Sk75sr-3e S5yt0023e02 Shop Manual - Part3

㨇34.
TRAVEL SYSTEM㨉
(4) Press fitting of master pin

Apply press fitting jig on master pin, and
strike it with a mallet to press fit.
Press fitting of master pin
(5) Adjusting crawler tension (See right Fig.)

After installing, adjust tension of crawler.
Tools: Socket: 19 mm
Adjusting crawler tension
34.1.2.3 CONSTRUCTION
Shoe assy
34-6
㨇34. TRAVEL SYSTEM㨉
34.1.2.4 MAINTENANCE STANDARDS

34.1.2.5 TOOLS AND JIGS

(1) Tightening tools (2) Jig
34-7
34.1.3 UPPER ROLLER

34.1.3.1 UPPER ROLLER ASSY
Upper roller assy
34.1.3.2 REMOVING
(1) Preparation for removal
Remove crawler (Above mentioned).
(2) Removing upper roller (1)
1.
Remove nuts on support tightening
section, and also remove capscrew (2)
M16X90.
Removing upper roller (1)
34.1.3.3 INSTALLING
Installing is done in the reverse order of removing.
(1) Inspection
Before reassembling, check it that it
rotates smooth manually and for leak.
(2) Installing upper roller (1)
1.
Fit it directing nut toward idler side.
2.
Insert it until collar comes in contact with
support.
3.
Fit it directing the countersinking mark of
shaft end upward. Installing upper roller (1)
4.
Apply Loctite #262 on capscrew M16X90,
and tighten it to the specified torque.
Tightening torque: 279 N-m (210 lbf-ft)
Installing upper roller (1)
34-8

Construction of upper roller
34.1.3.5 DISASSEMBLY AND ASSEMBLY

(1) Disassembly
1. Draining out oil
Remove plug (10) and drain out oil.
Tools: Allen wrench: 5 mm
2. Removing snap ring (9)
Mount the end face inside upper roller (1)
on stand jig (f) and separate snap ring
(9), using snap ring pliers.
3. Removing cover (4)
Take off cover (4) upwards, utilizing the
screwed hole for the plug.
Removing snap ring (9), cover (4), O-ring (7),

plate (3)
4. Removing O-ring (7)

Separate O-ring (7) from cover (4).
5. Removing plate (3)
Loosen 2 socket bolts (8) and draw out
plate (3) from roller (1).
Tools: Allen wrench: 10mm
6. Removing shaft (2)
Put the extrusion jig (g) against the end
face of shaft (2) and push shaft (2) with
collar (11) for floating seal (6), using a
press or hammer.
Extruding shaft (2)
34-9
7. Removing floating seal (6).

Take out floating seal (6) from roller (1).
Taking out floating seal (6)
8. Removing floating seal (6).

Remove from collar (3), floating seal (6)
that is located on the side from which shaft
(2) was disassembled.
Removing floating seal (6)
Collar (3) is press fitted into shaft (2). Therefore do not disassemble it.
9. Removing bushing (5)

Since the bushing is thin, machine it on a
lathe or scrape it off, take care so as not
to damage the bore of roller (1).
If the bushing is not worn much, mount
upper roller (1) on jig (f), insert jig (g) into
the end face of bushing (5) and push it out
with a press.
Pushing in bushing (5)
(2) Assembly
Assembly of the upper roller is done in the reverse order of disassembly.
1. Pressing the bushing (5).

Align inner hole of roller (1) and bushing
(5) and press fit it vertically with press so
that jig (h) for bushing push-in jig (h) is
inserted into bushing (5).
Pushing in bushing (5)
34-10
If you fail in this operation by pressing the bushing unevenly, the bushing is distorted and gets
unserviceable. In that case, do not re-use the bushing as it may develop malfunctioning after assembly.
2. Installing floating seals (6).

Two floating seals (6) make a pair. Attach
one floating seal to retainer fixed in shaft
(2), and another to the inside of upper
roller (1).
-Prior to placing floating seal (6) in, apply
engine oil lightly to seal surface.
Installing floating seal (6)
3. Inserting shaft (2).

Coat shaft (2) with a thin film of oil and
insert it into upper roller (1).
4. Installing plate (3).
Mount upper roller (1) on the stand jig (f)
and attach plate (3) to the end face of the
shaft with socket bolt (8). In that case, coat
the screwed part of socket bolt (8) with
Loctite #242 beforehand.
Tightening torque : 33 N-m (25 lbf-ft) Pressing the shaft (2)
5. Installing O-ring (7).

