is at or above the standard value, replace
the DPD differential pressure sensor.
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
haust differential pressure sensor Removal".
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
haust differential pressure sensor Installa-
tion".
13) If it is at or below the standard value, turn the
starter switch OFF.
14) Disconnect the harness connector from the oil
pressure sensor.
15) Turn ON the starter switch.
16) Measure the voltage between the DPD differ-
ential pressure sensor 5 V power supply cir-
cuit and GND of the DPD differential pressure
sensor harness connector.
Voltage： 4.5 V
84402826 - May 2011
4023G-48
17) If it is at or above the standard value, replace
the oil pressure sensor.
Refer to "1.Engine 1E.Lubrication(4HK1X) Oil
pressure sensor Removal".
Refer to "1.Engine 1E.Lubrication(4HK1X) Oil
pressure sensor Installation".
18) If it is at or below the standard value, turn the
starter switch OFF.
19) Disconnect the harness connector from the
fuel filter pressure sensor.
20) Turn ON the starter switch.
21) Measure the voltage between the DPD differ-
ential pressure sensor 5 V power supply cir-
cuit and GND of the DPD differential pressure
sensor harness connector.
Voltage： 4.5 V
22) If it is at or above the standard value, replace
the fuel filter pressure sensor.
Refer to "1.Engine 1C.Fuel System(4HK1X)
Fuel filter pressure sensor Removal".
Refer to "1.Engine 1C.Fuel System(4HK1X)
Fuel filter pressure sensor Installation".
23) If it is at or below the standard value, inspect
to see if there is a short circuit to the GND
with the DPD differential pressure sensor 5 V
power supply circuit between the ECM and the
DPD differential pressure sensor.
24) If a problem is discovered, repair the DPD
differential pressure sensor 5 V power supply
circuit.
25) Inspect to see if there is a short circuit to the
GND with the oil pressure sensor 5 V power
supply circuit between the ECM and oil pres-
sure sensor.
26) If a problem is discovered, repair the oil pres-
sure sensor 5 V power supply circuit.
27) Inspect to see if there is a short circuit to the
GND with the fuel filter pressure sensor 5 V
power supply circuit between the ECM and
fuel filter pressure sensor.
28) If a problem is discovered, repair the fuel filter
pressure sensor 5 V power supply circuit.
29) Replace the ECM.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Removal".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Installation".
30) Set the injector ID code on the ECM.
31) Perform the unit difference learning of the fuel
supply pump to the ECM.
2. DTC P0697 Confirm Resolution
1) Clear the DTC using the trouble diagnosis
scan tool.
2) Turn the starter switch OFF for 30 seconds or
longer.
3) Start the engine.
4) Perform a test-run.
5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.
 Engine-side Trouble

DTC P1093 (Flash Code 227) Fuel • The fuel hose between the fuel tank and the
fuel supply pump becomes negative pres-
Rail Pressure (FRP) Too Low sure state when the engine is running.
1. DTC P1093 Priority DTC • When the fuel hose is not connected se-
curely, the air can enter.
DTC P0087
DTC P0091 • When the engine RPM or the engine load
increases while the air has intruded in the
DTC P0092
fuel system, fluctuation in the common rail
DTC P0192
pressure is caused, and DTC P1093 may
DTC P0193
be detected.
DTC P0201
DTC P0202 16) Check that an appropriate clamp is used be-
DTC P0203 tween the fuel tank and the fuel supply pump.
DTC P0204 17) If a problem is discovered, replace the clamp.
DTC P2146 18) Operate the priming pump until the handle be-
DTC P2149 comes heavy.
2. DTC P1093 Diagnostics
ANNOTATION:
1) Turn OFF the starter switch.
2) Wait for the specified period of time until the • When a leak exists in the fuel system be-
fuel pressure is released from the common tween the priming pump and the fuel sup-
rail. ply pump, the pressing weight of the priming
Specified time: 2 min pump does not become heavy.
3) Turn ON the starter switch. 19) Start the engine.
4) Use the trouble diagnosis scan tool to check 20) Inspect the high-pressure side of the fuel sys-
if the fuel rail pressure sensor display is within tem and check for fuel leak between the fuel
the standard range. supply pump and common rail.
Voltage: 0.9 - 1.0 V
5) If the fuel rail pressure sensor display is out- ANNOTATION:
side the standard range, inspect the fuel pres- • The fuel may leak to the bottom section of
sure sensor harness connector for a contact the cylinder head cover from the high pres-
failure. sure hose inlet.
6) If a problem is discovered, repair the harness • The engine oil level increases when the fuel
connector. leaks to the bottom portion of the cylinder
7) Inspect the ECM harness connector for a con- head cover.
tact failure. • Inspect for fuel leaks into the engine oil.
8) If a problem is discovered, repair the harness
connector. 21) If fuel leak if found, fix the problem.
9) Inspect each circuit for high resistance. 22) Turn OFF the starter switch.
10) Repair the circuit if a problem is discovered. 23) Remove the fuel hose on the fuel supply pump
11) If the harness connector and each circuit are side from the fuel filter.
normal, replace the fuel pressure sensor. ANNOTATION:
Refer to "1.Engine 1C.Fuel System(4HK1X)
Common rail assembly Removal". • Use a pan to catch the fuel from the re-
Refer to "1.Engine 1C.Fuel System(4HK1X) moved fuel hose.
Common rail assembly Installation". • Clean the pressure gauge and connection
hose before connecting to the fuel pipe.
ANNOTATION: • The fuel supply pump may be damaged due
• Do not replace the fuel pressure sensor sep- to foreign matter that has entered in the con-
arately. nection hose.
When a problem is found, replace the com- 24) Connect the pressure gauge between the fuel
mon rail assembly. filter and the removed fuel hose.
12) Inspect to see if there is clogging with the fuel ANNOTATION:
system between the fuel tank and the fuel sup-
ply pump. • Confirm that the fuel system is connected
13) If a problem is discovered, repair the clogging securely.
of the fuel system. 25) Remove the air using the priming pump, and
14) Inspect the fuel hose between the fuel tank crank the engine for the specified period of
and the fuel supply pump for a cut and crack. time or shorter.
15) If a problem is discovered, replace the fuel Specified time: 5 s
hose.
ANNOTATION:
ANNOTATION:
• Repeat this until the engine starts.

84402826 - May 2011

4023G-49
 Engine-side Trouble
26) Leave the engine idling for the specified pe-
riod of time or longer.
specified time: 1 min
27) While keeping the engine rotating at the spec-
ified engine RPM for the specified period of
time, check the pressure gauge.
Specified time: 1 min
Rotational speed: 2500 min-1 {2500 r/min}
28) Check if the pressure gauge shows a negative
pressure value at or above the standard value
during inspection.
Specified value: 17.0 kPa {128 mmHg / 5
inHg}
ANNOTATION:
• Fuel clogging is checked with the negative
pressure amount in the fuel system.
29) If the negative pressure is at or above the
standard value, inspect to see if there is dam-
age or twisting
with the fuel system between the fuel supply
pump and the fuel tank.
30) If a problem is discovered, repair the fuel sys-
tem.
31) Inspect the fuel tank bent hose.
32) If a problem is discovered, repair the bent
hose.
33) Check to see if there is any foreign matter in
the fuel tank or any foreign matter which can
cause fuel clogging.
34) If a problem is discovered, repair it.
35) Replace the fuel filter element.
Refer to "1.Engine 1C.Fuel System(4HK1X)
Fuel filter element Removal".
Refer to "1.Engine 1C.Fuel System(4HK1X)
Fuel filter element Installation".
36) If the negative pressure is at or below the stan-
dard value, pinch the fuel hose at a position as
close as possible to the fuel tank, so that the
fuel does not flow.
ANNOTATION:
• The fuel pipe can be disconnected and
clogged with a plug.
37) Start the engine and use the idling control
switch to increase the RPM to the highest
level.
38) Check the pressure gauge.
Specified value: 27.0 kPa {203 mmHg / 8
inHg}
ANNOTATION:
• When the pressure gauge is likely to indi-
cate a value exceeding the standard value
during inspection, release the fuel being
blocked.
• Air mixture is checked with the negative
pressure amount while the fuel flow is being
blocked.
39) If the standard negative pressure cannot be
generated, inspect to see if there is a cut or
crack with the fuel hose.
84402826 - May 2011
4023G-50
40) If a problem is discovered, replace the fuel
hose.
41) Inspect to see if appropriate clamp is used.
42) If a problem is discovered, replace the clamp
with an appropriate one.
43) Turn OFF the starter switch.
44) Inspect the suction control valve harness con-
nector for a contact failure.
45) If a problem is discovered, repair the harness
connector.
46) Inspect the ECM harness connector for a con-
tact failure.
47) If a problem is discovered, repair the harness
connector.
48) Inspect each circuit for high resistance.
49) Repair the circuit if a problem is discovered.
50) If the suction control valve harness connector
and the ECM harness connector are normal
and there is no high resistance in each circuit,
replace the fuel supply pump and the fuel filter
element.
Refer to "1.Engine 1C.Fuel System(4HK1X)
Fuel supply pump Removal".
Refer to "1.Engine 1C.Fuel System(4HK1X)
Fuel supply pump Installation".
Refer to "1.Engine 1C.Fuel System(4HK1X)
Fuel filter element Removal".
Refer to "1.Engine 1C.Fuel System(4HK1X)
Fuel filter element Installation".
ANNOTATION:
• When replacing the fuel supply pump, it is
required to also replace the fuel filter ele-
ment at the same time.
51) Perform the unit difference learning of the fuel
supply pump to the ECM.
52) If the negative pressure is normal, turn OFF
the starter switch.
53) Restore the fuel system.
54) Start the engine.
55) Perform the injector stop test with the trouble
diagnosis scan tool.
56) Check to see if any injector does not change
the engine RPM when OFF is instructed.
57) If any injector does not change the engine
RPM when OFF is instructed, replace the rel-
evant injector.
Refer to "1.Engine 1C.Fuel System(4HK1X)
Injector Removal".
Refer to "1.Engine 1C.Fuel System(4HK1X)
Injector Installation".
58) When the injector has been replaced, set the
injector ID code on the ECM.
59) If the engine RPM changes when OFF is in-
structed to all injectors, replace the pressure
limiter valve.
Refer to "1.Engine 1C.Fuel System(4HK1X)
Common rail assembly Removal".
Refer to "1.Engine 1C.Fuel System(4HK1X)
Common rail assembly Installation".
ANNOTATION:
 Engine-side Trouble

• The pressure limiter valve may be fixed DTC P1112 (Flash Code 295)
open, or the operation pressure may de-
crease. Boost Temperature Sensor Circuit
• Do not replace the pressure limiter valve
separately. When a problem is found, re-
Low
place the common rail assembly. 1. DTC P1112 Priority DTC
DTC P0651
3. DTC P1093 Confirm Resolution
2. DTC P1112 Diagnostics
1) Clear the DTC using the trouble diagnosis
1) Turn OFF the starter switch.
scan tool.
2) Remove the harness connector from the
2) Turn the starter switch OFF for 30 seconds or
boost temperature sensor.
longer.
3) Check the boost temperature sensor display
3) Start the engine.
with the trouble diagnosis scan tool.
4) Perform a test-run.
Voltage： 4.5 V
5) Use the trouble diagnosis scan tool to confirm
4) If it is at or above the standard value, replace
that a DTC has not been detected.
the boost temperature sensor.
Refer to "1.Engine 1F.Induction(4HK1X)
Boost temperature sensor Removal".
Refer to "1.Engine 1F.Induction(4HK1X)
Boost temperature sensor Installation".
5) Inspect to see if there is a short circuit to the
GND with the signal circuit between the ECM
and boost temperature sensor.
6) If a problem is discovered, repair the signal
circuit.
7) Inspect the ECM harness connector for a con-
tact failure.
8) If a problem is discovered, repair the harness
connector.
9) If the harness connector is normal, replace the
ECM.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Removal".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Installation".
10) Set the injector ID code on the ECM.
11) Perform the unit difference learning of the fuel
supply pump to the ECM.
3. DTC P1112 Confirm Resolution
1) Clear the DTC using the trouble diagnosis
scan tool.
2) Turn the starter switch OFF for 30 seconds or
longer.
3) Start the engine.
4) Perform a test-run.
5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.

DTC P1113 (Flash Code 295)

Boost Temperature Sensor Circuit
High
1. DTC P1113 Priority DTC
DTC P0651
2. DTC P1113 Diagnostics
1) Turn OFF the starter switch.
2) Remove the harness connector from the
boost temperature sensor.
3) Turn ON the starter switch.

84402826 - May 2011

4023G-51
 Engine-side Trouble

4) Measure the voltage between the boost tem- ANNOTATION:

perature sensor signal circuit and a normal
GND. • The boost temperature sensor shares the
GND circuit with other sensors.
Voltage: 5.5 V
5) If it is at or above the standard value, inspect • The DTC set on a sensor which shares this
circuit may be detected.
to see if there is a short circuit to the battery
or ignition power supply with the signal circuit 17) If a problem is discovered, repair the GND
between the ECM and the boost temperature circuit.
sensor. 18) Inspect to see if there is an open circuit or
6) If a problem is discovered, repair the signal high resistance in the signal circuit between
circuit. the ECM and the boost temperature sensor.
7) Connect the test cable with fuse between the 19) If a problem is discovered, repair the signal
boost temperature sensor signal circuit and circuit.
GND circuit. 20) Inspect the ECM harness connector for a con-
8) Check the boost temperature sensor display tact failure.
with the trouble diagnosis scan tool. 21) If a problem is discovered, repair the harness
Voltage: 0.1 V connector.
9) If it is at or below the standard value, inspect to 22) If the harness connector is normal, replace the
see if there is a short circuit to the 5 V power ECM.
supply circuit with the signal circuit between Refer to "1.Engine 1J.Electrical(4HK1X) ECM
the ECM and the boost temperature sensor. Removal".
10) If a problem is discovered, repair the signal Refer to "1.Engine 1J.Electrical(4HK1X) ECM
circuit. Installation".
11) Inspect boost temperature sensor harness 23) Set the injector ID code on the ECM.
connector for a contact failure. 24) Perform the unit difference learning of the fuel
12) If a problem is discovered, repair the harness supply pump to the ECM.
connector.
13) If the harness connector is normal, replace the 3. DTC P1113 Confirm Resolution
boost temperature sensor. 1) Clear the DTC using the trouble diagnosis
Refer to "1.Engine 1F.Induction(4HK1X) scan tool.
Boost temperature sensor Removal". 2) Turn the starter switch OFF for 30 seconds or
Refer to "1.Engine 1F.Induction(4HK1X) longer.
Boost temperature sensor Installation". 3) Start the engine.
14) Connect the test cable with fuse between the 4) Perform a test-run.
boost temperature sensor signal circuit and a
normal GND. ANNOTATION:
15) Check the boost temperature sensor display • Run the engine for 3 minutes or longer.
with the trouble diagnosis scan tool.
Voltage: 0.1 V 5) Use the trouble diagnosis scan tool to confirm
16) If it is at or below the standard value, inspect that a DTC has not been detected.
to see if there is an open circuit or high resis-
tance with the GND circuit between the ECM
and the boost temperature sensor.

84402826 - May 2011

4023G-52
 Engine-side Trouble

DTC P1261 (Flash Code 34) DTC P1262 (Flash Code 34)
Injector Positive Voltage Control Injector Positive Voltage Control
Circuit Group 1 Circuit Group 2
1. DTC P1261 Diagnostics 1. DTC P1262 Diagnostics
1) Replace the ECM. 1) Replace the ECM.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Removal". Removal".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Installation". Installation".
2) Set the injector ID code on the ECM. 2) Set the injector ID code on the ECM.
3) Perform the unit difference learning of the fuel 3) Perform the unit difference learning of the fuel
supply pump to the ECM. supply pump to the ECM.
2. DTC P1261 Confirm Resolution 2. DTC P1262 Confirm Resolution
1) Clear the DTC using the trouble diagnosis 1) Clear the DTC using the trouble diagnosis
scan tool. scan tool.
2) Turn the starter switch OFF for 30 seconds or 2) Turn the starter switch OFF for 30 seconds or
longer. longer.
3) Start the engine. 3) Start the engine.
4) Perform a test-run. 4) Perform a test-run.
5) Use the trouble diagnosis scan tool to confirm 5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected. that a DTC has not been detected.

84402826 - May 2011

4023G-53
 Engine-side Trouble

DTC P1293 (Flash Code 211) Fuel 11) If the harness connector is normal, replace the
fuel filter pressure sensor.
Pressure Sensor Circuit Low Refer to "1.Engine 1C.Fuel System(4HK1X)
Fuel filter pressure sensor Removal".
1. DTC P1293 Priority DTC
Refer to "1.Engine 1C.Fuel System(4HK1X)
DTC P0697
Fuel filter pressure sensor Installation".
2. DTC P1293 Diagnostics
12) Inspect the signal circuit between the ECM
1) Turn OFF the starter switch. and the fuel filter pressure sensor.
2) Disconnect the harness connector from the
fuel filter pressure sensor. • There should be no open circuit or high re-
sistance.
3) Turn ON the starter switch.
4) Measure the voltage between the 5 V power • There should be no short to GND.
supply circuit of the fuel filter pressure sensor 13) If a problem is discovered, repair the signal
harness connector and normal GND. circuit.
Voltage: 4.5 V 14) Inspect the ECM harness connector for a con-
5) If it is at or below the standard value, inspect tact failure.
to see if there is an open circuit or high re- 15) If a problem is discovered, repair the harness
sistance with the 5 V power supply circuit be- connector.
tween the ECM and the fuel filter pressure 16) If the harness connector is normal, replace the
sensor. ECM.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
ANNOTATION:
Removal".
• The fuel filter pressure sensor shares the 5 Refer to "1.Engine 1J.Electrical(4HK1X) ECM
V power supply circuit with other sensors. Installation".
• The DTC set on a sensor which shares this 17) Set the injector ID code on the ECM.
circuit may be detected. 18) Perform the unit difference learning of the fuel
supply pump to the ECM.
6) If a problem is discovered, repair the 5 V
power supply circuit. 3. DTC P1293 Confirm Resolution
7) Connect the test cable with fuse between the
1) Clear the DTC using the trouble diagnosis
5 V power supply circuit and signal circuit of
scan tool.
the fuel filter pressure sensor harness con-
2) Turn the starter switch OFF for 30 seconds or
nector.
longer.
8) Check the fuel filter pressure sensor display
3) Start the engine.
with the trouble diagnosis scan tool.
4) Perform a test-run.
Voltage: 4.5 V
5) Use the trouble diagnosis scan tool to confirm
9) If it is at or above the standard value, inspect
that a DTC has not been detected.
to see if there is a contact failure with the fuel
filter pressure sensor harness connector.
10) If a problem is discovered, repair the harness
connector.

84402826 - May 2011

4023G-54
 Engine-side Trouble

DTC P1294 (Flash Code 211) Fuel 8) Inspect to see if there is a contact failure with
the fuel filter pressure sensor harness con-
Pressure Sensor Circuit High nector.
9) If a problem is discovered, repair the harness
1. DTC P1294 Priority DTC
connector.
DTC P0697
10) If the harness connector is normal, replace the
2. DTC P1294 Diagnostics
fuel filter pressure sensor.
1) Turn OFF the starter switch. Refer to "1.Engine 1C.Fuel System(4HK1X)
2) Disconnect the harness connector from the Fuel filter pressure sensor Removal".
fuel filter pressure sensor. Refer to "1.Engine 1C.Fuel System(4HK1X)
3) Check the fuel filter pressure sensor display Fuel filter pressure sensor Installation".
with the trouble diagnosis scan tool. 11) Inspect the ECM harness connector for a con-
Voltage: 0.1 V tact ailure.
4) If it is at or above the standard value, inspect 12) If a problem is discovered, repair the harness
the signal circuit between the ECM and the connector.
fuel filter pressure sensor. 13) If the harness connector is normal, replace the
ECM.
• There should be no short to the battery or Refer to "1.Engine 1J.Electrical(4HK1X) ECM
ignition power supply. Removal".
• There should be no short to the 5 V power Refer to "1.Engine 1J.Electrical(4HK1X) ECM
supply. Installation".
5) If a problem is discovered, repair the signal 14) Set the injector ID code on the ECM.
circuit. 15) Perform the unit difference learning of the fuel
6) Inspect to see if there is an open circuit or supply pump to the ECM.
high resistance in the GND circuit between the 3. DTC P1294 Confirm Resolution
ECM and the fuel filter pressure sensor.
1) Clear the DTC using the trouble diagnosis
ANNOTATION: scan tool.
• The fuel filter pressure sensor shares the 2) Turn the starter switch OFF for 30 seconds or
GND circuit with other sensors. longer.
• The DTC set on a sensor which shares this 3) Start the engine.
circuit may be detected. 4) Perform a test-run.
5) Use the trouble diagnosis scan tool to confirm
7) If a problem is discovered, repair the GND that a DTC has not been detected.
circuit.

84402826 - May 2011

4023G-55
 Engine-side Trouble

DTC P1404 (Flash Code 45) 9) Inspect the ECM harness connector for a con-
tact failure.
Exhaust Gas Recirculation (EGR) 10) If a problem is discovered, repair the harness
Closed Position Performance 11)
connector.
Inspect the EGR valve circuit between the
1. DTC P1404 Priority DTC ECM and the EGR valve for an open circuit
DTC P0404 and high resistance.
DTC P0409 12) If a problem is discovered, repair the EGR
2. DTC P1404 Diagnostics valve circuit.
13) Inspect the solenoid circuit between the ECM
1) Remove the EGR valve assembly from the and EGR valve.
engine.
Refer to "1.Engine 1H.Aux. Emission Control • There should be no short to GND.
Devices(4HK1X) EGR valve Removal". • There should be no short to the battery or
2) Inspect the EGR valve. ignition power supply.
• There should be no short to other circuits.
• There should be nothing to limit flow inside • There should be no short to EGR position
the EGR valve. sensor circuit.
• There should be no excessive accumulates
inside the EGR valve. 14) If a problem is discovered, repair the solenoid
• There should be no bending with the valve circuit.
shaft or valve itself inside the EGR valve. 15) If the circuit is normal, replace the EGR valve.
Refer to "1.Engine 1H.Aux. Emission Control
3) If a problem is discovered, repair or replace Devices(4HK1X) EGR valve Removal".
the EGR valve. Refer to "1.Engine 1H.Aux. Emission Control
Refer to "1.Engine 1H.Aux. Emission Control Devices(4HK1X) EGR valve Installation".
Devices(4HK1X) EGR valve Removal".
Refer to "1.Engine 1H.Aux. Emission Control 3. DTC P1404 Confirm Resolution
Devices(4HK1X) EGR valve Installation".
1) Clear the DTC using the trouble diagnosis
4) Turn OFF the starter switch.
scan tool.
5) Disconnect the harness connector from the
2) Turn the starter switch OFF for 30 seconds or
EGR valve.
longer.
6) Inspect the EGR valve harness connector for
3) Start the engine.
a contact failure.
4) Perform a test-run.
7) If a problem is discovered, repair the harness
5) Use the trouble diagnosis scan tool to confirm
connector.
that a DTC has not been detected.
8) Disconnect the harness connector from the
ECM.

84402826 - May 2011

4023G-56
 Engine-side Trouble

DTC P1455 (Flash Code 132) PM
Over Accumulation
1. DTC P1455 Diagnostics
1) Check with the operator if the DPD light has
blinked before.
2) If necessary, explain DPD regeneration.
• Check with the operator if the engine oper-
ating time was short.
• Ckeck with the operator if the idling time was
too long.
3) Inspect the DPD differential pressure sensor
hose.
• There should be no incorrect piping or dis-
connection.
4) If a problem is discovered, repair the hose.
5) Inspect the DPD differential pressure sensor.
• DPD differential pressure sensor unit should
not be damaged.
• There should be no dirt or foreign matter
blocking the DPD differential pressure sen-
sor entrance.
• There should be no detection error or slow
response from the DPD differential pressure
sensor.
6) If a problem is discovered, replace the DPD
differential pressure sensor.
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
haust differential pressure sensor Removal".
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
haust differential pressure sensor Installa-
tion".
7) When the DPD differential pressure sensor
has been replaced, perform the 0-point cor-
rection.
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
haust differential pressure sensor Inspection".
8) Inspect the exhaust system.
• There should be no absence or damage of
the exhaust pipe gasket.
• There should be no exhaust gas leak from
the exhaust system.
• The exhaust system should not be modified.
• There should be no damage or excessive
deposits on the oxidation catalyst.
9) If a problem is discovered, repair or replace
the exhaust system.
10) Inspect the DPD assembly.
Refer to "1.Engine 1G.Exhaust(4HK1X) DPD
assembly Inspection".
11) If a problem is discovered, replace the DPD
assembly.
12) If the DPD assembly has been replaced, use
the trouble diagnosis scan tool to perform
DPD regeneration data reset.
13) Inspect the mass air flow sensor with the trou-
ble diagnosis scan tool.
14) If a problem is discovered, replace the mass
air flow sensor.
15) Use the trouble diagnosis scan tool to check if
the boost pressure and atmospheric pressure
are operating properly.
16) Inspect the air cleaner element.
Refer to "1.Engine 1F.Induction(4HK1X) Air
cleaner element Inspection".
17) If a problem is discovered, replace the air
cleaner element.
18) Check the intake duct for a clogging, hole, and
leakage.
19) If a problem is discovered, replace the intake
duct.
20) Inspect the intake throttle valve for fixing.
21) If a problem is discovered, replace the intake
throttle valve.
Refer to "1.Engine 1B.Mechanical(4HK1X) In-
take throttle valve Removal".
Refer to "1.Engine 1B.Mechanical(4HK1X) In-
take throttle valve Installation".
22) Inspect the turbocharger assembly.
Refer to "1.Engine 1F.Induction(4HK1X) Tur-
bocharger assembly Inspection".
23) If a problem is discovered, replace the tur-
bocharger assembly.
Refer to "1.Engine 1F.Induction(4HK1X) Tur-
bocharger assembly Removal".
Refer to "1.Engine 1F.Induction(4HK1X) Tur-
bocharger assembly Installation".
24) Inspect the quality of fuel.
ANNOTATION:
• An appropriate fuel is used.
25) Turn the starter switch ON for 30 seconds.
ANNOTATION:
• Do not start the engine.
• This is for the DPD differential pressure sen-
sor to relearn.
26) Clear the DTC using the trouble diagnosis
scan tool.
27) Perform the DPD regeneration data reset with
the trouble diagnosis scan tool.
28) Turn the starter switch OFF for 30 seconds or
longer.
29) Start the engine.
30) Check the exhaust temperature (before the
filter) display with the trouble diagnosis scan
tool.
31) Confirm that the exhaust temperature is at or
below the standard value.
Specified value: 130 °C {266 °F}
32) If it is at or above the standard value, idle the
engine until it falls to or below the standard
value.
33) Check the exhaust differential pressure dis-
play when the exhaust temperature (in front
of the filter) display has reached the standard
value with the engine revolution increased to
the maximum revolution speed without load.
Specified value: 150 °C {302 °F}

84402826 - May 2011

4023G-57
 Engine-side Trouble
34) Use the trouble diagnosis scan tool to check if
the exhaust differential pressure data display
is at or below the standard value.
Specified value: 7.5 kPa {0.08 kgf/cm2 / 1.1
psi}
35) If it is at or above the standard value, replace
the DPD filter.
Refer to "1.Engine 1G.Exhaust(4HK1X) DPD
assembly Disassembly".
Refer to "1.Engine 1G.Exhaust(4HK1X) DPD
assembly Reassembly".
36) If the DPD filter has been replaced, use the
trouble diagnosis scan tool to perform DPD
regeneration data reset.
37) When a DTC has been detected, clear it using
the trouble diagnosis scan tool.
38) Turn the starter switch OFF for 30 seconds or
longer.
39) Perform the DPD forced slow regeneration
with the trouble diagnosis scan tool.
ANNOTATION:
• After the DPD forced slow regeneration is
completed, replace the engine oil.
40) Check the exhaust temperature (before the
filter) display with the trouble diagnosis scan
tool.
41) Confirm that the exhaust temperature is at or
below the standard value.
Specified value: 130 °C {266 °F}
42) If it is at or above the standard value, idle the
engine until it falls to or below the standard
value.
43) Check the exhaust differential pressure dis-
play when the exhaust temperature (in front
of the filter) display has reached the standard
value with the engine revolution increased to
the maximum revolution speed without load.
Specified value: 150 °C {302 °F}
44) Use the trouble diagnosis scan tool to check if
the exhaust differential pressure display is at
or below the standard value.
Specified value: 1.8 kPa {0.02 kgf/cm2 / 0.3
psi}
45) If it is at or above the standard value, perform
ash removal.
Refer to "1.Engine 1G.Exhaust(4HK1X) DPD
assembly Inspection".
2. DTC P1455 Confirm Resolution
1) Turn ON the starter switch.
2) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.
84402826 - May 2011
4023G-58
DTC P1471 (Flash Code 149)
DPD Insufficient Regeneration
1. DTC P1471 Diagnostics
1) Inspect the DPD differential pressure sensor
hose.
• There should be no incorrect piping or dis-
connection.
2) If a problem is discovered, repair the hose.
3) Inspect the DPD differential pressure sensor.
• DPD differential pressure sensor unit should
not be damaged.
• There should be no dirt or foreign matter
blocking the DPD differential pressure sen-
sor entrance.
• There should be no detection error or slow
response from the DPD differential pressure
sensor.
4) If a problem is discovered, replace the DPD
differential pressure sensor.
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
haust differential pressure sensor Removal".
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
haust differential pressure sensor Installa-
tion".
5) When the DPD differential pressure sensor
has been replaced, perform the 0-point cor-
rection.
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
haust differential pressure sensor Inspection".
6) Inspect the exhaust system.
• There should be no absence or damage of
the exhaust pipe gasket.
• There should be no exhaust gas leak from
the exhaust system.
• The exhaust system should not be modified.
7) If a problem is discovered, repair or replace
the exhaust system.
8) Inspect the exhaust gas temperature sensor.
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
haust gas temperature sensor Inspection".
9) If a problem is discovered, replace the ex-
haust gas temperature sensor.
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
haust gas temperature sensor Removal".
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
haust gas temperature sensor Installation".
10) Inspect the air cleaner element.
Refer to "1.Engine 1F.Induction(4HK1X) Air
cleaner element Inspection".
11) If a problem is discovered, replace the air
cleaner element.
12) Inspect the air intake system.
• There should be no crush, limited flow, or
damage of the duct between the air cleaner
and intake manifold.
• The intake system should not be modified.
• There should be no air leak with the intake
system.
 Engine-side Trouble

13) If a problem is discovered, repair the intake 20) If the situation falls in the area C or D, use
system. the trouble diagnosis scan tool to perform the
14) Use the trouble diagnosis scan tool to inspect DPD forced slow regeneration.
the mass air flow sensor.
15) If a problem is discovered, replace the mass ANNOTATION:
air flow sensor. • When a DTC has been detected, clear it
16) Turn the starter switch ON for 30 seconds. using the trouble diagnosis scan tool.
ANNOTATION: • After the DPD forced slow regeneration is
completed, replace the engine oil.
• Do not start the engine.
21) Check the exhaust temperature (before the
• This is for the DPD differential pressure sen-
sor to relearn. filter) display with the trouble diagnosis scan
tool.
17) Start the engine. 22) Confirm that the exhaust temperature is at or
18) Use the trouble diagnosis scan tool to check below the standard value.
the DPD accumulation status and the DPD Specified value： 130 °C {266 °F}
time status, and confirm the corresponding 23) If it is at or above the standard value, idle the
area from the DPD status table. engine until it falls to or below the standard
value.
24) Check the exhaust differential pressure dis-
play when the exhaust temperature (in front
of the filter) display has reached the standard
value with the engine revolution increased to
the maximum revolution speed without load.
Specified value： 150 °C {302 °F}
25) Use the trouble diagnosis scan tool to check if
the exhaust differential pressure display is at
DPD Ac- or below the standard value.
cumula- Specified value： 1.8 kPa {0.02 kgf/cm2 / 0.3
tion Sta- psi}
tus 26) If it is at or above the standard value, perform
ash removal.
Refer to "1.Engine 1G.Exhaust(4HK1X) DPD
assembly Inspection".
2. DTC P1471 Confirm Resolution
1) Turn ON the starter switch.
2) Use the trouble diagnosis scan tool to confirm
DPD Time Status that a DTC has not been detected.

19) If the situation falls in the area A or B, use

the trouble diagnosis scan tool to perform the
DPD forced regeneration.
ANNOTATION:
• When a DTC has been detected, clear it
using the trouble diagnosis scan tool.

84402826 - May 2011

4023G-59
 Engine-side Trouble

DTC P1621 (Flash Code 54) DTC P1655 (Flash Code 57)
Control Module Long Term Sensor Reference Voltage Circuit
Memory Performance 1. DTC P1655 Diagnostics
1. DTC P1621 Diagnostics 1) Turn OFF the starter switch.
2) Disconnect the harness connector from the
1) Confirm that the connecting sections of all boost sensor.
tools are securely connected. 3) Turn ON the starter switch.
2) Confirm that the programming device is oper- 4) Measure the voltage between the boost sen-
ating normally. sor 5 V power supply terminal and GND of the
3) Turn the starter switch OFF, and wait for 30 boost sensor harness connector.
seconds. Voltage： 5.5 V
4) Turn ON the starter switch. 5) If it is at or above the standard value, inspect
5) Use the trouble diagnosis scan tool to check to see if there is a short circuit to the battery or
if a DTC has been detected. ignition power supply with the boost sensor 5
6) If a DTC has been detected, replace the ECM. V power supply circuit between the ECM and
Refer to "1.Engine 1J.Electrical(4HK1X) ECM the boost sensor.
Removal". 6) If a problem is discovered, repair the boost
Refer to "1.Engine 1J.Electrical(4HK1X) ECM sensor 5 V power supply circuit.
Installation". 7) Inspect to see if there is a short circuit to the
7) Set the injector ID code on the ECM. battery or ignition power supply with the intake
8) Perform the unit difference learning of the fuel throttle position sensor 5 V power supply cir-
supply pump to the ECM. cuit between the ECM and the intake throttle
2. DTC P1621 Confirm Resolution valve.
8) If a problem is discovered, repair the intake
1) Clear the DTC using the trouble diagnosis throttle position sensor 5 V power supply cir-
scan tool. cuit.
2) Turn the starter switch OFF for 30 seconds or 9) Inspect to see if there is a short circuit to the
longer. battery or ignition power supply with the EGR
3) Start the engine. valve position sensor 5 V power supply circuit
4) Use the trouble diagnosis scan tool to confirm between the ECM and EGR valve.
that a DTC has not been detected. 10) If a problem is discovered, repair the EGR
valve position sensor 5 V power supply circuit.
11) If it is at or below the standard value, mea-
sure the voltage between the boost sensor 5
V power supply terminal and GND of the boost
sensor harness connector.
Voltage： 4.5 V
12) If it is at or above the standard value, replace
the boost sensor.
Refer to "1.Engine 1F.Induction(4HK1X)
Boost sensor Removal".
Refer to "1.Engine 1F.Induction(4HK1X)
Boost sensor Installation".
13) If it is at or below the standard value, turn the
starter switch OFF.
14) Remove the harness connector from the in-
take throttle valve.
15) Turn ON the starter switch.
16) Measure the voltage between the boost sen-
sor 5 V power supply terminal and GND of the
boost sensor harness connector.
Voltage： 4.5 V
17) If it is at or above the standard value, replace
the intake throttle valve.
Refer to "1.Engine 1B.Mechanical(4HK1X) In-
take throttle valve Removal".
Refer to "1.Engine 1B.Mechanical(4HK1X) In-
take throttle valve Installation".
18) If it is at or below the standard value, turn the
starter switch OFF.
19) Disconnect the harness connector from the
EGR valve.
20) Turn ON the starter switch.
84402826 - May 2011
4023G-60
 Engine-side Trouble

21) Measure the voltage between the boost sen- DTC P1669 (Flash Code 75) DPD
sor 5 V power supply terminal and GND of the
boost sensor harness connector. Lamp Control Circuit
Voltage： 4.5 V
1. DTC P1669 Diagnostics
22) If it is at or above the standard value, replace
the EGR valve. 1) Confirm that the monitor panel operates prop-
Refer to "1.Engine 1H.Aux. Emission Control erly.
Devices(4HK1X) EGR valve Removal". 2) Turn OFF the starter switch.
Refer to "1.Engine 1H.Aux. Emission Control 3) Inspect the fuse.
Devices(4HK1X) EGR valve Installation". 4) If a problem is discovered, replace the fuse.
23) If it is at or below the standard value, inspect
to see if there is a short circuit to the GND ANNOTATION:
with the boost sensor 5 V power supply circuit • When the fuse is blown again, repair the
between the ECM and the boost sensor. cause of fuse meltdown.
24) If a problem is discovered, repair the boost
5) Turn OFF the starter switch.
sensor 5 V power supply circuit.
6) Disconnect the harness connector from the
25) Inspect to see if there is a short circuit to the
ECM.
GND with the intake throttle position sensor 5
7) Turn ON the starter switch.
V power supply circuit between the ECM and
8) Check to see if the DPD light is off.
the intake throttle valve.
9) If the DPD light is not turned off, repair the
26) If a problem is discovered, repair the intake
short circuit to GND in the DPD light con-
throttle position sensor 5 V power supply cir-
trol circuit between the ECM and the monitor
cuit.
panel.
27) Inspect to see if there is a short circuit to the
10) Turn OFF the starter switch.
GND with the EGR valve position sensor 5
11) Remove the fuse.
V power supply circuit between the ECM and
12) Turn ON the starter switch.
EGR valve.
13) Measure the voltage between the DPD light
28) If a problem is discovered, repair the EGR
control circuit and GND of the ECM harness
valve position sensor 5 V power supply circuit.
connector.
29) Replace the ECM.
Voltage： 1.0 V
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
14) If it is at or above the standard value, repair
Removal".
the short circuit to the battery or ignition power
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
supply circuit in the DPD light control circuit
Installation".
between the ECM and the monitor panel.
30) Set the injector ID code on the ECM.
15) Turn OFF the starter switch.
31) Perform the unit difference learning of the fuel
16) Install the fuse.
supply pump to the ECM.
17) Connect the test cable with fuse between the
2. DTC P1655 Confirm Resolution DPD light control circuit and GND of the ECM
harness connector.
1) Clear the DTC using the trouble diagnosis 18) Turn ON the starter switch.
scan tool. 19) If the DPD light turns on, inspect the ECM
2) Turn the starter switch OFF for 30 seconds or harness connector for a contact failure.
longer. 20) If a problem is discovered, repair the harness
3) Start the engine. connector.
4) Perform a test-run. 21) If the harness connector is normal, replace the
5) Use the trouble diagnosis scan tool to confirm ECM.
that a DTC has not been detected. Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Removal".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Installation".
22) Set the injector ID code on the ECM.
23) Perform the unit difference learning of the fuel
supply pump to the ECM.
24) If the DPD light does not turn on, remove the
DPD light bulb from the monitor panel.
25) Inspect the DPD light bulb.
26) Replace the valve if a problem is discovered.
27) Inspect to see if there is an open circuit or high
resistance in the ignition power supply circuit
between the fuse and the monitor panel.
28) If a problem is discovered, repair the ignition
power supply circuit.

84402826 - May 2011

4023G-61
 Engine-side Trouble

29) Inspect to see if there is an open circuit or DTC P2146 (Flash Code 158) Fuel
high resistance in the DPD light control circuit
between the ECM and the monitor panel. Injector Group 1 Supply Voltage
30) If a problem is discovered, repair the control
circuit.
Circuit
31) Inspect the monitor panel harness connector 1. DTC P2146 Diagnostics
for a contact failure.
32) If a problem is discovered, repair the harness 1) Turn the starter switch OFF.
connector. 2) Disconnect the harness connector from the
33) When the harness connector is normal, re- cylinder head injector harness intermediate
place the monitor panel. connector.
3) Turn the starter switch ON.
2. DTC P1669 Confirm Resolution 4) Measure the voltage between the solenoid
control circuit and GND.
1) Clear the DTC using the trouble diagnosis
scan tool. ANNOTATION:
2) Turn the starter switch OFF for 30 seconds or
longer. • Solenoid control circuit and GND of the first
3) Turn the starter switch ON, and wait for 40 cylinder injector
seconds. • Solenoid control circuit and GND of the
4) Start the engine. fourth cylinder injector
5) Use the trouble diagnosis scan tool to confirm Voltage： 12.0 V
that a DTC has not been detected. 5) If it is at or below the standard value, inspect
to see if there is a short circuit to the GND
with the control circuit between the ECM and
injector harness intermediate connector.
6) If a problem is discovered, repair the control
circuit.
7) Inspect the charge voltage circuit between the
ECM and the injector harness intermediate
connector.
ANNOTATION:
• No short circuit to the battery or ignition
power is present.
• No short circuit to GND is present.
8) If a problem is discovered, repair the charge
voltage circuit.
9) If the charge voltage circuit between the ECM
and the injector harness intermediate connec-
tor is normal, replace the ECM.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Removal".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Installation".
10) Set the injector ID code on the ECM.
11) Perform the unit difference learning of the fuel
supply pump to the ECM.
12) Inspect the injector harness intermediate con-
nector for a contact failure.
13) If a problem is discovered, repair the injector
harness intermediate connector.
14) Disconnect the harness connector from the
ECM.
15) Inspect the ECM harness connector for a con-
tact failure.
16) If a problem is discovered, repair the harness
connector.
17) Inspect to see if there is an open circuit or
high resistance with the charge voltage circuit
between the ECM and the injector harness
intermediate connector.
18) If a problem is discovered, repair the charge
voltage circuit.

84402826 - May 2011

4023G-62
 Engine-side Trouble

19) Remove the cylinder head cover. DTC P2149 (Flash Code 159) Fuel
Refer to "1.Engine 1B.Mechanical(4HK1X)
Cylinder head cover Removal". Injector Group 2 Supply Voltage
20) Inspect the injector harness tightening nut for
looseness.
Circuit
21) If the injector harness tightening nut is loose, 1. DTC P2149 Diagnostics
tighten it.
22) Inspect to see if any foreign matter is attached 1) Turn the starter switch OFF.
to the injector terminal. 2) Disconnect the harness connector from the
23) If any foreign matter is attached to the injector cylinder head injector harness intermediate
terminal, remove it. connector.
24) Inspect the injector harness intermediate har- 3) Turn the starter switch ON.
ness connector for a contact failure. 4) Measure the voltage between the solenoid
25) If a problem is discovered, repair the interme- control circuit and GND.
diate harness connector. ANNOTATION:
26) Check if insulation resistance of the first cylin-
der and fourth cylinder injector is at or above • Solenoid control circuit and GND of the sec-
the standard value. ond cylinder injector
Resistance： 1.0 Ω • Solenoid control circuit and GND of the third
27) If it is at or below the standard value, replace cylinder injector
the relevant injector. Voltage: 12.0 V
Refer to "1.Engine 1C.Fuel System(4HK1X) 5) If it is at or below the standard value, inspect
Injector Removal". to see if there is a short circuit to the GND
Refer to "1.Engine 1C.Fuel System(4HK1X) with the control circuit between the ECM and
Injector Installation". injector harness intermediate connector.
28) Set the injector ID code on the ECM. 6) If a problem is discovered, repair the control
29) If it is at or above the standard value, repair or circuit.
replace the injector harness. 7) Inspect the charge voltage circuit between the
2. DTC P2146 Confirm Resolution ECM
and the injector harness intermediate connec-
1) Clear the DTC using the trouble diagnosis tor.
scan tool.
2) Turn the starter switch OFF for 30 seconds or ANNOTATION:
longer. • No short circuit to the battery or ignition
3) Start the engine. power is present.
4) Use the trouble diagnosis scan tool to confirm • No short circuit to GND is present.
that a DTC has not been detected.
8) If a problem is discovered, repair the charge
voltage circuit.
9) If the charge voltage circuit between the ECM
and the injector harness intermediate connec-
tor is normal, replace the ECM.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Removal".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Installation".
10) Set the injector ID code on the ECM.
11) Perform the unit difference learning of the fuel
supply pump to the ECM.
12) Inspect the injector harness intermediate con-
nector for a contact failure.
13) If a problem is discovered, repair the injector
harness intermediate connector.
14) Disconnect the harness connector from the
ECM.
15) Inspect the ECM harness connector for a con-
tact failure.
16) If a problem is discovered, repair the harness
connector.
17) Inspect to see if there is an open circuit or
high resistance with the charge voltage circuit
between the ECM and the injector harness
intermediate connector.
18) If a problem is discovered, repair the charge
voltage circuit.

84402826 - May 2011

4023G-63
 Engine-side Trouble

19) Remove the cylinder head cover. DTC P2228 (Flash Code 71)
Refer to "1.Engine 1B.Mechanical(4HK1X)
Cylinder head cover Removal". Barometric Pressure Circuit Low
20) Inspect the injector harness tightening nut for
1. DTC P2228 Priority DTC
looseness.
DTC P0651
21) If the injector harness tightening nut is loose,
2. DTC P2228 Diagnostics
tighten it.
22) Inspect to see if any foreign matter is attached 1) Turn OFF the starter switch.
to the injector terminal. 2) Disconnect the harness connector from the
23) If any foreign matter is attached to the injector atmospheric pressure sensor.
terminal, remove it. 3) Turn ON the starter switch.
24) Inspect the injector harness intermediate har- 4) Measure the voltage between the atmo-
ness connector for a contact failure. spheric pressure sensor 5 V power supply
25) If a problem is discovered, repair the interme- circuit and GND.
diate harness connector. Voltage: 4.5 V
26) Check if insulation resistance of the first cylin- 5) If it is at or below the standard value, inspect
der and fourth cylinder injector is at or above to see if there is an open circuit or high re-
the standard value. sistance with the 5 V power supply circuit be-
Resistance: 1.0 MΩ tween the ECM and the atmospheric pressure
27) If it is at or below the standard value, replace sensor.
the relevant injector. 6) If a problem is discovered, repair the 5 V
Refer to "1.Engine 1C.Fuel System(4HK1X) power supply circuit.
Injector Removal". 7) Connect the test cable with fuse between the
Refer to "1.Engine 1C.Fuel System(4HK1X) atmospheric pressure sensor 5 V power sup-
Injector Installation". ply circuit and the signal circuit.
28) Set the injector ID code on the ECM. 8) Check the atmospheric pressure sensor dis-
29) If it is at or above the standard value, repair or play with the trouble diagnosis scan tool.
replace the injector harness. Voltage: 4.5 V
9) If it is at or above the standard value, inspect
2. DTC P2149 Confirm Resolution
to see if there is a contact failure with the at-
1) Clear the DTC using the trouble diagnosis mospheric pressure sensor harness connec-
scan tool. tor.
2) Turn the starter switch OFF for 30 seconds or 10) If a problem is discovered, repair the harness
longer. connector.
3) Start the engine. 11) If the harness connector is normal, replace the
4) Use the trouble diagnosis scan tool to confirm atmospheric pressure sensor.
that a DTC has not been detected. 12) If it is at or below the standard value, inspect
the signal circuit between the ECM and the
atmospheric pressure sensor.
• There should be no open circuit or high re-
sistance.
• There should be no short to GND.
13) If a problem is discovered, repair the signal
circuit.
14) Inspect the ECM harness connector for a con-
tact failure.
15) If a problem is discovered, repair the harness
connector.
16) If the harness connector is normal, replace the
ECM.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Removal".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Installation".
17) Set the injector ID code on the ECM.
18) Perform the unit difference learning of the fuel
supply pump to the ECM.
3. DTC P2228 Confirm Resolution
1) Clear the DTC using the trouble diagnosis
scan tool.
2) Turn the starter switch OFF for 30 seconds or
longer.
3) Start the engine.
84402826 - May 2011
4023G-64
 Engine-side Trouble

4) Perform a test-run. DTC P2229 (Flash Code 71)

5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected. Barometric Pressure Circuit High
1. DTC P2229 Priority DTC
DTC P0651
2. DTC P2229 Diagnostics
1) Turn OFF the starter switch.
2) Disconnect the harness connector from the
atmospheric pressure sensor.
3) Check the atmospheric pressure sensor dis-
play with the trouble diagnosis scan tool.
Voltage: 0.1 V
4) If it is at or above the standard value, inspect
the signal circuit between the ECM and the
atmospheric pressure sensor.
• There should be no short to the battery or
ignition power supply.
• There should be no short to the 5 V power
supply.
5) If a problem is discovered, repair the signal
circuit.
6) Connect the test light between the atmo-
spheric pressure sensor GND circuit and
battery power supply.
7) If the test light comes on, inspect the atmo-
spheric pressure sensor harness connector
for a contact failure.
8) If a problem is discovered, repair the harness
connector.
9) If the harness connector is normal, replace the
atmospheric pressure sensor.
10) If the test light does not come on, inspect to
see if there is an open circuit or high resis-
tance with the GND circuit between the ECM
and the atmospheric pressure sensor.
11) If a problem is discovered, repair the GND
circuit.
12) Inspect the ECM harness connector for a con-
tact failure.
13) If a problem is discovered, repair the harness
connector.
14) If the harness connector is normal, replace the
ECM.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Removal".
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
Installation".
15) Set the injector ID code on the ECM.
16) Perform the unit difference learning of the fuel
supply pump to the ECM.
3. DTC P2229 Confirm Resolution
1) Clear the DTC using the trouble diagnosis
scan tool.
2) Turn the starter switch OFF for 30 seconds or
longer.
3) Start the engine.
4) Perform a test-run.
5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.

84402826 - May 2011

4023G-65
 Engine-side Trouble
DTC P2452 (Flash Code 142)
DPD Differential Pressure Sensor
Circuit
1. DTC P2452 Priority DTC
DTC P2456
2. DTC P2452 Diagnostics
1) Inspect the DPD differential pressure sensor
hose.
• There should be no incorrect piping or dis-
connection.
2) If a problem is discovered, repair the hose.
3) Inspect the DPD differential pressure sensor.
• DPD differential pressure sensor unit should
not be damaged.
• There should be no dirt or foreign matter
blocking the DPD differential pressure sen-
sor entrance.
• There should be no detection error or slow
response from the DPD differential pressure
sensor.
4) If a problem is discovered, replace the DPD
differential pressure sensor.
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
haust differential pressure sensor Removal".
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
haust differential pressure sensor Installa-
tion".
5) When the DPD differential pressure sensor
has been replaced, perform the 0-point cor-
rection.
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
haust differential pressure sensor Inspection".
6) Inspect the exhaust system.
• There should be no absence or damage of
the exhaust pipe gasket.
• There should be no exhaust gas leak from
the exhaust system.
• The exhaust system should not be modified.
7) If a problem is discovered, repair or replace
the exhaust system.
8) Inspect the DPD assembly.
Refer to "1.Engine 1G.Exhaust(4HK1X) DPD
assembly Inspection".
9) If a problem is discovered, replace the DPD
assembly.
10) If the DPD assembly has been replaced, use
the trouble diagnosis scan tool to perform
DPD regeneration data reset.
11) Turn OFF the starter switch.
12) Disconnect the harness connector from the
DPD differential pressure sensor.
13) Inspect the DPD differential pressure sensor
harness connector for a contact failure.
14) If a problem is discovered, repair the harness
connector.
15) Disconnect the harness connector from the
ECM.
16) Inspect the ECM harness connector for a con-
tact failure.
84402826 - May 2011
4023G-66
17) If a problem is discovered, repair the harness
connector.
18) Inspect the signal circuit between the ECM
and the DPD differential pressure sensor for
a high resistance.
19) If a problem is discovered, repair the signal
circuit.
20) If the harness connector and circuit are nor-
mal, replace the DPD differential pressure
sensor.
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
haust differential pressure sensor Removal".
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
haust differential pressure sensor Installa-
tion".
21) When the DPD differential pressure sensor
has been replaced, perform the 0-point cor-
rection.
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
haust differential pressure sensor Inspection".
22) Restore the actual unit.
23) Turn the starter switch ON for 30 seconds.
ANNOTATION:
• Do not start the engine.
• This is for the DPD differential pressure sen-
sor to relearn.
24) Clear the DTC using the trouble diagnosis
scan tool.
25) Perform the DPD regeneration data reset with
the trouble diagnosis scan tool.
26) Turn the starter switch OFF for 30 seconds or
longer.
27) Perform the DPD forced regeneration with the
trouble diagnosis scan tool.
ANNOTATION:
• When the DPD filter is replaced by a new
one, do not perform the DPD forced regen-
eration.
28) Use the trouble diagnosis scan tool to confirm
that the exhaust temperature (before the filter)
display is at or below the standard value.
Specified value: 130 °C {266 °F}
29) If it is at or above the standard value, idle the
engine until it falls to or below the standard
value.
30) Check the exhaust differential pressure dis-
play when the exhaust temperature (in front
of the filter) display has reached the standard
value with the engine revolution increased to
the maximum Revolution speed without load.
Specified value: 150 °C {302 °F}
31) Use the trouble diagnosis scan tool to check if
the exhaust differential pressure display is at
or above the standard value.
Specified value: 0.5 kPa {0.01 kgf/cm2 / 0.1
psi}
3. DTC P2452 Confirm Resolution
1) Turn ON the starter switch.
2) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.
 Engine-side Trouble
DTC P2453 (Flash Code 141)
DPD Differential Pressure Sensor
Circuit Range/Performance
1. DTC P2453 Priority DTC
DTC P2456
2. DTC P2453 Diagnostics
1) Inspect the DPD differential pressure sensor
hose.
• There should be no incorrect piping or dis-
connection.
2) If a problem is discovered, repair the hose.
3) Inspect the DPD differential pressure sensor.
• DPD differential pressure sensor unit should
not be damaged.
• There should be no dirt or foreign matter
blocking the DPD differential pressure sen-
sor entrance.
• There should be no detection error or slow
response from the DPD differential pressure
sensor.
4) If a problem is discovered, replace the DPD
differential pressure sensor.
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
haust differential pressure sensor Removal".
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
haust differential pressure sensor Installa-
tion".
5) When the DPD differential pressure sensor
has been replaced, perform the 0-point cor-
rection.
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
haust differential pressure sensor Inspection".
6) Inspect the exhaust system.
• There should be no missing or damage with
the gasket of the exhaust pipe.
• There should be no exhaust gas leak from
the exhaust system.
• The exhaust system should not be modified.
• There should be no flow limitation or crush
of the exhaust system.
7) If a problem is discovered, repair or replace
the exhaust system.
8) Turn OFF the starter switch.
9) Disconnect the harness connector from the
DPD differential pressure sensor.
10) Inspect the DPD differential pressure sensor
harness connector for a contact failure.
11) If a problem is discovered, repair the harness
connector.
12) Disconnect the harness connector from the
ECM.
84402826 - May 2011
4023G-67
13) Inspect the ECM harness connector for a con-
tact failure.
14) If a problem is discovered, repair the harness
15)
connector.
Inspect the signal circuit between the ECM
and the DPD differential pressure sensor for
a high resistance.
16) If a problem is discovered, repair the signal
circuit.
17) If the harness connector and signal circuit are
normal, replace the DPD assembly.
18) If the DPD assembly has been replaced, use
the trouble diagnosis scan tool to perform
DPD regeneration data reset.
19) Restore the actual unit.
20) Turn the starter switch ON for 30 seconds.
ANNOTATION:
• Do not start the engine.
• This is for the DPD differential pressure sen-
sor to relearn.
21) Clear the DTC using the trouble diagnosis
scan tool.
22) Perform the DPD regeneration data reset with
the trouble diagnosis scan tool.
23) Turn the starter switch OFF for 30 seconds or
longer.
24) Perform the DPD forced regeneration with the
trouble diagnosis scan tool.
25) Use the trouble diagnosis scan tool to confirm
that the exhaust temperature (before the filter)
display is at or below the standard value.
Specified value: 130 °C {266 °F}
26) If it is at or above the standard value, idle the
engine until it falls to or below the standard
value.
27) Check the exhaust differential pressure dis-
play when the exhaust temperature (in front
of the filter) display has reached the standard
value with the engine revolution increased to
the maximum revolution speed without load.
Specified value: 150 °C {302 °F}
28) Use the trouble diagnosis scan tool to check if
the exhaust differential pressure display is at
or below the standard value.
Specified value: 1.8 kPa {0.02 kgf/cm2 / 0.3
psi}
29) If it is at or above the standard value, perform
ash removal.
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
haust differential pressure sensor Inspection".
3. DTC P2453 Confirm Resolution
1) Turn ON the starter switch.
2) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.
 Engine-side Trouble

DTC P2454 (Flash Code 47) 11) If the harness connector is normal, replace the
DPD differential pressure sensor.
DPD Differential Pressure Sensor Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
Circuit Low haust differential pressure sensor Removal".
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
1. DTC P2454 Priority DTC haust differential pressure sensor Installa-
DTC P0697 tion".
2. DTC P2454 Diagnostics 12) When the DPD differential pressure sensor
has been replaced, perform the 0-point cor-
1) Turn OFF the starter switch. rection.
2) Disconnect the harness connector from the Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
DPD differential pressure sensor. haust differential pressure sensor Inspection".
3) Turn ON the starter switch. 13) If it is at or below the standard value, inspect
4) Measure the voltage between the DPD differ- the signal circuit between the ECM and the
ential pressure sensor 5 V power supply cir- DPD differential pressure sensor.
cuit and GND.
Voltage: 4.5 V • There should be no open circuit or high re-
5) If it is at or below the standard value, inspect sistance.
to see if there is an open circuit or high re- • There should be no short to GND.
sistance with the 5 V power supply circuit be-
14) If a problem is discovered, repair the signal
tween the ECM and the DPD differential pres-
circuit.
sure sensor.
15) Inspect the ECM harness connector for a con-
ANNOTATION: tact failure.
16) If a problem is discovered, repair the harness
• The DPD differential pressure sensor connector.
shares the 5 V power supply circuit with 17) If the harness connector is normal, replace the
other sensors. ECM.
• The DTC set on a sensor which shares this Refer to "1.Engine 1J.Electrical(4HK1X) ECM
circuit may be detected. Removal".
6) If a problem is discovered, repair the 5 V Refer to "1.Engine 1J.Electrical(4HK1X) ECM
power supply circuit. Installation".
7) Connect the test cable with fuse between the 18) Set the injector ID code on the ECM.
5 V power supply circuit and signal circuit of 19) Perform the unit difference learning of the fuel
the DPD differential pressure sensor. supply pump to the ECM.
8) Check the exhaust differential pressure dis- 3. DTC P2454 Confirm Resolution
play with the trouble diagnosis scan tool.
Voltage: 4.5 V 1) Clear the DTC using the trouble diagnosis
9) If it is at or above the standard value, inspect scan tool.
to see if there is a contact failure with the DPD 2) Turn the starter switch OFF for 30 seconds or
differential pressure sensor harness connec- longer.
tor. 3) Start the engine.
10) If a problem is discovered, repair the harness 4) Perform a test-run.
connector. 5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.

84402826 - May 2011

4023G-68
 Engine-side Trouble

DTC P2455 (Flash Code 47) 10) When the DPD differential pressure sensor
has been replaced, perform the 0-point cor-
DPD Differential Pressure Sensor rection.
Circuit High Refer to "1.Engine 1G.Exhaust(4HK1X) Ex-
haust differential pressure sensor Inspection".
1. DTC P2455 Priority DTC 11) If the test light does not come on, inspect to
DTC P0697 see if there is an open circuit or high resis-
2. DTC P2455 Diagnostics tance with the GND circuit between the ECM
and the DPD differential pressure sensor.
1) Turn OFF the starter switch.
2) Disconnect the harness connector from the ANNOTATION:
DPD differential pressure sensor.
• The DPD differential pressure sensor
3) Check the exhaust differential pressure dis-
shares the GND circuit with other sensors.
play with the trouble diagnosis scan tool.
• The DTC may be detected on a sensor
Voltage: 0.1 V
which shares this circuit.
4) If it is at or above the standard value, inspect
the signal circuit between the ECM and the 12) If a problem is discovered, repair the GND
DPD differential pressure sensor. circuit.
13) Inspect the ECM harness connector for a con-
• There should be no short to the battery or tact failure.
ignition power supply.
14) If a problem is discovered, repair the harness
• There should be no short to the 5 V power connector.
supply.
15) If the harness connector is normal, replace the
5) If a problem is discovered, repair the signal ECM.
circuit. Refer to "1.Engine 1J.Electrical(4HK1X) ECM
6) Connect the test light between the GND circuit Removal".
and battery power supply of the DPD differen- Refer to "1.Engine 1J.Electrical(4HK1X) ECM
tial pressure sensor. Installation".
7) If the test light comes on, inspect DPD differ- 16) Set the injector ID code on the ECM.
ential pressure sensor harness connector for 17) Perform the unit difference learning of the fuel
a contact failure. supply pump to the ECM.
8) If a problem is discovered, repair the harness
3. DTC P2455 Confirm Resolution
connector.
9) If the harness connector is normal, replace the 1) Clear the DTC using the trouble diagnosis
DPD differential pressure sensor. scan tool.
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex- 2) Turn the starter switch OFF for 30 seconds or
haust differential pressure sensor Removal". longer.
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex- 3) Start the engine.
haust differential pressure sensor Installa- 4) Perform a test-run.
tion". 5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.

84402826 - May 2011

4023G-69
 Engine-side Trouble
DTC P2458 (Flash Code 139)
DPD Regeneration Duration
1. DTC P2458 Description of DTC
The ECM detects PM accumulation failures from the
DPD differential pressure sensor installed near the
DPD itself.
When it is reached to a certain amount of PM accu-
mulations or a certain length of operating time, the
automatic regeneration of the DPD starts.
If the automatic regeneration cannot be completed
by some reason, the manual regeneration is re-
quested to the operator by blinking the orange DPD
indicator light on the display.
Once the DPD filter regeneration starts, it must be
finished within a certain time.
When DPD regeneration continues for longer than
the specified period of time, it sets DTC.
2. DTC P2458 Condition for setting the DTC
The starter switch is ON
The DPD filter regeneration has been completed
When the ECM detected that the DPD filter regener-
ation process took time longer than a certain period
of time for 3 consecutive times
3. DTC P2458 Action taken when the DTC sets
Failure is indicated in the monitor on the actual unit,
or the monitor is turned on.
ANNOTATION:
• Depending on the manufacturer of the actual unit,
the failure indication may not be shown.
Restricts the fuel injection amount.
84402826 - May 2011
4023G-70
DTC P042B (Flash Code 145)
Catalyst Temperature Sensor
Circuit Range/Performance
Sensor 2
1. DTC P042B Description of DTC
The exhaust temperature sensor 2 is installed on
the DPD housing.
The exhaust temperature sensor 2 is a variable re-
sistor, and measures the temperature of the ex-
haust gas before entering the oxidation catalyst.
The DTC is set when the ECM detects an abnor-
mally high exhaust temperature.
2. DTC P042B Condition for setting the DTC
DTC P042C and P042D are not set
The starter switch is ON
When the ECM has detected that the exhaust tem-
perature
2 has been 870 °C (1600 °F) or higher for 5 seconds
3. DTC P042B Action taken when the DTC sets
Failure is indicated in the monitor on the actual unit,
or the monitor is turned on.
ANNOTATION:
• Depending on the manufacturer of the actual unit,
the failure indication may not be shown.
Restricts the fuel injection amount.
 Engine-side Trouble

DTC P042C (Flash Code 49) DTC P042D (Flash Code 49)
Catalyst Temperature Sensor Catalyst Temperature Sensor
Circuit Low Sensor 2 Circuit High Sensor 2
1. DTC P042C Priority DTC 1. DTC P042D Description of DTC
DTC P0697 The exhaust temperature sensor 2 is installed on
2. DTC P042C Diagnostics the DPD housing.
The exhaust temperature sensor 2 is a variable re-
1) Turn OFF the starter switch.
sistor, and measures the temperature of the ex-
2) Disconnect the harness connector from the haust gas before entering the oxidation catalyst.
exhaust gas temperature sensor 2.
This sensor has a signal circuit and GND circuit.
3) Check the exhaust temperature sensor (be- The ECM supplies 5 V to the signal circuit, and the
fore the oxidation catalyst) display with the
GND circuit connects to GND.
trouble diagnosis scan tool. When the exhaust temperature sensor 2 is cold, the
Voltage： 4.5 V
resistance of the sensor is high.
4) If it is at or above the standard value, replace When the exhaust temperature rises, the resistance
the exhaust gas temperature sensor 2.
of the sensor decreases.
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex- The ECM detects a high voltage when the sensor
haust gas temperature sensor Removal".
resistance is high.
Refer to "1.Engine 1G.Exhaust(4HK1X) Ex- The ECM detects a low voltage when the sensor
haust gas temperature sensor Installation".
resistance is low.
5) Inspect to see if there is a short circuit to the The DTC is set when the ECM detects an abnor-
GND with the signal circuit between the ECM
mally low signal voltage.
and the exhaust gas temperature sensor 2.
2. DTC P042D Condition for setting the DTC
6) If a problem is discovered, repair the signal
DTC P0112, P0113, P0117, P0118, P060B, P2228,
circuit.
and P2229 are not set
7) Inspect the ECM harness connector for a con-
The battery voltage is between 18 and 32 V The
tact failure.
starter switch is ON
8) If a problem is discovered, repair the harness
The engine coolant temperature is 70 °C (158 °F)
connector.
or higher.
9) If the harness connector is normal, replace the
The fuel injection amount is a certain value or more
ECM.
The engine operating time is 0.5 - 10 minutes or
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
longer
Removal".
When the ECM has detected that the signal voltage
Refer to "1.Engine 1J.Electrical(4HK1X) ECM
of the exhaust temperature sensor 2 has been 4.85
Installation".
V or higher for 5 seconds.
10) Set the injector ID code on the ECM.
3. DTC P042D Action taken when the DTC sets
11) Perform the unit difference learning of the fuel
Failure is indicated in the monitor on the actual unit,
supply pump to the ECM.
or the monitor is turned on.
3. DTC P042C Confirm Resolution
ANNOTATION:
1) Clear the DTC using the trouble diagnosis
• Depending on the manufacturer of the actual unit,
scan tool.
the failure indication may not be shown.
2) Turn the starter switch OFF for 30 seconds or
longer. Restrict the fuel injection amount.
3) Start the engine. Stop the EGR control.
4) Perform a test-run.
5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.

84402826 - May 2011

4023G-71
 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 Diagnostics DPD differential pressure sensor installed near the
1) Replace the ECM. DPD it self.
Refer to "1.Engine 1J.Electrical(4HK1X) ECM When it is reached to a certain amount of PM accu-
Removal". mulations or a certain length of operating time, the
Refer to "1.Engine 1J.Electrical(4HK1X) ECM automatic regeneration of the DPD starts.
Installation". If the automatic regeneration cannot be completed
2) Set the injector ID code on the ECM. by some reason, the manual regeneration is re-
3) Perform the unit difference learning of the fuel quested to the operator by blinking the orange DPD
supply pump to the ECM. indicator light on the display.
If the ECM detects that learned exhaust differential
2. DTC P060B Confirm Resolution pressure is not within a predetermined range, it sets
1) Clear the DTC using the trouble diagnosis DTC.
scan tool. 2. DTC P242F Condition for setting the DTC
2) Turn the starter switch OFF for 30 seconds or The starter switch is ON
longer. The DPD differential pressure has been above the
3) Start the engine. calculated range for 30 seconds or longer.
4) Perform a test-run. 3. DTC P242F Action taken when the DTC sets
5) Use the trouble diagnosis scan tool to confirm Failure is indicated in the monitor on the actual unit,
that a DTC has not been detected. or the monitor is turned on.
ANNOTATION:
• Depending on the manufacturer of the actual unit,
the failure indication may not be shown.
Restrict the fuel injection amount.
Stop the EGR control.
Stop the DPD regeneration.

84402826 - May 2011

4023G-72
 Section

4023H

Main Unit-side Trouble

84402826 - May 2011

84402826 - May 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: 7066 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: 7404 Abnormally High Oil Temperature (95°C or higher) . . . . . . . . . . . . . . . . . . . . . . . . . 78

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

4023H-1 PRINTED IN FRANCE
Diagnostic Trouble Code: 7405 Abnormally High Boost Temperature (80°C or higher), 7406 Abnormally High Boost
Temperature (90°C or higher) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Diagnostic Trouble Code: 7420 Abnormally Low Alternator Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Diagnostic Trouble Code: 7421 Coolant Level Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Diagnostic Trouble Code: 7422 Abnormally Low Engine Oil Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Diagnostic Trouble Code: 7423 Air Cleaner Clogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Diagnostic Trouble Code: 7424 Return Filter Clogging (breaker specifications). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Diagnostic Trouble Code: 7425 Fuel Density Error Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Diagnostic Trouble Code: 7600 CAN Bus Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Diagnostic Trouble Code: 7601 Monitor Communication Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Diagnostic Trouble Code: 7602 ECM Communication Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Diagnostic Trouble Code: 7604 Computer B Communication Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Diagnostic Trouble Code: 7605 ECM Mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Diagnostic Trouble Code: 7606 EEPROM Data Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Diagnostic Trouble Code: 7607 Computer C Communication Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

4023H-2 PRINTED IN FRANCE
 Main Unit-side Trouble

Main Unit-side Trouble

Diagnostic Trouble Code: 7000 P1 Pressure Sensor Signal Abnormality
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7000 is displayed. Go to Step 2
Is diagnostic trouble code: 7000 displayed?
1. Inspect the connection status of each
connector.
2 2. Check whether diagnostic trouble code: Go to Step 3
7000 is displayed.
Is diagnostic trouble code: 7000 displayed?
1. Check the P1 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 8
Is it 4.75 V or higher?
Inspect for shorts to the power supply
1. Turn the key switch OFF and disconnect
CN. D45.
2. Turn the key switch ON. W400 harness defect
4 About 5 V Go to Step 5
3. Measure the voltage between the (short). Replace
ground and terminal 1 of the CN. D45
harness side.
Is it about 5 V?
1. Measure the voltage between the
ground and terminal 2 of the CN. D45 4.75 V or Y410 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. D45 0.25 V or BW420 harness de-
6 harness side. Go to Step 7
lower fect (short). Replace
Is it 0.25 V or lower?
Judge as a computer A defect.
7
…Replace computer A
1. Inspect the P1 pressure sensor.
2. Turn the key switch OFF.
3. Disconnect CN. D45.
8 4. Measure the resistance between termi- About 10 Go to Step 9 P1 pressure sensor
nals 1 and 3 of the CN. D45 P1 pressure kΩ defect. Replace
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. D45 W400 or Y410 har-
9 harness side. ness defect (short). Go to Step 10
2. Inspect for continuity between the Replace
ground and terminal 2 of the CN. D45
harness side.
Is there continuity?
1. Inspect for continuity between the
ground and terminal 3 of the CN. D45 BW420 harness de-
10 harness side. Go to Step 11 fect (disconnection).
Repair or replace
Is there continuity?

84402826 - May 2011

4023H-3
 Main Unit-side Trouble

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Measure the voltage between the W400 or W401 har-
ground and terminal 1 of the CN. D45 About 5 V ness defect (discon-
11 Go to Step 12
harness side. nection). Repair or
replace
Is it about 5 V?
1. Measure the voltage between the
ground and terminal 2 of the CN. D45 0.25 V or Computer A defect. Y410 harness defect
12 harness side. (disconnection). Re-
higher Replace
place
Is it 0.25 V or higher?

1 COMPUTER A
2 PRESS. SENSOR (P1)

84402826 - May 2011

4023H-4
 Main Unit-side Trouble

Diagnostic Trouble Code: 7001 P2 Pressure Sensor Signal Abnormality

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7001 is displayed. Go to Step 2
Is diagnostic trouble code: 7001 displayed?
1. Inspect the connection status of each
connector.
2 2. Check whether diagnostic trouble code: Go to Step 3
7001 is displayed.
Is diagnostic trouble code: 7001 displayed?
1. Check the P2 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. D46.
W400 or W401 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. D46
harness side.
Is it about 5 V?
1. Measure the voltage between the
ground and terminal 2 of the CN. D46 4.75 V or L411 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. D46 0.25 V or Computer A defect. BW420 or BW421
6 harness side. harness defect
lower Replace
(short). Replace
Is it 0.25 V or lower?
1. Inspect the P1 pressure sensor.
2. Turn the key switch OFF.
3. Disconnect CN. D46.
7 4. Measure the resistance between termi- About 10 Go to Step 8 P2 pressure sensor
nals 1 and 3 of the CN. D46 P2 pressure kΩ defect. Replace
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. D46 W400, W401, or
8 harness side. L411 harness defect Go to Step 9
2. Inspect for continuity between the (short). Replace
ground and terminal 2 of the CN. D46
harness side.
Is there continuity?
1. Inspect for continuity between the BW420 or BW421
ground and terminal 3 of the CN. D46 harness defect (dis-
9 harness side. Go to Step 10
connection). Repair
Is there continuity? or replace

84402826 - May 2011

4023H-5
 Main Unit-side Trouble

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Measure the voltage between the W400 or W401 har-
ground and terminal 1 of the CN. D46 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. D46 0.25 V or Computer A defect. L411 harness defect
11 harness side. (disconnection). Re-
higher Replace
place
Is it 0.25 V or higher?

1 COMPUTER A
2 PRESS. SENSOR (P1)

84402826 - May 2011

4023H-6
 Main Unit-side Trouble

Diagnostic Trouble Code: 7002 N1 Pressure Sensor Signal Abnormality

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7002 is displayed. Go to Step 2
Is diagnostic trouble code: 7002 displayed?
1. Inspect the connection status of each
connector.
2 2. Check whether diagnostic trouble code: Go to Step 3
7002 is displayed.
Is diagnostic trouble code: 7002 displayed?
1. Check the N1 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. D47.
W400 or W402 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. D47
harness side.
Is it about 5 V?
1. Measure the voltage between the
ground and terminal 2 of the CN. D47 4.75 V or Lg412 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. D47 0.25 V or Computer A defect. BW420 or BW422
6 harness side. harness defect
lower Replace
(short). Replace
Is it 0.25 V or lower?
1. Inspect the P1 pressure sensor.
2. Turn the key switch OFF.
3. Disconnect CN. D47.
7 4. Measure the resistance between termi- About 10 Go to Step 8 N1 pressure sensor
nals 1 and 3 of the CN. D47 N1 pressure kΩ defect. Replace
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. D47 W400, W402, or
8 harness side. Lg412 harness de- Go to Step 9
2. Inspect for continuity between the fect (short). Replace
ground and terminal 2 of the CN. D47
harness side.
Is there continuity?
1. Inspect for continuity between the BW420 or BW422
ground and terminal 3 of the CN. D47 harness defect (dis-
9 harness side. Go to Step 10
connection). Repair
Is there continuity? or replace

84402826 - May 2011

4023H-7
 Main Unit-side Trouble

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Measure the voltage between the W400 or W402 har-
ground and terminal 1 of the CN. D47 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. D47 0.25 V or Computer A defect. Lg412 harness de-
11 harness side. fect (disconnection).
higher Replace
Repair or replace
Is it 0.25 V or higher?

1 COMPUTER A
2 PRESS. SENSOR (N1)

84402826 - May 2011

4023H-8
 Main Unit-side Trouble

Diagnostic Trouble Code: 7003 N2 Pressure Sensor Signal Abnormality

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7003 is displayed. Go to Step 2
Is diagnostic trouble code: 7003 displayed?
1. Inspect the connection status of each
connector.
2 2. Check whether diagnostic trouble code: Go to Step 3
7003 is displayed.
Is diagnostic trouble code: 7003 displayed?
1. Check the N2 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. D48.
W400 or W403 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. D48
harness side.
Is it about 5 V?
1. Measure the voltage between the
ground and terminal 2 of the CN. D48 4.75 V or G413 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. D48 0.25 V or Computer A defect. BW420 or BW423
6 harness side. harness defect
lower Replace
(short). Replace
Is it 0.25 V or lower?
1. Inspect the N2 pressure sensor.
2. Turn the key switch OFF.
3. Disconnect CN. D48.
7 4. Measure the resistance between termi- About 10 Go to Step 8 N2 pressure sensor
nals 1 and 3 of the CN. D48 N2 pressure kΩ defect. Replace
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. D48 W400, W403, or
8 harness side. G413 harness defect Go to Step 9
2. Inspect for continuity between the (short). Replace
ground and terminal 2 of the CN. D48
harness side.
Is there continuity?
1. Inspect for continuity between the BW420 or BW423
ground and terminal 3 of the CN. D48 harness defect (dis-
9 harness side. Go to Step 10
connection). Repair
Is there continuity? or replace

84402826 - May 2011

4023H-9
 Main Unit-side Trouble

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Measure the voltage between the W400 or W403 har-
ground and terminal 1 of the CN. D48 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. D48 0.25 V or Computer A defect. G413 harness defect
11 harness side. (disconnection). Re-
higher Replace
pair or replace
Is it 0.25 V or higher?

1 COMPUTER A
2 PRESS. SENSOR (N2)

84402826 - May 2011

4023H-10
 Main Unit-side Trouble

Diagnostic Trouble Code: 7004 Overload Pressure Sensor Signal

Abnormality
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7004 is displayed. Go to Step 2
Is diagnostic trouble code: 7004 displayed?
1. Inspect the connection status of each
connector.
2 2. Check whether diagnostic trouble code: Go to Step 3
7004 is displayed.
Is diagnostic trouble code: 7004 displayed?
1. Check the overload pressure sensor
3 voltage on the service support screen. 4.75 V or Go to Step 4 When 0.25 V or
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. D52-1.
W400 or W409 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. D52-1
harness side.
Is it about 5 V?
1. Measure the voltage between the
ground and terminal 2 of the CN. D52-1 4.75 V or Gr419 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. D52-1 0.25 V or Computer A defect. BW420 or BW429
6 harness side. harness defect
lower Replace
(short). Replace
Is it 0.25 V or lower?
1. Inspect the overload pressure sensor.
2. Turn the key switch OFF.
3. Disconnect CN. D52-1. Overload pressure
7 4. Measure the resistance between termi- About 10 Go to Step 8 sensor defect. Re-
nals 1 and 3 of the CN. D52-1 overload kΩ place
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. D52-1 W400, W409, or
8 harness side. Gr419 harness de- Go to Step 9
2. Inspect for continuity between the fect (short). Replace
ground and terminal 2 of the CN. D52-1
harness side.
Is there continuity?
1. Inspect for continuity between the BW420 or BW429
ground and terminal 3 of the CN. D52-1 harness defect (dis-
9 harness side. Go to Step 10
connection). Repair
Is there continuity? or replace

84402826 - May 2011

4023H-11
 Main Unit-side Trouble

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Measure the voltage between the W400 or W409 har-
ground and terminal 1 of the CN. D52-1 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. D52-1 0.25 V or Computer A defect. Gr419 harness de-
11 harness side. fect (disconnection).
higher Replace
Repair or replace
Is it 0.25 V or higher?

1 COMPUTER A
2 PRESS. SENSOR (HBCV)

84402826 - May 2011

4023H-12
 Main Unit-side Trouble

Diagnostic Trouble Code: 7005 Bottom Pressure Sensor Signal

Abnormality
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7005 is displayed. Go to Step 2
Is diagnostic trouble code: 7005 displayed?
1. Inspect the connection status of each
connector.
2 2. Check whether diagnostic trouble code: Go to Step 3
7005 is displayed.
Is diagnostic trouble code: 7005 displayed?
1. Check the bottom 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. CR9.
2. Turn the key switch ON. W414 harness defect
4 About 5 V Go to Step 5
3. Measure the voltage between the (short). Replace
ground and terminal 1 of the CN. CR9
harness side.
Is it about 5 V?
1. Measure the voltage between the
ground and terminal 2 of the CN. CR9 4.75 V or Y434 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. CR9 0.25 V or Computer B defect. BW454 harness de-
6 harness side. lower Replace fect (short). Replace
Is it 0.25 V or lower?
Inspect the bottom pressure sensor.
1. Turn the key switch OFF.
2. Disconnect CN. CR9.
About 10 Bottom pressure sen-
7 3. Measure the resistance between termi- Go to Step 8
kΩ sor defect. Replace
nals 1 and 3 of the CN. CR9 bottom sen-
sor.
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. CR9 W414 or Y434 har-
8 harness side. ness defect (short). Go to Step 9
2. Inspect for continuity between the Replace
ground and terminal 2 of the CN. CR9
harness side.
Is there continuity?
1. Inspect for continuity between the
ground and terminal 3 of the CN. CR9 BW454 harness de-
9 harness side. Go to Step 10 fect (disconnection).
Repair or replace
Is there continuity?

84402826 - May 2011

4023H-13
 Main Unit-side Trouble

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Measure the voltage between the W414 harness defect
10 ground and terminal 1 of the CN. CR9 About 5 V Go to Step 11 (disconnection). Re-
harness side. pair or replace
Is it about 5 V?
1. Measure the voltage between the
ground and terminal 2 of the CN. CR9 0.25 V or Computer B defect. Y434 harness defect
11 harness side. (disconnection). Re-
higher Replace
pair or replace
Is it 0.25 V or higher?

84402826 - May 2011

4023H-14
 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

84402826 - May 2011

4023H-15
 Main Unit-side Trouble

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Measure the voltage between the W414 or W415 har-
ground and terminal 1 of the CN. CR10 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. CR10 0.25 V or Computer B defect. L435 harness defect
11 harness side. (disconnection). Re-
higher Replace
pair or replace
Is it 0.25 V or higher?

84402826 - May 2011

4023H-16
 Main Unit-side Trouble

Diagnostic Trouble Code: 7020 Upper Pressure Sensor Signal

Abnormality
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7020 is displayed. Go to Step 2
Is diagnostic trouble code: 7020 displayed?
1. Inspect the connection status of each
connector.
2 2. Check whether diagnostic trouble code: Go to Step 3
7020 is displayed.
Is diagnostic trouble code: 7020 displayed?
1. Check the upper 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. D50.
W400 or W405 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. D50
harness side.
Is it about 5 V?
1. Measure the voltage between the
ground and terminal 2 of the CN. D50 4.75 V or V415 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. D50 0.25 V or Computer A defect. BW420 or BW425
6 harness side. harness defect
lower Replace
(short). Replace
Is it 0.25 V or lower?
1. Inspect the upper pressure sensor.
2. Turn the key switch OFF.
3. Disconnect CN. D50.
7 4. Measure the resistance between termi- About 10 Go to Step 8 Upper pressure sen-
nals 1 and 3 of the CN. D50 upper 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. D50 W400, W405, or
8 harness side. V415 harness defect Go to Step 9
2. Inspect for continuity between the (short). Replace
ground and terminal 2 of the CN. D50
harness side.
Is there continuity?
1. Inspect for continuity between the BW420 or BW425
ground and terminal 3 of the CN. D50 harness defect (dis-
9 harness side. Go to Step 10
connection). Repair
Is there continuity? or replace

84402826 - May 2011

4023H-17
 Main Unit-side Trouble

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Measure the voltage between the W400 or W405 har-
ground and terminal 1 of the CN. D50 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. D50 0.25 V or Computer A defect. V415 harness defect
11 harness side. (disconnection). Re-
higher Replace
pair or replace
Is it 0.25 V or higher?

1 COMPUTER A
PRESS. SENSOR (PILOT UP-
2
PER)

84402826 - May 2011

4023H-18
 Main Unit-side Trouble

Diagnostic Trouble Code: 7021 Swing Pressure Sensor Signal

Abnormality
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7021 is displayed. Go to Step 2
Is diagnostic trouble code: 7021 displayed?
1. Inspect the connection status of each
connector.
2 2. Check whether diagnostic trouble code: Go to Step 3
7021 is displayed.
Is diagnostic trouble code: 7021 displayed?
1. Check the swing 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. D49.
W400 or W404 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. D49
harness side.
Is it about 5 V?
1. Measure the voltage between the
ground and terminal 2 of the CN. D49 4.75 V or GR414 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. D49 0.25 V or Computer A defect. BW420 or BW424
6 harness side. harness defect
lower Replace
(short). Replace
Is it 0.25 V or lower?
1. Inspect the swing pressure sensor.
2. Turn the key switch OFF.
3. Disconnect CN. D49.
7 4. Measure the resistance between termi- About 10 Go to Step 8 Swing pressure sen-
nals 1 and 3 of the CN. D49 swing 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. D49 W400, W404, or
8 harness side. GR414 harness de- Go to Step 9
2. Inspect for continuity between the fect (short). Replace
ground and terminal 2 of the CN. D49
harness side.
Is there continuity?
1. Inspect for continuity between the BW420 or BW424
ground and terminal 3 of the CN. D49 harness defect (dis-
9 harness side. Go to Step 10
connection). Repair
Is there continuity? or replace

84402826 - May 2011

4023H-19
 Main Unit-side Trouble

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Measure the voltage between the W400 or W404 har-
ground and terminal 1 of the CN. D49 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. D49 0.25 V or Computer A defect. GR414 harness de-
11 harness side. fect (disconnection).
higher Replace
Repair or replace
Is it 0.25 V or higher?

1 COMPUTER A
PRESS. SENSOR (PILOT
2
SWING)

84402826 - May 2011

4023H-20
 Main Unit-side Trouble

Diagnostic Trouble Code: 7022 Travel Pressure Sensor Signal

Abnormality
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7022 is displayed. Go to Step 2
Is diagnostic trouble code: 7022 displayed?
1. Inspect the connection status of each
connector.
2 2. Check whether diagnostic trouble code: Go to Step 3
7022 is displayed.
Is diagnostic trouble code: 7022 displayed?
1. Check the travel 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. D51.
W400 or W406 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. D51
harness side.
Is it about 5 V?
1. Measure the voltage between the
ground and terminal 2 of the CN. D51 4.75 V or YG416 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. D51 0.25 V or Computer A defect. BW420 or BW426
6 harness side. harness defect
lower Replace
(short). Replace
Is it 0.25 V or lower?
1. Inspect the travel pressure sensor.
2. Turn the key switch OFF.
3. Disconnect CN. D51.
7 4. Measure the resistance between termi- About 10 Go to Step 8 Travel pressure sen-
nals 1 and 3 of the CN. D51 travel 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. D51 W400, W406, or
8 harness side. YG416 harness de- Go to Step 9
2. Inspect for continuity between the fect (short). Replace
ground and terminal 2 of the CN. D51
harness side.
Is there continuity?
1. Inspect for continuity between the BW420 or BW426
ground and terminal 3 of the CN. D51 harness defect (dis-
9 harness side. Go to Step 10
connection). Repair
Is there continuity? or replace

84402826 - May 2011

4023H-21
 Main Unit-side Trouble

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Measure the voltage between the W400 or W406 har-
ground and terminal 1 of the CN. D51 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. D51 0.25 V or Computer A defect. YG416 harness de-
11 harness side. fect (disconnection).
higher Replace
Repair or replace
Is it 0.25 V or higher?

1 COMPUTER A
PRESS. SENSOR (PILOT
2
TRAVEL)

84402826 - May 2011

4023H-22
 Main Unit-side Trouble

Diagnostic Trouble Code: 7023 Arm-in Pressure Sensor Signal

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?
84402826 - May 2011
4023H-23
 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?

84402826 - May 2011

4023H-24
 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?

84402826 - May 2011

4023H-25
Main Unit-side Trouble

1 COMPUTER A
2 FUEL LEVEL SENSOR

84402826 - May 2011

4023H-26
 Main Unit-side Trouble

Diagnostic Trouble Code: 7041 Oil Temperature Sensor Signal

Abnormality
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7041 is displayed. Go to Step 2
Is diagnostic trouble code: 7041 displayed?
1. Inspect the connection status of each
connector.
2 2. Check whether diagnostic trouble code: Go to Step 3
7040 is displayed.
Is diagnostic trouble code: 7040 displayed?
1. Check the oil temperature sensor resis-
tance (or voltage) on the service support 67200 Ω (or When 111 Ω (or 0.5
3 screen. 4.93 V) or Go to Step 4 V) or lower, go to
higher Step 7
Is it 67200 Ω (or 4.93 V) or higher?
Inspect for disconnection.
1. Turn the key switch OFF and disconnect
CN. D56.
2. Measure the resistance between termi- Oil temperature sen-
4 Go to Step 5
nals 1 and 2 of the CN. D56 oil temper- sor defect. Replace
ature sensor side.(See the Oil tempera-
ture and resistance table.)
Is it the standard value?
1. Inspect for continuity between the BW491 or BW420
ground and terminal 1 of the CN. D56 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 YB490 harness de-
ground and terminal 2 of the CN. D56 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. D56.
YB490 harness de-
7 3. Inspect for continuity between the Go to Step 8
fect (short). Replace
ground and terminal 2 of the CN. D56
harness side.
Is there continuity?
1. Turn the key switch ON.
2. Measure the voltage between the BW491 or BW420
ground and terminal 1 of the CN. D56 0 V Computer A defect.
8 harness defect
harness side. Replace
(short). Replace
Is it 0 V?

84402826 - May 2011

4023H-27
Main Unit-side Trouble

1 COMPUTER A
2 HYD. OIL TEMP SENSOR

84402826 - May 2011

4023H-28
 Main Unit-side Trouble

Diagnostic Trouble Code: 7045 Monitor Thermistor Signal Abnormality

Standard
Step Action Yes No
value
Monitor defect. Replace

CAUTION
Contrast correction is
performed when the
1. Turn the key switch ON. monitor thermistor is
2. On the service support DIAG at an extremely high
screen, or low temperature.
check whether diagnostic trouble Even if the monitor
1
code: 7045 (●) is displayed. thermistor has a de-
fect, there is a correc-
Is diagnostic trouble code: 7045 (●) dis- tion function inside
played? the monitor, so the
monitor thermistor
does not need to be
replaced if the moni-
tor contrast is not sig-
nificantly affected.

84402826 - May 2011

4023H-29
 Main Unit-side Trouble

Diagnostic Trouble Code: 7060 Boom Angle Sensor Signal Abnormality

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

84402826 - May 2011

4023H-30
 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?