Fit O-ring (7) to the groove of cover (4).
-Apply grease to O-ring.
6. Installing cover (4).
Attach cover (4) to upper roller (1). Use a
press in this operation as a press fit is
used.
7. Installing snap ring (9).
Fix snap ring (9) into upper roller (1), using
snap ring pliers.
Installing plate (3), O-ring (7), cover (4), snap
ring (9)
34-11
8. Filling oil
Fill in 20 cc (1.22 cuoin) of engine oil API
grade CD #30 through the plug hole in
cover (4).
9. Installing plug (10).
Place seal tape around plug (10) and
screw it into the plug hole of cover (4).
Tightening torque : 23 N-m (17 lbf-ft)
-After assembling the upper roller, confirm
that oil is not leaking from it and that it
rotates smoothly by hand.
Filling oil
34-12
34.1.3.6 MAINTENANCE STANDARD

34-13
34.1.4 LOWER ROLLER (TRACK ROLLER)

34.1.4.1 LOWER ROLLER ASSY
Lower roller assy
34.1.4.2 REMOVAL
1. Preparation for removal
Loosen grease nipple to slacken the link.
Put wood blocks on the front and rear
sides of under section of lower frame, and
stabilize the machine.
2. Removing lower roller
Remove capscrew (2) M14X55.
Tools: Socket: 22mm
Weight of lower roller : Approx.15 kg (33
Holding up the lower frame
lbs)
(2) Where crawler is installed

1. Preparation for removal
Slacken crawler, and stop engine keeping
lower frame lifted up with front attachment.
2. Put safe blocks under the front and rear
sides of lower frame.
3. Remove lower roller
Remove capscrews (2) in the same
procedure as that shown in Fig. "Lower
roller assy".
Removing lower roller
34.1.4.3 INSTALLATION
(1) Securing lower roller temporarily
Apply Loctite #262 on 4 capscrews (2)
and tighten them temporarily.
(2) Securing lower roller regularly.
Tighten capscrews (2) to the specified
torque.
(3) Adjusting tension of crawler.
Tighten grease nipple and fill it with grease.
Adjusting tension of crawler
34-14

Construction of lower roller

(1) Disassembly
1. Drain oil
Remove plug (8) and drain out oil.
2. Removing pin (4)
Put both ends of lower roller assy on the
V-shaped blocks (K), apply push-out bar
(j) on upper end face of pin (4), and push
pin out striking with mallet.
Drawing out collar fixing pin (4)
3. Removing collar (7), O-ring (6)

Put lower roller on jig (m) for repair stand
so that the shaft is perpendicularly located,
apply pushout jig (P) on shaft end on
upper side, and push shaft (2) until the
O-ring separate from collar (7) with press
or mallet, and take out collar (7) and O-ring
(6).
4. Removing shaft (2)
In addition, push out and remove shaft (2)
together with the lower collar (7) and O-ring
(6).
Removing shaft (2), collar (7), O-ring (6)
The shaft (2) extrusion operation may cause the remaining lube oil to flow out. Prepare an oil
container beforehand.
34-15
5. Removing collar (7), O-ring (6)

Insert shaft (2) with collar (7) and O-ring
(6) removed in the said procedure into
roller (1) directing the collar (7) side
upward, and take out collar (7) and O-ring
(6) from shaft (2) in the same procedure as
that described in Item 3).
6. Removing floating seal (5) Removing floating seal (5)
Take out floating seal (5) from collar (7).
7. Removing floating seal (5)

Take out floating seal (5) from roller (1).
Removing floating seal (5)

Since thickness of bushing (3) is thin,
remove it through lathe or strip it with
care not damage inner hole of roller.
When the wear of bushing is not large,
place upper roller (1) on jig (m) for repair
stand and apply the end of push-out jig
on the end face of bushing (3) end, and
push it out striking it with mallet.
Extruding bushing (3)
Hammer the inside surface of roller lightly so as not to damage the surface. Put the extrusion jig (n)
uniformly over the circumference of bushing (3) and extrude it little by little.
(2) Installing
1. Attach O-ring (6) to one side
Install O-ring (6) to shaft groove.
-Replace O-ring with new one.
Attach O-ring (6) to one side
34-16
2. Press fitting bushing (3)