84402826 - May 2011

4023H-31
 Main Unit-side Trouble

Diagnostic Trouble Code: 7061 Arm Angle Sensor Signal Abnormality

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7061 is displayed. Go to Step 2
Is diagnostic trouble code: 7061 displayed?
1. Inspect the connection status of each
connector.
2 2. Check whether diagnostic trouble code: Go to Step 3
7061 is displayed.
Is diagnostic trouble code: 7061 displayed?
1. Check the arm 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. CR12.
BW457 or W414 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. CR12
harness side.
Is it about 5 V?
1. Measure the voltage between the
ground and terminal 2 of the CN. CR12 4.8 V or Br437 harness defect
5 harness side. Go to Step 6
lower (short). Replace
Is it 4.8 V or lower?
1. Measure the voltage between the
ground and terminal 3 of the CN. CR12 0.2 V BW454 or W417 har-
or Computer B defect.
6 harness side. ness defect (short).
lower Replace
Replace
Is it 0.2 V or lower?
Inspect the arm angle sensor.
1. Turn the key switch OFF.
2. Disconnect CN. CR12.
About 10 Arm angle sensor de-
7 3. Measure the resistance between termi- Go to Step 8
kΩ fect. Replace
nals 1 and 3 of the CN. CR12 arm angle
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. CR12 BW457, W414, or
8 harness side. Br437 harness defect Go to Step 9
2. Inspect for continuity between the (short). Replace
ground and terminal 2 of the CN. CR12
harness side.
Is there continuity?
1. Inspect for continuity between the BW454 or W417 har-
ground and terminal 3 of the CN. CR12 ness defect (discon-
9 harness side. Go to Step 10
nection). Repair or
Is there continuity? replace

84402826 - May 2011

4023H-32
 Main Unit-side Trouble

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Measure the voltage between the BW457 or W414 har-
ground and terminal 1 of the CN. CR12 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. CR12 0.2 V Br437 harness defect
or Computer B defect.
11 harness side. (disconnection). Re-
higher Replace
pair or replace
Is it 0.2 V or higher?

84402826 - May 2011

4023H-33
 Main Unit-side Trouble

Diagnostic Trouble Code: 7063

Return Filter Clogging Pressure
Switch Signal Abnormality
(Breaker specifications)
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7063 is displayed. Go to Step 2
Is diagnostic trouble code: 7063 displayed?
1. Inspect the connection status of each
connector and ground.
2 2. Check whether diagnostic trouble code: Go to Step 3
7063 is displayed.
Is diagnostic trouble code: 7063 displayed?
Inspect the return filter clog pressure switch.
1. Turn the key switch OFF and disconnect
CN. D81. Return filter clog
3 2. Inspect for continuity between terminals Go to Step 4 pressure switch de-
1 and 2 of the CN. D81 return filter clog fect. Replace
pressure switch side.
Is there continuity?
Inspect for disconnection.
1. Inspect for continuity between the BG652 harness de-
4 ground and terminal 1 of the CN. D81 Go to Step 5 fect (disconnection).
harness side. Repair or replace
Is there continuity?
1. Turn the key switch ON.
2. Measure the voltage between the YL538 harness de-
ground and terminal 2 of the CN. D81 About 5 V Computer A defect.
5 fect (disconnection).
harness side. Replace
Repair or replace
Is it about 5 V?

1 COMPUTER A
PRESS. SWITCH (FILTER IN-
2
DICATOR)

84402826 - May 2011

4023H-34
 Main Unit-side Trouble

(Other than breaker specifications)

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7063 is displayed. Go to Step 2
Is diagnostic trouble code: 7063 displayed?
1. Inspect the connection status of each
connector and ground.
2 2. Check whether diagnostic trouble code: Go to Step 3
7063 is displayed.
Is diagnostic trouble code: 7063 displayed?
Inspect for disconnection.
1. Turn the key switch OFF and disconnect
CN. D81. Jump harness defect
3 2. Inspect for continuity between terminals Go to Step 4 (disconnection). Re-
1 and 2 of the CN. D81 jump harness pair or replace
side.
Is there continuity?
1. Inspect for continuity between the
ground and terminal 1 of the CN. D81 BG652 harness de-
4 harness side. Go to Step 5 fect (disconnection).
Repair or replace
Is there continuity?
1. Turn the key switch ON.
2. Measure the voltage between the YL538 harness de-
ground and terminal 2 of the CN. D81 About 5 V Computer A defect.
5 fect (disconnection).
harness side. Replace
Repair or replace
Is it about 5 V?

1 COMPUTER A

84402826 - May 2011

4023H-35
 Main Unit-side Trouble

Diagnostic Trouble Code: 7065 Boom-up Pilot Pressure Sensor Signal

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

84402826 - May 2011

4023H-36
 Main Unit-side Trouble

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Measure the voltage between the WL432 or WL430
ground and terminal 1 of the CN. D53 About 5 V harness defect (dis-
10 Go to Step 11
harness side. connection). Repair
or replace
Is it about 5 V?
1. Measure the voltage between the
ground and terminal 2 of the CN. 120 0.25 V or Computer B defect. GW444 harness de-
11 harness side. fect (disconnection).
higher Replace
Repair or replace
Is it 0.25 V or higher?

84402826 - May 2011

4023H-37
 Main Unit-side Trouble

Diagnostic Trouble Code: 7066 Bucket-close Pilot Pressure Sensor

Signal Abnormality
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7067 is displayed. Go to Step 2
Is diagnostic trouble code: 7067 displayed?
1. Inspect the connection status of each
connector.
2 2. Check whether diagnostic trouble code: Go to Step 3
7067 is displayed.
Is diagnostic trouble code: 7067 displayed?
1. Check the bucket-close pilot pressure
sensor 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. D55.
WL431 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. D55
harness side.
Is it about 5 V?
1. Measure the voltage between the
ground and terminal 2 of the CN. D55 4.75 V or LR446 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. D55 0.25 V or Computer B defect. BL451 or BL450 har-
6 harness side. ness defect (short).
lower Replace
Replace
Is it 0.25 V or lower?
Inspect the bucket-close pilot pressure sen-
sor.
1. Turn the key switch OFF.
Bucket-close pilot
2. Disconnect CN. D55. About 10
7 Go to Step 8 pressure sensor de-
3. Measure the resistance between termi- kΩ
fect. Replace
nals 1 and 3 of the CN. D55 bucket-
close 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. D55 WL431, WL430, or
8 harness side. LR446 harness de- Go to Step 9
2. Inspect for continuity between the fect (short). Replace
ground and terminal 2 of the CN. D55
harness side.
Is there continuity?
1. Inspect for continuity between the BL451 or BL450 har-
ground and terminal 3 of the CN. D55 ness defect (discon-
9 harness side. Go to Step 10
nection). Repair or
Is there continuity? replace

84402826 - May 2011

4023H-38
 Main Unit-side Trouble

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Measure the voltage between the WL431 or WL430
ground and terminal 1 of the CN. D55 About 5 V harness defect (dis-
10 Go to Step 11
harness side. connection). Repair
or replace
Is it about 5 V?
1. Measure the voltage between the
ground and terminal 2 of the CN. D55 0.25 V or Computer B defect. LR446 harness de-
11 harness side. fect (disconnection).
higher Replace
Repair or replace
Is it 0.25 V or higher?

84402826 - May 2011

4023H-39
 Main Unit-side Trouble

Diagnostic Trouble Code: 7200 Swing Brake Solenoid Signal

Abnormality
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7200 is displayed. Go to Step 2
Is diagnostic trouble code: 7200 displayed?
1. Inspect the connection status of each
connector.
2. Inspect the fusible link F1 (65 A) fuse
and fuse box F13 (10 A) fuse to see if
2 either is blown. Go to Step 3
3. Check whether diagnostic trouble code:
7200 is displayed.
Is diagnostic trouble code: 7200 displayed?
Inspect the swing brake solenoid.
1. Turn the key switch OFF and disconnect
CN. D60.
Swing brake solenoid
3 2. Measure the resistance between termi- 34 Ω - 47 Ω Go to Step 4
defect. Replace
nals 1 and 2 of the CN. D60 swing brake
solenoid side.
Is it 34 Ω - 47 Ω?
Inspect for shorts.
1. Turn the key switch ON.
2. Measure the voltage between the W800 harness defect
4 0V Go to Step 5
ground and terminal 2 of the CN. D60 (short). Replace
harness side.
Is it 0 V?
1. Turn the key switch OFF.
2. Inspect for continuity between the R181, GR180, R105,
5 ground and terminal 1 of the CN. D60 or R104 harness de- Go to Step 6
harness side. fect (short). Replace
Is there continuity?
Inspect for disconnection.
W800 harness defect
Inspect for continuity between the ground
6 Go to Step 7 (disconnection). Re-
and terminal 2 of the CN. D60 harness side.
pair or replace
Is there continuity?
1. Turn the key switch ON.
2. Measure the voltage between the R181, GR180, R105,
ground and terminal 1 of the CN. D60 24 V Computer A defect. or R104 harness de-
7
harness side. Replace fect (disconnection).
Repair or replace
Is it 24 V?

84402826 - May 2011

4023H-40
 Main Unit-side Trouble

1 COMPUTER A 6 FUSE CONT 11 RELAY KEY ON

2 ENGINE COMPUTER 7 SWING BRAKE 12 FUSIBLE LINK FUSE BOX
PRESS. SENSOR (PILOT
3 8 RELAY BATTERY 13 KEY SWITCH
SWING)
PRESS. SENSOR (PILOT UP-
4 9 BATTERY (24 V)
PER)
5 CRANK ANGLE SENSOR 10 FUSIBLE LINK BACK UP

a CAN COMMUNICATION

84402826 - May 2011

4023H-41
 Main Unit-side Trouble

Diagnostic Trouble Code: 7201 Travel High-speed Solenoid Signal

Abnormality
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7201 is displayed. Go to Step 2
Is diagnostic trouble code: 7201 displayed?
1. Inspect the connection status of each
connector.
2. Inspect the fusible link F1 (65 A) fuse
and fuse box F13 (10 A) fuse to see if
2 either is blown. Go to Step 3
3. Check whether diagnostic trouble code:
7201 is displayed.
Is diagnostic trouble code: 7201 displayed?
Inspect the travel high-speed solenoid.
1. Turn the key switch OFF and disconnect
CN. D61. Travel high-speed
3 2. Measure the resistance between ter- 34 Ω - 47 Ω Go to Step 4 solenoid defect. Re-
minals 1 and 2 of the CN. D61 travel place
high-speed solenoid side.
Is it 34 Ω - 47 Ω?
Inspect for shorts.
1. Turn the key switch ON.
2. Measure the voltage between the L801 harness defect
4 0V Go to Step 5
ground and terminal 2 of the CN. D61 (short). Replace
harness side.
Is it 0 V?
1. Turn the key switch OFF.
2. Inspect for continuity between the R183, GR180,
ground and terminal 1 of the CN. D61 R105a, R104, or
5 Go to Step 6
harness side. R105 harness defect
(short). Replace
Is there continuity?
Inspect for disconnection.
L801 harness defect
Inspect for continuity between the ground
6 Go to Step 7 (disconnection). Re-
and terminal 2 of the CN. D61 harness side.
pair or replace
Is there continuity?
1. Turn the key switch ON. R183, GR180,
2. Measure the voltage between the R105a, R104, or
ground and terminal 1 of the CN. D61 24 V Computer A defect.
7 R105 harness defect
harness side. Replace
(disconnection). Re-
Is it 24 V? pair or replace

84402826 - May 2011

4023H-42
 Main Unit-side Trouble

1 COMPUTER A 5 FUSE CONT 9 FUSE KEY

2 ENGINE COMPUTER 6 2 STAGE TRAVEL 10 RELAY KEY ON
PRESS. SENSOR (PILOT
3 7 RELAY BATTERY 11 FUSIBLE LINK FUSE BOX
TRAVEL)
4 CRANK ANGLE SENSOR 8 BATTERY (24 V) 12 KEY SWITCH

a CAN COMMUNICATION

84402826 - May 2011

4023H-43
 Main Unit-side Trouble

Diagnostic Trouble Code: 7202 Pressure Boost Solenoid Signal

Abnormality
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7202 is displayed. Go to Step 2
Is diagnostic trouble code: 7202 displayed?
1. Inspect the connection status of each
connector.
2. Inspect the fusible link F1 (65 A) fuse
and fuse box F13 (10 A) fuse to see if
2 either is blown. Go to Step 3
3. Check whether diagnostic trouble code:
7202 is displayed.
Is diagnostic trouble code: 7202 displayed?
Inspect the pressure boost solenoid.
1. Turn the key switch OFF and disconnect
CN. D62.
Pressure boost sole-
3 2. Measure the resistance between termi- 34 Ω - 47 Ω Go to Step 4
noid defect. Replace
nals 1 and 2 of the CN. D62 pressure
boost solenoid side.
Is it 34 Ω - 47 Ω?
Inspect for shorts.
1. Turn the key switch ON.
2. Measure the voltage between the Y802 harness defect
4 0V Go to Step 5
ground and terminal 2 of the CN. D62 (short). Replace
harness side.
Is it 0 V?
1. Turn the key switch OFF.
2. Inspect for continuity between the R183, GR180, R105,
5 ground and terminal 1 of the CN. D62 or R104 harness de- Go to Step 6
harness side. fect (short). Replace
Is there continuity?
Inspect for disconnection.
Y802 harness defect
Inspect for continuity between the ground
6 Go to Step 7 (disconnection). Re-
and terminal 2 of the CN. D62 harness side.
pair or replace
Is there continuity?
1. Turn the key switch ON.
2. Measure the voltage between the R183, GR180, R105,
ground and terminal 1 of the CN. D62 24 V Computer A defect. or R104 harness de-
7
harness side. Replace fect (disconnection).
Repair or replace
Is it 24 V?

84402826 - May 2011

4023H-44
Main Unit-side Trouble

84402826 - May 2011

4023H-45
 Main Unit-side Trouble

PRESS. SENSOR (PILOT

1 COMPUTER A 7 13 BATTERY (24 V)
TRAVEL)
PRESS. SWITCH (1ST OP-
2 ENGINE COMPUTER 8 14 BACK UP FUSIBLE LINK
TION)
PRESS. SWITCH (2ND OP-
3 THROTTLE VOL. 9 15 RELAY KEY ON
TION)
4 PRESS. SENSOR (P1) 10 FUSE CONT 16 MONITOR DISPLAY
5 PRESS. SENSOR (P2) 11 2 STAGE RELIEF 17 FUSIBLE LINK FUSE BOX
PRESS. SENSOR (PILOT UP-
6 12 RELAY BATTERY 18 KEY SWITCH
PER)

a CAN COMMUNICATION

84402826 - May 2011

4023H-46
 Main Unit-side Trouble

Diagnostic Trouble Code: 7203 Travel Alarm Buzzer Signal Abnormality

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. On the service support DIAG screen,
check whether diagnostic trouble code:
1 7203 (●) is displayed. Go to Step 2
Is diagnostic trouble code: 7203 (●) dis-
played?
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 travel alarm.
1. Turn the key switch OFF and disconnect
CN. D69.
2. Connect terminal 1 of the CN. D69 travel
Travel alarm defect.
3 alarm side to the negative terminal of Go to Step 4
Replace
the battery and terminal 2 to the positive
terminal, and inspect the operation of
the travel alarm.
Does the travel alarm sound?
Inspect for shorts.
1. Turn the key switch ON.
2. Measure the voltage between the WL807 harness de-
4 0V Go to Step 5
ground and terminal 1 of the CN. D69 fect (short). Replace
harness side.
Is it 0 V?
1. Turn the key switch OFF.
2. Inspect for continuity between the GW215, R105, or
5 ground and terminal 2 of the CN. D69 R104 harness defect Go to Step 6
harness side. (short). Replace
Is there continuity?
Inspect for disconnection.
Inspect whether there is continuity between
WL807 harness de-
the ground and terminal 1 of the CN. D69
6 Go to Step 7 fect (disconnection).
harness side for 0.4 sec. after the key switch
Repair or replace
is turned ON.
Is there continuity?
1. Turn the key switch ON.
2. Measure the voltage between the GW215, R105, or
ground and terminal 2 of the CN. D69 24 V Computer A defect. R104 harness defect
7
harness side. Replace (disconnection). Re-
pair or replace
Is it 24 V?

84402826 - May 2011

4023H-47
 Main Unit-side Trouble

1 COMPUTER A 5 BACK UP FUSIBLE LINK 9 FUSIBLE LINK FUSE BOX

PRESS. SENSOR (PILOT
2 6 RELAY BATTERY 10 KEY SWITCH
TRAVEL)
3 FUSE CONT 7 RELAY KEY ON
4 TRAVEL ALARM 24 V, 107 dB 8 BATTERY (24 V)

84402826 - May 2011

4023H-48
 Main Unit-side Trouble

Diagnostic Trouble Code: 7204 Power Save Solenoid Signal Abnormality

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7204 is displayed. Go to Step 2
Is diagnostic trouble code: 7204 displayed?
1. Inspect the connection status of each
connector.
2. Inspect the fusible link F1 (65 A) fuse
and fuse box F13 (10 A) fuse to see if
2 either is blown. Go to Step 3
3. Check whether diagnostic trouble code:
7204 is displayed.
Is diagnostic trouble code: 7204 displayed?
Inspect the power save solenoid.
1. Turn the key switch OFF and disconnect
CN. D60.
Power save solenoid
3 2. Measure the resistance between termi- 34 Ω - 47 Ω Go to Step 4
defect. Replace
nals 1 and 2 of the CN. D60 power save
solenoid side.
Is it 34 Ω - 47 Ω?
Inspect for shorts.
1. Turn the key switch ON.
2. Measure the voltage between the G812 harness defect
4 0V Go to Step 5
ground and terminal 2 of the CN. D60 (short). Replace
harness side.
Is it 0 V?
1. Turn the key switch OFF.
2. Inspect for continuity between the R184, GR180, R105,
5 ground and terminal 1 of the CN. D60 or R104 harness de- Go to Step 6
harness side. fect (short). Replace
Is there continuity?
Inspect for disconnection.
G812 harness defect
Inspect for continuity between the ground
6 Go to Step 7 (disconnection). Re-
and terminal 2 of the CN. D60 harness side.
pair or replace
Is there continuity?
1. Turn the key switch ON.
2. Measure the voltage between the R184, GR180, R105,
ground and terminal 1 of the CN. D60 24 V Computer A defect. or R104 harness de-
7
harness side. Replace fect (disconnection).
Repair or replace
Is it 24 V?

84402826 - May 2011

4023H-49
Main Unit-side Trouble

84402826 - May 2011

4023H-50
 Main Unit-side Trouble

1 COMPUTER A 6 CRANK ANG (MRE) SENSOR 11 RELAY BATTERY

2 ENGINE COMPUTER 7 FUSE CONT 12 FUSIBLE LINK BACK UP
PRESS. SENSOR (PILOT
3 8 POWER SAVE 13 FUSIBLE LINK FUSE BOX
SWING)
PRESS. SENSOR (PILOT UP-
4 9 RELAY BATTERY 14 KEY SWITCH
PER)
PRESS. SENSOR (PILOT
5 10 BATTERY (24 V) 15 COMPUTER B
TRAVEL)

a CAN COMMUNICATION

84402826 - May 2011

4023H-51
 Main Unit-side Trouble

Diagnostic Trouble Code: 7205 Feed Pump Relay Signal Abnormality　

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7205 is displayed. Go to Step 2
Is diagnostic trouble code: 7205 displayed?
1. Inspect the connection status of each
connector.
2. Inspect the fusible link F (65 A) fuse and
2 fuse box F19 (30 A) fuse to see if either Go to Step 3
is blown.
Are 1 and 2 above both OK?
Inspect the feed pump relay.
1. Turn the key switch OFF and disconnect
CN. D83-1.
Feed pump relay de-
3 2. Inspect for continuity between terminals Go to Step 4
fect. Replace
1 and 2 of the CN. D83-1 feed pump
relay side.
Is there continuity?
Inspect for shorts.
VR845, W250,
1. Install CN. D83-1.
VR894, L846, or
2. Inspect for continuity between the
4 R105 harness defect Go to Step 5
ground and terminal 1 of the CN. D83-1
(short). Replace
harness side.
Is there continuity?
Inspect for disconnection.
VR845, W250,
1. Turn the key switch ON.
VR894, L846, or
2. Inspect for continuity between the Computer B defect.
5 R105 harness defect
ground and terminal 1 of the CN. D83-1 Replace
(disconnection). Re-
harness side.
pair or replace
Is there continuity?

84402826 - May 2011

4023H-52
 Main Unit-side Trouble

1 RELAY BATTERY 4 RELAY STOP 7 REFUEL PUMP

2 FUSIBLE LINK FUSE BOX 5 MANUAL/AUTO 8 MONITOR DISPLAY
3 RELAY PUMP 6 ALARM 24V,107dB

84402826 - May 2011

4023H-53
 Main Unit-side Trouble

Diagnostic Trouble Code: 7206 Option Line Switchover Solenoid Signal

Abnormality
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7206 is displayed. Go to Step 2
Is diagnostic trouble code: 7206 displayed?
1. Inspect the connection status of each
connector.
2. Inspect the fusible link F (65 A) fuse and
fuse box F20 (10 A) fuse to see if either
2 is blown. Go to Step 3
3. Check whether diagnostic trouble code:
7206 is displayed.
Is diagnostic trouble code: 7206 displayed?
Inspect the option line switchover solenoid.
1. Turn the key switch OFF and disconnect
CN. 162. Option line
3 2. Measure the resistance between termi- 34 Ω - 47 Ω Go to Step 4 switchover solenoid
nals 1 and 2 of the CN. 162 option line defect. Replace
switchover solenoid side.
Is it 34 Ω - 47 Ω?
Inspect for shorts.
1. Turn the key switch ON.
2. Measure the voltage between the LY806 harness de-
4 0V Go to Step 5
ground and terminal 2 of the CN. 162 fect (short). Replace
harness side.
Is it 0 V?
1. Turn the key switch OFF.
2. Inspect for continuity between the WL260 or SR105
5 ground and terminal 1 of the CN. 162 harness defect Go to Step 6
harness side. (short). Replace
Is there continuity?
Inspect for disconnection.
LY806 harness de-
Inspect for continuity between the ground
6 Go to Step 7 fect (disconnection).
and terminal 2 of the CN. 162 harness side.
Repair or replace
Is there continuity?
1. Turn the key switch ON.
2. Measure the voltage between the WL260 or SR105
ground and terminal 1 of the CN. 162 24 V Computer A defect. harness defect (dis-
7
harness side. Replace connection). Repair
or replace
Is it 24 V?

84402826 - May 2011

4023H-54
Main Unit-side Trouble

1 RELAY BATTERY 3 OPTION SELECT

2 FUSIBLE LINK FUSE BOX 4 CONTROLLER A

84402826 - May 2011

4023H-55
 Main Unit-side Trouble

Diagnostic Trouble Code: 7207 Free Swing Solenoid Signal Abnormality

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7207 is displayed. Go to Step 2
Is diagnostic trouble code: 7207 displayed?
1. Inspect the connection status of each
connector.
2. Inspect the fusible link F (65 A) fuse and
fuse box F6 (10 A) fuse to see if either
2 is blown. Go to Step 3
3. Check whether diagnostic trouble code:
7207 is displayed.
Is diagnostic trouble code: 7207 displayed?
Inspect the free swing solenoid.
1. Turn the key switch OFF and disconnect
CN. D64.
Free swing solenoid
3 2. Measure the resistance between termi- 34 Ω - 47 Ω Go to Step 4
defect. Replace
nals 1 and 2 of the CN. D64 free swing
solenoid side.
Is it 34 Ω - 47 Ω?
Inspect for shorts.
1. Turn the key switch ON.
2. Measure the voltage between the Br803 harness defect
4 0V Go to Step 5
ground and terminal 2 of the CN. D64 (short). Replace
harness side.
Is it 0 V?
1. Turn the key switch OFF.
2. Inspect for continuity between the R187, GR180, or
5 ground and terminal 1 of the CN. D64 SR105 harness de- Go to Step 6
harness side. fect (short). Replace
Is there continuity?
Inspect for disconnection.
Br803 harness defect
Inspect for continuity between the ground
6 Go to Step 7 (disconnection). Re-
and terminal 2 of the CN. D64 harness side.
pair or replace
Is there continuity?
1. Turn the key switch ON.
2. Measure the voltage between the R187, GR180, or
ground and terminal 1 of the CN. D64 24 V Computer A defect. SR105 harness de-
7
harness side. Replace fect (disconnection).
Repair or replace
Is it 24 V?

84402826 - May 2011

4023H-56
 Main Unit-side Trouble

Diagnostic Trouble Code: 7210 Liftcrane Buzzer Signal Abnormality

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7210 is displayed. Go to Step 2
Is diagnostic trouble code: 7210 displayed?
1. Inspect the connection status of each
connector.
2. Inspect the fusible link F1 (65 A) fuse
2 and fuse box F22 (15 A) fuse to see if Go to Step 3
either is blown.
Are 1 and 2 above both OK?
Inspect the liftcrane buzzer.
1. Turn the key switch OFF and disconnect
CN. CR5 and CN. CR6.
2. Connect the terminal of the CN. CR6
liftcrane buzzer side to the negative ter-
Liftcrane buzzer de-
3 minal of the battery and the terminal of Go to Step 4
fect. Replace
the CN. CR5 liftcrane buzzer side to the
positive terminal, and inspect the oper-
ation of the liftcrane buzzer.

Does the liftcrane buzzer sound?

Inspect for shorts.
1. Turn the key switch ON.
2. Measure the voltage between the VG815 harness de-
4 0V Go to Step 5
ground and the terminal of the CN. CR6 fect (short). Replace
harness side.
Is it 0 V?
1. Turn the key switch OFF.
2. Inspect for continuity between the BrW237, BrW236,
ground and the terminal of the CN. CR5 R111, R106, or
5 Go to Step 6
harness side. R105 harness defect
(short). Replace
Is there continuity?
Inspect for disconnection. BrW237, BrW236,
Turn the key switch ON and measure the R111, R106, or R105
6 voltage between the ground and the terminal About 24 V Go to Step 7 harness defect (dis-
of the CN. CR5 harness side. connection). Repair
Is it about 24 V? or replace
1. Turn the key switch OFF and disconnect
CN. CR4.
2. Inspect whether there is continuity be- VG815 harness de-
tween the terminal of the CN. CR6 har- Computer B defect.
7 fect (disconnection).
ness side and terminal 6 of the CN. CR4 Replace
Repair or replace
harness side.
Is there continuity?

84402826 - May 2011

4023H-57
 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?

84402826 - May 2011

4023H-58
 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

84402826 - May 2011

4023H-59
 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

84402826 - May 2011

4023H-60
 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

84402826 - May 2011

4023H-61
 Main Unit-side Trouble

PRESS. SENSOR (PILOT

1 COMPUTER A 4 7 ENGINE COMPUTER
TRAVEL)
PRESS. SENSOR (PILOT
2 5 CRANK ANGLE SENSOR
SWING)
PRESS. SENSOR (PILOT UP-
3 6 P1 FLOW
PER)

a CAN COMMUNICATION

1 COMPUTER A 3 WATER TEMP. SENSOR

2 ENGINE COMPUTER

84402826 - May 2011

4023H-62
 Main Unit-side Trouble

Diagnostic Trouble Code: 7242 Fan Proportional Valve Signal

Abnormality
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7242 is displayed. Go to Step 2
Is diagnostic trouble code: 7242 displayed?
1. Inspect the connection status of each
connector.
2 2. Check whether diagnostic trouble code: Go to Step 3
7242 is displayed.
Is diagnostic trouble code: 7242 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
7242 is displayed.
Is diagnostic trouble code: 7242 displayed?
Inspect for shorts.
1. Turn the key switch OFF and disconnect
CN. H1.
YG944 harness de- Computer B defect.
4 2. Inspect for continuity between the
fect (short). Replace Replace
ground and terminal 1 of the CN. H1
harness side.
Is there continuity?
Inspect the fan proportional valve.
1. Turn the key switch OFF.
2. Disconnect CN. H1. Fan proportional
5 3. Inspect for continuity between terminals Go to Step 6 valve defect. Re-
1 and 2 of the CN. H1 fan proportional place
valve side.
Is there continuity?
Inspect for disconnection.
YG494 harness de-
1. Disconnect CN. A54.
fect (disconnection)
2. Inspect for continuity between terminal
6 Go to Step 7 between CN. H1 and
1 of the CN. H1 female side and terminal
CN. A54. Repair or
5 of the CN. A54 female side.
replace
Is there continuity?
BY495 harness de-
1. Inspect for continuity between terminal fect (disconnection)
2 of the CN. H1 female side and terminal between CN. H1 and
7 15 of the CN. A54 female side. Go to Step 8
CN. A54. Repair or
Is there continuity? replace

1. Disconnect CN. A7. W908 harness defect

2. Inspect for continuity between terminal (disconnection) be-
8 5 of the CN. A54 male side and terminal Go to Step 9 tween CN. A54 and
1 of the CN. A7 female side. CN. A7. Repair or re-
Is there continuity? place
1. Inspect for continuity between terminal WB909 harness de-
15 of the CN. A54 male side and termi- fect (disconnection)
Computer B defect.
9 nal 4 of the CN. A7 female side. between CN. A54
Replace
and CN. A7. Repair
Is there continuity? or replace

84402826 - May 2011

4023H-63
 Main Unit-side Trouble

Diagnostic Trouble Code: 7246 2 Pumps Flow Solenoid Signal

Abnormality
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7246 is displayed. Go to Step 2
Is diagnostic trouble code: 7246 displayed?
1. Inspect the connection status of each
connector.
2. Inspect the fusible link F (65 A) fuse and
fuse box F20 (10 A) fuse to see if either
2 is blown. Go to Step 3
3. Check whether diagnostic trouble code:
7246 is displayed.
Is diagnostic trouble code: 7246 displayed?
Inspect the 2 pumps flow solenoid.
1. Turn the key switch OFF and disconnect
CN. 163.
2 pumps flow sole-
3 2. Measure the resistance between termi- 34 Ω - 47 Ω Go to Step 4
noid defect. Replace
nals 1 and 2 of the CN. 163 2 pumps
flow solenoid side.
Is it 34 Ω - 47 Ω?
Inspect for shorts.
1. Turn the key switch ON.
2. Measure the voltage between the YR805 harness de-
4 0V Go to Step 5
ground and terminal 3 of the CN. 163 fect (short). Replace
harness side.
Is it 0 V?
1. Turn the key switch OFF.
2. Inspect for continuity between the WL260, WL261, or
5 ground and terminal 1 of the CN. 163 SR105 harness de- Go to Step 6
harness side. fect (short). Replace
Is there continuity?
Inspect for disconnection.
YR805 harness de-
Inspect for continuity between the ground
6 Go to Step 7 fect (disconnection).
and terminal 3 of the CN. 163 harness side.
Repair or replace
Is there continuity?
1. Turn the key switch ON.
2. Measure the voltage between the WL260, WL261, or
ground and terminal 1 of the CN. 163 24 V Computer A defect. SR105 harness de-
7
harness side. Replace fect (disconnection).
Repair or replace
Is it 24 V?

84402826 - May 2011

4023H-64
Main Unit-side Trouble

1 RELAY BATTERY 3 OPTION 2SPEED

2 FUSIBLE LINK FUSE BOX 4 CONTROLLER A

84402826 - May 2011

4023H-65
 Main Unit-side Trouble

Diagnostic Trouble Code: 7247 Boom-down Proportional Valve Signal

Abnormality
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7247 is displayed. Go to Step 2
Is diagnostic trouble code: 7247 displayed?
1. Inspect the connection status of each
connector.
2 2. Check whether diagnostic trouble code: Go to Step 3
7247 is displayed.
Is diagnostic trouble code: 7247 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
7247 is displayed.
Is diagnostic trouble code: 7247 displayed?
Inspect for shorts.
1. Turn the key switch OFF and disconnect
CN. D41.
O902 harness defect Computer A defect.
4 2. Inspect for continuity between the
(short). Replace Replace
ground and terminal 1 of the CN. D41
harness side.
Is there continuity?
Inspect the boom-down proportional valve.
1. Turn the key switch OFF.
2. Disconnect CN. D41. Boom-down propor-
5 3. Inspect for continuity between terminals Go to Step 6 tional valve defect.
1 and 2 of the CN. D41 boom-down pro- Replace
portional valve side.
Is there continuity?
Inspect for disconnection.
O902 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. D41 female side and termi-
CN. D41. Repair or
nal 2 of the CN. A56 female side.
replace
Is there continuity?
O903 harness defect
Inspect for continuity between terminal 2 of
(disconnection) be-
the CN. D41 female side and terminal 10 of
7 Go to Step 8 tween CN. A56 and
the CN. A56 female side.
CN. D41. Repair or
Is there continuity?
replace
1. Disconnect CN. A3. O902 harness defect
2. Inspect for continuity between terminal (disconnection) be-
8 2 of the CN. A56 male side and terminal Go to Step 9 tween CN. A56 and
1 of the CN. A3 female side. CN. A3. Repair or re-
Is there continuity? place
O903 harness defect
Inspect for continuity between terminal 10 of
(disconnection) be-
the CN. A56 male side and terminal 4 of the Computer A defect.
9 tween CN. A56 and
CN. A3 female side. Replace
CN. A3. Repair or re-
Is there continuity?
place

84402826 - May 2011

4023H-66
Main Unit-side Trouble

1 CONTROLLER A
2 BOOM DOWN

84402826 - May 2011

4023H-67
 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

84402826 - May 2011

4023H-68
Main Unit-side Trouble

1 CONTROLLER B
2 ARM CLOSE

84402826 - May 2011

4023H-69
 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

84402826 - May 2011

4023H-70
Main Unit-side Trouble

1 CONTROLLER B
2 PROPORTIONAL S/V
3 OPT PRESS

84402826 - May 2011

4023H-71
 Main Unit-side Trouble

Diagnostic Trouble Code: 7251 Battery Control Relay Signal Abnormality

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7251 is displayed. Go to Step 2
Is diagnostic trouble code: 7251 displayed?
1. Inspect the connection status of each
connector.
2 Inspect the computer fuse (15 A) to see Go to Step 3
if it is blown.
Are 1 and 2 above both OK?
Inspect the battery control relay.
1. Turn the key switch OFF and disconnect
CN. A11.
Battery control relay
3 2. Inspect for continuity between terminals Go to Step 4
defect. Replace
1 and 2 of the CN. A11 battery control
relay side.
Is there continuity?
Inspect for shorts.
1. Install CN. A11.
W113, W112, W107,
2. Inspect for continuity between the
4 or W106 harness de- Go to Step 5
ground and terminal 1 of the CN. A11
fect (short). Replace
harness side.
Is there continuity?
Inspect for disconnection.
W113, W112, W107,
1. Turn the key switch ON.
W106, or OG804 har-
2. Inspect for continuity between the Computer A defect.
5 ness defect (discon-
ground and terminal 1 of the CN. A11 Replace
nection). Repair or
harness side.
replace
Is there continuity?

1 RELAY BATTERY 3 RELAY BATTERY RL

2 FUSE CONT 4 CONTROLLER A

84402826 - May 2011

4023H-72
 Main Unit-side Trouble

Diagnostic Trouble Code: 7252 Idle Stop Relay Signal Abnormality

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7252 is displayed. Go to Step 2
Is diagnostic trouble code: 7252 displayed?
1. Inspect the connection status of each
connector.
2. Inspect the fusible link F1 (65 A) fuse
2 and computer (15 A) fuse to see if either Go to Step 3
is blown.
Are 1 and 2 above both OK?
Inspect the idle stop relay.
1. Turn the key switch OFF and disconnect
CN. A12.
Idle stop relay defect.
3 2. Inspect for continuity between terminals Go to Step 4
Replace
1 and 2 of the CN. A12 idle stop relay
side.
Is there continuity?
Inspect for shorts.
1. Install CN. A12. W115, W114, W112,
2. Inspect for continuity between the W113, or W107 har-
4 Go to Step 5
ground and terminal 1 of the CN. A12 ness defect (short).
harness side. Replace
Is there continuity?
Inspect for disconnection.
W106, W107, W112,
1. Turn the key switch ON.
W113, W114, W115,
2. Inspect for continuity between the Computer B defect.
5 or LY824 harness de-
ground and terminal 1 of the CN. A12 Replace
fect (disconnection).
harness side.
Repair or replace
Is there continuity?

84402826 - May 2011

4023H-73
 Main Unit-side Trouble

1 RELAY BATTERY 3 RELAY IDLE STOP 5 KEY SWITCH

2 FUSE CONT 4 RELAY KEY ON 6 MONITOR DISPLAY

84402826 - May 2011

4023H-74
 Main Unit-side Trouble

Diagnostic Trouble Code: 7253 DPD Regeneration Request Output

Signal Abnormality
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7253 is displayed. Go to Step 2
Is diagnostic trouble code: 7253 displayed?
1. Inspect the connection status of each
connector.
2. Inspect the fusible link F (50 A) fuse and
2 fuse box F4 (10 A) fuse to see if either Go to Step 3
is blown.
Are 1 and 2 above both OK?
Inspect the DPF relay.
1. Turn the key switch OFF and disconnect
CN. A10. DPF relay defect.
3 Go to Step 4
2. Inspect for continuity between terminals Replace
1 and 2 of the CN. A10 DPF relay side.
Is there continuity?
Inspect for shorts.
1. Install CN. A10.
WR147, WR141, or
2. Inspect for continuity between the
4 WR140 harness de- Go to Step 5
ground and terminal 1 of the CN. A10
fect (short). Replace
harness side.
Is there continuity?
Inspect for disconnection.
WR147, WR141,
1. Turn the key switch ON.
WR140, or YL806
2. Inspect for continuity between the Computer A defect.
5 harness defect (dis-
ground and terminal 1 of the CN. A10 Replace
connection). Repair
harness side.
or replace
Is there continuity?

84402826 - May 2011

4023H-75
 Main Unit-side Trouble

1 FUSIBLE LINK BACK UP 3 RELAY DPF 5 ENGINE CONTROLLER

2 RELAY ECM 4 CONTROLLER A 6 RELAY BATTERY

84402826 - May 2011

4023H-76
 Main Unit-side Trouble

Diagnostic Trouble Code: 7400 Abnormally High Coolant Temperature

(105°C or higher)
Standard
Step Action Yes No
value
1. Start the engine and perform a warm-up
operation until the engine is fully
warmed up.
2. On the service support DIAG screen,
1 check whether diagnostic trouble code: Go to Step 2
7400 (●) is displayed.
Is diagnostic trouble code: 7400 (●) dis-
played?
2 Inspect the engine unit.

Diagnostic Trouble Code: 7401 Abnormally High Coolant Temperature

(110°C or higher)
Standard
Step Action Yes No
value
1. Start the engine and perform a warm-up
operation until the engine is fully
warmed up.
2. On the service support DIAG screen,
1 check whether diagnostic trouble code: Go to Step 2
7401 (●) is displayed.
Is diagnostic trouble code: 7401 (●) dis-
played?
2 Inspect the engine unit.

84402826 - May 2011

4023H-77
 Main Unit-side Trouble

Diagnostic Trouble Code: 7404 Abnormally High Oil Temperature (95°C

or higher)
Standard
Step Action Yes No
value
1. Start the engine and perform a warm-up
operation until the engine is fully
warmed up.
2. On the service support DIAG screen,
1 check whether diagnostic trouble code: Go to Step 2
7404 (●) is displayed.
Is diagnostic trouble code: 7404 (●) dis-
played?
2 Inspect the hydraulic oil temperature.

1 COMPUTER A
2 HYD. OIL TEMP SENSOR

84402826 - May 2011

4023H-78
 Main Unit-side Trouble

Diagnostic Trouble Code: 7405 Abnormally High Boost Temperature

(80°C or higher), 7406 Abnormally High Boost Temperature (90°C or
higher)
Standard
Step Action Yes No
value
1. Start the engine and perform a warm-up
operation until the engine is fully
warmed up.
2. On the service support DIAG screen,
1 check whether diagnostic trouble code Go to Step 2.
7405 (●) or 7406 (●) is displayed.
Is diagnostic trouble code 7405 (●) or 7406
(●) displayed?
2 Inspect the engine unit.

84402826 - May 2011

4023H-79
 Main Unit-side Trouble

Diagnostic Trouble Code: 7420 Abnormally Low Alternator Voltage

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. On the service support DIAG screen,
check whether diagnostic trouble code:
1 7420 (●) is displayed. Go to Step 2
Is diagnostic trouble code: 7420 (●) dis-
played?
1. Inspect the connection status of each
2 connector. Go to Step 3
Is 1 above OK?
Inspect for shorts.
1. Turn the key switch OFF and disconnect
CN. D14.
Br515 harness defect
3 2. Inspect for continuity between the Go to Step 4
(short). Replace
ground and terminal 2 of the CN. D14
harness side.
Is there continuity?
Inspect the alternator.
1. Start the engine.
2. Measure the voltage between the 10 V or Alternator defect.
4 Go to Step 5
ground and terminal 2 of the CN. D14 lower Replace
alternator side.
Is it 10 V or lower?
Inspect for disconnection.
1. Turn the key switch OFF.
2. Connect CN. D14.
3. Disconnect CN. A1. Br515 harness defect
10 V or Computer A defect.
5 4. Start the engine. (disconnection). Re-
lower Replace
5. Measure the voltage between the pair or replace
ground and terminal 8 of the CN. A1
harness side.
Is it 10 V or lower?

84402826 - May 2011

4023H-80
Main Unit-side Trouble

84402826 - May 2011

4023H-81
 Main Unit-side Trouble

1 COMPUTER A 6 FUSIBLE LINK FUSE BOX 11 STARTER MOTOR

2 RELAY STARTER CUT 7 FUSIBLE LINK BACK UP 12 ALTERNATOR
3 BATTERY (24 V) 8 FUSIBLE LINK SAFETY RL 13 RELAY STARTER
4 RELAY BATTERY 9 RELAY KEY ON
5 FUSE CONT 10 KEY SWITCH

84402826 - May 2011

4023H-82
 Main Unit-side Trouble

Diagnostic Trouble Code: 7421 Coolant Level Reduction

Standard
Step Action Yes No
value
1. Check that the "LOW COOLANT" dis-
play appears.
2. Fill with coolant.
3. Turn the key switch ON.
1 4. On the service support DIAG screen, Go to Step 2
check whether diagnostic trouble code:
7421 (●) is displayed.
Is diagnostic trouble code: 7421 (●) dis-
played?
1. Inspect the connection status of each
connector.
2. On the service support DIAG screen,
2 check whether diagnostic trouble code: Go to Step 3
7421 (●) is displayed.
Is diagnostic trouble code: 7421 (●) dis-
played?
Inspect the coolant level switch.
1. Turn the key switch OFF and disconnect
CN. D79.
Coolant level switch Computer A defect.
3 2. Inspect for continuity between terminals
defect. Replace Replace
1 and 2 of the CN. D79 coolant level
switch side.
Is there continuity?

1 COMPUTER A
LEVEL SWITCH (RESERVE
2
TANK)

84402826 - May 2011

4023H-83
 Main Unit-side Trouble

Diagnostic Trouble Code: 7422 Abnormally Low Engine Oil Pressure

Standard
Step Action Yes No
value
1. Start the engine and wait for 30 sec.
2. On the service support DIAG screen,
check whether diagnostic trouble code:
1 7422 (●) is displayed. Go to Step 2
Is diagnostic trouble code: 7422 (●) dis-
played?
2 Inspect the engine unit.

1 COMPUTER A
2 ENGINE COMPUTER
3 OIL PRESS SENSOR

84402826 - May 2011

4023H-84
 Main Unit-side Trouble

Diagnostic Trouble Code: 7423 Air Cleaner Clogging

Standard
Step Action Yes No
value
1. Check that the "AIR FILTER" display ap-
pears.
2. Clean or replace the air cleaner ele-
ment.
3. Start the engine and wait for 10 sec.
1 4. On the service support DIAG screen, Go to Step 2
check whether diagnostic trouble code:
7423 (●) is displayed.
Is diagnostic trouble code: 7423 (●) dis-
played?
1. Inspect the connection status of each
connector.
2. Check whether diagnostic trouble code:
2 7423 (●) is displayed. Go to Step 3
Is diagnostic trouble code: 7423 (●) dis-
played?
Inspect the air cleaner clog pressure switch.
1. Turn the key switch OFF and disconnect
CN. D80. Air cleaner clog pres-
3 Inspect for continuity between terminals sure switch defect. Go to Step 4
1 and 2 of the CN. D80 air cleaner clog Replace
pressure switch side.
Is there continuity?
Inspect for shorts.
1. Inspect for continuity between the
LW533 harness de- Computer A defect.
4 ground and terminal 2 of the CN. D80
fect (short). Replace Replace
harness side.
Is there continuity?

1 COMPUTER A
PRESS. SWITCH (AIR
2
CLEANER)

84402826 - May 2011

4023H-85
 Main Unit-side Trouble

Diagnostic Trouble Code: 7424 Return Filter Clogging (breaker

specifications)
Standard
Step Action Yes No
value
1. Check that the "HYD. OIL FILTER" dis-
play appears.
2. Replace the return filter.
1 3. Turn the key switch ON. Go to Step 2
4. Check whether diagnostic trouble code:
7424 is displayed.
Is diagnostic trouble code: 7424 displayed?
1. Inspect the connection status of each
connector and ground.
2 2. Check whether diagnostic trouble code: Go to Step 3
7424 is displayed.
Is diagnostic trouble code: 7424 displayed?
Inspect the return filter clog switch.
1. Turn the key switch OFF and disconnect
CN. D81. Return filter clog
Computer A defect.
3 2. Inspect for continuity between terminals pressure switch de-
Replace
1 and 2 of the CN. D81 return filter clog fect. Replace
switch side.
Is there continuity?

1 COMPUTER A
PRESS. SWITCH (FILTER IN-
2
DICATOR)

84402826 - May 2011

4023H-86
 Main Unit-side Trouble

Diagnostic Trouble Code: 7425 Fuel Density Error Signal Abnormality

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7425 is displayed. Go to Step 2
Is diagnostic trouble code: 7425 displayed?
1. View the fuel density data on the service
support CHK-MAIN-11 screen.
2. Turn the key switch OFF, but just before
doing so, record the fuel density data.
3. Turn the key switch OFF. The fuel is not appro-
4. Turn the key switch ON, and record the priate. Go to Step 4
2 fuel density data at this time. If the fuel density is a Go to Step 3
5. Compare the data from 2 and 4 above to borderline value, per-
check whether the difference between form fuel analysis.
the values has dropped by 0.01 g/cm3
or more.
Has the value dropped by 0.01 g/cm3 or
more?
1. While the diagnostic trouble code is dis-
played, turn the key switch OFF.
2. After checking that the display has
turned off, turn the key switch ON again.
3. When the diagnostic trouble code is dis- Check again from the
3 played, wait for at least 5 min. End
beginning of the step.
4. Turn the key switch OFF, turn the igni-
tion key ON again, and check whether
the error code is displayed.
Has the error code disappeared?
1. Check whether the customer has
changed gas station or fuel manufac- Have the customer If the fuel density is
turer. return to the previous clearly outside the
4
gas station or fuel standard, go to Step
Has the customer changed gas station or manufacturer. 5
fuel manufacturer?
1. Drain the fuel.
2. Check whether the fuel density sensor Check for fuel density
5 is dirty. Clean
sensor trouble.
Is the fuel density sensor dirty?

84402826 - May 2011

4023H-87
 Main Unit-side Trouble

Diagnostic Trouble Code: 7600 CAN Bus Abnormality

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7600 is displayed. Go to Step 2
Is diagnostic trouble code: 7600 displayed?
1. Inspect the connection status of each
connector.
2 2. Check whether diagnostic trouble code: Go to Step 3
7600 is displayed.
Is diagnostic trouble code: 7600 displayed?
Inspect for shorts.
1. Turn the key switch OFF and disconnect
P040, P042, P044,
CN. 50.
P046, P048, or
3 2. Inspect for continuity between the Go to Step 4
P050 harness defect
ground and terminal A of the CN. 50
(short). Replace
harness side.
Is there continuity?
1. Inspect for continuity between the PG041, PG043,
ground and terminal B of the CN. 50 PG045, PG047,
4 harness side. PG049, or P051 har- Go to Step 5
ness defect (short).
Is there continuity? Replace
P040, P042, P044,
P046, P048, P050,
1. Inspect for continuity between terminals PG041, PG043,
5 A and B of the CN. 50 harness side. PG045, PG047, Go to Step 6
Is there continuity? PG049, or P051 har-
ness defect (short).
Replace
Inspect the ECM, computer A, computer B,
and computer S units.
1. Connect CN. 50.
2. Disconnect CN. A0 and turn the key ECM defect. Re-
6 Go to Step 7
switch ON. place
3. Check whether diagnostic trouble code:
7600 is displayed.
Is diagnostic trouble code: 7600 displayed?
1. Turn the key switch OFF and connect
CN. A0.
2. Disconnect CN. C2 and turn the key
switch ON. Computer S defect. Computer A defect.
7
3. Check whether diagnostic trouble code: Replace Replace
7600 is displayed.
Is diagnostic trouble code: 7600 displayed?

84402826 - May 2011

4023H-88
 Main Unit-side Trouble

Diagnostic Trouble Code: 7601 Monitor Communication Abnormality

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7601 is displayed. Go to Step 2
Is diagnostic trouble code: 7601 displayed?
1. Inspect the connection status of each
connector.
2 2. Check whether diagnostic trouble code: Go to Step 3
7601 is displayed.
Is diagnostic trouble code: 7601 displayed?
Inspect for disconnection.
1. Turn the key switch OFF and disconnect
CN. A2 and CN. C1. WL061 harness de-
3 2. Inspect for continuity between terminal Go to Step 4 fect (disconnection).
10 of the CN. A2 harness side and ter- Repair or replace
minal 8 of the CN. C1 harness side.
Is there continuity?
1. Inspect for continuity between terminal
3 of the CN. A2 harness side and termi- W060 harness defect
4 nal 9 of the CN. C1 harness side. Go to Step 5 (disconnection). Re-
pair or replace
Is there continuity?
1. Turn the key switch ON.
2. Check whether diagnostic trouble code: Computer A defect. Monitor defect. Re-
5 7601 is displayed. Replace place
Is diagnostic trouble code: 7601 displayed?

1 COMPUTER A
2 MONITOR

a CAN COMMUNICATION

84402826 - May 2011

4023H-89
 Main Unit-side Trouble

Diagnostic Trouble Code: 7602 ECM Communication Abnormality

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7602 is displayed. Go to Step 2
Is diagnostic trouble code: 7602 displayed?
1. Inspect the connection status of each
connector.
2 2. Check whether diagnostic trouble code: Go to Step 3
7602 is displayed.
Is diagnostic trouble code: 7602 displayed?
1. Check whether diagnostic trouble codes
7603 and 7604 are displayed at the
same time. Inspect the connec-
3 Go to Step 4
tion status of CN. C2.
Are diagnostic trouble codes 7603 and 7604
displayed at the same time?
Inspect for disconnection.
1. Turn the key switch OFF and disconnect
P040 or P042 har-
CN. C2 and CN. A0.
ness defect (discon-
4 2. Inspect for continuity between terminal Go to Step 5
nection). Repair or
6 of the CN. C2 harness side and termi-
replace
nal 18 of the CN. A0 harness side.
Is there continuity?
1. Inspect for continuity between terminal PG041 or PG043
14 of the CN. C2 harness side and ter- ECM defect. Re- harness defect (dis-
5 minal 37 of the CN. A0 harness side. place connection). Repair
Is there continuity? or replace

84402826 - May 2011

4023H-90
 Main Unit-side Trouble

Diagnostic Trouble Code: 7604 Computer B Communication Abnormality

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7604 is displayed. Go to Step 2
Is diagnostic trouble code: 7604 displayed?
1. Inspect the connection status of each
connector.
2. Check whether diagnostic trouble codes
7602 and 7603 are displayed at the Inspect the connec-
2 Go to Step 3
same time. tion status of CN. C2.
Are diagnostic trouble codes 7602 and 7603
displayed at the same time?
Inspect for disconnection.
1. Turn the key switch OFF and disconnect
P040 or P048 har-
CN. C2 and CN. C7.
ness defect (discon-
3 2. Inspect for continuity between terminal Go to Step 4
nection). Repair or
6 of the CN. C2 harness side and termi-
replace
nal 8 of the CN. C7 harness side.
Is there continuity?
1. Inspect for continuity between terminal PG041 or PG049
14 of the CN. C2 harness side and ter- Computer S defect. harness defect (dis-
4 minal 16 of the CN. C7 harness side. Replace connection). Repair
Is there continuity? or replace

84402826 - May 2011

4023H-91
 Main Unit-side Trouble

Diagnostic Trouble Code: 7605 ECM Mismatch

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7605 is displayed. Go to Step 2
Is diagnostic trouble code: 7605 displayed?
1. Check for an error on the service sup-
port model selection screen. Correctly set the
2 Go to Step 3
model selection.
Is the model selection screen correct?
1. Check that the ECM which matches the Replace with an ECM
model is installed. ECM defect. Re-
3 that matches the
place
Does the ECM match the model? model.

1 COMPUTER A
2 ENGINE COMPUTER

a CAN COMMUNICATION

84402826 - May 2011

4023H-92
 Main Unit-side Trouble

Diagnostic Trouble Code: 7606 EEPROM Data Abnormality

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. On the service support DIAG screen,
check whether diagnostic trouble code:
1 7606 (●) is displayed. Go to Step 2
Is diagnostic trouble code: 7606 (●) dis-
played?
Rewriting of the com-
1. Check whether rewriting was performed puter changed the
on computer A before the diagnostic used space of the
trouble code was displayed. EEPROM. Computer A defect.
2
Was rewriting performed on computer A be- Turn the key switch Replace
fore the diagnostic trouble code was dis- OFF, and then turn
played? the key switch ON
again.

84402826 - May 2011

4023H-93
 Main Unit-side Trouble

Diagnostic Trouble Code: 7607 Computer C Communication Abnormality

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7607 is displayed. Go to Step 2
Is diagnostic trouble code: 7607 displayed?
1. Inspect the connection status of each
connector.
2. Check whether diagnostic trouble codes
7602, 7603, 7604 are displayed at the Inspect the connec-
2 Go to Step 3
same time. tion status of CN. A2.
Are diagnostic trouble codes 7602, 7603,
7604 displayed at the same time?
Inspect for disconnection.
1. Turn the key switch OFF and disconnect
P040 or V050 har-
CN. A2 and CN. A23.
ness defect (discon-
3 2. Inspect for continuity between terminal Go to Step 4
nection). Repair or
6 of the CN. A2 harness side and termi-
replace
nal 7 of the CN. A23 harness side.
Is there continuity?
1. Inspect for continuity between terminal PG041 or VG051
14 of the CN. A2 harness side and ter- Computer C defect. harness defect (dis-
4 minal 8 of the CN. A23 harness side. Replace connection). Repair
Is there continuity? or replace

84402826 - May 2011

4023H-94
 Section

4023K

Data Reference Values

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Non-operational P rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Two pump relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

4023K-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
4023K-2 PRINTED IN FRANCE
 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
Non operation P rotation reference value
Data display items Units It varies depending on the actual machine condi-
tion
Battery voltage V 28.3 - 28.5
Target engine rpm min-1 500
Engine speed min-1 1797 - 1801
Accelerator pedal position sensor 1 (APP1) V 0.0
Accelerator pedal position sensor 2 (APP2) V 0.0
Accelerator pedal position (APP) % 0
Fuel rail pressure sensor V 2.0 - 2.1
Fuel rail pressure feedback - Feedback mode
Coolant temperature sensor V 0.4 - 0.5
Coolant temperature °C 80 - 83
Intake temperature sensor V 2.4
Intake air temperature °C 27
Fuel temperature sensor V 1.3
Fuel temperature °C 44
Atmospheric pressure sensor V 1.9
Atmospheric pressure kPa 100
Boost temperature sensor voltage V 4.4
Boost pressure sensor kPa 118 - 119
First cylinder fuel correction amount mm3/st -
Second cylinder fuel correction amount mm3/st -
Third cylinder fuel correction amount mm3/st -
Fourth cylinder fuel correction amount mm3/st -
Engine mode - Fuel mode
EGR valve 1 drive duty % EGR valve 1 drive duty
ON/OF- Reverse the polarity of either 1, 2, or 3
EGR position 1
F (Example：1=ON, 2=ON, 3=OFF, etc)
ON/OF- Reverse the polarity of either 1, 2, or 3
EGR position 2
F (Example：1=ON, 2=ON, 3=OFF, etc)
ON/OF- Reverse the polarity of either 1, 2, or 3
EGR position 3
F (Example：1=ON, 2=ON, 3=OFF, etc)
ON/OF-
Ignition switch ON
F
ON/OF-
Starter switch ON
F
ON/OF- OFF
Glow relay
F ON immediately after the starter switch ON
Q adjustment compensation data 1 - -
Q adjustment compensation data 2 - -
Q adjustment compensation data 3 - -

84402826 - May 2011

4023K-3
 Data Reference Values

Two pump relief

TTwo Pump Relief reference value
Data display items Units
It varies depending on the actual machine
Battery voltage V 28.4 - 28.5
Target engine rpm min-1 500
Engine speed min-1 1898 - 1901
Accelerator pedal position sensor 1 (APP1) V 0.0
Accelerator pedal position sensor 2 (APP2) V 0.0
Accelerator pedal position (APP) % 0
Fuel rail pressure difference (actual – target) MPa -
Fuel rail pressure sensor V 3.3 - 3.5
Fuel rail pressure feedback - Feedback mode
Coolant temperature sensor V 0.4
Coolant temperature °C 83 - 85
Intake temperature sensor V 2.2
Intake air temperature °C 27
Fuel temperature sensor V 1.3
Fuel temperature °C 43 - 44
Atmospheric pressure sensor V 1.9
Atmospheric pressure kPa Approx. 100
Boost temperature sensor voltage V 4.3
Boost pressure sensor kPa 203 - 210
First cylinder fuel correction amount mm3/st -
Second cylinder fuel correction amount mm3/st -
Third cylinder fuel correction amount mm3/st -
Fourth cylinder fuel correction amount mm3/st -
Engine mode Fuel mode Fuel mode
EGR valve 1 drive duty % 19
Reverse the polarity of either 1, 2, or 3
EGR position 1 ON/OFF
(Example：1=ON, 2=ON, 3=OFF, etc)
Reverse the polarity of either 1, 2, or 3
EGR position 2 ON/OFF
(Example：1=ON, 2=ON, 3=OFF, etc)
Reverse the polarity of either 1, 2, or 3
EGR position 3 ON/OFF
(Example：1=ON, 2=ON, 3=OFF, etc)
Ignition switch ON/OFF ON
Starter switch ON/OFF OFF
OFF
Glow relay ON/OFF
ON immediately after the starter switch ON
Q adjustment compensation data 1 - -
Q adjustment compensation data 2 - -
Q adjustment compensation data 3 - -

84402826 - May 2011

4023K-4
 Section

4040

Electrical Wiring Diagram

84402826 - May 2011

84402826 - May 2011
 CONTENTS
Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Cab Main Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine and Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

84402826 EN - May 2011 Copyright © 2011 CNH FRANCE S.A.

4040-1 PRINTED IN FRANCE
 Electrical Wiring Diagram

Main Frame

84402826 EN - May 2011

4040-2
 Electrical Wiring Diagram
Detail of engine controller connec- CN. A50F Cab main harness: A CN. D18 Battery relay: IGN
1 Red adhesive tape 4 Green adhesive tape 7
tor CN. A51F Cab main harness: B CN. D19 Battery relay: IGN
2 Blue adhesive tape 5 Yellow adhesive tape CN. A55F Cab main harness: F CN. D68F Diode: Washer
3 White adhesive tape 6 Nameplate CN. A56F Cab main harness: G CN. D20 Battery relay: Coil
CN. D4M Connector: CAN CN. D21 Battery relay: Coil
CN. D3F Turbo computer CN. D31F Glow relay: 2
a CN. D76F must be fastened with CN. D58F must be fastened with g CN. D68F must be fastened with
d CN. A53F Cab main harness: D CN. D30F Glow relay: 1
red tape. red tape. red tape.
CN. D6F DPD register CN. D29F Glow relay: Coil
CN. D52F must be fastened with e CN. D38F must be fastened with CN. D69F must be fastened with
b h CN. D5F Barometric pressure sensor CN. D26F Fusible link: 15A
red tape. red tape. red tape.
CN. D44F must be fastened with CN. D75F must be fastened with CN. D4F must be fastened with red CN. D2F ECM: 2 CN. D25M Fusible link: 65A
c f i CN. D1F ECM: 1 CN. D24M Fusible link: 50A
red tape. red tape. tape.
CN. D50F Upper pressure sensor CN. D23M Fusible link: 50A
CN. D47F N1 pressure sensor CN. D27F Starter relay: B/C
CN. D81F Pressure switch: Filter CN. D40F Hydraulic pump: PTO CN. D54F Arm-in pressure sensor CN. D28F Starter relay: S/E
CN. D57F Fuel level sensor CN. D58F Solenoid valve joint connector * CN. D64F Free swing solenoid valve CN. D22M Battery relay: GND
* CN. D76F Feed pump harness CN. D81 Ground G2 CN. D35F MAF sensor CN. D77F Receiver dryer
CN. D65F Housing lamp CN. D63F Power save SOL. V CN. D55F Bucket-close pressure sensor CN. D67F Washer motor
* CN. D52F HBCV pressure sensor CN. D62F 2-stage relief SOL. V CN. D51F Travel pressure sensor CN. D16 Alternator: GND
CN. D73F Horn: H- CN. D61F 2-stage travel SOL. V CN. D41F Reducing valve: Boom CN. D15 Alternator: E
CN. D72F Horn: H+ CN. D59F Lock lever SOL. V CN. D42F Reducing valve: Arm CN. D14F Alternator: L/R
CN. D71F Horn: L- CN. D60F Swing brake SOL. V CN. D43F Reducing valve: Bucket CN. D13 Alternator: B
CN.D70F Horn: L+ CN. D37F Charge fuel pump CN. D32F DPD pressure sensor CN. D78F Air conditioner compressor
CN. D66F Boom lamp harness CN. D38F Diode: Pump CN. D33M DPD temperature sensor: CSF CN. D12 Starter motor: S
CN. D44F Electromagnetic proportional valve CN. D36F Fuel filter sensor CN. D34M DPD temperature sensor: DOC CN .D7F Engine harness: A
CN. D49F Swing pressure sensor CN. D53F Boom-up pressure sensor CN. D45F P1 pressure sensor CN. D8M Engine harness: B
CN. D80 Ground G1 CN. D79F Reserve tank switch CN. D46F P2 pressure sensor CN. D9M Engine harness: C
* CN. D74F Beacon harness * CN. D69F Travel alarm CN. D39F Hydraulic pump CN. D10M Engine harness: D
CN. A52F Cab main harness: C CN. D80M Air cleaner sensor CN. D56F Oil temperature sensor CN. D11M Engine harness: H
CN. A54F Cab main harness: E CN. D17 Battery relay: B CN. D48F N2 pressure sensor * CN. D75F Signal lamp harness

84402826 EN - May 2011

4040-3
 Electrical Wiring Diagram

Cab Main Harness

84402826 EN - May 2011

4040-4
 Electrical Wiring Diagram
*1 White adhesive tape *3 Blue ID tape CN. A10F DPD relay CN. A37F Memory clear
*2 Red ID tape *4 Fuse box CN. A11F Battery relay CN. A37M Memory clear: GND
CN. A12F Idle stop relay CN. A38F ECM joint connector
CN. A13F Starter cut relay CN. A39F Joint connector: CONT
a CN. A33M and A33F must be fas- e CN. A24 must be fastened with CN. A32F, 32M and 29F must be CN. A14F Neutral start relay CN. A40F Joint connector: GND
i
tened with red tape. red tape. fastened with red tape. CN. A15F Key ON CN. A41F Joint connector: A
CN. A31M and A31F must be con- CN. A16F Horn relay CN. A42F Joint connector: B
CN. A26F must be fastened with CN. A58 must be fastened with
b nected, then fastened with red f j
red tape. red tape. CN. A17F Lamp relay CN. A43 Ground: Cab
tape.
CN. A18F Lamp relay: CAB CN. A44F Cab harness: A
c CN. A30 and A38 must be fas- g CN. A34F and 35F must be fas- CN. A40F, 41F and 42F must be
k CN. A19F Beacon relay CN. A45F Cab harness: B
tened with red tape. tened with red tape. tied together with red tape.
CN. A23 must be fastened with CN. A25M and CN. A25F must be CN. A20F Room lamp relay CN. A46F Console harness: A
d h l Nameplate position CN. A21F Speaker relay: R CN. A47F Console harness: B
red tape. connected.
CN. A22F Speaker relay: L CN. A48F Console harness: C
CN. A23F Computer C harness CN. A49F Console harness: D
CN. A1F Computer A: 1 CN. A31M Hour meter: - CN. A24F Computer T harness CN. A50M Frame main harness: A
CN. A2F Computer A: 2 CN. A32F Option power supply CN. A25F EST-B connector CN. A51M Frame main harness: B
CN. A3F Computer A: 3 CN. A32M Option power supply: GND CN. A25M EST-B connector CN. A52M Frame main harness: C
CN. A4F Computer A: 4 CN. A33F Immobilizer CN. A26F EST-A harness CN. A53M Frame main harness: D
CN. A5F Computer B: 1 CN. A33M Immobilizer: GND CN. A27F Diagnostic connector CN. A54M Frame main harness: E
CN. A6F Computer B: 2 CN. A34F CAN CN. A28F DC/DC converter CN. A55M Frame main harness: F
CN. A7F Computer B: 3 CN. A35F CAN CN. A29F FMS harness CN. A56M Frame main harness: G
CN. A8F Computer B: 4 CN. A36F Diagnostic switch CN. A30F Diode CN. A57M Option line harness
CN. A9F ECM relay CN. A36M Diagnostic switch: GND CN. A31F Hour meter: + CN. A58F Horn jumper

84402826 EN - May 2011

4040-5
 Electrical Wiring Diagram

Engine Harness

84402826 EN - May 2011

4040-6
 Electrical Wiring Diagram
*1 SENSOR:WATER *7 SENSOR:OIL PRESSURE *13 SENSOR:FUEL TEMP *4 INJECTOR(#1.2.3) *10 SENSOR:IMT *16 SENSOR:CAM ANGLE(G)
*2 SWITCH:O/H *8 SENSOR:BOOST PRESSURE *14 SCV *5 INTAKE THROTTLE *11 EGR VALVE *17 SENSOR:NE.CRANK
*3 GLOW PLUG(CYL#2) *9 INJECTOR(#4.5.6) *15 TURBO VGS *6 SENSOR:COM.RAIL *12 SENSOR:BOOST TEMP

84402826 EN - May 2011

4040-7
 Electrical Wiring Diagram

Frame

84402826 EN - May 2011

4040-8
 Electrical Wiring Diagram
a Marking position; Align white tape of harness. c ID: H
b ID: L d Fasten pilot control line together.

*1 Round terminal M8 (floor ground)

*2 Round terminal M8
*3 KHR11160 Wire harness; Light (frame main)

Code Part name Q'ty Code Part name Q'ty

1 Battery cable; Relay (starter) 1 6 Sensor; Pressure (5 MPa) G1/4 7
2 Harness; Wire (frame main) 1 7 Bracket; Lamp 1
3 Wire; Ground (floor) 1 8 Light; Working 24 V × 70 W 1
4 Horn; Electric (LOW) 1 9 Alarm; Travel 1
5 Horn; Electric (HIGH) 1 10 Bracket; Alarm 1

CN.A50 Cab main harness: A (2-pin) CN.D51 Pressure sensor: Travel (3-pin)
HBCV harness (3-pin) (secured to harness with red
CN.A51 Cab main harness: B (8-pin) CN.D52
tape)
CN.A52 Cab main harness: C (8-pin) CN.D53 Pressure sensor: BOOM (3-pin)
CN.A53 Cab main harness: D (14-pin) CN.D54 Pressure sensor: Arm (3-pin) ID tape: Red
CN.A54 Cab main harness: E (22-pin) CN.D55 Pressure sensor: Bucket (3-pin)
CN.A55 Cab main harness: F (20-pin) CN.D57 Fuel level sensor (2-pin)
CN.A56 Cab main harness: G (18-pin) CN.D6 Register (2-pin)
CN.D1 ECM: 1 (60-pin) CN.D64 SV; Free swing (2-pin)
CN.D16 Alternator ground CN.D65 Lamp: Housing (2-pin)
CN.D2 ECM: 2 (94-pin) CN.D66 Boom lamp harness (2-pin)
CN.D3 Turbo computer (16-pin) CN.D67 Washer motor (2-pin)
Travel alarm (2-pin) (secured to harness with red
CN.D35 Suction air sensor (5-pin) CN.D69
tape)
CN.D70
CN.D41 Proportional valve: BOOM (2-pin) ID tape: None Horn (left)
CN.D71
CN.D72
CN.D42 Proportional valve: Arm (2-pin) ID tape: Red Horn (right)
CN.D73
Feed pump harness (3-pin) (secured to harness
CN.D43 Proportional valve: Bucket (2-pin) ID tape: Blue CN.D76
with red tape)
Option proportional valve harness (2-pin) (secured
CN.D44 CN.D77 Receiver dryer (2-pin)
to harness with red tape)
CN.D47 Pressure sensor: N1 (3-pin) CN.D79 LLC tank (2-pin)
CN.D49 Pressure sensor: Swing (3-pin) CN.D80 Ground G1
CN.D5 Barometric pressure sensor (3-pin) CN.D81 Filter indicator (2-pin) ID tape: Red
CN.D50 Pressure sensor: Upper (3-pin) CN.D85 Ground G2

84402826 EN - May 2011

4040-9
 Electrical Wiring Diagram

Engine and Pump

84402826 EN - May 2011

4040-10
 Electrical Wiring Diagram
ANNOTATION:
1. When assembling the ground terminals marked with a ※, it should be confirmed that the frame seating surface is not
coated. If the surface is coated, assembly should be performed after removing the coating.
2. Clean the terminal of the connectors marked with a * using cleaning agent (29) before mating, and then coat with an
anti-rust agent (30).
3. The clamp positions of the electrical wiring that comes out from connectors should be adjusted so that the wiring does
not form sharp rounded shapes. (Radius of curve = 10 mm or more)

a Be careful to assemble the battery cable in the correct direction.

*1 Starter motor (attached to engine main unit) *4 Round terminal M6

*2 Engine ground (attached to engine main unit) *5 Round terminal M5
*3 Engine harness (attached to engine main unit) *6 KRR16740 Harness; Wire (frame main)

Code Part name Q'ty

1 Sensor; Pressure (50 MPa) M18 × 1.5 2

2 Sensor; Pressure (5 MPa) G1/4 1
3 Sensor; Thermo 1

*CN.D10 Engine harness: D (16-pin) CN.D37 Charge fuel pump (2-pin)

*CN.D11 Engine harness: H (1-pin) CN.D39 Proportional valve; Horsepower control (2-pin)
*CN.D7 Engine harness: A (25-pin) CN.D40 Proportional valve: Flow control (2-pin)
*CN.D8 Engine harness: B (16-pin) CN.D46 Pressure sensor P2 (3-pin) ID tape: Blue
*CN.D9 Engine harness: C (14-pin) CN.D48 Pressure sensor N2 (3-pin)
CN.13 Alternator: B Electrical wiring color: Red CN.D56 Sensor; Oil temperature (2-pin)
Joint connector (8-pin) (secured to red tape
CN.15 Alternator: E Electrical wiring color: Black CN.D58
harness)
CN.45 Pressure sensor P1 (3-pin) ID tape: None CN.D59 SV; Lever lock (2-pin) ID tape: Blue
CN.D12 Starter motor: S CN.D60 SV; Swing brake (2-pin) ID tape: White
CN.D14 Alternator: L/R (2-pin) CN.D61 SV; 2-stage travel (2-pin) ID tape: Red
CN.D32 Pressure sensor; Exhaust gas (3-pin) CN.D62 SV; 2-stage relief (2-pin) ID tape: Yellow
Temperature sensor DPD (FRONT) (2-pin)
CN.D33 CN.D63 SV; Power save (2-pin), ID tape: Green
Connector color: White
Temperature sensor DPD (CENTER) (2-pin)
CN.D34 CN.D71 Compressor (1-pin)
Connector color: Gray
Beacon harness (2-pin) (secured to harness
CN.D36 Fuel filter (3-pin) CN.D75
with red tape)

84402826 EN - May 2011

4040-11
 Electrical Wiring Diagram

Attachments

84402826 EN - May 2011

4040-12
 Electrical Wiring Diagram

a Secure harness to the boom seating with a wire band

b Harness length from connector to wire band: 700 mm

c CN.D66 Connect to frame main harness

Code Part name Q'ty

1 Wire harness; Light (frame main) 1
2 Light; Working 1

84402826 EN - May 2011

4040-13
 Electrical Wiring Diagram

Battery

84402826 EN - May 2011

4040-14
 Electrical Wiring Diagram
ANNOTATION: CN.D10 Battery relay B ID tape: Red CN.D28 Starter relay S/E (2-pin)
CN.D17 Fuse 50 A ST (2-pin) Electrical wiring color: Red CN.D29 Glow relay coil (2-pin)
1. When assembling the ground terminals marked with a ※, it should be confirmed that the frame seating surface is not
coated. Glow relay1 (1-pin) Electrical wiring color: White
CN.D18 Battery relay IGN Electrical wiring color: Red CN.D30
If the surface is coated, assembly should be performed after removing the coating. stripe on red background
2. The clamp positions of the electrical wiring that comes out from connectors should be adjusted so that the wiring does CN.D19 Battery relay IGN Electrical wiring color: White CN.D31 Glow relay2 (1-pin) Electrical wiring color: Blue
not form sharp rounded shapes. (Radius of curve = 10 mm or more) CN.D20 Battery relay coil1 Electrical wiring color: Green CN.D67 Washer motor (2-pin)
Battery relay coil 2 Electrical wiring color: Red
CN.D21 CN.D74 Beacon harness (2-pin)
a Align indicator of battery with hole position. stripe on white background
b Fasten the air conditioner hose and harness together. CN.D22 Battery relay GND (1-pin) CN.D77 Receiver dryer (2-pin)
c Marking position; Align white tape of harness. Fuse 50 A +B (2-pin) Electrical wiring color: White
CN.D23 CN.D79 Switch; LLC tank (2-pin)
stripe on red background
*1 Glow relay (engine accessory) *5 Round terminal M8
*2 Starter relay (engine accessory) *6 Round terminal M4
*3 M10 (battery accessory) *7 KRR16741 Harness; Wire (frame main)
*4 M8 (battery accessory)

Code Part name Q'ty Code Part name Q'ty

1 Holder; Battery 2 6 Cable; Battery ground 1
2 Fuse; High current (model A3 50 A) 2 7 Battery 130E41R (with terminal) 2
3 Fuse (fusible link) 65 A 1 8 Cable; Battery bridge 1
4 Bracket; Battery relay 1 9 Cable; Battery B+ relay 1
5 Relay; Battery 1

CN.19 Fuse 20 A CONT (2-pin) CN.D25 Fuse 65 A IGN (2-pin)

CN.80 Pressure switch; Air cleaner (2-pin) CN.D27 Starter relay B/C (2-pin)

84402826 EN - May 2011

4040-15
Electrical Wiring Diagram

84402826 EN - May 2011

4040-16
 Section

5001A

Removal and Installation of Shoe Assembly

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of Shoe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Shoe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

5001A-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
5001A-2 PRINTED IN FRANCE
 Removal and Installation of Shoe Assembly

WARNING Do not loosen the check valve all at once.

Loosen it slowly while monitoring the grease output
• When loosening the grease cylinder check and shoe loosening.
valve, loosen it a little bit at a time. Use a rag to catch grease that trickles out of the
• The pressure inside the cylinder is very high, check valve.
so there is the danger of grease being ex-
pelled and the plug flying off.
The check valve adjustment procedure
should not be done in front of the check
valve.
• Do not get under the main unit when it is
jacked up.
Make sure to place the main unit on crossties
to prevent falling.

CAUTION
• Make sure to stop the engine for loosening
shoes and when removing master pins.

Items to prepare
• Wrenches (17 mm, 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 (17 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.

2. Use a box wrench (19 mm) to loosen the check

valve (1) to release grease, and then loosen the
track shoe tension.

WARNING
• If the check valve (1) is too loose, it may
fly off.
• Do not place your body in front.

84402826 - May 2011

5001A-3
 Removal and Installation of Shoe Assembly

4. Put wood planks (1) underneath the track shoe. 6. Remove the track shoe (1).
Straighten out the S-pin (3) attached to the master At this time, support with a wood plank (2) so the
pin (2) by striking one side of it with a hammer, and bottom track shoe (1) does not fall.
use a crowbar, etc. to remove it.

7. Start the engine, raise the lower side frame of the

5. Use a hammer (2) and striking rod (3) to push the track shoe removal side about 20 cm, slowly set the
master pin (1) out. travel lever to backwards, and move the track shoe
(1) to remove it from the lower frame.

84402826 - May 2011

5001A-4
 Removal and Installation of Shoe Assembly

Installation of Shoe Assembly
1. Raise the lower side frame about 20 cm.
Lift the track shoe (1) and align it with the sprocket
(2).
Pay attention to the backwards and forward direc-
tion of the track shoe.
3. Wrap the edge of the track shoe (1) onto the take-up
roller (2).
Place a wood plank (3) on the ground and lift the
bottom-side link to align the position where the mas-
ter pin is inserted.

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.

84402826 - May 2011

5001A-5
 Removal and Installation of Shoe Assembly

6. To adjust the track shoe tension, raise the lower 7. Adjust the tension so that the distance indicated
side frame with a wood plank (1) as shown in the with A between the frame bottom (1) of the center
diagram. area of the lower side frame and the lowest hanging
part of the top of the shoe plate (2) is 290 - 310 mm.

84402826 - May 2011

5001A-6
 Section

5001B

Removal and Installation of Shoe Plate

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of Shoe Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Shoe Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

5001B-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
5001B-2 PRINTED IN FRANCE
 Removal and Installation of Shoe Plate

CAUTION Installation of Shoe Plate

• Be sure to stop the engine before beginning 1. Install the shoe plate (1).
work.

Items to prepare
• Box wrench (30 mm)
• Grease
• Rag
• Cleaning fluid

Removal of Shoe Plate

1. Use a box wrench (30 mm) to remove the 4 shoe
bolts (1).

2. Use a box wrench (30 mm) to install the 4 shoe bolts

(1).
Bolt (1) tightening torque: 751 - 849 Nm

2. Remove the shoe plate (1).

84402826 - May 2011

5001B-3
Removal and Installation of Shoe Plate

84402826 - May 2011

5001B-4
 Section

5003A

Removal and Installation of Upper Roller

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of Upper Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Upper Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

5003A-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
5003A-2 PRINTED IN FRANCE
 Removal and Installation of Upper Roller

Job code 48138AB21 Removal of Upper Roller

1.
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
Use a box wrench (19 mm) to loosen the check
valve (1) to release grease, and then loosen the
track shoe tension.
WARNING
• If the check valve (1) is too loose, it may
fly off.
• Do not place your body in front.
Do not loosen the check valve all at once.
Loosen it slowly while monitoring the grease output
and shoe loosening.
Use a rag to catch grease that trickles out of the
check valve.

• Be sure to stop the engine before beginning

work.

Items to prepare
• Box wrenches (19 mm, 30 mm)
• Jack (That meets the lifting weight.)
• Rag
• Cleaning fluid
• Wood planks, etc.

2. Use a jack (3) to lift the top of the shoe, and then
insert wood planks (4) to separate the shoe (2) and
upper roller (1) by about 10 mm.

84402826 - May 2011

5003A-3
 Removal and Installation of Upper Roller

3. Use a box wrench (30 mm) to remove the 2 bolts Installation of Upper Roller
(2), and then remove the upper roller (1).
1. Use a jack (2) to lift the top of the shoe (1), and then
insert wood planks (3).

2. Use a box wrench (30 mm) to attach the 2 bolts (2),

and then install the upper roller (1).
• Apply Loctite.
• Bolt (2) tightening torque: 521 - 608 Nm

3. Tighten the check valve (1).

While monitoring the track shoe tension, inject
grease into the grease cylinder.

84402826 - May 2011

5003A-4
 Removal and Installation of Upper Roller

4. To adjust the track shoe tension, raise the lower side 5. Adjust the tension so that the distance indicated
frame as shown in the diagram. with A between the frame bottom (1) of the center
Place a wood plank (1) under the lower frame to area of the lower side frame and the lowest hanging
prevent falling. part of the top of the shoe plate (2) is 290 - 310 mm.

84402826 - May 2011

5003A-5
Removal and Installation of Upper Roller

84402826 - May 2011

5003A-6
 Section

5003B

Assembly and Disassembly of Upper Roller

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Configuration Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Dimension Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Jig Dimension Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

5003B-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
5003B-2 PRINTED IN FRANCE
 Assembly and Disassembly of Upper Roller

Job code 48138AC30 Configuration Diagram

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
Part name Part number Q'ty
parts with new parts.
High-strength bolt
<General cautions> 1 102R010Y016N 2
M10 x 16
• Be careful not to drop precision parts or let Reqd.
2 Loctite #262 KRC5007
bump them with other parts during work. amount
• Do not forcefully open or hit parts in an effort Cover (bolt stop-
3 KRA1719 1
to speed up operations. Pay careful attention per)
and proceed slowly so as not to damage any Plug with seal ny-
4 KHJ0300 1
parts, create any oil leaks, or compromise the lon
efficiency of the equipment, etc. 5 O-ring UHA0049 1
• Disassembled parts can easily rust or collect High-strength bolt
6 102R008Y025R 3
dust. Therefore, immediately after disassem- M8 x 25
bling parts, take precautions to prevent the 7 Thrust plate KRA1123 1
parts from rusting or collecting dust. 8 Shaft KRA1252 1
9 Bushing KRA1248 1
Items to prepare 10 Bushing KRA1249 1
• Hexagon wrench 6 mm 11 Roller KRA1718 1
• Hammer 12 Floating seal KBA0783 1
• Wrenches (13 mm, 17 mm) 13 Bracket KRA13740 1
• 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

84402826 - May 2011

5003B-3
 Assembly and Disassembly of Upper Roller

Dimension Diagram Jig Dimension Diagram

*1 Press fit length

A Bushing removal jig

B1 Bushing press-fit jig (10)
B2 Bushing press-fit jig (9)
C Floating seal installation jig

84402826 - May 2011

5003B-4
 Assembly and Disassembly of Upper Roller

Disassembly Procedures 4. Remove the cover (1).

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.
If the cover is difficult to remove, it is acceptable to
use an air hose (2) with an adapter or to pry it open
by inserting a flathead screwdriver into either end of
the cover.
• When using compressed air, be careful of flying
parts.

2. Face down the part of the roller from which the 5. Use a box wrench (17 mm) to remove the 2 bolts (2)
plug was removed and empty the oil from within the inside the roller, and then remove the thrust plate
roller. (1).
• It may take a few hours to completely empty the
oil.
• Place an oil pan (1) under the roller to catch the
oil.

6. Lift the roller (1) and remove the shaft (2).

3. Use a wrench (13 mm) to remove the 3 bolts (2)

from the cover (1), and then remove the cover.

84402826 - May 2011

5003B-5
 Assembly and Disassembly of Upper Roller

7. Remove the floating seal (2) on the roller (1).
Check whether the sliding surface has rusted or is
damaged. Also make sure the O-ring (3) on the seal
ring (4) is not twisted.
8. Remove the floating seal (2) on the shaft (1).
• The shaft and bracket (5) cannot be removed.
Check whether the sliding surface has rusted or
is damaged. Also make sure the O-ring (4) on the
seal ring (3) is not twisted.

9. Remove the O-ring (2) on the cover (1) side.

• Check whether the O-ring is twisted. If it is
twisted, replace it with a new one.

84402826 - May 2011

5003B-6
 Assembly and Disassembly of Upper Roller
10. Use a micrometer caliper (4), caliper (5), cylinder Assembly Procedures
gauge (6), to measure the roller (with bushing) (1),
bracket (2), and shaft (3) for wear and deformation. 1.
Replace with new parts as necessary.
2.
11. When replacing bushings (1) (2), use jig A (4) to
restrain it from the side where the shaft (3) was re-
moved and press it out with a pressing machine (5).
3.
84402826 - May 2011
5003B-7
Clean all parts.
• Find a clean location.
• Place a rubber plate or cloth on the work platform
so as not to damage the parts.
• In order to clean off adhered matter that forms
sharp points and causes scratches, immerse
parts in cleaning fluid (1) until dirt and grease
float to the top.
After cleaning the parts, air blow them to remove
any remaining cleaning fluid or debris.
If the bushing (2) was removed during disassembly,
put it into the roller (1).
Face up the thrust plate installation side, restrain
from above using jig B2 (3), and push in with the
pressing machine (4).
 Assembly and Disassembly of Upper Roller

4. Invert the roller (1) and insert the bushing (2). 7. Apply hydraulic oil to the floating seal (1).
Restraining from above using jig B1 (3), push in with
the pressing machine (4).
Push in all the way to the position where jig B1
stops.

8. Attach the shaft (2) to the roller (1).

5. Insert the floating seal (3) into the roller (1) and
bracket (2).
Use jig C (4) to press it into position.

9. Use a special fiber cloth to thoroughly wipe the sur-

face of the thrust plate (1) to prevent any dust or
scratches.

6. Use a special fiber cloth to wipe the surfaces of the

floating seals so as to increase adhesion and pre-
vent dust from entering.

84402826 - May 2011

5003B-8
 Assembly and Disassembly of Upper Roller

10. Install the thrust plate (1) with 2 bolts (2).
Degrease the bolts well, apply Loctite (3) to the bolt
openings, and tighten the bolts.
After tightening the bolts, mark them (4).
Bolt (2) tightening torque: 62.8 - 72.6 N・m
13. Inject compressed air (0.2 MPa) from the oil fill port
and immerse in water to check that there are no
leaks.

14. Inject engine oil (50 - 55 cc) into the roller. After
filling the engine oil, use a hexagon wrench (1) to
11. Install the cover (1) with 3 bolts (2). tighten the plug (2) (coated with seal nylon).
Degrease the bolts, apply Loctite (3) to the bolt After tightening the bolts, mark them (3).
openings, and tighten the bolts. • To reuse a plug, wrap it with seal tape.
After tightening the bolts, mark them (4). Plug (2) tightening torque: 24.5 N・m
Bolt (2) tightening torque: 31.4 - 37.2 N・m

12. Rotate the roller in the direction of the arrow and This completes the assembly.
check that it rotates smoothly.

84402826 - May 2011

5003B-9
Assembly and Disassembly of Upper Roller

84402826 - May 2011

5003B-10
 Section

5003C

Removal and Installation of Lower Roller

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of Lower Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Lower Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

5003C-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
5003C-2 PRINTED IN FRANCE
 Removal and Installation of Lower Roller

WARNING Removal of Lower Roller

• Do not get under the main unit when it is 1. Use a box wrench (19 mm) to loosen the check
jacked up. valve (1), and then loosen the shoe tension.
Make sure to place the main unit on wood Do not loosen the check valve all at once.
planks to prevent falling. Loosen it slowly while monitoring the grease output
• When loosening the grease cylinder check and shoe loosening.
valve, loosen it a little at a time and stop when
• Grease drains out, so provide rag (2) close to the
any grease appears. drain port.
The pressure inside the cylinder is very high,
so there is the danger of grease being ex-
pelled and the plug flying off if the check
valve is loosened too much.

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

Items to prepare
• Box wrenches (19 mm, 27 mm)
• Rag
• Cleaning fluid
• Wood planks, etc.

2. Jack up the side frame on the side where the roller

is being replaced, as shown in the diagram.
Jack up so that the shoe is floating about 5 cm,
and insert wood plank (1) under the lower frame to
prevent falling.

84402826 - May 2011

5003C-3
 Removal and Installation of Lower Roller

3. If it is impossible to insert wood planks (3) under Installation of Lower Roller

the lower frame, insert wood planks (3) between the
side frame and the link shoe (2) to separate the link
shoe and lower roller (1) by about 15 mm.
1. Insert wood planks (4) between the side frame and
the link show (3), use a box wrench (27 mm) to
install 4 bolts (2) and then install the lower roller (1).
• Bolt (2) tightening torque: 371 - 432 N·m

4. Use a box wrench (27 mm) to remove the 4 bolts

(2), then remove the lower roller (1).
2. Tighten the check valve (1).
While monitoring the track shoe tension, inject
grease into the grease cylinder.

3. 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.

84402826 - May 2011

5003C-4
 Removal and Installation of Lower Roller

4. Adjust the tension so that the distance indicated

with A between the lower frame (1) of the center
area of the lower side frame and the lowest hang-
ing part of the shoe plate (2) is 290 - 310 mm.

84402826 - May 2011

5003C-5
Removal and Installation of Lower Roller

84402826 - May 2011

5003C-6
 Section

5003D

Assembly and Disassembly of Lower Roller

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Configuration Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Dimension Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Jig Dimension Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

5003D-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
5003D-2 PRINTED IN FRANCE
 Assembly and Disassembly of Lower Roller

CAUTION Configuration Diagram

• 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> Part name Q'ty
• Be careful not to drop precision parts or let 1 Roller 1
bump them with other parts during work. 2 Shaft 1
• Do not forcefully open or hit parts in an effort 3 Bushing 2
to speed up operations. 4 Floating seal 2
Pay careful attention and proceed slowly so 5 O-ring 1A-G60 2
as not to damage any parts, create any oil 6 Collar 1
leaks, or compromise the efficiency of the
7 Plug with seal nylon 1
equipment, etc.
8 Wire clip 2
• Disassembled parts can easily rust or collect
dust. 9 Collar (without plug) 1
Therefore, immediately after disassembling
parts, take precautions to prevent the parts
from rusting or collecting dust.

Items to prepare
• Hexagon wrench (6 mm)
• Hammer
• Wire clip
• Pliers
• Gear puller
• Screwdriver
• Gear oil (Mobile Gear Oil SHC320)
• Specialty jigs
• Pressing machine
• Loctite
• Special fiber cloth (Kimwipe)
• Micrometer caliper
• Caliper
• Cylinder gauge

84402826 - May 2011

5003D-3
 Assembly and Disassembly of Lower Roller

Dimension Diagram Jig Dimension Diagram

A Bushing removal jig

B Bushing press-fit jig
C Floating seal installation jig

84402826 - May 2011

5003D-4
 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. Remove the wire clip (1).

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.

84402826 - May 2011

5003D-5
 Assembly and Disassembly of Lower Roller

6. Check whether the surface of the floating seal (2) 9. Remove the shaft (1).
sliding against the removed collar (1) has rusted or
is damaged.
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.

10. Check whether the surface of the floating seal (2)

sliding against the removed collar (1) on the oppo-
site side has rusted or is damaged.
Also make sure the O-ring (3) on the seal ring (4) is
not twisted.
• The O-ring cannot be reused.
7. Remove the floating seal (1) on the roller. Replace it with new part.
As described in step 6, check whether the sliding
surface has rusted or is damaged.
Also make sure the O-ring is not twisted.

11. As described in step 6,7, remove the floating seal

(1) on the opposite side.

8. Remove the O-ring (2) on the shaft (1).

• The O-ring cannot be reused.
Replace it with new part.

84402826 - May 2011

5003D-6
 Assembly and Disassembly of Lower Roller
12. Use a caliper (6), micrometer caliper (5), and cylin-
der gauge (7) to measure the roller (with bushing)
(1), collars (2) (3), and shaft (4) for wear and defor-
mation.
Replace with new parts as necessary.
13. 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.
84402826 - May 2011
5003D-7
Assembly Procedures
1. Clean all parts by immersing them in cleaning fluid
(1).
• Select a clean location.
• Place a rubber plate or cloth on the work platform
so as not to damage the parts.
2. After cleaning the parts, air blow them to remove
any remaining cleaning fluid or debris.
3. If the bushing (2) was removed during disassembly,
put it into the roller (1).
Restraining from above using jig B (3), push in with
the pressing machine (4).
Invert the roller and insert the bushing on the oppo-
site side in the same manner.
 Assembly and Disassembly of Lower Roller

4. Use jig C (5) to push the floating seal (4) into the 7. Attach O-rings (3) to the shaft (2) and mount into the
collars (2) (3) and roller (1) by hand. roller (1).

5. Use a special fiber cloth to wipe the surfaces of the 8. Install the collars (1) (2) on both sides.
floating seals so as to increase adhesion and pre-
vent dust from entering.

9. Attach the wire clip (1).

6. Apply gear oil to the floating seals (3) on the collars • When attaching the wire clip, secure the roller
(1) (2). main unit so that it does not roll.

84402826 - May 2011

5003D-8
 Assembly and Disassembly of Lower Roller

10. Turn the main unit and check that the roller rotates
properly.
12. Fill gear oil (125 cc) into the roller.
Use a hexagon wrench (6 mm) (2) to tighten the
plug (1) with the nylon seal applied.
• Mobile Gear Oil SHC320 is recommended for
use.
• To reuse a plug, wrap it with seal tape.
Plug (1) tightening torque: 24.5 N·m

11. Inject compressed air (0.2 MPa) from the oil fill port
and immerse in water to check that there are no
leaks.

This completes the assembly.

84402826 - May 2011

5003D-9
Assembly and Disassembly of Lower Roller

84402826 - May 2011

5003D-10
 Section

5004

Removal and Installation of the Sprocket

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

5004-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
5004-2 PRINTED IN FRANCE
 Removal and Installation of the Sprocket

WARNING Removal of Sprocket

• When loosening the check valve, loosen it a 1. Allow the bucket (1) to touch the ground so as to
little at a time and stop when any grease ap- elevate the shoe (2) of the side to be removed as in
pears. the diagram on the right.
The pressure inside the cylinder is very high,
so there is the danger of grease being ex-
pelled and the plug flying off if the check
valve is loosened too much.

CAUTION
• Before removing the shoes, be sure to bleed
off any air in the hydraulic circuits.
• Be sure to inspect the wire rope and other
lifting equipment before beginning work.
• Do not stand or pass under the suspended
load.

Items to prepare
2. Slowly rotate the shoe so that the shoe joint section
• Box wrenches (19 mm) (1) is aligned as in the diagram on the right.
• Wrenches（19 mm、24 mm） Place wood plank (2) under the shoe and return the
• Hammer (to remove the master pin) bucket to its original position.
• Striking jig (to remove the master pin) Perform air bleeding for the hydraulic line.
• Liftcrane (with the required lifting capacity) For details, see Air Bleed Procedures.
• Wire rope (with the required breaking load)
• Loctite #262
• Wood plank
• Rag
• Cleaning fluid

84402826 - May 2011

5004-3
 Removal and Installation of the 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.

6. Open the shoe (1) to the rear.

7. Use a wrench (24 mm) to remove the 22 bolts (1).

4. Pull out the S-pin (1) from the rear of the joint sec-
tion.

8. Use a wire rope (1) to lift the drive sprocket (2) and
remove it from the travel motor (3).

84402826 - May 2011

5004-4
 Removal and Installation of the Sprocket

Installation of Sprocket • Tightening torque M16: 267 - 312 N・m

To install, perform the reverse of the removal procedure.

84402826 - May 2011

5004-5
Removal and Installation of the Sprocket

84402826 - May 2011

5004-6
 Section

5005A

Removal and Installation of Take-up Roller

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of Take-up Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Take-up Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

5005A-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
5005A-2 PRINTED IN FRANCE
 Removal and Installation of Take-up Roller

WARNING Removal of Take-up Roller

• When loosening the grease cylinder check 1. Remove the shoe assembly.
valve, loosen it a little at a time. See the "Removal and Installation of Shoe Assem-
• The pressure inside the cylinder is very high, bly".
so there is a danger of grease being expelled 2. Use a crowbar (3) to pull off the take-up roller (1)
and the plug flying off. and recoil spring assembly from the side frame (2).
The check valve adjustment procedure
should not be done in front of the check
valve.
• Do not get under the machine when the main
unit is jacked up.
• Make sure to place the main unit on wood
planks or the like to prevent falling.
• Align the shoe assembly feed location and
stop the engine except when working.

Items to prepare
• Wrench (24 mm)
• Hammer
• Lifting equipment
• Loctite #262 3. Install the lifting equipment (4) on the take-up roller
• Striking jig (1) and recoil spring assembly (3) and hang them
• Liftcrane from the side frame (2) with the liftcrane.
• Crowbar
• Wood planks, etc.
• Rag

4. Place the take-up roller (1) and recoil spring assem-

bly (2) onto wood planks (4) as in the diagram.
Use a wrench (24 mm) to remove the take-up roller
bolt (3) and separate the roller and the recoil spring
assembly.

84402826 - May 2011

5005A-3
 Removal and Installation of Take-up Roller
Installation of Take-up Roller 2.
1. Place the take-up roller (1) and recoil spring assem-
bly (2) onto wood planks (4) as in the diagram. Use
a wrench (24 mm) to fasten the take-up roller (1)
and recoil spring assembly (2) with the bolt (3).
At this time, be sure to coat the bolt with Loctite
#262.
Installation bolt tightening torque: 267 - 312 N·m
3.
84402826 - May 2011
5005A-4
Install the lifting equipment (4) on the take-up roller
(1) and recoil spring assembly (3) as in the diagram,
lift them up with the liftcrane, and insert them into
the side frame (2).
Push in with the crowbar until the recoil spring as-
sembly contacts the grease cylinder.
Install the shoe assembly.
For details on installation, see the "Removal and
Installation of Shoe Assembly" procedure.
 Section

5005B

Assembly and Disassembly of Take-up Roller

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Configuration Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Dimension Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Jig Dimension Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

5005B-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
5005B-2 PRINTED IN FRANCE
 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.

Items to prepare
• Hexagon wrench (6 mm)
• Hammer
• Pliers
• Gear puller
• Screwdriver
• Engine oil (Shell Rimula Oil #30)
• Specialty jigs
• Pressing machine
• Loctite
• Special fiber cloth (Kimwipe)
• Micrometer caliper
• Caliper
• Cylinder gauge

84402826 - May 2011

5005B-3
 Assembly and Disassembly of Take-up Roller

Configuration Diagram Dimension Diagram

Part name Q'ty

1 Roller 1
2 Bushing 2
3 Floating seal 2
4 Hub (without plug) 1
5 O-ring 1A-G50 2
6 Hub pin 2
7 Shaft 1
Plug with seal ny-
8 1
lon
9 Hub 1

84402826 - May 2011

5005B-4
 Assembly and Disassembly of Take-up Roller

Jig Dimension Diagram Disassembly Procedures

1. After cleaning the roller with kerosene, use the
hexagon wrench (1) to remove the plug (2) from
the hub (3).
• The plug is coated with seal nylon, which comes
off when the plug is removed. Seal tape is neces-
sary for reusing.

A Bushing removal jig

B Bushing press-fit jig
C Floating seal installation jig

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.

84402826 - May 2011

5005B-5
 Assembly and Disassembly of Take-up Roller

3. Remove the hub pin (2) from the hub (1), and re- 5. Remove the floating seal (1) on the roller. As de-
move the hub (1) from the shaft (3). scribed in step 4, check whether the sliding sur-
face has rusted or is damaged. Also make sure the
• Only remove on one side. O-ring is not twisted.

4. Check whether the surface of the floating seal (1) 6. Remove the O-ring (2) on the shaft (1) and then pull
sliding against the removed hub has rusted or is the shaft (1) out.
damaged. Also make sure the O-ring (2) on the seal
ring (3) is not twisted. • The O-ring cannot be reused. Replace it with new
part.
• The O-ring cannot be reused. Replace it with new
part.

7. As described in step 3, remove the hub (1) on the

opposite side and check that the sliding surface of
the floating seal is not rusted and that the O-ring is
not twisted.

84402826 - May 2011

5005B-6
 Assembly and Disassembly of Take-up Roller

8. As described in step 5, remove the floating seal (1) 9. Use a micrometer caliper (4), cylinder gauge (5),
on the opposite side. 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. 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.

84402826 - May 2011

5005B-7
 Assembly and Disassembly of Take-up Roller

Assembly Procedures
1. Clean all parts.
• Find a clean location.
• Place a rubber plate or cloth on the work platform
so as not to damage the parts.
• In order to clean off adhered matter that forms
sharp points and causes scratches, immerse
parts in cleaning fluid (1) until dirt and grease
float to the top.

2. After cleaning the parts, air blow them to remove

any remaining cleaning fluid or debris.
• If the parts are to be left as is for a long time after
drying them, apply engine oil.
11. Invert the roller (1), use jig A (4) to push up against
the bushing (2), and press with a rod-shaped object
(3) (such as a shaft). The bushing comes off.

3. If the bushing (2) was removed during disassembly,

put it into the roller (1). Use a pressing machine (3)
to press in both the left and right sides.

84402826 - May 2011

5005B-8
 Assembly and Disassembly of Take-up Roller

4. Use the jigs (2) (3) attached to the pressing machine 6. Use jig C (3) to attach the floating seal (2) to the
to attach the bushing (1). Use the pressing machine roller (1) side.
to press from the opposite side. Next, use a special
fiber cloth to remove all dust and debris.

7. Use a special fiber cloth to thoroughly wipe the slid-

ing surface of the floating seal to prevent any dust
or scratches.

8. Apply engine oil to the floating seals (1) on the hubs

5. Attach the floating seal (2) to the hub (1). Use jig C
(2) (3).
(3) to press it into position.

84402826 - May 2011

5005B-9
 Assembly and Disassembly of Take-up Roller

9. After attaching the O-ring (4) to the shaft (1), attach 12. Inject compressed air (0.2 MPa) from the oil fill port
the shaft to the hub (2) and fasten it with the hub pin and immerse in water to check that there are no
(3). leaks.

10. Attach the shaft (2) to the roller (1). 13. Fill engine oil (120 cc) into the roller main unit.
• The roller main unit can be very unstable, so be
careful in securing it.

11. Install the opposite side hub (1) on the roller (2) and
fasten with the hub pin (3).
14. After filling the oil, use a hexagon wrench (6 mm) (2)
to tighten the plug (1) with the nylon seal applied.
• To reuse a plug, wrap it with seal tape.

84402826 - May 2011

5005B-10
 Section

5005C

Removal and Installation of Grease Cylinder

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of grease cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of grease cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

5005C-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
5005C-2 PRINTED IN FRANCE
 Removal and Installation of Grease Cylinder

WARNING Removal of grease cylinder

• When loosening the grease cylinder check
valve, loosen it a little at a time.
• The pressure inside the cylinder is very high,
so there is a danger of grease being expelled
and the plug flying off.
The check valve adjustment procedure
should not be done in front of 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.
1. Remove the shoe assembly.
See the "Removal and Installation of Shoe Assem-
bly" procedure.
2. Use a crowbar (3) to pull off the take-up roller (1)
and recoil spring assembly about 100 mm from the
side frame (2).
When removing the grease cylinder, use a wood
plank or the like (4) to prevent the take-up roller (1)
and recoil spring assembly from coming out.

Items to prepare
• Wrench (24 mm, 27 mm)
• Hammer
• Lifting equipment
• Loctite #262
• Striking jig
• Striking jig
• Crowbar
• Wood planks, etc. 3. Jack up the side frame on the side where the grease
• Rag cylinder is being removed as shown in the diagram.
Jack up so that the shoe is floating about 5 cm,
and insert wood plank (1) under the lower frame to
prevent falling.

4. Use a wrench (27 mm) to remove the bolts (1) and

washers (2), and then remove the track guard (3).

84402826 - May 2011

5005C-3
 Removal and Installation of Grease Cylinder

5. Install the wire (2) on the grease cylinder assem-
bly (1), and then lift it with the liftcrane so that it is
slightly tensed.
Installation of grease cylinder
To install, perform the reverse of the removal procedure.
Grease cylinder installation bolt tightening torque: 267 -
312 N・m
When installing bolts, coat the threaded sections with
Loctite #262.

6. Use a wrench or box wrench (24 mm) to remove the

bolt (1) and washer (2), and then remove the grease
cylinder (3).
Lower the liftcrane as is to lower to under the frame,
and then take out from between the lower rollers.

84402826 - May 2011

5005C-4
 Section

5005D

Assembly and Disassembly of Tension Shock Absorber

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Configuration diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Dimension diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Jig dimension diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

5005D-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
5005D-2 PRINTED IN FRANCE
 Assembly and Disassembly of Tension Shock Absorber

CAUTION Configuration diagram

• To ensure safe operations, wear protective
devices before beginning work and follow all
precautions.
• When removing devices or positioning de-
vices at the time of installation, use a removal
jig and a hammer or steel rod.
• Follow the precautions below when suspend-
ing the load.
• The liftcrane must be operated by a quali-
fied operator.
• Do not stand or pass under the suspended
load.
• Check the weight of the grease cylinder to
determine whether it can be carried by hand
or whether a liftcrane must be used.
Co-
• Be sure to repair any parts damaged during Part name Q'ty
de
disassembly, and prepare replacement parts
in advance. 1 Dust seal 1
• If any parts are significantly rusted or dirty, 2 Piston rod 1
clean them before disassembling. 3 U-packing 1
• Any foreign matter entering the equipment 4 Retaining ring 1
during assembly can create a malfunction. 5 Grease cylinder 1
Therefore, after thoroughly cleaning the 6 High-strength bolt 2
equipment with cleaning oil, air blow the 7 Spring washer 2
equipment, and assemble in a clean location. 8 Bracket 1
• When assembling touching parts, be sure to 9 Check valve assembly 1
coat them with new hydraulic oil.
• As a rule, replace all O-rings and other seal
parts with new parts.
General cautions
• Be careful not to drop precision parts or let
bump them with other parts during work.
• Do not forcefully open or hit parts in an effort
to speed up operations.
Pay careful attention and proceed with cau-
tion so as not to damage any parts, create any
oil leaks, or compromise the efficiency of the
equipment.
• Disassembled parts can easily rust or collect
dust.
Therefore, immediately after disassembling
parts, take precautions to prevent the parts
from rusting or collecting dust.

Items to prepare
• Hammer
• Wrenches (19 mm)
• Box wrench (19 mm)
• Screwdriver
• Specialty jigs
• Special fiber cloth (Kimwipe)
• Marking pen

84402826 - May 2011

5005D-3
 Assembly and Disassembly of Tension Shock Absorber

Dimension diagram Jig dimension diagram

A Dust seal press-fit jig

B Removal jig

84402826 - May 2011

5005D-4
 Assembly and Disassembly of Tension Shock Absorber

Disassembly procedures 3. Use the removal jig (B) to remove the dust seal (2)
from the grease cylinder (1).
1. Clean the grease cylinder with kerosene, remove
the bolt (1) and washer (2), and remove the bracket
(3).
Remove the check valve (5) from the grease cylin-
der (4).

4. Remove the retaining ring (2) from the piston rod

(1), and then use the removal jig (B) to remove the
U-packing (3).

2. Pull out the piston rod (2) from the grease cylinder
(1).

84402826 - May 2011

5005D-5
 Assembly and Disassembly of Tension Shock Absorber

Assembly procedures
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.
4. Use the jig (A) and hammer (C) to install the dust
seal (2) on the grease cylinder (1).
Apply grease to the lip section of the dust seal (2).
• Use a new dust seal (2).

• Immerse in kerosene until dust, grease, and other

adhered matter comes off and floats to the sur-
face.
2. Place parts in a finish cleaning container filled with
kerosene and clean while gently moving the parts.
After cleaning, wipe away the kerosene with a clean
rag.
• Place the parts in a location free of dust and mois-
ture and use compressed air to dry the parts. After
drying, coat parts with engine oil.
3. Install the U-packing (1) coated with grease onto the
piston rod (2), and then install the retaining ring (3).
• Use a new U-packing (1).
• Be careful that the U-packing (1) faces correctly.

5. Coat the surface of the piston rod (1) with grease

and insert into the grease cylinder (2).

84402826 - May 2011

5005D-6
 Assembly and Disassembly of Tension Shock Absorber

6. Tighten the check valve (1) to the grease cylinder

(2) to the specified tightening torque.
Install the bracket (3) and secure it with the spring
washer (4) and the bolt (5).
Check valve tightening torque: 48.99 - 68.61 N•m

This completes the assembly.

84402826 - May 2011

5005D-7
Assembly and Disassembly of Tension Shock Absorber

84402826 - May 2011

5005D-8
 Section

6001

Removal and Installation of Travel Motor

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of Travel Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

6001-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
6001-2 PRINTED IN FRANCE
 Removal and Installation of Travel Motor

WARNING Removal of Travel Motor

• When loosening the check valve, loosen it a 1. Allow the bucket (1) to touch the ground so as to
little at a time and stop when any grease ap- elevate the shoe (2) of the side to be removed as in
pears. the diagram on the right.
The pressure inside the cylinder is very high,
so there is the danger of grease being ex-
pelled and the plug flying off if the check
valve is loosened too much.

CAUTION
• Before removing the shoes, be sure to bleed
off any air in the hydraulic circuits.
• Be sure to inspect the wire rope and other
lifting equipment before beginning work.
• Do not stand or pass under the suspended
load.

Items to prepare
2. Slowly rotate the shoe so that the shoe joint section
• Box wrenches (19 mm, 24 mm) (3) is aligned as in the diagram on the right.
• Wrenches (19 mm, 27 mm, 41 mm) 3. Place wood planks (4) under the shoe and return
• Hammer (to remove the master pin) the bucket to its original position.
• Striking jig (to remove the master pin) 4. Perform air bleeding for the hydraulic line.
• Liftcrane (with the required lifting capacity) For details, see Air Bleed Procedures.
• Wire rope (with the required breaking load)
• Loctite #262
• Wood planks, etc.
• Rag
• Cleaning fluid

84402826 - May 2011

6001-3
 Removal and Installation of Travel Motor

5. Use a box wrench (19 mm) to rotate the grease 8. Open the shoe (2) to the rear.
cylinder check valve (5) and loosen the shoe ten-
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.

9. Use a wrench (19 mm) to remove the 4 bolts (10),

then remove the cover (11).

6. Pull out the S-pin (6) from the rear of the joint sec-
tion.

10. Use wrenches (27 mm for drain hose, 41 mm for

high-pressure hose) to remove the drain hose (13)
and 3 high-pressure hoses (12).
• Be sure to use plugs on the removed drain and
high-pressure hoses.

7. Place a striking jig (9) against the master pin (7) and
hit it with a hammer (8) to push the master pin out.

84402826 - May 2011

6001-4
 Removal and Installation of Travel Motor

11. Use a wrench (19 mm) to remove the pilot hoses 13. Use a box wrench (24 mm) to remove all 28 bolts
(15) (14) shown in the diagram. (18).

14. Remove the travel motor (16).

12. Attach the wire rope (17) to the travel motor (16) as
in the diagram.
Adjust the wire rope so that it is located at the center
of mass and lift it with the liftcrane so that it is slightly
tensed.

84402826 - May 2011

6001-5
 Removal and Installation of Travel Motor

Installation of Travel Motor 3. Use a wrench (19 mm) to remove the elbow joint (3)
and pilot hose (4) shown in the diagram.
1. Attach the travel motor to the lower frame as in the
diagram.
• Be careful of the installation angles.

2. Apply Loctite #262 to the installation bolt (2)

threaded sections and temporarily tighten all 28
bolts.
Use a wrench (24 mm) to tighten the top and bottom
alternately to the specified torque so that an even
tightening force acts on the opposing sides.

4. Use wrenches (27 mm for drain hose, 41 mm for

high-pressure hose) to install the drain hose (6) and
high-pressure hose (5).
Tightening torque M16: 267 - 312 N・m

84402826 - May 2011

6001-6
 Removal and Installation of Travel Motor

5. Use a wrench (19 mm) to install the cover (8) with 8. Tighten the check valve (12).
the 4 bolts (7). While monitoring the track shoe tension, inject
grease into the grease cylinder.

6. Wrap the shoe (9).

9. When adjusting the track shoe tension, raise the
lower side frame as shown in the diagram.
Place a wood plank (13) under the lower frame to
prevent falling.
Adjust the tension so that the distance indicated
with A between the frame bottom (14) of the center
area of the lower side frame and the lowest hang-
ing part of the top of the shoe plate (15) is 290 - 310
mm.

7. Insert the master pin (11).

Insert the S-pin (10) and bend it so that it cannot slip
out.

84402826 - May 2011

6001-7
Removal and Installation of Travel Motor

84402826 - May 2011

6001-8
 Section

6002

Assembly and Disassembly of Travel Motor

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Tools for Assembly and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Standard Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Secondary Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Special Tool (jig) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Measurement Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Motor Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Precautions before Motor Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Tightening Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Motor Parts Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Reduction Gear Parts Maintenance Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Motor Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Precautions before Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Assembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Hydraulic Oil and Gear Oil Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Initial Pre-conditioning Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Structural Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Internal Structure Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Part Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

6002-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
6002-2 PRINTED IN FRANCE
 Assembly and Disassembly of Travel Motor

Tools for Assembly and Disassembly

Use the tools indicated below for the assembly and disassembly of the motor.
Standard Tools
The standard tools required for the assembly and disassembly of this motor are indicated in Table 1.

Standardized
No. Type and dimen-
No. Tool name Part used with
Manufacturer sions
name
1 Nominal size 60 1-2-19
2 Nominal size 120 1-2-8
3 Nominal size 230
4 Nominal size 450 1-2-20
5 Nominal size 900 24, 28
Nominal size
6 Preset-type torque wrench JIS B4650 1-2-2-4, 1-2-11, 1-2-14, 29
1800
Nominal size
7 11
2800
Nominal size
8 1-2-7
4200
Nominal size
9 8, 14
5600
10 Rachet handle for socket wrench JIS B4641
11 Bolt width 2.5 mm 1-2-19
12 Bolt width 4 mm 1-2-8
13 Bolt width 6 mm 1-2-20
14 Hexagon bit for socket wrench Bolt width 8 mm 28
15 Bolt width 10 mm 1-2-11
16 Bolt width 12 mm 11、29
17 Bolt width 14 mm 1-2-2-4
18 Size T50 24
Torx T-shaped bit JASO F116-89
19 Size T90 8, 14
20 Bolt width 10 mm 1-2-14
Socket for socket wrench JIS B4636
21 Bolt width 27 mm 1-2-7
22 Bolt width 2.5 mm 1-2-19
23 Bolt width 4 mm 1-2-8
24 Bolt width 6 mm 1-2-20
25 Hexagon wrench JIS B4648 Bolt width 8 mm 28
26 Bolt width 10 mm 1-2-11
27 Bolt width 12 mm 11, 29
28 Bolt width 14 mm 1-2-2-4
29 Bolt width 10 mm 1-2-14
Wrench JIS B4630
30 Bolt width 27 mm 1-2-7
31 Longnose pliers JIS B4631 1-2-7
32 Snap ring pliers S-2 type 1-4-5
33 Flathead screwdriver JIS B4609 6 x 100 2, 1-27, 1-2, 1-21
34 Plastic hammer OF-05 Nominal size #3
Length of about
35 Punch
10 mm
36 Press 200 kgf or higher
37 Liftcrane For 400 kg
38 For M20
Eyebolt
39 For M12 1-2
40 Chain string (wire)

84402826 - May 2011

6002-3
 Assembly and Disassembly of Travel Motor

Secondary Materials
The secondary materials required for the assembly and disassembly of this motor are indicated in Table 2.

Standardized
No. Type and dimen-
No. Secondary materials name Part used with
Manufacturer sions
name
1 Seal tape 1-2-8
2 Adhesive Loctite 271 8, 14
1-1, 1-7, 1-6, 1-2-1, 1-2-2, 1-2-9,
GL-4#90
3 Gear oil 1-4-1, 1-4-2, 1-21, 1-4-4, 1-4-3, 1-5,
equivalent
1-4-2, 1-6
ISO VG46
4 Hydraulic oil
equivalent
1-2-2-5, 1-2-6-2, 1-2-6-4, 1-2-12, 1-2-
5 Grease Lithium-series
21, 1-16, 1-17, 1-23, 1-12, 1-15, 1-21
No.2 equiva-
6 White kerosene
lent oil
7 Liquid packing ThreeBond 1211 4, 27
For sliding sur-
8 Lapping plate 1-4-1, 1-4-2, 1-5、1-21
face repair
For sliding sur-
9 Lapping agent #1000
face repair
10 Copper plate
11 Tube brush For cleaning 1-2-1, 1-4-1
12 Bamboo brush For cleaning
13 Oil pan Oil pan
14 Plastic container For filling grease
15 Rag

84402826 - May 2011

6002-4
 Assembly and Disassembly of Travel Motor

Special Tool (jig)

The special tools required for the assembly and disassembly of this motor are indicated in Table 3 (For dimensions,
refer to Section 1003).

Standard-
Type and
ized No. Part used
No. Tool name dimen-
Manufac- with
sions
turer name
1 Pulley remover 1-8, 1-9
2 Bearing press-fit jig 1-8
3 Bearing press-fit jig 1-9
4 Floating seal mounting jig 2
5 Rod 3
6 Angular bearing press-fit jig 3
7 Shim thickness adjustment jig 5
8 Rod 1-2-2
10 Thrust plate selection jig 26
11 Oil seal press-fit jig 1-12
12 Brake piston positioning jig 1-15
13 Snap ring removal jig 1-4-5
14 Poppet seat removal jig 1-2-7-3

Measurement Device
The measurement devices required for assembly of this motor are indicated in Table 4.

Standard-
Type and
ized No. Part used
No. Tool name dimen-
Manufac- with
sions
turer name
1 Dial gauge JIS B7503 5, 26
Micrometer
2 JIS B7502 5, 26
caliper

84402826 - May 2011

6002-5
 Assembly and Disassembly of Travel Motor

Motor Disassembly Procedures 7. To prevent injuries during disassembly, prepare a

waist-high, stable work platform to perform work on.
Precautions before Motor Disassembly 8. The motor comprises high-precision parts.
For this reason, foreign matter adhering to parts can
Begin motor disassembly only after thoroughly reading be damaging.
the precautions below. Motor disassembly should be done in an inside
1. When performing disassembly, always wear pro- space without dust, and mud and dirt should be
tective gear such as a helmet, goggles and safety prevented from adhering to parts.
shoes. 9. The motor comprises high-precision parts.
2. Use the specified tools when performing disassem- For this reason, dents and scratches on part sur-
bly. faces can be damaging.
3. Remove all lines connected to the motor and re- Be very careful when handling parts during disas-
move the motor from the machine only after mak- sembly and do not create any dents or scratching.
ing sure that the machine is on a level surface and 10. To prevent personal injury and damage to parts dur-
there are no external forces acting on rotating parts, ing disassembly, do not force disassembly of parts
so that the machine does not operate uncontrollably which are especially tight to disassemble.
when the motor is removed.
4. To prevent foreign matter from entering the lines
and motor when removing the motor from the ma-
chine, sufficiently clean off mud and dirt adhered
around the motor before removing lines connected
to the motor.
5. When removing lines connected to the motor, hy-
draulic oil from inside the lines will spray out.
For this reason, remove these lines only after re-
moving pressure from inside the lines and prepar-
ing an oil pan.
To prevent injuries due to the motor falling when
transporting it by lifting the motor with a liftcrane,
lift the machine with the eyebolts mounted in the
positions indicated in the diagram below.
6. The motor is filled with hydraulic oil.
Before disassembling the motor, prepare an oil pan *1 Eyebolt
and drain the hydraulic oil from the motor. *2 Lifting

84402826 - May 2011

6002-6
 Assembly and Disassembly of Travel Motor

Tightening Torque
Table 5 indicates tightening torque for each fastening section.

Reference
Part name Screw size Bolt width Tightening torque
number
1-2-2-4 Plug M24 x 1.5 14 127 - 147 N・m
1-2-6-4 Hexagon socket head bolt M12 x 1.75 x 40 L 10 98 - 118 N・m
1-2-7 Relief valve assembly 1-5/16 12UNF 27 353 - 393 N・m
1-2-8 Plug NPTF1/16 4 8.8 - 10.8 N・m
1-2-11 Plug G1/2 10 112 - 124 N・m
1-2-14 Plug G1/2 10 112 - 124 N・m
1-2-17 Orifice M5 x 0.8 x 5 L 2.5 1.96 - 2.94 N・m
1-2-18 Orifice M5 x 0.8 x 5 L 2.5 1.96 - 2.94 N・m
1-2-19 Orifice M5 x 0.8 x 5 L 2.5 1.96 - 2.94 N・m
1-2-20 Plug G1/4 6 34.3 - 39.3 N・m
1-11 Hexagon socket head bolt M14 x 2.0 x 35 L 12 195 - 215 N・m
8 Bolt M20 x 2.0 x 70 L Torx T90 512 - 566 N・m
14 Bolt M20 x 2.0 x 130 L Torx T90 512 - 566 N・m
24 Screw M10 x 1.5 Torx T50 53.9 - 63.7 N・m
28 Hexagon socket head bolt M10 x 1.5 x 16 L 8 69.77 - 77.03 N・m
29 Plug G3/4 12 149 - 165 N・m

84402826 - May 2011

6002-7
 Assembly and Disassembly of Travel Motor

Disassembly Procedure CAUTION

Perform disassembly by observing the precautions listed
The plunger assembly and base plate are
in Section 1 and following the procedure indicated below.
fit together with a very small gap.
1. Removal of cap assembly For this reason, observe the following pre-
Secure the motor on top of the stable work platform, cautions when working.
loosen the 8 hexagon socket head bolts (1-2-6-4),
1) Do not try to force out the plunger
and remove the 2 cap assemblies (1-2-6).
assembly if it becomes stuck when
Next, remove the springs (1-2-4) and spring seats
being removed.
(1-2-3).
If it is forced out, this could scratch
CAUTION the inner diameter surface of the base
plate hole or the outer diameter sur-
The cap assemblies are pushed out by the face of the plunger assembly.
spring. If the plunger assembly becomes
For this reason, observe the following pre- stuck, lightly hit the end surface of
cautions when working. it with a plastic hammer to insert it
once into the base plate.
1) Loosen the hexagon socket head After this, check that the plunger as-
bolts evenly. sembly moves smoothly and remove
2) Loosen the hexagon socket head it again while rotating it.
bolts while pressing down the cap 2) Do not perform disassembly of the
assemblies. plunger assembly if it is not neces-
sary.
Disassembly can cause scratching
on the outside diameter surface of
the plunger assembly.
When disassembly is necessary, con-
tact our company.

2. Removal of plunger assembly

Lightly press the end of the plunger assembly
(1-2-2) to partially eject the plunger assembly from
the base plate (1-2-1).
Next, hold the end of the plunger assembly by hand
and remove the plunger assembly from the base
plate while rotating it. 3. Removal of relief valve assembly
Loosen the plug (1-2-7-6) and remove the relief
valve assembly (1-2-7).
At this time, each poppet seat (1-2-7-3) remains in
the base plate (1-2-1).

84402826 - May 2011

6002-8
 Assembly and Disassembly of Travel Motor
CAUTION
The relief valve assemblies are at a set
pressure.
The motor driving force and braking force
are both determined by this set pressure.
For this reason, do not perform the follow-
ing actions.
1) Loosen the nut (1-2-7-16) and do not
tamper with the locking screw (1-2-7-
15).
If this part is tampered with, the
set pressure of the relief valve will
change and the machine will no
longer display prescribed capabili-
ties.
2) Do not perform disassembly of the
relief valve assemblies.
The set pressure will change and the
machine will no longer display pre-
scribed capabilities.
4. Poppet seat removal
Use the poppet seat removal jig to remove each
poppet seat (1-2-7-3) from the base plate (1-2-1).
CAUTION
Do not perform disassembly if it is not nec-
essary.
84402826 - May 2011
6002-9
5. Removal of spool assembly
Loosen the plugs (1-2-11) (1-2-14) and remove the
plugs and spring (1-2-10).
Lightly press the end of the spool assembly (1-2-9)
to partially eject the spool assembly from the base
plate (1-2-1).
Next, hold the end of the spool assembly by hand
and remove the spool assembly from the base plate
while rotating it.
CAUTION
The spool assembly and base plate fit to-
gether with a very small gap.
For this reason, observe the following pre-
cautions when working.
1) Do not try to force out the spool as-
sembly if it becomes stuck when be-
ing removed.
If it is forced out, it could scratch
the inner diameter surface of the base
plate hole or the outer diameter sur-
face of the spool assembly.
If the spool assembly becomes stuck,
lightly hit its end surface with a plas-
tic hammer to insert it temporarily
into the base plate.
After this, check that the spool as-
sembly moves smoothly and remove
it again while rotating it.
2) Do not disassemble the spool assem-
bly unless it is necessary.
When disassembly is necessary, con-
tact our company.
6. Do not remove the plugs (1-2-8) unnecessarily.
Each orifice (1-2-22) (1-2-23) (1-2-19) is caulked to
prevent loosening.
Do not perform disassembly.
7. Removal of base plate
Loosen the hexagon socket head bolts (1-11) and
remove the base plate (1-2-1).
 Assembly and Disassembly of Travel Motor

CAUTION 8. Removal of valve plate

Use a flathead screwdriver to remove the valve
When removing the base plate, observe plate (1-21) from the base plate (1-2-1).
the following precautions.
CAUTION
1) The base plate is pushed upwards by
the springs (1-18). When removing the valve plate, observe
For this reason, loosen the hexagon the following precaution.
socket head bolts evenly when loos-
1) The valve plate sliding surface is eas-
ening. ily scratched.
2) Positioning pins (1-19) are mounted
If the sliding surface is scratched,
between the base plate and main unit. prescribed capabilities will disap-
For this reason, pull the base plate
pear, so prevent scratching from
(1-2-1) straight off in alignment with occurring.
the center axis of the motor when re-
moving it so that it does not become
stuck with the pins.
If it becomes stuck, lightly strike the
base plate with a plastic hammer to
put the pins in the correct position,
and then remove the base plate.
3) When removing the base plate, the
valve plate (1-21) is attached to the
base plate.
The valve plate sliding surface is eas-
ily scratched, so be careful not to let
the valve plate fall.

9. Removal of O-rings, pin and spring

Remove the O-rings (1-22) (1-23), pin (1-19), and
spring (1-18).

10. Removal of brake piston

Attach a pressured air nozzle to the flange (1-1) oil
path for the parking brake, and inject compressed
air to the parking brake cylinder chamber to raise
the brake piston (1-15) and remove it.
After removing the brake piston, remove the disk
plates (1-13) and friction plates (1-14), and remove
the D-rings (1-16) (1-17) from the brake piston.

84402826 - May 2011

6002-10
 Assembly and Disassembly of Travel Motor

CAUTION
When removing the cylinder block assem-
bly, observe the following precautions.
1) Hold the cylinder block assembly
with both hands and lightly rotate it
left and right to slowly remove it.
2) Be careful not to scratch the sur-
face of the cylinder block (1-4-1) that
slides against the valve plate (1-21).
If this surface is scratched, the ma-
chine will no longer display pre-
scribed capabilities.
3) Be careful not to scratch the piston
assembly (1-4-2) shoe sliding sur-
CAUTION
faces.
When removing the brake piston, observe If this surface is scratched, the ma-
the following precautions. chine will no longer display pre-
scribed capabilities.
1) When injecting compressed air from
the flange oil path for the parking
brake, do not let any compressed air
leak out.
2) When injecting compressed air from
the flange oil path for the parking
brake, the brake piston may fly off if
the pressure of the compressed air is
high, and this may cause injury.
For this reason, set the air pressure at
0.29 MPa or below, and hold down the
brake piston while performing work
so that it does not fly off.

12. Disassembly of cylinder block assembly

1) Mark the piston assemblies (1-4-2) and cylin-
der block (1-4-1) with permanent ink so that
parts can be reassembled in the exact same
configuration, and remove the piston assem-
blies and retainer plate (1-4-3) from the cylin-
der block.

11. Removal of cylinder block assembly

Remove the cylinder block assembly (1-4) from the
flange (1-1).

84402826 - May 2011

6002-11
 Assembly and Disassembly of Travel Motor
2) Mark the piston assemblies (1-4-2) and re- 4)
tainer plate (1-4-3) with permanent ink so that
parts can be reassembled in the exact same
configuration, and remove the piston assem-
blies from the retainer plate.
3) Remove the retainer holder (1-4-4) from the
cylinder block (1-4-1) and remove the pins
(1-4-9) from the cylinder block.
5)
13. Removal of swash plate
Remove the swash plate (1-5) from the flange (1-1).
84402826 - May 2011
6002-12
Secure the cylinder block (1-4-1) on the man-
ual press platform with the sliding surface fac-
ing up, remove the snap ring (1-4-5), press the
collar (1-4-8) with the jig to make the spring
(1-4-7) bend, and use snap ring pliers to re-
move the snap ring.
CAUTION
When removing the snap ring, ob-
serve the following precaution to pre-
vent injuries.
1) The snap ring is stiff and may
come off from the snap ring pli-
ers when the snap ring is being
removed, which could cause in-
jury.
When removing the snap ring,
make sure to use a disassembly
jig and check that the nails of
the snap ring pliers are in the
snap ring hole before removal.
Remove the collar (1-4-8), spring (1-4-7), and
spring seat (1-4-6) from the cylinder block
(1-4-1).
 Assembly and Disassembly of Travel Motor

CAUTION CAUTION
When removing the swash plate, observe When removing the shaft, observe the fol-
the following precautions. lowing precautions.
1) Be careful not to scratch the swash 1) Be careful not to scratch the splines
plate sliding surface. on the shaft.
If this surface is scratched, the ma- 2) Be careful not to scratch the sliding
chine will no longer display pre- section of the shaft oil seal (1-12).
scribed capabilities. Scratching this surface may cause oil
2) Piston assemblies (1-7) and steel leaking.
balls (1-6) may be attached to the
swash plate.
When these are attached, be careful
not to let them fall.

16. Draining reduction gear lubricating oil

14. Removal of piston assembly and steel ball
Remove the piston assemblies (1-7) from the flange
(1-1) and remove the springs (1-20).
Remove the steel balls (1-6) from the flange.
CAUTION
The steel balls are difficult to remove, so
use the following procedure to do this.
1) With the steel balls mounted on the
flange, use white kerosene or thinner
to degrease.
2) Use a magnet to remove the steel
balls from the flange.
Before disassembling the reduction gear section,
use the tap for securing the flange (1-1) and mount
two eyebolts in opposing positions to lift the reduc-
tion gear with a liftcrane.
Remove the plugs (29) in the 2 locations and drain
the reduction gear lubricating oil.
CAUTION
1) Prepare an oil pan before performing
work.
2) Do not lift to too high position when
lifting with the liftcrane. Perform
work with the reduction gear at the
lowest possible position (at about
knee height).

17. Removal of cover

Loosen and remove the hexagon socket head bolts
15. Removal of shaft
(28).
Remove the shaft (1-3) and ball bearing (1-8) from
After this, remove the cover (27).
the flange (1-1).

84402826 - May 2011

6002-13
 Assembly and Disassembly of Travel Motor

CAUTION 19. Removal of drive gear

Remove the driver gear (25).
Use the following procedure when remov-
ing the cover.
1) Liquid packing has been applied be-
tween the cover and housing (4).
For this reason, it is difficult to re-
move the cover.
Loosen the socket head bolt and
strike the top and side of the cover
with a plastic hammer after removing
the bolt.
2) Insert a flathead screwdriver in the
gap between the cover and housing
and remove the cover.

20. Removal of 1st stage holder assembly

Remove the 1st stage holder assembly comprising
the holder B (17), planetary gears B (21), needle
bearings (20), inner races (19), thrust plates (18),
thrust plates (22), thrust plate (23), and screws (24).

CAUTION
When removing the 1st stage holder as-
sembly, observe the following precaution.
When removing the assembly, be careful of
fingers getting caught.

18. Removal of thrust plate

Remove the thrust plate (26) from the thrust plate
(23) top surface.

84402826 - May 2011

6002-14
 Assembly and Disassembly of Travel Motor

21. Disassembly of 1st stage holder assembly CAUTION

Secure the 1st stage holder assembly with a vise
and warm the screws (24) with a dryer to loosen When loosening bolts, observe the follow-
them. ing precautions.
Remove the screws, thrust plate (23), thrust plates
(22), planetary gears B (21), needle bearings (20), 1) Loctite has been applied to the bolts
inner races (19) and thrust plates (18) from holder to prevent loosening.
B (17), in that order. For this reason, securely fix the
flanges.
CAUTION 2) When loosening bolts, use a tool
such as a steel pipe to reach the
When loosening the screws, observe the bolts.
following precautions. Straining excessively may cause
Loctite has been applied to the screws. back pain or injury.
For this reason, they do not loosen easily.
If they are scratched due to being forcibly
loosened, they cannot be used again.
Before loosening, warm the screws suffi-
ciently with a dryer.

24. Disassembly of holder C

Secure the flange (1-1) and loosen and remove the
bolts (8).
Holder C (6) is secured to the flange with the pins
(31).
22. Removal of sun gear C Mount the removal jig from the motor side and use
Remove sun gear C (15). the press to remove holder C.

CAUTION
When loosening bolts, observe the follow-
ing precautions.
1) Loctite has been applied to the bolts
to prevent loosening.
For this reason, securely fix the
flanges.
2) When loosening bolts, use a tool
such as a steel pipe to reach the
bolts.
Straining excessively may cause
back pain or injury.
23. Removal of planetary gear C
Secure the flange (1-1) and loosen the bolts (14) to
remove them.
Next, remove the thrust plates (13), planetary gears
C (12), needle bearings (11), inner races (10), and
thrust plates (9), in that order.

84402826 - May 2011

6002-15
 Assembly and Disassembly of Travel Motor

26. Removal of floating seal

Raise the outer circumference of the floating seals
(2) with a flathead screwdriver and remove the float-
ing seals.

27. Parts storage

This completes the disassembly.
When storing disassembled parts, place parts in
plastic bags in a cool, dark and dry location after
cleaning the parts and applying anti-rust oil.
If parts are stored in a hot, moist location, rust will
develop even if anti-rust oil is applied.
Also store them in a way so that dust does not col-
lect on them.

25. Separation of flange and housing

Mount the jig on the outer circumference brim end
surface of the housing (4), and then press the flange
(1-1) with the press to separate the housing and
flange.

84402826 - May 2011

6002-16
 Assembly and Disassembly of Travel Motor

Maintenance Standards
Motor Parts Maintenance Standards
Table 6 indicates maintenance standards for motor parts.
Check each part according to the motor parts maintenance standards in Table 6. When a permissible limit has been
exceeded or is near being exceeded, perform part repair or replacement according to repair and solution procedures.

Inspection and measure- Repair, solution proce-

Applicable part Permissible limit value
ment location dure
Lap the shoe sliding surface
0.8 a degree of roughness
(#1000)
Or the surface is rough or
1. Shoe sliding surface If the scratching cannot be
there is scratching at least
removed, replace the cylin-
0.02 mm deep.
der block assembly (1-4).
1.2a degree of roughness
Piston Assembly
Or the surface is rough or
(1-4-2) 2. Piston outer diameter
there is scratching at least
0.02 mm deep. Replace the cylinder block
3. Piston outer diameters assembly (1-4).
and cylinder block (4-1) Gap 0.060 mm
bore inner diameters
4. Shoe ball backlash 0.4 mm of backlash
Lap the sliding surface
0.8 a degree of roughness
(#1000)
1. Sliding surface against Or the surface is rough or
If the scratching cannot be
the valve plate there is scratching at least
removed, replace the cylin-
0.02 mm deep.
der block assembly (1-4).
Cylinder block 1.6 a degree of roughness
(1-4-1) Or the surface is rough or
2. Bore inner diameter
there is scratching at least
Replace the cylinder block
0.02 mm deep.
assembly (1-4).
3. Bore inner diameter and
piston assembly (4-2) outer Gap 0.060 mm
diameter
Diameter between parts
38.749 mm
Diameter of measurement
Cylinder block 1. Shaft bonding section Replace the cylinder block
pin
(1-4-1) spline assembly (1-4).
D3.333（V1 = 2.80） mm
Or breaking damage is oc-
curring.
0.8 a degree of roughness
There is scratching at least Lap the sliding surface
0.02 mm deep on the sliding (#1000)
Valve plate
1. Sliding surface surface. If the scratching cannot be
(1-21)
Or seizing is occurring. removed, replace the valve
There is abnormal wear on plate (1-21).
the sliding surface.
0.8 a degree of roughness
Retainer plate
There is scratching at least
(1-4-3) Replace the retainer plate
1. Sliding surface 0.02 mm deep on the sliding
Retainer holder and retainer holder.
surface.
(1-4-4)
Or seizing is occurring.

84402826 - May 2011

6002-17
 Assembly and Disassembly of Travel Motor

Inspection and measure- Repair, solution proce-

Applicable part Permissible limit value
ment location dure
Lap the sliding surface
0.8 a degree of roughness
(#1000)
There is abnormal wear or
1. Sliding surface If the scratching cannot be
scratching least 0.02 mm
removed, replace the valve
deep on the sliding surface.
plate (1-21).
Swash plate 1.6 a degree of roughness
(1-5) There is scratching at least
2. Steel ball mounting sec-
0.02 mm deep on the ball
tion spherical hole
surface or the surface is Replace the swash plate.
rough.
3. Steel ball mounting sec-
Ball depth 14.5 mm
tion spherical hole
1.6 a degree of roughness
Aside from the oil seal
1. Oil seal sliding section lip sliding imprint, there is
outer diameter scratching at least 0.02
mm deep or the surface is
rough.
Over-pin diameter
47.380 mm
Diameter of measurement
2. Cylinder block bonding
Shaft pin
section spline Replace the shaft.
(1-3) D3.00 mm
Or breaking damage is oc-
curring.
Diameter between parts
30.498 mm
Diameter of measurement
3. Drive gear bonding sec-
pin
tion spline
D3.33 mm
Or breaking damage is oc-
curring.
1. Exterior dimensions Height 38.2 mm
2. Sliding surface 2.5 a degree of roughness
Brake piston
(1-15) There is scratching at least Replace the brake piston.
3. Exterior 0.02 mm deep. Or the sur-
face is rough.
1. Exterior dimensions Thickness 3.2 mm
Disk plate There is deep scratching or Replace the disk plate.
(1-139) 2. Exterior friction material is peeling
off.
Flaking or pressure imprint-
Ball bearing 1. Rotation surface
ing is occurring.
(1-8)
Ball bearing There are rotation abnor- Replace the ball bearing.
(1-9) 2. Operation malities (abnormal noises,
rotation unevenness).
Lap the shoe sliding surface
1.6 a degree of roughness
(#1000)
Or the surface is rough or
1. Shoe sliding surface If the scratching cannot be
there is scratching at least
removed, replace using the
0.02 mm deep.
flange holder kit.
1.2 a degree of roughness
Piston Assembly
Or the surface is rough or
(1-7) 2. Piston outer diameter
there is scratching at least
0.02 mm deep. Replace using the flange
3. Piston outer diameters holder kit.
and flange holder (1-1) in- Gap 0.040 mm
ner diameters
4. Shoe ball backlash 1.0 mm of backlash

84402826 - May 2011

6002-18
 Assembly and Disassembly of Travel Motor

Inspection and measure- Repair, solution proce-

Applicable part Permissible limit value
ment location dure
0.8 a degree of roughness
There is scratching at least
1. Plunger outer diameter
0.02 mm deep. Or the sur-
Plunger assembly Replace using the base
face is rough.
(1-2-2) plate kit.
2. Plunger outer diameter
and base plate inner diam- Gap 0.060 mm
eter
0.8 a degree of roughness
1. Plunger assembly (2-2) There is scratching at least
mounting hole 0.02 mm deep. Or the sur-
face is rough.
2. Base plate inner diame-
ter and plunger outer diam- Gap 0.060
eter
Base plate 0.8 a degree of roughness Replace using the base
(1-2-1) 3. Spool assembly (2-11) There is scratching at least plate kit.
mounting hole 0.02 mm deep. Or the sur-
face is rough.
4. Base plate inner diame-
Gap 0.060 mm
ter and spool outer diameter
5. Relief valve assembly There is scratching at least
free piston sliding and seat 0.02 mm deep. Or the sur-
sections face is rough.
0.8 a degree of roughness
There is scratching at least
1. Spool outer diameter
Spool assembly 0.02 mm deep. Or the sur- Replace using the base
(1-2-9) face is rough. plate kit.
2. Spool outer diameter and
Gap 0.060 mm
base plate inner diameter
1. Sliding section against There is scratching at least
Free piston
the base plate and seat sec- 0.02 mm deep. Or the sur-
(1-2-7-9)
tion face is rough.
1. Sliding section against There is scratching at least
Relief housing
the free piston (outer diam- 0.02 mm deep. Or the sur-
(1-2-7-1)
eter) face is rough.
1. Exterior dimensions Free length 61.0 mm
Spring There is deformation and
(1-4-7) 2. Exterior scratching on the coil sur-
face.
1. Exterior dimensions Free length 39.0 mm
Spring There is deformation and
(1-18) 2. Exterior scratching on the coil sur- Replace using the relief
face. valve assembly.
1. Exterior dimensions Free length 41.5 mm
Spring There is deformation and
(1-20) 2. Exterior scratching on the coil sur-
face.
1. Exterior dimensions Free length 48.5 mm
Spring There is deformation and
(1-2-4) 2. Exterior scratching on the coil sur-
face.
1. Exterior dimensions Free length 28.3 mm
Spring There is deformation and
(1-2-10) 2. Exterior scratching on the coil sur-
face.
Replace each O-ring and oil
Each O-ring and oil seal During disassembly
seal.

84402826 - May 2011

6002-19
 Assembly and Disassembly of Travel Motor

Reduction Gear Parts Maintenance Standards

Table 7 indicates maintenance standards for reduction gear parts.
Check each part according to the reduction gear parts maintenance standards in Table 7. When a permissible limit
has been exceeded or is near being exceeded, perform part repair or replacement according to repair and solution
procedures.

Inspection and mea- Repair, solution proce-

Applicable part Permissible limit value
surement location dure
Across 6 teeth
Tooth thickness
66.649 mm
There is pitching on 10 % or Replace planetary gear B.
more of the tooth surface or
Planetary gear B (21) Tooth surface
breaking damage is occur-
ring.
Flaking is occurring on the
Inner diameter
inner diameter surface.
Replace the planetary gear,
Flaking is occurring on the
Needle bearing (20) Roller rotation surfaces needle bearing and inner
surface.
race.
Flaking is occurring on the
Inner race (19) Outer diameter surface
surface.
Across 3 teeth
Tooth thickness
29.908 mm
There is pitching on 10 % or Replace the drive gear.
more of the tooth surface or
Tooth surface
breaking damage is occur-
ring.
Drive gear (25) Over-pin diameter
38.989 mm
Diameter of measurement If replacing the drive gear,
Spline section pin inspect the shaft at the
D3.00 mm same time.
Or breaking damage is oc-
curring.
Diameter between parts
66.742 mm
Diameter of measurement
Tooth thickness of inter-
Holder B (17) pin Replace holder B.
nal tooth
D7.00 mm
Or breaking damage is oc-
curring.
Across 4 teeth
Tooth thickness
41.371 mm
There is pitching on 10 % or
Sun gear C (I5) Replace sun gear C.
more of the tooth surface or
Tooth surface
breaking damage is occur-
ring.
Across 6 teeth
Tooth thickness
65.662 mm
There is pitching on 10 % or Replace planetary gear C.
more of the tooth surface or
Planetary gear C (12) Tooth surface
breaking damage is occur-
ring.
Flaking is occurring on the
Inner diameter
inner diameter surface.
Replace the planetary gear,
Flaking is occurring on the
Needle bearing (11) Roller rotation surfaces needle bearing and inner
surface.
race.
Flaking is occurring on the
Inner race (10) Outer diameter surface
surface.

84402826 - May 2011

6002-20
 Assembly and Disassembly of Travel Motor

Inspection and mea- Repair, solution proce-

Applicable part Permissible limit value
surement location dure
Diameter between parts
330.449 mm
Tooth thickness Diameter of measurement
pin
Housing (4) D7.000 mm Replace the housing.
There is pitching on 10 % or
more of the tooth surface or
Tooth surface
breaking damage is occur-
ring.
Shim (5) During disassembly Replace the shim.
2-speed piston hole in-
ner diameter and piston Gap 0.040 mm
assembly outer diameter
Flange (1-1) 1.2 a degree of roughness Replace using the flange kit.
2-speed piston hole in- Or the surface is rough or
ner diameter there is scratching at least
0.02 mm deep.
Plate thickness 3.3 mm
Plate thickness 2.5 mm
Plate thickness 2.9 mm
Thrust plate (26) Thickness Plate thickness 2.0 mm Replace the thrust plate.
Plate thickness 2.7 mm
Or there is deep scratching
on the sliding surface.
Ball rotation surfaces Flaking is occurring.
Abnormal noise or un- Replace the angular bear-
Angular bearing (3)
Operation smooth rotation occurs with ing.
rotation.
There is deep scratching Replace the floating seal.
Sliding surface
that may cause oil leaking. When doing more disas-
sembly beyond this, be-
cause oil leaking may oc-
cur due to the seal ring
Floating seal (2)
Cracking is occurring on the slide imprints not matching
O-ring up of reused seals when
surface.
reassembly is done, re-
place these seals before
reassembly.
Each O-ring During disassembly Replace each O-ring.

84402826 - May 2011

6002-21
 Assembly and Disassembly of Travel Motor

Motor Assembly Procedures Assembly Procedure

Perform assembly by observing the precautions listed in
Precautions before Motor Assembly Section 1 and following the procedure indicated below.
Begin motor assembly only after thoroughly reading the 1. Assembly of reduction gear section
precautions below.
1) Attachment of floating seal to flange
1. When performing assembly, always wear protective After confirming the items below concerning
gear such as a helmet, goggles and safety shoes. the floating seals (2), use the floating seal in-
2. Use the specified tools when performing assembly. stallation jig to attach the floating seals to the
3. To prevent injuries during disassembly, prepare a flange (1-1).
waist-high, stable work platform to perform work on.
4. The motor comprises high-precision parts. Confirmation items:
For this reason, foreign matter adhering to parts can 1) Check that there is no dirt adhered to
be damaging. the floating seal mounting surfaces on
Motor assembly should be done in an inside space the flange.
without dust, and mud and dirt should be prevented 2) Thoroughly degrease the floating seal
from adhering to parts. mounting surfaces on the flange.
5. The motor comprises high-precision parts. 3) Check that there is no dirt adhered
For this reason, dents and scratching on part sur- to the O-ring surfaces on the floating
faces can be damaging. seals.
Be very careful when handling parts during assem- 4) Thoroughly degrease the O-ring sur-
bly and do not create any dents or scratching. faces on the floating seals.
6. Be sure to repair any damage discovered during
disassembly and prepare replacement parts before
beginning assembly.
7. Remove metal fragments and foreign matters from
all parts and check that there are no burrs or dents
on parts before beginning assembly.
If there are burrs or dents, use a whetstone to re-
move them.
8. When performing assembly, apply clean hydraulic
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. 2) Attachment of angular bearing to housing
11. Be careful not to damage O-rings and backup rings Use the press-fit jig or press to press fit the
during assembly. angular bearings (3) to the housing (4).
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
specified tightening torque indicated in "Tightening
Torque".
Tightening torque should be controlled with a torque
wrench.
14. After assembly is complete, plug all ports leading
into the motor to prevent dirt from entering.

3) Attachment of floating seal to housing

After confirming the items below concerning
the floating seals (2), use the floating seal in-
stallation jig to attach the floating seals to the
housing (4).
Confirmation items:

84402826 - May 2011

6002-22
 Assembly and Disassembly of Travel Motor

1) Check that there is no dirt adhered to
the floating seal mounting surface on
the housing.
2) Thoroughly degrease the floating seal
mounting surface on the housing
3) Check that there is no dirt adhered
to the O-ring surfaces on the floating
seals.
4) Thoroughly degrease the O-ring sur-
faces on the floating seals.
1) Use the shim thickness adjustment jig to
press the inner ring end sections of the
angular bearings (3) with a load of 2.94
kN.
2) Measure the H level dimensions at this
time for the angular bearings inner ring
end surfaces and flange (1-1) end sur-
face.
3) Measure the h level dimensions of
holder C (6).
4) Select a shim and install it so that the
shim thickness is appropriate to the di-
mensions (H-h).

CAUTION
1) Do not reuse shims.
2) Be sure to perform this
procedure properly.
If precompression adjust-
ment is not done properly,
reduction gear damage
could occur during opera-
tion.
3) Clean the measurement
4) Attachment of the housing to the flange surfaces.
After confirming the items below, use a
liftcrane to attach the housing to the flange so
that the floating seal (2) section of the flange
(1-1) is aligned with the floating seal section
of the housing (4).
Confirmation items:
1) Check that there is no dirt adhered to
the seal ring sliding surfaces of the
floating seals.
2) Apply reduction gear lubricating oil or
hydraulic oil all around the seal ring
sliding surfaces of the floating seals.
3) When attaching the flange and hous-
ing, attach them after checking that
the axis center is aligned.
*1 Press load of 2.94 kN
*2 H dimensions
*3 h dimensions

*1 Press load of 661.0514 lbf

*2 H dimensions
*3 h dimensions

6) Holder attachment
Secure the flange (1-1) and stand the pins
(31) straight up on the flange in 4 locations.
Use grease to attach the shim selected in 5)
to holder C (6), and press fit the shim while it
5) Shim thickness selection is aligned with the pin holes on the holder.
Select the precompression adjustment shim Mount the washers (7) on the holder, apply
(5) thickness according to the following pro- Loctite to the threaded sections, and tighten
cedure. the bolts (8) to the specified torque.

84402826 - May 2011

6002-23
 Assembly and Disassembly of Travel Motor
CAUTION
1) Check that the pins (31) have
not fallen.
2) The loosening stop spikes
should be attached to the wash-
ers.
Put the spikes on the holder
seating surface side to mount
them.
3) Thoroughly clean the bolt
threaded sections and apply
Loctite after degreasing.
4) Also thoroughly clean the inter-
nal areas of the screw holes of
the flange, and thoroughly de-
grease them.
84402826 - May 2011
6002-24
Be careful to attach the wash-
ers (7) in the correct direction.
*
Attach them in the direction
shown in the diagram above.
*1 Holder side
*2 Bolt seating surface side
7) Planetary gear attachment
Attach the thrust plates (9) to planetary gear
C (12).
Next, attach the needle bearings (11) to the
planetary gears.
Finally, after attaching the inner races (10),
join the flange trunnion sections (4 locations)
with the internal diameter sections of the inner
races to attach the planetary gears.
CAUTION
1) When attaching the thrust
plates to the planetary gears,
make sure the shear droop on
the thrust plates created by the
press is facing the 1-1 flange
side.
2) When finally attaching the plan-
etary gears to the flange, attach
them so that the internal teeth of
the housing (4) engage with the
planetary gear teeth.
3) Be careful with the attach-
ment directions of the planetary
gears.
 Assembly and Disassembly of Travel Motor

Make the shear droop side face Mount so that the C2 chamfer
*1
the holder C (6) side. side is the seating surface side
*1
Thrust plate (9) attachment di- for the hexagon socket head
*2 bolts.
rection

9) Sun gear C attachment

8) Thrust plate attachment
After checking that the snap ring (16) is
Mount the thrust plates (13) on the planetary
mounted on sun gear C (15), mount sun gear
gears (12) in such a way that the chamfers
C in the middle of the 4 planetary gears C
of the bolt hole sections are the neck bottom
(12).
section of the bolts (14).
After mounting, mount the bolts that have had CAUTION
Loctite applied to the threaded sections and
tighten them to the specified torque. Mount the sun gear C so that the teeth
engage with the teeth of the planetary
CAUTION gears.
1) Be careful with the mounting di-
rection of the thrust plates.
Mistakes could cause scratch-
ing on the bolt neck sections
and this could result in damage.
2) Thoroughly clean the bolt
threaded sections and apply
Loctite after degreasing.
3) Also thoroughly clean the inter-
nal areas of the screw holes of
the flange (1-1), and thoroughly
degrease them.

10) Holder attachment

Engage the internal teeth of holder B (17) with
the teeth of sun gear C (15) and attach the
holder to sun gear C.

11) Planetary gear attachment

Attach the thrust plates (18) to planetary gear
B (21).
Next, attach the needle bearings (20) to the
planetary gears.
Finally, after attaching the inner races (19),
join the holder B (17) trunnion sections (3 lo-
cations) with the internal diameter sections of
the inner races to attach the planetary gears
to the holder.

84402826 - May 2011

6002-25
 Assembly and Disassembly of Travel Motor

CAUTION planetary gears. Also engage the teeth of the

planetary gears with the drive gear teeth.
1) When attaching the thrust
plates to the planetary gears, CAUTION
make sure the shear droop on 1) Be careful with the attachment
the thrust plates created by the
direction of the thrust plates.
press is facing the holder side. 2) Thoroughly clean and degrease
2) When finally attaching the plan-
the screw holes and threaded
etary gears to the holder, attach sections of holder B (17).
so that the internal teeth of the
housing (4) engage with the
planetary gear teeth.
3) Be careful with the attach-
ment directions of the planetary
gears.

Make the shear droop side face

*1
the planetary gear C (12) side.
Thrust plate (13) attachment di-
*2
rection

13) Thrust plate attachment

Make the shear droop side face Measure the level difference between the
*1
the holder B (17) side. housing (4) end surface and the thrust plate
Thrust plate (18) attachment di- (23) end surface with the thrust plate selec-
*2 tion jig, and select and attach a thrust plate
rection
(26) according to the table below.

12) Drive gear attachment Level differ-

Attach the thrust plates (22) to planetary gear ence dimen- Appropriate thrust plate
B (21), and attach the thrust plate (23). sions (mm)
Insert the screws (24) with Loctite applied in 1.20 - 0.67 20941-62306
the threaded sections and tighten them to the
0.66 - 0.04 20941-62307
specified torque.
Make the spline-side of the drive gear (25) 0.03 - -0.16 20941-62308
face the motor section attachment side and -0.17 - -0.41 20941-62309
attach the drive gear in the middle of the 3 -0.42 - -0.80 B0841-23017

84402826 - May 2011

6002-26
 Assembly and Disassembly of Travel Motor
CAUTION
Align the center hole of the thrust
plate with the protruding section of
the drive gear (25) and attach.
*1 Measure the level difference
2.
84402826 - May 2011
6002-27
14) Cover attachment
Thoroughly clean off any foreign matter from
the housing (4) end surface and cover (27)
matching surface.
Next, thoroughly degrease the housing end
surface and cover matching surface.
Additionally, apply liquid packing to the cen-
tering location corners on the housing attach-
ment surface-side of the cover, and align the
housing screw holes and bolt openings on the
cover to mount the cover on the housing.
Finally, mount the hexagon socket head bolts
(28) and tighten them to the specified torque.
15) Plug attachment
Remove the O-rings (30) attached to the plugs
(29), and replace them with new O-rings.
Next, attach plugs to the oil fill, oil drain and
oil check ports (3 total) on the cover (27) and
tighten them to the specified torque.
This completes assembly of the reduction
gear parts.
Next is assembly of motor parts.
Perform assembly while referring to "[2] As-
sembly of motor section".
Assembly of motor section
1) Oil seal attachment
Check whether the oil seal is mounted on the
flange (1-1), and use an oil seal press-fit jig to
press fit the oil seal (1-12) to the flange if it is
not mounted already.
 Assembly and Disassembly of Travel Motor

CAUTION
1) Press fit the oil seal after ap-
plying grease to the internal di-
ameter surface of flange oil seal
press-fit section and the oil seal
outside diameter section.
2) Press fit the oil seal after apply-
ing grease to the lip section of
the oil seal inner diameter.
3) When press fitting the oil seal,
push it vertically with the press.
Slanting will cause damage to
the oil seal outer diameter sur-
face. 3) Steel ball attachment
4) When press fitting the oil seal, Attach steel balls (1-6) to the spherical hole
be careful not to scratch the lip sections of the flange (1-1).
section of the oil seal internal
diameter. CAUTION
Scratching may cause oil leak-
ing and reduction gear internal Before attaching the steel balls, ap-
damage could occur during mo- ply hydraulic oil to the inner diameter
tor operation. surface of the spherical holes of the
flange.

2) Piston assembly attachment

Attach the springs (1-20) to the flange (1-1) 4) Shaft attachment
holes for attaching the piston assemblies Use the bearing press-fit jig to press fit the ball
(1-7). bearing (1-8) to the shaft (1-3).
Next, attach the piston assemblies to the Next, attach the shaft to the center of the
flange. flange (1-1).

CAUTION CAUTION

1) Attach springs in the center of 1) When attaching the ball bearing,

the hole when attaching. attach it vertically.
2) When attaching the piston as- 2) After attaching the shaft, check
semblies, have the cylinder sec- that it rotates smoothly.
tions facing down.
3) Before attaching the piston as-
semblies, apply hydraulic oil to
the internal diameter surface of
the flange mounting holes and
the outer diameter of the piston
assembly cylinder sections.
4) After attaching the piston as-
semblies, check that the piston
assemblies move smoothly.

84402826 - May 2011

6002-28
 Assembly and Disassembly of Travel Motor

1) Point the surface of the cylinder block

(1-4-1) that slides against the valve plate
(1-21) upwards and place the cylinder
block on the work platform of the hand
press.
Point the slanted surface of the spring
seat (1-4-6) down and attach it to the
cylinder block. Place both the spring
(1-4-7) and collar (1-4-8) on top of spring
seat with the collar on top.

5) Swash plate attachment

Point the slanted surface of the swash plate
(1-5) upwards and attach the swash plate to
the flange (1-1).

CAUTION
1) Attach by matching the rear
surface spherical holes of the
swash plate with the steel balls
(1-6).
2) Attach the swash plate after ap-
plying hydraulic oil to the sur- Cylinder block attachment di-
*1
face of the steel balls. rection
3) After attaching the swash plate,
check that it moves smoothly. 2) Use the jig to press the top surface of
the collar (1-4-8) to attach the snap ring
(1-4-5).

6) Assembly of cylinder block assembly

84402826 - May 2011

6002-29
 Assembly and Disassembly of Travel Motor

CAUTION
1) The snap ring is stiff and
may come off from the
snap ring pliers when
the snap ring is being at-
tached, which could cause
injury.
Make sure to use a jig
when attaching the snap
ring, and check that the
nails of the snap ring pli-
ers are in the snap ring
hole before attachment.
2) When retracting the snap 4) Attach the retainer holder (1-4-4) to the
ring is difficult, use the cylinder block (1-4-1).
snap ring pliers that are
one size bigger.
3) When pressing in the col-
lar (1-4-8), make the cen-
ters of the cylinder block
and press align with each
other.

5) Place the side of the retainer plate

(1-4-3) with a taper on the outer circum-
ference down, and attach the 9 piston
assemblies (1-4-2) to the retainer plate.

3) Point the surface of the cylinder block

(1-4-1) that slides against the valve plate
(1-21) down and place the cylinder block
on the work platform.
Insert the 3 pins (1-4-9) into the diagonal
holes of the cylinder block (1-4-1).

CAUTION
1) When placing the cylinder
block on the work plat-
form, check that there is
no foreign matter on the 6) Attach the piston assemblies (1-4-2) to
work platform. the cylinder block (1-4-1).
2) Be careful not to scratch
the surface of the cylinder CAUTION
block that slides against 1) Apply hydraulic oil to the
the valve plate. 9 cylinder block piston at-
Scratching may cause a tachment holes before at-
reduction in motor perfor- taching the piston assem-
mance and early damage blies.
to the motor. 2) Apply hydraulic oil to the
3) Apply grease to the pin spherical surface of the re-
holes before attaching the tainer holder (1-4-4) before
pins. attaching it.

84402826 - May 2011

6002-30
 Assembly and Disassembly of Travel Motor
7) Cylinder block assembly attachment
Place the valve plate (1-21) sliding surface
side of the cylinder block assembly (1-4) up-
wards, engage the internal teeth splines of
the retainer holder (1-4-4) and cylinder block
(1-4-1) with the external teeth splines of the
shaft (1-3), and attach the cylinder block as-
sembly to the inside of the flange (1-1).
CAUTION
1) When performing attachment,
check that the piston assem-
blies (1-4-2), retainer plate
(1-4-3) and retainer holder do
not come off from the cylinder
block assembly.
2) Before performing attachment,
apply hydraulic oil to the swash
plate (1-5) surface and sliding
surfaces of the piston assem-
blies.
84402826 - May 2011
6002-31
8) Disk plate attachment
Engage the internal teeth of the disk plates
(1-13) with the external teeth of the cylinder
block (1-4-1) and attach the disk plates to the
flange (1-1).
Also, align the arc sections on the external
circumference of the friction plates (1-14) with
the notch sections of the flange and attach the
friction plates to the flange.
Attach in this manner, attaching the disk
plates before the friction plates.
CAUTION
The disk plates are wet type disk.
Before attachment, immerse the fric-
tion material parts in hydraulic oil and
have the friction materials thoroughly
absorb the hydraulic oil.
9) Brake piston attachment
Attach the D-rings (1-16) (1-17) to the brake
piston (1-15).
Next, place the large bore side of the brake
piston upwards and attach it to the flange
(1-1).
CAUTION
1) Thoroughly apply grease when
attaching the D-rings.
2) Attach the brake piston after
using a positioning jig to align
the flange base plate (1-2-1)
knock pin hole and brake piston
knock pin hole so that they are
arranged in a straight line.
3) When attaching the brake pis-
ton, apply grease to the outer
circumference of the brake pis-
ton and inner diameter section
of the flange.
4) Push and attach the brake pis-
ton evenly all around so that it
does not become slanted.
If the brake piston is attached at
a slant, this could cause opera-
tional problems or the D-rings to
break.
 Assembly and Disassembly of Travel Motor

11) Valve plate attachment

Place the base plate (1-2-1) on top of the work
platform and press fit the ball bearing (1-9) in
the center of the base plate using the bearing
press-fit jig.
Attach the valve plate (1-21) to the base
plate after checking that the pins (1-19) are
mounted to the base plate.

CAUTION
1) Place the copper alloy side of
the valve plate up to attach it.
2) Thoroughly apply grease to the
matching surface between the
base plate and valve plate to
prevent the valve plate from
falling.
3) Be careful not to scratch the
copper alloy surface of the valve
plate.

10) Spring attachment

Insert the springs (1-18) into the 8 spring
mounting holes on the brake piston (1-15).

12) Base plate attachment

Attach O-ring (1-23) and the 4 O-rings (1-22)
to the top surface of the flange (1-1).
Attach the pins (1-19) to the base plate (1-2-
1).
Place the valve plate (1-21) mounting surface
of the base plate downwards and tighten it to
the flange with the hexagon socket head bolts
(1-11).

84402826 - May 2011

6002-32
 Assembly and Disassembly of Travel Motor

CAUTION Next, check that the O-rings (1-2-12) are

mounted to the plug (1-2-14), attach the
Caution: spring guide (1-2-13), and then attach the
plug to the base plate and tighten it to the
1) Apply grease to the O-ring specified torque.
(1-23).
2) Do not apply grease to the CAUTION
O-rings (1-22).
3) Attach the pins with their ta- 1) Attach the spool assembly to
pered sections up. the base plate so that the base
4) Attach the base plate after ap- plate line port side is on the
plying hydraulic oil to the valve front and the spool assembly
plate surface and cylinder block spring mounting side is on the
(1-4-1) surface. right.
5) Be careful that the valve plate Attaching in the opposite direc-
does not fall because the valve tion may cause problems such
plate mounting surface of the as switching errors.
base plate is pointing down 2) Attach the spool assembly af-
when the base plate is attached. ter applying hydraulic oil to the
6) Check the mounting position of outer circumference.
the O-rings on the flange and 3) After attaching the spool as-
the position of the holes for the sembly, check that it moves
oil path on the base plate to at- smoothly.
tach the base plate.
7) Check the position of the knock
pins mounted to the base plate,
the spring (1-18) mounting
holes on the base plate and the
flange-side pin holes, and the
spring positions, and then at-
tach the base plate.
8) When tightening the socket
head bolts, screw in all of the
bolts around the circumference
evenly.

14) Relief valve assembly attachment

Attach the relief valve assemblies (1-2-7) to
the base plate (1-2-1) and tighten to the spec-
ified torque after checking that poppet seat
(1-2-7-3) is mounted on the end of each re-
lief valve assemblies.

CAUTION
1) Replace the O-ring (1-2-7-7) with
new one before attaching the re-
lief valve assemblies.
2) Check that the O-ring (1-2-7-17)
13) Spool assembly attachment
and backup rings (1-2-7-18) are
Attach the spring (1-2-10) to the spool as-
mounted on the each poppet
sembly (1-2-9) and attach the assembly to the
seat (1-2-7-3).
base plate (1-2-1).
3) Apply grease to the O-rings and
After attaching the spool assembly, check that
backup rings before attaching
the O-rings (1-2-12) are mounted to the plug
the relief valve assemblies.
(1-2-11), attach the plug to the base plate, and
tighten it to the specified torque.

84402826 - May 2011

6002-33
 Assembly and Disassembly of Travel Motor

16) Cap assembly attachment

Attach the spring seats (1-2-3) and springs
(1-2-4) to the plunger assembly (1-2-2) in that
order.
Check that the O-ring (1-2-6-2) is mounted
to the cap assembly (1-2-6), and then mount
the spring seat (1-2-5) on the cap assembly
and attach the cap assembly to the base plate
(1-2-1).
Finally, tighten the hexagon socket head bolts
(1-2-6-4) to the specified torque.

CAUTION
1) Apply grease to the O-ring.
15) Plunger assembly attachment 2) The cap assemblies are pushed
Attach the base plate (1-2-1) to the plunger by the springs.
assembly (1-2-2). Push the cap assemblies down
by hand when tightening the
CAUTION socket head bolts.
1) Apply hydraulic oil to the 3) When tightening the hexagon
plunger assembly outer circum- socket head bolts, evenly
ference before attachment. tighten the 4 bolts.
2) Attach the plunger assembly If the cap assemblies are tight-
slowly and in a straight line ened at a slant, this could cause
while rotating it. damage O-rings and cause oil
3) If the plunger assembly be- leaking.
comes stuck, do not force it too
much and lightly strike it with a
hammer.

This completes assembly of the motor.

84402826 - May 2011

6002-34
 Assembly and Disassembly of Travel Motor
Motor Installation
Inspection
Before placing the motor in the hydraulic shovel, perform inspection for the following items. If there is a problem,
perform the given procedure.
Inspection item before installation
Are there any damaged areas?
Are there any missing parts?
Is there any looseness in the tighten-
ing sections of the bolts?
Dirt around ports
Are all of the port areas completely contact our company's service plant
air-tight?
Is there any rust on the port sections
or the installation sections on the ma-
chine?
Oil leaking from ports and connection Contact our company's service plant if
surfaces oil leaking is discovered.
Solution for solving problem
When installing a motor stored af-
When installing a new motor
ter maintenance inspection
Contact our company's service plant
concerning damage that occurred
during shipping. Replace damaged parts.
Replace parts that have been dam-
aged during storage.
Contact our company's service plant
concerning parts lost during shipping.
Purchase lost parts.
Purchase parts that have been lost
during storage.
If there is looseness in bolts just af-
ter delivery of the motor, contact our
company's service plant for instruc-
tions on tightening bolts to the spec- When there is looseness with bolts,
ified torque. disassemble again and inspect the
If there is bolt loosening on a stored motor for rust on the inside.
motor, contact our company's service
plant as there is a chance that rust has
formed internally.
When ports for lines are dirty, per- When ports for lines are dirty, per-
form air blowing with compressed air, form air blowing with compressed air,
or cleaning with water vapor or high- or cleaning with water vapor or high-
pressure jet to remove dirt. pressure jet to remove dirt.
When checking just after delivery
When the plugs for each of the ports
When the plugs for each of the ports
are loose, use after removing dirt ad-
are loose or there are no plugs on the
hered to the ports.
ports, perform disassembly for confir-
When there are no plugs on the ports,
mation that dirt has not entered the
motor or there is no rust.
as dirt has probably entered the mo-
tor.
When checking after storage
Contact our company's service plant
as rust has probably formed inside the
motor.
If there is light rusting, use the motor
Contact our company's service plant
after removing the rust.
after confirming the presence of rust.
If rusting is severe, replace parts.
If oil leaking is discovered, there is
probably a problem with air-tightness
and rust may have formed inside the
motor, so perform disassembly again
to check for rust.
84402826 - May 2011
6002-35
 Assembly and Disassembly of Travel Motor

Hydraulic Oil and Gear Oil Filling

1. Fill the inside of the piston motor case with hydraulic oil
Before performing a driving check, fill the inside of the piston motor case with about 500 cc of hydraulic oil from
the piston motor drain port to prevent problems at the start of driving in sliding sections of the piton motor.
When using a hand pump or a small-quantity electric pump for oil filling, make the internal case pressure of the
piston motor 0.3 MPa or less.
2. Reduction gear lubricating oil check
Use the oil fill, oil drain and oil check ports for reduction gear lubricating oil shown in Diagram 8 to check that the
reduction gear case contains the stipulated level of lubricating oil.
How to check the quantity of reduction gear lubricating oil in a new motor
Remove the lubricating oil check port plug and check that lubricating oil flows out.
If lubricating oil seems to be flowing out, return the oil check port plug to its original position and tighten it to the
specified torque.
If lubricating oil does not flow out even though the oil check port is open, open the oil fill port and fill with oil until
reduction gear lubricating oil flows out from the oil check port.
After filling with oil, return the plugs for the oil fill port and oil check port and tighten them to the specified torque.

CAUTION
When motors are shipped from the plant they are filled with Nippon Oil Hypoid Gear Oil 90 lubricating
oil to the stipulated volume (5.0 L).

Diagram 8. Oil fill, oil drain and oil check ports for reduction gear lubricating oil and stipulated oil volume

Reduction gear lubricating oil

*1
fill port
Reduction gear lubricating oil
*2
check port
*3 Lubricating oil level

84402826 - May 2011

6002-36
 Assembly and Disassembly of Travel Motor

Initial Pre-conditioning Operation

Slowly operate the machine and perform air-bleeding for inside the motor circuit and inside the line according the
Operator's Manual for the Machine Main Unit.
First, perform an operation check by repeating "C direction rotation and stopping and A direction rotation and stopping"
a number of times at low-speed rotation.
At this time, remaining air inside the circuit may cause abnormal noises from the valves, etc. The abnormal noises
will stop as air is bled out while operation is done repeatedly at low speed.
If abnormal noises go away through repeated operation over a while, there is no problem with the motor and it can
be used as is.
If operation is done repeatedly and abnormal noises do not stop, there is an abnormality within the motor and it should
be replaced.
Check for the presence of oil leaking from the motor, line port sections, each line and each piece of equipment.
When oil leaking has been confirmed, retighten the bolts and line joints at the location where the leak is occurring to
the specified torque.
After checking is completed, raise the pressure and perform load operation, and check that no abnormal noises or
vibrations, etc. are occurring in the motor.
IMPORTANT:
• When tightening lines, etc. after confirming oil leaking, make sure to have operation of hydraulic devices stopped.
• Make sure that the operating pressure on the motor is low when checking for oil leaking.
If the operating pressure is high and there is oil leaking, there is the danger of oil spraying out.

84402826 - May 2011

6002-37
 Assembly and Disassembly of Travel Motor

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.
1. Piston motor troubleshooting

Trouble phe-
Suggested cause Countermeasure and solution
nomenon
After investigating whether pressure is reaching
There is an operation problem in a piece of
the motor inlet side, investigate the causes of
equipment other than the piston motor or reduc-
problems and countermeasures for each piece
tion gear.
of equipment and perform inspection and repair.
Perform disassembly and clean and remove dirt
If the cause is in the motor itself, there is dirt
from parts before reassembling the motor.
clogging an operation section or there is an op-
If parts are damaged due to dirt, replace the
eration problem.
parts.
Operate the main relief valve of the circuit and
Motor inlet side pressure is low.
raise the set pressure.
The motor does
not rotate Perform disassembly and replace abnormally
There is abnormal wear on the sliding sections worn parts.
of the piston motor and pressure oil is escaping. After completely removing surface scratching,
burrs, etc. and cleaning, perform reassembly.
Damage is occurring with the main parts of the
Perform disassembly and replace damaged
piston motor.
parts.
In this instance, abnormal noise is coming from
Perform reassembly after cleaning parts.
the piston motor.
Investigate the load conditions and adjust the
The load on the piston motor is too large and
load to an amount appropriate to the set pres-
the relief valve is operating.
sure of the relief valve.
After investigating whether the required flow is
The cause resides in the hydraulic pump, pres-
being supplied to the piston motor inlet side, in-
sure control valve, flow control valve, etc. Re-
vestigate the causes of problems and counter-
quired oil flow is not being supplied to the piston
measures for each piece of equipment and per-
motor and rotation is insufficient.
form inspection and repair.
Motor rotation
Pressure oil is moving from the high-pressure Perform disassembly, investigate the status of
speed is insuffi-
side to the low-pressure side due to wear on wear on the sliding sections of the piston motor,
cient
the sliding sections of the piston motor (volume and perform repair or replacement according to
efficiency reduction) and speed is insufficient. the maintenance standards.
There is looseness in the piston motor base
Retighten the base plate fastening bolts to the
plate fastening bolts. Internal leaking is in-
specified torque.
creased and speed is insufficient.
There is wear on the sliding sections of the pis-
Perform disassembly, check the status of wear
ton motor and high-pressure oil is leaking and
on the sliding sections, and perform repair or re-
flowing out from the drain port, which is causing
placement according to the maintenance stan-
speed to greatly decrease and causing rotation
Motor rotation dards.
variation.
variation is high
Perform disassembly, check the status of wear
When going down an incline, the double counter
on the double counter balance valve, and per-
balance valve is causing hunting and rotation
form repair or replacement according to the
variation.
maintenance standards.
The shaft is touching driven parts due to prob-
lems with shaft core alignment, and this is pro- Make the shaft core alignment accurate.
ducing noise.
Noise is high
There is wear or damage on the piston motor Perform disassembly and replace damaged
bearings or damage has occurred on springs, parts such as bearings or springs.
etc. and noise is being produced. Perform reassembly after cleaning parts.

84402826 - May 2011

6002-38
 Assembly and Disassembly of Travel Motor

Trouble phe-
Suggested cause Countermeasure and solution
nomenon
There is looseness in bolts on matching sur- Retighten the fastening bolts to the specified
faces, etc. and oil leaking is occurring. torque.
Perform disassembly and replace seals.
Check the hydraulic oil temperature.
Oil leaking is occurring due to damage to oil When the temperature of the hydraulic oil is
seals, O-rings, packings, etc. 80 °C or higher during operation, recheck the
cooler and reduce the temperature of the hy-
draulic oil to below 80 °C.
Perform disassembly, check the status of wear
Oil leak The amount of drain oil is high due to wear on on the sliding sections, and perform repair or re-
the sliding sections of the piston motor and oil placement according to the maintenance stan-
leaking is occurring due to damage to the oil dards.
seals. Replace oil seals.
Perform reassembly after cleaning parts.
Perform disassembly and replace oil seals.
Drain pressure has increased due to clogging
Perform drain line cleaning and remove foreign
in the drain line or because the drain line is long
matter.
and thin, and this has damaged the oil seals and
Recheck lines and minimize resistance in line
oil leaking is occurring.
paths.
The amount of hydraulic oil in the hydraulic tank Check the amount of hydraulic oil in the hy-
has decreased and aeration is occurring due to draulic tank and fill with hydraulic oil according
tank taking in air. to the instructions on the machine main unit.
Hydraulic oil within the motor lines and motor Check the motor installation direction and cor-
Cavitation is circuit is flowing out while hydraulic devices are rect it.
causing abnor- turned off because the motor installation direc- Check that the oil surface within the hydraulic
mal noise, rota- tion is inappropriate or the hydraulic tank posi- tank is above the motor, and either modify it so
tion variation and tion is inappropriate, and this is causing aeration that it is above the motor or set up a self-supply
pressure varia- to occur within the motor just after the motor is circuit so that the insides of the motor circuit and
tion. started. lines are fully supplied with oil before driving.
When the motor is pumping, pressure on the
Perform disassembly and perform repair or re-
motor inlet side becomes negative due to dou-
placement of the double counter balance valve
ble counter balance valve operation problem,
according to the maintenance standards.
and cavitation occurs.
The load is too large and this caused the engine Check the load conditions and change the load
to stall. to an appropriate amount.
Motor rotation Investigate specifications values (especially
stopped during flow amount and motor speed).
operation Seizing occurred in the sliding sections of the If the motor speed has exceeded the upper limit,
piston motor and the motor stopped rotating. lower the flow amount.
It is not possible to reuse the inside of the motor,
so the motor should be replaced.

84402826 - May 2011

6002-39
 Assembly and Disassembly of Travel Motor

2. Parking brake troubleshooting

Trouble phe-
Suggested cause Countermeasure and solution
nomenon
Perform disassembly and replace the parking
Parking brake torque has decreased due to disk
brake disk.
wear.
Perform reassembly after cleaning parts.
The motor rotates The disk surface has been altered due to con- Perform disassembly and replace the disk.
if it is stopped with tact errors, etc., and the parking brake torque Also, repair the surface of the disk companion
external load act- has decreased. parts and perform reassembly.
ing on the motor. The springs are worn or damaged and the park- Perform disassembly and replace the spring.
ing brake torque is reduced. Perform reassembly after cleaning parts.
The external load is too large and the parking Check the external load and change the load to
brake capabilities are insufficient. an appropriate amount.
O-rings are damaged and pressure oil is escap- Perform disassembly and replace the O-rings.
ing, so the parking brake cannot be released. Perform reassembly after cleaning parts.
Foreign matter is clogging the orifice inside the
Motor drive force Perform disassembly and remove foreign mat-
parking brake release oil path and pressure oil
is not being pro- ter from the orifice.
is not reaching the parking brake cylinder cham-
duced. Perform reassembly after cleaning parts.
ber, which prevents the parking brake from be-
Motor is heating Also, flush the inside of the line.
ing released.
up to an abnormal
degree. Drain pressure has increased due to clogging
Clean the drain line.
in the drain line or because the drain line is long
Also, recheck the line system and minimize re-
and thin, and the parking brake cannot be re-
sistance in the line path.
leased.

84402826 - May 2011

6002-40
 Assembly and Disassembly of Travel Motor

3. Relief valve troubleshooting

Trouble phe-
Suggested cause Countermeasure and solution
nomenon
There is foreign matter caught between the pop-
Perform disassembly and remove foreign mat-
pet seat and poppet on the relief valve, which
ter.
is causing seating problems, and high-pressure
Perform reassembly after cleaning parts.
oil is leaking to the low-pressure side.
Replace the relief valve.
The relief valve spring is damaged and high-
Disassemble the motor and reassemble it after
pressure oil is leaking to the low-pressure side.
cleaning each part.
The motor does
The relief valve spring is worn and the set pres-
not rotate or motor
sure is decreased, which causes the relief to op- Replace the relief valve.
rotation is slow.
erate at low pressure.
There is foreign matter caught in the seat sec-
Remove the relief valve and remove foreign
tion of the free piston and base plate of the relief
matter.
valve and the set pressure has decreased.
There is foreign matter clogging the orifice set
Remove the relief valve and remove foreign
in the poppet of the relief valve, and the set
matter.
pressure has decreased.
There is foreign matter caught between the pop-
Perform disassembly and remove foreign mat-
pet seat and poppet on the relief valve, which is
ter.
causing seating problems, and the relief valve
Perform reassembly after cleaning parts.
does not close.
Replace the relief valve.
The relief valve spring is damaged and the relief
Disassemble the motor and reassemble it after
does not close.
cleaning each part.
The motor does The relief valve spring is worn and the set
not stop or stop- pressure has decreased, which has caused the Replace the relief valve.
ping is slow. brake force to decrease.
There is foreign matter caught in the seat sec-
tion of the free piston and base plate of the re- Remove the relief valve and remove foreign
lief valve, and the set pressure and brake force matter.
have decreased.
There is foreign matter clogging the orifice set
Remove the relief valve and remove foreign
in the poppet of the relief valve, and the set
matter.
pressure and brake force have decreased.
There is foreign matter caught in the sliding sec-
Replace the relief valve.
tion of the poppet and the poppet is not moving.
Shock at stopping
There is foreign matter caught in the free piston Remove the relief valve and reassemble after
is high
and the piston is not moving. removing foreign matter.
The relief set pressure is too high. Replace the relief valve.