Align inner hole of roller (1) and bushing
(3) and press fit it vertically in capacity of
press fit load, 3600kg (7940 lbs), in the
condition that bushing push-in jig (g) is
inserted into bushing (3).
-Apply molybdenum disulfide grease on
press-fit section of bushing, and press-fit it
in ordinary temperature.
-Bushing which fails to press-fit because of Press fitting bushing (3)
the one-side pressing should not be fitted.
3. Press fitting collar (7)

Fit O-ring to the one side of shaft (2)
mating pin hole of collar (7) on which
floating seal (5) is fit with pin hole of shaft
(2) in advance.
-Care should be taken not to damage
O-ring (6) while press-fitting collar (7) to
shaft.
4. Inserting pin (4)
Press-fit pin (4) to pin hole on aligning pin
Inserting pin (4)
holes of shaft (2) and collar (7).
5. Attach floating seal (5) to roller side

Fit floating seal (5) to inner holes on both
ends of roller (1).
-Check that the seal surface is free from
flaws, rusts, etc. before reusing the floating
seal.
6. Inserting roller (1)
Insert roller (1) from the side where collar
(7), O-ring (6) is not press-fitted to the
shaft (2).
Inserting roller (1)
34-17
7. Installing O-ring (6)

Install O-ring (6) to shaft groove.
-Replace O-ring with new one.
8. Press fitting collar (7)
Press-fit collar (7) to shaft (2).
-Press-fit collar (7) on aligning pin (4) hole.
9. Inserting pin (4)
Press-fit pin (4) described in to the pin hole
mating pin hole of collar (7) with pin hole
on the end side of shaft (2).
Installing O-ring (6), collar (7)
10. Filling oil

Remove plug (8) and fill in 90 cc (5.49
cuoin) of engine oil API grade CD #30.
11. Check it for leakage
Before tightening plug (8), check it for
leakage in the condition of air pressure
0.2 MPa (28 psi).
12. Installing plug (8)
Apply oil resistant sealant on plug (8), and
tighten it in the plug hole on the collar (7)
end face. Installing filling oil plug (8)
Tightening torque : 23 Nom (17 lbf-ft)
After assembling the lower roller, confirm that oil is not leaking and that the roller rotates smoothly by
hand.
34-18

Lower roller (Track roller)
34-19
34-20
34.1.5 FRONT IDLER (IDLER ADJUSTER ASSY)

34.1.5.1 FRONT IDLER ASSY

Front idler assy
34.1.5.2 REMOVING
Remove crawler. (Above mentioned)
(2) Removing idler assy
Sling idler assy, and push it forward with
bar.
Weight of front idler assy (one side): 73
kg (160 lbs)
(3) Installing
Installing is done in the reverse order of
removing.
Removing and installation the front idler
Keep away from the front side of front idler.
(4) Where idling assy (1) has to be separated

Loosen capscrew (4), and separate idler
assy (1) from idler adjuster assy (2).
Tools: Socket: 19mm
Weight of idler assy : 46 kg (101 lbs)
Weight of idler adjuster assy : 27 kg (60
lbs)
-The separated idler assy (1) should be

placed on square timbers.
Separating idler assy (1) from idler adjuster
34-21
34.1.5.3 IDLER ASSY

34.1.5.3.1 CONSTRUCTION
Idler assy
34.1.5.3.2 REMOVING AND INSTALLING

(1) Removing
1. Drain oil
Remove plug (8) on the side of collar (3)
to drain.
2. Removing pin (5)
Apply pin push bar (jig R) to the top of
pin, and push out striking bar (jig R)
lightly by hammer. Removing pin (5)
3. Removing collar (3)

Put idler (1) on stand (U), apply push-out
jig (S) on shaft (2), push out shaft (2) with
collar (3), then remove collar (3).
Removing collar (3)
4. Removing collar (3) from shaft (2)

If removal of collar (3) on the opposite side
is required, turn over front idler and
proceed with the procedure described in
Par. 3.
Removing collar (3)
34-22