84402826 - May 2011

6002-41
 Assembly and Disassembly of Travel Motor
4. Counter balance valve troubleshooting
Trouble phe-
Suggested cause
nomenon
Pressure oil is not reaching the motor inlet and
the plunger is not switching.
Pressure is reaching the motor inlet, but foreign
The motor does matter is clogging the orifice in the pilot oil path
not rotate or motor and the plunger is not switching.
rotation is slow.
There is foreign matter caught in the plunger
and it is not switching.
There is foreign matter caught in the plunger, so
the plunger does not return and brake force has
decreased.
There is damage to the plunger spring, so the
The motor does plunger does not return and brake force has
not stop or stop- decreased.
ping is slow. Foreign matter is clogging the orifice in the pilot
oil path, and the plunger does not return or re-
turn is slow.
The plunger spring is not fit in place.
The check valve is not fit in place.
The check valve spring is damaged.
The check valve spring is not fit in place.
When an exter-
There is foreign matter caught in the plunger
nal load acts on
and plunger movement is not smooth.
the motor and
pumping opera- The diameter of the pilot oil path orifice is wrong. Attach the correct orifice.
tion is done, rota-
tion variation oc- The pilot oil path orifice is not fit in place.
curs.
84402826 - May 2011
6002-42
Countermeasure and solution
After investigating whether pressure oil is
reaching the motor inlet side, investigate the
causes of problems and countermeasures for
each piece of equipment and perform inspec-
tion and repair.
Measure the pressure of the return side inside
the motor circuit, and check that the pressure
has increased.
After this, perform disassembly and remove for-
eign matter.
Next, perform reassembly.
Perform disassembly and remove foreign mat-
ter.
Investigate the degree of damage according to
the maintenance standards and reassemble the
plunger if reusing is possible.
If scratching makes the plunger unusable, re-
place it using the base plate kit.
Perform disassembly and remove foreign mat-
ter.
Investigate the degree of damage according to
the maintenance standards and reassemble the
plunger if reusing is possible.
If it is unusable, replace it using the base plate
kit.
Perform disassembly and replace the spring af-
ter removing foreign matter.
Perform disassembly and remove foreign mat-
ter.
Next, perform reassembly.
Fit the spring correctly in place.
Fit the check valve correctly in place.
Perform disassembly and replace the spring af-
ter removing foreign matter.
Fit the spring correctly in place.
Perform disassembly and remove foreign mat-
ter. After this, clean the plunger and perform
reassembly.
Attach the orifice in the correct position.
 Assembly and Disassembly of Travel Motor

Trouble phe-
Suggested cause Countermeasure and solution
nomenon
Perform disassembly and remove foreign mat-
ter.
There is foreign matter caught in the plunger, Investigate the degree of damage according to
plunger movement is poor, and counter balance the maintenance standards and reassemble the
functions are not fulfilled. plunger if reusing is possible.
If reusing is impossible, perform replacement
When an external with the base plate kit.
load acts on the Perform disassembly and replace the spring
motor and pump- There is damage to the plunger spring and
and perform reassembly after removing foreign
ing operation is counter balance functions are not fulfilled.
matter.
done, cavitation The plunger spring is not fit correctly in place
occurs and abnor- Fit the spring correctly in place.
and counter balance functions are not fulfilled.
mal noise is cre-
ated. There is damage to the check valve spring and Perform disassembly and replace the spring af-
counter balance functions are not fulfilled. ter removing foreign matter.
The check valve spring is not fit in place and
Fit the spring correctly in place.
counter balance functions are not fulfilled.
Foreign matter is clogging the orifice in the pilot
Perform disassembly and reassemble after re-
oil path, and counter balance functions are not
moving foreign matter.
fulfilled.

84402826 - May 2011

6002-43
 Assembly and Disassembly of Travel Motor

5. 2-speed control function section troubleshooting

Trouble phe-
Suggested cause Countermeasure and solution
nomenon
After investigating whether pilot pressure oil is
reaching the Ps port, investigate the causes of
Pilot pressure oil is not reaching the Ps port.
problems and countermeasures for each piece
of equipment and perform inspection and repair.
After performing disassembly and removing for-
eign matter, investigate the degree of damage
There is foreign matter caught between the
according to the maintenance standards and
spool and base plate, and the spool does not
Will not switch to switch. perform reassembly if reusing is possible.
high-speed rota- If reusing is impossible, perform replacement
tion with the base plate kit.
There is abnormal wear in the 2-speed control
Perform disassembly and replace using the
piston section, and pressure oil is leaking into
flange holder kit.
the case.
The 2-speed control piston is not fit in place. Attach the 2-speed piston in the correct position.
Foreign matter is clogging the orifice in the
Perform disassembly and reassemble after re-
2-speed oil path, and pressure oil is not reach-
moving foreign matter.
ing the 2-speed control piston.
Switching to high-
speed rotation oc-
curs, but switch-
There is abnormal wear in the 2-speed control
ing to low-speed Perform disassembly and replace using the
piston section, and pressure oil is leaking into
rotation occurs if flange holder kit.
the case.
the hydraulic oil
temperature in-
creases.
Even if the speed control switch is set to low Investigate whether the Ps port pressure is 0.5
speed, the Ps port pressure does not decrease. MPa or lower and recheck the line system.
Perform disassembly and replace the spring af-
The 2-speed control valve spring is damaged.
ter removing foreign matter.
The 2-speed control valve spring is not fit in
Attach the spring in the correct position.
place.
After performing disassembly and removing for-
Not switching to eign matter, investigate the degree of damage
low-speed rota- There is foreign matter caught between the according to the maintenance standards.
tion spool and base plate, and the spool does not
Perform reassembly if reusing is possible.
return.
If reusing is impossible, perform replacement
with the base plate kit.
Foreign matter is clogging the orifice in the
Perform disassembly and reassemble after re-
2-speed oil path, and pressure cannot escape
moving foreign matter.
from inside the 2-speed control piston chamber.
The 2-speed control valve spring is worn and
Perform disassembly and replace the spring.
the switching pressure is reduced.
Switching to low-
speed rotation oc- Foreign matter is clogging the pilot line, and the
Clean the inside of the line and remove foreign
curs, but switch- pilot pressure increases up to switchover pres-
matter.
ing to high-speed sure due to leaking from the 2-speed control
Also, recheck the line system.
rotation occurs valve.
during operation.

84402826 - May 2011

6002-44
 Assembly and Disassembly of Travel Motor

6. Reduction gear troubleshooting

Trouble phe-
Suggested cause Countermeasure and solution
nomenon
After investigating whether pressure is reaching
There is an operation problem in a piece of
the motor inlet side, investigate the causes of
equipment other than the piston motor or reduc-
problems and countermeasures for each piece
tion gear.
of equipment and perform inspection and repair.
There is an operation problem in the motor
See [1] - [5] in troubleshooting.
aside from the reduction gear.
A load exceeding the motor output torque is op- After investigating the load, remove the load
erating. acting on the motor.
Replace the reduction gear.
No rotation Investigate whether an excessive external load
The reduction gear angular bearing is damaged
is acting on the motor.
and will not rotate.
If the external load is excessive, remove this
load.
The gear inside the reduction gear is damaged
and it does not rotate.
The bearing inside the reduction gear is dam-
Replace the reduction gear.
aged and it does not rotate.
The spline inside the reduction gear is damaged
and it does not rotate.
The gear inside the reduction gear is damaged.
The bearing inside the reduction gear is dam- Replace the reduction gear.
aged.
Abnormal noise Perform disassembly and check the status of
is coming from damage.
the reduction gear There is wear on the sliding section of the re- If damage is discovered, replace the reduction
during driving. duction gear and interference between parts is gear.
occurring. In there are no parts that are especially dam-
aged, replace worn parts and reassemble after
cleaning.
Check that there are no locations from which oil
is leaking.
Perform disassembly and check the status of
Reduction gear lubricating oil is insufficient. damage within the reduction gear.
If damage is discovered, replace the reduction
gear. Fill with lubricating oil to the specified
volume.
The reduction Adjust the lubricating oil amount to the specified
There is too much reduction gear lubricating oil.
gear section is volume.
heating up to an The bearing inside the reduction gear is dam-
abnormal degree. Replace the reduction gear.
aged.
Perform disassembly and check the status of
internal damage.
An abnormal thrust load is occurring in the re- If damage is discovered, replace the reduction
duction gear due to inappropriate thrust plate gear.
selection. If no especially notable amount of damage is
discovered, replace the thrust plate with another
one of the correct thickness.

84402826 - May 2011

6002-45
 Assembly and Disassembly of Travel Motor

Trouble phe-
Suggested cause Countermeasure and solution
nomenon
Remove the cover, reapply liquid packing, and
There is looseness in fastening bolts on the re-
tighten the cover to the specified torque.
duction gear cover, and oil leaking is occurring.
Fill with lubricating oil to the specified volume.
Plugs for the oil fill, oil drain and oil check ports Retighten the plugs to the specified torque.
on the reduction gear cover are loose, and oil After tightening, fill with lubricating oil to the stip-
leaking is occurring. ulated volume.
Replace the O-rings for the plugs.
O-rings for oil fill, oil drain and oil check ports on
After replacement, tighten the plugs to the spec-
the reduction gear cover are deteriorating, and
ified torque and fill with lubricating oil to the stip-
oil leaking is occurring.
ulated volume.
Oil leaking is oc- There is cracking in the housing and oil leaking
curring Replace the reduction gear.
is occurring.
There is foreign matter caught on the sliding Disassemble the reduction gear, remove for-
surface of the floating seal and oil leaking is eign matter from the floating seal and perform
occurring. reassembly.
Oil leaking is occurring due to corrosion on the
sliding surface of the floating seal.
The O-ring of the floating seal is deteriorated or Disassemble the reduction gear and replace the
damaged and oil leaking is occurring. floating seal.
The seal collar of the floating seal is split and oil
leaking is occurring.

84402826 - May 2011

6002-46
 Assembly and Disassembly of Travel Motor

Structural Diagram

84402826 - May 2011

6002-47
Assembly and Disassembly of Travel Motor

84402826 - May 2011

6002-48
Assembly and Disassembly of Travel Motor

84402826 - May 2011

6002-49
 Assembly and Disassembly of Travel Motor

Internal Structure Diagram

84402826 - May 2011

6002-50
Assembly and Disassembly of Travel Motor

84402826 - May 2011

6002-51
 Assembly and Disassembly of Travel Motor

Part Table
Code Part name Q'ty Code Part name Q'ty Code Part name Q'ty
1 Piston motor 1 1-2-19 Orifice 2 1-28 Plug 1
1-1 Flange 1 1-2-20 Plug 5 2 Floating seal 2
1-2 Base plate assembly 1 1-2-21 O-ring 5 3 Angular bearing 2
1-2-1 Base plate 1 1-2-22 Orifice 3 4 Housing 1
1-2-2 Plunger assembly 1 1-2-23 Orifice 1 5* Shim t = 0.05 1
Hexagon socket
1-2-2-1 Spool 1 1-2-24 8 5* Shim t = 0.1 1
head bolt
1-2-2-2 Check valve 2 1-3 Shaft 1 5* Shim t = 0.3 1
Cylinder block as-
1-2-2-3 Spring 2 1-4 1 5* Shim t = 0.5 1
sembly
1-2-2-4 Plug 2 1-4-1 Cylinder block 1 5* Shim t = 1.0 1
1-2-2-5 O-ring 2 1-4-2 Piston Assembly 9 6 Holder C 1
1-2-3 Spring seat 2 1-4-3 Retainer plate 1 7 Washer 8
1-2-4 Spring 2 1-4-4 Retainer holder 1 8 Bolt 8
1-2-5 Cap 2 1-4-5 Snap ring 1 9 Thrust plate 4
1-2-6 O-ring 2 1-4-6 Spring seat 1 10 Inner race 4
Relief valve assem-
1-2-7 2 1-4-7 Spring 1 11 Needle bearing 4
bly
1-2-7-1 Relief housing 1 1-4-8 Collar 1 12 Planetary gear C 4
1-2-7-2 Poppet 1 1-4-9 Pin 3 13 Thrust plate 4
1-2-7-3 Poppet seat 1 1-5 Swash plate 1 14 Bolt 4
1-2-7-4 Spring seat 1 1-6 Steel ball 2 15 Sun gear C 1
1-2-7-5 Spring 1 1-7 Piston Assembly 2 16 Snap ring 1
1-2-7-6 Plug 1 1-8 Ball bearing 1 17 Holder B 1
1-2-7-7 O-ring 1 1-9 Ball bearing 1 18 Thrust plate 3
1-2-7-9 Free piston 1 1-10 Pin 1 19 Inner race 3
1-2- Hexagon socket
O-ring 1 1-11 10 20 Needle bearing 3
7-10 head bolt
1-2-7-11 Backup ring 2 1-12 Oil seal 1 21 Planetary gear B 3
1-2-
Spring guide 1 1-13 Disk plate 3 22 Thrust plate 3
7-13
1-2-
O-ring 1 1-14 Friction plate 2 23 Thrust plate 1
7-14
1-2-
Locking screw 1 1-15 Brake piston 1 24 Screw 3
7-15
1-2-
Nut 1 1-16 D-ring 1 25 Drive gear 1
7-16
1-2-
O-ring 1 1-17 D-ring 1 26 * Thrust plate t = 3.6 1
7-17
1-2-
Backup ring 2 1-18 Spring 8 26 * Thrust plate t = 2.3 1
7-18
1-2-8 Plug 8 1-19 Pin 4 26 * Thrust plate t = 2.8 1
1-2-9 Spool assembly 1 1-20 Spring 2 26 * Thrust plate t = 3.0 1
1-2-9-1 Spool A 1 1-21 Valve plate 1 26 * Thrust plate t = 3.2 1
1-2-9-2 Spool C 1 1-22 O-ring 4 27 Cover 1
Hexagon socket
1-2-10 Spring 1 1-23 O-ring 1 28 16
head bolt
1-2-11 Plug 1 1-24 Nameplate 1 29 Plug 3
1-2-12 O-ring 2 1-25 Rivet 2 30 O-ring 3
1-2-13 Spring guide 1 1-26 Plug 2 31 Pin 4
1-2-14 Plug 1 1-27 Plug 1

* 1 is selected and used.

84402826 - May 2011

6002-52
 Section

6003

Removal and Installation of Swing Unit

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of Swing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Swing Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

6003-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
6003-2 PRINTED IN FRANCE
 Removal and Installation of Swing Unit

WARNING Removal of Swing Unit

• Be sure to release hydraulic pressure before 1. Use a hexagon wrench (5 mm) to remove the 4 bolts
beginning work. (1), and then remove the air breather (2) on the
hydraulic oil tank.
Tightening torque for bolt installation: 2.94 - 4.90
CAUTION N·m
• 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℃℃ or below
before removing it. Working on this product
while it is still hot can cause burns. Addition-
ally, always bleed out the pressure before re-
moving any line from this product. Removing
a pressurized line can result in oil spraying 2. Attach the specialty adapter (3) to the area where
out and causing injury or oil leak. the air breather was removed, and set the vacuum
pump.
Items to prepare Create negative pressure in the hydraulic oil tank
• Wrenches (13 mm, 14 mm, 19 mm, 22 mm, 27 mm, using the vacuum pump (4).
36 mm, 41 mm)
• Hexagon wrench (5 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
• Cap
• Plug
• Liftcrane (with the required lifting capacity)
• Rag 3. Use a wrench (19 mm) to remove the 6 bolts (5),
• Cleaning fluid and then remove the center cover (6).
• Wood planks, etc.

4. Use the wrenches (22 mm, 27 mm, 36 mm, 41 mm)

to remove the hoses (7) (8) (9) (10) (11) (12) from
the swing motor.
• Mark the swing motor and hoses so that the con-
nectors can be matched during assembly.

84402826 - May 2011

6003-3
 Removal and Installation of Swing Unit

• Attach caps or plugs to the swing motor and hoses 6. Use a wrench (13 mm) to remove the bolt (15) on
to prevent any entry of water, dust or dirt. the clamp (16) for the hose.
• 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.

7. Use a box wrench (36 mm) to remove the 9 bolts

(18) from the swing unit.
Tightening torque for bolt installation: 784 - 914
N·m

8. Wrap the wire rope (20) around the swing motor and
5. Use a wrench (19 mm) to remove the 3 bolts (13), lift it with a liftcrane.
and then remove the under cover (14).
• A knock pin (19) is driven into the installation sec-
tion of the swing unit. Apply lubricating oil to the
knock pin and pull it out together with the main unit
of the swing motor while hitting with a hammer.

84402826 - May 2011

6003-4
 Removal and Installation of Swing Unit

9. Thoroughly check that the location is safe before

lowering the swing unit on wood planks (21).
• Thoroughly secure the swing unit so that it does
not fall over.

84402826 - May 2011

6003-5
 Removal and Installation of Swing Unit

Installation of Swing Unit

1. To install, perform the reverse of the removal procedure.
When installing the swing unit, be careful with the position of the knock pin.
The tightening torque for the bolts for installing the swing unit on the swing frame is 784 - 914 N·m.
2. Before driving, be sure to fill the inside of the motor casing with hydraulic oil from the oil fill port (1).
Use the level gauge (2) to check that gear oil for the reduction gear is filled to the stipulated volume.

84402826 - May 2011

6003-6
 Section

6004

Assembly and Disassembly of Swing Unit

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Swing Reduction Gear Breakdown Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Swing Reduction Gear Structure Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

6004-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
6004-2 PRINTED IN FRANCE
 Assembly and Disassembly of Swing Unit

Job code 35352AF10 Disassembly

1. Making a reference mark on the unit matching sur-
CAUTION face
It is useful for reassembly to place a reference mark
1. Read and understand the contents of this (*1) on the matching surface of the casing K1 (1)
maintenance manual before performing and ring gear (2) with paint, etc.
disassembly, reassembly, inspection, re-
pair, or other such work of this product.
2. Handle this product according to the sep-
arate "Usage Precautions".
3. When removing this product from the
equipment it is mounted on, stop that
equipment system and wait for the surface
temperature of this product to fall to about
40℃℃ 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 and cap
leak. Remove the level gauge (4) and cap (3).
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 3. Gear oil draining
fully recovered. Loosen the plug (6) (10 mm hexagon socket diam-
Using this product at a sub-par perfor- eter) to drain the gear oil.
mance level may result in product damage. • Gear oil cannot be reused.
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.

84402826 - May 2011

6004-3
 Assembly and Disassembly of Swing Unit

4. Removal of motor Assembly

Remove the pipe (3) and the pipe (5), and loosen
and remove the hexagon socket head bolts (7) (10
mm hexagon diameter).
Use the make-up port (G1) to raise the motor and
remove it.
• Liquid packing has been applied to the matching
surface of the casing K1 (1) and ring gear (2), so
use the notch sections (*1) in the diagram on the
right to remove the motor.
1. Application of liquid packing
After cleaning and degreasing the reduction gear
ring gear (1) and the motor casing K1 (5) match-
ing surfaces, apply (*1) liquid packing (ThreeBond
Co.,Ltd. "1215" gray or the equivalent) as shown in
the diagram on the right.

2. Motor installation
Lift the motor and gently fit it to the reduction gear,
then tighten the hexagon socket head bolts (2) (10
mm hexagon diameter) to the tightening torque of
90 N·m.
Install pipes (4) (3).
• Align the casing K1 (5) and ring gear (1) according
to the reference mark (*1) made before disassem-
bly.

This completes the disassembly.

84402826 - May 2011

6004-4
 Assembly and Disassembly of Swing Unit

3. Installation of level gauge 4. Gear oil filling

Insert the level gauge (6). Tighten the plug of the oil drain hose.
Fill with gear oil (9.7 L) from the gear oil fill port.
Tighten the gear oil fill port cap (4).

This completes the assembly.

84402826 - May 2011

6004-5
 Assembly and Disassembly of Swing Unit

Swing Reduction Gear Breakdown Diagram

84402826 - May 2011

6004-6
 Assembly and Disassembly of Swing Unit

Swing Reduction Gear Structure Diagram

1 Hexagon socket head bolt (12) 12 Thrust plate (3) 23 Roller bearing
2 Swing motor 13 Needle bearing (6) 24 Hose
3 Retaining ring 14 2nd stage planetary gear (3) 25 Drain plug
4 1st stage sun gear 15 Nut 26 Shaft
5 Pin (3) 16 Lock plate 27 O-ring
6 Spring pin (3) 17 Bolt (2) 28 Oil seal
7 Thrust plate (3) 18 Thrust plate (2) 29 Sleeve
8 Needle bearing (3) 19 2nd stage carrier 30 Roller bearing
9 1st stage planetary gear (3) 20 2nd stage sun gear 31 Housing
10 Pin (3) 21 1st stage carrier 32 Hexagon socket head bolt (12)
11 Spring pin (3) 22 Ring gear

84402826 - May 2011

6004-7
Assembly and Disassembly of Swing Unit

84402826 - May 2011

6004-8
Section

8001A

Overall view

84402826 - May 2011

84402826 - May 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

8001A-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
8001A-2 PRINTED IN FRANCE
 Overall view

This page is intentionally left blank

84402826 - May 2011

8001A-3
 Overall view

Overall view

84402826 - May 2011

8001A-4
 Overall view

1 Housing left side 3 Pomp chamber 5 Fuel tank

2 Swing body center section 4 Hydrauric oil tank

84402826 - May 2011

8001A-5
 Overall view

PUMP CHAMBER HYDRAULIC EQUIPMENT LAYOUT

84402826 - May 2011

8001A-6
 Overall view

Horsepower control electro-

1 Hydraulic pump 5 P2 pressure sensor 9
magnetic proportional
Hydraulic oil temperature sen-
2 Accumulator 6 P1 pressure sensor 10
sor
3 Pilot filter 7 Pilot pump
4 5 stack solenid valve 8 N2 pressure sensor

84402826 - May 2011

8001A-7
 Overall view

SWING BODY CENTER SECTION HYDRAULIC EQUIPMENT

84402826 - May 2011

8001A-8
Overall view

1 Swing motor
2 Center joint
3 Control valve

84402826 - May 2011

8001A-9
 Overall view

HOUSING LEFT SIDE HYDRAULIC EQUIPMENT LAYOUT

Cushion valve (with heat cir-

1
cuit)
2 Swing pilot pressure sensor
3 Oil cooler

84402826 - May 2011

8001A-10
 Overall view

LAYOUT OF HYDRAULIC EQUIPMENT IN CAB

1 Travel remote control valve

Upper operation remote control
2
valve

84402826 - May 2011

8001A-11
Overall view

84402826 - May 2011

8001A-12
Section

8001B

Port Diagram

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Hydraulic Pump (standard model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5 Stack Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Stack Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Remote Control Valves (upper, travel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Remote Control Valves (left-right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Remote Control Valve (travel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Cushion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-way Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2-way Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Direction Valve/Shut-off Valve/Relief Valve (electromagnetic proportional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Direction Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Shut-off Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Relief Valve (electromagnetic proportional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Manifold Under Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Manifold (accumulator section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Manifold (hydraulic oil tank section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Center Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

8001B-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
8001B-2 PRINTED IN FRANCE
 Port Diagram

Hydraulic Pump (standard model)

Port Port name Port size

A1, A2 Discharge port SAE6000psi 3/4
B1 Suction port SAE2500psi 2-1/2
Dr Drain port G3/4-20
P1 Proportional valve primary pressure port G1/4-13
P2 P2 port G1/4-13
Psv Servo assist port G1/4-15
Pi1, Pi2 Negative control port G1/4-15
a1, a2, a4 Gauge port G1/4-15
a5, a6 Gauge port G3/8-17
a7, a8 Gauge port G1/4-15
A3 Gear pump discharge port G1/2-19
B3 Gear pump suction port G3/4-20

84402826 - May 2011

8001B-3
 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

84402826 - May 2011

8001B-4
 Port Diagram

Port Port size Port name Port Port size Port name
P1 SAE6000psi 1 Pressure line pb3 G1/4 Left swing pilot line
SAE5000psi
A1 Left travel (forward) line pb4 G1/4 Boom 2-down drain line
3/4
SAE5000psi
B1 Left travel (backward) line pb5 G1/4 Arm 1-in pilot line
3/4
A2 SAE5000psi 1 Option line pb7 G1/4 Bucket-close pilot line
B2 SAE5000psi 1 Option line pb8 G1/4 Boom 1-down pilot line
SAE5000psi
A3 Swing right line pb9 G1/4 Arm 2-in pilot line
3/4
SAE5000psi Negative control power save
B3 Swing left line Pn1 G1/4
3/4 signal
Negative control power save
A5 SAE5000psi 1 Arm-out line Pn2 G1/4
signal
B5 SAE5000psi 1 Arm-in line PH G1/4 Pressure boost signal port
T1 Return line Ps1 G1/4 Negative control line
pb1 G1/4 Left travel backward pilot line T8 G1/4 Heat circuit line
pb6 G1/4 Right travel backward pilot line Pb2 G1/4 Option line

84402826 - May 2011

8001B-5
 Port Diagram

Port Port size Port name Port Port size Port name
P2 SAE6000psi 1 Pressure line pa7 G1/4 Bucket-open pilot line
SAE5000psi
A6 Right travel (forward) line pa3 G1/4 Right swing pilot line
3/4
SAE5000psi
B6 Right travel (backward) line pa8 G1/4 Boom 1-up pilot line
3/4
A7 SAE5000psi 1 Bucket-open line pa4 G1/4 Boom 2-up pilot line
B7 SAE5000psi 1 Bucket-close line pa9 G1/4 Arm 2-out pilot line
A8 SAE5000psi 1 Boom-up line pa5 G1/4 Arm 1-out pilot line
SAE5000psi
B8 Boom-down line PA G1/4 Upper signal
3/4
T2 Return line PT G1/4 Travel signal
pa1 G1/4 Left travel forward pilot line Ps2 G1/4 Negative control line
Swing priority variable orifice
pa6 G1/4 Right travel forward pilot line Pbu G1/4
switch signal
DR3 G1/4 Straight travel drain line Pa2 G1/4 Option line

84402826 - May 2011

8001B-6
 Port Diagram

5 Stack Solenoid Valve

Port Port size

C2 G1/4
C3 G1/4
C1 G1/4

View from bottom

Port Port size

B G3/8
T G3/8

Port Port size

C5 G1/4
C4 G1/4
P G3/8
84402826 - May 2011
8001B-7
 Port Diagram

1 Power save 3 Swing lock 5 Travel high speed

2 Lever lock 4 Pressure boost

84402826 - May 2011

8001B-8
 Port Diagram

2 Stack Solenoid Valve

B port side A port side

Port Port size

A1 G1/4
B1 G1/4
A2 G1/4
B2 G1/4
T G1/4

84402826 - May 2011

8001B-9
 Port Diagram

Remote Control Valves (upper, travel)

Remote Control Valves (left-right)

Right side Left side

Right
Port name Left side Port name Port size
side
1 Bucket close 1 Swing right G3/8
2 Boom down 2 Arm in G3/8
3 Bucket open 3 Swing left G3/8
4 Boom up 4 Arm out G3/8
P Pressure P Pressure G1/4
T Return T Return G3/8

84402826 - May 2011

8001B-10
 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

84402826 - May 2011

8001B-11
 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

84402826 - May 2011

8001B-12
 Port Diagram

4-way Selector Valve

Port Port name *ISO type Port size

Right remote control valve side
A G1/4
port/boom up
Right remote control valve side
C G1/4
port/boom down
Right remote control valve side
D G1/4
port/bucket open
Right remote control valve side
B G1/4
port/bucket close
Left remote control valve side
E G1/4
port/arm out
Left remote control valve side
G G1/4
port/arm in
Left remote control valve side
H G1/4
port/swing left
Left remote control valve side
F G1/4
port/swing right
1 Cushion valve side port G1/4
3 Cushion valve side port G1/4
4 Cushion valve side port G1/4
2 Cushion valve side port G1/4
8 Cushion valve side port G1/4
6 Cushion valve side port G1/4
7 Cushion valve side port G1/4
5 Cushion valve side port G1/4

84402826 - May 2011

8001B-13
 Port Diagram

2-way Selector Valve

Remote control valve side Cushion valve side

Port Port name *ISO type Port size Port Port name *ISO type Port size
Remote control valve side/swing-
A G3/8 1 Cushion valve side port G3/8
left port
Remote control valve side/arm-in
B G3/8 2 Cushion valve side port G3/8
port
Remote control valve side/swing-
C G3/8 3 Cushion valve side port G3/8
right port
Remote control valve side/arm-out
D G3/8 4 Cushion valve side port G3/8
port

Direction Valve/Shut-off 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

84402826 - May 2011

8001B-14
 Port Diagram

Shut-off Valve

Port Port size

A G1
B G1
T G3/4
PP G1/4
DR G1/4

84402826 - May 2011

8001B-15
 Port Diagram

Relief Valve (electromagnetic proportional)

Port Port size Port Port size

A G1 C G3/4
B G1 T G3/4

HBCV

B port opening side

Port Port size Remarks

SAE6000psi 1 Arm HBCV
A Boom
SAE J6000psi 1
HBCV
SAE6000psi 1 Arm HBCV
B Boom
SAE J6000psi 1
HBCV
C G1/4
DR G3/8
PL G1/4

84402826 - May 2011

8001B-16
 Port Diagram

Manifold Under Cab

Port Port size Port Port size Port Port size

P1 G3/8 P5 G1/4 T4 G1/4
P2 G3/8 T1 G3/8 T5 G1/4
P3 G3/8 T2 G3/8
P4 G1/4 T3 G3/8

Manifold (accumulator section)

Port Port size

P G1/2
P1 G1/4
P2 G1/4
P3 G1/2
P0 G3/8

84402826 - May 2011

8001B-17
 Port Diagram

Manifold (hydraulic oil tank section)

Port Port size Port Port size Port Port size

D G1/2 D5 G1/4 T1 G3/8
D1 G3/8 D6 G1/4 N2 G1/4
D2 G1/4 T G1/2

84402826 - May 2011

8001B-18
 Port Diagram

Swing Motor

Port Port Port

Port Port name Port Port name Port Port name
size size size
PA, Pressure measuring
A Main port A G3/4 G1/4 PR Brake release port G1/4
PB port
B Main port B G3/4 DBG Gear oil drain port G1/2 GIN Gear oil fill port RC3/4
DB Drain port G1/2 M Make-up port G1

84402826 - May 2011

8001B-19
 Port Diagram

Travel Motor

Port Port name Port size

P1, P2 Main port G1
T Drain port G1/2
Ps Pilot port G1/4
Pm1,
Pressure detection port G1/4
Pm2

84402826 - May 2011

8001B-20
 Port Diagram

Center Joint

Port Port name Port size

A, A' Main port (forward right) G3/4
B, B' Main port (forward left) G3/4
C, C' Main port (backward right) G3/4
D, D' Main port (backward left) G3/4
Drain port *E (2 locations), E' (1
E, E' G1/2
location)
Pilot port *F (2 locations), F' (1
F, F' G1/4
location)

84402826 - May 2011

8001B-21
Port Diagram

84402826 - May 2011

8001B-22
 Section

8001C

Pump P-Q Diagram

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Pump P-Q Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Pump P-Q Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

8001C-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
8001C-2 PRINTED IN FRANCE
 Pump P-Q Diagram

Pump P-Q Diagram

Pump P-Q Diagram

Discharge flow
Q［L/min］

Discharge pressure Pd［Kgf/cm2 ］

Discharge pressure Pd［MPa］

84402826 - May 2011

8001C-3
Pump P-Q Diagram

84402826 - May 2011

8001C-4
 Section

8001D

Pressure Measurement and Adjustment Procedures

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Procedures for Pressure Measurement from the Monitor Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Monitor and switch panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pressure Measurement Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operating Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PROCEDURES FOR MEASURING HYDRAULIC OIL TEMPERATURE FROM THE MONITOR DISPLAY . . . . . . 4
Hydraulic Oil Temperature Measurement Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operating Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Procedures for Pressure Measurement by Installing Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Items to Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pressure Measuring Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Structure and Operation Explanation of Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Location of Relief Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pressure Measurement Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pressure Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Main Pressure Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Attachment pressure measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Boom-down pressure measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Travel pressure measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Swing pressure measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Option line pressure measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pilot Pressure Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Pressure gauge installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Negative Control Pressure Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Pressure gauge installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Main Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Pressure measurement and adjustment preparation work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Main relief pressure adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Overload relief pressure adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Swing relief pressure adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Swing relief pressure adjustment — CX250C LR only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Pilot Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

8001D-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
8001D-2 PRINTED IN FRANCE
 Pressure Measurement and Adjustment Procedures

Procedures for Pressure

Measurement from the Monitor
Display
Monitor and switch panel

1 Liquid crystal monitor 3 Design panel

2 Switch panel 4 Diffuser

Pressure Measurement Method

The P1, P2, N1, and N2 pressure can be measured from the monitor display. (The pilot pressure cannot be mea-
sured.)
Operating Method
1. If both the travel speed select switch and the attachement select switch on the switch panel are held down, the
display switches to the service support screen.
2. CHECK the select service support screen.
3. MACHINE STATUS the select service support screen.
4. The respective pressures are displayed "P1" (P1 pump main pressure), "P2" (P2 pump main pressure), "N1" (N1
negative control pressure), and "N2" (N2 negative control pressure) columns.
* MENU switch is held down the display returns to the normal screen.

a Normal screen
b Service support screen

84402826 - May 2011

8001D-3
 Pressure Measurement and Adjustment Procedures

PROCEDURES FOR MEASURING HYDRAULIC OIL TEMPERATURE

FROM THE MONITOR DISPLAY
Hydraulic Oil Temperature Measurement Method
The hydraulic oil temperature can be measured from the monitor display.
Operating Method
1. If both the travel speed select switch and the attachement select switch on the switch panel are held down, the
display switches to the service support screen.
2. CHECK the select service support screen.。
3. MACHINE STATUS the select service support screen.
4. The hydraulic oil temperature is displayed in the "Hyd.OIL TEMP" column.

84402826 - May 2011

8001D-4
 Pressure Measurement and Adjustment Procedures

Procedures for Pressure Measurement by Installing Pressure Gauge

Preparations
Role (worker 1: work supervisor, pressure
Workers 2
adjustment)
Role (worker 2: operator)

Items to Prepare

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

Pressure Measuring Ports

There are the following 3 ports for pressure measurement.
• Main pressure: pressure ports (P1, P2)
(Remove the Main pressure sensor, then Install the pressure gauge.)
• Negative control pressure: pressure ports (N1, N2)
(Remove the negative control pressure sensor, then Install the pressure gauge.)
• Pilot pressure: pressure port (P3)

84402826 - May 2011

8001D-5
Pressure Measurement and Adjustment Procedures

84402826 - May 2011

8001D-6
 Pressure Measurement and Adjustment Procedures

1 Pump 3 Pressure port: P1 5 Pressure port: N2

2 Pressure port: P2 4 Pressure port: N1 6 Pressure port: P3

84402826 - May 2011

8001D-7
 Pressure Measurement and Adjustment Procedures

Structure and Operation Explanation of Control Valve

Location of Relief Valves
Tool Pressure per
Set pressure rotation of Measuring
Position Adjusting
Lock nut (MPa) adjusting port
screw screw (MPa)
a Main Hexagon diam- Hexagon diam-
34.3 21.3 Monitor P1
(normal use) eter 27 mm eter 27 mm
1 Main
Hexagon diam- Hexagon diam-
b (boosted pres- 36.8 28.4 Monitor P1
eter 32 mm eter 27 mm
sure)
2 Boom up 38.7 21.2 Monitor P2
3 Boom down 29.4 21.2 Monitor P2
4 Arm in Hexagon diam- 38.7 21.2 Monitor P1
5 Arm out eter 17 mm Hexagon diam- 38.7 21.2 Monitor P1
6 Bucket close eter 6 mm 38.7 21.2 Monitor P2
7 Bucket open 38.7 21.2 Monitor P2
Hexagon diam-
8 Pilot 3.92 2.0
eter 24.25 mm

Detailed diagram of main relief valve adjustment

*1 Pressure boost lock nut

*2 Pressure boost adjusting screw
Standard pressure adjusting
*3
screw
*4 Standard lock nut

84402826 - May 2011

8001D-8
 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

84402826 - May 2011
8001D-9
 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.

84402826 - May 2011

8001D-10
 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
Install the pressure gauge (2) on the adapter (1) and
Boom 2 pumps flow Boom 1 pump flow
fasten it.

Pressure gauge
for 60 MPa G1/4
Port size

Install the adapter (2) on the gauge port (1).

84402826 - May 2011

8001D-11
 Pressure Measurement and Adjustment Procedures

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℃
1 pump: P1 port
Measuring port
2 pumps: P2 port
Boosted pressure: 36.8 MPa
Set pressure
Standard: 34.3 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.

Bucket Bucket Boom

Lever operation Arm out Arm in Boom up
open close down
Engine speed 2000 min-1
Work mode SP mode
Oil temperature 45-55℃
1 pump flow measuring port P1 P1 P2 P2 P2 P2
2 pumps flow measuring port P2 P2 No No P1 P1
Pressure boost 36.8 MPa 29.4 MPa
Standard pressure 34.3 MPa 29.4 MPa

84402826 - May 2011

8001D-12
 Pressure Measurement and Adjustment Procedures

Boom-down pressure measurement Travel pressure measurement

For pressure measurement with the boom down, put the 1. Install the stopper (1) on the crawler sprocket sec-
arm cylinder at its out stroke end, open the bucket, put tion (2) and lock the travel motor.
the bucket tip on the ground, carry out the boom-down 2. Measure with the following operations.
operation, and measure.
Engine speed 2000 min-1
Work mode SP mode (1st speed)
Lever operation Travel relief
Oil temperature 45 - 55℃
Left travel: P1 port
Measuring port
Right travel: P2 port
Set pressure 34.3 MPa

a Boom-down relief

84402826 - May 2011

8001D-13
 Pressure Measurement and Adjustment Procedures

Swing pressure measurement Option line pressure measurement

1. Do not let the bucket move even if swing pressure 1. Close the option line stop valve (1).
is relieved with a swing operation such as digging a
hole.
2. Measure with the following operations.

Engine speed 2000 min-1

Work mode SP mode
Lever operation Swing relief
Oil temperature 45 - 55℃
Measuring port P1 port
Set pressure 28.9 MPa

2. Switch the attachment select switch of the monitor

to the option line to be measured (breaker, crusher).
3. Measure with the following operations.

Engine speed 2000 min-1

Work mode SP mode
Pedal operation Option relief
Oil temperature 45 - 55°C
1 pump: P2 port
Measuring port
2 pumps: P1 port

* Adjust the set pressure to match the specifications of

the attachment used.

84402826 - May 2011

8001D-14
 Pressure Measurement and Adjustment Procedures

Pilot Pressure Measurement Install the pressure gauge (1) and measure the pres-
sure.
Pressure gauge installation
Engine speed 2000 min-1
Remove the plug with the wrench (1) to install a pressure
gauge at the pump pressure measuring port (P3). Work mode SP mode
Oil temperature 45 - 55℃
Measuring port P3 port
Set pressure 3.92 MPa

Pressure gauge
for 10 MPa G1/4
Port size

Install the adapter (1).

84402826 - May 2011

8001D-15
 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.)

Pressure gauge
for 10 MPa G1/4
Port size

Install the adapter (1) of the pressure gauge at the port

where the N1 or N2 pressure sensor was removed and
install the pressure gauge (2).
Measure the negative control pressure for each opera- Engine speed 2000 min-1
tion. Work mode SP mode
Oil temperature 45 - 55℃
P1 pump side: N1 port
Measuring port
P2 pump side: N2 port
Set pressure 3.92 MPa max.

84402826 - May 2011

8001D-16
 Pressure Measurement and Adjustment Procedures

Pressure Adjustment For boosted pressure

1. Loosen the standard lock nut (27 mm) (1) and
Main Pressure Adjustment tighten the adjusting screw (27 mm) (2).
Fasten with a wrench (27 mm) so that the pres-
Pressure measurement and adjustment sure boost adjusting screw does not turn.
preparation work
Pressure is adjusted with control valves.
The following preparations are required for adjusting
with control valves.
1. Engine hood opening and closing
Unfasten the 2 latches (2) on the engine hood (1)
and open the engine hood (1).Pull the latches (2) to
release the locks.

2. After tightening until the adjusting screw stops

turning, tighten the pressure boost lock nut (1).

2. Cover removal
Remove the 5 bolts (1), then remove the cover (2).

3. Start the engine and run it at maximum rotation.

4. Move the arm lever to the in side, set the relief
state, and hold.
5. Loosen the pressure boost lock nut (32 mm) (1)
and adjust the set pressure with the adjusting
screw (27 mm) (2).
• When lower than the set pressure, tighten.

• When higher than the set pressure, first lower

below the set pressure, then adjust on the tight-
ening side.
6. After adjustment, fasten the adjusting screw with
a wrench (27 mm), then tighten the lock nut.

84402826 - May 2011

8001D-17
 Pressure Measurement and Adjustment Procedures

7. After locking, check the pressure on the boosted For standard pressure
pressure side.
1. Loosen the standard lock nut (27 mm) (1).
Repeat [1] - [7] until the set pressure is correctly ad-
justed.

2. Loosen the adjusting screw (1), lower below the

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.

84402826 - May 2011

8001D-18
 Pressure Measurement and Adjustment Procedures

Main relief pressure adjustment

Engine speed 2000 min-1
Work mode SP mode
Lever operation Arm-in relief
Oil temperature 45 - 55℃
Measuring port P1 port
Boosted pressure:36.8
Measurement pressure MPa
Standard:34.3 MPa
Boosted pressure: 28.4
Pressure per rotation of MPa/rotation
adjusting screw Standard: 21.3 MPa/rota-
tion

Before adjusting, remove the pilot hose for the pressure

boost signal (2) connected to the main relief valve (1),
then insert the plug (3) into the hose side.
The procedures for boosted pressure and standard
pressure are different.

4 Control valve
5 Wrench (19 mm)

84402826 - May 2011

8001D-19
 Pressure Measurement and Adjustment Procedures

Overload relief pressure adjustment 1 Control valve

2 Boom down
3 Bucket close
Engine speed 2000 min-1 4 Boom up
Work mode SP mode 5 Arm-out
Oil temperature 45 - 55℃ 6 Bucket open
Measuring port P1/P2 port
Boom down: 29.4 MPa
Measurement pressure
Others: 38.7 MPa
Pressure per rotation of
21.2 MPa/rotation
adjusting 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
pressure. (Except for boom down)

84402826 - May 2011

8001D-20
 Pressure Measurement and Adjustment Procedures

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.

Pressure adjustment
Example: Arm-out (1) overload relief adjustment

2. After adjustment, lock the lock nut (1).

1. Loosen the lock nut (1) with the wrench (2) and
adjust by turning the adjusting screw (3) with the
hexagon wrench (4).
• 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.
3. After adjusting the overload relief pressure, adjust
the boosted pressure and standard pressure to
their normal values referencing the main pressure
adjustment procedure.
* For the position of each overload relief, see the
"Control Valve Relief Locations".

84402826 - May 2011

8001D-21
 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℃
Measuring port P1 port
Measurement pressure 28.9 MPa
Pressure per rotation of
11.6 MPa/rotation
adjusting 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.

84402826 - May 2011

8001D-22
 Pressure Measurement and Adjustment Procedures

Swing relief pressure adjustment — CX250C 3. After adjustment, lock the lock nut (1).
LR only
Engine speed 2000 min-1
Work mode SP mode
Oil temperature 45 - 55℃
Measuring port P1 port
Measurement pressure 27.0 MPa
Pressure per rotation of
11.6 MPa/rotation
adjusting 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.

84402826 - May 2011

8001D-23
 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 2000 min-1

Lever operation Neutral
Measuring port P3
Set pressure 3.92 MPa

84402826 - May 2011

8001D-24
 Section

8001E

Hydraulic Pump Flow Measurement Procedures

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Hydraulic Pump Flow Measurement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Items to Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Work Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Flow Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

8001E-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
8001E-2 PRINTED IN FRANCE
 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
84402826 - May 2011
8001E-3
 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)

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

84402826 - May 2011

8001E-4
 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)
IN side(2), then fasten with the spanner.
Install the (prepared) hydraulic hose (5) on the flow
meter (1) OUT side (4), then fasten with the span-
ner.
Installs the adapter (6) to have instralled in opposite
in 8..
11. Remove the cover.
12. Remove the pilot hose for the boosted pressure sig-
nal, then plug the hose side. (See "Main Relief
Pressure Adjustment".)
This completes the preparation for flow measurement.

84402826 - May 2011

8001E-5
 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

84402826 - May 2011

8001E-6
 Section

8001F

Drain Volume Measurement Procedures

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Travel Motor Drain Volume Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Swing Motor Drain Volume Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

8001F-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
8001F-2 PRINTED IN FRANCE
 Drain Volume Measurement Procedures

Preparations 3. Always lay a rag (2) underneath before removing

the drain hose (1).
Measuring conditions Use a wrench (27 mm) to remove the drain hose
(1).(Always install a cap on the removed drain hose
(1).)
Engine speed 2000 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
elevate one shoe crawler (1) as in the diagram on 4. Install the extension hose for measurement (1) on
the right. the side of the motor from which the drain hose was
removed.

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

remove the cover (2). 5. Prepare a waste oil can (1) and measuring con-
Tightening torque for bolt installation：63.7 - 73.5 tainer (2) and set them as in the diagram on the
N•m right.

84402826 - May 2011

8001F-3
 Drain Volume Measurement Procedures

6. 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.

7. 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 (2).)
After 30 sec., move the extension hose to the waste
oil can (1).
Measure the volume of oil in the measuring con-
tainer (1) as the drain volume for 30 sec. a 30 seconds

84402826 - May 2011

8001F-4
 Drain Volume Measurement Procedures

Swing Motor Drain Volume at the same time the motor starts.(At starting, start
measurement with a stop watch (2).)
Measurement After 60 sec., move the extension hose (3) to the
waste oil can (4).
1. Remove the 2 drain hoses (1) and put plugs in the
Measure the volume of oil in the measuring con-
hose side of each. (wrench size: 27 mm, clamp 22
tainer (1) as the drain volume for 60 sec.
mm (hose side))
Measure at least 3 times each for left and right.

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-
tor, see "Swing relief pressure adjustment".
In SP mode, relieve the swing operation and move
the extension hose to the measuring container (1) a 60 seconds

84402826 - May 2011

8001F-5
Drain Volume Measurement Procedures

84402826 - May 2011

8001F-6
 Section

8001G

Air Bleed Procedure

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Boom Cylinder HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Arm Cylinder HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

8001G-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
8001G-2 PRINTED IN FRANCE
 Air Bleed Procedure

CAUTION
Always bleed off any air in the hydraulic cir-
cuits after replacing the hydraulic oil, repairing
or replacing hydraulic equipment, or removing
hydraulic pipes.

Air bleed procedure mode (when bleeding, follow the procedure be-
low.)
Hydraulic
Cylinder air Swing motor Travel motor
pump air Check
bleeding air bleeding air bleeding
bleeding
Hydraulic oil or hydraulic pump re-
placement

Cylinder replacement

Swing motor replacement

Travel motor replacement

* Failure to completely bleed off all the air can reduce

the service life of hydraulic equipment and lead to
damage.

84402826 - May 2011

8001G-3
 Air Bleed Procedure

Hydraulic Pump Travel Motor

1. Loosen the air bleed plug (1) and check that oil 1. Remove the bolts (2) , then remove the cover (1).
oozes from the air bleed port (2)s. Tightening torque for bolt installation：63.7 - 73.5
If oil does not ooze out, remove the air bleed plug N•m
(1), and fill hydraulic oil(3) from the air bleed port (2)
into the pump (4) case.
Temporarily tighten the air bleed plug (1).
Run the engine at low idle, slightly loosen the air
bleed port, and run until oil oozes from the air bleed
port (2) section.
Completely tighten the air bleed plug (1).

2. Use a hexagon wrench (6 mm) (1) to remove the air

bleed plug (2) as in the figure on the left.

3. Pour in about 500 cc of hydraulic oil (1) from the air

bleed port.
When inside the motor is filled with hydraulic oil (1)
, tighten the air bleed plug.

4. Start the engine and execute a slow travel opera-

tion.
5. Repeatedly travelling forward and backward bleeds
off the air.

84402826 - May 2011

8001G-4
 Air Bleed Procedure

Swing Motor HBCV

1. Run the engine at low idle, use a hexagon wrench
(8 mm) (3) to remove the air bleed plug (2) as in the
figure on the right.
Check that oil oozes from the air bleed port section.
* Do not execute a swing operation.
CAUTION
The HBCV air bleeding work requires 2 work-
ers: an operator and an air bleed worker.
Decide the signals beforehand and work safely.
Set the main unit so that the arm HBCV is at the
highest position.

Boom Cylinder HBCV

1. Start the engine and lower the boom without jacking
up the main unit.
2. In the above state, loosen the hose mouthpiece (1)
at the position in the figure.
Foaming hydraulic oil comes out from the hose
mouthpiece section.
When foaming hydraulic oil stops coming out,
tighten the hose mouthpiece (1).

1 Drain hose

2. If oil does not ooze out, stop the engine for now, and
fill hydraulic oil (2) from the air bleed port (1) into the
motor case.
Temporarily tighten the air bleed plug.
Run the engine at low idle, slightly loosen the air
bleed port (1) , and run until oil oozes from the air
bleed port (1) section.

3. Completely tighten the air bleed plug.

4. With the engine at low idle, slowly swing evenly left
and right at least 2 rotations.

Check
2 HBCV
After the air bleeding is complete, stop the engine for at
least 5 minutes to allow any air bubbles in the hydraulic 3. Execute steps 2. for the opposite side boom cylin-
oil tank to dissipate. der too.
4. Check boom operations.
If there is a delay in the operation response, bleed
the air again with the same procedure.

84402826 - May 2011

8001G-5
 Air Bleed Procedure

Arm Cylinder HBCV

For arm-in operations, bleed the air from the arm cylin-
der HBCV (1) using the same procedure as for boom
cylinder HBCV air bleeding.

2 Hose mouthpiece

84402826 - May 2011

8001G-6
 Section

8002

Removal and Installation of Hydraulic Oil Tank

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of Hydraulic Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Hydraulic Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

8002-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
8002-2 PRINTED IN FRANCE
 Removal and Installation of Hydraulic Oil Tank

WARNING Removal of Hydraulic Oil Tank

• Keep away from fire.
• Bleed off the pressure in the hydraulic oil
tank before beginning work.
• The temperature of the hydraulic oil is high
immediately after stopping the engine. Wait
until the hydraulic oil temperature has de-
creased (to 40°C or less) before beginning
work.
1. Drain the oil from the hydraulic oil tank. (For details,
see "Draining Oil from Hydraulic Oil Tank".)
2. Use a wrench (19 mm) to remove the 6 bolts (1),
and then remove the under cover (2).
Tightening torque for bolt installation: 63.7 - 73.5
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.

Items to prepare
• Wrenches (7 mm, 19 mm, 22 mm, 24 mm, 27 mm, 36
mm) 3. Prepare a waste oil can (1) under the hydraulic oil
• Eyebolts (M12 x 2) tank.
• Shackle (with the required lifting capacity) x 2
• Wire rope (with the required breaking load)
• Liftcrane (with the required lifting capacity)
• Marking pen
• Caps
• Plugs
• Waste oil can
• Rag
• Cleaning fluid
• Wood plank

4. Use a wrench (7 mm) to loosen the hose bands (1),

and then remove the hose (2).
• Use caps to cover the hose to prevent any entry
of water, dust or dirt.

84402826 - May 2011

8002-3
 Removal and Installation of Hydraulic Oil Tank

5. Use a wrench (19 mm) to remove the 5 bolts (1),

and then remove the center cover (2).

6. Use a wrench (7 mm) to loosen the hose bands (1),

and then remove the drain hoses (2) and (3).
• Use caps to cover the lines to prevent any entry
of water, dust or dirt.

Drain hose (use 27 mm

1
wrench)
Drain hose (use 27 mm
2
wrench)
Drain hose (use 22 mm
3
wrench)
7. Use wrenches (19 mm, 22 mm, 27 mm, 36 mm) to Drain hose (use 19 mm
remove the drain hoses. 4
wrench)
• Mark the hydraulic oil tank and hoses so that the Drain hose (use 19 mm
5
connectors match at the time of assembly. wrench)
• Attach caps or plugs to the hydraulic oil tank and Drain hose (use 19 mm
6
hoses to prevent any entry of water, dust or dirt. wrench)
• Clean the hydraulic oil tank and hoses by spray- Drain hose (use 19 mm
7
ing them with a parts cleaner to prevent scratches wrench)
and prevent dirt from accumulating on the con- Drain hose (use 19 mm
nectors. 8
wrench)
Drain hose (use 22 mm
9
wrench)
Pump drain hose (use 36 mm
10
wrench)

84402826 - May 2011

8002-4
 Removal and Installation of Hydraulic Oil Tank

8. Cut the hose bands on the tank side, and tie the 10. Use a wrench (19 mm) to remove the 3 bolts (1) for
hoses together. the L-shaped frame (2) between the control valve
and the hydraulic oil tank, and then remove the
L-shaped frame.

9. Use a wrench (19 mm) to remove the 7 bolts (1), and

then remove the top cover (2) from the hydraulic oil
tank.

84402826 - May 2011

8002-5
 Removal and Installation of Hydraulic Oil Tank

11. Use a wrench (24 mm) to remove the 4 bolts (1) 13. Use a wrench (19 mm) to remove the 5 bolts (1)
and 4 collars (2) from the bottom of the hydraulic oil from the fuel tank side cover (2), and then remove
tank. the side cover.
• Depending on the machine, there may be height
adjustment shims between the tank and the
frame.
Do not lose them.
Also, mark or write down the location where they
are and how many.
Tightening torque for bolt installation: 232.4 - 276.0
N・m

14. Use a wrench (19 mm) to remove the 4 bolts (1),

and then remove the side covers (tank) (2).

12. Use a wrench (19 mm) to remove the 2 bolts (2)

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

15. 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.

84402826 - May 2011

8002-6
Removal and Installation of Hydraulic Oil Tank

16. Thoroughly check that the location is safe before

lowering the hydraulic oil tank on wood plank (1).
• Thoroughly secure the hydraulic oil tank so that it
does not fall down.

84402826 - May 2011

8002-7
 Removal and Installation of Hydraulic Oil Tank

Installation of Hydraulic Oil Tank For bolts for which the torque is not specified, check
of the "About This Shop Manual Section • Tightening
To install, perform the reverse of the removal procedure. Torque • Retightening Torque Table" in the explanation
Tighten bolts being installed to the specified torque. in the materials.

84402826 - May 2011

8002-8
 Section

8003

Removal and Installation of Hydraulic Pump

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

8003-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
8003-2 PRINTED IN FRANCE
 Removal and Installation of Hydraulic Pump

Job code 35106AO05 Removal of Hydraulic Pump

1. Use a wrench (19 mm) to remove the 6 bolts (1),
WARNING and then remove the under cover (2).
• Be sure to release hydraulic pressure before
beginning work.

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

Items to prepare
• Wrenches (13 mm, 17 mm, 19 mm, 22 mm, 27 mm,
36 mm) • Remove the engine hood.
• Hexagon wrenches (8 mm, 10 mm) For details, see "Removal and Installation of En-
• Nylon sling (with the required breaking load) gine Hood".
• Liftcrane (with the required lifting capacity) • Remove the side door (right). (For details, see
• Marking pen "Removal and Installation of Side Door".)
• Cap
• Plug 2. Close the drain cock (1).
• Rag
• Cleaning fluid
• Wood planks, etc.

3. Use pliers to loosen the hose bands (1), and then

remove the 2 hoses (2).
Use a wrench (13 mm) to remove the 2 bolts (3) and
2 washers, and then remove the pre-filter (4).

84402826 - May 2011

8003-3
 Removal and Installation of Hydraulic Pump

4. Use a wrench (27 mm) to remove the hose (1), 7. Use a wrench (19 mm) to remove the 7 bolts (1),
use a wrench (19 mm) to remove the hose (2), use and then remove the cover (2) (3).
a wrench (22 mm) to remove the hose (3), use a
wrench (17 mm) to remove the 2 bolts (4) and 2
washers, and then remove the pilot filter (5).
• Remove the 5 stack solenoid. (For details, see
"Removal and Installation of 5 Stack Solenoid".)

8. Use a wrench (19 mm) to remove the 6 bolts (1),

and then remove the front duct cover (2).

9. Use a wrench (19 mm) to remove the 2 bolts (1),

and then remove the rear duct cover (2).

5. Remove the muffler. (For details, see "Removal and

Installation of Muffler".)
6. Use a wrench (19 mm) to remove the 8 bolts (1),
and then remove the duct cover (2).

84402826 - May 2011

8003-4
 Removal and Installation of Hydraulic Pump

10. Use a wrench (19 mm) to remove the 4 bolts (1), • Clean the pump and hoses by spraying with a
and then remove the center duct cover (2). parts cleaner to prevent scratches and prevent
dirt from accumulating on the connectors.

11. Remove the hoses and connectors that are con-

nected to the pump. 12. Secure the pump with a liftcrane and nylon sling (1)
• Use a hexagon wrench (8 mm) to remove the 8 so that it does not fall during removal and installation
hose bolts (1), and remove the pressure hose (2). operations.
• Use a wrench (36 mm) to remove the drain hose
(3).
• Use a wrench (27 mm) to remove the pilot hose
(4).
• Use a wrench (36 mm) to remove the suction hose
(5).
• Remove the connector (6).

13. Use a wrench (19 mm) to remove the 12 bolts (1)

from the pump.

• Use a wrench (19 mm) to remove the hydraulic

pilot hoses (7).
• Use a hexagon wrench (10 mm) to remove the 4
suction line bolts (8) and remove the suction line
(9).
• Mark the pump and hoses so that the connectors
match at the time of assembly.
• Attach caps or plugs to the pump and hoses to
prevent any entry of water, dust or dirt.

84402826 - May 2011

8003-5
 Removal and Installation of Hydraulic Pump

14. Use a liftcrane and the nylon sling (1) to pull the
pump out from the shaft and lift the pump.
Installation of Hydraulic Pump
• When installing the bolts, tighten them to the specified
torque.
If the torque is not specified for a bolt, see the "Bolt
Size and Torque Table".
• Fill the pump case with hydraulic oil from the drain port
so that no air remains in the pump case.
Additionally, when there is a 2nd option gear pump,
bleed off air from the air bleed port on the top surface
of the power take-off case.
1. Use a liftcrane and nylon sling (1) to secure the
pump.

15. Thoroughly check that the location is safe before

placing the pump on the wood plank (1).
• Thoroughly secure the pump so that it does not
fall over.

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

(1).
Bolt (1) tightening torque: 63.7 - 72.6 N·m

4. Connect the hoses and connectors to the pump.

84402826 - May 2011

8003-6
 Removal and Installation of Hydraulic Pump

• Use a hexagon wrench (10 mm) to install the suc- 6. Use a wrench (19 mm) to instal the 2 bolts (1), and
tion line bolts (1), and install the suction line (2). then instal the rear duct cover (2).
• Use a wrench (19 mm) to install the hydraulic pilot
hoses (3).

7. Use a wrench (19 mm) to instal the 6 bolts (1), and

then instal the front duct cover (2).

• Install the connectors (4).

• Use a wrench (36 mm) to install the suction hose
(5).
• Use a wrench (27 mm) to install the pilot hose (6).
• Use a wrench (36 mm) to install the drain hose
(7).
• Use a hexagon wrench (8 mm) to install the 8
hose bolts (8), and install the pressure hose (9).

8. Use a wrench (19 mm) to instal the 7 bolts (1), and

then instal the cover (2) (3).

5. Use a wrench (19 mm) to instal the 4 bolts (1), and

then instal the center duct cover (2).

84402826 - May 2011

8003-7
 Removal and Installation of Hydraulic Pump

9. Use a wrench (19 mm) to instal the 8 bolts (1), and 11. Use pliers to tighten the hose bands (1) and install
then instal the duct cover (2). the 2 hoses (2).
Use a wrench (13 mm) to install the 2 bolts (3) and
2 washers, and then install the pre-filter (4).

10. Use a wrench (27 mm) to install the hose (1), use a
wrench (19 mm) to install the hose (2), use a wrench
(22 mm) to install the hose (3), use a wrench (17 12. Open the drain cock (1).
mm) to install the 2 bolts (4) and 2 washers, and
install the pilot filter (5).
• Install the 5 stack solenoid. (For details, see "Re-
moval and Installation of 5 Stack Solenoid".)

• Install the side door (right).(For details, see "Re-

moval and Installation of Side Door".)
• Install the engine hood.(For details, see "Removal
and Installation of Engine Hood".)
13. Use a wrench (19 mm) to install the 6 bolts (1) and
install the under cover (2).
Bolt (1) tightening torque: 63.7 - 73.5 N・m

84402826 - May 2011

8003-8
 Section

8004

Removal and Installation of Control Valve

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

8004-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
8004-2 PRINTED IN FRANCE
 Removal and Installation of Control Valve

Job code 35359AB10 Removal of Control Valve

1. Extend the attachment and bring in contact with the
WARNING ground.
• Keep away from fire. • Drain the oil from the hydraulic oil tank. (For de-
• Be sure to release hydraulic pressure before tails, see "Draining Oil from Hydraulic Oil Tank")
beginning work.

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

Items to prepare
• Wrenches (7 mm, 19 mm, 22 mm, 24 mm)
• Hexagon wrenches (8 mm, 10 mm)
• Wire cutters 2. After opening the engine hood, use a wrench (19
• Eyebolts (M10 x 2) mm) to remove the 5 bolts (1), then remove the top
• Shackle (with the required lifting capacity) x 2 cover (2).
• Wire rope (with the required lifting capacity)
• Liftcrane (with the required lifting capacity)
• Marking pen
• Cap
• Plug
• Rag
• Cleaning fluid
• Wood planks, etc.

3. Use a wrench (19 mm) to remove the 3 bolts (2),

and then remove the under cover (1).

84402826 - May 2011

8004-3
 Removal and Installation of Control Valve

4. Remove the connectors (1) (2) from the pressure 6. Use a wrench (7 mm) to remove the hose band (2),
sensor. then remove the low-pressure hose (1).

5. Use a wrench (7 mm) to remove the hose band (2), 7. Use a wrench (17 mm) to remove the 2 bolts (1),
and then remove the low-pressure hose (1). then remove the bracket (2).

8. Use wrenches (19 mm, 22 mm) and hexagon

wrenches (8 mm, 10 mm) to remove the control
valve lines and hoses.
• Mark the lines and hoses so that the connectors
match at the time of assembly.
• Use caps or plugs to cover the lines and hoses 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.

84402826 - May 2011

8004-4
 Removal and Installation of Control Valve

10. Install the 2 eyebolts (1) (M10) on the control valve.

11. Install the shackles (2) on the eyebolts, then use the
liftcrane and wire ropes (3) to lift the control valve
(1).

12. Place the control valve (1) on wood planks (2).

9. Use a wrench (24 mm) to remove the 4 bolts (1)

from the control valve.

84402826 - May 2011

8004-5
 Removal and Installation of Control Valve

Installation of Control Valve 4. Use wrenches (19 mm, 22 mm) and hexagon
wrenches (8 mm, 10 mm) to install the control valve
1. Install the 2 eyebolts (1) (M10) on the control valve. lines and hoses.

2. Install the shackles (2) on the eyebolts, then use the

liftcrane and wire ropes (3) to lift the control valve
(1) in such a way that it does not interfere with the
housing, engine parts and pipes.

3. Use a wrench (24 mm) to install the 4 bolts (1) for

the control valve.
Bolt (1) tightening torque: 267 - 312 N·m

84402826 - May 2011

8004-6
 Removal and Installation of Control Valve

5. Use a wrench (17 mm) to install the 2 bolts (1), then 8. Install the connectors (1) (2) on the pressure sensor.
install the bracket (2).

9. Use a wrench (19 mm) to install the 3 bolts (2), and

6. Use a wrench (7 mm) to install the hose band (2), then install the under cover (1).
then install the low-pressure hose (1). Bolt (1) tightening torque: 63.7 - 73.8 N·m

7. Use a wrench (7 mm) to install the hose band (2), 10. Use a wrench (19 mm) to install the top cover (2)
then install the low-pressure hose (1). with the bolt (1).

84402826 - May 2011

8004-7
Removal and Installation of Control Valve

84402826 - May 2011

8004-8
 Section

8005A

Removal and Installation of Bucket Cylinder

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of Bucket Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Bucket Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

8005A-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
8005A-2 PRINTED IN FRANCE
 Removal and Installation of Bucket Cylinder

CAUTION Removal of Bucket Cylinder

• Stop the machine on a level location with • Remove the bucket. (For details, see "Removal and
good footing. Installation of Bucket".)
• Be sure to stop the engine before beginning • Remove the bucket link. (For details, see "Removal
work. and Installation of Bucket Link".)
• When working together with others, always 1. Bring the arm (1) top in contact with the ground.
be sure to exchange signals and pay ade- Retract the bucket cylinder rod.
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 (19 mm, 36 mm)
• Hammer
• Striking rod
• Liftcrane (with the required lifting capacity)
• Nylon sling (with the required lifting capacity)
2. Tie the cylinder rod with wire (1) so that it cannot
• Grease
come out.
• Rag
• Cleaning fluid
• Crosstie
• Wire

3. Turn the key switch (1) OFF and stop the engine.

84402826 - May 2011

8005A-3
 Removal and Installation of Bucket Cylinder

4. Switch the key switch ON again, and then turn the • Use caps or plugs to cover the hoses and lines to
control lever (1) about 10 times to bleed out any prevent any entry of water, dust or dirt.
pressure. • Clean the hoses and lines by spraying them with
a parts cleaner to prevent scratches and prevent
Note:
dirt from accumulating on the connectors.
Do not operate the bucket at this time.

8. Use a liftcrane and nylon sling (2) to secure the

5. Move the travel lever (1) back and forth about 5
bucket cylinder (1).
times to bleed off the pressure.
Return the key switch to OFF. • Wrap the nylon sling to the inside of the line so
that it is not crushed.

6. Press the air breather button (1) on top of the hy-

draulic oil tank to release the pressure inside the 9. Use a wrench (19 mm) to remove the bolt (1) and
tank. washer (2).

7. Use 2 wrenches (36 mm) to remove the hoses (1)

(2).

84402826 - May 2011

8005A-4
 Removal and Installation of Bucket Cylinder

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.
Installation of Bucket Cylinder
• Tighten lines and bolts being installed to the specified
torque.
• When the torque is not specified, check the "Bolt Size
and Torque Table".
1. Clean each pin and pin hole.

11. Lift the bucket cylinder (1) and then place it on the
crosstie.
2. Tie the cylinder rod with wire (1) so that it cannot
come out.

3. Use a liftcrane and nylon sling (2) to lift the bucket

cylinder (1).
• Wrap the nylon sling to the inside of the line so
that it is not crushed.

4. Align the bucket cylinder (1) with the arm and use a
hammer (3) to push in the pin (2).
• If a pin is hard to insert, the cylinder is tilted.
• When inserting the pin, be careful not to damage
the installed O-rings or dust seals.

84402826 - May 2011

8005A-5
 Removal and Installation of Bucket Cylinder

6. Use 2 wrenches (36 mm) to install the hoses (1) (2).

• Install the bucket link. (For details, see "Removal
and Installation of Bucket Link".)
• Install the bucket. (For details, see "Removal and
Installation of Bucket".)

5. Use a wrench (19 mm) to install the bolt (1) and

washer (2).

84402826 - May 2011

8005A-6
 Section

8005B

Removal and Installation of Arm Cylinder

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of Arm Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Arm Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

8005B-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
8005B-2 PRINTED IN FRANCE
 Removal and Installation of Arm Cylinder

CAUTION Removal of Arm Cylinder

• Stop the machine on a level location with 1. Use a liftcrane and nylon sling (1) to secure the arm
good footing. cylinder (2).
• 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
• Wrenches (19 mm, 36 mm, 41 mm) 2. Use a wrench (19 mm) to remove the bolt (1) and
• Nylon sling (with the required lifting capacity) washer (2).
• 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.

84402826 - May 2011

8005B-3
 Removal and Installation of Arm Cylinder

4. Start the engine, move the arm out at idle, and re- 7. Switch the key switch ON again, and then turn the
tract the arm cylinder (1) rod. control lever (1) about 10 times to bleed out any
pressure.
Do not operate the arm at this time.

5. Tie the cylinder rod with wire (1) so that it cannot

come out.
8. Move the travel lever (1) back and forth about 5
times to bleed off the pressure.
Switch the key switch OFF.

6. Turn the key switch (1) OFF and stop the engine.

9. Press the air breather button (1) on top of the hy-

draulic oil tank to release the pressure inside the
tank.

10. Use a wrench (41 mm) to remove the hose (1) and
use a wrench (36 mm) to remove the hose (2).
• Use caps or plugs to cover the hoses and lines to
prevent any entry of water, dust or dirt.
• Clean the hoses and lines by spraying them with
a parts cleaner to prevent scratches and prevent
dirt from accumulating on the connectors.

84402826 - May 2011

8005B-4
 Removal and Installation of Arm Cylinder

• If a pin is hard to remove, there is a load on the

pin.
• When removing the pin, be careful not to damage
the installed dust seals.

11. Use a wrench (19 mm) to remove the grease hose

(1).
• Use caps or plugs to prevent any entry of water,
dust or dirt.
14. Place the arm cylinder (1) on the crosstie.

12. Use a wrench (19 mm) to remove the bolt (1) and
washer (2).

13. Use a hammer (2) and striking rod (3) to push the
pin (1) out.

84402826 - May 2011

8005B-5
 Removal and Installation of Arm Cylinder

Installation of Arm Cylinder

• Tighten lines and bolts being installed to the specified
torque.
• When the torque is not specified, check the "Bolt Size
and Torque Table".
1. Clean each pin and pin hole.

5. Use a wrench (19 mm) to tighten the bolt (1) and

washer (2).

2. Tie the cylinder rod with wire (1) so that it cannot

come out.

6. Use a wrench (19 mm) to attach the grease hose

(1).

3. Use a liftcrane and nylon sling (2) to lift the arm

cylinder (1).
• Wrap the nylon sling to the inside of the line so
that it is not crushed.

7. Use a wrench (41 mm) to attach the hose (1) and

use a wrench (36 mm) to attach the hose (2).

4. Align the arm cylinder with the boom and use a ham-
mer (2) to push in the pin (1).
• If a pin is hard to insert, there is a load on the pin.
• When inserting the pin, be careful not to damage
the installed dust seals.

84402826 - May 2011

8005B-6
 Removal and Installation of Arm Cylinder

8. Start the engine, move the arm in at idle, and extend 10. Use a wrench (19 mm) to tighten the bolt (1) and
the arm cylinder (1) rod. washer (2).
• Grease up.

9. Align the arm cylinder (1) with the arm pin hole and
use a hammer (3) to insert the pin (2).
Be careful. The arm and arm cylinder rod may come
out of place at this time.

84402826 - May 2011

8005B-7
Removal and Installation of Arm Cylinder

84402826 - May 2011

8005B-8
 Section

8005C

Removal and Installation of Boom Cylinder

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of Boom Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Boom Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

8005C-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
8005C-2 PRINTED IN FRANCE
 Removal and Installation of Boom Cylinder

CAUTION Removal of Boom Cylinder

• 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.
• When removing only the boom cylinder, put the attach-
ments in the temporary decommissioning posture.
• 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).

Items to prepare
• Wrenches (19 mm, 30 mm, 36 mm)
• Crowbar
• Wire rope (with the required lifting capacity)
• Liftcrane (with the required lifting capacity)
• Nylon sling
• Marking pen
• Cap
• Plug
2. Use a wrench (19 mm) to remove the grease hoses
• Hammer
on the left and right sides (1).
• Striking rod
• Grease • Use caps or plugs to prevent any entry of water,
• Rag dust or dirt.
• Cleaning fluid
• Crosstie
• Wire

3. Use 2 wrenches (30 mm) to remove the 2 double

nuts (1) and bolt (2), and then remove the fastening
ring (3).
Also, remove the cab side in the same way.

84402826 - May 2011

8005C-3
 Removal and Installation of Boom Cylinder

4. Use a hammer (2) and striking rod (3) to push the 7. Switch the key switch ON again, and then turn the
pin (1) out. control lever (1) about 10 times to bleed out any
Start the engine, lower the boom at idle, and retract pressure.
the boom cylinder (right) (left) rods.

8. Move the travel lever (1) back and forth about 5

5. Tie the cylinder rods on the left and right sides with times to bleed off the pressure.
wire (1) so that they cannot come out.
• Switch the key switch OFF.

6. Turn the key switch (1) OFF and stop the engine.
9. Press the air breather button (1) on top of the hy-
draulic oil tank to release the pressure inside the
tank.

10. Use a wrench (36 mm) to remove the hose (1).

Also, remove the cab side in the same way.
• Mark the lines and hoses so that the connectors
match at the time of assembly.
• Use caps or plugs to cover the hoses and lines to
prevent any entry of water, dust or dirt.
• Clean the hoses and lines by spraying them with
a parts cleaner to prevent scratches and prevent
dirt from accumulating on the connectors.

84402826 - May 2011

8005C-4
 Removal and Installation of Boom Cylinder

12. Use a crowbar to remove the pin (1).

Also, remove the cab side in the same way.

11. Use a wrench (19 mm) to remove the bolt (1) and
washer (2).
Also, remove the cab side in the same way.
13. Use a liftcrane and nylon slings (1) to lift the boom
cylinders (right) (left) (2) (3) and remove.
• Place the boom cylinders (right) (left) (2) (3) on
crossties.

84402826 - May 2011

8005C-5
 Removal and Installation of Boom Cylinder

Installation of Boom Cylinder 4. Align the boom cylinders (right) (left) with the swing
frame pin holes and use a hammer (2) to push in
• Tighten bolts being installed to the specified torque. the pin (1).
• When the torque is not specified, check the "Bolt Size
and Torque Table". • When inserting the pin, be careful not to damage
the installed dust seals.
1. Clean each pin and pin hole.

5. Use a wrench (19mm) to tighten the bolt (1) and

2. Tie the cylinder rods on the left and right sides with washer (2).
wire (1) so that they cannot come out. Also, attach the cab side in the same way.

3. Use a liftcrane and nylon slings (1) to lift the boom 6. Use wrench (36 mm) to install the hose (1).
cylinders (right) (left) (2) (3). Also, install the cab side hose in the same way.

84402826 - May 2011

8005C-6
 Removal and Installation of Boom Cylinder

7. Start the engine, raise the boom at idle, and extend
the boom cylinder (right) (left) (1) (2) rods.
Align the boom cylinder (right) (left) (1) (2) with the
boom pin holes and use a hammer (4) to push in
the pin (3).
• If the insertion of a shim is possible according to
the tolerance adjust the shim.
9. Use a wrench (19 mm) to attach the grease hoses
on the right and left sides (1).
• Grease up.
• When installing as far as the boom, first install
the bucket, bucket link, bucket cylinder, arm, arm
cylinder according to their respective removal and
installation procedures.

8. Use 2 wrenches (30 mm) to attach the 2 double nuts

(1) and bolt (2), and install the fastening ring (3).
Also, install the cab side in the same way.

84402826 - May 2011

8005C-7
Removal and Installation of Boom Cylinder

84402826 - May 2011

8005C-8
 Section

8006

Removal and Installation of Center Joint

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of Center Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Center Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

8006-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
8006-2 PRINTED IN FRANCE
 Removal and Installation of Center Joint

Job code 35354AA10 Removal of Center Joint

1. Use a hexagon wrench (5 mm) to remove the 4 bolts
CAUTION (1), and then remove the air breather (2) on the
hydraulic oil tank.
• Be sure to stop the engine before beginning
work.
• Be sure to inspect the wire rope and other
lifting equipment before beginning work.
• Do not stand or pass under the suspended
load.

Items to prepare
• Wrenches (17 mm, 19 mm, 27 mm, 36 mm)
• Hexagon wrenches (5 mm, 6 mm)
• Box wrench (19 mm)
• Specialty adapter for vacuum pump connection
• Vacuum pump (vacuum pump power supply)
• Extension cable
• Marking pen
Cap 2. Attach the specialty adapter (1) to the area where
•
Plug the air breather is removed, and set the vacuum
•
Wire rope (with the required breaking load) pump (2).
•
Liftcrane (with the required lifting capacity) Create negative pressure in the hydraulic oil tank
•
Wood planks, etc. using the vacuum pump.
•
• Rag
• Cleaning fluid
• Waste oil can

3. Use a box wrench (19 mm) to remove the 8 bolts

(2), and then remove the lower under covers (1).

84402826 - May 2011

8006-3
 Removal and Installation of Center Joint

4. Prepare a waste oil can (1) to receive the oil that 7. Use a wrench (19 mm) to remove the 2 bolts (2),
spills out under the center joint. and then remove the center joint lock bar (1).

5. Use a wrench (36 mm) to remove the travel hoses
(1) and a wrench (27 mm) to remove the drain hoses
(2).
• Mark the center joint and hoses so that the con-
nectors match at the time of assembly.
• Attach caps or plugs to the center joint and hoses
to prevent any entry of water, dust or dirt.
• Clean the center joint and hoses by spraying them
with a parts cleaner to prevent scratches and pre-
vent dirt from accumulating on the connectors.
8. Use a wrench (36 mm) to remove the 4 travel hoses
(1).
• Mark the hoses so that the connectors can be
matched during assembly.
• Attach caps or plugs to the hoses to prevent any
entry of water, dust or dirt.
• Clean the hoses by spraying them with a parts
cleaner to prevent scratches and prevent dirt from
accumulating on the connectors.

9. Wrap wire ropes (1) around the center joint and sus-
6. Use a wrench (19 mm) to remove the pilot hoses (1) pend it with a liftcrane so that the center joint does
and a wrench (27 mm) to remove the drain hose (2). not fall during removal and installation operations.
• Attach caps or plugs to the center joint and hoses
to prevent any entry of water, dust or dirt.
• Clean the center joint and hoses by spraying them
with a parts cleaner to prevent scratches and pre-
vent dirt from accumulating on the connectors.

84402826 - May 2011

8006-4
 Removal and Installation of Center Joint

10. Use a wrench (19 mm) to remove the 4 bolts (1) Installation of Center Joint
from the center joint.
Tighten bolts being installed to the specified torque.
For bolts for which the torque is not specified, check the
"Bolt Size and Torque Table".
1. Wrap the wire rope (2) around the center joint (1)
and lift it with a liftcrane.

11. Use the wire ropes (2) and liftcrane to lift the center
joint (1).
Thoroughly check that the location is safe before
lowering the center joint on wood planks.

2. Use a wrench (19 mm) to tighten the 4 bolts (1) for

the center joint.

3. Use a wrench (36 mm) to install the 4 travel hoses

(1).

84402826 - May 2011

8006-5
 Removal and Installation of Center Joint

4. Use a wrench (19 mm) to install the 2 bolts (2), then
install the center joint lock bar (1).
Bolt (2) tightening torque: 88.3 - 107 N·m
• Apply Loctite #262 to the bolts.
7. Use a box wrench (19 mm) to install the 8 bolts (2)
and install the lower under cover (1).
• Bolt (2) tightening torque: 63.9 - 73.5 N·m

8. Use a hexagon wrench (5 mm) to install the 4 bolts

5. Use a wrench (19 mm) to install the pilot hose (1) (1), then install the air breather (2) on the hydraulic
and a wrench (27 mm) to install the drain hose (2). oil tank to the location from which the specialty
adapter for the vacuum pump was removed.

6. Use a wrench (36 mm) to install the travel hoses (1)

and a wrench (27 mm) to install the drain hoses (2).

84402826 - May 2011

8006-6
 Section

8007A

Removal and Installation of Travel Remote Control Valve

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of Travel Remote Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Travel Remote Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

8007A-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
8007A-2 PRINTED IN FRANCE
 Removal and Installation of Travel Remote Control Valve

Job code 35356AK19 Removal of Travel Remote Control

Valve
WARNING
1. Remove the floor mat (1).
• Be sure to release hydraulic pressure before
beginning work.

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

Items to prepare
• Wrench (19 mm)
• Hexagon wrench (8 mm)
• Phillips screwdriver
• Marking pen
• Cap
• Plug 2. Use a hexagon wrench (8 mm) to remove the 2 bolts
• Rag (2) on both the left and right sides, and then remove
• Cleaning fluid the left and right travel pedals (1).

3. Use a hexagon wrench (8 mm) to remove the 2 bolts

(2) on both the left and right sides of the lever, and
then remove the levers (1).

84402826 - May 2011

8007A-3
 Removal and Installation of Travel Remote Control Valve

4. Use a wrench (19 mm) to remove the 6 bolts (2), 6. Use a wrench (19 mm) to remove the 2 hose
and then remove the under cover (1). adapters (1).

5. Use a wrench (19 mm) to remove the 6 hoses (1). 7. Use a hexagon wrench (8 mm) to remove the 2 bolts
(1) on both the left and right sides of the travel lever.
• Mark the valve and hoses so that the connectors
match at the time of assembly.
• Install caps or plugs to the valve and hoses to
prevent any entry of water, dust or dirt.
• Clean the valve and hoses by spraying with a
parts cleaner to prevent scratches and prevent
dirt from accumulating on the connectors.

8. Pull up the travel remote control valve (1) into the

cab, and then remove the travel remote control
valve.

84402826 - May 2011

8007A-4
 Removal and Installation of Travel Remote Control Valve

Installation of Travel Remote 4. Use a wrench (19 mm) to install the 6 hoses (1).
Tightening torque: 25.4 - 31.4 N・m/44.0 - 54.0 N・
Control Valve m
Be careful not to connect the hydraulic hoses in incorrect
locations.
Before installing the hoses, check that the hose adapters
are not loose and retighten them to the specified torque.
When the torque is not specified, check the "Bolt Size
and Torque Table".
1. Pull down the travel remote control valve (1) into the
cab, then install the travel remote control valve.

5. Use a wrench (19 mm) to install the 6 bolts (2) and

install the under cover (1).

2. Use a hexagon wrench (8 mm) to install the 2 bolts

(1) on both the left and right sides of the travel lever.

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).

3. Use a wrench (19 mm) to install the 2 hose adapters

(1).

84402826 - May 2011

8007A-5
 Removal and Installation of Travel Remote Control Valve

7. Use a hexagon wrench (8 mm) to install the 2 bolts 8. Install the floor mat (1).
(2) on both the left and right sides, then install the
left and right travel pedals (1).

84402826 - May 2011

8007A-6
 Section

8007B

Removal and Installation of Operation Remote Control Valve

84402826 - May 2011

84402826 - May 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

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

8007B-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
8007B-2 PRINTED IN FRANCE
 Removal and Installation of Operation Remote Control Valve

Job code 35355AA12 Removal of Operation Remote

Control Valve (left side)
WARNING
1. Roll up the boot (1) of the control lever and use
• Be sure to release hydraulic pressure before the Phillips screwdriver or box wrench (10 mm) to
beginning work. remove the 2 bolts (2) of the console top cover.

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

Items to prepare
• Wrenches (19 mm, 22 mm)
• Box wrench (10 mm)
• Hexagon wrench (5 mm)
• Phillips screwdriver
• Marking pen
• Cap
• Plug
• Rag 2. Use the Phillips screwdriver to remove the 2 screws
• Cleaning fluid (2), and then remove the handle of the tilt lever (1).

3. Use a hexagon wrench (5 mm) to remove the 2 bolts

(2), and remove the grip (1) of the gate lock lever.

84402826 - May 2011

8007B-3
 Removal and Installation of Operation Remote Control Valve

4. Use the Phillips screwdriver to remove the 2 screws 7. Roll up the boot (1) of the control lever, remove the
(1) of the console top cover. connector (2) of the horn switch, and cut the wire
band (3).

5. Remove the 3 connectors (2) and remove the con-

sole top cover (1). 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).

6. Use the Phillips screwdriver or box wrench (10 mm)

to remove the 5 bolts (2), then remove the cover (1).
9. Roll back the hose cover (1).

10. Use a wrench (22 mm) to remove the 6 hoses (1).

• Mark the joystick remote control valve and hoses
so that the connectors match at the time of as-
sembly.
• Use caps and plugs to cover the joystick remote
control valve and hoses to prevent any entry of
water, dust or dirt.
• Clean the joystick remote control valve and hoses
by spraying them with a parts cleaner to prevent
scratches and prevent dirt from accumulating on
the connectors.

84402826 - May 2011

8007B-4
 Removal and Installation of Operation Remote Control Valve

Installation of Operation Remote

Control Valve (left side)
1. Clean all the parts with a rag.

11. Use the hexagon wrench (5 mm) to remove the 3

bolts (1) and 3 washers (2).

2. Install the joystick remote control valve (1).

12. Remove the joystick remote control valve (1).

3. Use the hexagon wrench (5 mm) 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

84402826 - May 2011

8007B-5
 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).

84402826 - May 2011

8007B-6
 Removal and Installation of Operation Remote Control Valve

11. Use a hexagon wrench (5 mm) to install the 2 bolts
(2), and install the grip (1) of the gate lock lever.
Removal of Operation Remote
Control Valve (right side)
1. Roll up the boot (1) of the control lever and use
the Phillips screwdriver or box wrench (10 mm) to
remove the 2 bolts (2) of the console top cover.

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.

84402826 - May 2011

8007B-7
 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
connector (2) of the horn switch, and cut the wire
band (3).
9. Use a wrench (22 mm) to remove the 6 hoses (1).
• Mark the joystick remote control valve and hoses
so that the connectors match at the time of as-
sembly.
• Use caps and plugs to cover the joystick remote
control valve and hoses to prevent any entry of
water, dust or dirt.
• Clean the joystick remote control valve and hoses
by spraying them with a parts cleaner to prevent
scratches and prevent dirt from accumulating on
the connectors.

84402826 - May 2011

8007B-8
 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

84402826 - May 2011

8007B-9
 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).

84402826 - May 2011

8007B-10
 Removal and Installation of Operation Remote Control Valve

11. Use the Phillips screwdriver to install the 2 screws 12. Use the Phillips screwdriver or box wrench (10 mm)
(2), then install the handle of the tilt lever (1). to install the 2 bolts (2) for the console top cover and
cover the control lever boot (1).

84402826 - May 2011

8007B-11
Removal and Installation of Operation Remote Control Valve

84402826 - May 2011

8007B-12
 Section

8007C

Removal and Installation of 5 Stack Solenoid

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of 5 Stack Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of 5 Stack Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

8007C-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
8007C-2 PRINTED IN FRANCE
 Removal and Installation of 5 Stack Solenoid

Job code 35350AL06 Removal of 5 Stack Solenoid Valve

1. Attach the specialty adapter (1) to the area where
WARNING the air breather is removed, and set the vacuum
pump (2).
• Be sure to release hydraulic pressure before Create negative pressure in the hydraulic oil tank
beginning work.
using the vacuum pump.

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

Items to prepare
• Wrenches (13 mm, 17 mm, 19 mm, 22 mm)
• Marking pen
• Cap
• Plug
• Rag
• Cleaning fluid

2. Use a wrench (13 mm) to remove the 2 cover bolts

(1) and then remove the cover (2).

84402826 - May 2011

8007C-3
 Removal and Installation of 5 Stack Solenoid

3. Remove the 5 connectors (1). • 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.

4. Use wrenches (19 mm, 22 mm) to remove the hoses

(1) (2) (3).
• Mark the solenoid valve and hose so that the con-
nector matches at the time of assembly.
• Use a cap or a plug to cover the solenoid valve
and hose to prevent any entry of water, dust or
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.

6. Use wrenches (19 mm, 22 mm) to remove the hoses

(1) (2) (3).
• Mark the solenoid valve and hose so that the con-
nector matches at the time of assembly.
• Use a cap or a plug to cover the solenoid valve
and hose to prevent any entry of water, dust or
dirt.
5. Use a wrench (22 mm) to remove the hoses (1) (2).
• Clean the solenoid valve and hose by spraying
• Mark the solenoid valve and hose so that the con- them with a parts cleaner to prevent scratches
nector matches at the time of assembly. and prevent dirt from accumulating on the con-
• Use a cap or a plug to cover the solenoid valve nector.
and hose to prevent any entry of water, dust or
dirt.

84402826 - May 2011

8007C-4
 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), then
install the 5 stack solenoid valve (1).

2. Use wrenches (19 mm, 22 mm) to install the hoses

(1) (2) (3).

1 Pilot hose (use 19 mm wrench)

2 Pilot hose (use 19 mm wrench)
3 Pilot hose (use 22 mm wrench)

7. Use a wrench (17 mm) to remove the 2 bolts (2),

and then remove the 5 stack solenoid valve (1).

1 Pilot hose (use 19 mm wrench)

2 Pilot hose (use 19 mm wrench)
3 Pilot hose (use 22 mm wrench)

• The hose connections are as follows.

84402826 - May 2011

8007C-5
Removal and Installation of 5 Stack Solenoid

3. Use a wrench (22 mm) to install the hoses (1) (2).

4. Use wrenches (19 mm, 22 mm) to install the hoses

(1) (2) (3).

1 Solenoid valve
5. Install the 5 connectors (1).
*1 Hose assembly
*2 Code
Solenoid valve (left side) de-
*3
tails
Solenoid valve (right side) de-
*4
tails

84402826 - May 2011

8007C-6
 Removal and Installation of 5 Stack Solenoid

• The electrical connector connection colors are in- 6. Use a wrench (13 mm) to install the 2 cover bolts
dicated below. (1), then install the cover (2).

7. Use a hexagon wrench (5 mm) to tighten the 4 bolts

(1), then remove the air breather (2) on the hydraulic
oil tank.
• Bolt (1) tightening torque: 2.94 - 4.9 N·m

84402826 - May 2011

8007C-7
Removal and Installation of 5 Stack Solenoid

84402826 - May 2011

8007C-8
 Section

8007D

Removal and Installation of Cushion Valve

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of Cushion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Cushion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

8007D-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
8007D-2 PRINTED IN FRANCE
 Removal and Installation of Cushion Valve

Job code 35350AF50 Removal of Cushion Valve

1. Attach the specialty adapter (1) to the area where
WARNING the air breather is removed, and set the vacuum
pump (2).
• Be sure to release hydraulic pressure before Create negative pressure in the hydraulic oil tank
beginning work.
using the vacuum pump.

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

Items to prepare
• Wrenches (17 mm, 19 mm, 22 mm)
• Hexagon wrench (5 mm)
• Marking pen
• Cap
• Plug
• Waste oil can
• Rag
• Cleaning fluid
2. Use a wrench (19 mm) to remove the 5 bolts (2),
and then remove the under cover (1).

3. Prepare the waste oil can (1).

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

84402826 - May 2011

8007D-3
 Removal and Installation of Cushion Valve

scratches and prevent dirt from accumulating on 5. Use a wrench (17 mm) to remove the 4 bolts (1)
the connectors. on the cushion valve bottom, and then remove the
cushion valve.

*2 Use 22 mm wrench
*3 Use 19 mm wrench

84402826 - May 2011

8007D-4
 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.

2 Use 22 mm wrench
3 Use 19 mm wrench

• The hose connections are as follows.

84402826 - May 2011

8007D-5
Removal and Installation of Cushion Valve

3 Swing right
4 Bucket close
5 Heat circuit line
6 Arm out
7 Boom down
8 Swing left
9 Bucket open
10 Pressure sensor (swing)
Swing priority switching pilot
11
line
12 Drain line

3. Use a wrench (19 mm) to tighten the 5 bolts (2) and

install the under cover (1).

4. Use a hexagon wrench (5 mm) to tighten the 4 bolts

(1) and install the air breather (2) on the hydraulic
oil tank.
• Bolt (1) tightening torque: 2.94 - 4.9 N·m

1 Arm in
2 Boom up

84402826 - May 2011

8007D-6
 Section

8008

Procedures for Assembly and Disassembly of Hydraulic

Pump Main Unit

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

8008-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
8008-2 PRINTED IN FRANCE
 Procedures for Assembly and Disassembly of Hydraulic Pump
Main Unit
Tools Disassembly procedures
The table below shows the tools required for assembly 1. Select a location for disassembly.
and disassembly of the K3V/K5V pump.The bolts and
plugs may vary by pump type. • Select a clean location.
• Place a rubber plate or cloth on the work platform
so as not to damage the parts.
Tool name Tool dimensions
4, 5, 6, 8, 14, 17 (B dimen- 2. Use cleaning oil to remove any dirt or rust from the
Hexagon wrench surface of the regulator.
sion, mm)
Socket wrench, dou- 3. Remove the hexagon socket head bolts (412, 413),
ble-head (single- 19, 27 mm and remove the regulator from the pump main unit.
head) wrench • Be careful not to lose the O-rings.
Monkey wrench Medium-sized
Flathead screwdriver
Screwdriver
(medium size) x 2
Plastic hammer
With adjustable specified
Torque wrench
torque tightening
Snap ring pliers For stop ring, TSR-160
Key material steel rod, 10 x
Steel rod
8 x 200
Tweezers
Bolt M8, L = about 50

4. Remove the hexagon socket head bolts (438), and

remove the cover (C) (629).
• The cover (C) is assembled with an adjusting
screw (C) (628), adjusting ring (C) (627), lock nut
(630), hexagon nuts (801, 802), and hexagon
socket head locking screw (924).
Do not loosen these screws and nuts.
Loosening causes the adjusted pressure and flow
setting to change.

84402826 - May 2011

8008-3
 Procedures for Assembly and Disassembly of Hydraulic Pump
Main Unit
5. After removing the cover (C) (629) subassembly, 8. Remove the locking rings (858), and remove the
remove the outer spring (625), inner spring (626), fulcrum plug (614) and adjusting plug (615).
and spring seat (C) (624) from the compensation
section, and pull out the adjusting ring (Q) (645), • The fulcrum plug (614) and adjusting plug (615)
can be easily removed by pulling them out with
pilot spring (646), and spring seat (644) from the
an M6 bolt.
pilot section.
• The adjusting ring (Q) (645) can be easily re-
moved by pulling it out with an M4 bolt.

6. Remove the hexagon socket head bolts (436, 438),

and remove the pilot cover (641).
When the pilot cover is removed, remove the set
spring (655) from the pilot section.

9. Remove lever 2 (613).

Do not pull out the pin (875).
• It can be easily removed by using a pair of tweez-
ers.

7. Remove the stop ring (814), and remove the spring

seating (653), return spring (654), and sleeve (651).
• The sleeve (651) is assembled with a retaining
ring (836).
• When removing the stop ring (814), the return
spring (654) will fly out, so be careful not to lose it.

84402826 - May 2011

8008-4
 Procedures for Assembly and Disassembly of Hydraulic Pump
Main Unit
10. Pull out the pin (874), and remove the feedback
lever (611).
• Use a fine steel rod to push out the pin (874) (pin
diameter D4) from above without touching lever 1
(612).
11. Remove lever 1 (612).
Do not pull out the pin (875).
12. Pull out the pilot piston (643) and spool (652).
13. Pull out the piston case (622), compensation piston
(621), and compensation rod (623) to complete dis-
assembly of the regulator.
• The piston case (622) can be removed by pushing
out the compensation rod (623) from the opposite
side of the piston case.
* The component parts are small, so be very careful not
to lose them.
84402826 - May 2011
8008-5
Assembly procedures
The assembly procedure is the reverse of the disas-
sembly procedure. However, follow the precautions
below.
1. Be sure to repair any parts damaged during dis-
assembly, and prepare replacement parts in ad-
vance.
2. Any foreign matter entering the equipment can
create a malfunction. Therefore, after thoroughly
cleaning the equipment with cleaning oil, air blow
the equipment, and perform assembly in a clean
location.
3. Make sure to tighten bolts and plugs of each sec-
tion to the specified torque.
4. Be sure to apply clean hydraulic oil to sliding sec-
tions before assembly.
5. As a rule, replace all seals such as O-rings with
new parts.
1. Install the compensation rod (623) into the compen-
sation hole on the casing (601).
2. Insert the pin press fit in lever 1 (612) into the groove
on the compensation rod, and install lever 1 on the
pin press fit in the casing.
3. Install the spool (652) and sleeve (651) in the casing
spool hole.
• Check that the spool and sleeve slide smoothly in
the casing without catching.
• Be careful to assemble the spool in the correct
direction.
*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.
 Procedures for Assembly and Disassembly of Hydraulic Pump
Main Unit
• At this time, check that the backlash from the
movement of the feedback lever is not too great
and that the feedback lever does not catch on
anything.
9. Install the return spring (654) and spring seating
(653) into the spool hole, and install the stop ring
(814).

a Lever (1) side

Lever (2) side (Fulcrum plug,
b
adjusting plug side)

5. Install the pilot piston (643) into the flow control hole
on the casing.
10. Assemble the set spring (655) into the spool hole,
• Check that the pilot piston slides smoothly without assemble the compensation piston (621) and piston
catching. case (622) into the compensation hole, install the
6. Insert the pin press fit in lever 2 (613) into the groove pilot cover (641), and tighten the hexagon socket
on the pilot piston, and assemble lever 2. head bolts (436, 438).

7. Assemble the fulcrum plug (614) and install the
locking ring (858) so that the pins press fit in the
fulcrum plug are inserted into the pin holes on lever
2.
11. Install the spring seating (644), pilot spring (646),
and adjusting ring (645) into the pilot hole, and in-
stall the spring seating (624), inner spring (626), and
outer spring (625) into the compensation hole.
• Be careful to install the spring seating in the cor-
rect direction.

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.
84402826 - May 2011
8008-6
 Procedures for Assembly and Disassembly of Hydraulic Pump
Main Unit
12. Assemble the cover (C) (629) set with the adjusting This completes the assembly.
screw (628), adjusting ring (C) (627), lock nut (630),
hexagon nuts (801, 802), and the hexagon socket
head locking screw (924), and tighten the hexagon
socket head bolts (438).

84402826 - May 2011

8008-7
Procedures for Assembly and Disassembly of Hydraulic Pump
Main Unit

84402826 - May 2011

8008-8
 Section

8010

Pump Main Unit Maintenance Standards

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Replacement standards for worn parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Standards for repairing cylinders, valve plates, and swash plates (shoe plates) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overall View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Attached diagram 1. pump assembly cross-section diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Drive Shaft Front Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Drive Shaft Rear Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Part Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Operation explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Regulator adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Tables and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Procedures for Assembly and Disassembly of Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Disassembly preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Disassembly procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Assembly procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Diagram 1. Front-side regulator assembly cross-section diagram (KR3K-9Y04-HV). . . . . . . . . . . . . . . . . . . . . 24
Diagram 2. Rear-side regulator assembly cross-section diagram (KR3K-9Y04-HV) . . . . . . . . . . . . . . . . . . . . . 28

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

8010-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
8010-2 PRINTED IN FRANCE
 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

84402826 - May 2011

8010-3
 Pump Main Unit Maintenance Standards

Standards for repairing cylinders, valve plates, and swash plates (shoe
plates)
Valve plate (sliding section)
Surface roughness re-
Swash plate (shoe plate 3-Z
quiring repair
section)
Cylinder Standard surface rough-
0.4 Z or lower (lapping)
Surface roughness ness (repair value)

Tightening torque
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

84402826 - May 2011

8010-4
 Pump Main Unit Maintenance Standards

Overall View
Attached diagram 1. pump assembly cross-section diagram

Drive shaft front side Drive shaft rear side

84402826 - May 2011

8010-5
 Pump Main Unit Maintenance Standards

Drive Shaft Front Side

84402826 - May 2011

8010-6
 Pump Main Unit Maintenance Standards

Drive Shaft Rear Side

84402826 - May 2011

8010-7
 Pump Main Unit Maintenance Standards

Part Table
Code Part name Q'ty Component part No. (Q'ty) or type
04 Gear pump 1 set ZX10LBRZ1-07A-V
011 Piston subassembly 2 sets 151 (9PC), 152 (9PC)
013 Cylinder subassembly (R) 1 set 141 (1PC), 313 (1PC)
014 Cylinder subassembly (L) 1 set 141 (1PC), 314 (1PC)
030 Swash plate subassembly 2 sets 212 (1PC), 214 (1PC)
041 Check valve 1 subassembly 2 sets 541 (1PC), 543 (1PC), 545 (1PC)
042 Check valve 2 subassembly 2 sets 541 (1PC), 544 (1PC), 545 (1PC)
Electromagnetic proportional pressure
079 1 set KDRDE5KR-V3-V
reducing valve, casing subassembly
530 Tilting pin subassembly 2 sets 531 (1PC), 548 (1PC)

1 Right rotation valve plate

2 Left rotation valve plate

Code Part name Q'ty Code Part name Q'ty

111 Drive shaft (F) 1 532 Servo piston 2
113 Drive shaft (R) 1 534 Stopper (L) 2
116 1st gear 1 535 Stopper (S) 2
123 Cylinder roller bearing 2 541 Seat 4
124 Needle roller bearing 2 543 Stopper 1 2
127 Bearing spacer 4 544 Stopper 2 2
141 Cylinder block 2 545 Steel ball 4
151 Piston 18 548 Feedback pin 2
152 Shoe 18 702 O-ring 2
153 Holder plate 2 710 O-ring 2
156 Spherical bushing 2 717 O-ring 4
157 Cylinder spring 18 724 O-ring 16
211 Shoe plate 2 725 O-ring 6
212 Swash plate 2 726 O-ring 2
214 Tilting bushing 2 728 O-ring 4
251 Swash plate support board 2 732 O-ring 2
261 Seal cover (F) 1 774 Oil seal 1
271 Pump casing 2 789 Backup ring 2
312 Valve block 1 792 Backup ring 2
313 Valve plate (R) 1 806 Hexagon nut 2
314 Valve plate (L) 1 808 Hexagon nut 2
326 Cover 1 824 Stop ring 2
401 Hexagon socket head bolt 8 885 Valve plate pin 2
406 Hexagon socket head bolt 4 886 Spring pin 4
414 Hexagon socket head bolt 4 901 Eyebolt 2
466 VP plug 2 953 Hexagon socket head stop screw 2
467 VP plug 2 954 Stop screw 2
468 VP plug 4 981 Nameplate 1
490 Insert plug 27 983 Strike rivet 2
531 Tilting pin 2

84402826 - May 2011

8010-8
 Pump Main Unit Maintenance Standards

Operation explanation
1. Flow control
The pump discharge flow is controlled as desired with the pilot pressure Pi.（See the Pilot pressure Pi）

Discharge
volume Q

Pilot pressure Pi

1) When the pilot pressure Pi increases, the pilot piston (643) moves to the right and stops at the location
where the pilot spring (646) force and hydraulic pressure force balance each other.
The pin (875) fixed to lever 2 (613) fits into the crimped groove section [A section] of the pilot piston, so
lever 2 rotates through the movement of the pilot piston with point B [fastened by the fulcrum plug (614)
and pins (876)] as the fulcrum.
The pin (897) fixed to the feedback lever (611) projects into the large opening [C section] of lever 2, so as
lever 2 rotates, the pin (897) moves to the right.
The pin (548) fixed to the tilting pin (531) that shakes the swash plate is bonded to the 2-side width section
[D section] of the feedback lever.
Therefore, as the pin (897) moves, the feedback lever rotates with section D as the fulcrum.
Since the spool (652) is linked to the feedback lever via the pin (874), the spool moves to the right.
When the spool moves, the discharge pressure P1 is led to the servo piston large-bore chamber via the
spool and Cl port.
The discharge pressure P1 is always led to the servo piston small-bore chamber, but the servo piston is
moved to the right due to the surface area difference and the tilting angle is reduced.
When the servo piston moves to the right, point D also moves to the right.
The return spring (654) is mounted on the spool.
Since force pulling the spool to the left is always acting, the pin (897) is pressed into the large opening (C
section) of lever 2.
Because of this, accompanying the point D movement, the feedback lever rotates around the point C as
the fulcrum and the spool moves to the left.
This movement causes the open section between the sleeve (651) and the spool (652) to begin to close,
and the servo piston stops at the point the open section fully closes.
Flow reduction operation
2) Flow increase operation
When the pilot pressure Pi decreases, the pilot piston (643) is moved to the left by the pilot spring (646)
force and lever 2 (613) rotates with point B as the fulcrum.
The pin (897) is pressed in the large opening [C section] of lever 2 by the return spring (654) via the spool
(652), pin (874), and feedback lever (611), so accompanying rotation of lever 2, the feedback lever rotates
with point D as the fulcrum and the spool moves to the left.When the spool moves, the Cl port opens to the
tank port, so the pressure in the large-diameter section of the servo piston drains out, the servo piston is
moved to the left by the discharge pressure P1 of the small-diameter section and the flow increases.
Accompanying the movement of the servo piston, point D moves to the left, the feedback lever rotates with
point C as the fulcrum, and the spool moves to the right.
This operation continues until the open section between the spool and sleeve closes, and then the servo
piston stops at the point the open section fully closes.

84402826 - May 2011

8010-9
 Pump Main Unit Maintenance Standards

2. Horsepower control

Discharge
volume Q

Discharge pressure
（1.33P1 + 0.67P2）

The pump tilting angle decreases when the load pressure increases and overload of the power source is pre-
vented and overload of the self pump is prevented.
The regulator utilizes a method to control horsepower in which a hydraulic force that is the sum of the self pump
pressure multiplied by 1.33 and the counterpart pump pressure multiplied by 0.67 is transmitted as a signal.

Compensation piston surface area

Self pump pressurized area: counterpart pump pressurized area = 2 : 1

1) Overload prevention operation

When the self pump discharge pressure P1 or the counterpart pump discharge pressure P2 rises, since
P1 and P2 act on the stepped section of the compensation piston (621), the compensation rod (623) is
pressed to the right and moves to the location where the force of the outer spring (625) and inner spring
(626) balance out the hydraulic pressure force.
The movement of the compensation rod is transmitted to lever 1 through the pin (875) and lever 1 rotates
around the pin (876) (point E) fastened to the casing (601).
The pin (897) fixed to the feedback lever (611) projects into the large opening [F section] of lever 1, so as
lever 1 rotates, the feedback lever rotates with point D as the fulcrum and the spool (652) moves to the right.
When the spool moves, the discharge pressure P1 is led to the large-bore chamber of the servo piston via
the Cl port, the servo piston is moved to the right, and the pump discharge flow is decreased to prevent
overload of the power source.
The servo piston movement is transmitted to the feedback lever via point D.
The feedback lever rotates with point F as the fulcrum and the spool moves to the left.
The spool moves until the open section with the sleeve (651) closes, and then the servo piston stops at the
point the open section closes.
2) Flow return operation
If the self pump discharge pressure P1 or the counterpart pump discharge pressure P2 decreases, the
compensation rod (623) is pressed back by the springs (625, 626) and lever 1 rotates about point E.
Accompanying the lever 1 rotation, the feedback lever rotates around point D as the fulcrum and the spool
moves to the left.
Because of this, the Cl port opens to the tank port, the servo piston large-diameter section pressure drains
off, the servo piston moves to the left and the pump discharge flow increases.
The movement of the servo piston is transmitted to the spool by the feedback mechanism, and this operation
continues until the open section between the spool and the sleeve closes.

84402826 - May 2011

8010-10
 Pump Main Unit Maintenance Standards

3. Low tilting (low flow) command priority mechanism

Discharge
volume Q

Discharge pressure
（1.33P1 + 0.67P2）

The flow control and the horsepower control tilting command is transmitted to the feedback lever and spool via
the large openings [C and F sections] of lever 1 and lever 2, but since the C and F sections have a structure in
which a pin (D4) projects into a large hole (D8), the pin (897) only contacts the lever that makes the tilting smaller
and the D8 hole for the lever on the side that has the larger tilting command state is free rather than being in
contact with the pin (897).
This type of mechanical selection method gives priority to flow control and horsepower control commands with
low tilting.
4. Power shift control (decreased horsepower control)

Discharge
volume Q

Discharge pressure
（P1 + P2）

Use the power shift pressure Pf to arbitrarily control the pump set horsepower.(See the Discharge pressure (P1
+ P2)）
When the power shift pressure Pf increases, the compensation rod (623) is moved to the right via the pin (898)
and the compensation piston (621), so the pump tilting angle and the horsepower setting are reduced in the same
way as was explained with the overload prevention operation of horsepower control.
By contrast, as the power shift pressure Pf decreases, the horsepower setting increases.

84402826 - May 2011

8010-11
 Pump Main Unit Maintenance Standards

Regulator adjustment
The adjusting screws on this regulator can be used to adjust the maximum flow, minimum flow, horsepower control
properties, and flow control properties. (Each of the adjustment amounts is shown in "6. (1) Regulator adjustment
amount list".)
1. Maximum flow adjustment

Discharge
volume Q

Pilot pressure Pi

Loosen the hexagon nut (808) and tighten (or loosen) the locking screw (954) to adjust the maximum flow.
This only changes the maximum flow.
It does not change the other control properties.
2. Minimum flow adjustment

Discharge
volume Q

Pilot pressure Pi

Loosen the hexagon nut (808) and tighten (or loosen) the hexagon socket head locking screw (953) to adjust (or
tighten) the minimum flow.
Similar to the maximum flow adjustment, this does not change other control properties.
However, if the hexagon socket head locking screw is tightened too much, the required power may increase at
the time of maximum discharge pressure (during relief), so adjust this carefully.

84402826 - May 2011

8010-12
 Pump Main Unit Maintenance Standards

3. Input horsepower adjustment

This regulator uses the simultaneous full-horsepower method.
Therefore, when changing the horsepower setting, adjust the adjusting screw of both the front and rear pumps
to the same amount.
The pressure change value resulting from adjustment is the value when pressure boost is simultaneously per-
formed with both pumps.
1) Outer spring adjustment

Discharge
volume Q

Discharge pressure
（P1 + P2）

Loosen the hexagon nut (630) and tighten (or loosen) the adjusting screw (C) (628) to adjust the outer
spring.
As the adjusting screw is tightened, the control diagram shifts to the right as in the diagram on the right and
the input horsepower increases.
When the adjusting screw (C) is rotated N times, the inner spring setting also changes.
Therefore, return the adjusting ring (C) (627) by rotating it N x A times in the opposite direction.
2) Inner spring adjustment

Discharge
volume Q

Discharge pressure
（P1 + P2）

Loosen the hexagon nut (802) and tighten (or loosen) the adjusting ring (C) (627).
As the adjusting screw is tightened, the flow increases as in the diagram on the right and the input horse-
power increases.

84402826 - May 2011

8010-13
 Pump Main Unit Maintenance Standards

4. Flow control properties adjustment

Discharge
volume Q

Pilot pressure Pi

Loosen the hexagon nut (801) and tighten (or loosen) the hexagon socket head locking screw (924) to adjust the
flow control properties.
As the hexagon socket head locking screw is tightened, the control diagram shifts to the right as in the diagram
on the right.

84402826 - May 2011

8010-14
 Pump Main Unit Maintenance Standards

Tables and diagrams

Speed (min-1) 2030
Adjusting screw (954) tightening amount (rotation) +1/4
Maximum flow adjustment
Flow change volume (L/min) 6.3
Adjusting screw (953) tightening amount (rotation) +1/4
Minimum flow adjustment
Flow change volume (L/min) 5.1
Adjusting screw (628) tightening amount (rotation) +1/4
Compensation control start pressure change vol-
1.75
Outer spring adjustment ume (MPa)
Input horsepower Input torque change volume (N•m) 71.6
adjustment A 1.9
Adjusting screw (925) tightening amount (rotation) +1/4
Inner spring adjustment Flow change volume (L/min) 12.1
Input torque change volume (N•m) 63.7
Adjusting ring (627) tightening amount (rotation) +1/4
Flow control properties adjustment Flow control start pressure change volume (MPa) 0.15
Flow change (L/min) 16.4

84402826 - May 2011

8010-15
 Pump Main Unit Maintenance Standards

(KR3K-9Y04-HV) (KR3K-9X04-HV)
Front side regulator Rear side regulator

Diagram 1. Regulator operation explanation diagram

84402826 - May 2011

8010-16
 Pump Main Unit Maintenance Standards

Diagram 2-1. Regulator breakdown diagram (front side)

ANNOTATION:
(N), (M), (L), and (K) in the diagram indicate pump casing installation positions

84402826 - May 2011

8010-17
 Pump Main Unit Maintenance Standards

Diagram 2-2. Regulator breakdown diagram (Rear side)

ANNOTATION:
(Z), (Y), (X), and (W) in the diagram indicate pump casing installation positions

84402826 - May 2011

8010-18
 Pump Main Unit Maintenance Standards

Procedures for Assembly and Disassembly of Regulator

Tools
Tool name Tools dimensions
Hexagon wrench 4, 5, 6 (B dimension, mm)
Socket wrench, double-head (single-head) wrench
Monkey wrench Small-sized (maximum 36 mm)
Screwdriver
Plastic hammer
Torque wrench
Pliers For stop ring, x 2
Steel rod Diameter D4 or less, L = 100
Tweezers
Bolt M4, L = about 50

Disassembly preparations
1. These regulators comprise small precision parts, so assembly and disassembly operations are somewhat com-
plex.
2. The pressure-flow settings of the front side regulator and the rear side regulator differ, so mark the regulators
when disassembling to differentiate between the drive side and the driven side.
3. When disassembling the regulators, read this disassembly procedure thoroughly before following the sequence
below.
The numbers in parentheses after the part names are the codes indicated in "Diagram 1.
Front-side regulator assembly cross-section diagram" "Diagram 2.
Rear-side regulator assembly cross-section diagram".

84402826 - May 2011

8010-19
 Pump Main Unit Maintenance Standards

Disassembly procedures 5. After removing the cover (C) (629) subassembly,

1. Select a location for disassembly.
• Select a clean location.
• Place a rubber plate or cloth on the work platform
so as not to damage the parts.
2. Use cleaning oil to remove any dirt or rust from the
surface of the regulator.
3. Remove the hexagon socket head bolts (412, 413),
and remove the regulator from the pump main unit.
• Be careful not to lose the O-rings.
remove the outer spring (625), inner spring (626),
and spring seat (C) (624) from the compensation
section, and pull out the adjusting ring (Q) (645),
pilot spring (646), and spring seat (644) from the
pilot section.
• The adjusting ring (Q) (645) can be easily re-
moved by pulling it out with an M4 bolt.

6. Remove the hexagon socket head bolts (436, 438),

and remove the pilot cover (641).
When the pilot cover is removed, remove the set
spring (655) from the pilot section.
4. Remove the hexagon socket head bolts (438), and
remove the cover (C) (629).
• The cover (C) is assembled with an adjusting
screw (C) (628), adjusting ring (C) (627), lock nut
(630), hexagon nuts (801, 802), and hexagon
socket head locking screw (924).
Do not loosen these screws and nuts.
Loosening causes the adjusted pressure and flow
setting to change.

7. Remove the stop ring (814), and remove the spring

seating (653), return spring (654), and sleeve (651).
• The sleeve (651) is assembled with a retaining
ring (836).
• When removing the stop ring (814), the return
spring (654) will fly out, so be careful not to lose it.

84402826 - May 2011

8010-20
 Pump Main Unit Maintenance Standards

8. Remove the locking rings (858), and remove the
fulcrum plug (614) and adjusting plug (615).
• The fulcrum plug (614) and adjusting plug (615)
can be easily removed by pulling them out with
an M6 bolt.
10. Pull out the pin (874), and remove the feedback
lever (611).
• Use a fine steel rod to push out the pin (874) (pin
diameter D4) from above without touching lever 1
(612).

9. Remove lever 2 (613). 11. Remove lever 1 (612).

Do not pull out the pin (875).
• It can be easily removed by using a pair of tweez-
ers.
Do not pull out the pin (875).
12. Pull out the pilot piston (643) and spool (652).
13. Pull out the piston case (622), compensation piston
(621), and compensation rod (623) to complete dis-
assembly of the regulator.
• The piston case (622) can be removed by pushing
out the compensation rod (623) from the opposite
side of the piston case.
* The component parts are small, so be very careful not
to lose them.

84402826 - May 2011

8010-21
 Pump Main Unit Maintenance Standards

Assembly procedures
The assembly procedure is the reverse of the disas-
sembly procedure. However, follow the precautions
below.
1. Be sure to repair any parts damaged during dis-
assembly, and prepare replacement parts in ad-
vance.
2. Any foreign matter entering the equipment can
create a malfunction. Therefore, after thoroughly
cleaning the equipment with cleaning oil, air blow
the equipment, and perform assembly in a clean
location.
3. Make sure to tighten bolts and plugs of each sec-
tion to the specified torque.
4. Be sure to apply clean hydraulic oil to sliding sec-
a Lever (1) side
tions before assembly.
5. As a rule, replace all seals such as O-rings with Lever (2) side (Fulcrum plug,
b
new parts. adjusting plug side)

1. Install the compensation rod (623) into the compen-

sation hole on the casing (601). 5. Install the pilot piston (643) into the flow control hole
2. Insert the pin press fit in lever 1 (612) into the groove on the casing.
on the compensation rod, and install lever 1 on the • Check that the pilot piston slides smoothly without
pin press fit in the casing. catching.
3. Install the spool (652) and sleeve (651) in the casing
spool hole. 6. Insert the pin press fit in lever 2 (613) into the groove
on the pilot piston, and assemble lever 2.
• Check that the spool and sleeve slide smoothly in
the casing without catching.
• Be careful to assemble the spool in the correct
direction.

7. Assemble the fulcrum plug (614) and install the

locking ring (858) so that the pins press fit in the
fulcrum plug are inserted into the pin holes on lever
2.

*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.
84402826 - May 2011
8010-22
 Pump Main Unit Maintenance Standards

• At this time, check that the backlash from the
movement of the feedback lever is not too great
and that the feedback lever does not catch on
anything.
9. Install the return spring (654) and spring seating
(653) into the spool hole, and install the stop ring
(814).
11. Install the spring seating (644), pilot spring (646),
and adjusting ring (645) into the pilot hole, and in-
stall the spring seating (624), inner spring (626), and
outer spring (625) into the compensation hole.
• Be careful to install the spring seating in the cor-
rect direction.

12. Assemble the cover (C) (629) set with the adjusting
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.

84402826 - May 2011

8010-23
 Pump Main Unit Maintenance Standards

Diagram 1. Front-side regulator assembly cross-section diagram (KR3K-9Y04-HV)

Hydraulic circuit diagram

84402826 - May 2011

8010-24
Pump Main Unit Maintenance Standards

84402826 - May 2011

8010-25
 Pump Main Unit Maintenance Standards

a DETAIL OF STAMP FOR TYPE AND

SERIAL NUMBER
b TYPE
c SERIAL NUMBER

Code Part name Q'ty Component part No. (q'ty) or type

050 Shuttle valve subassembly 1 set 545 (1PC), 546 (1PC), 547 (1PC)
Electromagnetic proportional pressure reduc-
079 1 set KDRDE5K-31/30C50-102
ing valve

Part num- Part num-

Part name Q'ty Part name Q'ty
ber ber
- Regulator subassembly 1 651 Sleeve 1
412 Hexagon socket head bolt 2 652 Spool 1
413 Hexagon socket head bolt 2 653 Spring seating 1
418 Hexagon socket head bolt 2 654 Return spring 1
436 Hexagon socket head bolt 4 655 Set spring 1
438 Hexagon socket head bolt 8 656 Blind cover 1
466 VP plug 1 708 O-ring 1
467 VP plug 1 722 O-ring 3
496 Insert plug 12 724 O-ring 9
545 Steel ball 1 725 O-ring 1
546 Seat 1 1 727 O-ring 1
547 Seat 2 1 728 O-ring 1
601 Casing 1 730 O-ring 1
611 Feedback lever 1 732 O-ring 1
612 Lever (1) 1 733 O-ring 1
613 Lever (2) 1 734 O-ring 1
614 Fulcrum plug 1 735 O-ring 1
615 Adjusting plug 1 753 O-ring 1
621 Compensation piston 1 755 O-ring 3
622 Piston case 1 756 O-ring 1
623 Compensation rod 1 763 O-ring 1
624 Spring seating (C) 1 801 Hexagon nut 1
625 Outer spring 1 802 Hexagon nut 1
626 Inner spring 1 814 Stop ring 1
627 Adjusting ring (C) 1 836 Retaining ring 1
628 Adjusting screw (C) 1 858 Locking ring 2
629 Cover (C) 1 874 Pin 1
630 Lock nut 1 875 Pin 2
631 Pf sleeve 1 876 Pin 2
641 Pilot cover 1 887 Pin 1
643 Pilot piston 1 897 Pin 1
644 Spring seating (Q) 1 898 Pin 1
645 Adjusting ring (Q) 1 924 Hexagon socket head locking screw 1
646 Pilot spring 1

84402826 - May 2011

8010-26
Pump Main Unit Maintenance Standards

Tightening torque
Tightening torque
Part No. Screw size
N•m
412, 413 M8 29
418 M5 6.9
436, 438 M6 12
466 G1/4 36
467 G3/8 74
496 NPTF 1/16 8.8
630 M30 x 1.5 160
801 M8 16
802 M10 19

84402826 - May 2011

8010-27
 Pump Main Unit Maintenance Standards

Diagram 2. Rear-side regulator assembly cross-section diagram (KR3K-9Y04-HV)

Hydraulic circuit diagram

84402826 - May 2011

8010-28
Pump Main Unit Maintenance Standards

84402826 - May 2011

8010-29
 Pump Main Unit Maintenance Standards

a DETAIL OF STAMP FOR TYPE AND

SERIAL NUMBER
b TYPE
c SERIAL NUMBER

Code Part name Q'ty Component part No. (q'ty) or type

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

Part num- Part num-

Part name Q'ty Part name Q'ty
ber ber
- Regulator subassembly 1 651 Sleeve 1
412 Hexagon socket head bolt 2 652 Spool 1
413 Hexagon socket head bolt 2 653 Spring seating 1
436 Hexagon socket head bolt 4 654 Return spring 1
438 Hexagon socket head bolt 8 655 Set spring 1
466 VP plug 1 656 Blind cover 1
467 VP plug 1 708 O-ring 1
496 Insert plug 6 722 O-ring 3
545 Steel ball 1 724 O-ring 9
546 Seat 1 1 725 O-ring 1
547 Seat 2 1 727 O-ring 1
601 Casing 1 728 O-ring 1
611 Feedback lever 1 730 O-ring 1
612 Lever (1) 1 732 O-ring 1
613 Lever (2) 1 733 O-ring 1
614 Fulcrum plug 1 734 O-ring 1
615 Adjusting plug 1 735 O-ring 1
621 Compensation piston 1 753 O-ring 1
622 Piston case 1 755 O-ring 3
623 Compensation rod 1 756 O-ring 1
624 Spring seating (C) 1 763 O-ring 1
625 Outer spring 1 801 Hexagon nut 1
626 Inner spring 1 802 Hexagon nut 1
627 Adjusting ring (C) 1 814 Stop ring 1
628 Adjusting screw (C) 1 836 Retaining ring 1
629 Cover (C) 1 858 Locking ring 2
630 Lock nut 1 874 Pin 1
631 Pf sleeve 1 875 Pin 2
641 Pilot cover 1 876 Pin 2
643 Pilot piston 1 887 Pin 1
644 Spring seating (Q) 1 897 Pin 1
645 Adjusting ring (Q) 1 898 Pin 1
646 Pilot spring 1 924 Hexagon socket head locking screw 1

84402826 - May 2011

8010-30
Pump Main Unit Maintenance Standards

Tightening torque
Part No. Screw size Tightening torque N•m
412, 413 M8 29
436, 438 M6 12
466 G1/4 36
467 G3/8 74
496 NPTF 1/16 8.8
630 M30×1.5 160
801 M8 16
802 M10 19

84402826 - May 2011

8010-31
Pump Main Unit Maintenance Standards

84402826 - May 2011

8010-32
 Section

8011

Procedures for Assembly and Disassembly of Control Valve

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cautions for disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal of long cap and pull out of main spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly of arm 1 parallel-tandem spool, neutral cut spool section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly of arm regeneration release valve section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly of load check valve section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassembly of antidrift valve section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly of relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly of option section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly of straight travel signal control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassembly of other plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassembly of add-on section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassembly of valve housing union bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cautions for assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cautions for O-Ring handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cautions for spool handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Adhesive application method (for male thread section and female thread section of parts requiring adhe-
sion) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Procedure for assembly of sub-assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly of spool assembly (main spool) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly of arm 1 parallel-tandem spool assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Assembly of neutral cut spool assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Assembly of antidrift valve assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Procedure for assembly of control valve main unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assembly of relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assembly of load check valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assembly of antidrift valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assembly of option section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assembly of arm regeneration release valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assembly of arm 1 parallel-tandem spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assembly of neutral cut spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assembly of main spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Assembly of straight travel signal control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Assembly of add-on section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Assembly of other plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Internal structure diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Part list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Procedures for assembly and disassembly of main relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Procedures for assembly and disassembly of overload relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Procedures for assembly and disassembly of low-pressure relief valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Procedures for assembly and disassembly of add-on main relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Relief valve adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
8011-1 PRINTED IN FRANCE
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Troubles and countermeasures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

8011-2 PRINTED IN FRANCE
 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.

84402826 - May 2011

8011-3
 Procedures for Assembly and Disassembly of Control Valve

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

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.

84402826 - May 2011

8011-4
 Procedures for Assembly and Disassembly of Control Valve

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].

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).

84402826 - May 2011

8011-5
 Procedures for Assembly and Disassembly of Control Valve

Disassembly of load check valve section

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 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.

84402826 - May 2011

8011-6
 Procedures for Assembly and Disassembly of Control Valve

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).
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.

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.

84402826 - May 2011

8011-7
 Procedures for Assembly and Disassembly of Control Valve

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).

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).

84402826 - May 2011

8011-8
 Procedures for Assembly and Disassembly of Control Valve

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.

84402826 - May 2011

8011-9
 Procedures for Assembly and Disassembly of Control Valve

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

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)

84402826 - May 2011

8011-10
 Procedures for Assembly and Disassembly of Control Valve

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

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.

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.

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

84402826 - May 2011

8011-11
 Procedures for Assembly and Disassembly of Control Valve

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.
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

84402826 - May 2011

8011-12
 Procedures for Assembly and Disassembly of Control Valve

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

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

84402826 - May 2011

8011-13
 Procedures for Assembly and Disassembly of Control Valve

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

84402826 - May 2011

8011-14
 Procedures for Assembly and Disassembly of Control Valve

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.
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).

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

84402826 - May 2011

8011-15
 Procedures for Assembly and Disassembly of Control Valve

Internal structure diagram

84402826 - May 2011

8011-16
 Procedures for Assembly and Disassembly of Control Valve

a [FOR HOOK BOLT] 2-M10 x 1.5 c

M10 x 1.5,THREAD DEPTH 12 e 4-M16 x 2 THREAD DEPTH 27
THREAD DEPTH 14
[FOR HOOK BOLT] 5-M10 x 1.5 RETIGHTEN AFTER NO.75
b d
THREAD DEPTH 17 LOCKED

*1 ARM 1 *3 SWING *5 TRAVEL

*2 BOOM 2 *4 OPTION

84402826 - May 2011

8011-17
Procedures for Assembly and Disassembly of Control Valve

84402826 - May 2011

8011-18
 Procedures for Assembly and Disassembly of Control Valve

a RETIGHTEN AFTER NO.75 LOCKED

6.6 - 7.2 N・m
b M10 x 1.5 THREAD DEPTH 17

*1 ARM 2 *3 BUCKET *5 STRAIGHT TRAVEL

*2 BOOM 1 *4 TRAVEL

84402826 - May 2011

8011-19
Procedures for Assembly and Disassembly of Control Valve

84402826 - May 2011

8011-20
 Procedures for Assembly and Disassembly of Control Valve

*1 PARALLEL LINE *5 CYLINDER PORT *9 BUCKET CLOSE Û OPEN

*2 TANK *6 ATTACHMENT 1 *10 TRAVEL
*3 DRAIN *7 ARM 2 IN Û OUT *11 STRAIGHT TRAVEL
*4 PILOT *8 BOOM 1 DOWN Û UP

84402826 - May 2011

8011-21
Procedures for Assembly and Disassembly of Control Valve

84402826 - May 2011

8011-22
 Procedures for Assembly and Disassembly of Control Valve

*1 ARM 1 OUT Û IN *7 CYLINDER LINE *13 CYLINDER

*2 BOOM 2 UP Û DOWN *8 PILOT *14 STRAIGHT TRAVEL LINE
*3 SWING *9 (SUB VALVE) *15 COMMON CHECK LINE
*4 OPTION *10 (CAP) *16 PARALLEL
*5 TRAVEL *11 TANK
*6 DRAIN *12 BRIDGE LINE

84402826 - May 2011

8011-23
Procedures for Assembly and Disassembly of Control Valve

84402826 - May 2011

8011-24
 Procedures for Assembly and Disassembly of Control Valve

*1 TANK *4 BOOM 1 *7 OPTION

*2 BOOM 2 *5 TRAVEL
*3 UP Û DOWN *6 STRAIGHT TRAVEL

84402826 - May 2011

8011-25
Procedures for Assembly and Disassembly of Control Valve

84402826 - May 2011

8011-26
 Procedures for Assembly and Disassembly of Control Valve

*1 SWING *3 BUCKET *5 OUT Û IN

*2 OPEN Û CLOSE *4 ARM 1 *6 ARM 2

84402826 - May 2011

8011-27
 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

84402826 - May 2011

8011-28
 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).

84402826 - May 2011

8011-29
 Procedures for Assembly and Disassembly of Control Valve

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)
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).

84402826 - May 2011

8011-30
 Procedures for Assembly and Disassembly of Control Valve

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

84402826 - May 2011

8011-31
 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).

84402826 - May 2011

8011-32
 Procedures for Assembly and Disassembly of Control Valve

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.
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.

84402826 - May 2011

8011-33
 Procedures for Assembly and Disassembly of Control Valve

Troubles and countermeasures

Control valves overall

Trouble content Conceivable cause Countermeasure

1.The oil temperature is abnormally high.
2.Dirty hydraulic oil
3.Line port joint tightened too much
4.The valve housing was warped during
installation.
The spool does not move 5.The pressure is too high.
through its stroke.
6.The spool is bent.
7.Return spring damage
8.The spring or cap is out of place.
9.The temperature distribution within the
valve is not uniform.
10.Debris is clogging inside the valve.
11.Pilot pressure insufficient
1.Oil leak from cylinder
2.Oil from the spool is bypassing.
3.Oil leak from overload relief valve
The load cannot be held.
4.Oil leak from antidrift valve
1.There is debris jammed in the load
When the spool is switched 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.
Eliminate the section that is providing re-
sistance to the oil flow in the line.
Replace the hydraulic oil and at the same
time, clean the circuits.
Check the torque.
Loosen the installation bolts and check.
Attach a pressure gauge to the pump and
the cylinder port and check the pressure.
Replace the spool as an assembly.
Replace the damaged part.
Loosen the cap, center it, then tighten it.
Warm up the circuits as a whole.
Remove (flush out) the debris.
Inspect for the pilot valve and pilot relief
pressure.
Check the cylinder seal section.
Check for spool damage.
Clean the valve housing seat section and
relief valve seat section.
Disassemble the antidrift valve and clean
the seat section for each part.
If a seat section is damaged, replace the
poppet or lap the poppet and seat sec-
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.
Disassemble and clean the check valve.
seat section.

Relief valve

Trouble content Conceivable cause Countermeasure

Pressure does not rise at all.
The relief pressure is unstable.
The relief pressure is wrong.
Oil leak
1.Either the main poppet, sleeve, or
pilot poppet is stuck open or there is
debris jammed in the valve seat sec-
tion.
1.The pilot poppet seat section is Replace the relief valve.
damaged.
2.The piston or main poppet is stuck.
1.Seat section worn by debris
Set the pressure again, then tighten
2.The lock nut and adjuster are loose.
the lock nut to the specified torque.
1.Relief valve seat section damage
Replace the relief valve.
2.Each part is stuck due to debris.
Replace the adjuster or installation
3.An O-ring is worn.
section O-ring.

Hydraulic system overall

84402826 - May 2011
8011-34
 Procedures for Assembly and Disassembly of Control Valve

Trouble content Conceivable cause Countermeasure

1.Pump trouble
2.Relief valve trouble
3.Cylinder trouble
4.Pump load pressure is high.
The hydraulic system is not working
5.There is a crack in the valve.
properly or is not working at all.
6.The spool does not move through its
full stroke.
7.The tank oil level is too low.
8.The filter in the circuit is clogged.
9.The circuit line is throttled.
Check the pressure or replace the
pump.
Replace the relief valve.
Repair or replace.
Check the circuit pressure.
Replace the valve as an assembly.
Check the spool movement.
Fill the hydraulic oil.
Clean or replace the filter.
Check the line.

84402826 - May 2011

8011-35
Procedures for Assembly and Disassembly of Control Valve

84402826 - May 2011

8011-36
 Section

8012

Procedures for Operation/Assembly and Disassembly of

Hydraulic Cylinder (made by KYB)

84402826 - May 2011

84402826 - May 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Precautions for Installing the Cylinder on the Machine Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Usage Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Maintenance and Inspection Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Maintenance Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Trouble Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Storage Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Storing Parts Individually (In principle, store indoors.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
When Mounted on Vehicle Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Recommended Anti-rust Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Assembly and Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
General Work Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Inspection after Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Required Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
General Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Special Jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Special Jigs Part Number List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Drain the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Secure the Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Removal of Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Pull out the Piston Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Fasten the Piston Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Remove the Piston Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Removal of Piston etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Disassembly of the Retraction Side Cushion Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Remove the Piston Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Disassembly of the Buffer Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Disassembly of U-ring and Wiper Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Removal of O-ring and Backup Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Disassembly of Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Removal of Pin Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Cleaning and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Installation of Pin Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Replacement of Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Assembly of Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Assembly of Piston Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Assembly of Piston Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Insertion of Piston Rod into the Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

8012-1 PRINTED IN FRANCE
 Cylinder Head Tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Installation of Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Test Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Usage Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Structural Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Boom Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Arm Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Bucket Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

8012-2 PRINTED IN FRANCE
 Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Specifications and Structure Diagram (including the assembly diagram
and parts table)
In this manual, explanation is done using a product with a representative structure for a construction machine hydraulic
cylinder (KCH-6 model).
For details on the specifications and structure of the product being used, see the attached structural diagram.
Basic functions
Hydraulic cylinders are a type of hydraulic actuator.
A hydraulic cylinder converts the energy of pressure supplied from the hydraulic pump into a large force of linear
motion. By operating the hydraulic pressure direction switchover valve, one can switch the direction of operation
between extension and retraction.
This linear motion with large force and the switchover of the operation direction are the basic functions.
Function of Each Location
This manual explains the functions of each section of the cylinder using one of our products with a typical structure.
There may be some slight differences with the product being used, but the functions are the same.
Cylinder Head Assembly
The cylinder head assembly has the function of bearing the piston rod (2) by the bushing (4) press fit into the inner
diameter of the cylinder head (3). The seal system of the inner diameter of the cylinder head prevents oil from leaking
to the outside and prevents foreign matter from getting into the cylinder. The cylinder head assembly also has the
function of supplying and discharging high-pressure oil from inside the cylinder tube to the retraction side port.

1 Cylinder tube 5 O-ring 9 Wiper ring

2 Piston rod 6 Buffer ring 10 O-ring
3 Cylinder head 7 U-ring 11 Backup ring
4 Bushing 8 Backup ring 12 Installation bolt

• Bushing
The bushing is press fit to the inside surface of the cylinder head (3) and touches the piston rod (2). Together with
the slide rings (18) (19) on the outer circumference of the piston, the bushing divides the lateral load applied to the
cylinder and moves linearly relative to the piston rod. Furthermore, it supports one end of the piston rod and has
the function of minimizing eccentricity which has a negative impact on the sealing.
• Buffer ring
The buffer ring (6) has the function of buffering the pressure and heat applied on the U-ring (7) by the hydraulic oil
to improve durability.
• U-ring and backup ring
The U-ring (7) seals the pressure oil within the cylinder. The U-ring also has the function of forming an appropriate
oil film on the surface of the piston rod in order to prevent rust of the piston rod (2). The backup ring (8) has the
function of suppressing extrusion of the U-ring into the gap between the piston rod and the cylinder head (3) when
the pressure operates and of improving durability.
• Wiper ring
The wiper ring (9) is positioned in the opening where the piston rod (2) comes out from and goes into the cylinder.
This wiper ring (9) prevents dust and water from getting into the cylinder from the outside. It also has the function
of wiping off any mud sticking to the surface of the piston rod as the piston rod moves.

84402826 - May 2011

8012-3
 Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Piston Assembly
The piston assembly has the function of transmitting the propulsion of the cylinder. A seal ring (16) is mounted on the
center of the piston (15) to prevent the flow of pressure oil from either the left or right chamber to the other chamber.
There are slide rings (18) (19) mounted at each end of the seal ring. They have the function of a bearing to receive
the cylinder lateral load.

1 Cylinder tube 16 Seal ring 21 Steel ball

2 Piston rod 17 Backup ring 22 Cushion ring
13 Cushion ring 18 Slide ring 23 Cushion seal
14 Cushion seal 19 Slide ring 24 Stopper
15 Piston 20 Locking screw 25 Snap ring

Use caution with the direction

a of the cut surfaces during in-
stallation
b Face the "slit" to the piston side.

For some cylinder sizes, the piston (15) and nut (21) are separate.

84402826 - May 2011

8012-4
 Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)

1 Cylinder tube 17 Backup ring 23 Steel ball

2 Piston rod 18 Slide ring 24 Cushion ring
13 Cushion ring 19 Slide ring 25 Cushion seal
14 Cushion seal 20 Shim 26 Stopper
15 Piston 21 Nut 27 Snap ring
16 Seal ring 22 Locking screw

Use caution with the direction

a of the cut surfaces during in-
stallation
b Face the "slit" to the piston side.

Example of parts numbers for separated piston and nut

• Seal ring and backup ring
The seal ring (16) is positioned at the center of the piston (15) and uses the tension force of the O-ring to seal the
ring-shaped gap between the piston and the cylinder tube (1) and form chambers with a high-pressure side and a
low-pressure side with the piston as the boundary. The backup ring (17) has the function of suppressing extrusion
of the seal ring into the gap between the piston and the cylinder tube when the pressure operates and of improving
durability.
• Slide ring
Slide rings are positioned at both ends of the seal ring (16) and contact the inside surface of the cylinder tube (1).
Together with the bushing (4) positioned on the inside surface of the cylinder head (3), the slide ring divides the
lateral load applied to the cylinder and moves linearly relative to the inside surface of the cylinder tube.
Furthermore, it supports one end of the piston rod (2) and has the functions of minimizing eccentricity, which has a
negative impact on the sealing, and buries and captures any impurities trapped between the cylinder tube and the
slide rings (18) (19).
• Cushion ring (for separated piston and nut)
When the cylinder is fully extended, the cylinder head (3) and the cushion ring (13) fit together. When it is fully
retracted, the cylinder bottom and the cushion ring fit together. In both cases, this forms a ring-shaped gap and
squeezes the oil to reduce the cylinder collision speed at full extension or full retraction and thus soften the impact.
84402826 - May 2011
8012-5
 Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Pipe Assembly
The pipe assembly is mounted on the extension side and retraction side ports of the cylinder tube assembly. It has the
function of supplying and discharging high-pressure oil by connecting with the hydraulic circuits of the machine body.

28 Pipe assembly
29 Pipe assembly

84402826 - May 2011

8012-6
 Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Handling Precautions
Precautions for Installing the Cylinder on the Machine Body
• When installing the cylinder on the machine body or removing it from the machine body, secure the piston rod at
the fully retracted position, check safety, and suspend.

CAUTION
Never suspend the cylinder from the line section. This would not only pose the danger of falling but
could also damage the cylinder.
Use a band to secure the piston rod in the fully retracted state.
If the piston rod is not in the fully retracted state, it could be easily damaged. This could create the
need for repair or make the piston rod unusable.
Also, not securing the piston rod is dangerous because the piston rod might fly out unexpectedly.

• Do not weld after the cylinder has been mounted on the machine body.
CAUTION
Electric welding on the cylinder or even at a position separated from the cylinder can generate a spark
within the cylinder and damage parts.
This could cause extensive damage, making it necessary to replace parts or replace the cylinder.

• When painting the machine body, mask the piston rod and wiper ring.
CAUTION
If the cylinder is operated with paint sticking to the piston rod surface and the wiper ring, the wiper
ring does not function adequately, greatly interfering with cylinder functions. For example, dirt and
paint from the outside may get into the cylinder easily and damage seal parts and cause an oil leak.

• Clean the cylinder before installing it.

84402826 - May 2011

8012-7
 Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Usage Cautions
• Use under the determined conditions.
CAUTION
Use of hydraulic oil other than that specified can cause rapid deterioration of and damage to seal parts.
If the relief valve is set to a value higher than that on the assembly diagram, there is a danger of this
leading to cylinder damage.
General sealing materials cannot handle high ambient temperature (about 100℃ ℃ 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.

84402826 - May 2011

8012-8
 Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Maintenance and Inspection Cautions
• Always carry out daily maintenance inspections.
CAUTION
The most important point for realizing the cylinder functions for a longer time is "daily maintenance
inspections".
In order to ensure adequate functioning, execute "Maintenance Inspection and Service".
Constantly clean off any mud, water, dust, oil or grease stuck to the piston rod and keep the piston
rod in a clean state.
However, do not use water or the like to clean the wiper ring section and seal section. Wipe with a rag.
When leaving the machine unused for a week or longer, apply anti-rust oil to the surface of the piston
rod in order to prevent rusting.

• Use genuine KYB parts for replacement parts.

CAUTION
If replacement parts are used that are not genuine KYB parts, adequate functioning cannot be attained.
Always use genuine KYB parts.
Specialty jigs have been produced so that assembly work and disassembly work can be done safely
and quickly, so order them.

• Be careful about assembly and disassembly too.

CAUTION
Disassembling a cylinder still installed on the machine body is extremely dangerous because it can
cause unexpected movement of the machine body.
Always remove the cylinder from the machine body before disassembling it.
Assembling with dirty hands can get dirt inside the cylinder and not only reduce the cylinder service
life but also damage other hydraulic equipment.
Assemble under clean conditions.
Use the thread part tightening torque indicated in the diagram.
If the torque is either too low or too high, this can cause thread damage.

• Strictly observe the cylinder storage standards.

CAUTION
Execute according to "Assembly and Disassembly Procedures".

84402826 - May 2011

8012-9
 Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Maintenance Inspection and Service
In order to ensure that hydraulic cylinders function properly for a long time, periodically carry out maintenance in-
spection and service based on the "Autonomous inspection table". Repair any trouble locations quickly based on the
Trouble Diagnostics.

CAUTION
For periodic inspection and service, first work to prevent any hazard to operators. Strive to prevent
hazards by working with an attitude based on good sense.

Inspection and ser- Mont-

Inspection and service detail Daily Yearly Remarks
vice location hly
Is the cylinder clean (especially rod sliding ○
sections)?
Appearance Is any oil leaking from line installation sec- ○
tions or other fixed sections?
Is there missing or peeling paint or rust? ○
Is operation smooth and free of abnormal ○
noise and any other abnormality?
Is the responsiveness good? ○
Is any oil leaking from sliding sections? ○
Operation
Are there internal leaks? ○
Is the operating pressure normal? ○
Is the overload relief valve set pressure nor- ○
mal?
Is hydraulic oil dirty or deteriorated? ○
Hydraulic oil Is hydraulic oil replaced periodically? ○
Are filters inspected periodically? ○
Is the supply of grease to pins adequate? ○
Do pin sections have any abnormal noises ○
or seizing?
Section for installa- Do pin sections have any backlash or wear? ○
tion with main unit Are pin seals normal? ○
Are any installation screws loose or fallen ○
out?
Retighten installation screws. ○
Are sliding sections worn? ○ When leaving pis-
Are sliding sections scratched or dented? ○ ton rod sliding
Is sliding section plating peeling off? ○ sections exposed
Piston rod section
Are sliding sections bent? ○ for long periods,
Are there any welding section cracks or apply anti-rust oil
○ to the piston rod.
damage?
Are there any loose bolts or nuts (screws)? ○
Retighten installation screws (bolts and nuts ○
Cylinder tube section (screws)).
(including line sec-
tions) Are there any welding section cracks or ○
damage?
Are there large dents on the tube? ○

84402826 - May 2011

8012-10
 Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Trouble Diagnostics
Hydraulic cylinder trouble, countermeasure and solution
It is not easy to discover trouble locations.
The table below shows general symptoms, suggested causes and also solutions.
For repairs, see the suggested causes and solutions in the table.
The cause of machine problems are often not rooted in just a single part. Problems are often due to the relationship
of one part with another.
In some cases, solutions are required other than those given in the table.
In such a case, contact with our company to investigate the problem and its cause further and take appropriate mea-
sures.

Item Symptom
Piston rod sliding section oil leak
1
(For the judgment values, see "Inspection after Assembly".)
2 Cylinder head matching section oil leak
3 Pipe and cylinder tube welding section oil leak
4 Operation defect

84402826 - May 2011

8012-11
 Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Item Symptom Related part Cause
A sliding surface has rust and
scratches that catch on a fin-
gernail.
Piston rod
Plating is peeling off.
There is foreign matter caught
in the inner or outer diameter
section.
There are scratches on the in-
ner or outer diameter section.
Piston rod sliding The lips and groove section are 2. When operating the cylinder for
1
section oil leak locally carbonized (scorched).
The packing has lost its rubber 1. Replace.
elasticity and is in tatters.
Rod packing
(Buffer ring and
U-ring)
The lip section is defective all
the way around.
There is major extrusion of the
packing heel section.
84402826 - May 2011
8012-12
Countermeasure and solution
1. Remove the scratches with a
whetstone to make the sliding
surface smooth (1.5 s max.).
If the oil leak continues, the rod
scratches may have damaged
the U-ring or other seal, so dis-
assemble and inspect.
2. If the scratches or rust cover too
large an area to be repaired with
a whetstone, replace the piston
rod and the U-ring, wiper ring,
or other seal and the piston rod
bearing part.
1. Replate or replace the piston rod.
2. At this time, inspect the seals and
piston rod bearing part as well
and replace any that are dam-
aged.
1. Remove the foreign matter.
2. If the packing is damaged, re-
place it.
Replace.
1. This may be scorching due to adi-
abatic compression of air remain-
ing in the cylinder.
the first time after replacing a
packing, run at low pressure and
low speed to adequately bleed off
the air.
2. This may be the end of the pack-
ing service life, deterioration of
the hydraulic oil, or high temper-
ature of the hydraulic oil.
1) Replace with a new hy-
draulic oil.
2) Check the temperature of
the hydraulic oil.(The oil
temperature should be no
higher than 80℃.)
3) Check for local high tem-
perature.
1. Replace.
2. Abnormally high pressure may
be operating on the packing.
1) Check the pressure during
operation.
2) There may be trouble with
the buffer ring section.
Inspect the buffer ring sec-
tion.
 Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Item Symptom Related part Cause Countermeasure and solution
1. As a rule, replace the rod packing
too at the same time.
2. Abnormally high pressure is often
Backup ring The part is greatly deformed. the cause.
The check items for this are the
same as those given above for
packing heel section extrusion.
There is foreign matter caught
Remove the foreign matter.
in the lip.
Wiper ring The lip is damaged.
There is other abnormal dam- Replace.
age.
Piston rod sliding
1 There is major wear of the
section oil leak
bushing and the gap with the
piston rod exceeds the limit on Replace.
Bearing part inner diameter wear in "Usage
(bushing) Limits".
1. Replace.
There are large scratches on a
2. Inspect the piston rod sliding sur-
sliding surface.
faces for scratches and rust.
1. Remove the scratches or rust
with a whetstone.
A seal mounting section has
Cylinder head 2. If the repair does not solve the
scratches and rust.
problem, replace the cylinder
head.
1. Remove the foreign matter.
2. If the O-ring is damaged, replace
it.
3. Tube interior surface inspection:
If there are any scratches or rust,
use a whetstone to make the sur-
There is foreign matter caught face smooth.
O-ring in the inner or outer diameter. 4. Cylinder head O-ring groove in-
There is damage to the O-ring. spection: Same as above
5. Backup ring inspection: If the
backup ring is deformed or ex-
truded, replace it.
Check the above and replace the
O-ring.
The part is deformed or ex-
Backup ring Replace together with the O-ring.
truded.
1. Disassemble the cylinder head
Cylinder head and inspect the O-ring and
2 matching section backup ring.
oil leak If there is damage, replace.
2. Check the tube and cylinder head
Cylinder
A part is loose. threads for damage and if there is
head
any damage, replace.
3. When the inspection is complete,
tighten to the specified torque.
See "Assembly Procedures".
4. Stop rotation.
There is looseness, stretching Replace all the bolts and tighten to the
Bolt
or breakage. specified torque.
1. Replace with a new one.
2. Oil leaks at matching sections
may be caused by abnormally
high pressure (including cush-
Cylinder tube There is abnormal swelling.
ion pressure), so if the tube is
swollen or deformed, replace it
with a new one.
Also inspect the circuit pressure.

84402826 - May 2011

8012-13
 Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Item Symptom Related part Cause Countermeasure and solution
CAUTION
Replace with a new one.
Pipe and cylinder
Pipe and cylinder There are cracks on the weld- The crack progresses and ultimately
tube welding sec-
tube ing section. the part fractures.
tion oil leak
A fracture is extremely dangerous, so
if a crack is seen, quickly stop work
3 and replace that part.
Welding over a crack is ineffective.
Tighten to the specified torque ac-
Line fastening bolt is loose.
cording to the work procedure.
Oil leak from cylin- The line is bent. Replace with a new one.
der line connec- Pipe assembly 1. Use a whetstone to make the sur-
tion section There are scratches on a con- face smooth.
tact surface. 2. If the oil leak does not stop, re-
place.
1. Replace with a new one.
The bending is large and ex-
2. There may also be damage to
ceeds the stipulated bend
Piston rod seals and sliding parts, so inspect
warp.
Cylinder tube them.
(Bend warp: See "Mainte-
If there is any abnormality, re-
nance Standards".)
place.
Operation defect Replace with a new one.
Movement is not Cylinder tube There are dents. Inspect the seal and sliding parts the
smooth. same as above.
1. Replace with a new one.
Abnormal wear of sliding parts
Inspect the seal and sliding parts
Piston rod and damage
the same as above.
Cylinder tube Foreign matter caught at the
2. Remove the foreign matter.
Sliding part piston section or the cylinder
Inspect the seal and sliding parts
head sliding section
the same as above.
Replace with a new one.
There are scratches, wear, or
Piston seal Also inspect the cylinder tube interior
other damage.
4 surfaces.
1. Use honing or a whetstone to
eliminate the scratches and rust
and make the surface smooth.
Internal oil leak There are scratches and rust
Cylinder tube If the scratches cover too large an
The piston rod ex- on interior surface.
area to be repaired, replace the
tends and retracts cylinder tube with a new one.
on its own and 2. Replace with a new piston seal.
drops abnormally
1. Tighten to the specified torque.
during operation.
See "Assembly Procedures".
Also, the stipu-
2. The piston rod thread section
lated speed is not
could be stretched.
output. Piston nut Tightening is insufficient.
Measure the diameter where the
rod and piston fit together and if
this area is tapered, replace the
piston rod assembly.
Inspect the amount of valve leakage
Valves Leak from valve.
and perform maintenance.

84402826 - May 2011

8012-14
 Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Item Symptom Related part Cause Countermeasure and solution
Bleed out the air.
1. Cylinder with no air bleeding
Bleed out the air by moving the
cylinder back and forth at few
times at low pressure and low
speed.
2. Cylinder with air bleeding (air
breather)
After securing the machine so
Operation is un- There is air remaining in the that the cylinder does not move,
Air
steady. cylinder. bleed the air from the air breather.

HINT
The cylinder may extend or retract
somewhat when the cylinder stops
suddenly.
This phenomenon occurs due to the
4 compressibility of the hydraulic oil.
This occurs particularly easily for
cylinders with long strokes.
The impact is high
when switching The gap between the installa- Measure the pin and pin bushing di-
Pin bushing
over between ex- tion section and the pin bushing mensions and replace any part that
Pin
tension and re- is enlarged. exceeds its specified dimension.
traction.
The oil or grease feed is inade-
Cylinder sliding Apply oil or grease.
Pin bushing quate.
operations make
Pin There is seizing at matching Replace with a new part and apply oil
sounds.
section. or grease.
CAUTION
The hydraulic oil expands and contracts with changes in temperature and pressure.
This causes the cylinder to extend and retract too, so it can be mistaken for an internal oil leak.
For internal oil leaks, always check the temperature and pressure under the same conditions.

84402826 - May 2011

8012-15
 Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Storage Standards
When a hydraulic cylinder is shipped from the plant, every measure is taken, but in order to prevent trouble during
storage and to extend the product service life, pay attention to the following items.
Storing Parts Individually (In principle, store indoors.)
• Store parts off the floor and do not store in any location with high temperature and humidity, corrosive gas or liquids.
• Before shipment, we operate the cylinder with hydraulic oil to which a fixed quantity of vaporizing anti-rust agent
has been added (in order to prevent rust within the cylinder), carry out the pre-shipping inspection, retract the pis-
ton rod with ultra-dry air (condensation point -35℃ 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

For inside cylinder
For piston rod
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
Vaporizing anti-rust oil
a. Ferro Gard #1009 (from USC Limited)
b. Knuckle Oil #105S (from Parker Industries, Inc.)
For both a. and b., add 3 - 5 % of the hydraulic oil.
By volume,
Ferro Gard: 5/100
Knuckle Oil: 3/100
Anti-rust P-1300 (from the Nippon Oil Corporation)

84402826 - May 2011

8012-16
 Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Assembly and Disassembly Procedures
Preparations
Prepare the Following before Starting Disassembly:
1. Work platform preparation
Prepare a sufficiently spacious, solid and stable work surface so that parts will not fall or move during work.
2. Tool and materials preparation
Prepare the tools and materials shown on the following pages.

General Work Precautions

1. Thoroughly clean any dirt or mud from the outside walls of the cylinder before starting disassembly.
2. Each part has been manufactured with a high degree of precision, so be careful not to let parts bump each other
or fall when handling them.
3. If parts are struck or pried off with excessive force during work because they are tight, this may cause burrs or
damage which causing reduction in performance or oil leaking.
Perform work carefully and thoroughly.
4. If a cylinder is left disassembled, humidity and dirt can cause rust on parts.
If a pause in the work is unavoidable, be careful to prevent rust and keep off dust.

Maintenance Standards
Replace sliding parts and seal parts as follows.
1. Bushing
When 1/4 of the circumference is worn brown over the entire length.
2. Seals and slide rings
Replace with new parts when the cylinder is disassembled.
3. Pin bushing
When there is severe seizing.
4. Piston rod
When the piston rod is bent 0.5 mm/1 m or more.

84402826 - May 2011

8012-17
 Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
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

84402826 - May 2011

8012-18
 Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Required Tool
General Tool

No. Tool name Q'ty

Screwdriver (flathead screw-

1 1
driver)

2 Hexagon wrench 1 set

3 Vise 1

4 Wrench (for piston nuts) 1 set

5 Punch 1

6 Torque wrench 1 set

84402826 - May 2011

8012-19
Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
No. Tool name Q'ty

7 Hammer (plastic hammer) 1

8 Monkey wrench 1

9 Scoop 1 set

84402826 - May 2011

8012-20
 Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Special Jig
Cylinder assembly requires the following special jigs.

Jig name Sketch

For bushing removal and

press fitting

For wiper ring press fit-

ting

Seal ring insertion jig

Seal ring calibration jig

For cylinder head inser-

tion

For piston insertion

(The following page has a list of jig part numbers.)

84402826 - May 2011

8012-21
 Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Special Jigs Part Number List
• Select jigs for the cylinder head according to the rod diameter.
• Select jigs for the piston according to the cylinder bore.

CASE Tool
Description (applicable rod diameter in mm) Illustration
Number
KHV0511 Cylinder head assembly and disassembly jig (65)
KHV0512 Cylinder head assembly and disassembly jig (70)
KHV0513 Cylinder head assembly and disassembly jig (75)
KHV0514 Cylinder head assembly and disassembly jig (80)
KHV0515 Cylinder head assembly and disassembly jig (85)
KHV0516 Cylinder head assembly and disassembly jig (90)
KHV0517 Cylinder head assembly and disassembly jig (95)
KHV0518 Cylinder head assembly and disassembly jig (100)
KHV0519 Cylinder head assembly and disassembly jig (105)
KHV0520 Cylinder head assembly and disassembly jig (110)
KHV0521 Cylinder head assembly and disassembly jig (115)
KHV0522 Cylinder head assembly and disassembly jig (120)

CASE Tool
Description (applicable cylinder bore diameter in mm) Illustration
Number
KHV0526 Seal ring insertion and calibration jig (100)
KHV0527 Seal ring insertion and calibration jig (105)
KHV0528 Seal ring insertion and calibration jig (110)
KHV0529 Seal ring insertion and calibration jig (115)
KHV0530 Seal ring insertion and calibration jig (120)
KHV0531 Seal ring insertion and calibration jig (125)
KHV0532 Seal ring insertion and calibration jig (130)
KHV0533 Seal ring insertion and calibration jig (135)
KHV0534 Seal ring insertion and calibration jig (140)
KHV0535 Seal ring insertion and calibration jig (145)
KHV0536 Seal ring insertion and calibration jig (150)
KHV0537 Seal ring insertion and calibration jig (160)
KHV0539 Seal ring insertion and calibration jig (170)

84402826 - May 2011

8012-22
 Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Disassembly Procedures Removal of Cylinder Head
Drain the Oil Use a hexagon wrench to loosen the cylinder head tight-
ening bolts and remove them.
Secure the Cylinder Passing a pipe through the hexagon wrench as in the
diagram below makes the work easier.
Secure the cylinder in a vertical or horizontal position. A
vertical position makes assembly and disassembly eas-
ier. When securing the cylinder, use the bottom pin hole
to stop rotation and secure the direction of the axis.
(When securing the cylinder, if a line or the like inter-
feres, remove it.)

1 About 1.5 m
2 Cylinder secured
Line band (Removal is unnec-
3 essary when replacement is
unnecessary.)

84402826 - May 2011

8012-23
 Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Pull out the Piston Rod CAUTION
1. Check that the line caps are removed.
2. Put the oil pan at the retraction side (cylinder head • When assembling and disassembling
with the cylinder secured horizontally,
side) port.
work paying particular attention to the
3. With the piston rod pulled out all the way, slowly pull
following points.
out the cylinder head and remove it.
In the work of removing the piston rod,
4. Pull out the piston rod together with the cylinder
there is a danger of the piston rod falling
head and place them on crossties.
and damaging parts right after it is re-
CAUTION moved.
Work carefully while holding the rod hor-
• When assembling and disassembling izontal and in contact with the crossties.
with the cylinder secured vertically, work
paying particular attention to the follow-
ing points.
In the work of removing the piston rod,
the cylinder head may come out of the
cylinder tube ahead of the piston due to
friction with the packing, creating a con-
dition in which there is space between
the cylinder head and the piston.
If the work is done in that state, the cylin-
der head may suddenly slip out and in-
jure the operator.
Always work with the cylinder head
touching the piston.
a Crosstie
Working in the horizontal
b
state
c Beware of falling

a Beware of falling

84402826 - May 2011

8012-24
 Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Fasten the Piston Rod
Use the rod head bolt width or pin hole to set up a rota-
tion stopper.
84402826 - May 2011
8012-25
Remove the Piston Nut
1. Remove the locking screw (3).
Locking screw is caulked in with a punch at 2 loca-
tions on the outer circumference.
Cut away the caulked sections with a hand drill (1),
and then loosen the locking screw.
2. Remove the steel ball (2) at the bottom of the locking
screw (3).
3. Remove the piston nut.
• The piston nut is tightened with the torque speci-
fied in the assembly diagram.
• Loosening a piston nut requires about 1.5 times
that torque. Prepare the power wrench (6) that
uses the hydraulic jack (4) and hydraulic cylinder
(5).
* For a one-piece type piston and nut, apply the
wrench to the hexagonal section of the piston and
loosen the piston directly.
 Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Removal of Piston etc. Disassembly of the Retraction Side Cushion
Remove the piston (9), cushion ring (8), and cylinder Ring
head (7) in that order.

1. Remove the piston nut. Disassembly cannot be

done with the nut attached.
2. Remove the snap ring (12). Remove by gently tap-
ping with a plastic hammer in such a way as not to
scratch the piston rod (11) or cushion ring (14).
3. When the cushion ring (14) is slid to the piston rod
thread (11) side, the stopper (split in two) (15) can
be removed.
4. Remove the cushion ring (14).
5. The cushion seal (13) has a split opening, so spread
the opening wide and remove the cushion seal.

84402826 - May 2011

8012-26
 Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Remove the Piston Seal Disassembly of the Buffer Ring
1. The slide rings (22) and backup ring (20) can be 1. The buffer ring (27) is mounted in the groove on the
removed easily by hand. inner diameter of the cylinder head. When removing
2. Stand up a flathead screwdriver (23) as in the di- this seal, stick in a sharp tool and lift it up, and then
agram on the right and tap with a hammer to cut insert a scoop and take it out.
through the seal ring (16), and then remove the seal
* The removed seal parts cannot be reused.
ring.
3. Pull out the O-ring (19) with a scoop.
* The removed seal parts cannot be reused.

Disassembly of U-ring and Wiper Ring

1. Use a screwdriver to remove the U-ring (26) and
backup ring (25).
10 Screw 2. The wiper ring (24) is press fit.
Stick a screwdriver straight down into the rubber
17 Piston
and tap it to remove the wiper ring.
18 Vise
21 Hardwood * The removed seal parts cannot be reused.
Removal of O-ring and Backup Ring
1. Pull out the O-ring (29) and backup ring (30) with a
scoop.

84402826 - May 2011

8012-27
 Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Disassembly of Bushing Removal of Pin Bushing
1. Raise the snap ring (28) with a screwdriver, and 1. Remove the wiper ring (24) from the tube and piston
then remove it from the cylinder head. rod. Remove it by using a screwdriver in the same
2. For the bushing (33), use the bushing removal jig manner as for the cylinder head.
(32) as in the diagram on the right and press out 2. Use the metal block (35) to remove the pin bushing
the bushing with a press. (37).

31 Bushing 34 Press
36 Jig
a Press with the press.
Cleaning and Storage
Clean the removed parts with white kerosene, and then
apply hydraulic oil, cover the parts, and store them.
If they are left disassembled, there is a danger of their
collecting rust and dust and not being able to function
adequately after they are assembled again.

84402826 - May 2011

8012-28
 Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Assembly Procedures
CAUTION
If a part with peeling paint is assembled, the
peeled off paint can get inside the cylinder.
This causes oil leaks, so work being very care-
ful to prevent this.
Installation of Pin Bushing
1. Use the installation jig to press fit onto the piston rod
(4) and into the tube.
(Apply hydraulic oil in advance.)
2. Use the metal block (5) to install the wiper ring (6).
Replacement of Seals
1. When disassembling the cylinder, replace all the
seals.
2. O-rings
• Clean the mounting groove well, and then mount
the backup ring (7) and O-ring (8).
Foreign matter in the groove section would cause
an oil leak.
• Be careful about the location of the backup ring.
• Apply grease or hydraulic oil to the backup ring
and O-ring so that they slide easily, and then
assemble them. If they are sliding poorly, O-ring
may become twisted during assembly, which
causes oil leaks.

1 Press
2 Installation jig
3 Pin bushing
9 Cylinder head

84402826 - May 2011

8012-29
 Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Assembly of Cylinder Head Assembly
1. Use the bushing press fit jig (10) to press fit the
bushing (11).
Apply hydraulic oil to the inside surface of the cylin-
der head in advance and after press fitting, check
that there is no level difference at the bushing.
2. Use the wiper ring press fit jig (15) to press fit the
wiper ring (16).
3. Mount the backup ring (18) and U-ring (19) in the
U-ring groove (17) in that order.
• Check the assembly direction of the U-ring and
mount it carefully so as not to scratch it. Installing
backwards can cause an oil leak.
• After mounting, check that there are no wrinkles
or other permanent deformation remaining in the
U-ring.
Assembly of Piston Assembly
1. Attach the seal ring (24).
• Attach the back-up ring (23) for one side and the
O-ring (25) on the piston (26) in advance, place on
the press platform, and use the seal ring insertion
jig (22) as in the diagram to assemble the seal
ring.
2. Calibrate the seal ring.
• Mount the seal ring (24) and the other backup
ring (23), and then immediately calibrate with the
seal ring calibration jig (27) so that the seal ring
does not remain expanded. (Strictly observe this
instruction.)
Since the seal ring is stretched when it is
mounted, if it is not calibrated, "Insertion of Piston
Rod into the Tube" is not possible.
3. Assemble the slide ring.
• Spread the cut section of the slide ring the min-
imum with both hands and install from the axial
direction.
If it is spread too wide, it cannot be mounted.
* Consult with our company about jigs.

4. Mount the buffer ring (20).

Be careful with the attachment directions of the
seals.
If the seal is attached backwards, extraordinarily
high pressure will be generated between the seal
and the U-ring (19), causing deformation and break-
age of the cylinder.
5. Assemble the bushing retainer snap ring (21).

12 Cylinder head
13 Pressing base
14 Press

84402826 - May 2011

8012-30
 Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Assembly of Piston Rod Assembly
1. Secure the piston rod (31).
2. Assemble the cylinder head (32) on the piston rod
(31).
Be careful that the wiper ring and U-ring lips do not
catch on the stepped section. Use the cylinder head
insertion jig (30) as in the diagram on the right to
assemble the cylinder head on the piston rod.
• Apply grease or oil and assemble being careful
not to scratch the packing.
1) Assemble the cushion ring before assembling
the piston nut.
The cushion ring cannot be assembled with
the piston nut attached.
2) Mount in the groove with the side of the cush-
ion seal with the slit (*4) facing the screw side.
3) Assemble with the part of the cushion ring pro-
cessed to be flat facing as in the diagram be-
low.
4) Insert the stopper (40) into the groove. Press
the cushion ring (39) all the way to the stopper
and strike in the snap ring (37). Strike gently
with a plastic hammer in such a way as not to
scratch the piston rod (4) or cushion ring.

28 Metal block
29 Press
*1 Flat surface processing
*3 Face the slit to the screw side.
3. If there is a cushion on the extension side, assemble
the cushion ring (33) and cushion seal (34) with the
following procedure. 35 Piston
36 Screw
1) Insert into the groove with the side of the cush-
ion seal with the slit (*2) facing the piston side.
2) Assemble with the part of the cushion ring pro- CAUTION
cessed to be flat facing as in the diagram. Make sure that the cushion seal and cush-
ion ring face the correct direction.
If they are installed backwards, the cush-
ion will not be effective.
After installing the cushions, check that
the extension and retraction cushion rings
move up and down and left and right.

5. Tighten the piston nut.

4. When there is a cushion on the retraction side
Assemble the cushion ring (39) and cushion seal
(38) with the following procedure.
• Always tighten the piston nut to the specified
torque given on the assembly diagram.
• If the tightening torque is insufficient, this causes
internal leaks, nut looseness, and screw cutting
• Also, if the tightening torque is excessive, exten-
sion side cushion ring swelling and piston contact
surface deformation occur.
• In order to tighten correctly, clean and degrease
the piston and nut and piston rod thread section

84402826 - May 2011

8012-31
 Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
adequately (with paint thinner) before tightening
the nut.
6. Stop the piston from turning.
• After tightening the piston nut, put in the steel ball
(43), tighten the locking screw (42) to the specified
torque given on the assembly diagram, and then
caulk (41) with the punch (44) at 2 locations on
the outer circumference.
Insertion of Piston Rod into the Tube
1. Secure the tube (47) vertically or horizontally.
2. Insert the piston rod (4) into the tube (47).
• If the tube is secured vertically, the piston rod en-
ters the tube due to its own weight.
• When the piston section is entering the tube, be
careful that the slide rings (46) do not fall out.

45 Jig; Nylon pipe (split in two)

Slide ring (Shift the abutment
46 phase 180° from one ring to the
next.)

84402826 - May 2011

8012-32
 Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Cylinder Head Tightening Installation of Line
Align the cylinder head with the position on the assem- 1. Check that the O-ring is in the groove correctly.
bly diagram, and then tighten the bolts to the speci- 2. Tighten the port section bolts to the specified torque
fied torque given on the assembly diagram in the order given on the assembly diagram.
shown in the diagram below. 3. Tighten the line bands to the torque on the assembly
diagram, the same on both sides, so that no abut-
ment gap occurs.

Bolt tightening order

*5 Tighten the bolts.

*6 Be careful about the O-rings.
*7 No abutment opening gap
*8 Normal: OK
*9 There is a gap: Not OK
*10 Band for securing the line

84402826 - May 2011

8012-33
 Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
CAUTION Test Operation
1. In order to fill the inside of the cylinder with oil, after it
When installing the cylinder lines and the ma-
is installed on the machine body, move the cylinder
chine body rubber hoses, nipples, etc., assem-
through its full stroke slowly 8 times or more. If
ble securing the cylinder line port section with
the cylinder is suddenly moved from the start, the
a wrench.
hydraulic oil may be aerated.
If one tightens without securing the port sec-
2. If the cylinder has air bleeding, pressurize so that
tion, the line may bend, oil may leak, and the
the air bleed side is the pressure side (return oil
machine body may get in the way.
side) and bleed off the air.
3. Apply oil and grease to the pins at both ends.

84402826 - May 2011

8012-34
 Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Usage Limits
Below are the usage limits for the main sliding sections.
Use them for reference for maintenance.
• Piston rod outer diameter wear limit

Nominal diameter Minimum outer diameter

Solution
(mm) (mm)
65 - 80 -0.023 Replace or replate.
85 - 120 -0.027 Replace or replate.

• Rod bushing inner diameter wear limit

Maximum inner diameter

Nominal diameter (mm) Standard inner diameter (mm) Solution
(mm)
55 - 75 +0.060 - +0.190 +0.30 Replace the bushing.
80 - 120 +0.060 - +0.195 +0.30 Replace the bushing.

• Piston slide ring thickness wear limit

Nominal diameter (mm) Standard thickness (mm) Minimum thickness (mm) Solution
95 - 160 t2.42 - 2.48 t2.37 Replace the slide ring.
165 - 250 t2.92 - 2.98 t2.87 Replace the slide ring.

84402826 - May 2011

8012-35
 Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Structural Diagram
Boom Cylinder

After tightening, punch caulk in 2 locations on the

*1 *8 With plastic cap
circumference
*2 Hexagon bolt width 105 mm *9 100 mm or greater (both sides)
*3 Outer circumference surface knurling processing *10 Internal thread effective depth 18 mm
*4 Cushion stroke *11 Hexagon bolt width 36 mm
*5 To bottom pin center *12 Manufacturing No. stamping position for right
Use caution with the direction of the cut surfaces
*6 *13 Manufacturing No. stamping position for left
during installation
*7 Slit direction is as in diagram

L1 Maximum retracted length 1855 mm

L2 Stroke 1335 mm
84402826 - May 2011
8012-36
 Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Code Part name Q'ty Code Part name Q'ty
01 Tube subassembly 1 19 Slide ring 2
02 Rod subassembly 1 20 Locking screw 1
03 Cylinder head 1 21 Steel ball 1
04 Bushing 1 22 Pin bushing 2
05 Snap ring 1 23 Wiper ring 4
06 Buffer ring 1 24 Pipe subassembly 1
07 U-ring 1 25 Pipe subassembly 1
08 Backup ring 1 26 O-ring 2
09 Wiper ring 1 27 Hexagon socket head bolt 8
10 O-ring 1 28 Band subassembly 1
11 Backup ring 1 29 Band 1
12 Hexagon socket head bolt 12 30 Bolt 2
13 Cushion ring 1 31 Washer 2
14 Cushion seal 1 32 Pipe holder 2
15 Piston 1 33 Bolt 1
16 Seal ring assembly 1 34 Spring washer 1
17 Backup ring 2 35 Grease nipple 1
18 Slide ring 2

84402826 - May 2011

8012-37
 Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Arm Cylinder

84402826 - May 2011

8012-38
 Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
After tightening, punch caulk in 2 Internal thread effective depth 21
*1 *5 To bottom center *9
locations on the circumference mm at 2 locations
Use caution with the direction of
*2 Hexagon bolt width 120 mm *6 the cut surfaces during installa- *10 105 mm or greater (both sides)
tion
Outer circumference surface
*3 *7 Slit direction is as in diagram *11 Hexagon bolt width 36 mm
knurling
Manufacturing number stamping
*4 Cushion stroke *8 *12 With plastic cap
position

L1 Maximum retracted length 2240 mm

L2 Stroke 1660 mm

Code Part name Q'ty Code Part name Q'ty

01 Tube subassembly 1 22 Locking screw 1
02 Rod subassembly 1 23 Steel ball 1
03 Cylinder head 1 24 Cushion ring 1
04 Bushing 1 25 Cushion seal 1
05 Snap ring 1 26 Stopper 2
06 Buffer ring 1 27 Snap ring 1
07 U-ring 1 28 Pin bushing 2
08 Backup ring 1 29 Wiper ring 4
09 Wiper ring 1 30 Joint 1
10 O-ring 1 31 Pipe subassembly 1
11 Backup ring 1 32 O-ring 2
12 Hexagon socket head bolt 10 33 Hexagon socket head bolt 8
13 Cushion ring 1 34 Band subassembly 1
14 Cushion seal 1 35 Band 1
15 Piston 1 36 Bolt 2
16 Seal ring assembly 1 37 Washer 2
17 Backup ring 2 38 Pipe holder 1
18 Slide ring 2 39 Bolt 1
19 Slide ring 2 40 Spring washer 1
20 Shim 1 41 Grease nipple 1
21 Nut 1

84402826 - May 2011

8012-39
 Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Bucket Cylinder

84402826 - May 2011

8012-40
 Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
After tightening, punch caulk in 2 Manufacturing No. stamping po-
*1 *4 Cushion stroke *7
locations on the circumference sition
*2 Hexagon bolt width 105 mm *5 To bottom pin center *8 97 mm or greater
Use caution with the direction of
Outer circumference surface Internal thread effective depth 18
*3 *6 the cut surfaces during installa- *9
knurling processing mm at 2 locations
tion

L1 Maximum retracted length 1635 mm

L2 Stroke 1070 mm

Code Part name Q'ty Code Part name Q'ty

01 Tube subassembly 1 19 Locking screw 1
02 Rod subassembly 1 20 Steel ball 1
03 Cylinder head 1 21 Pin bushing 1
04 Bushing 1 22 Wiper ring 2
05 Snap ring 1 23 Pin bushing 1
06 Buffer ring 1 24 Wiper ring 2
07 U-ring 1 25 Joint 1
08 Backup ring 1 26 Pipe subassembly 1
09 Wiper ring 1 27 O-ring 2
10 O-ring 1 28 Hexagon socket head bolt 8
11 Backup ring 1 29 Band subassembly 1
12 Hexagon socket head bolt 12 30 Band 1
13 Cushion ring 1 31 Bolt 2
14 Piston 1 32 Washer 2
15 Seal ring assembly 1 33 Pipe holder 1
16 Backup ring 2 34 Bolt 1
17 Slide ring 2 35 Spring washer 1
18 Slide ring 2 36 Grease nipple 2

84402826 - May 2011

8012-41
Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)

84402826 - May 2011

8012-42
 Section

8013

Procedures for Assembly and Disassembly of Operation

Remote Control Valve

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Procedures for Assembly and Disassembly of Operation Remote Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Required Tools and Tightening Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Causes of Trouble and Countermeasures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

8013-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
8013-2 PRINTED IN FRANCE
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

84402826 - May 2011

8013-3
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.

84402826 - May 2011

8013-4
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.

84402826 - May 2011

8013-5
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.

84402826 - May 2011

8013-6
Procedures for Assembly and Disassembly of Operation Remote
Control Valve
• Scratching can easily occur if cleaning of a part bris and moisture being dispersed into the atmos-
is begun just after parts are immersed in white phere.
kerosene, so let each part sit in white kerosene
Preventing rust on parts
until debris and grease sufficiently loosen from the
Apply an anti-rust agent to each part.
surface of the part and float to the surface.
• If the white kerosene is dirty, this will encourage • Rust will form on parts if they are left as is af-
damage to parts and result in reduced perfor- ter cleaning, and this will cause reduced perfor-
mance after reassembly. Thoroughly manage the mance of functions after reassembly.
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-

84402826 - May 2011

8013-7
Procedures for Assembly and Disassembly of Operation Remote
Control Valve
Assembly Procedures 4. Install O-rings (2) on the plugs (1).

1. Insert washer (4), secondary pressure spring (3)

and spring seating (2) onto each of the spool (1) in
that order.

5. Install seal (1) on the plug (2).

• Install so that the seal lips are as shown in the
diagram below.
2. Press in the spring seating (1) and move it to the
side while bending the secondary pressure spring
(2) to pass the seating over the larger hole and in-
stall it on each of the spools.
• Do not press in the spring seating by 6 mm or
more.

3 Push rod

a Hydraulic oil application

3. Install the return springs (1) in the casing (2).

Install the pressure reducing valve assembly (3) in
the casing (2).
• Install them in the positions they were in before
disassembly.

84402826 - May 2011

8013-8
Procedures for Assembly and Disassembly of Operation Remote
Control Valve
6. Install push rods (1) into the plugs (2). 9. Install the plate (1).
• Apply hydraulic oil to surface of the push rod.

10. Use a jig, and tighten the joint (1) to the casing (2)
to the specified torque.
7. Install the plug assembly (1) in the casing (2). Tightening torque: 44.2 - 50.0 N·m
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.

11. Install the disk (1) onto the joint (2).

• Screw the disk in until it is equally touching each
of the 4 push rods (3).
Secondary pressure will cause faulty operation of
8. If the return spring is strong, use the plate (1) to the machine if the disk is screwed in too much,
install all 4 plug assemblies at the same time and so pay attention to adjustment of the tightening
temporarily tighten them with the joint (2). position.
• Be careful of the plug assemblies and plate flying
off.

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.
• Tightening torque: 63.7 - 73.5 N·m
• During tightening, do not move the disk position.

84402826 - May 2011

8013-9
Procedures for Assembly and Disassembly of Operation Remote
Control Valve
• Inject vapor corrosion inhibitor into each port, and
then place plugs in the ports.

13. Apply grease to the rotating section of the joint and

to the top of the push rods (1).

14. Install the bellows (1).

• Be careful not to tear the bellows.

84402826 - May 2011

8013-10
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
2. Secondary pressure spring (241) is bro-
Secondary pressure is ken or worn.
not rising. 3. The gap between spool (201) and the
casing (101) is abnormally large.
4. There is backlash in the handle section.
1. Sliding parts are sticking.
Secondary pressure is
2. Tank line pressure is variable.
unstable.
3. Air is getting into lines.
Secondary pressure is 1. Tank line pressure is high.
high. 2. Sliding parts are sticking.
1. Maintain primary pressure.
2. Replace it with new part.
3. Replace the remote control valve as one
unit.
4. Assemble and disassemble and/or re-
place the handle section.
1. Repair the sticking sections.
2. Return directly to the oil tank.
3. Perform operation several times and let
out air.
1. Return directly to the oil tank.
2. Repair the sticking sections.