With idler (1) mounted on the stand, tap
bushing (4) lightly by hammer, while placing
the bushing drawing rod (T) against the
end face of bushing (4) evenly all round, till
it comes out.
6. Removing floating seals (6)
Take out floating seals (6) from idler (1),
Removing bushing (4)
collar (3). If you intend to re-use floating
seals (6), confirm that there is no scoring
and rusting on the contact surface and
store the floating seals in pairs by placing
card board between the sealing faces.
7. Removing O-ring (7)
Separate O-ring (7) from shaft (2).
(2) Assembly
1. Pressing in bushing (4)
Align inner hole of idler (1) and bushing (4)
and press fit it vertically with press so that
jig (V) for bushing press-fitting is inserted
into bushing (4).
2. Installing O-ring (7)
Fit O-ring (7) to O-ring groove on shaft (2).
Pressing in bushing (4)
-Apply grease to O-ring
3. Installing collar (3) (See right Fig.)

Press fit the O-ring (7) installed side of
shaft (2) into collar (3), and drive pin (5).
4. Installing floating seal (6)
Fit the half of floating seal (6) on each
side of collar (3) and idler (1).
Installing collar (3), shaft (2)
5. Inserting idler (1)

Insert floating seal (6) fitted side of idler (1)
into shaft (2).
6. Installing floating seal (6)
Fit floating seal (6) on the other side of
idler (1).
Inserting idler (1) and installing floating seal

(6)
34-23
7. Installing collar (3)

Fit the half of floating seal (6) on the
other collar (3), press fit it in shaft (2),
and drive pin (5) in with hummer.
8. Filling oil and Inspection
Fill in 150~160 cc (9.15~9.76 cu-in) of
engine oil API grade CD #30 through the
plug hole of collar (3), wind seal tape and
Installing collar (3) and filling oil
tighten plug (8).
-After installing the idler assy to the idler adjuster assy, make certain that no oil leaks from floating
seal and plug (8) and that idler (1) rotates smoothly.
34.1.5.3.3 MAINTENANCE STANDARD
Front idler
34-24
34.1.5.3.4 TOOLS AND JIGS

34-25
34.1.5.4 IDLER ADJUSTER ASSY

34.1.5.4.1 CONSTRUCTION
Idler adjuster assy
34.1.5.4.2 DISASSEMBLY AND ASSEMBLY

(1) Disassembly
1. Spring set special jig
Before disassembling and assembling the
idler adjuster assy, prepare spring setting
jig (V).
Capacity of hydraulic jack : more than 10
tons (22000 lbs)
Tools: Spanner: 46 mm
2. Preparation for working
Place a hydraulic jack between the jig base
and the stand.
Loosen the holding-down nuts of the jig
and draw out the retainer plate upward. Spring set special jig (V)
Large power is needed to set the spring. Prepare a special jig before disassembly and assembly.
34-26
3. Draw out grease cylinder (See Fig. "Idler

adjuster assy".)
Draw out piston (6) from grease cylinder (1)
of the idler adjuster assy.
4. Removing oil seal (8), O-ring (7)
(See Fig. "Idler adjuster assy".)
Remove oil seal (8) and O-ring (7) from
grease cylinder (1).
5. Slinging work idler adjuster
Set the idler adjuster assy on the stand of
the jig, with its bracket (2) side facing up.
Slinging work idler adjuster
6. Fixing idler adjuster assy

Fit retainer plate to bracket (2), tighten
holding-down nuts alternately, and secure
idler adjuster assy.
Fixing idler adjuster assy
7. Compression of spring (5)

Remove spring pin (4), press spring (5)
lifting it with jack so that nut (3) can be
turned freely, and remove nut (3).
Compression of spring (5)
8. Removing bracket (2)

Allow the hydraulic jack to retract slowly
till the spring is extended to its free
length. Remove the retainer plate and take
off bracket (2), cover (10).
The free length of the spring: 320 mm
(12.6 in)
Removing retainer plate, bracket (2)
34-27
9. Removing spring (5), grease cylinder (1)

Hook lifting eye nut (W) to screw M36 X
P3 on grease cylinder (1) top end and
hoist it. Then, remove the set of grease
cylinder (1) and spring (5) using crane from
the jig.
Remove spring (5) and grease cylinder (1),
in that order.
Removing spring (5), grease cylinder (1)
34-28
(2) Assembly
Assembly is done in the reverse order of disassembly.
1. Installing spring (5), grease cylinder (1)

Insert grease cylinder (1) into spring (5)
and attach lifting eye nut (W) to screw M36
X P3 at the tip of the grease cylinder. Lift
the grease cylinder by crane and erect it in
the center of the jig stand upright.
2. Fixing idler adjuster assy
Install bracket (2), cover (10) on top of
spring (5). Center the rod of grease Attach spring (5) and grease cylinder (1) to
cylinder (1) and the holes in bracket (2). the jig
Attach the retainer plate and four
holding-down nuts. Fasten the nuts evenly
all round and fix the idler adjuster assy to
the jig body.
3. Compressing spring (5) and tightening nut

(3)
Extend the hydraulic jack, compress spring
(5) to a set length and screw in nut (3) to
the screwed part at the tip of grease
cylinder (1).
Set length of the spring: 270 mm (10.63 in)
4. Installing spring pin (4)
Tighten nut (3) till the holes for locking
spring pins (4) are aligned. Then fit spring
pin (4).
Compression of spring (5), and attaching nut
(3) and spring pin (4)
5. Removing idler adjuster assy

Remove idler adjuster assy from jig.
Removing idler adjuster assy
34-29
6. Installing oil seal (8), O-ring (7)

Fit oil seal (8) and O-ring (7) to grease
cylinder (1).
-Grease oil seal (8) and O-ring (7).
7. Filling grease cylinder(1) with grease.
Fill up grease in cylinder (1), remove the
grease nipple from piston (6) to discharge
the inside air, and press in the piston by
hand.
Grease cylinder (1)
-Direct grease nipple hole downward to
make air discharge easier.
8. Installing grease nipple
Tighten grease nipple to piston (6).
Tools: Socket: 19 mm,
34.1.5.4.3 MAINTENANCE STANDARD
34-30
34.1.6 SPROCKET
34.1.6.1 REMOVING
Remove crawler referring to "34.1.2
CRAWLER", lift up crawler frame with
attachment, and put it on square timbers
to float and stabilize.

Preparation for removal
(2) Removing sprocket

Loosen 15 capscrews (1-3) M14, for the
attaching of the sprocket by means of a
socket and remove the sprocket (2).
Weight of sprocket: 27 kg (60 lbs)

Removing sprocket
34.1.6.2 INSTALLING
(1) Check before installing
Check the mating portion of the travel
reduction unit and the sprocket, eliminate
burrs and contamination thoroughly and
install the sprocket.
(2) Installing sprocket temporarily
Coat the sprocket attaching capscrews
with Loctite #262 and fasten the sprocket
temporarily.
(3) Installing sprocket completely
Remove the wooden blocks under the
truck frame, bring the machine down on the Installing sprocket completely
ground and tighten the sprocket.
34-31
34.1.6.3 MAINTENANCE STANDARD (YT51D01001P1)

PITCH 77.87mm (3.10in) NUMBER OF TEETH 21
SPECIFICATION Dia. 41.26mm
ROLLER DIA. PITCH DIA. 522.468 (20.57in)
(1.62in)
Sprocket
34-32
34.1.6.4 SPROCKET TOOTH PROFILE GAUGE

Tooth profile gauge
34-33
34.1.7 TRAVEL MOTOR

34.1.7.1 TRAVEL MOTOR
Installing travel motor
34.1.7.2 REMOVING
Remove crawler, lift up crawler frame
using attachment, and put it on square
timbers to float and stabilize.
(2) Removing cover (1)
Remove sems-bolt (2) and also remove
covers (1).
(3) Preparation of oil pan
Removing and installing cover (1)
34-34
(4) Removing hydraulic pipe

Release pressure from travel circuit, and
bleed air in hydraulic oil tank, then remove
all pipes connecting to travel motor. Then
plug up all pipes and joint section to
protect them from entry of dust.
Tools: Spanner: 19 mm, 22 mm, 24 mm,
27 mm, 32 mm
Refer to "Hydraulic pipe plug" 4.1
(See Chapter 11. TOOLS) Removing and installing hydraulic pipe
(5) Removing sprocket

Removing 15 (one side) capscrews (3) M14
X 35.
Removing and installing sprocket
(6) Loosening travel motor attaching bolts (2)