84402826 - May 2011

8013-11
Procedures for Assembly and Disassembly of Operation Remote
Control Valve

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
84402826 - May 2011
8013-12
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
84402826 - May 2011
8013-13
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

84402826 - May 2011

8013-14
 Section

8014

Procedures for Assembly and Disassembly of Travel

Remote Control Valve

84402826 - May 2011

84402826 - May 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

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

8014-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
8014-2 PRINTED IN FRANCE
 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

84402826 - May 2011

8014-3
 Procedures for Assembly and Disassembly of Travel Remote
Control Valve
Maintenance Procedures
Disassembly Procedures
1. Use a shock plate to secure the remote control valve
in a vise, then remove the bellows (1) from the cover
(2).
• Be careful not to tear the bellows.
2. Use a hexagon wrench (1) on the hexagon socket
head locking screws to loosen them.
Be careful, as application of Loctite #241 makes the
loosening torque high.
3. Place a round rod (D8 mm or less) against one end
of the cam shafts (1) and lightly strike it with a ham-
mer to remove the shafts.
84402826 - May 2011
8014-4
4. Remove the cams (1) as an assembly with the lock-
ing screws and lock nuts left attached.
Record the positions of the cams in relation to the
covers (2).
• Be careful when removing, as the push rods (3)
may fly off.
5. Use a hexagon wrench (1) on the hexagon socket
head bolts to loosen and remove them.
6. Remove the cover (1).
• Record the positions of the covers in relation to
the casings (4).
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.)
 Procedures for Assembly and Disassembly of Travel Remote
Control Valve
7. Remove push rods (2) from the plugs (1). 10. Remove the damping springs (2) (3) from the casing
Record the positions of the plugs in relation to the (1).
push rods. Record the positions of the damping springs in re-
Be careful not to scratch the surface of the push lation to the casing holes.
rods.
Be careful when removing, as the plugs may fly off.

11. Remove the spring seating (2) from the casings (1).

8. Remove the plugs (1) with the grease caps and • Record the positions of the spring seating in rela-
NHU packings left attached. tion to the casing holes.
Record the positions of the plugs in relation to the
casing holes.
Be careful when removing parts, as the pistons (3)
may fly off due to the damping springs (2).

12. Use a magnet, etc. to remove steel balls (1).

Be careful not to lose the steel balls.

9. Remove the pistons (1).

Record the positions of the pistons in relation to the
casing holes.

84402826 - May 2011

8014-5
 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-
15. Remove the pressure reducing valve assembly (1) sary during assembly, handle them as part of the
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.

84402826 - May 2011

8014-6
 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.

23. Remove the O-rings (2) from the plugs (1).

20. Separate the spools (1), spring seating (2), sec-

ondary pressure springs (3), washers 2 (4), and
washers 3 (5).
Handle as an assembly until assembly is performed.
Washers 2 are used for pre-set adjustment of the
secondary pressure springs, so thickness is differ-
ent for each spool assembly. Additionally, these are
sometimes not used, so record the status for each
assembly.

24. Cleaning parts

• Clean all parts by placing them in a rough clean-
ing container filled with white kerosene. (rough
cleaning)
• Scratching can easily occur if cleaning of parts
is begun just after parts are immersed in white
kerosene, so let each part sit in white kerosene
until debris and grease sufficiently loosen off from
the surface of parts and float to the surface.
• If the white kerosene is dirty, this will encourage
damage to parts and result in reduced perfor-
21. Remove the grease cups (2) from the plugs (1). mance after reassembly. Thoroughly manage the
level of cleanliness of the white kerosene.
• Clean each part by placing it in a finish cleaning
container filled with white kerosene, and thor-
oughly clean each part, including the interior,
while slowly rotating it (finish cleaning).
Use a clean rag to thoroughly remove any white
kerosene stuck to parts.
• Do not dry parts with compressed air, as this will
damage parts and cause rust to form due to de-
bris and moisture being dispersed into the atmos-
phere.
• Preventing rust on parts
Apply an anti-rust agent to each part.
Rust will form on parts if they are left as is af-
ter cleaning, and this will cause reduced perfor-
mance of functions after reassembly.

84402826 - May 2011

8014-7
 Procedures for Assembly and Disassembly of Travel Remote
Control Valve
Assembly Procedures
1. Install the washers 3 (5), washers 2 (4), secondary
pressure springs (3), and the spring seating (2) onto
each of spools (1) in that order.
Washers 2 are used for pre-set adjustment of the
secondary pressure springs, so thickness is differ-
ent for each spool assembly. Additionally, these are
sometimes not used.
Check the status recorded during disassembly and
attach parts accordingly.

3. Install the return springs (1) in the casing (2).

• Install them in the positions they were in before
disassembly.

2. Place the bottom end of the spools (1) perpendicu-

lar on a level work platform, push the spring seating
(2) down, and install the 2 half-circle washers 1 (3)
onto the spring seating in such a way that they are
not on top of each other.

4. Install the pressure reducing valve subassemblies

(1) assembled in steps 1) and 2) above into the cas-
ing (2).
• Install them in the positions they were in before
disassembly.

• Install the washers 1 so that the sharp edge side

(a) faces up and the washer catches the head of
the spool.
Do not press in the spring seating by 4 mm or
more.

• When installing the pressure reducing valve sub-

assemblies, be careful not to strongly strike the
casing corners (b) with the bottom ends of the
spools.

84402826 - May 2011

8014-8
 Procedures for Assembly and Disassembly of Travel Remote
Control Valve
7. Install the steel balls (1) into the bushings.

5. Install O-rings (1) (2) on the casing (3).

8. Install the spring seating (1) into the bushings.
• Install them in the positions they were in before
disassembly.

6. Tighten the damper casing (1) and casing (2) with

the hexagon socket head bolts (3) to the specified
torque.
• Install them in the positions they were in before
disassembly. 9. Install the damping springs (2) (3) in the casing (1).
• Tighten the 2 hexagon socket head bolts (3) • Install them in the positions they were in before
evenly, and tighten the damper casing (1) in a disassembly.
parallel orientation.
• Hexagon socket head bolt (3) tightening torque:
7.8 - 9.8 N·m

84402826 - May 2011

8014-9
 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).

14. Install push rods (2) into the plugs (1).

• Before installing push rods, apply hydraulic oil to
the rod surfaces.
12. Install NHU packings into the plugs (1). Do not press the rods in strongly, as this may dam-
age the NHU packing lip sections.

• When installing the NHU packings (1), be careful

of the installation direction. (See the diagram.)
Before installing NHU packings, apply a thin layer
of grease.

84402826 - May 2011

8014-10
 Procedures for Assembly and Disassembly of Travel Remote
Control Valve
15. Install the push rod subassemblies assembled in 18. Tighten the hexagon socket head bolts to the spec-
steps 11), 12), 13), 14) above into the casing (1). ified torque.
• Be careful that the cover is horizontal.
• Hexagon socket head bolt tightening torque:
45.2 - 64.8 N·m

16. Use special tool 1 on the covers (1) to press down

the bushings, and lightly strike the bushings with a
hammer to press fit them.
• Be careful that the ends of the bushings do not
stick out from within the cover. 19. Temporarily install the locking screws (3) and lock
nuts (2) on the cams (1).

17. Install the covers (1) on the casing (2).

20. Install the cams (1) on the covers (2).
• Install them in the positions they were in before
disassembly. • Install them in the positions they were in before
• Be careful of the cover rising up due to the damp- disassembly.
ing springs.

84402826 - May 2011

8014-11
 Procedures for Assembly and Disassembly of Travel Remote
Control Valve
21. While holding the cams (1), insert the cam shafts
(2) from the outside.
22. Apply Loctite #241 or the equivalent to the surfaces
of the hexagon socket head locking screws (1).
23. Tighten the hexagon socket head locking screws to
the specified torque.
• Hexagon socket head locking screw tightening
torque: 5.9 - 7.9 N·m
84402826 - May 2011
8014-12
24. Adjust the height of the locking screws so that the
top surface of the cams (1) and the bottom surface
of the covers (2) are parallel, and tighten the lock
nuts to the specified torque after rotating the cams
left and right to check if there is any neutral back-
lash.
Even if the push rods are pressed in too much by the
locking screws, backlash during neutral will occur.
Use caution as this may cause sudden movement
when starting the engine.
• Locking screw tightening torque: 29.9 - 36.7 N·m
25. Tilt the cams (1) and fill the grease cups of the plugs
with grease while coating the top of the push rods
with grease.
• For grease application and filling, use a flat object
made of soft material so as to not scratch the push
rod or plug surfaces.
26. After mounting the top end of the bellows (1) on the
cams, mount the bottom end into the grooves on the
covers (2).
• Before mounting the bottom end of the bellows
into the grooves of the covers, spray anti-rust oil
on the parts within the bellows.
• Be careful that the bellows are properly mounted
in the grooves and not twisted, as this may reduce
anti-rust and anti-moisture protection.
Procedures for Assembly and Disassembly of Travel Remote
Control Valve

84402826 - May 2011

8014-13
 Procedures for Assembly and Disassembly of Travel Remote
Control Valve
Causes of Trouble and Countermeasures and Cross-section Diagram
It is not easy to discover trouble locations.
A few problems that may 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".
Also, 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 (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.

84402826 - May 2011

8014-14
Procedures for Assembly and Disassembly of Travel Remote
Control Valve

Hydraulic symbols Cross section B-B

Attached diagram 1. Remote control valve assembly cross-section diagram

84402826 - May 2011

8014-15
 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
217 Washer 2 4 423 Hexagon socket head locking screw 2
218 Spring seating 4 471 Locking screw 4
220 Hexagon socket head bolt 2 472 Lock nut 4
224 Piston 2D085 4 501 Bellows 2
225 Steel ball 2

Tightening torque list

Code Screw size Tightening torque Code Screw size Tightening torque
220 M6 8.8 ± 1 N·m 423 M6 6.9 ± 1 N·m (Loctite coating)
271 M12 55 ± 9.8 N·m 472 M10 33.3 ± 3.4 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)

84402826 - May 2011

8014-16
 Section

8016

Assembly and Disassembly of Cushion Valve

84402826 - May 2011

84402826 - May 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

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

8016-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
8016-2 PRINTED IN FRANCE
 Assembly and Disassembly of Cushion Valve

Disassembly Procedures
This valve has a structure that forms small gaps. It is precision processed and the parts are carefully selected and fit
together, so do not disassemble it as much as possible.
If assembly and disassembly is unavoidable, pay attention to the following. (The product warranty may be invalidated.)
• Only disassemble in a clean location with minimal dirt.
• Use only clean tools and cleaning oil and handle them with care.
• Use plugs, caps to cover ports to prevent any entry of dirt and clean the outside of the assembly.
• Check the internal structure before starting work, and carefully study the disassembly objective and scope.

Reverse Operation Spool Section Check Plunger Section with Throttle

1. Remove the plugs (1) and O-rings (2). 1. Remove the plugs (1) and O-rings (2).
• Remove the springs (3). • Remove the springs (3) and remove the check
• Remove the spools (4) with the cap screws and plungers (4).
O-rings assembled in them.
CAUTION
The check plungers have similar shapes,
so identify them in such a way that no
one will mix them up with each other.

Diagram 1
2. Fasten the spool (3) assemblies taken out in 1. in a
vise.

CAUTION
Diagram 3
Use a piece of wood (jig) (4) to prevent
scratches.

• Remove the cap screws (1) and O-rings (2).

Diagram 2

84402826 - May 2011

8016-3
 Assembly and Disassembly of Cushion Valve

Shuttle Valve Section

1. Remove the plugs (1) and O-rings (2) (3).
• Remove the steel balls (4).

Diagram 4

84402826 - May 2011

8016-4
 Assembly and Disassembly of Cushion Valve

Assembly Procedures
This valve has a structure that forms small gaps.
It is precision processed and the parts are carefully selected and fit together, so do not disassemble it as much as
possible.
If assembly and disassembly is unavoidable, pay attention to the following. (The product warranty may be invalidated.)
• Only assemble in a clean location with minimal dirt.
• Use only clean tools and cleaning oil and handle them with care.
• Clean the disassembled parts and prepared parts.
• Study the internal structure before starting the work and prepare the parts required by the disassembly objective
and scope.

Reverse Operation Spool Section CAUTION

1. Assemble the cap screw (1) with O-ring (2) on the The spool assemblies are symmetrical left/
spool (3). right, so the insertion direction does not
matter.
• Tightening torque: 9.8 - 14.7 N·m
CAUTION • Insert the springs (2) and assemble the plugs (3)
with the O-rings (4) attached.
Use a piece of wood (jig) (4) to prevent • Tightening torque: 39.2 - 49.0 N·m
scratches.

Diagram 6
Diagram 5
2. Insert the spool assemblies (1) assembled in 1. into
the body.

84402826 - May 2011

8016-5
 Assembly and Disassembly of Cushion Valve

Check Plunger Section with Throttle Shuttle Valve Section

1. Insert the check plungers (1). 1. Insert the steel balls (1).

CAUTION • Assemble the plugs (2) with the O-rings (3) (4)
attached.
The check plungers have similar shapes, • Tightening torque: 39.2 - 49.0 N·m
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

84402826 - May 2011

8016-6
 Assembly and Disassembly of Cushion Valve

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

84402826 - May 2011

8016-7
 Assembly and Disassembly of Cushion Valve

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

84402826 - May 2011

8016-8
 Section

8017A

Removal and Installation of Arm HBCV

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of arm HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of arm HBCV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

8017A-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
8017A-2 PRINTED IN FRANCE
 Removal and Installation of Arm HBCV

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).
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 (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 (22 mm) to remove the hoses (1) and hexagon socket head bolts (1), and then remove the
(2). arm HBCV (2).
• Mark the HBCV and hoses so that the connectors
match at the time of assembly.
• Use caps or plugs to cover the hoses and HBCV
to prevent any entry of water, dust or dirt.
• Clean the hoses and HBCV by spraying them with
a parts cleaner to prevent scratches and prevent
dirt from accumulating on the connectors.

Installation of arm HBCV

To install, perform the reverse of the removal procedure.
The tightening torque for line installation and HBCV in-
stallation is 74.9 - 109.9 N•m.

84402826 - May 2011

8017A-3
Removal and Installation of Arm HBCV

84402826 - May 2011

8017A-4
 Section

8017B

Removal and Installation of Boom HBCV

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of Boom HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of boom HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

8017B-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
8017B-2 PRINTED IN FRANCE
 Removal and Installation of Boom HBCV

CAUTION • Clean the HBCV and lines by spraying them with

a parts cleaner to prevent scratches and prevent
• Stop the machine on a level location with dirt from accumulating on the connectors.
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.
• Be sure to release hydraulic pressure before
beginning work.

Items to prepare
• Wrench (19 mm, 22 mm, 27 mm)
• Hexagon wrench (8 mm)
• Marking pen
• Caps
• Plugs 3. Use a hexagon wrench (8 mm) to remove the 4
• Rag hexagon socket head bolts (1), and then remove the
• Cleaning fluid boom HBCV (2).
• Crossties

Removal of Boom HBCV

1. Use wrenches (19 mm, 22 mm) to remove the hoses
from the tool box side boom HBCV (1), (2), (3) and
(4).
• Mark the HBCV and hoses so that the connectors
match at the time of assembly.
• Use caps or plugs to cover the HBCV and lines to
prevent any entry of water, dust or dirt.
• Clean the HBCV and lines by spraying them with
a parts cleaner to prevent scratches and prevent
dirt from accumulating on the connectors.
4. Use wrenches (19 mm, 22 mm) to remove the hoses
(1), (2), (3) and (4) from the cab side boom HBCV
in Step 1.
Use a wrench (27 mm) to remove the boom bottom
pressure sensor (5).
• Mark the HBCV and hoses so that the connectors
match at the time of assembly.
• Use caps or plugs to cover the HBCV and lines to
prevent any entry of water, dust or dirt.
• Clean the HBCV and lines by spraying them with
a parts cleaner to prevent scratches and prevent
dirt from accumulating on the connectors.

1 Pilot hose (use 19 mm wrench)

Drain hose (use 22 mm
2
wrench)
Drain hose (use 22 mm
3
wrench)
4 Pilot hose (use 22 mm wrench)

2. Use a hexagon wrench (8 mm) to remove the 4

hexagon socket head bolts (1), and then remove the
line (2).
• Use caps or plugs to cover the HBCV and lines to
prevent any entry of water, dust or dirt.
84402826 - May 2011
8017B-3
 Removal and Installation of Boom HBCV

1 Pilot hose (use 22 mm wrench) 6. Use a hexagon wrench (8 mm) to remove the 4
Drain hose (use 19 mm hexagon socket head bolts (1), and then remove the
2 boom HBCV (2).
wrench)
3 Pilot hose (use 22 mm wrench)
4 Pilot hose (use 22 mm wrench)

5. Use a hexagon wrench (8 mm) to remove the 4

hexagon socket head bolts (1), and then remove the
line (2).
• Use caps or plugs to cover the HBCV and line to
prevent any entry of water, dust or dirt.
• Clean the HBCV and line by spraying them with
a parts cleaner to prevent scratches and prevent
dirt from accumulating on the connectors.

Installation of boom HBCV

To install, perform the reverse of the removal procedure.
The tightening torque for line installation and HBCV in-
stallation is 41.6 - 60.8 N•m.

84402826 - May 2011

8017B-4
 Section

8018

Assembly and Disassembly of Center Joint

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Configuration Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Dimension Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Jig Dimension Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

8018-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
8018-2 PRINTED IN FRANCE
 Assembly and Disassembly of Center Joint
CAUTION
• The following cautions for hydraulic equip-
ment should be observed with these parts.
• To ensure safe operations, wear protective
devices for the work and follow all precau-
tions.
• When removing devices or positioning de-
vices at the time of installation, use a removal
jig and a hammer or steel rod.
• Make sure that the jig is used for disassembly
of the axle and rotor.
• 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 load to deter-
mine 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 V-rings, O-rings, and other
sliding parts, be sure to coat them with new
grease.
• As a rule, replace all O-rings and other seal
parts with new parts.
84402826 - May 2011
8018-3
CAUTION
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.
• Make sure that foreign matter such as debris
and moisture does not enter.
• The work platform used should be solid, sta-
ble, and sufficiently spacious.
Also, items should be clean and free of debris
and moisture.
Remove debris and moisture before perform-
ing work.
• Inspect, remove debris and moisture, and
clean tools and jigs before work.
• Jigs and tools that are appropriate to the con-
tents of work should be used.
Items to prepare
• Hexagon wrenches (6 mm, 14 mm, or 17 mm)
• Torque wrench
• Socket wrenches (6 mm, 14 mm, or 17 mm)
• Lights
• Mirror
• Specialty jigs
 Assembly and Disassembly of Center Joint

Configuration Diagram

Code Part name

1 Axle
2 V-ring
3 O-ring
4 Packing ring
5 Hexagon socket head bolt
6 O-ring
7 Cover
8 Thrust plate
9 Rotor
10 Loctite

84402826 - May 2011

8018-4
 Assembly and Disassembly of Center Joint

Dimension Diagram

Maximum gap 10.0

1 Axle 7 Cover *1
Minimum gap 8.5
Maximum gap 0.7 Minimum
2 V-ring 8 Thrust plate *2
gap 0.3
2 x M12, screw depth 18 mm,
3 O-ring 9 Rotor *3
bottom hole depth 23 mm
4 Packing ring 10 Loctite #262 *4 G1/2-A class
5 Hexagon socket head B 11 Company nameplate *5 G1/4-A class
6 O-ring 12 Parker rivet *6 4 x G3/4-A class

Do not coat any processed surfaces marked with a symbol or port processed surfaces.

84402826 - May 2011

8018-5
 Assembly and Disassembly of Center Joint

Jig Dimension Diagram 1 Axle removal jig

M16 - M20 full threaded bolt
Axle removal jig 2
L = 370 - 420 mm
3 M16 - M20 female thread
Hexagon socket head bolt (5)
4
M8 x 25
Backing plate
Axle (1) outer diameter - about
5
5 mm
t = about 5 mm

Cover (7) installation dimen-

*1
sions

Removal jig (for O-ring and

1
V-ring)

84402826 - May 2011

8018-6
 Assembly and Disassembly of Center Joint

Disassembly Procedures 4. Use axle removal jig 1 to push out the axle (2) from
the rotor (1).
1. Use a hexagon wrench (6 mm) to remove the 4
hexagon socket head bolts (3) from the rotor (1), • Do not strike it with the hammer at this time.
then remove the cover (2).

5. Use removal jig 1 or the like to remove the V-ring

2. Remove the O-ring (2) from the rotor (1). (2) from the axle (1).

3. Use a hexagon wrench (6 mm) to remove the 4 6. Use removal jig 1 or the like to remove the O-ring
hexagon socket head bolts (2), then remove the (2) and packing ring (3) from the rotor (1).
thrust plate (1).

84402826 - May 2011

8018-7
 Assembly and Disassembly of Center Joint

Assembly Procedures 3. Use cleaning fluid or compressed air to clean the

rotor (1).
1. Place parts in a rough cleaning container filled with After cleaning, check inside the rotor and in the
kerosene (1) to clean off any adhered matter that groove sections for burrs, barbs and scratches and
can form sharp points and cause scratches. for scratches caused by striking.
• Immerse in kerosene until dust, grease, and other
adhered matter comes off and floats to the sur-
face.

4. Check the quantity of packing rings (1) and O-ring

2. Place parts in a finish cleaning container filled with
kerosene (1) 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.
(2).
Coat with grease and install in the sequence below.
• Set one packing ring (1) in each of the 7 grooves
from the 2nd groove on the axle insertion side to
the thrust plate side.
• Set the O-ring (2) in the front-most groove on the
axle insertion side.
• Use new packing rings (1) and a new O-ring (2).

84402826 - May 2011

8018-8
 Assembly and Disassembly of Center Joint

5. After installing the O-ring and packing rings on the
rotor (1), use the mirror to check for any parts that
are sticking out or are twisted.
Also, check for installation mistakes.
After checking, coat with grease. After coating with
grease, check again for any parts sticking out, etc.
8. Using a hexagon wrench (6 mm), coat the hexagon
socket head bolts (3) with Loctite, install the thrust
plate (2) on the axle (1), and tighten to the specified
tightening torque.
• Bolt (3) tightening torque: 31.4 - 37.3 N·m

6. Install the V-ring (2) on the axle (1) and coat suffi- 9. Install the O-ring (2) on the rotor (1).
ciently with grease. • Use new O-ring (2).
Be careful that no water or dirt gets into the grease.
• Use a new V-ring (2).

10. Using a hexagon wrench (6 mm), coat the hexagon

socket head bolts (3) with Loctite #262, install the
7. Install the axle (2) on the rotor (1). cover (2) on the rotor (1), and tighten to the specified
Set in a way that the V-ring will not be cut or dam- tightening torque.
aged. • Bolt (3) tightening torque: 31.4 - 37.3 N·m

This completes the assembly.

84402826 - May 2011

8018-9
Assembly and Disassembly of Center Joint

84402826 - May 2011

8018-10
 Section

8019

Assembly and Disassembly of Swing Motor

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Causes of Trouble and Solutions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Maintenance Standard Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Swing Motor Internal Structural Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

8019-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
8019-2 PRINTED IN FRANCE
 Assembly and Disassembly of Swing Motor

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.

84402826 - May 2011

8019-3
 Assembly and Disassembly of Swing Motor

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.

84402826 - May 2011

8019-4
 Assembly and Disassembly of Swing Motor

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.

Symptom Cause Solution

1) Insufficient oil flow amount
1) Check the pump discharge volume
Motor speed is not 2) High temperature and severe leak
and the circuit up to the motor.
reaching the set of oil
2) Lower the temperature of the oil.
value. 3) Wear or damage on each sliding
3) Replace.
section

4) Hydraulic motor does not rotate.

Symptom Cause Solution

1) Disassemble and inspect. Replace
1) Wear on the friction plate
parts worn beyond the limit.
2) Brake piston sticking
2) Disassemble and inspect.
Insufficient braking 3) Brake release pressure cannot be
3) Inspect and repair circuit.
torque released.
4) Disassemble and inspect.
4) Spool for brake release sticking
5) Disassemble and inspect. Replace
5) Damaged friction plate spline
damaged part.

5) Severe hydraulic motor slipping

Investigate the amount of oil drained from the hydraulic motor. Motor operation is normal if the amount is
500 cc/min or less.

Symptom Cause Solution

1) Disassemble and inspect.
1) Operation problems with relief
Slipping is severe valve 1) Repair or replace sticking
when an external section.
1) Plunger sticking
driving torque acts on 2) Disassemble and clean.
2) Clogged plunger orifice
the hydraulic motor.
2) Check seating section and replace
2) Plunger seating problem
scratched part.

6) Oil leak
1) Oil leak from oil seal

Symptom Cause Solution

1) Debris lodged in lip causing
scratching. 1) Replace oil seal.
2) Shaft scratched or worn 2) Stagger the position of the lip and
Oil leak from oil seal 3) Pressure within the casing becom- shaft or replace.
ing abnormally high caused oil seal 3) Repair any clogged drain line.
lip to turn up. 4) Disassemble and repair.
4) Shaft rusted.

2) Oil leak from matching surface

Symptom Cause Solution

1) Insert O-ring and assemble cor-
1) O-ring has not been inserted. rectly.
Oil leak from match- 2) Scratched O-ring 2) Replace.
ing surface 3) Scratched seal surface 3) Disassemble and repair.
4) Loosened or damaged bolt 4) Tighten to the specified torque or
replace.
84402826 - May 2011
8019-5
 Assembly and Disassembly of Swing Motor

Maintenance Standard Table

1. 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.

Recom-
Standard mended
dimen- replace-
Item Solution
sions ment
(mm) value
(mm)
Clearances between piston and cylinder
bore 0.028 0.058 Replace the piston or cylinder.
(D-d)
Piston and shoe caulking section back-
0 0.3 Replace the piston and shoe assembly.
lash (δ)
Shoe thickness (t) 5.5 5.3 Replace the piston and shoe assembly.
Friction plate thickness 2.0 1.6 Replace.

Clearance (D-d) Piston and shoe backlash (δ)

Shoe thickness (t)

84402826 - May 2011

8019-6
 Assembly and Disassembly of Swing Motor

2. Sliding surface repair standards

If the roughness of the sliding surface in any section exceeds the standard values below, repair or replace.

Surface roughness
Part name Standard surface roughness
requiring repair
Shoe 0.8 - Z (Ra = 0.2) (lapping) 3 - Z (Ra = 0.8)
Shoe plate 0.4 - Z (Ra = 0.1) (lapping) 3 - Z (Ra = 0.8)
Cylinder 1.6 - Z (Ra = 0.4) (lapping) 12.5 - Z (Ra = 3.2)
Valve plate 0.8 - Z (Ra = 0.2) (lapping) 6.3 - Z (Ra = 1.6)

Note:
1) Using lapping, make the degree of surface roughness of each sliding surface equal to or lower than the
standard value.
2) If the plate spring and cylinder spherical surface sliding section are rough, these should be replaced as
a set.

84402826 - May 2011

8019-7
 Assembly and Disassembly of Swing Motor

Required Tools
1. Bolt tightening torque
Tightening torque values for bolts used in the motor are indicated in Table 3. When assembling, securely tighten
bolts to the values in Table 3.

Tightening torque Applicable

Screw size Name
N·m part code
Hexagon socket
M20 431 401
head bolt
M33 x P1.5 Relief valve 177 051
M36 x P1.5 ROMH plug 539 469
PF1/4 ROH plug 36 467

If there is a variance with the part codes listed above, see the assembly cross-section diagram.
2. Tools for assembly and disassembly
The necessary tools for assembly and disassembly are indicated in Tables 4 and 5. The bolts and plugs used
vary for each type, so prepare tools based on examination beforehand.

Applicable
Name Size Bolt width Tools
part code
Hexagon socket
M20 17 401 Hexagon wrench
head bolt
Hexagon wrench, socket
Relief valve M33 x P1.5 41 051
wrench
ROMH plug M36 x P1.5 17 469 Hexagon wrench
ROH plug PF1/4 6 467 Hexagon wrench

If there are variances with the plugs and bolts listed above, see the assembly cross-section diagram.

Tools Dimensions
Screwdriver Flathead Medium-sized x 2
Steel rod About size 10 x 8 x 200 1
Plastic hammer
Hammer 1 each
Hammer
Torque adjustment range
• For 5 - 10 N·m
Torque wrench • For 10 - 45 N·m
• For 40 - 275 N·m
• For 75 - 550 N·m
Slide hammer bearing puller
Brake piston removal jig See the next page

84402826 - May 2011

8019-8
 Assembly and Disassembly of Swing Motor

Jig 1 Brake piston removal jig

2 Brake piston
3 Casing

84402826 - May 2011

8019-9
 Assembly and Disassembly of Swing Motor

Disassembly 5. Remove the ROH plug (469) from valve casing H0

(303) and take out the springs and plungers.
1. Wrap the wire rope around the outer circumference Be careful not to scratch the plunger seating sec-
of the motor, lift the motor with a liftcrane, and clean tions.
with white kerosene. After cleaning, dry the motor
using compressed air.
• To prevent foreign matter from entering the motor,
mask each port with tape, etc. Also clean off ad-
hered dirt and dust.
2. From the drain plug, drain the oil inside the housing.
3. Point the shaft end of the drive shaft downwards and
place a reference mark (*1) on the matching surface
of valve casing H0 (303) and casing JA1 (301) with
paint, etc.
• Select a clean location. Place a rubber plate or
cloth on the work platform so as not to damage
the parts.
6. Loosen the hexagon socket head bolt (401) and re-
move valve casing H0 (303) from casing JA1 (301).
• The valve casing H0 (303) will rise up from the
casing JA1 (301) when the bolts are removed due
to the force of the brake springs (712).
7. Remove valve plate B (131) from valve casing H0
(303).
• Do this carefully so as not to let valve plate B (131)
fall from valve casing H0 (303). (Valve plate B
(131) may be attached to the cylinder side.)
• When prying open the matching surface with a
screwdriver, be careful not to scratch the surface.

4. Loosen the relief valves (051) and remove them

from valve casing H0 (303).
• Be sure to replace the O-ring (051-1). The O-ring
(051-1) is damaged when the relief valve is loos-
ened.

8. Take out the brake springs (712) from the brake pis-
ton (702).

84402826 - May 2011

8019-10
 Assembly and Disassembly of Swing Motor

9. Use a jig and remove the brake piston (702) from

casing JA1 (301).
• Apply the tips of the jig to the grooves of the brake
piston, and pull straight up.

10. Reposition the motor on its side, and remove the

cylinder (111) from the drive shaft. Next, remove
the pistons (121), holder plate (123), plate spring
(114), and shoe plate (124).
• Be careful not to scratch the sliding surfaces of
the cylinder (111), shoe (122), etc.

13. Perform the following as necessary. Do not reuse a

removed bearing.
• Use a press to remove the inner race of the roller
bearing (443) from the drive shaft (101). When
using a steel rod to hit the inner race of the roller
bearing, hit the inner race evenly while being care-
ful not to damage the bearing.
• Using a steel rod, tap from the housing section
side of the oil seal, and pull out the outer race of
the roller bearing from the housing.
• Use a slide hammer bearing puller (*3) to remove
the roller bearing (404) from valve casing H0
11. Take out the friction plate (742) and separator plate (303).
(743) from casing JA1 (301).

12. Take out the drive shaft (101) and shoe plate (124).
• The spline will damage the oil seal (491) when the
drive shaft is removed, so wrap the spline section
of the drive shaft with vinyl tape, etc. (*2).

84402826 - May 2011

8019-11
 Assembly and Disassembly of Swing Motor

Assembly
1) Check each part for scratches from use or from
disassembly. If there are any scratches, remove them
with a whetstone or sandpaper of the necessary grain,
clean with pure cleaning oil, then dry off with an air
blower.
2） Replace seal parts with new ones.
3） Thoroughly clean all parts with cleaning fluid and
dry with compressed air.
4 ） When assembling sliding sections, apply clean
hydraulic oil before assembling.
1. Place the housing on an appropriate platform with
the cover on top.
2. If the roller bearing (443) was removed, shrink fit
This completes the disassembly.
the inner race of the roller bearing to the drive shaft
(101).
• Be careful with the direction of the flange of the
roller bearing.

3. Use a jig to insert the oil seal (491) into casing JA1
(301).
• Be careful with the direction of the oil seal.
• Apply a thin layer of grease to the oil seal lip sec-
tion.
• Be careful to evenly hit it without scratching the
outer circumference.

84402826 - May 2011

8019-12
 Assembly and Disassembly of Swing Motor

4. Use a steel rod to install the outer race of the roller 7. Set the plate spring (114) on the holder plate (123),
bearing (443) into casing JA1 (301). and then set the pistons (121).

5. Mount the drive shaft (101) in casing JA1 (301). 8. Install the piston subassembly (10) on the cylinder
(111).
• Carefully insert it so as not to scratch the lip sec-
tion of the oil seal (491).
• Wrap vinyl tape, etc. around the shaft spline sec-
tion to protect it.

9. Align the piston subassembly (10) and cylinder

(111) with the drive shaft spline and insert into the
housing.
6. Lay casing JA1 (301) horizontal and insert the shoe
plate (124).
• Install with the larger chamfered side of the shoe
plate (124) on the casing JA1 side.
• Apply a thin layer of grease to the matching sur-
face to prevent it from falling out.

10. Set the housing down with the oil seal side facing
downwards, and alternately install separator plates
(743) and friction plates (744) in that order to the
housing. Install the 4 separator plates and 3 friction
plates.

84402826 - May 2011

8019-13
 Assembly and Disassembly of Swing Motor

13. Install the brake springs (712) into the brake piston
(702).

14. If the roller bearing (444) was removed, use a ham-

mer and steel rod to insert it into valve casing H0
(303).

11. Mount the O-rings (706) (707) on casing JA1 (301).

• If grease is applied to the O-ring, it will not break
easily when inserting the brake piston.

15. Install valve plate B (131) in valve casing H0 (303).

• Apply a thin layer of grease to the matching sur-
face (*1) of the valve plate.

12. Install the brake piston (702) into the housing.

84402826 - May 2011

8019-14
 Assembly and Disassembly of Swing Motor
16. Mount the O-ring (472) to the cover.
• Apply grease to the O-ring.
17. Install valve casing H0 (303) on casing JA1 (301)
and tighten with the bolt (401).
• Be careful with the installation direction of the
valve.
• Make sure that valve plate B (131) does not fall
over.
• Make sure that the brake springs (712) do not fall
over.
Tightening torque: 430 N·m
18. Insert plungers H2 (351) and springs (355) into
valve casing H0 (303) and tighten the ROMH plugs
(469) with the O-rings (488) mounted on them.
• Check that plunger H2 (351) moves smoothly.
Tightening torque: 539 N·m
84402826 - May 2011
8019-15
19. Mount the relief valve (051) in valve casing H0
(303).
Tightening torque: 177 N·m
20. Assembly confirmation
Open the input/output ports, apply 3.2 - 4.9 MPa of
pilot pressure to the brake release port to check if
the output shaft rotates smoothly for at least 1 ro-
tation with about 30 - 40 N·m of torque. There is
an assembly problem if it does not rotate, so disas-
semble again and adjust it.
• At this time, have the drain port open.
This completes the assembly.
• Check that the set pressure of the relief assembly is
at the correct pressure after the hydraulic motor is in-
stalled in the actual machine.
Relief internal structural diagram
Assembly and Disassembly of Swing Motor

1 Seat 7 Piston
2 Poppet 8 Cap
3 Spring 9 Backup ring
4 Spring seat 10 O-ring
5 Shim 11 Holder
6 Liner

84402826 - May 2011

8019-16
 Assembly and Disassembly of Swing Motor

Swing Motor Internal Structural Diagram

84402826 - May 2011

8019-17
Assembly and Disassembly of Swing Motor

a Brake spring layout diagram

Code Part name Q'ty

052 Reverse prevention valve subassembly 1 set
100 Casing 1
151 ROH plug 2
161 O-ring 2
162 O-ring 2
163 O-ring 2
171 Hexagon socket head bolt 4
2
400 Reverse prevention valve
sets
400-1 O-ring 2
400-2 Backup ring 2

Code Part name Q'ty

2
051 Relief valve
sets
051-1 O-ring 2
10 Piston subassembly 1 set
101 Drive shaft 1
111 Cylinder 1
114 Plate spring 1
121 Piston 9
122 Shoe 9
123 Holder plate 1
124 Shoe plate 1
131 Valve plate B 1
20 Valve casing H0 subassembly 1 set
301 Casing JA1 1
303 Valve casing H0 1
351 Plunger H2 2
355 Spring H2 2
390 Nameplate 1
391 Driving tack 2
401 Hexagon socket head bolt 4
443 Cylinder roller bearing 1
444 Cylinder roller bearing 1
451 Pin 2
469 ROMH plug 2
472 O-ring 1
488 O-ring 2
491 Oil seal 1
702 Brake piston 1
706 O-ring 1
707 O-ring 1
712 Brake spring 14
742 Friction plate 3
743 Separator plate 4
2
983 Masking plug
sets
984 Masking plug 1 set
985 Masking plug 1 set
986 Masking plug 1 set
994 Insert plug 1 set

84402826 - May 2011

8019-18
 Assembly and Disassembly of Swing Motor

Bolt and plug tightening torque

Part
Screw size ・m)
Tightening torque (N・ Width across flat (mm)
No.
051 M33 x 1.5 177 41
151 G1/4 36 6
171 M8 29 6
400 M22 x 1.5 69 24
401 M20 430 17
469 M36 x 1.5 539 17
984 G1/2 2.7 8
985 G1 5.6 14
986 G1/4 0.9 6
994 Rc3/4 98 14

84402826 - May 2011

8019-19
Assembly and Disassembly of Swing Motor

84402826 - May 2011

8019-20
 Section

8020A

Explanation of Hydraulic Circuit and Operations (standard

model)

84402826 - May 2011

84402826 - May 2011
 CONTENTS Boom-down load holding valve circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Boom-down load holding valve circuit (with HBCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Arm Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Travel Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Arm-out circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Travel low-speed circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Arm-out circuit (with HBCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Travel high-speed circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Arm-in forced regenerative circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Straight travel circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Arm-in forced regenerative circuit (with HBCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Straight travel circuit (with HBCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Arm-in load holding valve circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Swing Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Arm-in load holding valve circuit (with HBCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Swing speed limit control circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Bucket Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Bucket-open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Swing relief cut-off control circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Bucket-close regenerative circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Swing priority circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Negative Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Swing priority circuit (with HBCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Negative control circuit (power save solenoid OFF). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Swing brake circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Negative control power save circuit (power save solenoid ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Swing parking circuit (lever in neutral) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Negative control circuit (bucket close, power save solenoid OFF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Swing parking circuit (brake release) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Horsepower Boost Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Swing parking circuit (machine stop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Arm-in Horsepower Boost Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Boom Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Boom-up circuit (independent operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Travel Horsepower Boost Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Boom-up circuit (independent operation) (with HBCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Other Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Cushion circuit (arm-out operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Boom-up circuit (compound boom-up + arm-in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Cushion circuit (arm-out operation stopped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Boom-up circuit (compound boom-up + arm-in) (with HBCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Cushion circuit (arm-out → arm-in operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Boom-down regenerative circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Heat circuit (lever in neutral) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Boom-down regenerative circuit (with HBCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Auto pressure boost circuit (bucket close) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Boom-down tilting prevention circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Boom-down tilting prevention circuit (with HBCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

84402826 EN - May 2011 Copyright © 2011 CNH FRANCE S.A.

8020A-1 PRINTED IN FRANCE
 Explanation of Hydraulic Circuit and Operations (standard model)

Travel Circuit
Travel low-speed circuit

84402826 EN - May 2011

8020A-2
 Explanation of Hydraulic Circuit and Operations (standard model)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

1 Travel motor 7 Travel high speed 13 Check valve

2 Travel high-speed select switch 8 Lever lock 14 Oil cooler
3 Computer A 9 5 stack solenoid valve 15 Backward left
4 Control valve 10 Console lever lock switch 16 Forward left
5 Travel (left) 11 Hydraulic pump 17 Backward right
6 Travel (right) 12 Travel remote control valve 18 Forward right

As an example, this section explains the forward travel operation.

The travel motor 2-stage tilting angle is a large angle side.Even if the travel switchover is set to the high-speed side, switching
the key switch OFF and then ON again always returns the system to this state.
By operating the travel remote control valve to the forward side, the pilot pressure oil is fed to the control valve pa1 port and
switches the left travel spool to the forward side.
At the same time, the oil is also fed to the pa6 port to switch the right travel spool to the forward side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port and the discharge oil from hydraulic pump A2 enters
the control valve P2 port.
Each flows to the respective travel motor and causes forward travel through the left and right travel spools being switched.
The return oil from the travel motor goes through the left and right travel spools and returns to the hydraulic oil tank.
The travel high-speed solenoid valve goes OFF, the travel motor Ps port oil connects with the tank line, and the travel motor
tilting angle moves to the large tilting side.

84402826 EN - May 2011

8020A-3
 Explanation of Hydraulic Circuit and Operations (standard model)
Travel high-speed circuit

84402826 EN - May 2011

8020A-4
 Explanation of Hydraulic Circuit and Operations (standard model)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

1 Travel motor 7 Travel high speed 13 Check valve

2 Travel high-speed select switch 8 Lever lock 14 Oil cooler
3 Computer A 9 5 stack solenoid valve 15 Backward left
4 Control valve 10 Console lever lock switch 16 Forward left
5 Travel (left) 11 Hydraulic pump 17 Backward right
6 Travel (right) 12 Travel remote control valve 18 Forward right

As an example, this section explains the forward travel operation.

Sets the travel motor 2-stage tilting angle to a small angle to set high speed.
The travel motor has an automatic switchover function that switches the speed to low speed according to the load pressure
on the travel motor only during high-speed travel conditions.
By operating the travel remote control valve to the forward side, the pilot pressure oil is fed to the control valve pa1 port and
switches the left travel spool to the forward side.
At the same time, the oil is also fed to the pa6 port to switch the right travel spool to the forward side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port and the discharge oil from hydraulic pump A2 enters
the control valve P2 port.
Each flows to the respective travel motor and causes forward travel through the left and right travel spools being switched.
The return oil from the travel motor goes through the left and right travel spools and returns to the hydraulic oil tank.
Electrical signals are sent to the computer A by operation of the travel high-speed select switch and the computer A sends
electrical signals to the travel high-speed solenoid valve.
Due to the switching of the travel high-speed solenoid valve, the pilot pressure (3.9 MPa) from the C1 port enters the left and
right travel motor Ps ports through the center joint and sets the travel motor tilting angle to a small angle to raise the speed.

84402826 EN - May 2011

8020A-5
 Explanation of Hydraulic Circuit and Operations (standard model)
Straight travel circuit

84402826 EN - May 2011

8020A-6
 Explanation of Hydraulic Circuit and Operations (standard model)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

1 Travel motor 10 Straight travel signal (left) 19 Boom cylinder

2 Boom (up) 11 Straight travel signal (right) 20 Travel remote control valve
3 Boom (down) 12 Travel high-speed select switch 21 Check valve
4 Cushion valve 13 Computer A 22 Oil cooler
Remote control valve
5 14 Travel high speed 23 Backward left
(boom, bucket)
6 Control valve 15 Lever lock 24 Forward left
7 Travel (left) 16 5 stack solenoid valve 25 Forward right
8 Travel (right) 17 Console lever lock switch 26 Backward right
9 Straight travel valve 18 Hydraulic pump

As an example, this section explains simultaneous forward travel and boom-up operations.
By operating the travel remote control valve to the forward side, the pilot pressure oil is fed to the control valve pa1 port and
switches the left travel spool to the forward side.
In the same way, oil is also fed to the pa6 port to switch the right travel spool to the forward side.
Furthermore, the right forward travel pilot pressure oil separated internally from the control valve pa6 port switches the straight
travel signal (right).
On the other hand, the travel pilot pressure oil separated internally from the pa1 port switches the straight travel signal (left)
via the straight travel signal (right).
The discharge oil from hydraulic pump A1 enters the control valve P1 port and the discharge oil from hydraulic pump A2 enters
the control valve P2 port.
Each flows to the respective travel motor and causes forward travel through the left and right travel spools being switched.
If a boom-up operation is carried out during travel, the pilot pressure oil is fed via the cushion valve to the control valve pa4
port and switches the boom (1) and (2) spools to the up side.
The upper (boom, arm, bucket, swing, option) pilot pressure oil separated internally from the control valve pa4 port is fed to
the straight travel valve via the straight travel signal (left) and the straight travel spool is switched.
The amount of switching of the straight travel spool varies with the upper pilot pressure.
(Because the pilot pressure is low for slight upper operation, the amount of switching of the straight travel spool is slight to
prevent sharp reduction in the travel speed.)
Through the straight travel valve being switched, it is possible for the control valve P1 pressurized oil to drive the left and right
travel motors and for the control valve P2 pressurized oil to drive the boom.
Because the left and right motors are driven by 1 pump, the left and right motors have the same pressure and straight travel
is possible.
Furthermore, the P2 excess pressurized oil is fed to the travel side via the check valve with travel merge orifice to minimize
the drop in speed.
The same operations are carried out when travel and an upper actuator other than for the boom are operated simultaneously.

84402826 EN - May 2011

8020A-7
 Explanation of Hydraulic Circuit and Operations (standard model)
Straight travel circuit (with HBCV)

84402826 EN - May 2011

8020A-8
 Explanation of Hydraulic Circuit and Operations (standard model)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

1 Travel motor 10 Straight travel signal (left) 19 Boom cylinder

2 Boom (up) 11 Straight travel signal (right) 20 Travel remote control valve
3 Boom (down) 12 Travel high-speed select switch 21 Check valve
4 Cushion valve 13 Computer A 22 Oil cooler
Remote control valve
5 14 Travel high speed 23 Backward left
(boom, bucket)
6 Control valve 15 Lever lock 24 Forward left
7 Travel (left) 16 5 stack solenoid valve 25 Forward right
8 Travel (right) 17 Console lever lock switch 26 Backward right
9 Straight travel valve 18 Hydraulic pump

As an example, this section explains simultaneous forward travel and boom-up operations.
By operating the travel remote control valve to the forward side, the pilot pressure oil is fed to the control valve pa1 port and
switches the left travel spool to the forward side.
In the same way, oil is also fed to the pa6 port to switch the right travel spool to the forward side.
Furthermore, the right forward travel pilot pressure oil separated internally from the control valve pa6 port switches the straight
travel signal (right).
On the other hand, the travel pilot pressure oil separated internally from the pa1 port switches the straight travel signal (left)
via the straight travel signal (right).
The discharge oil from hydraulic pump A1 enters the control valve P1 port and the discharge oil from hydraulic pump A2 enters
the control valve P2 port.
Each flows to the respective travel motor and causes forward travel through the left and right travel spools being switched.
If a boom-up operation is carried out during travel, the pilot pressure oil is fed via the cushion valve to the control valve pa4
port and switches the boom (1) and (2) spools to the up side.
The upper (boom, arm, bucket, swing, option) pilot pressure oil separated internally from the control valve pa4 port is fed to
the straight travel valve via the straight travel signal (left) and the straight travel spool is switched.
The amount of switching of the straight travel spool varies with the upper pilot pressure.
(Because the pilot pressure is low for slight upper operation, the amount of switching of the straight travel spool is slight to
prevent sharp reduction in the travel speed.)
Through the straight travel valve being switched, it is possible for the control valve P1 pressurized oil to drive the left and right
travel motors and for the control valve P2 pressurized oil to drive the boom.
Because the left and right motors are driven by 1 pump, the left and right motors have the same pressure and straight travel
is possible.
Furthermore, the P2 excess pressurized oil is fed to the travel side via the check valve with travel merge orifice to minimize
the drop in speed.
The same operations are carried out when travel and an upper actuator other than for the boom are operated simultaneously.

84402826 EN - May 2011

8020A-9
 Explanation of Hydraulic Circuit and Operations (standard model)

Swing Circuit
Swing speed limit control circuit

84402826 EN - May 2011

8020A-10
 Explanation of Hydraulic Circuit and Operations (standard model)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

1 Swing motor 9 Travel pilot pressure sensor 17 P1 pressure sensor

2 Swing 10 Upper pilot pressure sensor 18 P1 flow control proportional valve
3 Cushion valve 11 Computer A 19 Hydraulic pump
Horsepower control proportional
4 Right swing 12 Lever lock 20
valve
5 Left swing 13 Swing brake 21 P2 pressure sensor
6 Swing pilot pressure sensor 14 5 stack solenoid valve 22 Check valve
7 Remote control valve (arm, swing) 15 Console lever lock switch 23 Oil cooler

This control is for suppressing increases in the swing speed accompanying increased pump flow. (Only in SP mode)
For independent swing operation, due to the swing pilot pressure sensor and P1 pressure sensor input electric signal, the
computer A outputs a signal to the P1 flow control proportional valve.
The discharge oil from the hydraulic pump A3 is fed to the P1 flow control proportional valve.
The hydraulic pump A1 side discharge flow is reduced to 280 L/min by the signal output from the computer A to the P1 flow
control proportional valve.

84402826 EN - May 2011

8020A-11
 Explanation of Hydraulic Circuit and Operations (standard model)
Swing relief cut-off control circuit

84402826 EN - May 2011

8020A-12
 Explanation of Hydraulic Circuit and Operations (standard model)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

1 Swing motor 9 Travel pilot pressure sensor 17 P1 pressure sensor

2 Swing 10 Upper pilot pressure sensor 18 P1 flow control proportional valve
3 Cushion valve 11 Computer A 19 Hydraulic pump
Horsepower control proportional
4 Right swing 12 Lever lock 20
valve
5 Left swing 13 Swing brake 21 P2 pressure sensor
6 Swing pilot pressure sensor 14 5 stack solenoid valve 22 Check valve
7 Remote control valve (arm, swing) 15 Console lever lock switch 23 Oil cooler
N1 negative control pressure sen-
8 Control valve 16
sor

This control aims for an energy-saving effect by controlling the pump in such a way as to minimize the excess oil drained from
the swing motor relief valve for the starting pressure boost for a independent sharp swing operation.
When a swing operation starts, due to the swing pilot pressure sensor and P1 pressure sensor input electrical signals, com-
puter A outputs a signal to the hydraulic pump P1 flow control proportional valve.
The discharge oil from the hydraulic pump A3 is fed to the P1 flow control proportional valve.
The output signal from computer A to the P1 flow control proportional valve controls the pilot pressure to reduce the hydraulic
pump A1 side discharge flow.
Also, the input signal from hydraulic pump P1 pressure sensor controls the pilot pressure to gradually increase the discharge
flow.

84402826 EN - May 2011

8020A-13
 Explanation of Hydraulic Circuit and Operations (standard model)
Swing priority circuit

84402826 EN - May 2011

8020A-14
 Explanation of Hydraulic Circuit and Operations (standard model)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

1 Swing motor 10 Remote control valve (arm, swing) 19 Arm load holding valve check valve
2 Arm (in) 11 Lever lock 20 Regeneration release valve
3 Arm (out) 12 Swing brake 21 Control valve
4 Right swing 13 5 stack solenoid valve 22 Swing priority variable orifice
5 Left swing 15 Arm cylinder 23 Arm (2)
6 Cushion valve 16 Arm (1) 24 Upper pilot pressure sensor
7 Swing pilot pressure sensor 17 Swing 25 Hydraulic pump
8 Shuttle valve 18 Arm load holding valve spool 26 Check valve
9 Computer A 15 Arm cylinder 27 Oil cooler

The swing pilot pressure is fed to the Pc3' port via the shuttle valve and holds the swing priority variable orifice to the right side.
By metering the parallel circuit, for arm and swing simultaneous operation, the swing pressure is boosted to secure the swing
force for pressing digging.
As an example, this section explains the right-swing and arm-in operation.
By moving the remote control valve to the right swing side, the pilot pressure oil is fed via the shuttle valve to the control valve
pa3 port and switches the spool to the right swing side.
At this time, by moving the remote control valve to the arm-in side, the pilot pressure oil is fed via the cushion valve to the
control valve pb5 port and switches the spool to the arm-in side.
At the same time, the pilot pressure oil from the shuttle valve S port is fed to the control valve Pc3' port to move the swing
priority variable orifice to the right side and hold it.
The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the 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 discharge oil from hydraulic pump A2 enters the control valve P2 port, is fed from the parallel oil path to the arm (2) spool
and merges upstream of the arm (1) spool.
Switching the spool lets the oil flow into the arm cylinder bottom and the arm-in operation is carried out.
When the right swing and arm-in operations are carried out at the same time, the swing priority variable orifice on the control
valve P1 port parallel oil path moves and narrows, so the pressure is boosted to secure the swing force for pressing digging.

84402826 EN - May 2011

8020A-15
 Explanation of Hydraulic Circuit and Operations (standard model)
Swing priority circuit (with HBCV)

84402826 EN - May 2011

8020A-16
 Explanation of Hydraulic Circuit and Operations (standard model)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

1 Swing motor 10 Remote control valve (arm, swing) 19 Arm load holding valve check valve
2 Arm (in) 11 Lever lock 20 Regeneration release valve
3 Arm (out) 12 Swing brake 21 Control valve
4 Right swing 13 5 stack solenoid valve 22 Swing priority variable orifice
5 Left swing 15 Arm cylinder 23 Arm (2)
6 Cushion valve 16 Arm (1) 24 Upper pilot pressure sensor
7 Swing pilot pressure sensor 17 Swing 25 Hydraulic pump
8 Shuttle valve 18 Arm load holding valve spool 26 Check valve
9 Computer A 15 Arm cylinder 27 Oil cooler

The swing pilot pressure is fed to the Pc3' port via the shuttle valve and holds the swing priority variable orifice to the right side.
By metering the parallel circuit, for arm and swing simultaneous operation, the swing pressure is boosted to secure the swing
force for pressing digging.
As an example, this section explains the right-swing and arm-in operation.
By moving the remote control valve to the right swing side, the pilot pressure oil is fed via the shuttle valve to the control valve
pa3 port and switches the spool to the right swing side.
At this time, by moving the remote control valve to the arm-in side, the pilot pressure oil is fed via the cushion valve to the
control valve pb5 port and switches the spool to the arm-in side.
At the same time, the pilot pressure oil from the shuttle valve S port is fed to the control valve Pc3' port to move the swing
priority variable orifice to the right side and hold it.
The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the 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 discharge oil from hydraulic pump A2 enters the control valve P2 port, is fed from the parallel oil path to the arm (2) spool
and merges upstream of the arm (1) spool.
Switching the spool lets the oil flow into the arm cylinder bottom and the arm-in operation is carried out.
When the right swing and arm-in operations are carried out at the same time, the swing priority variable orifice on the control
valve P1 port parallel oil path moves and narrows, so the pressure is boosted to secure the swing force for pressing digging.

84402826 EN - May 2011

8020A-17
 Explanation of Hydraulic Circuit and Operations (standard model)
Swing brake circuit

84402826 EN - May 2011

8020A-18
 Explanation of Hydraulic Circuit and Operations (standard model)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

1 Swing motor 7 Hydraulic pump 13 Computer A

2 Cushion valve 8 Check valve 14 Control valve
3 Right swing 9 Lever lock 15 Oil cooler
4 Left swing 10 Swing brake 16 Upper pilot pressure sensor
5 Swing pilot pressure sensor 11 5 stack solenoid valve
6 Remote control valve (arm, swing) 12 Console lever lock switch

As an example, this section explains the brake circuit operation after the end of a right swing operation.
When the remote control valve is returned to neutral from a right swing operation, the pilot pressure oil is cut off and the control
valve swing spool returns to neutral.
The pressurized oil fed to the swing motor A port from the control valve A3 port is cut.
At the same time, the destination location is eliminated for the pressurized oil flowing from the swing motor B port to the control
valve B3 port, so the pressure rises to the swing motor relief valve set pressure.
The pressure generated here becomes a brake force and stops the motor.
When the swing is stopped, the swing motor continues to rotate for a while due to inertial force.In order to make up the shortfall
in the oil volume, oil is supplied from the make-up line connected to the swing motor Mu port from the control valve T3 port to
open the make-up check valve and oil is suctioned in to prevent cavitation.

84402826 EN - May 2011

8020A-19
 Explanation of Hydraulic Circuit and Operations (standard model)
Swing parking circuit (lever in neutral)

84402826 EN - May 2011

8020A-20
 Explanation of Hydraulic Circuit and Operations (standard model)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

1 Swing motor 7 Check valve 13 Computer A

2 Cushion valve 8 Oil cooler 14 Control valve
3 Right swing 9 Lever lock 15 Upper pilot pressure sensor
4 Left swing 10 Swing brake 16 Hydraulic pump
5 Swing pilot pressure sensor 11 5 stack solenoid valve
6 Remote control valve (arm, swing) 12 Console lever lock switch

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.

84402826 EN - May 2011

8020A-21
 Explanation of Hydraulic Circuit and Operations (standard model)
Swing parking circuit (brake release)

84402826 EN - May 2011

8020A-22
 Explanation of Hydraulic Circuit and Operations (standard model)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure 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 Check valve
5 Swing pilot pressure sensor 11 Console lever lock switch 17 Oil cooler
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 PR 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 pa3 port
via the shuttle valve and switches the swing spool to the right swing side.
At the same time, computer A detects the swing pilot pressure sensor signal, judges that there is a swing operation, the
electrical signal output from computer A goes OFF, and the swing brake solenoid valve is switched.The pilot pressure oil is
fed to the swing motor PR port from the swing brake solenoid valve C2 port to release the swing parking brake.
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 A port and the right swing operation is carried out.
The pressurized oil from the swing motor B port goes through the swing spool and returns to the hydraulic oil tank.
When this is followed by an attachment operation, the pilot pressure is detected by the control valve PA port pressure sensor
and the swing parking brake continues to be released.
After the swing operation ends, if about 5 sec. pass with no upper operation, the swing brake 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 mechani-
Key switch
sensor sensor valve cal brake
OFF 0 MPa 0 MPa OFF ON
ON 0 MPa 0 MPa ON ON
ON 0.5 MPa min. 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.

84402826 EN - May 2011

8020A-23
 Explanation of Hydraulic Circuit and Operations (standard model)
Swing parking circuit (machine stop)

84402826 EN - May 2011

8020A-24
 Explanation of Hydraulic Circuit and Operations (standard model)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

1 Swing motor 7 Check valve 13 Computer A

2 Cushion valve 8 Oil cooler 14 Control valve
3 Right swing 9 Lever lock 15 Upper pilot pressure sensor
4 Left swing 10 Swing brake 16 Hydraulic pump
5 Swing pilot pressure sensor 11 5 stack solenoid valve
6 Remote control valve (arm, swing) 12 Console lever lock switch

When the machine is stopped (the key is switched OFF), the swing motor P port oil goes from the swing brake solenoid C2
port through the lever lock solenoid and returns to the hydraulic oil tank, holding the swing parking brake hold status.

84402826 EN - May 2011

8020A-25
 Explanation of Hydraulic Circuit and Operations (standard model)

Boom Circuit
Boom-up circuit (independent operation)

84402826 EN - May 2011

8020A-26
 Explanation of Hydraulic Circuit and Operations (standard model)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

1 Cushion valve 9 Control valve 17 Computer A

Boom load holding valve check
2 Boom (up) 10 18 P1 pressure sensor
valve
3 Boom (down) 11 Boom (1) 19 P2 pressure sensor
4 Boom (2) 12 Boom cylinder 20 Hydraulic pump
Remote control valve (boom,
5 13 Travel pilot pressure sensor 21 Check valve
bucket)
6 Lever lock 14 Upper pilot pressure sensor 22 Oil cooler
7 Boost pressure relief 15 Console lever lock switch
8 5 stack solenoid valve 16 Monitor display

By operating the remote control valve to the boom-up side, the pilot pressure oil is fed via the cushion valve to the control
valve pa4 port and the boom (2) spool is switched.
At the same time, the pilot pressure oil from the pa4 port separated in the internal path is fed to the boom (1) pilot port and
switches the boom (1) spool to the up side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port, is fed from the parallel oil path to the boom (2)
spool and merges downstream of the boom (1) spool.
The discharge oil from hydraulic pump A2 is fed to the boom (1) spool via the parallel oil path, merges with the discharge
oil from boom (2), flows through the boom load holding valve check valve and into the boom cylinder bottom side and the
boom-up operation is carried out.
The boom cylinder rod side return oil goes through the boom (1) spool and returns into the hydraulic oil tank.

84402826 EN - May 2011

8020A-27
 Explanation of Hydraulic Circuit and Operations (standard model)
Boom-up circuit (independent operation) (with HBCV)

84402826 EN - May 2011

8020A-28
 Explanation of Hydraulic Circuit and Operations (standard model)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

1 Cushion valve 9 Control valve 17 Computer A

Boom load holding valve check
2 Boom (up) 10 18 P1 pressure sensor
valve
3 Boom (down) 11 Boom (1) 19 P2 pressure sensor
4 Boom (2) 12 Boom cylinder 20 Hydraulic pump
Remote control valve (boom,
5 13 Travel pilot pressure sensor 21 Check valve
bucket)
6 Lever lock 14 Upper pilot pressure sensor 22 Oil cooler
7 Boost pressure relief 15 Console lever lock switch 23 Boom HBCV check valve
8 5 stack solenoid valve 16 Monitor display

By operating the remote control valve to the boom-up side, the pilot pressure oil is fed via the cushion valve to the control
valve Pa4 port and the boom (2) spool is switched. At the same time, the pilot pressure oil from the Pa4 port separated in the
internal path is fed to the boom (1) pilot port and switches the boom (1) spool to the up side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port, is fed from the parallel oil path to the boom (2)
spool and merges downstream of the boom (1) spool. The discharge oil from hydraulic pump A2 is fed to the boom (1) spool
via the parallel oil path, merges with the discharge oil from boom (2), pushes open the boom load hold valve check valve,
flows through the boom cylinder HBCV check valve and into the bottom side, and the boom-up operation is carried out.
The boom cylinder rod side return oil goes through the boom (1) spool and returns into the hydraulic oil tank.

84402826 EN - May 2011

8020A-29
 Explanation of Hydraulic Circuit and Operations (standard model)
Boom-up circuit (compound boom-up + arm-in)

84402826 EN - May 2011

8020A-30
 Explanation of Hydraulic Circuit and Operations (standard model)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

1 Arm cylinder 12 Arm (1) 23 Travel pilot pressure sensor

2 Arm (in) 13 Boom (2) 24 Upper pilot pressure sensor
3 Arm (out) 14 Arm load holding valve spool 25 Console lever lock switch
4 Boom (up) 15 Load holding valve check valve 26 Monitor display
5 Boom (down) 16 Regeneration release valve 27 Computer A
6 Cushion valve 17 Control valve 28 P1 pressure sensor
Remote control valve (boom,
7 18 Swing priority variable orifice 29 P2 pressure sensor
bucket)
8 Remote control valve (arm, swing) 19 Arm (2) 30 Hydraulic pump
Boom load holding valve check
9 Lever lock 20 31 Check valve
valve
10 Boost pressure relief 21 Boom (1) 32 Oil cooler
11 5 stack solenoid valve 22 Boom cylinder

As an example, this section explains the boom-up + arm-in compound operation (leveling work).
For leveling work, the boom-up pilot pressure oil is fed to the pbu port, the swing priority variable orifice is moved to the left
side and the restriction on the flow to the arm is released to smooth the arm movement.
By operating the remote control valve to the boom-up side and arm-in side, the pilot pressure oil is fed via the cushion valve
to the control valve pa4 port and pb5 port and switches the boom (1) and arm (1) spools.
At the same time, pressurized oil separated from the boom (1) side pilot internal path is fed from the pa8 port to the pbu port
and the swing priority variable orifice spool is switched to the left side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the parallel oil path to the boom (2)
and arm (1) spools.
Because the swing priority variable orifice spool in the parallel oil path is moved, the restriction on flow to the arm is released
and the oil flows through the arm (1) spool and into the arm cylinder bottom side.
This makes arm-in operation movement smooth.
The arm cylinder rod side return oil goes through the load holding valve check valve and the arm (1) spool and returns to the
hydraulic oil tank.
The discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed from the parallel oil path to the boom (1)
spool.
Switching the spool lets the oil flow through the boom load holding valve check valve and into the boom cylinder bottom side
and the boom-up operation is carried out.
When the circuit has an HBCV, the discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed from the
parallel oil path to the boom (1) spool.
Switching the spool lets the oil flow through the boom load holding valve check valve and HBCV check valve and into the
boom cylinder bottom side and the boom-up operation is carried out.
The boom cylinder rod side return oil goes through the boom (1) spool and returns to the hydraulic oil tank.

84402826 EN - May 2011

8020A-31
 Explanation of Hydraulic Circuit and Operations (standard model)
Boom-up circuit (compound boom-up + arm-in) (with HBCV)

84402826 EN - May 2011

8020A-32
 Explanation of Hydraulic Circuit and Operations (standard model)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

1 Arm cylinder 12 Arm (1) 23 Upper pilot pressure sensor

2 Arm (in) 13 Boom (2) 24 Console lever lock switch
3 Arm (out) 14 Arm load holding valve spool 25 Monitor display
4 Boom (up) 15 Load holding valve check valve 26 Computer A
5 Boom (down) 16 Regeneration release valve 27 P1 pressure sensor
6 Cushion valve 17 Control valve 28 P2 pressure sensor
Remote control valve (boom,
7 18 Swing priority variable orifice 29 Hydraulic pump
bucket)
8 Remote control valve (arm, swing) 19 Arm (2) 30 Check valve
Boom load holding valve check
9 Lever lock 20 31 Oil cooler
valve
10 Boost pressure relief 21 Boom cylinder 32 HBCV check valve
11 5 stack solenoid valve 22 Travel pilot pressure sensor

As an example, this section explains the boom-up + arm-in compound operation (leveling work).
For leveling work, the boom-up pilot pressure oil is fed to the pbu port, the swing priority variable orifice is moved to the left
side and the restriction on the flow to the arm is released to smooth the arm movement.
By operating the remote control valve to the boom-up side and arm-in side, the pilot pressure oil is fed via the cushion valve
to the control valve pa4 port and pb5 port and switches the boom (1) and arm (1) spools.
At the same time, pressurized oil separated from the boom (1) side pilot internal path is fed from the pa8 port to the pbu port
and the swing priority variable orifice spool is switched to the left side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the parallel oil path to the boom (2)
and arm (1) spools.
Because the swing priority variable orifice spool in the parallel oil path is moved, the restriction on flow to the arm is released
and the oil flows through the arm (1) spool and into the arm cylinder bottom side.
This makes arm-in operation movement smooth.
The arm cylinder rod side return oil goes through the load holding valve check valve and the arm (1) spool and returns to the
hydraulic oil tank.
The discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed from the parallel oil path to the boom (1)
spool.
Switching the spool lets the oil flow through the boom load holding valve check valve and into the boom cylinder bottom side
and the boom-up operation is carried out.
When the circuit has an HBCV, the discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed from the
parallel oil path to the boom (1) spool.
Switching the spool lets the oil flow through the boom load holding valve check valve and HBCV check valve and into the
boom cylinder bottom side and the boom-up operation is carried out.
The boom cylinder rod side return oil goes through the boom (1) spool and returns to the hydraulic oil tank.

84402826 EN - May 2011

8020A-33
 Explanation of Hydraulic Circuit and Operations (standard model)
Boom-down regenerative circuit

84402826 EN - May 2011

8020A-34
 Explanation of Hydraulic Circuit and Operations (standard model)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

1 Load holding valve check valve 9 Boom (down) 17 Boom cylinder

Remote control valve (boom,
2 Check valve 10 18 Boom (1)
bucket)
3 Oil cooler 11 Lever lock 19 Travel pilot pressure sensor
4 P1 pressure sensor 12 Boost pressure relief 20 Upper pilot pressure sensor
5 Orifice 13 5 stack solenoid valve 21 Console lever lock switch
6 Bleed-off 14 Control valve 22 Monitor display
7 Cushion valve 15 P2 pressure sensor 23 Computer A
8 Boom (up) 16 Hydraulic pump

By moving the remote control valve to the boom-down side, the pilot pressure oil is fed via the cushion valve to the control
valve pb8 port and switches the boom (1) spool to the down side.
The discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed from the parallel oil path to the boom (1)
spool.
Switching the spool lets the oil flow into the boom cylinder rod side and the boom-down operation is carried out.
The pilot pressure oil from the pb8 port separated in the internal path is fed to the load holding valve spool and moves the
spool to the left.
In this way, the load holding valve check valve spring chamber oil is connected to the tank line through the load holding valve
spool, the spring chamber pressure drops, and the load holding valve check valve is opened.
When the circuit has an HBCV, the pilot pressure oil separated in the internal path operates on the HBCV PL port and switches
the spool.
This opens the HBCV check valve.
The boom cylinder bottom side pressurized oil goes through the load holding valve check valve (passes through the HBCV
check valve and goes through the load holding valve check valve when the circuit has an HBCV) and is metered by the boom
(1) spool regeneration orifice.
Through this, the return oil pushes open the check valve in the spool and is regenerated on the cylinder rod side.
The lower the cylinder rod side load pressure, the greater the volume of regeneration.
When the cylinder rod side load pressure becomes high, the check valve is closed and the cylinder bottom return oil goes
through the boom spool (1) without regeneration and returns to the hydraulic oil tank.
Because the circuit is configured in such a way that, even if the boom (1) spool is at full stroke, negative control pressure is
generated by the center bypass bleed-off oil path and the pump does not discharge full flow, the shortfall is made up for with
regeneration and engine output can be used effectively.

84402826 EN - May 2011

8020A-35
 Explanation of Hydraulic Circuit and Operations (standard model)
Boom-down regenerative circuit (with HBCV)

84402826 EN - May 2011

8020A-36
 Explanation of Hydraulic Circuit and Operations (standard model)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

1 Load holding valve check valve 9 Boom (down) 17 Boom cylinder

Remote control valve (boom,
2 Check valve 10 18 Boom (1)
bucket)
3 Oil cooler 11 Lever lock 19 Travel pilot pressure sensor
4 P1 pressure sensor 12 Boost pressure relief 20 Upper pilot pressure sensor
5 Orifice 13 5 stack solenoid valve 21 Console lever lock switch
6 Bleed-off 14 Control valve 22 Monitor display
7 Cushion valve 15 P2 pressure sensor 23 Computer A
8 Boom (up) 16 Hydraulic pump 24 Boom HBCV check valve

By moving the remote control valve to the boom-down side, the pilot pressure oil is fed via the cushion valve to the control
valve pb8 port and switches the boom (1) spool to the down side.
The discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed from the parallel oil path to the boom (1)
spool.
Switching the spool lets the oil flow into the boom cylinder rod side and the boom-down operation is carried out.
The pilot pressure oil from the pb8 port separated in the internal path is fed to the load holding valve spool and moves the
spool to the left.
In this way, the load holding valve check valve spring chamber oil is connected to the tank line through the load holding valve
spool, the spring chamber pressure drops, and the load holding valve check valve is opened.
When the circuit has an HBCV, the pilot pressure oil separated in the internal path operates on the HBCV PL port and switches
the spool.
This opens the HBCV check valve.
The boom cylinder bottom side pressurized oil goes through the load holding valve check valve (passes through the HBCV
check valve and goes through the load holding valve check valve when the circuit has an HBCV) and is metered by the boom
(1) spool regeneration orifice.
Through this, the return oil pushes open the check valve in the spool and is regenerated on the cylinder rod side.
The lower the cylinder rod side load pressure, the greater the volume of regeneration.
When the cylinder rod side load pressure becomes high, the check valve is closed and the cylinder bottom return oil goes
through the boom spool (1) without regeneration and returns to the hydraulic oil tank.
Because the circuit is configured in such a way that, even if the boom (1) spool is at full stroke, negative control pressure is
generated by the center bypass bleed-off oil path and the pump does not discharge full flow, the shortfall is made up for with
regeneration and engine output can be used effectively.

84402826 EN - May 2011

8020A-37
 Explanation of Hydraulic Circuit and Operations (standard model)
Boom-down tilting prevention circuit

84402826 EN - May 2011

8020A-38
 Explanation of Hydraulic Circuit and Operations (standard model)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

1 Load holding valve check valve 9 Lever lock 17 Travel pilot pressure sensor
2 Check valve 10 Boost pressure relief 18 Upper pilot pressure sensor
3 Oil cooler 12 Control valve 19 Console lever lock switch
4 Bleed-off 13 P2 pressure sensor 20 Monitor display
5 Cushion valve 14 Hydraulic pump 21 Computer A
6 Boom (up) 15 Boom cylinder 22 P1 pressure sensor
7 Boom (down) 16 Boom (1)

By operating the remote control valve all the way to the boom-down side at once, even if the boom spool goes its full stroke,
negative control pressure is generated by the center bypass bleed-off oil path and the circuit is such that the hydraulic pump
does not discharge full flow, so the generation of high pressure is restrained and main unit tilt is reduced.
Since the shortfall in the oil volume is compensated by the regenerative circuit, the engine output can be used effectively.

84402826 EN - May 2011

8020A-39
 Explanation of Hydraulic Circuit and Operations (standard model)
Boom-down tilting prevention circuit (with HBCV)

84402826 EN - May 2011

8020A-40
 Explanation of Hydraulic Circuit and Operations (standard model)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

1 Load holding valve check valve 9 Lever lock 17 Travel pilot pressure sensor
2 Check valve 10 Boost pressure relief 18 Upper pilot pressure sensor
3 Oil cooler 12 Control valve 19 Console lever lock switch
4 Bleed-off 13 P2 pressure sensor 20 Monitor display
5 Cushion valve 14 Hydraulic pump 21 Computer A
6 Boom (up) 15 Boom cylinder 22 P1 pressure sensor
7 Boom (down) 16 Boom (1) 23 Boom HBCV check valve

By operating the remote control valve all the way to the boom-down side at once, even if the boom spool goes its full stroke,
negative control pressure is generated by the center bypass bleed-off oil path and the circuit is such that the hydraulic pump
does not discharge full flow, so the generation of high pressure is restrained and main unit tilt is reduced.
Since the shortfall in the oil volume is compensated by the regenerative circuit, the engine output can be used effectively.

84402826 EN - May 2011

8020A-41
 Explanation of Hydraulic Circuit and Operations (standard model)
Boom-down load holding valve circuit

84402826 EN - May 2011

8020A-42
 Explanation of Hydraulic Circuit and Operations (standard model)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

Boom load holding valve check

1 9 5 stack solenoid valve 17 Console lever lock switch
valve
2 Load holding valve spool 10 Control valve 18 Monitor display
3 Cushion valve 11 Check valve 19 Computer A
4 Boom (up) 12 Oil cooler 20 P1 pressure sensor
5 Boom (down) 13 Boom cylinder 21 P2 pressure sensor
Remote control valve (boom,
6 14 Boom (1) 22 Hydraulic pump
bucket)
7 Lever lock 15 Travel pilot pressure sensor
8 Boost pressure relief 16 Upper pilot pressure sensor

When the remote control valve boom operation lever is in neutral, the oil at the boom cylinder bottom side is sealed by the
load holding valve check valve, reducing internal leakage from the main spool and reducing the natural drop of the boom.
By moving the remote control valve to the boom-down side, the pilot pressure oil is fed via the cushion valve to the control
valve pb8 port and switches the boom spool to the down side.
The discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed from the parallel oil path to the boom (1).
Switching the spool lets the oil flow into the boom cylinder bottom side and the boom-down operation is carried out.
The pilot pressure oil from the pb8 port separated in the internal path is fed to the load holding valve spool and moves the
spool to the left.
In this way, the load holding valve check valve spring chamber oil is connected to the tank line through the load holding valve
spool, the spring chamber pressure drops, and the load holding valve check valve is opened.
The boom cylinder bottom side pressurized oil goes through the load holding valve check valve and the boom (1) spool and
returns to the hydraulic oil tank.

84402826 EN - May 2011

8020A-43
 Explanation of Hydraulic Circuit and Operations (standard model)
Boom-down load holding valve circuit (with HBCV)

84402826 EN - May 2011

8020A-44
 Explanation of Hydraulic Circuit and Operations (standard model)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

Boom load holding valve check

1 9 5 stack solenoid valve 17 Console lever lock switch
valve
2 Load holding valve spool 10 Control valve 18 Monitor display
3 Cushion valve 11 Check valve 19 Computer A
4 Boom (up) 12 Oil cooler 20 P1 pressure sensor
5 Boom (down) 13 Boom cylinder 21 P2 pressure sensor
Remote control valve (boom,
6 14 Boom (1) 22 Hydraulic pump
bucket)
7 Lever lock 15 Travel pilot pressure sensor 23 Boom HBCV check valve
8 Boost pressure relief 16 Upper pilot pressure sensor

When the remote control valve boom operation lever is in neutral, the oil at the boom cylinder bottom side is sealed by the
load holding valve check valve, reducing internal leakage from the main spool and reducing the natural drop of the boom.
By moving the remote control valve to the boom-down side, the pilot pressure oil is fed via the cushion valve to the control
valve pb8 port and switches the boom spool to the down side.
The discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed from the parallel oil path to the boom (1).
Switching the spool lets the oil flow into the boom cylinder bottom side and the boom-down operation is carried out.
The pilot pressure oil from the pb8 port separated in the internal path is fed to the load holding valve spool and moves the
spool to the left.
In this way, the load holding valve check valve spring chamber oil is connected to the tank line through the load holding valve
spool, the spring chamber pressure drops, and the load holding valve check valve is opened.
The boom cylinder bottom side pressurized oil goes through the load holding valve check valve and the boom (1) spool and
returns to the hydraulic oil tank.

84402826 EN - May 2011

8020A-45
 Explanation of Hydraulic Circuit and Operations (standard model)

Arm Circuit
Arm-out circuit

84402826 EN - May 2011

8020A-46
 Explanation of Hydraulic Circuit and Operations (standard model)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

1 Arm cylinder 9 Control valve 17 Computer A

2 Arm (in) 10 Load holding valve check valve 18 P1 pressure sensor
3 Arm (out) 11 Arm (1) 19 P2 pressure sensor
4 Cushion valve 12 Arm (2) 20 Hydraulic pump
5 Remote control valve (arm, swing) 13 Travel pilot pressure sensor 21 Check valve
6 Lever lock 14 Upper pilot pressure sensor 22 Oil cooler
7 Boost pressure relief 15 Console lever lock switch 23 Cushion valve
8 5 stack solenoid valve 16 Monitor display

By moving the remote control valve to the arm-out side, the pilot pressure oil is fed via the cushion valve to the control valve
pa5 port and pa9 port and switches the arm (1) and (2) spools to the out side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the center bypass oil path to the
arm (1) spool.
The discharge oil from hydraulic pump A2 enters the control valve P2 port, flows from the center bypass oil path and through
the arm (2) spool front arm merge oil path and merges upstream of the arm (1) spool.
Switching the arm spool lets the oil flow through the load holding valve check valve and into the arm cylinder rod side, carrying
out the arm-out operation.
When the circuit has an HBCV, switching the arm spool lets the oil flow through the load holding valve check valve to push
open the arm cylinder HBCV check valve and flow into the rod side, carrying out the arm-out operation.
The arm cylinder bottom side return oil goes through the arm (1) and (2) spools and returns to the hydraulic oil tank.

84402826 EN - May 2011

8020A-47
 Explanation of Hydraulic Circuit and Operations (standard model)
Arm-out circuit (with HBCV)

84402826 EN - May 2011

8020A-48
 Explanation of Hydraulic Circuit and Operations (standard model)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

1 Arm cylinder 10 Load holding valve check valve 19 P2 pressure sensor

2 Arm (in) 11 Arm (1) 20 Hydraulic pump
3 Arm (out) 12 Arm (2) 21 Check valve
4 Cushion valve 13 Travel pilot pressure sensor 22 Oil cooler
5 Remote control valve (arm, swing) 14 Upper pilot pressure sensor 23 Cushion valve
6 Lever lock 15 Console lever lock switch 24 Arm HBCV check valve
7 Boost pressure relief 16 Monitor display 25 Arm HBCV
8 5 stack solenoid valve 17 Computer A
9 Control valve 18 P1 pressure sensor

By moving the remote control valve to the arm-out side, the pilot pressure oil is fed via the cushion valve to the control valve
pa5 port and pa9 port and switches the arm (1) and (2) spools to the out side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the center bypass oil path to the
arm (1) spool.
The discharge oil from hydraulic pump A2 enters the control valve P2 port, flows from the center bypass oil path and through
the arm (2) spool front arm merge oil path and merges upstream of the arm (1) spool.
Switching the arm spool lets the oil flow through the load holding valve check valve and into the arm cylinder rod side, carrying
out the arm-out operation.
When the circuit has an HBCV, switching the arm spool lets the oil flow through the load holding valve check valve to push
open the arm cylinder HBCV check valve and flow into the rod side, carrying out the arm-out operation.
The arm cylinder bottom side return oil goes through the arm (1) and (2) spools and returns to the hydraulic oil tank.

84402826 EN - May 2011

8020A-49
 Explanation of Hydraulic Circuit and Operations (standard model)
Arm-in forced regenerative circuit

84402826 EN - May 2011

8020A-50
 Explanation of Hydraulic Circuit and Operations (standard model)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

1 Load holding valve spool 10 Cushion valve 19 Travel pilot pressure sensor
2 Load holding valve check valve 11 Remote control valve (arm, swing) 20 Upper pilot pressure sensor
3 Oil cooler 12 Lever lock 21 Console lever lock switch
4 Regeneration check valve 13 Boost pressure relief 22 Monitor display
5 Metering large 14 5 stack solenoid valve 23 Computer A
6 Metering small 15 Control valve 24 P1 pressure sensor
7 Forced regeneration release valve 16 Arm cylinder 25 P2 pressure sensor
8 Arm (in) 17 Arm (1) 26 Hydraulic pump
9 Arm (out) 18 Arm (2) 27 Check valve

By moving the remote control valve to the arm-in side, the pilot pressure oil is fed via the cushion valve to the control valve
pb5 port and pb9 port and switches the arm (1) and (2) spools to the in side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the center bypass oil path to the
arm (1) spool.
The discharge oil from hydraulic pump A2 enters the control valve P2 port, flows from the center bypass oil path and through
the arm (2) spool front arm merge oil path and merges upstream of the arm (1) spool.
Switching the arm spool lets the oil flow into the arm cylinder bottom side and the arm-in operation is carried out.
The pilot pressure oil from the pb5 port separated in the internal path is fed to the load holding valve spool and moves the
spool to the right.
In this way, the load holding valve check valve spring chamber oil is connected to the tank line through the load holding valve
spool, the spring chamber pressure drops, and the load holding valve check valve is opened.
The arm cylinder rod side pressurized oil goes through the load holding valve check valve and the arm (1) spool and is metered
by the forced regeneration release valve.Through this, the return oil pushes open the check valve in the arm (1) spool and is
forcibly regenerated on the cylinder bottom side, securing the arm speed for leveling work etc.
When the cylinder bottom load pressure becomes high, the forced regeneration release valve is switched to the large metering
side and the opening becomes larger.
Through this, the check valve in the spool is closed and the cylinder rod side return oil returns to the hydraulic oil tank via the
arm spool (1) and forced regeneration release valve without being regenerated.

84402826 EN - May 2011

8020A-51
 Explanation of Hydraulic Circuit and Operations (standard model)
Arm-in forced regenerative circuit (with HBCV)

84402826 EN - May 2011

8020A-52
 Explanation of Hydraulic Circuit and Operations (standard model)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

1 Load holding valve spool 11 Remote control valve (arm, swing) 21 Console lever lock switch
2 Load holding valve check valve 12 Lever lock 22 Monitor display
3 Oil cooler 13 Boost pressure relief 23 Computer A
4 Regeneration check valve 14 5 stack solenoid valve 24 P1 pressure sensor
5 Metering large 15 Control valve 25 P2 pressure sensor
6 Metering small 16 Arm cylinder 26 Hydraulic pump
7 Forced regeneration release valve 17 Arm (1) 27 Check valve
8 Arm (in) 18 Arm (2) 28 Arm HBCV check valve
9 Arm (out) 19 Travel pilot pressure sensor 29 Arm HBCV
10 Cushion valve 20 Upper pilot pressure sensor

By moving the remote control valve to the arm-in side, the pilot pressure oil is fed via the cushion valve to the control valve
pb5 port and pb9 port and switches the arm (1) and (2) spools to the in side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the center bypass oil path to the
arm (1) spool.
The discharge oil from hydraulic pump A2 enters the control valve P2 port, flows from the center bypass oil path and through
the arm (2) spool front arm merge oil path and merges upstream of the arm (1) spool.
Switching the arm spool lets the oil flow into the arm cylinder bottom side and the arm-in operation is carried out.
The pilot pressure oil from the pb5 port separated in the internal path is fed to the load holding valve spool and moves the
spool to the right.
In this way, the load holding valve check valve spring chamber oil is connected to the tank line through the load holding valve
spool, the spring chamber pressure drops, and the load holding valve check valve is opened.
The arm cylinder rod side pressurized oil goes through the load holding valve check valve and the arm (1) spool and is metered
by the forced regeneration release valve.Through this, the return oil pushes open the check valve in the arm (1) spool and is
forcibly regenerated on the cylinder bottom side, securing the arm speed for leveling work etc.
When the cylinder bottom load pressure becomes high, the forced regeneration release valve is switched to the large metering
side and the opening becomes larger.
Through this, the check valve in the spool is closed and the cylinder rod side return oil returns to the hydraulic oil tank via the
arm spool (1) and forced regeneration release valve without being regenerated.

84402826 EN - May 2011

8020A-53
 Explanation of Hydraulic Circuit and Operations (standard model)
Arm-in load holding valve circuit

84402826 EN - May 2011

8020A-54
 Explanation of Hydraulic Circuit and Operations (standard model)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

1 Load holding valve spool 9 Boost pressure relief 17 Console lever lock switch
2 Load holding valve check valve 10 5 stack solenoid valve 18 Monitor display
3 Oil cooler 11 Control valve 19 Computer A
4 Arm (in) 12 Arm cylinder 20 P1 pressure sensor
5 Arm (out) 13 Arm (1) 21 P2 pressure sensor
6 Cushion valve 14 Arm (2) 22 Hydraulic pump
7 Remote control valve (arm, swing) 15 Travel pilot pressure sensor 23 Check valve
8 Lever lock 16 Upper pilot pressure sensor

When the remote control valve arm operation lever is in neutral, the oil at the arm cylinder rod side is sealed by the load
holding valve check valve, reducing internal leakage from the main spool and reducing the natural drop of the arm.
By moving the remote control valve to the arm-in side, the pilot pressure oil is fed via the cushion valve to the control valve
pb5 port and pb9 port and switches the arm (1) and (2) spools to the in side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the center bypass oil path to the
arm (1) spool.
The discharge oil from hydraulic pump A2 enters the control valve P2 port, flows from the center bypass oil path and through
the arm (2) spool front arm merge oil path and merges upstream of the arm (1) spool.
Switching the arm spool lets the oil flow into the arm cylinder bottom side and the arm-in operation is carried out.
The pilot pressure oil from the pb5 port separated in the internal path is fed to the load holding valve spool and moves the
spool to the right.
In this way, the load holding valve check valve spring chamber oil is connected to the tank line through the load holding valve
spool, the spring chamber pressure drops, and the load holding valve check valve is opened.
The arm cylinder rod side pressurized oil goes through the load holding valve check valve and the arm (1) spool and returns
to the hydraulic oil tank.

84402826 EN - May 2011

8020A-55
 Explanation of Hydraulic Circuit and Operations (standard model)
Arm-in load holding valve circuit (with HBCV)

84402826 EN - May 2011

8020A-56
 Explanation of Hydraulic Circuit and Operations (standard model)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

1 Load holding valve spool 10 5 stack solenoid valve 19 Computer A

2 Load holding valve check valve 11 Control valve 20 P1 pressure sensor
3 Oil cooler 12 Arm cylinder 21 P2 pressure sensor
4 Arm (in) 13 Arm (1) 22 Hydraulic pump
5 Arm (out) 14 Arm (2) 23 Check valve
6 Cushion valve 15 Travel pilot pressure sensor 24 Arm HBCV check valve
7 Remote control valve (arm, swing) 16 Upper pilot pressure sensor 25 Arm HBCV
8 Lever lock 17 Console lever lock switch
9 Boost pressure relief 18 Monitor display

When the remote control valve arm operation lever is in neutral, the oil at the arm cylinder rod side is sealed by the load hold
valve check valve, reducing internal leakage from the main spool and reducing the natural drop of the arm.
By moving the remote control valve to the arm-in side, the pilot pressure oil is fed via the cushion valve to the control valve
Pb5 port and Pb9 port and switches the arm (1) and (2) spools to the in side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the center bypass oil path to the
arm (1) spool. The discharge oil from hydraulic pump A2 enters the control valve P2 port, flows from the center bypass oil
path and through the arm (2) spool front arm merge oil path and merges upstream of the arm (1) spool.
Switching the arm spool lets the oil flow into the arm cylinder bottom side and carries out the arm-in operation.
The pilot pressure oil from the Pb5 port separated in the internal path flows into the HBCV PL port and switches the spool.
This opens the HBCV check valve.
The pilot pressure oil from the Pb5 port separated in the internal path is fed to the load hold valve spool and moves the spool
to the right. In this way, the load hold valve check valve spring chamber oil is connected to the tank line through the load hold
valve spool, the spring chamber pressure drops, and the load hold valve check valve is opened.
The arm cylinder rod side pressurized oil goes through the HBCV check valve, load hold valve check valve and the arm (1)
spool and returns to the hydraulic oil tank.