Apply match marks on travel motor and
crawler frame, and remove 24 (one side)
capscrews (2) M16 X 40.
Removing and installing travel motor

attaching bolts
(7) Slinging travel motor assy

Sling travel motor with nylon sling applied
on the side close to sprocket installing
section and remove the motor.
Weight of motor: About. 88 kg (198 lbs)
Slinging travel motor
34-35
34.1.7.3 INSTALLING
Installing of the travel motor piping is performed in the reverse order of removal.
1. Cleaning
Check that contact surface of travel motor and crawler frame is free from burr and stain.
2. Tightening torque
Tighten capscrew and hydraulic pipes to the torque specified in "Tightening Torque".
3. Fill inside from motor drain port to casing with hydraulic oil before piping for drain. When starting
operation, operate motor in low idling and at low speed for several minutes, and check it for
possible oil leakage and noise.
Tightening Torque
Parts Size Tools No. Remarks
N-m(lbf-ft)
Capscrew M14 22 (1-3) 181 (134) Apply loctite #262
M16 24 2 279 (210) Apply loctite #262
Flareless nut for ø10 X 1.5 19 - 49 (36)
pipes, sleeve ø15 X 2.0 27 - 118 (87)
ø18 X 2.5 32 - 147 (110)
Connector PF1/4 19 - 36.3 (27)
PF3/8 22 - 73.6 (54)
PF1/2 27 - 108 (80)
34-36
34.1.8 SWING BEARING

34.1.8.1 SWING BEARING ASSY

Swing bearing assy
34.1.8.2 REMOVING
(1) Matchmarks
Remove upper structure, apply matchmarks
on inner race of swing bearing and lower
frame.
(2) Remove 30 capscrews (2) M16 X 85 for
installation inner race.
Matchmarks
(3) Removing grease

Remove grease in grease bath.
(4) Removing swing bearing
Attach eyebolt on swing bearing (1) and
sling it.
Weight of swing bearing: 99.3 kg (219 lbs)

Removing and installing swing bearing
34-37
34.1.8.3 INSTALLING
(1) Cleaning
Clean it completely so that installing
surfaces of swing bearing and lower frame
are free from dust and dirt.
(2) Installing
Install swing bearing on lower frame
meeting the matchmarks and positioning the
S mark on inner race as shown in the right
Fig..
(3) Temporary fastening of inner race
Coat the threads of the capscrews (2) with
Loctite #262 and tighten all the capscrews Location of S mark on swing bearing
(2) temporarily.
(4) Regular tightening of inner race

Tighten the capscrews (2) at 180 degrees
intervals alternately to a specified torque.
Tools: Socket: 24 mm,
(5) Filling grease
Fill grease bath with 4.9 kg (11 lbs) of
grease NLGI-2 (molybdenum disulfide
grease) or equivalent.
Removing and installing capscrew (2)
Sectional view of swing bearing
34-38

(1) Disassembly
1. Remove seal (9) fitted in the groove in the
outer circumference under inner race (1)
and seal (8) fitted in the groove in the
inner circumference on top of outer race (2)
and place them level on a square wooden
block or something.
2. Remove taper pin (7), using a hammer and
an extrusion rod.
3. Remove plug (6), utilizing an pull bolt
inserted in the screwed hole in the center Disassembling swing bearing
of the plug and using a puller.
4. While rotating outer race (2) little by little,

take out ball (3) and retainer (4) through
plug hole, in that order.
Removing balls (3) and retainers (4)
(2) Installing
1. Thoroughly remove the grease from the
groove of the seal (8) located on the inner
surface of the outer race (2) and from the
groove of the seal (9) located on the
surface of the inner race (1).
Coat the grooves with adhesive Cyano
Bond P0-1 equivalent. fit seal (9) and place
it on a surface plate.
Fitting balls (3)
2. Lower outer race (2) to the position where

upper surface of inner race (1) and lower
portion of seal groove is mated, put
adjusting washer under outer race (2) so
that outer raceway surface of ball (3) aligns
with inner raceway, and support it.
3. Insert ball (3) and retainer (4), on which
grease is applied, through plug (6) hole on
outer race (2), alternately.
Fitting retainer (4)
34-39
To insert ball (3) and retainer (4), use a push rod, etc., to protect persons from injury from inserting
fingers into plug hole.
4. Fit plug (6) to outer race (2) while checking it for direction and position of taper pin hole.
5. Coat seal (8) with adhesive Cyano Bond P0-1 equivalent and fit it in the groove of outer race (2).
6. Check that grease nipple (10) is properly fitted, and fill it with grease. Then, check bearing for
smooth rotation and flaws on seal lip portion.

Maintenance standard concerning wear of swing bearing is described in the section 13.6 MEASURING
SWING PERFORMANCES of "Maintenance Standard and Test Procedure" in this manual.
34-40
34.2 DISASSEMBLING AND ASSEMBLING
34.2.1 TRAVEL MOTOR

(1) General view

HYDRAULIC CIRCUIT
34-41
(2) Structure of Travel unit
34-42
(3) Parts list

No. Parts Q'ty No. Parts Q'ty
1 TRAVEL GEAR ASSY 1 14 SPRING 1
1-1 CASING BODY 1 15 SPRING 1
1-2 FLOATING SEAL 1 16 STEEL BALL 2
1-3 BALL BEARING 2 17 PIN 3
1-4 RING NUT 1 18 SNAP RING 1
1-5 CASING GEAR 1 19 SPRING PIN 1
1-6 SUN GEAR A 1 20 BRAKE PISTON 1
1-7 PLANETARY GEAR A 3 21 FRICTION PLATE 2
1-8 NEEDLE BEARING A 3 22 STEEL PLATE 2
1-9 CARRIER 1 23 SPRING 10
1-10 SUN GEAR B 1 24 PLATE 1
1-11 PLANETARY GEAR B 4 25 PLUG 2
1-12 BUSHING 4 26 POPPET 2
1-13 NEEDLE BEARING B 4 27 SPRING 2
1-15 THRUST PLATE 2 1 28 O-RING 2
1-16 THRUST PLATE 3 1 30 O-RING 1
1-17 THRUST PLATE 4 4 31 BACK UP RING 1
1-18 SCREW 8 32 O-RING 1
1-19 WASHER 1 33 BACK UP RING 1
1-20 PARALLEL PIN 1 34 O-RING 1
1-21 COVER 1 41 PIN 2
1-22 SPRING WASHER 12 42 BOLT 8
1-23 BOLT 12 43 MOTOR COVER 1
1-24 PLUG 2 44 SPOOL 1
1-25 O-RING 2 45 PUSHER 2
2 SHAFT 1 46 SPRING 2
3 CYLINDER BARREL 1 47 COVER 2
4 BALL RETAINER 1 48 O-RING 2
5 RETAINER 1 50 ORIFICE 1
6 CAM 1 51 SPOOL 1
7 PISTON ASSY 9 56 ORIFICE 1
7-1 PISTON 9 57 STEEL BALL 2
7-2 SLIPPER 9 58 PLUG 2
8 VALVE PLATE 1 59 O-RING 4
9 PLATE 1 60 RELIEF VALVE ASSY 2
10 PISTON ASSY 1 60-1 BODY 2
10-1 PISTON 1 60-2 POPPET 2
10-2 PUSHER 1 60-3 ROD 2
11 BALL BEARING 1 60-4 SEAT 2
12 BALL BEARING 1 60-5 PISTON 2
13 OIL SEAL 1 60-7 NUT CAP 2
34-43
No. Parts Q'ty No. Parts Q'ty

60-8 SPRING 2 65 PLUG 3
60-11 O-RING 2 67 NAME PLATE 1
60-12 O-RING 2 68 RIVET 2
60-13 O-RING 2 73 SPRING 1
60-15 BACK UP RING 2 74 PLUG 1
60-16 BACK UP RING 4 75 O-RING 1
61 PLUG 2 80 PLUG 1
62 O-RING 2 81 O-RING 1
63 PLUG 6
34-44
34.2.1.2 JIGS
(1) Jig for floating seal fitting

34-45
34.2.1.3 DISASSEMBLING
(1) Disassembling
1. Clean the outside surface of travel unit
prior to disassembly. Be sure to attach the
parts to the original positions.
For this purpose, we strongly recommend
to record the original positions of parts
before and during disassembling.
2. Remove the drain plug and drain lubricating
oil.
The travel unit oil capacity is 1.35L. Place
the travel unit on flat and clean ground.
3. Remove the relief valves (1) on both sides.
Remove the relief valve (1) first, and the removal of 8 bolts (2) and the motor cover (3) becomes
easier.
4. Loosen 8 bolts (2) and remove cover (3).
Be careful not to drop the valve plate.