84402826 EN - May 2011

8020A-57
 Explanation of Hydraulic Circuit and Operations (standard model)

Bucket Circuit
Bucket-open circuit

84402826 EN - May 2011

8020A-58
 Explanation of Hydraulic Circuit and Operations (standard model)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

1 Cushion valve 8 Control valve 15 Computer A

2 Bucket (close) 9 Bucket 16 P1 pressure sensor
3 Bucket (open) 10 Bucket cylinder 17 P2 pressure sensor
Remote control valve (boom,
4 11 Travel pilot pressure sensor 18 Hydraulic pump
bucket)
5 Lever lock 12 Upper pilot pressure sensor 19 Check valve
6 Boost pressure relief 13 Console lever lock switch 20 Oil cooler
7 5 stack solenoid valve 14 Monitor display

By moving the remote control valve to the bucket-open side, the pilot pressure oil is fed via the cushion valve to the control
valve pa7 port and switches the bucket spool to the open side.
The discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed from the parallel oil path to the bucket
spool.
Switching the spool lets the oil flow into the bucket cylinder rod side and the bucket-open operation is carried out.
The bucket cylinder bottom side pressurized oil goes through the bucket spool and returns to the hydraulic oil tank.

84402826 EN - May 2011

8020A-59
 Explanation of Hydraulic Circuit and Operations (standard model)
Bucket-close regenerative circuit

84402826 EN - May 2011

8020A-60
 Explanation of Hydraulic Circuit and Operations (standard model)
Pressure line Pilot tank line pressure, the greater the volume of regeneration. When the cylinder rod side load pressure becomes high, the check valve is
Tank line Electric line closed and the cylinder bottom side return oil goes through the bucket spool without regeneration and returns to the hydraulic
Pilotpressure line oil tank.

1 Regeneration check valve 9 Boost pressure relief 17 Monitor display

2 Oil cooler 10 5 stack solenoid valve 18 Computer A
3 Orifice 11 Control valve 19 P1 pressure sensor
4 Cushion valve 12 Bucket 20 P2 pressure sensor
5 Bucket (close) 13 Bucket cylinder 21 Hydraulic pump
6 Bucket (open) 14 Travel pilot pressure sensor 22 Check valve
Remote control valve (boom,
7 15 Upper pilot pressure sensor
bucket)
8 Lever lock 16 Console lever lock switch

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 pb7 port and switches the bucket spool to the close side.
The discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed from the parallel oil path to the bucket
spool. Switching the spool lets the oil flow into the bucket cylinder bottom and the bucket-close operation is carried out.
The bucket cylinder rod side pressurized oil is metered by the bucket spool regeneration orifice.Through this, the return oil
pushes open the check valve in the spool and is regenerated on the cylinder bottom side. The lower the cylinder rod side load

84402826 EN - May 2011

8020A-61
 Explanation of Hydraulic Circuit and Operations (standard model)

Negative Control Circuit

Negative control circuit (power save solenoid OFF)

84402826 EN - May 2011

8020A-62
 Explanation of Hydraulic Circuit and Operations (standard model)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

Horsepower control proportional

1 P1 negative control relief 8 Lever lock 15
valve
2 P2 negative control relief 9 Power save 16 P1 flow control proportional valve
3 Control valve 10 5 stack solenoid valve 17 Hydraulic pump
N1 negative control pressure sen-
4 Travel pilot pressure sensor 11 18 Check valve
sor
5 Upper pilot pressure sensor 12 P1 pressure sensor 19 Oil cooler
6 Computer A 13 P2 pressure sensor
N2 negative control pressure sen-
7 Console lever lock switch 14
sor

When the remote control valve operation lever is set to neutral, the discharge oil from hydraulic pumps A1 and A2 goes from
the control valve P1 and P2 ports through the center bypass oil path, and through the downstream negative control variable
relief, and returns to the hydraulic oil tank.
The discharged oil from pilot pump A3 enters the 5 stack solenoid valve P port, flows through the power save solenoid valve,
is fed to the control valve Pn1 and Pn2 ports, and holds the P1 and P2 negative control relief at the set pressure of 2.55 MPa.
The negative control pressure oil separated from the center bypass oil path is fed from the Ps1 and Ps2 ports to the hydraulic
pump Pi1 and Pi2 ports, moves the pump tilting to the minimum flow side, and the pump discharge flow is reduced.

84402826 EN - May 2011

8020A-63
 Explanation of Hydraulic Circuit and Operations (standard model)
Negative control power save circuit (power save solenoid ON)

84402826 EN - May 2011

8020A-64
 Explanation of Hydraulic Circuit and Operations (standard model)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

Horsepower control proportional

1 Control valve 7 Power save 13
valve
2 Travel pilot pressure sensor 8 5 stack solenoid valve 14 P1 flow control proportional valve
N1 negative control pressure sen-
3 Upper pilot pressure sensor 9 15 Hydraulic pump
sor
4 Computer A 10 P1 pressure sensor 16 Check valve
5 Console lever lock switch 11 P2 pressure sensor 17 Oil cooler
N2 negative control pressure sen-
6 Lever lock 12
sor

The purpose of this control is to reduce fuel consumption during standby by reducing the back pressure for the negative control
signal.
When the remote control valve operation lever is set to neutral, the non-operation state signal enters the computer A from the
travel pilot pressure sensor and the upper pilot pressure sensor installed on the control valve PT port and PA port.
After about 1 sec., the power save solenoid valve is excited and switched ON by the signal output from computer A, and the
oil path is switched.
The pressurized oil from the control valve negative control relief Pn1 and Pn2 ports goes through the power save solenoid
valve and returns to the hydraulic oil tank.
Therefore, the negative control relief set pressure is switched to low pressure to further reduce the A1 and A2 pump discharge
pressure.
With the system running this way, the negative control signal is cut off and the P1 and P2 pump discharge volume increases.
The discharge oil from pilot pump A3 enters the 5 stack solenoid valve P port, flows through the power save solenoid valve, is
fed to the hydraulic pump P2 port from the C5 port, moves the A2 side pump tilting to the minimum flow side, and this reduces
the discharge flow.
At the same time, the discharge oil from the pilot pump A3 is fed to the hydraulic pump P1 port by the signal from computer
A to the P1 flow restriction proportional valve, moves the A1 side pump tilting to the minimum flow side, and this reduces the
discharge flow.

84402826 EN - May 2011

8020A-65
 Explanation of Hydraulic Circuit and Operations (standard model)
Negative control circuit (bucket close, power save solenoid OFF)

84402826 EN - May 2011

8020A-66
 Explanation of Hydraulic Circuit and Operations (standard model)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

1 Control valve 8 Computer A 15 P2 pressure sensor

Remote control valve (boom, N1 negative control pressure sen-
2 Travel pilot pressure sensor 9 16
bucket) sor
N2 negative control pressure sen-
3 Upper pilot pressure sensor 10 Console lever lock switch 17
sor
4 Cushion valve 11 Lever lock 18 P1 flow control proportional valve
5 Bucket (close) 12 Power save 19 Hydraulic pump
6 Bucket (open) 13 5 stack solenoid valve 20 Check valve
7 Bucket cylinder 14 P1 pressure sensor 21 Oil cooler

As an example, this section explains the bucket-close operations.

By moving the remote control valve to the bucket-close side, the pilot pressure oil is fed via the cushion valve to the control
valve pb7 port and switches the bucket spool to the close side.
The discharge oil from the hydraulic pump A2 enters the control valve P2 port, is fed to the bucket spool, flows into the bucket
cylinder bottom side because of the spool switching and the bucket-close operation is carried out.
At the same time, the upper pilot pressure sensor signal is detected and through the signal output from computer A to switch
OFF the power save solenoid valve, pilot pressure oil enters the negative control relief, and the pressure becomes the set
pressure of 2.55 MPa.
Because the bucket spool switches and the pressurized oil on the center bypass downstream side is cut off, the Pi2 pump
negative control pressure oil from the Ps2 port is eliminated, the pump tilting moves to the increase side, and the flow is
increased.
Also, the command milli-amp to the P1 flow control proportional valve is lowered and the pressurized oil from the hydraulic
pump A3 is cut off, but the negative control pressurized oil is fed from the control valve Ps1 port to the Pi1 port, moves the
pump tilting to the minimum flow side, and the hydraulic pump A1 discharge volume is reduced.

84402826 EN - May 2011

8020A-67
 Explanation of Hydraulic Circuit and Operations (standard model)

Horsepower Boost Circuits

Arm-in Horsepower Boost Circuit

84402826 EN - May 2011

8020A-68
 Explanation of Hydraulic Circuit and Operations (standard model)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

1 Arm (in) 9 Arm pilot pressure sensor 17 Computer A

N1 negative control pressure sen-
2 Arm (out) 10 Control valve 18
sor
3 Cushion valve 11 Arm (1) 19 P1 pressure sensor
4 Remote control valve (arm, swing) 12 Arm (2) 20 P2 pressure sensor
N2 negative control pressure sen-
5 Lever lock 13 Travel pilot pressure sensor 21
sor
6 Boost pressure relief 14 Upper pilot pressure sensor 22 Hydraulic pump
7 5 stack solenoid valve 15 Console lever lock switch 23 Check valve
8 Arm cylinder 16 Monitor display 24 Oil cooler

For the arm-in operation, the horsepower boost signal is output to the hydraulic pump horsepower control proportional valve
from computer A by the arm pilot pressure sensor input signal and P1 pressure sensor and P2 pressure sensor input signals.
The hydraulic pump discharged volume is increased by the horsepower boost signal to the horsepower control proportional
valve from computer A.
Condition under which the arm-in horsepower boost control is entered
Arm-in pilot pressure 0.5 MPa {72.5 psi} or higher (arm-in operation)
P1＋P2 45 MPa {6527 psi}
Conditions under which the arm-in horsepower boost control is ended
Arm-in pilot pressure 0.3 MPa {43.5 psi} or lower (arm-in operation end)
P1＋P2 45 MPa {6527 psi}
When either occurs

84402826 EN - May 2011

8020A-69
 Explanation of Hydraulic Circuit and Operations (standard model)
Travel Horsepower Boost Circuit

84402826 EN - May 2011

8020A-70
 Explanation of Hydraulic Circuit and Operations (standard model)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

N1 negative control pressure sen-

1 Travel motor 8 Computer A 15
sor
N2 negative control pressure sen-
2 Travel remote control valve 9 Control valve 16
sor
3 Travel high speed 10 Travel (left) 17 Hydraulic pump
4 Lever lock 11 Travel (right) 18 Check valve
5 5 stack solenoid valve 12 Travel pilot pressure sensor 19 Oil cooler
6 Console lever lock switch 13 P1 pressure sensor
7 Travel high-speed select switch 14 P2 pressure sensor

Travel Horsepower Boost Circuit

For travel single operation, the horsepower boost signal is output to the hydraulic pump horsepower control proportional valve
from computer A by the travel pilot pressure sensor input signal.
The hydraulic pump discharged volume is increased by the horsepower boost signal to the horsepower control proportional
valve from computer A.
Conditions under which the travel horsepower boost control is entered
Travel pilot pressure 0.5 MPa {72.5 psi} or higher.
SP mode
Conditions under which the travel horsepower boost control is ended
Travel pilot pressure 0.3 MPa {43.5 psi} or lower.
AUTO mode, H mode

84402826 EN - May 2011

8020A-71
 Explanation of Hydraulic Circuit and Operations (standard model)

Other Circuits
As examples, this section explains the cases when an arm-out operation is carried out, when an arm-out operation is stopped,
and when an arm-out operation is followed by an arm-in operation.
Cushion circuit (arm-out operation)

84402826 EN - May 2011

8020A-72
 Explanation of Hydraulic Circuit and Operations (standard model)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

Remote control valve (arm,

1 Arm (in) 7 13 Console lever lock switch
swing)
2 Arm (out) 8 Lever lock 14 Hydraulic pump
3 Cushion spool 9 5 stack solenoid valve 15 Check valve
4 Orifice 10 Control valve 16 Oil cooler
5 Check valve 11 Arm (1)
6 Cushion valve 12 Arm (2)

When a remote control valve arm-out operation is carried out, the pilot pressure oil enters from the remote control valve 2 port
into the cushion valve, pushes up the internal check valve, and is fed to the control valve pa5 and pa9 ports.
At the same time, the cushion valve cushion spool is switched to the left.
The arm-in side oil pushed out from the control valve pb9 and pb5 ports passes from the cushion valve B port through the
cushion spool switched to the left and returns to the hydraulic oil tank.
At this time, the warmed oil from the return line enters the remote control valve through the cushion spool from the cushion
valve R port and returns to the hydraulic oil tank, so heat performance is improved.

84402826 EN - May 2011

8020A-73
 Explanation of Hydraulic Circuit and Operations (standard model)
Cushion circuit (arm-out operation stopped)

84402826 EN - May 2011

8020A-74
 Explanation of Hydraulic Circuit and Operations (standard model)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

1 Arm (in) 6 Remote control valve (arm, swing) 11 Arm (2)

2 Arm (out) 7 Lever lock 12 Console lever lock switch
3 Cushion spool 8 5 stack solenoid valve 13 Hydraulic pump
4 Orifice 9 Control valve 14 Check valve
5 Cushion valve 10 Arm (1) 15 Oil cooler

When the remote control valve arm-out operation is returned to neutral, the oil pushed out from the control valve pa5 and pa9
ports flows to the cushion valve D port through the cushion orifice and returns from the remote control valve to the hydraulic
oil tank.
Through this orifice, the arm spool moves to the neutral position without returning sharply, so the cushioning is improved.

84402826 EN - May 2011

8020A-75
 Explanation of Hydraulic Circuit and Operations (standard model)
Cushion circuit (arm-out → arm-in operation)

84402826 EN - May 2011

8020A-76
 Explanation of Hydraulic Circuit and Operations (standard model)
Pressure line Pilot tank line
Tank line Electric line
Pilot pressure line

1 Arm (in) 6 Remote control valve (arm, swing) 11 Arm (2)

2 Arm (out) 7 Lever lock 12 Console lever lock switch
3 Cushion spool 8 5 stack solenoid valve 13 Hydraulic pump
4 Orifice 9 Control valve 14 Check valve
5 Cushion valve 10 Arm (1) 15 Oil cooler

When the lever is operating all at once from an arm-out operation to an arm-in operation (arm rattling operation), the pilot
pressure oil is fed from the remote control valve 2 port into the cushion valve A port, pushes up the internal check valve, and
reaches the control valve pb5 port and pb9 port.
At the same time, the cushion valve cushion spool is switched to the right.
At this time, the oil pushed out from the pa5 and pa9 ports does not pass through the cushion orifice, but passes through the
cushion spool that has been switched to the right and returns to the hydraulic oil tank, so response is improved.s

84402826 EN - May 2011

8020A-77
 Explanation of Hydraulic Circuit and Operations (standard model)
Heat circuit (lever in neutral)

84402826 EN - May 2011

8020A-78
 Explanation of Hydraulic Circuit and Operations (standard model)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

1 Arm (in) 5 Lever lock 9 Hydraulic pump

2 Arm (out) 6 5 stack solenoid valve 10 Check valve
3 Cushion valve 7 Control valve 11 Oil cooler
4 Remote control valve (arm, swing) 8 Console lever lock switch

The pilot line is equipped with a heat circuit to prevent response delay at low temperatures.
When the remote control valve operation lever is set to neutral, the discharge oil from hydraulic pumps A1 and A2 goes from
the control valve P1 and P2 ports through the center bypass oil path, and returns to the hydraulic oil tank.
The pressurized oil from the control valve T8 port is fed to the cushion valve R port and returns through the cushion spool to
the hydraulic oil tank.
By circulating the oil inside the cushion spool, the temperature of the oil in the cushion valve is raised to improve heat perfor-
mance.

84402826 EN - May 2011

8020A-79
 Explanation of Hydraulic Circuit and Operations (standard model)
Auto pressure boost circuit (bucket close)

84402826 EN - May 2011

8020A-80
 Explanation of Hydraulic Circuit and Operations (standard model)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

1 Cushion valve 8 Control valve 15 Computer A

2 Bucket (close) 9 Bucket 16 P1 pressure sensor
3 Bucket (open) 10 Bucket cylinder 17 P2 pressure sensor
Remote control valve (boom,
4 11 Upper pilot pressure sensor 18 Hydraulic pump
bucket)
5 Lever lock 12 Console lever lock switch 19 Check valve
6 Boost pressure relief 13 Digging force incresed 20 Oil cooler
7 5 stack solenoid valve 14 Monitor display

When an attachment is operated, this circuit boosts the control valve main relief set pressure from 34.3 MPa to 36.8 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 pb7 port and switches the bucket spool to the close side.
At the same time, the output signal from the upper pilot pressure sensor that detected the pressurized oil separated from the
pilot internal path is input to computer A, which judges that there is upper operation.
Furthermore, computer A judges that there is a boost in the main pump P1 and P2 pressure, outputs the ON (24 V) signal to
the pressure boost relief solenoid, switches the valve, and the pilot pressure oil is fed to the control valve main relief valve PH
port to hold the pressure boost relief set pressure for 8 sec.
There is no boost for the option circuit and during travel operation.

84402826 EN - May 2011

8020A-81
Explanation of Hydraulic Circuit and Operations (standard model)

84402826 EN - May 2011

8020A-82
 Section

8020B

Explanation of Hydraulic Circuit and Operations (option)

84402826 - May 2011

84402826 - May 2011
 CONTENTS
Option Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Breaker circuit (independent operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Double-acting circuit (hydraulic fork). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Multi-purpose circuit (breaker Q control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Multi-purpose circuit (2 pumps flow crusher) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2nd option circuit (hydraulic rotation fork) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

84402826 EN - May 2011 Copyright © 2011 CNH FRANCE S.A.

8020B-1 PRINTED IN FRANCE
 Explanation of Hydraulic Circuit and Operations (option)

Option Circuits
Breaker circuit (independent operation)

84402826 EN - May 2011

8020B-2
 Explanation of Hydraulic Circuit and Operations (option)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

N1 negative control pressure sen-

1 Control valve 9 Breaker switch 17
sor
N2 negative control pressure sen-
2 Manifold 10 Option remote control valve 18
sor
3 Relief valve 11 Option pilot pressure switch 19 P1 flow control proportional valve
4 Breaker 12 Console lever lock switch 20 Hydraulic pump
5 Travel pilot pressure sensor 13 Lever lock 21 Check valve
6 Upper pilot pressure sensor 14 5 stack solenoid valve 22 Oil cooler
7 Computer A 15 P1 pressure sensor
8 Monitor display 16 P2 pressure sensor

By operating the option remote control valve to the breaker side, the pilot pressure oil is fed to the control valve pa2 port and
switches the option spool.
The discharge oil from hydraulic pump A1 is fed from the control valve P1 port through the parallel oil path and fed to the
option spool.
Switching the spool lets the oil flow from the relief valve A port through the B port and into the breaker.
The breaker set pressure is set by this relief valve.
At this time, the option pilot pressure switch signal is detected, the P1 flow control proportional valve is controlled by the output
signals from the computer A to adjust the discharge flow.
The return oil from the breaker goes through the manifold and returns to the hydraulic oil tank.
Because the breaker operating flow can be set to 5 levels on the service support screen of the monitor display with the ON
signal from the breaker switch in the cab, the optimum operating flow can be selected.

84402826 EN - May 2011

8020B-3
 Explanation of Hydraulic Circuit and Operations (option)
Double-acting circuit (hydraulic fork)

84402826 EN - May 2011

8020B-4
 Explanation of Hydraulic Circuit and Operations (option)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

1 Control valve 6 Computer A 11 Option remote control valve

2 Hydraulic fork 7 Lever Lock 12 Option pilot pressure switch
3 Travel pilot pressure sensor 8 5 stack solenoid valve 13 Check valve
4 Upper pilot pressure sensor 9 Console lever lock switch 14 Oil cooler
5 Monitor display 10 Hydraulic pump

As an example, this section explains the case in which the hydraulic fork attachment is used.
By operating the option remote control valve to the fork close side, the pilot pressure oil is fed to the control valve pa2 port
and switches the option spool to the close side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port, is fed from the parallel oil path to the option spool,
flows into the hydraulic fork because of the option spool switching and operates to the close side.
At this time, the option pilot pressure switch signal is detected and the auto idle function is released.
The return oil from the hydraulic fork goes through the option spool and returns to the hydraulic oil tank.

84402826 EN - May 2011

8020B-5
 Explanation of Hydraulic Circuit and Operations (option)
Multi-purpose circuit (breaker Q control)

84402826 EN - May 2011

8020B-6
 Explanation of Hydraulic Circuit and Operations (option)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

N1 negative control pressure sen-

1 Control valve 9 Monitor display 17
sor
N2 negative control pressure sen-
2 3-direction valve 10 Option switchover solenoid valve 18
sor
3 Shut-off valve 11 Console lever lock switch 19 P1 flow control proportional valve
4 Breaker 12 Lever lock 20 Hydraulic pump
5 Option remote control valve 13 5 stack solenoid valve 21 Check valve
Horsepower control proportional
6 Option pilot pressure switch 14 22 Oil cooler
valve
7 Multi-purpose circuit switch 15 P1 pressure sensor
8 Computer A 16 P2 pressure sensor

When the switch in the cab is flipped to the breaker side, the ON signal (24 V) is output from the computer A to the option
switchover solenoid valve to switch the valve.
The pilot pressure oil flows from the option switchover solenoid valve B1 port to the A1 port and is fed to the 3-direction valve
PP port and shut-off valve PP port and each valve is switched.
Always switch the 2 pumps flow select switch to the 1 pump side.
By operating the option remote control valve to the breaker side, the pilot pressure oil is fed to the control valve pa2 port and
switches the option spool.
The discharge oil from hydraulic pump A1 is fed from the control valve P1 port through the parallel oil path and fed to the
option spool.
Switching the spool lets the oil flow from the shut-off valve A port through the B port and into the breaker.
The breaker set pressure is set by the relief valve built into the shut-off valve.
At this time, the option pilot pressure switch signal is detected, the P1 flow control proportional valve is controlled by the output
signals from the computer A to adjust the discharge flow.
The return oil from the breaker returns from the 3-direction valve A1 port through the T1 port and to the hydraulic oil tank.
Because the breaker operating flow can be set to 5 levels on the service support screen of the monitor display, the optimum
operating flow can be selected.

84402826 EN - May 2011

8020B-7
 Explanation of Hydraulic Circuit and Operations (option)
Multi-purpose circuit (2 pumps flow crusher)

84402826 EN - May 2011

8020B-8
 Explanation of Hydraulic Circuit and Operations (option)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

1 3-direction valve 10 Monitor display 19 5 stack solenoid valve

2 Shut-off valve 11 Computer A 20 Console lever lock switch
Horsepower control proportional
3 Crusher 12 Multi-purpose circuit switch 21
valve
4 Option switchover solenoid valve 13 2 pumps flow select switch 22 P1 pressure sensor
5 2 pumps flow solenoid valve 14 Control valve 23 P2 pressure sensor
N1 negative control pressure sen-
6 Option remote control valve 15 Neutral cut valve 24
sor
N2 negative control pressure sen-
7 Check valve 16 Travel pilot pressure sensor 25
sor
8 Oil cooler 17 Upper pilot pressure sensor 26 P1 flow control proportional valve
9 Option pilot pressure switch 18 Lever lock 27 Hydraulic pump

When the 2 pumps flow select switch in the cab is flipped to the 2 pumps flow side, the ON signal (24 V) is output from the
computer A to the 2 pumps flow solenoid valve to switch the valve.
When the multi-purpose circuit switch is flipped to the crusher side, the crusher circuit is formed without outputting a signal
from the computer A to the option switchover solenoid valve and without switching the valve.
At this time, the pilot signal does not go to the 3-direction valve or to the shut-off valve and the 3-direction valve forms the A
⇔ B circuit.
By operating the option remote control valve to the crusher close side, the pilot pressure oil is fed to the control valve pa2 port
and switches the option spool.
At the same time, the pilot pressure oil flows from the solenoid valve for 2 pumps flow B2 port to the A2 port and is fed to the
control valve pcc port and the control valve neutral cut valve is switched.
The discharge oil from hydraulic pump A2 enters the control valve P2 port and goes through the center bypass oil path and
since the neutral cut valve has closed the port to the tank, the oil goes from the P3 port via the P4 port and merges on the
upstream side of the option spool.
The discharge oil from hydraulic pump A1 is fed from the control valve P1 port through the parallel oil path and fed to the
option spool.
Switching the spool lets the oil flow from the shut-off valve A port through the B port and into the crusher.
At this time, the option pilot pressure switch signal is detected, the P1 flow control proportional valve is controlled by the output
signals from the computer A to adjust the discharge flow.
The return oil from the crusher returns from the 3-direction valve A port through the B port and the option spool and returns
to the hydraulic oil tank.
Because the crusher operating flow can be set to 5 levels on the service support screen of the monitor display, the optimum
operating flow can be selected.

84402826 EN - May 2011

8020B-9
 Explanation of Hydraulic Circuit and Operations (option)
2nd option circuit (hydraulic rotation fork)

84402826 EN - May 2011

8020B-10
 Explanation of Hydraulic Circuit and Operations (option)
Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

1 Control valve 6 Console lever lock switch 11 2nd option pilot pressure switch
2 Travel pilot pressure sensor 7 2nd option remote control valve 12 Monitor display
3 Upper pilot pressure sensor 8 Check valve 13 Computer A
4 Lever lock 9 Oil cooler 14 4th pump
5 5 stack solenoid valve 10 Hydraulic rotation fork 15 Hydraulic pump

As an example, this section explains the case in which the hydraulic rotation fork attachment is used.
By operating the 2nd option remote control valve to the right swing side, the pilot pressure oil is fed to the control valve par2
port.
The 4th hydraulic pump OUT discharge oil is fed to the control valve Pr port, goes through the 2nd option spool and flows to
the hydraulic rotation fork to operate to the right swing side.
At this time, the 2nd option pilot pressure switch signal is detected and the auto idle function is released.
The return oil from the hydraulic rotation fork goes through the 2nd option spool and returns to the hydraulic oil tank.
The oil in the 2nd option drain line returns to the hydraulic oil tank without going through the control valve.

84402826 EN - May 2011

8020B-11
 Explanation of Hydraulic Circuit and Operations (option)

This page is intentionally left blank

84402826 EN - May 2011

8020B-12
 Section

8030A

Structure and Operation Explanation of Hydraulic Pump

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Structure and Operation Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Hydraulic Pump Internal Structure Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overall View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Drive Shaft Front Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Drive Shaft Rear Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Part Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Regulator Operation Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Regulator Operation Explanation Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Front Side Regulator Internal Structure Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Rear Side Regulator Internal Structure Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Gear Pump Internal Structure Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Structure and Operation Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

8030A-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
8030A-2 PRINTED IN FRANCE
 Structure and Operation Explanation of Hydraulic Pump

Structure and Operation Explanation

This pump has a structure with 2 pumps positioned on the same shaft coupled with the 1st gear (116) and rotational
force is distributed to different shafts by the gear structure. The 2 pumps are driven by transmitting the rotation of the
power source to the front side drive shaft (111). Auxiliary pumps installed on different shafts can also be driven at the
same time.
The pump can be roughly divided into the rotary group, which is the main part of the pump rotating, the swash plate
group, which changes the discharge flow, the valve block group, which switches between oil suction and discharge,
and the PTO group that transmits the gear pump drive shaft.
The rotary group is made up of 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).
The shoe is caulked to the piston and forms the spherical joint, reduces the thrust force generated by the load pres-
sure, and has a pocket section for balancing the hydraulic pressure for sliding 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 (313) 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 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 back and forth on the swash plate
support board via the tilting pin spherical section and changes the tilting angle (α).
The valve block group comprises the valve block (312), valve plate (313), 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, looking at 1 piston, while the cylinder block turns one rotation, the piston moves away from the valve plate
(oil intake stroke) for 180° of the cylinder block rotation, 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.

84402826 - May 2011

8030A-3
 Structure and Operation Explanation of Hydraulic Pump

Hydraulic Pump Internal Structure

Diagram
Overall View

Drive shaft front side Drive shaft rear side

84402826 - May 2011

8030A-4
 Structure and Operation Explanation of Hydraulic Pump

Drive Shaft Front Side

84402826 - May 2011

8030A-5
 Structure and Operation Explanation of Hydraulic Pump

Drive Shaft Rear Side

84402826 - May 2011

8030A-6
 Structure and Operation Explanation of Hydraulic Pump

Part Table

Code Part name Q'ty Component part No. (Q'ty) or type

04 Gear pump 1 set ZX10LBRZ1-07A-V
011 Piston subassembly 2 sets 151 (9PC), 152 (9PC)
013 Cylinder subassembly (R) 1 set 141 (1PC), 313 (1PC)
014 Cylinder subassembly (L) 1 set 141 (1PC), 314 (1PC)
030 Swash plate subassembly 2 sets 212 (1PC), 214 (1PC)
041 Check valve 1 subassembly 2 sets 541 (1PC), 543 (1PC), 545 (1PC)
042 Check valve 2 subassembly 2 sets 541 (1PC), 544 (1PC), 545 (1PC)
Electromagnetic proportional pressure
079 1 set KDRDE5KR-V3-V
reducing valve, casing subassembly
530 Tilting pin subassembly 2 sets 531 (1PC), 548 (1PC)

1 Right rotation valve plate

2 Left rotation valve plate

Code Part name Q'ty Code Part name Q'ty

111 Drive shaft (F) 1 532 Servo piston 2
113 Drive shaft (R) 1 534 Stopper (L) 2
116 1st gear 1 535 Stopper (S) 2
123 Cylinder roller bearing 2 541 Seat 4
124 Needle roller bearing 2 543 Stopper 1 2
127 Bearing spacer 4 544 Stopper 2 2
141 Cylinder block 2 545 Steel ball 4
151 Piston 18 548 Feedback pin 2
152 Shoe 18 702 O-ring 2
153 Holder plate 2 710 O-ring 2
156 Spherical bushing 2 717 O-ring 4
157 Cylinder spring 18 724 O-ring 16
211 Shoe plate 2 725 O-ring 6
212 Swash plate 2 726 O-ring 2
214 Tilting bushing 2 728 O-ring 4
251 Swash plate support board 2 732 O-ring 2
261 Seal cover (F) 1 774 Oil seal 1
271 Pump casing 2 789 Backup ring 2
312 Valve block 1 792 Backup ring 2
313 Valve plate (R) 1 806 Hexagon nut 2
314 Valve plate (L) 1 808 Hexagon nut 2
326 Cover 1 824 Stop ring 2
401 Hexagon socket head bolt 8 885 Valve plate pin 2
406 Hexagon socket head bolt 4 886 Spring pin 4
414 Hexagon socket head bolt 4 901 Eyebolt 2
466 VP plug 2 953 Hexagon socket head stop screw 2
467 VP plug 2 954 Stop screw 2
468 VP plug 4 981 Nameplate 1
490 Insert plug 27 983 Strike rivet 2
531 Tilting pin 2

84402826 - May 2011

8030A-7
 Structure and Operation Explanation of Hydraulic Pump

Regulator
Regulator Operation Explanation
1. Flow control
• Operation explanation (See the Regulator Operation Explanation Diagram.)
1) Flow control
The pump discharge flow is controlled as desired with the pilot pressure Pi as in the diagram below.

Discharge flow amount Q

Pilot pressure Pi

1) Flow reduction operation

When the pilot pressure Pi increases, the pilot piston (643) moves to the right and stops at the location
where the pilot spring (646) force and hydraulic pressure balance each other. The pin (875) fixed to
lever 2 (613) fits into the grooved section of the pilot piston (643), so, through the movement of the pilot
piston (643), lever 2 rotates with the B section (fastened by the fulcrum plug (614) and pin (876)) as
the fulcrum. The pin (897) fixed to the feedback lever (611) projects into the large opening (C section)
of lever 2 (613), so as lever 2 (613) rotates, the pin (897) moves to the right. The pin (548) fixed to
the tilting pin (531) that shakes the swash plate (212) is bonded to the bolt width section (D section)
of the feedback lever (611). Therefore, as the pin (897) moves, the feedback lever (611) rotates with
D section as the fulcrum. Since the spool (652) is linked to the feedback lever (611) via the pin (874),
the spool (652) moves to the right.
When the spool (652) moves, the discharge pressure Pd1 is led to the servo piston large-diameter
chamber via the spool and CI port. The discharge pressure Pd1 is always led to the servo piston
small-diameter chamber. As a result, the servo piston is moved to the right due to the surface area
difference and reduces the flow.
When the servo piston (532) moves to the right, the D section also moves to the right. The return
spring (654) is mounted on the spool (652). Since force pulling the spool to the left is always operating,
the pin (897) is pressed into the large opening (C section) of lever 2 (613). Therefore, accompanying
the D section movement, the feedback lever (611) rotates around the C section as the fulcrum and
the spool (652) moves to the left. This movement causes the open section between the sleeve (651)
and the spool (652) to begin to close, and the servo piston (532) stops at the point the open section
fully closes.
2) Flow increase operation
When the pilot pressure Pi decreases, the pilot piston (643) is moved to the left by the pilot spring
(646) force and lever 2 (613) rotates with the B section as the fulcrum. The pin (897) is pressed in
the large opening (C section) of lever 2 (613) by the return spring (654) via the spool (652), pin (874),
and feedback lever (611), so accompanying rotation of lever 2 (613), the feedback lever (611) rotates
with the D section as the fulcrum and the spool (652) moves to the left.
When the spool (652) moves, the CI port opens to the tank port, so the pressure in the large-diameter
chamber of the servo piston drains out, the servo piston (532) is moved to the left by the discharge
pressure Pd1 of the small-diameter section and the flow increases.
Accompanying the movement of the servo piston (532), the D section moves to the left, the feedback
lever (611) rotates with the C section as the fulcrum and the spool (652) moves to the right. This
operation continues until the open section between the spool (652) and sleeve (651) closes, and then
the servo piston stops at the point the open section fully closes.
3) High-pressure selection function
The pilot pressure Pi, which serves as the flow control signal, is the pressure for which high pressure
is selected from among multiple command pressures via the shuttle valve subassembly (050).
KR3K-9Y04-HV selects the higher pressure from Pi1 or the proportional valve 2nd pressure and
KR3K-9X04-HV selects the higher pressure from Pi2 or the external command pressure P2.

84402826 - May 2011

8030A-8
 Structure and Operation Explanation of Hydraulic Pump

2. Horsepower control
1) Horsepower control
As the load pressure increases, the pump tilting angle decreases and the overload of the engine is pre-
vented as in the diagram below. Since this regulator uses the simultaneous full-horsepower control method,
the tilting angles (displacement volumes) of the 2 pumps are controlled to be the same value as in the fol-
lowing equation.
Tin = Pd1 x q/2π + Pd2 x q/2π = (Pd1 + Pd2) x q/2π
(q: Displacement volume)
Horsepower control is the same as flow control and is briefly explained below.
(See the pages on Flow control for the detailed movement of each part.)

Discharge flow amount Q

Discharge pressure (Pd1 + Pd2)

1) Overload prevention operation

When the self pump discharge pressure Pd1 or the counterpart pump discharge pressure Pd2 rises,
since Pd1 and Pd2 operate on the stepped section of the compensation piston (621), the compen-
sation rod (623) is pressed to the right and moves to the location where the force of the outer spring
(625) and inner spring (626) balance out the hydraulic pressure force. The movement of the compen-
sation rod (623) is transmitted to lever 1 (612) through the pin (875) and lever 1 (612) rotates around
the pin (876) (E section) fastened to the casing (601). The pin (897) fixed to the feedback lever (611)
projects into the large opening (F section) of lever 1 (612), so as lever 1 (612) rotates, the feedback
lever (611) rotates with the D section as the fulcrum and the spool (652) moves to the right.
When the spool (652) moves, the discharge pressure Pd1 is led to the large-diameter section of the
servo piston via the CI port, the servo piston (532) is moved to the right, and the pump discharge flow
is decreased to prevent overload of the power source.
The servo piston (532) movement is transmitted to the feedback lever (611) via the D section. The
feedback lever (611) rotates with the F section as the fulcrum and the spool (652) moves to the left.
The spool (652) moves until the open section between the spool (652) and sleeve (651) closes, and
then the servo piston stops at the point the open section fully closes.
2) Flow return operation
If the self pump discharge pressure Pd1 or the counterpart pressure pump discharge pressure Pd2
decreases, the compensation rod (623) is pressed back by the outer spring (625) and the inner spring
(626) and lever 1 (612) rotates about the E section. Accompanying the lever 1 (612) rotation, the
feedback lever (611) rotates around the D section as the fulcrum and the spool (652) moves to the left.
Because of this, the CI port opens to the tank port, the servo piston large-diameter section pressure
drains off, the servo piston (532) moves to the left and the pump discharge flow increases.
The movement of the servo piston (532) is transmitted to the spool (652) by the feedback mechanism,
and this operation continues until the open section between the spool (652) and the sleeve (651)
closes.

84402826 - May 2011

8030A-9
 Structure and Operation Explanation of Hydraulic Pump

3. Low tilting (low flow) command priority mechanism

As above, the flow control and the horsepower control tilting command is transmitted to the feedback lever (611)
and spool (652) via the large opening (C and F sections) of lever 1 (612) and lever 2 (613), but since the C and F
sections have a structure in which a pin (D5) projects into a large hole (D9), the pin (897) only contacts the lever
that makes the tilting smaller and the D9 hole for the lever on the side that has the larger tilting command state
does not contact the pin (897), but is free. This type of mechanical selection method gives priority to flow control
and horsepower control commands with low tilting.
4. Power shift control (decreased horsepower control)
Use the power shift pressure Pf to arbitrarily control the pump set horsepower as in the diagram below.
When the power shift pressure Pf increases, the compensation rod (623) is moved to the right via the pin (898)
and the compensation piston (621), so the pump tilting angle is reduced and the horsepower setting is reduced
in the same way as was explained for the operation to prevent overload of the horsepower control. By contrast,
as the power shift pressure Pf decreases, the horsepower setting increases.

Discharge flow amount Q

Discharge pressure (Pd1 + Pd2)

84402826 - May 2011

8030A-10
 Structure and Operation Explanation of Hydraulic Pump

Regulator Operation Explanation Diagram

Connected to CI port servo pis-

*1
ton large bore chamber

84402826 - May 2011

8030A-11
 Structure and Operation Explanation of Hydraulic Pump

KR3K-9Y04-HV KR3K-9X04-HV
Front side Rear side

Hydraulic circuit diagram

84402826 - May 2011

8030A-12
 Structure and Operation Explanation of Hydraulic Pump

Front Side Regulator Internal Structure Diagrams

Hydraulic circuit
84402826 - May 2011
8030A-13
 Structure and Operation Explanation of Hydraulic Pump

1 Front side regulator

2 Rear side regulator

Component part No. (Q'ty) or

Code Part name Q'ty
type
Shuttle valve 545 (1PC), 546 (1PC), 547
050 1 set
subassembly (1PC)
Electromag-
netic propor-
079 1 set KDRDE5K-31/30C50-102
tional pressure
reducing valve

Code Part name Q'ty Code Part name Q'ty Code Part name Q'ty
- Regulator subassem-
1 626 Inner spring 1 728 O-ring 1
bly
Hexagon socket head
412 2 627 Adjusting ring (C) 1 730 O-ring 1
bolt
Hexagon socket head
413 2 628 Adjusting screw (C) 1 732 O-ring 1
bolt
Hexagon socket head
436 4 629 Cover (C) 1 733 O-ring 1
bolt
Hexagon socket head
438 8 630 Lock nut 1 734 O-ring 1
bolt
466 VP plug 1 631 Pf sleeve 1 735 O-ring 1
467 VP plug 1 641 Pilot cover 1 753 O-ring 1
496 Insert plug 12 643 Pilot piston 1 755 O-ring 3
545 Steel ball 1 644 Spring seating (Q) 1 756 O-ring 1
546 Seat 1 1 645 Adjusting ring (Q) 1 763 O-ring 1
547 Seat 2 1 646 Pilot spring 1 801 Hexagon nut 1
601 Casing 1 651 Sleeve 1 802 Hexagon nut 1
611 Feedback lever 1 652 Spool 1 814 Stop ring 1
612 Lever 1 1 653 Spring seating 1 836 Stop ring 1
613 Lever 2 1 654 Return spring 1 858 Locking ring 2
614 Fulcrum plug 1 655 Set spring 1 874 Pin 1
615 Adjusting plug 1 656 Blind cover 1 875 Pin 2
621 Compensation piston 1 708 O-ring 1 876 Pin 2
622 Piston case 1 722 O-ring 3 887 Pin 1
623 Compensation rod 1 724 O-ring 9 897 Pin 1
624 Spring seating (C) 1 725 O-ring 1 898 Pin 1
Hexagon socket head
625 Outer spring 1 727 O-ring 1 924 1
stop screw

84402826 - May 2011

8030A-14
 Structure and Operation Explanation of Hydraulic Pump

Rear Side Regulator Internal Structure Diagram

Hydraulic circuit
84402826 - May 2011
8030A-15
 Structure and Operation Explanation of Hydraulic Pump

Component part No. (Q'ty) or

Code Part name Q'ty
type
Shuttle valve sub- 545 (1PC), 546 (1PC), 547
050 1 set
assembly (1PC)

Code Part name Q'ty Code Part name Q'ty

- Regulator subassembly 1 651 Sleeve 1
412 Hexagon socket head bolt 2 652 Spool 1
413 Hexagon socket head bolt 2 653 Spring seating 1
418 Hexagon socket head bolt 2 654 Return spring 1
436 Hexagon socket head bolt 4 655 Set spring 1
438 Hexagon socket head bolt 8 656 Blind cover 1
466 VP plug 1 708 O-ring 1
467 VP plug 1 722 O-ring 3
496 Insert plug 6 724 O-ring 9
545 Steel ball 1 725 O-ring 1
546 Seat 1 1 727 O-ring 1
547 Seat 2 1 728 O-ring 1
601 Casing 1 730 O-ring 1
611 Feedback lever 1 732 O-ring 1
612 Lever 1 1 733 O-ring 1
613 Lever 2 1 734 O-ring 1
614 Fulcrum plug 1 735 O-ring 1
615 Adjusting plug 1 753 O-ring 1
621 Compensation piston 1 755 O-ring 3
622 Piston case 1 756 O-ring 1
623 Compensation rod 1 763 O-ring 1
624 Spring seating (C) 1 801 Hexagon nut 1
625 Outer spring 1 802 Hexagon nut 1
626 Inner spring 1 814 Stop ring 1
627 Adjusting ring (C) 1 836 Stop ring 1
628 Adjusting screw (C) 1 858 Locking ring 2
629 Cover (C) 1 874 Pin 1
630 Lock nut 1 875 Pin 2
631 Pf sleeve 1 876 Pin 2
641 Pilot cover 1 887 Pin 1
643 Pilot piston 1 897 Pin 1
644 Spring seating (Q) 1 898 Pin 1
Hexagon socket head stop
645 Adjusting ring (Q) 1 924 1
screw
646 Pilot spring 1

KSJ12240-D00S3

84402826 - May 2011

8030A-16
 Structure and Operation Explanation of Hydraulic Pump

Gear Pump
Gear Pump Internal Structure Diagram

Hydraulic circuit

*1 To main pump

Component part No. (Q'ty) or

Code Part name Q'ty
type
307 (1PC), 308 (1PC), 351
Gear case (1PC)
350 1 set
subassembly 353 (1PC), 354 (1PC), 361
(1PC)

84402826 - May 2011

8030A-17
 Structure and Operation Explanation of Hydraulic Pump

Code Part name Q'ty Code Part name Q'ty Code Part name Q'ty
307 Poppet 1 353 Drive gear 1 466 VP plug 1
308 Seat 1 354 Driven gear 1 700 Angle ring 1
309 Ring 1 355 Filter 1 710 O-ring 1
310 Spring 1 361 Front case 1 725 O-ring 1
311 Adjusting screw 1 433 Flange socket 2 732 O-ring 1
312 Lock nut 1 434 Flange socket 2 850 Locking ring 1
351 Gear case 1 435 Flange socket 4

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.

84402826 - May 2011

8030A-18
 Section

8030B

Structure and Operation Explanation of Travel Motor

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Explanation of Component Device Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Double Counter Balance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Crossover Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Automatic 2-speed Switchover Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Parking Brake Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Piston Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Reduction Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

8030B-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
8030B-2 PRINTED IN FRANCE
 Structure and Operation Explanation of Travel Motor

Explanation of Component Device Operation

Double Counter Balance Valve
The purpose of the "double counter balance valve" is to control the speed of the motor according to the feed flow.
Therefore, motor rotation getting away due to external load is prevented.
As the roles of the double counter balance valve, there are
1. The overrun prevention function that controls the piston motor speed to match feed quantity in the state of rota-
tion at or higher than the speed determined by the flow feed from the piston motor for the external load (below,
pumping action).
2. The brake function used together with the crossover relief valve to make up the brake circuit that gradually stops
the rotation of the piston motor by applying braking force to the piston motor rotation.
3. The high-pressure selection shuttle valve function for releasing the parking brake through its own pressure.
Diagram 3 shows a structural diagram of the standard double counter balance valve.
This section explains the operations of each function using this standard double counter balance valve.

Diagram 3 Double counter balance valve structural diagram (stopped state)

a Oil path C1 f Oil path B k Spring chamber 2

c Damper chamber A1 g Oil path C2
e Spring chamber 1 i Damper chamber A2

1) Stopped state (Diagram 3)

When the control valve is in neutral (the motor stopped), since pressure is generated at neither the P1 port
nor the P2 port, the M1 and M2 ports are locked (hydraulically) with the spool (1) and the check valves (2-1)
(2-2) and the piston motor does not rotate.

84402826 - May 2011

8030B-3
 Structure and Operation Explanation of Travel Motor

2) Motor starting (Diagram 4)

When the pressure oil discharged from the hydraulic pump is led to the double counter balance valve P1
port, the check valve (2-1) moves to the left against the spring (3), the oil path C1 (a) is opened, pressure
oil flows from the M1 port into the piston motor and attempts to rotate the piston motor.
On the other hand, the return oil from the piston motor flows from the M2 port into the double counter balance
valve, and then flows to the check valve (2-2). The P1 port side goes to high pressure and operates the
spring chamber 1 (e) and the damper chamber A1 (c), and that oil pressure moves the plunger (1) to the
right against the opposite side spring (7-2) with force proportional to the pressure.
At this time, the M2 port return oil flows through the oil path B (f) in the circumferential notch section of the
plunger (1) and into the P2 port while generating back pressure at the M2 port and this return oil returns to
the tank through the control valve and the piston motor starts rotating.
3) Counter balance function (Diagram 4)
During piston motor rotation, if the piston motor is forced to rotate by the external load, pumping action
occurs in the piston motor, and it runs wild.
In this case, since the P1 port section becomes the suction side of the pump action, that pressure drops.
At the same time, the pressure also drops in the spring chamber 1 (e) and the damper chamber A1 (c).
Therefore, the plunger (1) is moved to the left by the spring (7-2), oil path B (f) is closed, and when the
return oil flow stops, the suction side flow stops at the same time.
When the flow of oil through oil path B (f) is stopped, in an instant, the P1 port side pressure rises again
due to the hydraulic pump discharge oil and this moves the plunger (1) to the right.
In this way, the plunger (1) moves in small steps when there is pumping action due to the external load to
hold the opening surface area of oil path B (f) in an appropriate state.
Therefore, rotation of the piston motor at a speed appropriate to the feed flow from the hydraulic pump is
maintained and vacuum in the hydraulic circuit is prevented. This prevents the piston motor from running
wild.

Diagram 4 Double counter balance valve when motor rotating

g Oil path C2
i Damper chamber A2
k Spring chamber 2

84402826 - May 2011

8030B-4
 Structure and Operation Explanation of Travel Motor

4) Piston motor braking (Diagram 5)

The double counter balance valve makes up the brake circuit together with the crossover relief valve.
When the control valve is returned to neutral, the pressure oil from the hydraulic pump is cut off and the P1
and P2 ports go to the same pressure.
Therefore, the plunger (1) moves to the neutral position, and the oil path B (f) opening surface area becomes
small.
On the other hand, because the piston motor still attempts to rotate due to the inertial energy of the external
load (piston motor pumping action), the M2 port pressure rises and acts as a braking force on the rotation
of the piston motor.
At this time, when the M2 port side pressure reaches the set pressure for the relief valve (8), the M1 port
side poppet (8-1) moves to the left against the spring (8-2) and the pressure oil escapes to the M1 port side.
In this way, the shock pressure due to the M2 port side inertial energy is controlled and at the same time
the occurrence of a vacuum on the M1 port side is prevented.

Diagram 5 Double counter balance valve and relief valve during piston motor braking

a Oil path C1 e Spring chamber 1 i Damper chamber A2

c Damper chamber A1 g Oil path C2 k Spring chamber 2

84402826 - May 2011

8030B-5
 Structure and Operation Explanation of Travel Motor

5) High-pressure selection shuttle valve function (Diagram 6 and Diagram 7)

The double counter balance valve has a high-pressure selection shuttle valve function added for releasing
the parking brake through its own pressure.
When pressure oil is fed from the P1 port, the plunger (1) moves to the right side creating the state in
Diagram 6.
Therefore, the motor case drain oil path F (m) is closed, the oil path D (l) to the parking brake cylinder
chamber E (p) is opened, the pressure oil is led into oil path G (o) via the orifice (n) and flows into the
parking brake cylinder chamber E (p), releasing the parking brake.
Also, when the piston motor stops, the plunger (1) returns to the neutral state of diagram 7, the oil path D
(l) closes, and the motor case drain oil path F (m) opens, so the oil in the parking brake cylinder chamber
E (p) is led to the motor case drain and the parking brake operates.

Diagram 6 High-pressure selection function High-pressure selection

84402826 - May 2011

8030B-6
Structure and Operation Explanation of Travel Motor

Diagram 7 High-pressure selection function Release to motor case drain

84402826 - May 2011

8030B-7
 Structure and Operation Explanation of Travel Motor

Crossover Relief Valve

The purpose of the "crossover relief valve" is to determine the motor drive force and braking force.
Therefore, this valve has a shockless function to soften the shock of motor starting and stopping in order to provide
good operability.
Diagram 8 shows the structure of the relief valve.
This relief valve has a shockless function for reducing the shock that occurs at the start of startup and braking of the
differential surface area type direct action relief valve.

Diagram 8 Structure of relief valve

1. Relief valve operation and functions
When the control valve moves and the piston motor is started up or braked, when the poppet (2-9-2) front surface
pressure rises above the set pressure, this pressure wins out over the spring (2-9-5), the poppet (2-9-2) moves to
the right and separates from the poppet seat (2-9-3), and the high-pressure oil at the poppet (2-9-2) front surface
bypasses to the low-pressure oil path.
In this way, by allowing the high-pressure oil to bypass to the low-pressure oil path, the shock pressure due to
the inertial energy of the high-pressure oil path is controlled and at the same time the occurrence of a vacuum in
the low-pressure oil path is prevented.

Diagram 9 Shockless function operation

84402826 - May 2011

8030B-8
 Structure and Operation Explanation of Travel Motor

2. Shockless function (Diagram 10)

When the relief valve starts to operate, the shockless piston (2-9-9) moves to the left.
Therefore, inside the spring chamber D, the pressure is held low.
Therefore, the surface of the poppet (2-9-2) pressurized area becomes S1, a quite large pressurized area com-
pared to the pressurized area S1 - S2 for the normal relief valve setting.
Therefore, while the shockless piston (2-9-9) movement is completing, the relief valve operating pressure is held
to about 1/3 of the normal set pressure, absorbing the shock pressure due to the inertial energy of the high-
pressure oil path.
When the shockless piston movement is complete, the pressure inside the spring chamber D rises, the pressure
in front and behind the poppet (2-9-2) become equal, and the relief valve operates with its normal set pressure.

Pressure Pressure

Time Time
Conventional type Shockless type
Diagram 10 Shockless function and pressure wave comparison

q Area S2
r Area S1
s Spring chamber D

Operating the relief valve in 2 stages in this way reduces the shock that occurs when the piston motor is started or
braked and provides good operability.
Diagram 10 compares the pressure waveforms of the conventional type and the shockless type.

84402826 - May 2011

8030B-9
 Structure and Operation Explanation of Travel Motor

Automatic 2-speed Switchover Mechanism

This motor has the automatic "2-speed switchover mechanism" that can switch the motor between 2 speeds, low
speed and high speed.
1. Motor low-speed (high-capacity) position
Diagram 11 shows the state with the motor capacity fixed to the low-speed (high-capacity) position. When the
speed control switch is set to low speed and the pilot pressure acting on the Ps port is released to the tank, the
motor capacity control valve built into the motor is fixed to the low-speed (high-capacity) position.
2. Automatic 2-speed position that selects the motor capacity according to the load pressure
Diagram 12 shows the state of the automatic 2-speed position that selects the motor capacity according to the
load pressure.
When the speed control switch is set to high speed and the regulation pressure is allowed to operate on the Ps
port, the pressure oil operating on the Ps port operates on the front surface of the motor capacity control valve
built into the motor and the position becomes the automatic 2-speed position that switches the motor capacity
according to the load pressure going to the motor.
3. High-speed motor state for automatic 2-speed position
Diagram 13 shows the high-speed motor state for the automatic 2-speed position.
When the regulation pilot pressure is allowed to operate on the Ps port, the pilot pressure oil operates on the
pilot hydraulic chamber on the motor capacity control valve front surface via oil path A and this pushes the motor
capacity control valve to the right. Also, the load pressure Pin on the motor operates on the motor load pressure
chamber via oil path B and pushes the motor capacity control valve to the left. When Pin is lower than the motor
capacity control pressure P determined by the ratio of the pilot pressure pressurized area and the motor load
pressure pressurized area, the motor capacity control valve is held in the state in Diagram 13 and the motor
operates in high-speed (low-capacity) mode.
4. Low-speed motor state for automatic 2-speed position
Diagram 14 shows the low-speed motor state for the automatic 2-speed position.
When the load pressure pin on the motor rises and becomes higher than the motor capacity control pressure
P discussed above, the motor capacity control valve moves to the left, switching the motor to low-speed (high-
capacity) mode, so the motor operates at low speed.

84402826 - May 2011

8030B-10
Structure and Operation Explanation of Travel Motor

Diagram 11 Motor high-speed (high-capacity) fixed mode

t Pilot pressure
u Pressure in motor
v Motor load pressure

84402826 - May 2011

8030B-11
Structure and Operation Explanation of Travel Motor

Diagram 12 Automatic 2-speed control mode using load pressure

t Pilot pressure
u Pressure in motor
v Motor load pressure

84402826 - May 2011

8030B-12
Structure and Operation Explanation of Travel Motor

Diagram 13 Motor high-speed (low-capacity) position for automatic 2-speed mode

t Pilot pressure w Pilot oil pressure chamber

u Pressure in motor x Oil path A
v Motor load pressure y Motor load pressure chamber

84402826 - May 2011

8030B-13
Structure and Operation Explanation of Travel Motor

Diagram 14 Motor low-speed (high-capacity) position for automatic 2-speed mode

t Pilot pressure w Pilot oil pressure chamber

u Pressure in motor x Oil path A
v Motor load pressure y Motor load pressure chamber

84402826 - May 2011

8030B-14
 Structure and Operation Explanation of Travel Motor

Parking Brake Function

The "parking brake function" is built into the piston motor. When the motor is stopped, the mechanical brake operates
to prevent the motor from being rotated due to external load by locking the motor shaft.
Diagram 15 shows a structural diagram of the parking brake section.
The parking brake is made up of the disks (1) coupled with the cylinder block (z), the friction plate (2) mounted between
the disks, the brake piston (3), and the spring (4) that applies force to the brake piston.
A. Releasing the parking brake (Diagram 15)
When pressure oil is fed from the P1 port and attempts to start driving the piston motor, when the "High-pressure
selection shuttle valve function" explained in Item E of "[1] Double Counter Balance Valve" leads pressure oil to the
parking brake cylinder chamber E (ac) via oil path D, the hydraulic pressure force (aa) operates on the brake piston
(3) and moves it to the left against the spring (4).As a result, the force pressing the disks (1) disappears, the disks
(1) enter the free state, and the parking brake is released.
B. Operating the parking brake (Diagram 16)
When the control valve is returned to the neutral position, the feed of pressure oil to the P1 port is cut off, and an
attempt is made to stop the piston motor, because the "High-pressure selection shuttle valve function" explained in
Item E of "[1] Double Counter Balance Valve" connects oil path D to motor case drain oil path F, the pressure oil
in the parking brake cylinder chamber E (ac) is led to the motor case drain and the pressure drops.Therefore, the
brake piston (3) is moved to the right side by the spring (4), the disks (1) are tightened with the force (ad) of the
spring (4) by the brake piston (3) and motor case (ab), so the piston motor shaft is locked and the parking brake
operates.

Diagram 15 Parking brake released state Diagram 16 Parking brake engaged state

84402826 - May 2011

8030B-15
 Structure and Operation Explanation of Travel Motor

Piston Motor
The "piston motor" is a swash plate-type piston motor that converts the fluid energy of the pressure oil sent from the
hydraulic pump into mechanical energy and outputs high-speed, low-torque power.
A swash plate-type piston motor is used as the piston motor.
Diagram 17 shows a structural diagram of the piston motor.
9 pistons (4-2) are incorporated in the cylinder block (4-1) and the end of the cylinder block (4-1) touches a valve plate
(22) that has 2 sausage-shaped ports, B and C. The pressure oil discharged from the hydraulic pump flow in from the
P1 port or the P2 port and while the piston motor rotates, flows out from the P2 port or P1 port.
Also, the drain oil in the case that has leaked from the sliding sections and the gap returns to the hydraulic tank from
the base plate (2-1) T1 or T2 port.
1. The high-pressure oil from the P1 port enters the valve plate (22) sausage-shaped B port, the piston (4-2) is
pressurized, and the top of the swash plate (5) rotates and moves from top dead center to bottom dead center.
2. The P2 port becomes the low-pressure side and while the piston (4-2) rotates and moves from bottom dead
center to top dead center, the oil is discharged to the P2 port via the valve plate (22) sausage-shaped C port.
3. Accompanying the reciprocal movement of the piston (4-2), the cylinder block (4-1) and the shaft (3) spline cou-
pled to it rotate in the counter-clockwise direction of the arrow in the diagram.
4. When the piston motor rotates clockwise, the P1 port side becomes the low-pressure side and the P2 port side
becomes the high-pressure side.
In this way, the piston motor converts the fluid energy of the pressure oil sent from the hydraulic pump into mechanical
energy and outputs high-speed, low-torque rotation power. Also, the piston motor torque and speed are determined
by the pressure and flow. Therefore, the larger the pressure and flow, the higher the piston motor torque and speed.

Diagram 17 Piston motor structural diagram

a C port
b B port

84402826 - May 2011

8030B-16
 Structure and Operation Explanation of Travel Motor

Reduction Gear
Diagram 18 shows a structural diagram of the reduction gear.
The reduction gear structure combines in two stages the simple planetary reduction gear system made up of the drive
gear, sun gear, holder, planetary gear, and ring gear (with teeth cut in the inner diameter of the housing).
When pressure oil flows into the piston motor, the piston motor shaft rotates at high speed and power is input to the
reduction gear section.In the reduction gear section, this high-speed rotation has its speed reduced in 2 stages by
the simple planetary 2-stage reduction system. Low-speed, high-torque output is obtained from the rotation of the
housing with ring gears (1-3) (2-3).
1. 1st stage reduction section operation
The 1st stage reduction section comprises the drive gear (1-1), planetary gear A (1-2), ring gear (1-3), holder
(1-4), needle bearing (1-5), and inner race (1-6).
The planetary gear A (1-2) meshes with the drive gear (1-1). When the drive gear (1-1) rotates clockwise, the
planetary gear A (1-2) rotates counter-clockwise. On the other hand, since it meshes with the ring gear, it kicks
the tooth of the ring gear and tries to revolve clockwise around the circumference of the drive gear (1-1).
Because the planetary gear (1-2) is fixed in a state in which it rotates freely on the holder (1-4) via the needle
bearing (1-5), this clockwise revolution movement is transmitted to the holder (1-4) and the holder (1-4) starts to
rotate in the clockwise direction.
Also, since the holder (1-4) is spline coupled with the 2nd stage sun gear (2-1), this holder (1-4) rotation is trans-
mitted to the 2nd stage sun gear (2-1).
2. 2nd stage reduction section operation
The 2nd stage reduction section comprises the sun gear (2-1), planetary gear B (2-2), ring gear (2-3), holder
(2-4), needle bearing (2-5), and inner race (2-5).
The planetary gear B (2-2) meshes with the sun gear (2-1). When the sun gear (2-1) rotates clockwise, the
planetary gear B (2-2) rotates counter-clockwise.
The planetary gear B (2-2) is fixed in a state in which it rotates freely on the holder (2-4) via the needle bearing
(2-5). Furthermore, the holder (2-4) is coupled to the flange (5) by the bolts (3) (4) and the flange (5) is fastened
to the frame of the machine main unit, so it cannot rotate.
Therefore, the planetary gear B (2-2) cannot revolve as in the 1st stage reduction section and rotates counter-
clockwise at the position at which it was incorporated. Also, because the planetary gear B (2-2) is meshed with
the ring gear, the counter-clockwise revolution of the planetary gear B (2-2) is transmitted to the ring gear and
the ring gear is rotated counter-clockwise.
Through the above action, the housings (1-3) (2-3) with the ring gear cut into their inner diameters receive the
force of the planetary gears (2-2) (1-2) and rotate. This transmits power to the driven section of the machine main
unit which is coupled with the housings (1-3) (2-3).

84402826 - May 2011

8030B-17
Structure and Operation Explanation of Travel Motor

Diagram 18 Reduction gear structural diagram　

a Piston motor shaft

Secured to machine main unit
b
frame
c Connected to driven section of
machine

84402826 - May 2011

8030B-18
 Section

8030C

Structure and Operation Explanation of Swing Motor

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Swing Motor Operation Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Hydraulic Motor Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Valve Casing Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Brake Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Relief Valve Operation Explanation (relief valve model: KRD22EK10). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Swing Motor Internal Structure Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

8030C-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
8030C-2 PRINTED IN FRANCE
 Structure and Operation Explanation of Swing Motor

Swing Motor Operation

Explanation
Hydraulic Motor Section
As the diagram below shows, when the high-pressure oil passes through the valve plate (1) inlet-side port (a) and flows
into the cylinder, the hydraulic pressure operates on the piston (5) and a force F is generated in the axial direction.
This force F is divided into 2 vectors, a force F1 perpendicular to the swash plate (3) via the shoe (2) and a force F2
perpendicular to the shaft.
This force F2 is transmitted to the cylinder block (4) via the piston (5), generating a rotational couple around the output
shaft.
9 pistons (5) are arrayed in the cylinder block. Rotation torque is transmitted sequentially to the output shaft (6) by
multiple pistons (5) linked with the high-pressure oil inlet-side port.
When the oil in and out directions are reversed, the rotation of the output shaft (6) also reverses.
The theoretical output torque T [N·m] is given by the following equation.

Diagram 1 Motor section operation explanation diagram

q Compartments per rotation

[cm3]
p Effective pressure difference
[MPa]

*1 Low-pressure oil *3 Outlet

*2 High-pressure oil *4 Inlet

84402826 - May 2011

8030C-3
 Structure and Operation Explanation of Swing Motor

Valve Casing Section

1. Anti-cavitation check section
Because the system using this type of motor does not have a valve with a counter-balance function, the motor
sometimes rotates more than the quantity of oil fed.
In order to prevent cavitation due to insufficient oil, there is a check valve to take in the oil shortfall.

Diagram 2 Hydraulic circuit diagram

1 M port
2 Control valve

84402826 - May 2011

8030C-4
 Structure and Operation Explanation of Swing Motor

Brake Section
The cylinder (111) is coupled with the drive shaft (101) by the gear. Also, the separator plate (743) is constrained for
circumferential rotation by the arc groove cut into the casing (301).
When the friction plate (742) that is gear coupled to the cylinder outer circumference section is pressed to the casing
(301) by the brake spring (712) via the separator plate (743) and the brake piston (702), friction force is generated
between the friction plate and casing and between the separator plate and the brake piston. The drive shaft is con-
strained and braked by this friction force.
On the other hand, when brake release pressure is applied to the oil chamber (1) formed between the brake piston
and the casing and the hydraulic pressure (3) wins out over the spring force (2), the brake piston moves, the force
pressing the friction plate against the casing disappears, and the brake is released.

Diagram 3 Brake operation diagram

84402826 - May 2011

8030C-5
 Structure and Operation Explanation of Swing Motor

Relief Valve Operation Explanation (relief valve model: KRD22EK10)

1. Operation explanation for when the relief valve is pressurized
In the case where the P port is pressurized with the tank pressure,the P and R ports are initially at the tank
pressure and the valve status is as shown in Diagram 4 (1).
At the pressure where there is balance between the hydraulic pressure determined by the product of the pressure
P and the pressurized area A1 of the plunger (301) on the one hand and the hydraulic pressure determined by
the product of the spring (321) load FSP and plunger (301) pressurized area A2 and the g chamber pressure Pg
on the other, the relief valve starts to operate.
After that, the g chamber pressure rises and the piston (302) starts its stroke.
Accompanying this movement, the load on the spring (321) increases.
Through the operation above, the relief pressure P is increased from P1 to Ps in the pressure boost time t1.
This process is explained below in terms of the relationship between the movement state of the parts in diagrams
4-(2) - (4) and the relief pressure.
1) State shown in Diagram 4-(2)
When the relief valve P port is pressurized, pressure is generated in the g chamber via the orifice m in the
plunger (301).
When the hydraulic pressure operating on the plunger (301) increases and reaches the pressure at which
it balances the spring (321) load FSP, the relief valve carries out the relief operation at pressure P1.
The relationship at this time is expressed by the following equation.
P1 x A1 = FSP1 + Pg1 x A2 FSP1: Initial set load for the spring (321)
2) State shown in Diagram 4-(3)
The g chamber pressure operates on pressurized areas A3 and A4 of the piston (302).
When this hydraulic pressure becomes larger than the load on the spring (321), the piston starts to move
to the left.
At this time, the oil in the h chamber formed between the piston and the adjusting plug (401) is discharged
into the g chamber via the orifice n set up on the piston (302) while the piston moves to the left, so the h
chamber functions as a damping chamber.
Through this, the spring load gradually increases until the piston reaches the adjusting plug end section
and the relief pressure P rises smoothly.
3) State shown in Diagram 4-(4)
When the piston (302) reaches the adjusting plug (401) end section, it does not move farther to the left, so
the constant relief state is reached and the relief pressure is held at P2.
Through the processes (1) - (4) above, the relief pressure varies as in Diagram 5.
2. Operation explanation for when the relief valve is depressurized
In the case where the P port pressure falls,the P port pressure and the g chamber pressure fall together to the
tank pressure when the pressurization of the P port ends.
Through this process, the plunger (301) which was open moves to the left and is placed in the seat (401).
At the same time, the piston (302) also is moved to the right by the spring (321) and returns to the state in Diagram
4-(1).

84402826 - May 2011

8030C-6
 Structure and Operation Explanation of Swing Motor

Diagram 4 Relief valve operation explanation diagram

a Orifice m c A1 pressurized area e g chamber

b h chamber d Orifice n

84402826 - May 2011

8030C-7
Structure and Operation Explanation of Swing Motor

Diagram 5 Pressure boost characteristics

84402826 - May 2011

8030C-8
 Structure and Operation Explanation of Swing Motor

Swing Motor Internal Structure Diagram

84402826 - May 2011

8030C-9
Structure and Operation Explanation of Swing Motor

Brake spring layout diagram

84402826 - May 2011

8030C-10
Structure and Operation Explanation of Swing Motor

Code Part name Q'ty

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

Code Part name Q'ty

051 Relief valve 2 sets
051-1 O-ring 2
10 Piston subassembly 1 set
101 Drive shaft 1
111 Cylinder 1
114 Plate spring 1
121 Piston 9
122 Shoe 9
123 Holder plate 1
124 Shoe plate 1
131 Valve plate B 1
20 Valve casing H2 subassembly 1 set
301 Casing K1 1
303 Valve casing H2 1
351 Plunger H2 2
355 Spring H2 2
390 Nameplate 1
391 Driving tack 2
401 Hexagon socket head bolt 4
443 Cylinder roller bearing 1
444 Cylinder roller bearing 1
451 Pin 2
469 ROMH plug 2
472 O-ring 1
488 O-ring 2
491 Oil seal 1
702 Brake piston 1
706 O-ring 1
707 O-ring 1
712 Brake spring 14
742 Friction plate 3
743 Separator plate 4
983 Masking plug 2 sets
984 Masking plug 1 set
985 Masking plug 1 set
986 Masking plug 1 set

84402826 - May 2011

8030C-11
Structure and Operation Explanation of Swing Motor

84402826 - May 2011

8030C-12
 Section

8030D

Structure and Operation Explanation of Control Valve

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Structure and Operation Explanation of Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Basic configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

8030D-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
8030D-2 PRINTED IN FRANCE
 Structure and Operation Explanation of Control Valve

Structure and Operation Explanation of Control Valve

Basic configuration
This valve is based on the main unit housing which combines the P1 side housing and P2 side housing with the rear
surfaces against each other and has a configuration that makes it possible to mount the inlet, add-on section, and
outlet on the P2 side housing top.
Operation
1. When all spools in neutral
1) Neutral path [Fig. 1, Fig. 2]
1) When Pn1 and Pn2 ports are pressurized
The oil fed from the P1 port enters the tank path (Ta) from the neutral path (L1) through the low-
pressure relief orifice (Lc1) and returns to ports T1 - T8.
The oil fed from the P2 port enters the tank path (Ta) from the neutral path (R1) through the low-
pressure relief orifice (Rc1) and returns to the T1 - T8 ports.
The pressure in the pressure chambers (L2) and (R2) upstream from the low-pressure relief valve is
led into the pump from the ps1 and ps2 ports and controls the P1 and P2 pump discharge volume.
Also, if excess oil flows into the neutral path (L1), the poppet opens to provide low-pressure relief.
This prevents the ps1 and ps2 port pressures from becoming abnormally high.
2) When Pn1 and Pn2 ports are not pressurized
In this case, the low-pressure relief poppets open at lower pressure than in (a).
Therefore, the oil fed from the P1 port enters the tank path (Ta) from the neutral path (L1) primarily
through the low-pressure relief valve discharge port (L3) and returns to the T1 - T8 ports.
Also, the oil fed from the P2 port enters the tank path (Ta) from the neutral path (R1) primarily through
the low-pressure relief valve discharge port (R3) and returns to the T1 - T8 ports.

84402826 - May 2011

8030D-3
Structure and Operation Explanation of Control Valve

84402826 - May 2011

8030D-4
Structure and Operation Explanation of Control Valve

84402826 - May 2011

8030D-5
 Structure and Operation Explanation of Control Valve

1 Low-pressure relief valve (L) 6 Travel 11 Arm 2

2 Arm 1 7 Outlet 12 Boom 1
3 Boom 2 8 Attachment 2 13 Bucket
4 Swing 9 Inlet 14 Straight travel
5 Option 10 Attachment 1 15 Low-pressure relief valve (R)

a (Section 5) f P1 side k (Section 7)

b (Section 4) g (Section R2 ) l (Section 6)
c (Section 3) h (Section R1) m (Section ST)
d (Section 2) i (Section 9) n P2 side
e (Section 1) j (Section 8)

84402826 - May 2011

8030D-6
Structure and Operation Explanation of Control Valve

84402826 - May 2011

8030D-7
Structure and Operation Explanation of Control Valve

84402826 - May 2011

8030D-8
 Structure and Operation Explanation of Control Valve

Variable arm regeneration ori-

1 6 Travel 11 Boom 1
fice
2 Arm 1 7 Attachment 2 12 Bucket
3 Boom 2 8 Attachment 1 13 Travel
4 Swing 9 Neutral cut 14 Straight travel
5 Option 10 Arm 2

a Open j (Section R2 ) s Down

b Close k (Cylinder extension) t Up
c (Section 5) l (Cylinder retraction) u (Section 8)
d Up m Down v Close
e Down n Up w Open
f (Section 4) o (Section R1) x (Section 7)
g (Section 3) p Close y (Section 6)
h (Section 2) q Open z (Section ST)
i (Section 1) r (Section 9)

84402826 - May 2011

8030D-9
 Structure and Operation Explanation of Control Valve

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.

84402826 - May 2011

8030D-10
 Structure and Operation Explanation of Control Valve

Straight travel signal control

1 5 Boom 9 Option
valve
2 Travel 6 Arm 10 Add-on (main pump)
Main unit housing section (op-
3 7 Bucket
tion)
4 Plate assembly 8 Swing

a RCV Remote control valve c RCV Remote control valve e RCV Remote control valve
b MCV d MCV f MCV

84402826 - May 2011

8030D-11
 Structure and Operation Explanation of Control Valve

2. Independent operation
1) Travel spool switchover [Fig. 4 and Fig. 5]
When a travel spool is switched by pressurizing from the travel (section 1) pilot port Pb1 (Pa1), the oil fed
from the P1 port flows from the neutral path (L1) through the spool neck section and into the B1 (A1) port.
The return oil returns to the tank path (Ta) from the A1 (B1) port through the spool neck section.
When a travel spool is switched by pressurizing from the travel (section 6) pilot port Pb6 (Pa6), the oil fed
from the P2 port flows from the neutral path (R1) through the spool neck section or path (S6-1) and into the
B6 (A6) port.
For independent travel operation, the parallel path (R3) and the path (S6-1) have the same pressure, so
the poppet (S6-2) does not open. The return oil returns to the tank path (Ta) from the A6 (B6) port through
the spool neck section.

1 Switching state 3 Option

2 Neutral state 4 Travel

a (Section 2)
b (Section 6)

84402826 - May 2011

8030D-12
Structure and Operation Explanation of Control Valve

1 Switching state 3 Travel

2 Neutral state 4 Straight travel

a (Section 1)
b (Section ST)

84402826 - May 2011

8030D-13
 Structure and Operation Explanation of Control Valve

2) Option spool switchover [Fig. 4]

When the option spool is switched by pressurizing from the option (section 2) pilot port Pb2 (Pa2), the
neutral path (L1) is closed. The oil fed from the P1 port flows from the parallel path (L3) through the load
check valve (S2-2), path (S2-1), and the spool neck section, and into the B2 (A2) port.
The return oil returns to the tank path (Ta) from the A2 (B2) through the spool neck section.
Also, when oil is fed from the P4 port, it passes through the inside of the load check valve (S2-2) and merges
with path (S2-1).

1 Switching state 3 Option

2 Neutral state 4 Travel

a (Section 2)
b (Section 6)

84402826 - May 2011

8030D-14
Structure and Operation Explanation of Control Valve

1 Switching state 3 Travel

2 Neutral state 4 Straight travel

a (Section 1)
b (Section ST)

84402826 - May 2011

8030D-15
 Structure and Operation Explanation of Control Valve

3) Swing spool switchover [Fig. 6]

When the swing spool is switched by pressurizing from the swing (section 3) pilot port Pb3 (Pa3), the neutral
path (L1) is closed. The oil fed from the P1 port flows from the parallel path (L3) through the load check
valve (S3-2), path (S3-1), and the spool neck section, and into the B3 (A3) port.
The return oil returns to the tank path (Ta) from the A3 (B3) through the spool neck section.

1 Switching state 3 Swing

2 Neutral state 4 Bucket

a (Section 3)
b (Section 7)

84402826 - May 2011

8030D-16
 Structure and Operation Explanation of Control Valve

4) Bucket spool switchover [Fig. 7 and Fig. 8]

1) Close (regeneration) [Fig. 7]
When the bucket spool is switched by pressurizing from the bucket (section 7) pilot port Pb7, the
neutral path (R1) is closed. The oil fed from the P2 port flows through the parallel path (R3), the load
check valve (S7-2), path (S7-1), and the spool neck section, and into the B7 port.
At the same time, the return oil from the A7 port returns to the tank path (Ta).
After part of the return oil pushes open the poppet (S7-3) inside the bucket spool, it merges into the
B7 port to prevent cylinder head side cavitation.
Cylinder speed increase and P2 port pressure reduction effects also accompany depending on the
port pressure conditions.

Bucket close (regeneration)

1 Neutral state 3 Swing

2 Switching state 4 Bucket

a (Section 3)
b (Section 7)

84402826 - May 2011

8030D-17
Structure and Operation Explanation of Control Valve

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.

Bucket open

1 Neutral state 3 Swing

2 Switching state 4 Bucket

a (Section 3)
b (Section 7)

84402826 - May 2011

8030D-18
 Structure and Operation Explanation of Control Valve

5) Boom spool switchover [Fig. 9, Fig. 10, and Fig. 11]

1) Neutral [Fig. 9]
This valve mounts an anti-drift valve on the boom 1 cylinder head (A8) side.
In neutral, the poppet (AD1) is reliably seated by the pressure of the A8 port itself led through path
(AD2) and the spool (AD3) into the spring chamber (AD4) to cut off the return oil from the A8 port.

Neutral

1 Boom 2
2 Boom 1

a (Section 4)
b (Section 8)

84402826 - May 2011

8030D-19
Structure and Operation Explanation of Control Valve

2) Boom up (2 pumps flow) [Fig. 10]

When the boom 1 spool is switched by pressurizing from the boom 1 (section 8) pilot port Pa8, the
neutral path (R1) is closed. The oil fed from the P2 port flows through the parallel path (R3), the load
check valve (S8-2), and the spool neck section and into the A8 port.
When the boom 2 spool is switched by pressurizing from the boom 2 (section 4) pilot port Pa4, the
neutral path (L1) is closed. The oil fed from the P1 port flows through the parallel path (L3), the load
check valve (S4-2), the spool neck section, and path (4) and merges into the A8 port. The return oil
returns to the tank path (Ta) from the B8 port through the spool neck section.

Up (2 pumps flow)

1 Boom 2
2 Boom 1

a (Section 4)
b (Section 8)

84402826 - May 2011

8030D-20
Structure and Operation Explanation of Control Valve

3) Boom down (regeneration) [Fig. 11]

When the boom 1 spool is switched by pressurizing from the boom 1 (section 8) pilot port pb8, the
neutral path (R1) is closed. The oil fed from the P2 port flows through the parallel path (R3), the load
check valve (S8-2), and the spool neck section and into the B8 port.
The pilot pressure applied to pb8 at this time moves the anti-drift valve spool (AD3) through the path
built into the housing at the same time that the spool is switched and reduces the pressure of the
spring chamber (AD4) to open the poppet (AD1).
Through this movement, the cutoff of the A8 port is released before the spool is switched.
After that, the return oil from the A8 port returns to the tank path (Ta).
Part of the return oil pushes open the poppet (S8-3) inside the boom 1 spool, passes through path
(S8-1), and merges into the B8 port to prevent cylinder rod side cavitation.
Cylinder speed increase and P2 port pressure reduction effects also accompany depending on the
port pressure conditions.

Down (regeneration)

1 Boom 2
2 Boom 1

a (Section 4)
b (Section 8)

84402826 - May 2011

8030D-21
 Structure and Operation Explanation of Control Valve

6) Arm spool switchover [Fig. 12 - 15]

1) Neutral [Fig.12]
This valve mounts an anti-drift valve on the arm 1 cylinder rod side.
In neutral, the poppet (AD1) is led through path (AD2) and the spool (AD3) into the spring chamber
(AD4). It is reliably seated by the pressure of the A5 port itself to cut off the return oil from the A5 port.

Neutral

1 Arm 1
2 Arm 2

a (Section 5)
b (Section 9)

84402826 - May 2011

8030D-22
Structure and Operation Explanation of Control Valve

2) Arm in (2 pumps flow) [Fig. 13]

When the arm 1 spool is switched by pressurizing from the arm 1 (section 5) pilot port Pb5, the oil fed
from the P1 port flows from the neutral path (L1) through the load check valve (S5-2), path (S5-1),
and the spool neck section and into the B5 port. When the arm 2 spool is switched by pressurizing
from the arm 2 (section 9) pilot port Pb9, the oil fed from the P2 port flows from the neutral path (R1)
through the load check valve (S9-2), path (S9-1), the spool neck section, and path (6) and merges
into the B5 port.
The pilot pressure applied to pb5 at this time moves the anti-drift valve spool (AD3) through the path
built into the housing at the same time that the spool is switched and reduces the pressure of the
spring chamber (AD4) to open the poppet (AD1). Through this movement, the cutoff of the A5 port is
released before the spool is switched.
After that, the return oil from the A5 port splits into the flow through the regeneration check in the spool
that is regenerated at the B5 port and the flow returning to the tank path (Ta) through the regeneration
control valve.
(For details on the regeneration function, see the regeneration valve operation explanation in next
section 3).)

Arm in (2 pumps flow)

1 Arm 1
2 Arm 2

a (Section 5)
b (Section 9)

84402826 - May 2011

8030D-23
Structure and Operation Explanation of Control Valve

3) Arm in (variable regeneration) [Fig. 14]

For an arm-in operation, after the return oil from the A5 port passes through the notch (a), it divides
into 2 paths:
1. The return oil returns to the tank path (Ta) through the fixed orifice (d) in the 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)

84402826 - May 2011

8030D-24
Structure and Operation Explanation of Control Valve

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)

84402826 - May 2011

8030D-25
 Structure and Operation Explanation of Control Valve

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

84402826 - May 2011

8030D-26
 Structure and Operation Explanation of Control Valve

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.

84402826 - May 2011

8030D-27
Structure and Operation Explanation of Control Valve

2) Overload relief valve [Fig. 18]

There is an overload relief valve at the boom 1, arm 1, bucket, and add-on cylinder ports to prevent
any abnormal rise in actuator pressure, for example due to an external force.
This relief valve is also equipped with a function for preventing cavitation (suction function) by taking
in oil from the tank when the cylinder port pressure becomes negative pressure.

a Suction function Operating

84402826 - May 2011

8030D-28
 Structure and Operation Explanation of Control Valve

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.

84402826 - May 2011

8030D-29
 Structure and Operation Explanation of Control Valve

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

84402826 - May 2011

8030D-30
Structure and Operation Explanation of Control Valve

2) Main unit circuit [Fig. 20]

When the straight travel spool is switched, the oil fed from the P1 port flows from the neutral path (L1)
to travel (section 1) and at the same time passes through path (2), the straight travel spool neck sec-
tion, and the neutral path (R1) and into travel (section 6) and feeding to travel left and right becomes
possible.
On the other hand, when the oil fed from the P2 port flows to the parallel path (R3), at the same time
it passes through the straight travel spool neck section and path (1) and into the parallel path (L3), so
it becomes possible to feed oil to the entire front system.
When the front system is switched during travel and that pressure becomes higher than the load
pressure on travel (section 6), part of the oil fed from the P2 port pushes up the poppet (S6-2) from
the parallel path (R3) and the oil flows through the orifice at the poppet tip and merges into path (S6-1).
This softens the shock on the machine body of the sharp drop in speed caused by the switchover to
1 pump travel.
As described above, because travel (sections 1 and 6) operates with the oil fed from the P1 port and
operations other than travel are operated with oil fed from the P2 port, travel curving is prevented and
straight travel characteristics are maintained during compound operations.

84402826 - May 2011

8030D-31
 Structure and Operation Explanation of Control Valve

1 Switching state 3 Straight travel

2 Travel 4 Travel

a (Section 1)
b (Section 6)
c (Section ST)

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

1 Main spool

84402826 - May 2011

8030D-32
 Structure and Operation Explanation of Control Valve

2) Release signal application

1) When the pi port is pressurized, the piston (2) moves and the spool (3) operates.
2) Furthermore, the spool (3) operates the poppet (4).
3) Then, the operation of the poppet (4) cuts off the connection between the A5 port and the spring
chamber (d).

1 Main spool

3) Ending hold state

1) When the piston (2) operates further, the spring chamber (d) passes from path (c) through path (e)
and is connected to the drain chamber [DR] through the (T2) section.
2) The spring chamber (d) pressure becomes the drain pressure and the main poppet (1) operates.

1 Main spool

84402826 - May 2011

8030D-33
 Structure and Operation Explanation of Control Valve

5. Relief valve
1) Main relief valve operation
1) This relief valve is incorporated between the neutral path "HP" and the low-pressure path "LP". The
oil passes through the metering hole of the main poppet (C) and charges the interior space (D). Also,
the sleeve (E) and the main poppet (C) seat securely operating on the different surface areas [A] and
[B].

2) When the neutral path "HP" pressure reaches the set pilot poppet spring force, the pilot poppet (F)
opens. The oil flows around the poppet, passes through the notch hole (G), and is led to the low-
pressure path "LP".

84402826 - May 2011

8030D-34
 Structure and Operation Explanation of Control Valve

3) Because the pilot poppet has opened, the (D) pressure drops and the main poppet (C) opens, so the
oil flows directly into the path "LP".

"Boosted pressure operation"

When pressure is applied to the pilot port "PH", the piston (H) is moved to the set position by the plug (I).
Because of this, the pilot spring force rises and the "HP" pressure rises.

2) Overload relief valve operation

1) This relief valve is incorporated between the cylinder port "HP" and the low-pressure path "LP". The
oil passes through the metering hole of the piston (C) and charges the interior space (G). The sleeve
(K) and the main poppet (D) seat securely operating on the different surface areas [A] and [B].

84402826 - May 2011

8030D-35
Structure and Operation Explanation of Control Valve

2) When the cylinder port "HP" pressure reaches the set pilot poppet spring force, the pilot poppet (E)
opens. The oil flows around the poppet, passes through the notch hole (H), and is led to the low-
pressure path "LP".

3) Because the pilot poppet (E) has opened, oil flow is generated through the orifice (I) of the piston (C),
a pressure difference is generated between the path "HP" and the rear side of the piston (C), and the
piston (C) moves and seats with the poppet (E).

4) The flow of oil from the path "HP" to the rear side of the poppet (D) is only through the ring-shaped
gap between the poppet (D) and the piston (C) and through the orifice (F), so the pressure difference
increases.
Because of this, the poppet (D) opens and the oil flows directly into the path "LP".

84402826 - May 2011

8030D-36
 Structure and Operation Explanation of Control Valve

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)

84402826 - May 2011

8030D-37
 Structure and Operation Explanation of Control Valve

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

84402826 - May 2011

8030D-38
 Structure and Operation Explanation of Control Valve

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

84402826 - May 2011

8030D-39
 Structure and Operation Explanation of Control Valve

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

84402826 - May 2011

8030D-40
 Structure and Operation Explanation of Control Valve

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.

84402826 - May 2011

8030D-41
 Structure and Operation Explanation of Control Valve

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".

84402826 - May 2011

8030D-42
Structure and Operation Explanation of Control Valve

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".

84402826 - May 2011

8030D-43
Structure and Operation Explanation of Control Valve

84402826 - May 2011

8030D-44
 Section

8030E

5 Stack Solenoid Valve Operation Explanation

84402826 - May 2011

84402826 - May 2011
 CONTENTS

External Shape Diagram and Component Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Operation Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

8030E-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
8030E-2 PRINTED IN FRANCE
 5 Stack Solenoid Valve Operation Explanation

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

84402826 - May 2011

8030E-3
 5 Stack Solenoid Valve Operation Explanation

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
Electromagnetic switchover valve S2
Electromagnetic switchover valve S4
→ Oil passing through when valve excited
→ Oil passing through when valve not excited
→ Oil passing to C5 when valve excited Oil passing to
C4 when valve not excited

84402826 - May 2011

8030E-4
 Section

8030F

Structure and Operation Explanation of Upper Pilot Valve

(remote control valve)

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Structural Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

8030F-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
8030F-2 PRINTED IN FRANCE
 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.

84402826 - May 2011

8030F-3
 Structure and Operation Explanation of Upper Pilot Valve
(remote control valve)
Operation
Operation of the remote control valve is explained based on the hydraulic circuit diagram (Diagram 1) and operation
explanation diagrams (Diagram 2 - Diagram 4).
Diagram 1 is a typical usage example for the remote control valve.

Diagram 1 Remote control valve usage example

1 Pilot valve 3 Main pump 5 Hydraulic motor

2 Pilot pump 4 Control valve 6 Hydraulic cylinder

84402826 - May 2011

8030F-4
 Structure and Operation Explanation of Upper Pilot Valve
(remote control valve)
1. When the handle is in neutral (See Diagram 2.)
The force of the secondary pressure setting spring (241) that determines the remote control valve output pressure
does not operate on the spool (201). Therefore, the spool (201) is pushed up by the return spring (221) (spring
seating (216)) and the output ports (2, 4) are connected with the T port. Therefore, the output pressure is the
same as the tank pressure.

Diagram 2 When the handle is in neutral

84402826 - May 2011

8030F-5
 Structure and Operation Explanation of Upper Pilot Valve
(remote control valve)
2. When the handle is tilted (See Diagram 3.)
When the handle is tiled and the push rod (212) is moved through a stroke, the (spring seating (216)) spool (201)
moves down and the oil fed from the pilot pump flows out to the ports (2, 4) through the P port and the ports (2,
4) and pressure is generated.

Diagram 3 When the handle is tilted

84402826 - May 2011

8030F-6
 Structure and Operation Explanation of Upper Pilot Valve
(remote control valve)
3. When the handle is held (See Diagram 4.)
When the handle is tilted and the pressure of the ports (2, 4) rises to a pressure equivalent to the set spring force
(241), the hydraulic pressure and the spring force are in balance. When the ports (2, 4) pressure becomes higher
than the set pressure, the ports (2, 4) and the P port close and the ports (2, 4) and the T port open. When the
ports (2, 4) pressure becomes lower than the set pressure, the ports (2, 4) and the P port open and the ports (2,
4) and the T port close, so the secondary pressure is held constant.

Diagram 4 When handle held (secondary pressure at or above set pressure)

1 T port
2 P port

4. Operation in area in which the handle tilt is large (depends on the model)
For certain models, when the handle is flipped down beyond a certain angle, the spool top end section touches
the push rod bore bottom section and the output pressure goes into the state of still being connected with the P
port pressure.
Furthermore, with the structure in which the spring seating and spring are installed inside the push rod, when
the handle is flipped down beyond a certain angle, the push rod bore bottom section and the spring touch. That
spring force changes the 2nd pressure gradient and after that the push rod bore bottom section and the spring
seating top end section touch, and the output pressure remains connected to the P port.

84402826 - May 2011

8030F-7
 Structure and Operation Explanation of Upper Pilot Valve
(remote control valve)
Structural Diagram

Code Part name Q'ty

101 Casing 1
151 Plate 1
201 Spool 4
211 Plug 4
212-1 Push rod 2
212-2 Push rod 2
213 Seal 4
214 O-ring 4
216-1 Spring seating 1 2
216-2 Spring seating 1 2
217 Washer 2 4
221-1 Spring (port 1) 1
221-2 Spring (port 3) 1
84402826 - May 2011
8030F-8
Structure and Operation Explanation of Upper Pilot Valve
(remote control valve)
Code Part name Q'ty
221-3 Spring 2
241-1 Spring 2
241-2 Spring 2
301 Joint 1
302 Disk 1
312 Adjusting nut 1
501 Bellows 1

84402826 - May 2011

8030F-9
Structure and Operation Explanation of Upper Pilot Valve
(remote control valve)

84402826 - May 2011

8030F-10
 Section

8030G

Structure and Operation Explanation of Travel Pilot Valve

(remote control valve))

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pressure Reduction Valve Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operating Section Damping Mechanism Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Structural Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

8030G-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
8030G-2 PRINTED IN FRANCE
 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

1 Remote control valve 4 Control valve

2 Pilot pump 5 Hydraulic motor
3 Main pump 6 Hydraulic cylinder

84402826 - May 2011

8030G-3
 Structure and Operation Explanation of Travel Pilot Valve
(remote control valve))
Pressure Reduction Valve Section
1. For the neutral state
The spool (301) is pushed up by the return spring (335) via the spring seating (311) and washer 1 (215) and is in
the neutral position shown in the assembly cross-section diagram.
Therefore, since the output port is connected only to port T by the spool switching function, the pressure at output
ports 1 and 2 is the same as the pressure at port T.
2. When the remote control valve operation section is tilted from the neutral state
In the assembly cross-section diagram, when the cam (420) is rotated clockwise, the port 1 side push rod (214)
is pushed down, the spool moves down via washer 1, the spring seating, the secondary pressure setting spring
(324), washer 2 (217), and washer 3 (313), the port P and port 1 are connected, and the oil fed from the pilot
pump flows to port 1 and generates pressure.
When the port 1 pressure rises to the pressure equivalent to the secondary pressure setting spring force that
has been set by tilting the operation section, the hydraulic pressure on the spool and the spring force come into
balance and the port 1 output pressure is held constant. The port 2 spool stays in the neutral state and the oil
from the control valve is discharged via port T.
Some specifications are of the type that near the maximum angle of the operation section, a push rod directly
touches the spool top section and forcibly pushes in the spool to connect port P and the output port so that they
have the same pressure.

Operating Section Damping Mechanism Section

1. For the neutral state
The push rod is pushed up by the damping springs (333, 337) via the piston (224) and is in the position shown
in the assembly cross-section diagram.
2. When the operation section is tilted from the neutral state (See Damping operation explanation diagram (1).)
In the assembly cross-section diagram, when the cam is rotated clockwise, the port 1-side push rod is pushed
down and the piston moves down (2-1).
At this time, the oil in the damping piston chamber is discharged from the piston metering hole and the pressure
generated at this time generates damping force.
On the other hand, the port 2-side push rod is moved up by the damping spring via the piston.
At this time, the tank chamber oil is suctioned in through the 3 ball check sections made up of bushings (223)
and steel balls (225) and into the damping piston chamber.
The oil outside the piston chamber drains out from the path that leads from the casing top end section to port T.
3. When the operation section is tilted back from a full tilt (See Damping operation explanation diagram (2).)
In the assembly cross-section diagram, after the cam is fully tilted clockwise then rotated counter-clockwise, the
port 2-side push rod is pushed down and the piston moves down.
At this time, as described above, the oil in the damping piston chamber is discharged from the piston metering
hole and the pressure generated at this time generates damping force (3-1).
On the other hand, the port 1-side push rod is moved up by the return spring (335) and the damping spring (3-2).
At the same time, the tank chamber oil is suctioned in through the 3 ball check sections made up of bushings
and steel balls and into the damping piston chamber (3-3).
Also, the oil outside the piston chamber drains out from the path that leads from the casing top end section to
the tank port (3-4).
In other words, the structure is such that damping force works for either tilt operation, from the neutral position to
the full tilt position or from the full tilt position to the neutral position.

84402826 - May 2011

8030G-4
 Structure and Operation Explanation of Travel Pilot Valve
(remote control valve))
Damping operation explanation diagram
1. Operation when lever is moved through its stroke from the neutral position

1 Push rod 3 Piston

2 Orifice 4 Piston chamber

84402826 - May 2011

8030G-5
 Structure and Operation Explanation of Travel Pilot Valve
(remote control valve))
2. Lever stroke state and operation when lever is moved back

*1 Neutral *3 (Þ during operation)

*2 Full stroke 12.5° *4 Oil drains to T.

84402826 - May 2011

8030G-6
 Structure and Operation Explanation of Travel Pilot Valve
(remote control valve))
Structural Diagram

Code Part name Q'ty Code Part name Q'ty

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
84402826 - May 2011
8030G-7
 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

84402826 - May 2011

8030G-8
 Section

8030H

Structure and Operation Explanation of Cushion Valve

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operation Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

8030H-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
8030H-2 PRINTED IN FRANCE
 Structure and Operation Explanation of Cushion Valve

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

84402826 - May 2011

8030H-3
 Structure and Operation Explanation of Cushion Valve

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.

84402826 - May 2011

8030H-4
 Structure and Operation Explanation of Cushion Valve

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)

84402826 - May 2011

8030H-5
 Structure and Operation Explanation of Cushion Valve

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.

84402826 - May 2011

8030H-6
 Structure and Operation Explanation of Cushion Valve

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.

84402826 - May 2011

8030H-7
Structure and Operation Explanation of Cushion Valve

84402826 - May 2011

8030H-8
 Section

9002

Removal and Installation of Counterweight

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

9002-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
9002-2 PRINTED IN FRANCE
 Removal and Installation of Counterweight

CAUTION Removal of Counterweight

• Be sure to stop the engine before beginning 1. Remove the following before beginning work.。
work.
• Engine hood, gas damper and lock stay
• Be sure to inspect the wire rope and other • Rear view camera and electrical parts bracket
lifting equipment before beginning work.
• Do not stand or pass under the suspended 2. Remove the 2 rubber plugs (2) from the top of the
load. counterweight (1).
• Thoroughly secure the removed counter-
weight with the wire ropes and liftcrane so
that it does not fall over.

Items to prepare
• Box wrench (50 mm)
• Eyebolt (M42)
• Balance lifting device
• Shackles (with the required lifting capacity) x 4
• Wire rope (with the required breaking load x 4)
• Liftcrane (with the required lifting capacity)
• Wood planks, etc.
• Rag
• Cleaning fluid
3. Install the 2 eyebolts (M42) (1) in place of the re-
moved caps.
• Apply lubricating oil to the eyebolts.
• Fully tighten the eyebolts, and then loosen them
by a half turn.

4. Connect the eyebolts to the shackles (1), and then

use the wire ropes (2) and liftcrane to secure the
counterweight so that it does not fall during removal
and installation operations.

84402826 - May 2011

9002-3
 Removal and Installation of Counterweight

5. Use a box wrench (50 mm) to remove the 4 bolts (1) 7. Thoroughly check that the location is safe before
and spacers (2) on the lower section of the counter- lowering the counterweight on wood planks (1).
weight.
• Thoroughly secure the counterweight with the
wire ropes and liftcrane so that it does not fall
over.

6. Use the wire ropes and liftcrane to lift and remove

the counterweight.
• Move the counterweight about 50 cm to the rear
while lifting it so that it does not interfere with the
housing, engine parts and pipes.

84402826 - May 2011

9002-4
 Removal and Installation of Counterweight

Installation of Counterweight
1. Connect the shackles (1) to the eyebolts, and thor-
oughly secure the counterweight with the wire ropes
(2) and liftcrane so that it does not fall over.
3. Use a box wrench (50 mm) to attach the 4 bolts (1)
and spacers (2) on the lower section of the counter-
weight.
• Bolt (1) tightening torque: 1862 - 2058 N·m

2. Use the wire ropes and liftcrane to lift and install the 4. Remove 2 eyebolts (M42) (1).
counterweight.
• Suspend the counterweight so that it does not in-
terfere with the housing, engine parts and pipes.

5. Attach the 2 rubber plugs (1) in place of the removed

eyebolts.

6. Install the following after finishing work.

• Engine hood, gas damper and lock stay
• Rear view camera and electrical parts bracket

84402826 - May 2011

9002-5
Removal and Installation of Counterweight

84402826 - May 2011

9002-6
 Section

9003A

Removal and Installation of Bucket

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

9003A-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
9003A-2 PRINTED IN FRANCE
 Removal and Installation of Bucket

CAUTION Removal of Bucket

• Stop the machine on a level location with • Place the back of the bucket parallel to the ground.
good footing. 1. Use a screwdriver to remove the pin (2) rings (1),
• Be sure to stop the engine before beginning and then remove the bucket side and arm side pins.
work.
• When working together with others, always
be sure to exchange signals and pay ade-
quate attention to safety.
• Always wear protective devices (protective
eyewear and safety shoes, etc.) when work-
ing with a hammer.

Items to prepare
• Hammer
• Striking rod
• Screwdriver
• Grease
• Rag
• Cleaning fluid
2. Use a hammer (4) and striking rod (5) to push the
bucket side pin (3) and arm side pin (2) out, and
then remove the bucket (1).
• When removing the pin, be careful not to damage
the installed O-rings or dust seals.

84402826 - May 2011

9003A-3
 Removal and Installation of Bucket

Installation of Bucket
1. Clean each pin and pin hole.

3. Use a screwdriver to attach the pin (2) rings (1), and

then insert the bucket side and arm side pins.
• Grease up.
2. Place the back of the bucket parallel to the ground.
Use a hammer (4) to press in the bucket side pin (3)
and arm side pin (2), and then install the bucket (1).
• If a pin is hard to insert, there is a load on the pin.
Do not force it in. Adjust the bucket installation
position.
• When inserting the pin, be careful not to damage
the installed O-rings or dust seals.

84402826 - May 2011

9003A-4
 Section

9003B

Removal and Installation of Bucket Link

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of Bucket Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Bucket Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

9003B-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
9003B-2 PRINTED IN FRANCE
 Removal and Installation of Bucket Link

CAUTION Removal of Bucket Link

• Stop the machine on a level location with • Remove the bucket. (For details, see "Removal and
good footing. Installation of Bucket".)
• Be sure to stop the engine before beginning 1. Place the bucket link (1) parallel to the ground.
work.
• When working together with others, always
be sure to exchange signals and pay ade-
quate attention to safety.
• Always wear protective devices (protective
eyewear and safety shoes, etc.) when work-
ing with a hammer.

Items to prepare
• 2 wrenches (30 mm)
• Hammer
• Striking rod
• Grease
• Rag
• Cleaning fluid
2. Use 2 wrenches (30 mm) to remove the double nuts
(1), and then pull out the bolts (2) (3).

3. Use a hammer (3) and striking rod (4) to push the

pin (2) out and remove the bucket link (1).

84402826 - May 2011

9003B-3
 Removal and Installation of Bucket Link

4. Use a hammer (4) and striking rod (5) to push out Installation of Bucket Link
the pin (3) and remove the arm links (1) (2).
1. Clean each pin and pin hole.
• When removing the pin, be careful not to damage
the installed O-rings or dust seals.

2. Use a hammer (4) to push in the pin (1) and install

the arm links (2) (3).
• If a pin is hard to insert, there is a load on the pin.
• When inserting the pin, be careful not to damage
the installed O-rings or dust seals.

3. Place the bucket link (1) parallel to the ground.

Use a hammer (3) to push in the pin (2) and install
the bucket link (1).

4. Use 2 wrenches (30 mm) to attach the double nuts

(1), and then install the bolts (2) (3).
• Grease up.
• Install the bucket. (For details, see "Removal and
Installation of Bucket".)

84402826 - May 2011

9003B-4
Removal and Installation of Bucket Link

84402826 - May 2011

9003B-5
Removal and Installation of Bucket Link

84402826 - May 2011

9003B-6
 Section

9003C

Removal and Installation of Arm

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

9003C-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
9003C-2 PRINTED IN FRANCE
 Removal and Installation of Arm

Job code 39121AA10 Removal of Arm

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.
• Do not stand or pass under the suspended
load.
• 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".)
1. Bring the arm (1) top in contact with the ground and
use a liftcrane and nylon sling (2) to secure it.
At this time, insert the arm cylinder pin (3) and se-
cure with the nylon sling.

Items to prepare
• Wrench (19 mm)
• Hammer
• Striking rod
• Nylon sling (with the required lifting capacity)
• Liftcrane (with the required lifting capacity)
• Grease
• Rag
• Cleaning fluid
• Crosstie 2. Use a wrench (19 mm) to remove the bolt (1) and
washer (2).

3. Use a hammer (3) and striking rod (4) to push the

pin (2) out and remove the arm (1).
• If a pin is hard to remove, there is a load on the
pin.
• When removing the pin, be careful not to damage
the installed dust seals.
• Be very careful. When the pin is removed, the
arm may fall slightly.
• Be very careful. The arm may fall over to the side.

84402826 - May 2011

9003C-3
 Removal and Installation of Arm

Installation of Arm
• Tighten bolts being installed to the specified torque.
• When the torque is not specified, check the "Bolt Size
and Torque Table".
1. Clean each pin and pin hole.

4. Lift the arm and then place it on the crosstie.

2. Bring the arm (1) top in contact with the ground and
use a liftcrane and nylon sling (2) to secure it.
At this time, insert the arm cylinder pin (3) and se-
cure with the nylon sling.

3. Align the arm (1) with the boom and use a hammer
(3) to push in the pin (2) and then install the arm (1).
• If a pin is hard to insert, there is a load on the pin.
• When inserting the pin, be careful not to damage
the installed dust seals.

4. Use a wrench (19 mm) to tighten the bolt (1) and

washer (2).
• Install the arm cylinder. (For details, see "Re-
moval and Installation of Arm Cylinder".)

84402826 - May 2011

9003C-4
 Removal and Installation of Arm

• 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".)

84402826 - May 2011

9003C-5
Removal and Installation of Arm

84402826 - May 2011

9003C-6
 Section

9003D

Removal and Installation of Boom

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

9003D-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
9003D-2 PRINTED IN FRANCE
 Removal and Installation of Boom

CAUTION Removal of Boom

• Stop the machine on a level location with • Remove the bucket. (For details, see "Removal and
good footing. Installation of Bucket".)
• Be sure to stop the engine before beginning • Remove the bucket link. (For details, see "Removal
work. and Installation of Bucket Link".)
• When working together with others, always • Remove the bucket cylinder. (For details, see "Re-
be sure to exchange signals and pay ade- moval and Installation of Bucket Cylinder".)
quate attention to safety. • Remove the arm cylinder. (For details, see "Removal
• Always wear protective devices (protective and Installation of Arm Cylinder".)
eyewear and safety shoes, etc.) when work- • Remove the arm. (For details, see "Removal and In-
ing with a hammer. stallation of Arm".)
• Be sure to inspect the nylon sling and other • This section explains the procedure for when attaching
lifting equipment before beginning work. the boom cylinder to the frame.
• Do not stand or pass under the suspended When removing the boom cylinder too, see "Removal
load. and Installation of Boom Cylinder".
1. Bring the boom (1) top in contact with the ground.
Items to prepare
• Wrenches (10 mm, 19 mm, 27 mm, 30 mm, 41 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
2. Use a wrench (19 mm) to remove the grease hoses
on the left and right sides (1).
• Use caps or plugs to prevent any entry of water,
dust or dirt.

84402826 - May 2011

9003D-3
 Removal and Installation of Boom

3. Use a wrench (30 mm) to remove the double nuts 6. Tie the cylinder rods on the left and right sides with
(1) and bolt (2), and then remove the fastening ring wire (1) so that they cannot come out.
(3).
Also, remove the cab side in the same way.

7. Use a wrench (10 mm) to remove the grease nipple

(1), and then secure the base of the boom cylinders
4. Use a hammer (2) and striking rod (3) to push the (right) (left) with the batten (2).
pin (1) out.
Use a liftcrane and nylon slings (4) to hold the boom
cylinders (right) (left) so that they does not fall.

8. Lower the boom cylinders (right) (left) and let them

rest on the batten (1).

5. Start the engine, lower the boom at idle, and retract

the boom cylinder (1) (2) rod.

84402826 - May 2011

9003D-4
 Removal and Installation of Boom

9. Install the pin (1) removed in Step 4. 11. Use a wrench (19 mm) to remove the bolt (1) and
Use a wrench (30 mm) to tighten the bolt (3) with washer (2).
the 2 double nuts (2), and then install the fastening
ring (4).
Also, install the cab side in the same way.

12. Use a slide hammer (1) (24 mm) to remove the pin
(2).

10. Wrap nylon slings (1) around the pins on the left and
right sides installed in Step 9 and secure with the
liftcrane.

13. Back up the machine and remove the boom (1).

84402826 - May 2011

9003D-5
 Removal and Installation of Boom

Installation of Boom 4. Tie the cylinder rods on the left and right sides with
wire (10) so that they cannot come out.
• This section explains the procedure for when not in-
stalling the boom cylinder.
• Tighten bolts being installed to the specified torque.
• When the torque is not specified, check the "Bolt Size
and Torque Table".
1. Clean each pin and pin hole.

5. Align the boom with the swing frame pin hole and
use a slide hammer (1) (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 (30 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 (19 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.

84402826 - May 2011

9003D-6
 Removal and Installation of Boom

7. Start the engine, raise the boom at idle, and extend 10. Use a wrench (19 mm) to attach the grease hoses
the boom cylinder (1) (2) rod. on the right and left sides (1).

8. Use a hammer (2) to push in the pin (1).
Use a liftcrane and nylon slings (3) to hold the boom
cylinders (right) (left) so that they does not fall.
11. Bring the boom (1) top in contact with the ground.
• When installing the boom cylinder too, see "Re-
moval and Installation of Boom Cylinder".
• Install the arm. (For details, see "Removal and
Installation of Arm".)
• Install the arm cylinder. (For details, see "Re-
moval and Installation of Arm Cylinder".)
• Install the bucket cylinder. (For details, see "Re-
moval and Installation of Bucket Cylinder".)
• Install the bucket link. (For details, see "Removal
and Installation of Bucket Link".)
• Install the bucket. (For details, see "Removal and
Installation of Bucket".)

9. Use a wrench (30 mm) to attach the double nuts (1)

and bolt (2), and install the fastening ring (3).
Also, install the cab side in the same way.

84402826 - May 2011

9003D-7
Removal and Installation of Boom

84402826 - May 2011

9003D-8
 Section

9004

Removal and Installation of Operator's Seat

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of Operator's Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Operator's Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

9004-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
9004-2 PRINTED IN FRANCE
 Removal and Installation of Operator's Seat

Job code 90120AD17 3. Use a wrench (13 mm) to remove the 2 bolts (1)
from the rear of the seat.
Tightening torque for bolt (1) installation: 19.6 N·m
Items to prepare
• 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.

Installation of Operator's Seat

To install, perform the reverse of the removal procedure.
Tighten bolts being installed to the specified torque.

84402826 - May 2011

9004-3
Removal and Installation of Operator's Seat

84402826 - May 2011

9004-4
 Section

9005A

Removal and Installation of Cab Assembly

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of Cab Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Cab Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

9005A-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
9005A-2 PRINTED IN FRANCE
 Removal and Installation of Cab Assembly

Job code 90150AA08 Removal of Cab Assembly

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.
• Remove the operator's seat. (For details, see "Re-
moval and Installation of Operator's Seat".)
1. Use a box wrench (13 mm) to remove the 6 bolts
(1), and then remove the trim rear assembly (2).
Tightening torque for bolt (1) installation: 5.9 - 7.8
N·m

Items to prepare
• Wrenches (10 mm, 12 mm, 13 mm, 19 mm, 41 mm)
• Box wrenches (10 mm, 13 mm, 19 mm)
• Longnose pliers
• Flathead screwdriver
• Eyebolt (M24 x 4)
• Chains (wire ropes) (with the required breaking load)
• Liftcrane (with the required lifting capacity)
• Lubricating oil
• Rag
• Cleaning fluid
• Wood planks, etc. 2. Use a box wrench (10 mm) to remove the 3 bolts
(1), and then remove the air conditioner ducts on
both sides (2) (3).
Tightening torque for bolt (1) installation: 2.9 - 3.9
N·m

3. 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

84402826 - May 2011

9005A-3
 Removal and Installation of Cab Assembly

4. Use a flathead screwdriver or longnose pliers to re- 7. Use a wrench (13 mm) to remove the bolts (2) for
move the clip pins (1), and then remove the air con- the ground wire (1) connecting the cab and frame.
ditioner ducts (2) by pulling them forward.

8. Remove the connector (1) and wire band (2), and

5. Use a wrench (13 mm) to remove the 2 bolts (2), then use a wrench (13 mm) to remove the 2 bolts
and then remove the bracket (1) and air conditioner (3).
duct (3).

9. Remove the washer fluid hose (

6. Remove the radio antenna (1). ).

84402826 - May 2011

9005A-4
 Removal and Installation of Cab Assembly

10. Use a wrench (13 mm) to remove the 4 bolts (1), use 13. Use a wrench (10 mm) to remove the 2 bolts (1),
a wrench (12 mm) to remove the 3 bolts (4) and 2 and then remove the bracket (2).
nuts (2), and then remove the rear brackets (3) (5).

14. Remove the connector (1).

11. Use a wrench (13 mm) to remove the 3 bolts (1),
and then remove the bracket (2).

15. Remove the 4 connectors (1) and the 2 wire bands

(2).
12. Use a flathead screwdriver or longnose pliers to re-
move the 2 clips (1), and then remove the suction
ducts (2) (3).

16. Remove the 4 caps (1) from the top of the cab.

84402826 - May 2011

9005A-5
 Removal and Installation of Cab Assembly

17. Install the 4 eyebolts (M24) (1) in place of the re- 19. Use a wrench (19 mm) to remove the 8 cab bolts
moved caps. (1) and 4 nuts (2).
• Fully tighten the eyebolts, and then loosen them
by a half turn.

18. Use chains (1) and liftcrane to secure the cab.

20. Use a wrench (41 mm) to remove the anchor bolt

(1).

84402826 - May 2011

9005A-6
 Removal and Installation of Cab Assembly

21. Use chains (1) and liftcrane to remove the cab (2). 22. Thoroughly check that the location is safe before
lowering the cab on wood planks (1).
• Thoroughly secure the cab with the chains and
liftcrane so that it does not fall down.

84402826 - May 2011

9005A-7
 Removal and Installation of Cab Assembly

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.

84402826 - May 2011

9005A-8
 Section

9005B

Removal and Installation of Wiper

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of Wiper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

9005B-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
9005B-2 PRINTED IN FRANCE
 Removal and Installation of Wiper

Items to prepare 2. Use the Phillips screwdriver to remove the 1 screw

(1), and then remove the wiper (2).
• Wrench (17 mm)
• Phillips screwdriver

Removal of Wiper
1. Use a wrench (17 mm) to remove the 1 nut (1), and
then remove the wiper arm (2).
Tightening torque for nut (1) installation: 12 - 16 N·m

Installation of Wiper
To install, perform the reverse of the removal procedure.
Tighten bolts being installed to the specified torque.

84402826 - May 2011

9005B-3
Removal and Installation of Wiper

84402826 - May 2011

9005B-4
 Section

9005C

Removal and Installation of Wiper Controller

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of Wiper Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Wiper Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

9005C-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
9005C-2 PRINTED IN FRANCE
 Removal and Installation of Wiper Controller

Job code 55518BH01 2. Remove the connector (2) from the wiper controller
(1).
Items to prepare
• Wrench (10 mm)
• Box wrench (10 mm)
• Phillips screwdriver
• Flathead screwdriver

Removal of Wiper Controller

1. Use the Phillips screwdriver or box wrench (10 mm)
to remove the 4 bolts (1), and then remove the side
rear B trim (2).

3. Use a flathead screwdriver to slightly bend the 4 in-

stallation clips (1), and then remove the wiper con-
troller (2).

Installation of Wiper Controller

To install, perform the reverse of the removal procedure.
Tighten bolts being installed to the specified torque.
If the torque is not specified, see the "Tightening Torque"
section.

84402826 - May 2011

9005C-3
Removal and Installation of Wiper Controller

84402826 - May 2011

9005C-4
 Section

9005D

Removal and Installation of Wiper Motor

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

9005D-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
9005D-2 PRINTED IN FRANCE
 Removal and Installation of Wiper Motor

Job code 55518AZ46 3. 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),
Items to prepare
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

84402826 - May 2011

9005D-3
 Removal and Installation of Wiper Motor

6. Use a box wrench (10 mm) to remove the 4 bolts
(1), and then remove the wiper motor assembly (2).
Installation of Wiper Motor
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.

84402826 - May 2011

9005D-4
 Section

9005E

Removal and Installation of Monitor

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

9005E-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
9005E-2 PRINTED IN FRANCE
 Removal and Installation of Monitor

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.

84402826 - May 2011

9005E-3
Removal and Installation of Monitor

84402826 - May 2011

9005E-4
 Section

9005F

Removal and Installation of Cab Front Glass

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of Cab Front Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Cab Front Glass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

9005F-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
9005F-2 PRINTED IN FRANCE
 Removal and Installation of Cab Front Glass

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),
4. Remove the covers (1) (2) for the bracket.
and then remove the cover (1).

5. Use a wrench (10 mm) to remove the 3 bolts (1),

2. Use a Phillips screwdriver to remove the screw
and then remove the front glass left lower bracket
(1), and then install the removed screw (1) into the
(2).
screw hole (2).
Tightening torque for bolt (1) installation: 880 - 1270
• The assist spring is locked. N·cm

84402826 - May 2011

9005F-3
 Removal and Installation of Cab Front Glass

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).

84402826 - May 2011

9005F-4
 Section

9005G

Window Lock Adjustment Procedures

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Window Lock (front side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Window Lock (rear side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

9005G-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
9005G-2 PRINTED IN FRANCE
 Window Lock Adjustment Procedures

Items to prepare 3. Set the cab front glass (1) in place.

• Wrench (10 mm)
• Phillips screwdriver
• Rag
• Cleaning fluid

Window Lock (front side)

1. Release the lock with the lever (1), and then remove
the lock of the cab front glass.

4. Use a wrench (10 mm) to retighten the 2 bolts (1).

2. Use a wrench (10 mm) to loosen the 2 bolts (1).

84402826 - May 2011

9005G-3
 Window Lock Adjustment Procedures

Window Lock (rear side) 3. Set the cab front glass (1) in place.

1. Use a Phillips screwdriver to remove the 8 clips (2),

and then remove the cover (1).

4. Use a wrench (10 mm) to retighten the 4 bolts (1).

2. Use a wrench (10 mm) to loosen the 4 bolts (1).

84402826 - May 2011

9005G-4
 Section

9005H

Tightening torque

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

9005H-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
9005H-2 PRINTED IN FRANCE
 Tightening torque

Tightening torque
When installing cab inner and outer parts, for bolts and screws for which the torque is not specified, tighten according
to the following.

Bolt nominal di-

ameter M3 x 0.5 M4 x 0.7 M5 x 0.8 M6 x 1.0 M8 x 1.25 M10 x 1.5
(size)
N•m 0.59 - 0.79 1.27 - 1.86 2.45 - 3.53 4.52 - 6.14 9.84 - 14.74 19.58 - 28.4
kgf•m 0.06 - 0.08 0.13 - 0.19 0.25 - 0.36 0.43 - 0.63 1.00 - 1.50 2.0 - 2.9

84402826 - May 2011

9005H-3
Tightening torque

84402826 - May 2011

9005H-4
 Section

9006

Air Conditioner Overall Diagram

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Air Conditioner Overall Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Equipment Layout Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Air Conditioner Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Explanation of Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Explanation of Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Air Mix Motor Actuator Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Blow Mode Motor Actuator Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Refresh/Recirculate Switch Motor Actuator Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Blower Amp Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Compressor Clutch Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
COOLMAX Control and HOTMAX Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Abnormality Detection and Control after Abnormality Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Monitor Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Door Switch Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Actuator Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Air Mix Motor Actuator Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Refresh/Recirculate Switch Motor Actuator Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Mode Motor Actuator Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Self-diagnosis Function with Panel Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Abnormality Display and Self-check Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Abnormality Display Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Explanation of Abnormality Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Explanation of Monitor Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Part Function and Good/Poor Judgment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Blower Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Air Mix Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Refresh/Recirculate Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Blow Mode Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Evaporator Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Dual Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Solar Radiation Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Inside Air Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

9006-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
9006-2 PRINTED IN FRANCE
 Air Conditioner Overall Diagram

Air Conditioner Overall Diagram

Frame

84402826 - May 2011

9006-3
 Air Conditioner Overall Diagram

Code Part name Q'ty Code Part name Q'ty Code Part name Q'ty
Compressor; Air con-
1 Cooler hose (Liquid 2) 1 5 1 9 Dryer receiver (D60.5) 1
ditioner
2 Cooler hose (Suction) 1 6 Slide shaft 1 10 Cooler hose (Liquid 1) 1
Rubber hose 16 x Tension pulley (With Bracket receiver
3 2 7 1 11 1
5600 cover) (D60.5)
Cooler hose (Dis-
4 1 8 Air condenser 1 12 V belt B-45.5 1
charge)

a Air conditioner unit
b Engine
c Heater (Engine return)
d White marking
White marking
e Heater (Engine output) i Must be connected with the air
conditioner unit.
f Heater (Unit outlet) j Clamp
g Heater (Unit inlet)
Must be connected with the air
h
conditioner unit.
84402826 - May 2011
9006-4
 Air Conditioner Overall Diagram

* in the diagram indicates a clamp position. Figures indicate hose lengths.

84402826 - May 2011

9006-5
 Air Conditioner Overall Diagram

Cab

84402826 - May 2011

9006-6
Air Conditioner Overall Diagram

84402826 - May 2011

9006-7
 Air Conditioner Overall Diagram

Code Part name Q'ty Code Part name Q'ty Code Part name Q'ty
1 Solar radiation sensor 1 8 Duct; H and C box 1 15 Duct; Intake-B (Fresh) 1
2 Duct; Face-A 1 9 Bracket; Box 1 16 Unit; Air conditioner 1
3 Duct; Def-A 1 10 Box; Hot and cool 1 17 Duct; Foot 1
4 Grille; Air vent 7 11 Duct; Vent (Left) 1 18 Duct; Def-B
5 Duct; Face-B 1 12 Duct; Vent (Right) 1 19 Control panel (AC) 1
6 Duct; Def-C 1 13 Air filter (Fresh) 1 20 Drain hose 2
7 Duct; Face-C 1 14 Duct; Intake-A (Fresh) 1 21 Flange plate 1

a e Should be connected with the

Monitor display
b Trim side; Front (Right)
c Trim side; Front (Left)
d Heater hose (Eng.Return)
Heater hose (Eng.Out) i
console harness.
f Cooler hose (Suction) j Wire harness (Console)
g Cooler hose (Liquid) k Floor
h Cover; Top (Console left)

84402826 - May 2011

9006-8
 Air Conditioner Overall Diagram

Equipment Layout Diagram

84402826 - May 2011

9006-9
 Air Conditioner Overall Diagram

Code Part name Code Part name Code Part name

1 Motor actuator (mode)
2 Compressor relay
3 Blower OFF relay
Motor actuator (refresh/recir-
4 7 Blower amp
culate switch)
5 Interior temperature sensor 8 Motor actuator (air mix)
6 Blower motor 9 Evaporator sensor

84402826 - May 2011

9006-10
 Air Conditioner Overall Diagram

Circuit Diagram
Air Conditioner Circuit Diagram

84402826 - May 2011

9006-11
Air Conditioner Overall Diagram

84402826 - May 2011

9006-12
 Air Conditioner Overall Diagram

5 V system
5 V are always applied.
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.

84402826 - May 2011

9006-13
 Air Conditioner Overall Diagram

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

84402826 - May 2011

9006-14
 Air Conditioner Overall Diagram

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.

84402826 - May 2011

9006-15
 Air Conditioner Overall Diagram

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

84402826 - May 2011

9006-16
 Air Conditioner Overall Diagram

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

84402826 - May 2011

9006-17
 Air Conditioner Overall Diagram

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.

84402826 - May 2011

9006-18
 Air Conditioner Overall Diagram

*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.

84402826 - May 2011

9006-19
 Air Conditioner Overall Diagram

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

84402826 - May 2011

9006-20
 Air Conditioner Overall Diagram

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.

84402826 - May 2011

9006-21
 Air Conditioner Overall Diagram

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.

84402826 - May 2011

9006-22
 Air Conditioner Overall Diagram

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

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.

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.
84402826 - May 2011
9006-23
 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＞
84402826 - May 2011
9006-24
 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.

84402826 - May 2011

9006-25
 Air Conditioner Overall Diagram

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 -

84402826 - May 2011

9006-26
 Air Conditioner Overall Diagram

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

84402826 - May 2011

9006-27
 Air Conditioner Overall Diagram

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.

84402826 - May 2011

9006-28
 Air Conditioner Overall Diagram

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°

84402826 - May 2011

9006-29
 Air Conditioner Overall Diagram

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?

84402826 - May 2011

9006-30
 Air Conditioner Overall Diagram

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

84402826 - May 2011

9006-31
 Air Conditioner Overall Diagram

Self-diagnosis Function with Panel Display

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

a This segment is displayed only in the monitor mode

below.
b Error is displayed on the 3-digit 7-segment display.

Explanation of Abnormality Display

Explanation of Monitor Mode
2. When sensor abnormality is displayed, the sensor status (disconnection, short) can be checked in monitor mode.

84402826 - May 2011

9006-32
 Air Conditioner Overall Diagram

Part Function and Good/Poor Judgment

Control Panel
Function of each switch

1 Main power switch
2 Auto control switch
3 Temperature control switch
4 Air flow select switch 7 Diffuser select switch
Refresh/recirculate select
5 Air conditioner ON/OFF switch 8
switch
6 Defrost switch

Through the operation of its internal microcomputer, the control panel compares, operates on, and processes the
sensor input signals and control panel switch input signals, switches the output side actuators (refresh/recirculate
switching, mode switching, air mix) and comprehensively controls the fan motor and compressor.
Also, it is equipped with self-diagnosis functions to make trouble diagnosis easier. (For details see the air conditioner
troubleshooting.)

84402826 - May 2011

9006-33
 Air Conditioner Overall Diagram

Blower Amp
The power transistor receives the base current from the control unit and changes the speed of the fan motor.
Blower amp inspection
The blower amp can be easily judged by removing the blower amp connector and checking for continuity across
the blower amp terminals.

Terminal No.
Continuity
1 2 3
+ --- - Yes (4.7 kΩ)
Tester - + --- No
+ - --- Yes (diode parallel forward direction)

a Temperature fuse: 132 - 138 °C

84402826 - May 2011

9006-34
 Air Conditioner Overall Diagram

Relay

4-pole relays are used for the blower OFF relay and compressor relay.
Blower OFF relay
This relay receives the signal from the control amp and switches the blower OFF relay ON.
When the blower OFF relay is switched ON, the power supply voltage is fed to the blower motor via the blower amp
and the blower motor is started.
Compressor relay
The compressor relay is switched ON/OFF by the control amp compressor control.
Relay inspection contents
1. Relay
2. Coil resistor: 320Ω
3. Specification voltage: DC 20 - 30 V
4. Be careful. The coil side of this relay must be installed with the poles facing correctly.
5. Inspection: Inspect for continuity between 3 and 4 under the conditions below.

20 - 30 V applied between term8inals 1 and 2 : Continuity

No voltage applied between terminals 1 and 2 : No continuity

84402826 - May 2011

9006-35
 Air Conditioner Overall Diagram

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) - +

84402826 - May 2011

9006-36
 Air Conditioner Overall Diagram

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.

84402826 - May 2011

9006-37
 Air Conditioner Overall Diagram

Blow Mode Actuator

CAUTION
The air conditioning system voltage specifications are 24 V, but the motor actuator has 12 V specifica-
tions.

The blow mode actuator is installed at the center of the air conditioner unit contained behind the link cover. It opens
and closes the mode door via the link.
Built into the blow mode actuator is the potentio-meter which switches linked with the actuator shaft.
When blow mode is determined by the temperature control switch, the control unit reads in the potentio-meter position
in the actuator and determines whether the motor turns forward or in reverse.
The contacts move linked with the motor. When the contacts move open or the control unit output signal goes OFF,
the motor stops.
Evaporator Sensor
In order to prevent the evaporator from freezing, the evaporator blow temperature is detected and the compressor
ON/OFF is controlled.

• Evaporator sensor inspection method (specifications value)

Disconnect the evaporator sensor from the main harness and measure the resistance between the sensor side
connector terminals using the tester.

Resistance between When the sensor section detection temperature is 0 °C : 7.2 kΩ

terminals When the sensor section detection temperature is 25 °C : 2.2 kΩ

84402826 - May 2011

9006-38
 Air Conditioner Overall Diagram

Dual Pressure Switch

• The dual pressure switch is installed on the receiver dryer.

When there is pressure trouble in the coolant high-pressure side line (abnormally high pressure or abnormally low
pressure), the dual pressure switch contacts open up to cut off the compressor power and protect the cooling cycle.

Dual pressure switch specifications

1 (Low-pressure side)
2 (High-pressure side)

• Simple inspection method for dual pressure switch

1. With the cooling cycle stopped, disconnect the connector from the switch and check the conductance between
the switch side connector terminals using the tester.
If there is conductance, the switch is normal. (When the outside air temperature is 0 °C or higher)
2. Connect the gauge manifold high-pressure side hose to the high-pressure side charge port.
With the cooling cycle operating, the condenser front surface is covered with a plate shaped object and the high
pressure rises.
If the compressor stops around 3.14 MPa, the switch is normal.
3. With the coolant removed, check the conductance between the switch side connector terminals using the tester.
If there is no conductance, the switch is normal.

84402826 - May 2011

9006-39
 Air Conditioner Overall Diagram

Solar Radiation Sensor

This is the air conditioner solar radiation correct sensor. It detects the strength of sunlight with a photodiode, converts
it into milli-amp and sends that to the controller.

• Solar radiation sensor inspection method

Disconnect the solar radiation sensor connector from the harness and measure the voltage between the sensor
side connector terminals using the tester's voltage measurement mode.
The voltage must be different when light is striking the photoreceiver section and when it is not. (The voltage is
about 0 V when absolutely no light is striking the photoreceiver.)

CAUTION
Always measure with the tester in voltage measurement mode (V mode).
Measuring in resistance mode (Ω mode) would destroy the sensor.

Inside Air Sensor

The inside air sensor is installed in the inside air side intake port of the air conditioner unit and switches the tempera-
ture inside the cab to the resistance.
This resistance value is converted into a voltage value in the control panel and processed.
Inside air sensor inspection method
Remove the inside air sensor connector from the main harness and measure the resistance between the sensor
side connector terminals using the tester.
Inside air sensor inspection details (specifications)
Resistance between terminals
For 0 °C: 7.2 kΩ ± 3 %
For 25 °C: 2.2 kΩ ± 3 %

84402826 - May 2011

9006-40
 Section

9007

Assembly and Disassembly of Air Conditioner Units

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of Blower Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Replacement of Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Replacement of Blower Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal of Heater Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal of Heat Case Right/Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Replacement of Evaporator and Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation of Evaporator Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Replacement of Motor Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

9007-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
9007-2 PRINTED IN FRANCE
 Assembly and Disassembly of Air Conditioner Units

CAUTION Replacement of Blower Motor

• Be sure to stop the engine before beginning CAUTION
work.
Do not remove the fan from the blower motor.
CAUTION
1. Remove the cooling hose (2) from the air condi-
• When replacing the evaporator, re-supply tioner unit (1).
and check the compressor oil quantity.
• Remove the 3 Phillips screws (3) and remove the
blower motor (4).
Removal of Blower Unit Screw size
Phillips screws (3): M5 x 14
1. Remove the connectors connected to the refresh/
recirculate motor actuator connector (1), blower mo- • The installation procedure is the reverse of the
tor connector (2), inside air sensor connector (3), removal procedure.
evaporator sensor connector (4) and relay connec-
tor (5).

2. Remove the filter cover (1) and inside air filter (2).
• Remove the 4 Phillips screws (3) and remove the
intake case (4).
Screw size
Phillips screws (3): M5 x 16 (T1)

84402826 - May 2011

9007-3
 Assembly and Disassembly of Air Conditioner Units

Replacement of Blower Amp Removal of Heater Core

CAUTION CAUTION
Never disassemble the blower amp. Remove while being careful not to apply exces-
Removing with the power on can suddenly in- sive force to the pipe.
crease the blower amp temperature, damaging
the part. 1. Drain the coolant.
Also, touching the surface could cause burns.
• Remove the 4 Phillips screws (1) and remove the
1. Remove the connector (1) from the blower amp (2). link cover (2).
Screw size
• Remove the 2 Phillips screws (3) and remove the Phillips screws (1): M5 x 16
blower amp (2).
Screw size • Remove the mode actuator connector (3), and re-
Phillips screws (3): M4 x 16 move the heater core (4).

• The installation procedure is the reverse of the • The installation procedure is the reverse of the
removal procedure. removal procedure.

84402826 - May 2011

9007-4
 Assembly and Disassembly of Air Conditioner Units

Removal of Heat Case Right/Left Replacement of Evaporator and

CAUTION
At this time, perform work with the heater core
removed from the heater case.
The evaporator sensor cord is sandwiched in
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
Phillips screws (1): M4 x 16
Expansion Valve
CAUTION
Be careful of the O-rings getting caught, etc.
when installing the expansion valve.
The evaporator sensor cord is sandwiched in
the groove of the HVAC unit, so carefully check
it and remove it while making sure not to dam-
age it.
1. Turn the HVAC unit upside down and place it on a
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

84402826 - May 2011

9007-5
 Assembly and Disassembly of Air Conditioner Units
Installation of Evaporator Sensor
CAUTION
Be careful that the sensor cord does not get
squeezed in the case when the case is assem-
bled.
Make sure to install the harness holder (1) and thermis-
tor holder (2) in the original position of the evaporator (4)
as shown in the diagram.
• Install the evaporator sensor (3) end and thermistor
holder (2) as shown in the diagram.
a Thermistor holder position
b 20 mm
c 73 mm
d 9th row
e 27th row
84402826 - May 2011
9007-6
Replacement of Motor Actuator
1. Replacement of mode motor actuator
Remove the link cover.
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)
2. Replacement of air mix motor actuator
Remove the link cover.
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 damper
lever, and then install the new motor actuator (1).
The installation procedure is the reverse of the re-
moval procedure.
Screw size
Phillips screws (3): M4 x 16 (T1)
 Assembly and Disassembly of Air Conditioner Units

3. Replacement of refresh/recirculate motor actuator

Remove the link cover.
Remove the connector (2) from the motor actuator
(1).
Remove the 3 Phillips screws (3) securing the motor
actuator (1), remove the lever pin (4) attached to
the motor actuator (1) from the slot hole, and then
install the new motor actuator (1). The installation
procedure is the reverse of the removal procedure.
Screw size
Phillips screws (3): M4 x 16 (T1)

84402826 - May 2011

9007-7
Assembly and Disassembly of Air Conditioner Units

84402826 - May 2011

9007-8
 Section

9009

Removal and Installation of Compressor

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

9009-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
9009-2 PRINTED IN FRANCE
 Removal and Installation of Compressor

Job code 50200AA26 Removal of Compressor

1. Remove the connector (1).
WARNING
• Be careful when loosening the lines. The air
conditioner circuit is filled with high-pressure
gas, so there is the danger of gas splaying
out.

CAUTION
• Be sure to stop the engine before beginning
work.
• When removing and installing the compres-
sor, check the compressor oil quantity.

Items to prepare
Wrench (13 mm) 2. Use a box wrench (13 mm) to loosen the bolts (1)
•
Box wrench (13 mm) on the lines in the 2 locations, and then remove the
•
Rag 2 lines (2) (3).
•
• Cleaning fluid • Always remove the low-pressure side line (2) first.
• Attach caps or plugs to the compressor and lines
to prevent any entry of water, dust or dirt.
Tightening torque for bolt (1) installation: 19.6 -
24.5 N·m

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

and then remove the compressor (2).
Tightening torque for bolt (1) installation: 19.6 - 29.4
N·m

84402826 - May 2011

9009-3
 Removal and Installation of Compressor

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".

84402826 - May 2011

9009-4
 Section

9010

Removal and Installation of Condenser

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

9010-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
9010-2 PRINTED IN FRANCE
 Removal and Installation of Condenser

Job code 50200AK72 Removal of Condenser

1. Use a wrench (17 mm) to press the lower line on
WARNING the condenser side (1), and then use a wrench (19
mm) to loosen and remove the sleeve nut of the
• Be careful when loosening the lines. The air low-pressure side line (2).
conditioner circuit is filled with high-pressure
gas, so there is the danger of gas splaying • Always remove the low-pressure side line first.
out. • Attach caps or plugs to the condenser and line to
prevent any entry of water, dust or dirt.
CAUTION • Clean the lines by spraying with a parts cleaner to
prevent scratches and prevent dirt from accumu-
• Be sure to stop the engine before beginning lating on the connectors.
work. Tightening torque for line (1) installation: 11.8 -
14.7 N·m
CAUTION
• When removing and installing the condenser,
resupply and check the compressor oil quan-
tity.

Items to prepare
• Wrenches (13 mm, 17 mm, 19 mm, 22 mm)
• Cap
• Plug
• Rag
• Cleaning fluid

2. Use a wrench (22 mm) to press the upper line on

the condenser side (1), and then use a wrench (22
mm) to loosen and remove the sleeve nut of the
high-pressure side line (2).
• The "H" cap indicates the high-pressure side line.
• 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: 19.6 -
24.5 N·m

84402826 - May 2011

9010-3
 Removal and Installation of Condenser

3. Use a wrench (13 mm) to remove the 4 bolts (1),
and then remove the condenser (2).
• Bolt (1) tightening torque: 17.7 - 21.6 N·m
Installation of Condenser
• To install, perform the reverse of the removal proce-
dure.
Tighten the lines and bolts to the specified torque.
If the torque is not specified for a bolt, see the "Bolt
Size and Torque Table".
• Make sure to resupply and check the compressor oil
quantity.
The compressor contains 135 cc of oil.
The oil quantity being low will cause compressor seiz-
ing and a reduction in durability. The oil quantity being
high will cause a reduction in cooling capabilities.
Make sure to check the oil quantity and adjust if
needed.
Resupply quantity: 40 cc
Resupply oil: SP-10 or SP-20 (P.A.G. oil)
• Perform air conditioner gas charging.
For details, see "Gas Filling Procedures".

84402826 - May 2011

9010-4
 Section

9011

Removal and Installation of Receiver Dryer

84402826 - May 2011

84402826 - May 2011
 CONTENTS

Removal of Receiver Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Receiver Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

9011-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
9011-2 PRINTED IN FRANCE
 Removal and Installation of Receiver Dryer

Job code 50200AN92 Removal of Receiver Dryer

1. Remove the connector (1).
WARNING
• Be careful when loosening the lines.
The air conditioner circuit is filled with high-
pressure gas, so there is the danger of gas
splaying out.

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

CAUTION
• When replacing the receiver dryer, resupply
and check the compressor oil quantity. 2. Use a wrench (10 mm) to remove the 2 bolts (2)
from the line (1).
Items to prepare
• Attach caps or plugs to the receiver dryer and line
• Wrench (10 mm) to prevent any entry of water, dust or dirt.
• Cap • Clean the receiver dryer and line by spraying them
• Plug with a parts cleaner to prevent scratches and pre-
• Rag vent dirt from accumulating on the connectors.
• Cleaning fluid • Bolt (2) tightening torque: 7.8 - 11.8 N·m

* When connecting the hoses, be sure not to mis-

take the IN and OUT sides.

IN: Hose from the condenser

1
outlet (LIQUID1 hose)
OUT: Hose that goes to the
2 air conditioner unit (LIQUID2
hose)

84402826 - May 2011

9011-3
 Removal and Installation of Receiver Dryer

3. Use a wrench (10 mm) to remove the 1 bolt (1), and
then remove the receiver dryer (2).
Installation of Receiver Dryer
• To install, perform the reverse of the removal proce-
dure.
When installing the lines and bolts, tighten them to the
specified torque.
If the torque is not specified, see the "Bolt Size and
Torque Table".
• Check the compressor oil quantity.
The compressor contains 135 cc of oil.
The oil quantity being low will cause compressor seiz-
ing and a reduction in durability. The oil quantity being
high will cause a reduction in cooling capabilities.
Make sure to check the oil quantity and adjust if
needed.
Resupply quantity: 20 cc
Resupply oil: SP-10 or SP-20 (P.A.G. oil)
• Perform air conditioner gas charging.
For details, see "Gas Filling Procedures".

84402826 - May 2011

9011-4
 Section

9015

Work Precautions

84402826 - May 2011

84402826 - May 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Vacuuming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Gas Filling Operation, High-pressure Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Gas Filling Operation, Low-pressure Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.

9015-1 PRINTED IN FRANCE
84402826 - May 2011 Copyright © 2011 CNH FRANCE S.A.
9015-2 PRINTED IN FRANCE
 Work Precautions

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.

84402826 - May 2011

9015-3
 Work Precautions

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

84402826 - May 2011

9015-4
 Work Precautions

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

84402826 - May 2011

9015-5
 Work Precautions

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

84402826 - May 2011

9015-6
 Work Precautions

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).

9 Low-pressure gauge
10 High-pressure gauge

84402826 - May 2011

9015-7
 Work Precautions

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.

84402826 - May 2011

9015-8
 Work Precautions

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.

84402826 - May 2011

9015-9
 Work Precautions

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 bubbles are visible. The glass then be-
is correct comes transparent and turns to a pale,
milky-white color.

When overfilling After the AC is turned ON, no air bubbles

occurred at all are visible.

When filling was After the AC is turned ON, air bubbles are
insufficient 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.
84402826 - May 2011
9015-10
 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.

84402826 - May 2011

9015-11
 BOX FUSE(ATTACHMENT FOR CAB MAIN HARNESS)
8R 105 8R 105 2 8R 105
5RW 103 5RW 103 1 5RW 103
F34 F41 F42 F43 F44

3R 105d

3R 105b
3R 105e

3R 105c

3R 105a
180,215,242,250,260,267
400,410,411,412,413,414,415,416,419,420,430,444,445,446,450,490,492,532,534,535,538,559,660,800,801,802,803,805,0806,807,812,813,900,901,902,903,904,905,906,907,908,909,910,911

5RW 020
DIESEL ENGINE

(CN.A50
YAZAKI
1
2
(F20)

(F19)

(F18)

(F17)

(F16)

(F15)

(F14)

(F13)

(F12)

(F10)
FUSIBLE LINK FUSE FUSIBLE LINK FUSIBLE LINK

(F11)

58L
(F9)

(F8)

(F7)

(F6)

(F5)

(F4)

(F3)

(F2)

(F1)
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 SAFETY RL
20 19 18 17 16 15 14 13 12 11 20 19 18 17 16 15 14 13 12 11 ALTERNATOR

15A

15A

10A

10A

10A

10A

10A

20A

15A
50A 15A 65A 50A

10A

15A

10A

15A

10A

10A

10A

15A

15A
1 1 1 1 8B 797 E 24V 50A

5A

5A
SUMITOMO SUMITOMO 2
(CN.A41) (CN.A42) 2 2 2 M6
YAZAKI

WIPER / WASHER
YAZAKI YAZAKI YAZAKI

BLOWER MOTOR
YAZAKI

CIGAR LIGHTER
M8

TRAVEL ARALM
(CN.D15)

(BOOM,HOUSE)
1 2 3 1 2 3 1 2 3

COMPRESSOR
REFUEL PUMP

2
1

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

10

12
13
14
15
16
17
18
19
20

10

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
7
8
9

1
2
3
4
5
6

6
5
4
3
2
1

1
2
3
4
5
6
DC / DC
YAZAKI YAZAKI YAZAKI (CN.D16)

SPARE

SPARE

(GATE)
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
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
G2

P 40i
P 40j

1.25W 109
1.25W 108
1.25W 107
1.25WR 141
1.25WR 142
1.25WR 145
1.25WR 146
1.25WR 147
1.25WR 148
1.25Y 870 1.25Y 870

1.25W 112

1.25W 110
1.25W 111
1.25G 510 0.75R R

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
1.25WR 235
WL 267

1.25RW 140
1.25W 205

0.85VW 170
1.25Br 515 0.75L L

0.85OR 225

1.25LW 200

0.85R 130
1.25RB 150
3 2

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
K7

(CN.D19)
RL 166 0.85G 507

YAZAKI
(CN.D17)

(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
RELAY BATTERY
601,602,603,701,702,703 G1 (CN.D13)
STARTER MOTOR
CONTROLLER A 503,504,505,515,520,521,530,536,537,539,558,804,808,809
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
M8 M8 YAZAKI
60R 001 B
M10
M
RELAY RELAY RELAY RELAY DPF RELAY RELAY

10 11 12 13 14 15 16 17 18 19 20
6 7 8 9
ＰＯＷＥＲ　２４Ｖ 1.25W 108 V 097 (CN.D21) 5Y 004 S
M1

0.85BG 660
1 1
A1 ECM KEY ON BATTERY RL IDLE STOP RELAY NEUTRAL START STARTER CUT M10 M10 M10 M10

7 8 9 10 11 12 13 14
4 5 6

(CN.D11)
58Y
YAZAKI
12 1.25W 108a VG 098 2 M4 YAZAKI YAZAKI M5

- + - +
(CN.D12)

(CN.C21)
SDL
YAZAKI
ＰＯＷＥＲ　２４Ｖ 11 G 099 (CN.D20)

6 5 4 3
2
3

1
24V 5.0kw

(CN.A44)
VR 595 M4

(CN.C3)
YAZAKI
22 4

YAZAKI
P1

60B 799
2
1
SDL
GND_2 1.25BG 601 Br 596 5BW

SDL
2 5 5L 021 1

1.25WR 511
1.25G 501
1 2 3 4 5

1
GLOW PLUG

1 2 3

B
1.25BG 601a BG 612
13 6
X37

YR 882a
LR 881a
1 4 2 1
GND_3 0.85B 701 MONITOR DISPLAY 12V 12V

14 13 12 11
(CN.D9)
SWP
YAZAKI
5 5

7 6 5 4
YAZAKI

10 9 8
R1

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

3
1
2
5
4

3
1
2
5
4

3
1
2
5
4

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

1.25WR 141

1.25WR 146
1.25WR 147

1.25WR 145
0.85WR 511 1.25WR 511 0.75Y 390 0.75YR

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

0.85Y 011

0.85LR 373
0.85YL 808
0.85LgR 500

0.85LY 824

0.85GrR 012
0.85BrR 010
V
NPN_OUT1 SOL SWING BRAKE 6 W 800 H1 CAN L 6 PG 041b 6 PG 041b 0.85YR 882 5 YR 882 0.85Br 515 4 1.25Br 515 0.75WR 391 3 0.75LR 7
W
NPN_OUT2 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
LCD DISPLAY
RELAY STARTER
NPN_OUT3 SOL 2 STAGE RELIEF 7 Y 802 TxD(RS232C) 8 WL 061b 8 WL 061b P 040b 7 P 040b 373 0.85RY 840 6 0.75RY 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
NPN_OUT4 FREE SWING 3 Br 803 RxD(RS232C) 9 W 060b 9 W 060b PG 041b 8 PG 041b 303 7
K2 0.75G 359 6 Br 2 V

508
509
TFT FULL COLOR

118
10 11 12 13 14 15 16 17 18 19 20
5 6 7 8 9

1
NPN_OUT5 RL BATTERY 8 0.85O 804 GND(RS232C) 19 BL 064b 19 BL 064b WL 061b 9 WL 061b 142 8 0.85B 779 1 5R 003 0.75L 360 7 L 3 W

517
519
I/O

NPN_OUT6 SOL OPT 2SPEED 14 YR 805 5V-OUT PGM_WRITE 3 V 097 3 V 097 W 060b 10 W 060b 140 370 2 5Y 004 0.75B 361 9 0.75B 8 GND

(CN.D28)
SWP
YAZAKI
NPN_OUT7 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 0.75BW 693b 4 0.75BW
070MIULTI

1 2
NPN_OUT8 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
INTAKE THROTTLE
AMP

NPN_OUT9 RL DPF 0.85YL 808 8V-OUT CAMERA+ R 960 R 960 BW 950 BW 950 112 511 0.75BR 392 BL

(CN.A52)
17 10 10 13 12

(CN.D27)
1 2
YAZAKI
DC-MOTOR

YAZAKI
1 2 3 4

NPN_OUT10 SIG WASHER 19 V 809

P10 CAMERA GND 11 B 961 11 B 961 1.25BG 610 14 1.25BG 610 515 515 0.85G 509 1 0.85GrR 012 1 0.75GR 393 13 G

SDL

(CN.D31)

58
YAZAKI
A/D-IN THERMO SN 010 012 0.85L 372 0.85B 750 0.75P 326 VW BL

1
13 13 2 2 11 2
M

1
040/070HYBRID I/O

CN-A
AGND 14 14 840 840 14 G 1
SWITCH PANEL

1 2 3 4 5
(CN.E2)
AMP
PWM_OUT1 PUMP POWER(OUT) 0.85Y 900 SCL(12C) 845

9 10 11 12 13 14 15 16 17 18
3 16 16 6

5 6 7 8
S11 M24

(CN.D29)
CN-A
YAZAKI
PWM_RTN1 PUMP POWER(RTN) 6 0.85BY 901 SDA(12C) 17 17 824 L 5 Vcc
WIPER
AMP

PWM_OUT2 BOOM DOWN(OUT) 0.85O 902 GND 1.25BG 611 1.25BG 611 VW OUT

2
1
1 15 15 3
S12

(CN.A45)
PWM_RTN2 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
K36 K35 K5 K3 K11
22 21 20 19 18 17 16 15 14 13 12
11 10 9 8 7 6 5 4 3 2 1

0.85L 904

SDL
PWM_OUT3 P1 FLOW(OUT) 2
S10

1 2 3 4

(CN.D38)
MT090
SUMITOMO
PWM_RTN3 P1 FLOW(RTN) 5 0.85BL 905 1.25W 119 1

520
521
RELAY RELAY RELAY RELAY RELAY RELAY RELAY EGR VALVE

BG 613
BG 614
W.LAMP

1 2
SHLD GND CAMERA1 SIG Y 962 Y 962 1.25G 754
8
S2
1 1
K37 SPEAKER:R SPEAKER:L ROOM LAMP BEACON HORN LAMP:CAB LAMP:UPPER K10 2

0.85WR 512
0.85Br 516
7 CAMERA1 GND 11 W 963 11 W 963 0.75WR 386 5 0.75WR 5
M20
(CN.A4)

(CN.A21) (CN.A22) (CN.A20) (CN.A19) (CN.A16) (CN.A18) (CN.A17) U

S-G BOOT_CNT 11 WR 062
TRAVEL MODE
CAMERA2 SIG 2 YB 967 2 YB 967 0.85BrR 210 1 0.85BrR 210 0.75WB 387 6 0.75WB 6 M
FWE 12 WR 063 S4
IDLE MODE
CAMERA2 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
SW_IN12 LM MAG SW 9 YR 541 CAMERA3 SIG 3 YR 972 3 YR 972 0.85WR 282 3 0.85WR 282 0.75RG 356 8 0.75LW 8 GND
S86 YAZAKI

(CN.D37)
58W
YAZAKI
M25

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
SW_IN13 LM MODE 10 CAMERA3 GND 13 13 4 (CN.D81) SOLENOID VALVE 1 1 1

(CN.E3)
DL090
SUMITOMO
1 2
DPF CLEAN

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
6 5 4 3 2 1
12 11 10 9 8 7

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 840 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 0.75RW 352 4 0.75L 4 VCC
(CN.A3)

RXD 12 PL 056 S88 D-IN4 DOOR SW 7 OL 593 7 OL 593 LY 824 8 0.85LY 824 SUMITOMO SUMITOMO
LOCK
9
(BLUE TAPE)
Y2
040MIULTI

3
1
2
5
4

3
1
2
5
4

3
1
2
5
4

3
1
2
5
4

3
1
2
5
4

3
1
2
5
4

3
1
2
5
4
MENU MT090
RS232C_TXD 3 W 060a D-IN5 ONE TIME WIPER 8 YG 594 8 YG 594 LG 825 9 LG 825 10
(CN.C2)

S89 (CN.A30) SWING CRANK ANG(MRE)

(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 11
24V

WG 831

WG 823
SENSOR

G 888

OR 826

LW 841
LgW 190
LgW 191
LG 825

LG 832

LG 842
2 1 (S2)

LR 880
RL 164

RL 165
DISPLAY SEL
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9

1 2
0.85GW 216
0.85GW 217
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

1.25GR 875

1.25LW 200
1.25LW 201
RS232C_GND

0.85R 885
0.85RB 292

0.85RB 293

0.85RB 290
2 10 10 11 2 2 2 12

0.85Y 980

0.85YB 984

1.25Y 870
0.85L 981

0.85LB 985
S90 BRAKE

1.25GrR 195
1.25GrR 196
D-OUT1 WIPER-INT GR 820 GR 820 YL 591 YL 591
70W Vcc
GND 5 14 14 12 (WHITE TAPE)
Y3 13 1

(CN.E4)
YAZAKI
TRIP / CAMERA
(CN.A2)

B49

1 2 3
GND 13 D-OUT2 WIPER-CNT 15 Lg 821 15 Lg 821 V 592 13 14 3 OUT(PULSE)

(CN.D66)
SWP
YAZAKI

(CN.G2)
CN-A
YAZAKI
LR 881
2STAGE LAMP

(CN.D61)
SWP
YAZAKI
CAN_H 6 P 040c D-OUT3 RL FUEL PUMP 16 VG 822 16 VG 822 YG 594 14 YG 594 GR 180 1 0.75GR 180 0.75R 182 1 0.75R
E2 15 2 GND

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 16
+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)
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 Y4 COMMON RAIL PRESS
26 25 24 23 22 21 20 19 18 17 16 15 14
13 12 11 10 9 8 7 6 5 4 3 2 1

2STAGE LAMP 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 983 829,834850,851,852,853,880,882,885,943 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 0.75G 812 0.75Y 802 2 0.75B RELIEFE 1.25B 757 2 0.85B 1
70W

(CN.E5)
AMP
1 2 3
L 530 BW 950 Lg 813 0.75W 310 VW
SW_1 IDLE SW 15 22 7
Y5 1 2
B52

(CN.D65)
CN-A
YAZAKI
(YELLOW TAPE)
SW_2 ANTI-THEFT 16 VG 531
S1
WL 807 8 0.85WL 807
E1 0.75R 311 6 GrB 3
(CN.A1)

2
1
R3 S51 POWER

(CN.D63)
SWP
YAZAKI
12 13 14 15 16 17 18 19 20 21 22
1 2 3 4 5 6 7 8 9 10 11

SW_3 COOLANT 8 GrR 532 ＳＵＮＬＯＡＤ　ＳＥＮＳＯＲ VG 822 9 0.85VG 822 0.75R 184 1 0.75R 0.75G 312 15 WB
CAMERA (S4)
7 8 9 10 11 12 13

1 2
4 5 6

(See page 2/2) 0.85R 130 1 0.85R 130 KEY SWITCH LR 880 10 0.85LR 880 0.75G 812 2 0.75B SAVE 0.75B 690b 11 0.75B
TRAVEL
WB 949 0.85RB 290 0.85RB 290 YR 882 0.85YR 882
Y6 0.85WL 807 B
（ＣＮ．Ｃ４）

1 2 11 1 12
THROTTLE VOL. LIMIT SWITCH CONNECTION (GREEN TAPE)
H2
ＹＡＺＡＫＩ

B61 OFF ACC ALARM BOOST PRESS

(CN.C6)

SN_IN1 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
１．０Ⅲ

B G1 G2 ACC M ST
AMP

X30 (GATE) 24V,107dB SENSOR

1 2 3

0.85GL 492 0.85LgR 500 0.85LgR 500 0.85R 885 0.85R 885 0.75L 314 LW
ON

(CN.D69)
SWP
YAZAKI
SN_IN2 SN FUEL LEVEL 15 4 13 10
0.85Y 410 A4 0.85BrR 010 0.85BrR 010 ＨＥＡＴ 0.85GW 943 0.85GW 943 0.75G 315 Br 0.75RW

1 2
POT_IN1 SN_P P1 21 WIPER 5 14 SOLENOID VALVE 17 1

(CN.E6)
SUMITOMO
ST

1 2 3
0.85L 411 0.85RY 840 0.85RY 840 ＯＦＦ 0.85LR 242 0.75BW 691b 0.75BW 0.75L
POT_IN2 SN_P P2 9 CONTROLER R 970 1 TO CAMERA 3 6 15 14 2
B47
(CN.C5)
1 2

C
FREE

(CN.D64)
SWP
YAZAKI
POT_IN3 SN_P N1 22 0.85Lg 412 0.85GR 845 7 0.85GR 845 16 0.75R 187 1 0.75R 2W 250 1 16 0.75RL 3
(BLUE TAPE) ＡＣＣ
AMP

B 971 2
Y18
040

1 2
POT_IN4 SN_P N2 10 0.85G 413 WIPER SW.IN(INT) 11 GR 820 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
YR 972 3 ＯＮ

Br 834
0.85GR 414 WIPER SW.IN(CNT) Lg 821 0.85B 720 0.85B 720 2B 764 REFUEL PUMP 0.75GW 320 0.75L

(CN.C20)
POT_IN5 SN_P SWING 23 12 9 18 2 24

10 11 12 13 14 15 16 17 18 19 20
5 6 7 8 9
(NO TAPE)

1 2
3 4
YAZAKI
WR 973 4 OIL PRESS

0.85B
A/D

0.85Y
ＳＴ

0.85L
0.85V 415 WASHER SW. IN V 809 0.85BG 620 0.85BG 620 (See page 2/2) 0.75RG 321 0.75RL

(CN.D76)
58W
YAZAKI
SWP
POT_IN6 SN_P UPPER 12 13 10 19 19
0.85YG 416 POWER (24V) IN 0.85BrR 210
SENSOR

1 2
POT_IN7 SN_P TRAVEL 24 1 20 18

3
ROOM LAMP 3 2 1 1 2

5 6 7 8 9 10
1 2
WASHER CONT.(+) 0.85WY 829 0.75GR 180 0.75WB 322 0.75WB

(CN.B6)
MT090
SUMITOMO
0.75WB
POT_IN8 13 2
E4 1 30 1

(CN.A46)
SDL
YAZAKI
TO CAMERA 2

(CN.E7)
SUMITOMO
YAZAKI

(CN.A55)
(CN.C8)

1
2
3
YAZAKI

R 965
1 2

1
2

YAZAKI
YAZAKI

(CN.D68)
MT090
SUMITOMO

1 2 3
0.85LY 418 WASHER CONT.(-) 0.75R 181 0.85WV 830 0.75YB 323 0.75LY 0.75LY

1 2
B21
POT_IN9 SN_ANG THROTTLE 25 3 ２４Ｖ，１０Ｗ (RED TAPE) SDL 1 2 3 2 1 25 2
090

B 966 SWP

SDL
2

4
2
5
3
6
1

1 2
POT_IN10 SN_POWER LOAD 26 0.85Gr 419 WINDOW CONTROL 9 (CN.B2) 4 5 6 0.75R 182 3 0.85B 756 2 0.75BY 324 20 0.75BY 0.75BY 3
(CN.B3)

1 2 3 4
YB 967 3

3 4

(CN.D58)
SWP
YAZAKI
OFF
(CN.C22)

0.85G 503 REV. SIG. 0.85G 485 G 888 G 888 0.75R 183

0.85VW 170
0.85BO 428
COMP_IN1 KEY ON

5 6 7 8
1 2 3 4
7 7 2 1 4 21

0.85Y 408
(CN.C19)

0.85RY 840
YAZAKI

0.85LY 418
YAZAKI

1 2
3 4
YAZAKI
WB 968
1
2

4
CN-A

COMP_IN2 SW GATE LEVER 0.85RY 520 STOP SIG. 0.85L 486 Y 843 Y 843 0.85RY 844 CN-A 0.75R 184 0.75YG 342 0.75YG

0.85R 130

0.85RB 290
20 DOOR 1 2 2 5 31

0.85LgR 500
SWP

0.85BrR 010
0.85Br 515 WINDOW LIMIT SW. L 530 0.85L 530 0.85GR 845 (CN.B1) 0.75R 185 WASHER
COMP_IN3 BATTERY CHARGE 8 4 ON 1 1 6 22
SW_IN1 AVcc 11 0.85W 400 WIPER MOTOR(CW) 8
5 0.85LR 827 YG 594 2 0.85YG 594 7 0.75BR 344 9 0.75BR FUEL TEMP.SENSOR
0.85BO 428 WIPER MOTOR(CCW) 0.85LB 828 X29 G 850 0.85G 850 0.75R 187 0.85WV 829 0.75G 345 0.75RL 0.75YG t C
M

(CN.E8)
ECO-J
AMP
SW_IN2 AGND 1 6 ＬＩＭＩＴ　ＳＷ 3 8 1 13 1
(CN.C9)
YAZAKI
1 2
3 4

M4 B3

1 2
SW_IN3 AGND 14 0.85BW 420 GND 10 1.25B 710 （ＤＯＯＲ） O 851 4 0.85O 851 0.85B 755 2 23 0.75LW 2
24V

(CN.D67)
CN-A
YAZAKI
SW_IN4 SW AIR CLEANER 16 LW 533 LW 841 5 0.85LW 841 0.75WR 365 7 0.75WR
SW_IN5 P-SW OPT1 3 VY 534
M3 S53 1 OL 593 2 OL 593
R 960 1 TO CAMERA 1 YL 591 6 0.85YL 591 RADIO AM / FM STEREO 0.75GW 366 2 0.75GY
P15

2
1
KNOB (RIGHT)
B 961 2 (NO TAPE) P3 24V,2A <NA>
4 5 6
1 2 3

SW_IN6 P-SW OPT2 17 GY 535 2 Y 843 4 Y 843 GL 852 7 0.85GL 852 0.85Y 900 1 0.75Y 900 26
(CN.C7)
YAZAKI

Y 962 HYD.OIL TEMP BOOST TEMP.SENSOR

CN-A

SW_IN7 SW FREE SWING GW 536 WIPER MOTOR BG 613 BG 613 3 OL 853 0.85OL 853
S16 0.85O 902 0.85O 902 0.75R 340 0.75RB
(CN.C23)

4 3 1 8 2 3
I/O

(CN.C18) SENSOR
YAZAKI

BUCK UP
1 2
3 4

HORN LOW
YAZAKI
1
2
3

W 963 4
B2
CN-A

WG 537 0.85L 530 L 0.85L 904 0.75L 904 0.85LR 880 0.75R 0.75BR t C

(CN.E9)
PACKARD
SW_IN8 SW HBCV / TRVL ALM 18 3 6 3 8 1
IDLE SW
SWP

(LEFT)
B92 B51

GND
4 5 6 7 8
1

ACC
(CN.A47)
SDL
YAZAKI

R(+)

1 2
L(+)
t C

R(-)
YL 538 0.85LR 0.85LR 827 0.85BG 625 L 0.85G 906 0.85G 906 0.75YB 490 0.75RL

L(-)
SW_IN9 SW FILTER IND 5 1 7 4 2 YAZAKI(CN.D70) 27 2
24V,370Hz
SW_IN10 SW ENG STOP 19 LB 539 M 0.85LB 3 0.85LB 828 ＤＯＯＲ　ＯＰＥＮ：ＣＬＯＳＥ 0.85YG 594 4 Y S11 0.85W 908 5 0.75BW 491 1 0.85B 760
111dB
4 0.75G

U1 X28

4 5 6 7 8
1
ＤＯＯＲ　ＣＬＯＳＥ：ＯＰＥＮ

2 3
0.85BG 626 Y WIPER 0.85V 910 0.85VR 910

(CN.B4)
62C
YAZAKI

(CN.D56)
SWP
YAZAKI
SW_IN11

GrR
6 2 5 6 YAZAKI(CN.D71) 28

OW
(CN.C10)

GR
1 2
3 4

Gr
YAZAKI

S31

G
H4

B
0.85G 0.85G 485 0.85G 850 G
X8

1 2
SW_IN12 4 3 7 32
SPEAKER(R) FUEL LEVEL EGR INTAKE TEMP.SENSOR

2 3
0.85L 0.85L 486 RL 167 0.85B 723 G 1ST.ACT
SW_IN13 6
DC/DC(24V/12V) 8 8
SENSOR R5 HORN HIGH

1
2
3
4
5
6
7
8
9
S/V(R)

(CN.E10)
YAZAKI
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 0.75WR 1 t C
CONVERTER
S32 (RIGHT)
B86
(CN.C24)

B93

1 2
R
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) 0.75GY 2
1
2

(CN.D7)
NMW
MITSUBISHI
32
27
22
17
14
10
24V,370Hz

5
CN-A

RL 162
２４Ｖ 1 2 3 4
0.85BL 983 24V IN (MAIN) 0.85OR 225 GW 536 0.85GW 536 1ST.ACT 0.85BL 905 0.75BL 905 0.85BG 660 0.75B 0.85B 761

1.25B 728
0.85RB 291
4 6 3 11 1

0.85Y 980

0.85BY 982

31 30 29 28
26 25 24 23
21 20 19 18

13
0.85L 981

0.85BL 983

9 8 7 6
4 3 2 1
S/V(L)
5 6 7 8 9 111dB
0.85LB 985 24V IN (BACKUP) RL 163 WG 537 0.85WG 537 0.85GB 907 0.85GB 907

(CN.D57)
SWP
YAZAKI
2 2 4 12 YAZAKI(CN.D73)
YAZAKI

16 15
12 11
GND 0.85B 708 YL 558 0.85YL 558 0.85YL 818 0.85YL 818

1 2
5 5 13
ACC PA PRESS. SENSOR WATER TEMP.SENSOR
X15 H5 SPEAKER(L)
12V OUT(BACKUP) 3 0.85RY 280 YB 570 6 0.85YB 570 (CN.B13) 14 B42

(CN.E11)
SUMITOMO
SOCKET KNOB (LEFT) (P1)
CONTROLLER B
P2

(CN.D74)
SWP
YAZAKI
t C
B1
12V OUT(MAIN) 1 0.85WR 281 V 571 7 0.85V 571 0.85WB 909 15 0.85R 885 1 0.75RB 1
BEACON

1 2
X2

3
S15

1 2
0.85B 712 0.85WR 282 1 0.85BL 983 GND 4 0.85BW 709 Br 834 8 0.85Br 834 0.85VG 911 16 0.85VG 911 0.75W 400 1 0.85B 762 2 0.75BY 2
12V

(CN.D45)
ECO-J
AMP
M8 YAZAKI
(CN.C25)

L
YAZAKI

1 2 3
1 ＰＯＷＥＲ　２４Ｖ 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 0.75R 3
A13
1
2

HORN (CN.B22)
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

9 10 11 12 13 14 15 16 17 18
5 6 7 8
12 10 7
S69 YAZAKI(CN.B14)
18 3

(CN.D75)
SWP
YAZAKI
0.85L 981 0.85L 981 0.85YL 591 Y 0.85WR 281 0.75R 886
X36
ＰＯＷＥＲ　２４Ｖ 11 11 4 1
RADIO (NOT USED)
E51 CIGAR LIGHTER YAZAKI(CN.B15)

4 5 6 7 8
1

1 2
0.85BY 982 0.85BY 982 0.85BG 627 Y 0.85BW 709 0.75B 763

(CN.B5)
62C
YAZAKI
22 12 5 MUTE 2 OVER HEAT SW.
YAZAKI(CN.B16) PRESS. SENSOR
24V,5A
B44
2 3
4 5 6 7

(CN.A56)
GND_2 2 1.25BG 602 0.85BL 983 13 0.85BL 983 0.85GL 852 3 G
S33 M4
X35

YAZAKI
(CN.A28)

(P2) ISUZU(CN.A24)
YAZAKI

ＬＩＭＩＴ　ＳＷ 12V OUTPUT

2 3
1.25BG 602a 0.85B 713 0.85YR 220 0.85RY 280 0.85RY 280 0.85B 726 G

SDL
13 14 8 2ND.ACT
S52

1 2 3 4
（ＷＩＮＤＯＷ） (FOR RADIO) DUAL SWITCH
PA

P-G S/V(R)
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

(CN.D46)
ECO-J
AMP
(RECIVER DRYER) CAM ANG (MRE)
(CN.C14) (CN.C13)
S34

1 2 3
0.85B 702a O 590 O 590 0.85BW 709 0.85BW 709 0.85B 727 O 0.75L 411
S70
16 6 16 2 2
SENSOR

(CN.B17)
SWP
YAZAKI
S54

(CN.D77)
090
SUMITOMO
N-G GND 9 BG 614 3 BG 614 17 2ND.ACT 0.75BW 421 3 0.85GW 943 2
HORN VOL.SW

1 2
S/V(L)
9 10 11 12 13 14 15 16 17 18
1 2 3 4

1 2
20 YAZAKI(CN.A31F) 2 18 AIR SUSPENSION 1.25W 944 1 1 Vcc

(CN.E12)
SUMITOMO
9 10
L-G
B87

1 2 3
GND_A 10 6 3 5 3 OUT(PULSE)
PRESS. SENSOR
B43
(CN.A49)
SDL
YAZAKI

5 2 ＷＩＮＤＯＷ　ＯＰＥＮ：ＣＬＯＳＥ 1.25GR 875 0.85YR 221 1.25R 0.85W 400 0.75W 400 GND
21 1 1
M 1
(N1)
2

(CN.D78)
SWP
YAZAKI
A-G 4 1 ＷＩＮＤＯＷ　ＣＬＯＳＥ：ＯＰＥＮ 1.25B 714 0.85B 720 1.25B 0.85BW 420 0.75BW 420 0.75R 316 Y
NPN_OUT1 6 4 2 2 MAGNET CLUTCH 17
7 8
0.85Y 410 0.75Y 410 0.85W 402 0.75L 317 T
Y8

1
NPN_OUT2 4 3 1 (COMPRESSOR) 18
5 6 7 8

(CN.D47)
ECO-J
AMP
10
1
2
3
4
5
6
7
8
9

CARLING

(CN.B18)
MT090
SUMITOMO

1 2 3
NPN_OUT3 SOL POWER SAVE 7 G 812 YAZAKI(CN.A26F) 0.85YR 222 1 0.85L 411 4 0.75L 411 0.85Lg 412 2 0.75G 318 19 OB
VC2 24V SUCTION CONT.VALVE

1 2
NPN_OUT4 SOL FAN REVERSE Lg 813 0.85R 1.25GR 875 0.85B 721 0.85Lg 412 0.85Lg 412 0.85BW 422 1.25W 944 1.25G 0.75BL 692b 0.75BW
X6
3 (CN.C12) 2 5 3 1 15
24V
1 2 3
4 5 6

(CN.C11)
YAZAKI

(CN.E13)
MT090
SUMITOMO
NPN_OUT5 8 0.85LR 881 0.85W 1.25B 714 0.85G 413 6 0.75G 413 3 2
70W
CN-A

LAMP
Y35
I/O

1 2
NPN_OUT6 14 0.85YR 882 VR 230 1 VR 230 0.85GR 414 7 0.85GR 414 7 1
(CAB) YAZAKI(CN.A27F) PRESS. SENSOR
NPN_OUT7 15
E3
1.25WR 235
0.85LR 240
2 1.25WR 235
0.85LR 240
0.85V 415
0.85YG 416
8 0.85V 415
0.85YG 416
(N2) B40 0.75RG 394
0.75RW 396
20 0.75RB
0.75RW
NPN_OUT8 18 3 ENG STOP BEACON<EU> 9 16
PUMP
NPN_OUT9 BUCKET CLOSE (PWM) 17 0.85YL 818
MEMORY CLEAR 1.25WR 148 4 0.85WR 148 S9 S85 0.85Gr 419 10 0.85Gr 419 0.75W 403 1 10

(CN.D48)
ECO-J
AMP
PUMP INJ1 (#1)

(CN.D39)
SWP
YAZAKI
X23

1 2 3
NPN_OUT10 19 YAZAKI(CN.A28F) BG 635 0.85LG 302 5 0.85LG 302 0.85WL 430 11 0.85WL 430 0.75G 413 2 0.75Y 900 1 11
YAZAKI(CN.A37M)
Y7

1 2

(CN.E14)
MT090
SUMITOMO
0.85R 1.25GR 876 BrY 084 LB 539 6 0.85LB 539 0.85BL 450 12 0.85BL 450 0.75BW 423 3 0.75BY 901 2 1.25R 374 5 1.25W 4 1
IMMOBILIZER 24V POWER
040/070HYBRID I/O

YAZAKI(CN.A37F)
Y63

1 2
VG 531 0.85W 1.25B 715 0.85Y 408 0.85Y 408 0.85GW 444 0.85GW 444 1.25G 375 1.25L
PWM_OUT1 ARM CLOSE (OUT) 3 0.85G 906 BG 637
YAZAKI(CN.A33F) X9 LAMP 70W 0.85LY 418
7
8 0.85LY 418
9
6
10
3
9
6
10
3 0.85VG 445
13
14 0.85VG 445 1.25R 378
1
6 1.25WR
8
1
2

(CAB) DIAG SW PRESS. SENSOR

10

10
YAZAKI(CN.A33M) YAZAKI(CN.A29F)
B22

1
2
3
4
5
6
7
8
9

1
2
3
4
5
6
7
8
9
PWM_RTN1 ARM CLOSE (RTN) 6 0.85GB 907 BG 634 0.85BO 428 9 0.85BO 428 5 2 5 2 0.85LR 446 15 0.85LR 446 1.25Br 379 2 1.25LW 5
M8 M8
E3 X24 YAZAKI(CN.A36M) 4 1 4 1 (PILOT SWING) P1 INJ3 (#4)

(CN.D40)
ECO-J
AMP
AMP

PWM_OUT2 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 0.75L 904 1 1.25R 376 8 1.25R 2
TO CONTROLLER C YAZAKI(CN.A36F)
Y11

1 2

(CN.E15)
MT090
SUMITOMO
0.85WR 148
0.85WB 909 YAZAKI YAZAKI PG 041g PG 041g 0.85GL 492 0.85GL 492 0.85W 404 0.75BL 905 1.25RW 377 1.25LY

0.85BG 620
0.85LG 302
PWM_RTN2 FAN SPEED (RTN)

0.85LB 539

0.85B 722
4 11 17 1 2 4 6 1

0.85LG 842
FLOW

(CN.D49)
ECO-J
AMP
(CN.C17) (CN.C32) CARLING CARLING
Y65

1 2
22 21 20 19 18 17 16 15 14 13 12

1 2 3
11 10 9 8 7 6 5 4 3 2 1

PWM_OUT3 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 1.25R 380 13 1.25RB 3 2
0.85VG 911 WL 266 A BG 631 1 BG 631 BW 950 BW 950 (CN.B7) (CN.B10) GrR 532 0.85GrR 532 0.85BW 424 1.25RG 381 1.25LR
PWM_RTN3 OPT PRESS (RTN) 5 2
X25 RL 166 RL 166
13 19 3 9 7
SHLD GND 8 0.85G 505
0.85RY 521
3 X5 B
C P 040
2
3 P 040h
0.85GW 943 14 0.85GW 943 LW 533
YL 538
20 0.85LW 533
0.85YL 538
12
INJ2 (#3)
7 4 21 14
EST CONNECTOR A
(CN.A8)

PRESS. SENSOR PROPORTIONAL S/V

PG 041 PG 041h
B26
1 2 3
7 8 9 10 11 12 13 14

D 4

(CN.A19)
YAZAKI
(CN.D10)
D
SUMITOMO
S-G

(CN.E16)
MT090
SUMITOMO
YR 067 YB 570 LB 559

20 19 18 17
16 15 14 13
12 11 10 9
BOOT_CNT

5 6 7 8
1 2 3 4
11 5 22 1

8 7 6 5
4 3 2 1
(PILOT UPPER)
Y64
3 2 1
14 13 12 11 10 9 8 7

PL 081 PL 081
F A B

BOOM
(CN.52)
HD10
DEUTSCH

E 5

(CN.D41)
SWP
YAZAKI

1 2
YR 068 V 571 0.85O 902
G

(CN.A48)
SDL
YAZAKI
E

FWE
Y59
12 6 1 2
F 6 SOL3

6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22

1 2
H

SW_IN12 9 P 040e 7 0.85W 405 1 0.85BO 903 2 UP

(CN.D50)
ECO-J
AMP
C
(CN.A23)

G
YAZAKI

1 2 3
PG 041e 0.85V 415
SW_IN13 10 8 CAN
S13 OVER LOAD WARNING<EU> FREE SWING<NA> S22 2 (NO TAPE)
INJ4 (#2)
4 5 6
SDL

YR 541 9 P 040j H 0.85BW 425 3

6 5 4

LED
X31 YAZAKI(CN.A34F)
(CN.A26)
SDL
YAZAKI
6 5 4 3 2 1
12 11 10 9 8 7

J ARM

(CN.D42)
SWP
YAZAKI
3 4 5 6
1

(CN.E17)
MT090
SUMITOMO
O 542 10 PG 041j 0.85G 906 1 1

(CN.A54)
Y60
SOL2
Y66
YAZAKI(CN.A35F)

YAZAKI

1 2

1 2
TXD 4 PL 056 LG 833 11 0.85GB 907 2 2
(CN.A7)

PRESS. SENSOR CLOSE

SDL
B27
A
PW 055

1 2 3 4 5
2

RXD 12 12 9 10 (RED TAPE)

(PILOT TRAVEL)
EST CONNECTOR B

7 8 9 10 11 12
6 5 4 3 2 1

RS232C_TXD Y 065a 1.25B 703 9 10 6 3

3 13 OPT POWER 10

10
6 3
DEUTSCH

1
2
3
4
5
6
7
8
9

1
2
3
4
5
6
7
8
9
5 2 BUCKET

(CN.D43)
SWP
YAZAKI
A/C PANEL & A/C UNIT
(CN.A25)

YL 066a 1.25BG 603 1.25B 749 0.85W 406 0.75R 185

X26
RS232C_RXD 10 14 1 1 1
X3 5 2

(CN.D51)
ECO-J
AMP
SOL1 FUEL FILTER
YAZAKI(CN.A32M) 4 1
Y61
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9

60B 798
1 2
(See page 2/2)
S28

1 2 3
RS232C_GND 2 BY 069 1.25W 205 2 4 1 0.85YG 416 2 0.85YL 818 2
TRAVEL ALARM<NA> 7 8 CLOSE
SENSOR
DT

YAZAKI(CN.A32F)
X4 7 8
0.85WG 537

0.85GW 536
P 040i 0.85BW 426
0.85BG 623

0.85BG 622
GND 5 3 3

0.85YR 223
(BLUE TAPE)

0.85Br 834
CARLING
M10
(CN.A6)

GND 13 WB 245 1 4 BG 633 CARLING WL 260 1 0.75WB 334 2

TO GPS UNIT VC2

(CN.D36)
PACKARD
VC2
CAN_H 6 P 040d W 060a 7 Y 065b 2 5 BG 632 (CN.B9) LY 806 2 0.75GW 335 3
B88

1 2
(CN.B11)

0.85BW 429

3
X27

0.85Gr 419
PG 041d WL 061a YL 066b 1.25RB 150 V 050 YR 805 0.75BW 336

0.85W 409
CAN_L 14 12 3 1 6 3 1
PROPORTIONAL S/V
Y62

( See page 2/2)

OPTION LINE
16 15 14 13 12 11 10 9

X32
8 7 6 5 4 3 2 1

+5V_OUT 11 WR 062 4 BG 636 4 2 0.85G 506 7 PL 080 13 RL 167 VY 534 4

CONNECTOR
DIAGNOSTIC

BL 064a 0.85Br 517 0.85G 507 GY 535 0.85VR 910 0.85VR 910 OPT
(CN.A27)
DIAG
AMP

FREQUENCY_IN 1 11 3 8 5 5 1 1
26 25 24 23 22 21 20 19 18 17 16 15 14
13 12 11 10 9 8 7 6 5 4 3 2 1

3 2 1 EXSHAUST PRESS
8 7 6 5 4
3
4 3 2 1

(CN.A24)
SDL
YAZAKI

FREQUENCY_GND 9 Y 065a 1 W 060b 4 9 2 P 040k G 850 6 YAZAKI 0.85VG 911 2 0.85VG 911 2 PRESS
(CN.A29)

PRESS. SENSOR SENSOR

B45
YAZAKI

TO DRM

2
3
1
YL 066a WL 061b PG 041k O 851 SDL
AVcc 7 3 5 10 8
X34 7
(HBCV)
SDL

(CN.D44-1)
ECO-J
AMP
(CN.D52)
X33
2 1

YR 067 P 040f PG 041i 0.85Y 085 GL 852 0.75WB 331

(CN.D44)
SWP
YAZAKI
SW_1 15 6 6 11 3 10 9 10 9 8 1

(CN.D32)
SUMITOMO
7 8 9 10 11 12 13
1 2 3

YAZAKI(CN.B24) (FOR CRANE)

BL 064b

1 2 3
BY 069 PG 041f PB 082 0.85BG 629 3 6 3 6 OL 853 1.25W 405 0.75P 332
B89

1 2

1 2
SW_2 16 8 7 12 1 9 1 2
(CN.A5)

(CN.B23)
PA
YAZAKI

YAZAKI(CN.B25)

(CN.G6)
ECO-J
AMP
(NOT USED) 2 5 (FOR FAN REVERSE) 2 5

1 2 3
SW_3 8 9 8 1.25B 740 13 4 BG 640 10 1.25Gr 425 2 0.75BW 333 3
1 4 1 4
5 14 VG 051 6 8 7 8 7 1.25BW 445 3
LEVEL SWITCH S55
10

10
4 5 6

4
5
6
1
2