Be careful not to damage the valve plate. Valve plate is located at the internal surface side of the
motor cover.
34-46
Raise the motor cover and insert 2 flat-blade screwdrivers in the space between the casing and the
body, and pry them slowly and the motor cover can be removed with relative ease.
(Do not damage the O-ring on the mating surface.)
5. Place the motor cover (3) on the wood

blocks (5).
6. Remove the backup rings (6) and O-rings

(7) from the relief valve (1).
7. Remove the cover (8) from the motor cover

(3) as shown by the right figure.
The strong spring force is applied to the cover (8). Loosen bolts gradually with care to ensure safe
and prevent the cover from damaging when removing.
34-47
8. Remove the spring (9), pusher (10), and

spool (11) from the motor cover. These
parts are located under the cover (8).
9. Remove the plug (12) from top of the

motor cover.
10. Remove the spring (13) and spool (14)

from the motor cover. These parts are
located under the plug (12).
11. Remove 2 plugs (15).
34-48
12. Remove the O-rings (16) from respective

plugs. And remove the steel balls (17) from
the motor cover.

13. Remove the plug (18) from the motor cover.
14. Remove the spring (19) and poppet (20)

from under the plug (18). Remove the
O-ring (21) from the plug (18).
15. Turn the motor cover over. And remove the

valve plate (22) from the motor cover.
34-49
16. Remove the bearing (23) if required.
17. Next, remove the 3 O-rings (24) (25) from

the casing body.
18. Remove the brake piston from the casing

body. The brake piston rises from the
casing body by the air blow from "A" port.
Be sure to cover the brake piston to prevent being injured by springing out of the brake piston in
blowing air in.
34-50
19. Remove the O-rings (27) (28) and the

backup rings (29) (30) from the brake
piston.

20. Using the steel wire or magnet, remove the

friction 2 plates (31) and 2 steel plates
from the body casing.
Do not remove the cylinder barrel yet.
34-51
21. Place the travel unit on the wood blocks as

shown by the photo. And block the unit to
prevent from rolling.
Remove the cylinder barrel assembly (33)
22. Make sure that reassemble the retainer

(34), piston assembly (35), and cylinder
barrel to the original position.
To avoid misassembling, record the
original positions of parts before
disassembling.
23. Remove the retainer (34) and piston
assembly (35) from the cylinder barrel
(36). And remove the piston assembly
from the retainer.
24. Remove the retainer ball (37) from the

cylinder barrel.
34-52
25. Remove 3 pins (38) from the cylinder barrel.

26. Using the suitable jig in diameter, compress

the plate (39) slightly with the press
machine. And remove the snap ring (40).
Then, remove the plate (39) and plate (42)
from the cylinder barrel.
The strong spring force is applied to the plate (39).
During disassembling the cylinder barrel, use a press machine and hold the spring in compressed state
to ensure the safety and to prevent the parts damage.
34-53
27. Remove the cam (43) from the body casing.
28. Remove the 2 steel balls (44) and piston

(45) from the body casing. And remove
the spring (46) which is located under the
piston.
34-54
29. Place the travel motor unit on the wood

blocks.
To avoid the damage of X shaft, do not
place the travel motor unit on a flat board
directly, and place the unit on the wood
blocks surely. Remove 12 bolts (47) and 12
washers (48).

30. Using a soft head hammer, tap and

loosen the sealant between the cover (49)
and gear casing (50).
And remove the cover (49).
34-55
31. Remove 3 bolts (51) and the thrust plate

(52).
32. Remove the sun gear (53), 3 planetary

gears (54), and 3 bearings (55).
33. Remove the carrier (56).
34-56
34. Remove the 3 inner races from the shaft of

carrier, if required.

35. Remove the sun gear (58).
36. Remove 4 bolts (59) and the thrust plate

(60).
34-57
37. Remove each of 4 planetary gears (61),

bearings (62), bushings (63), and plates
(64).
38. Remove the bolt (65) and the washer (66).
39. Using a magnet, remove the pin (67). If it

is difficult to remove, follow the next
procedures.
a.
Apply an adhesive tape or a magnet plate
to cover the thread hole as shown by the
photo.
b.
Drill a hole in the pin (67).
c.
Do the tapping work in the drilled hole of
the pin (67).
d.
Screw a suitable bolt in the thread hole,
and lift up the pin.
40. Remove the ring nut (68) from the body
34-58
casing.
41. Using a crane, remove the gear casing (50)


42. Remove one of the angular bearings (69)

from the gear casing.
43. Turn the gear casing over. Remove the

floating seal (72) and the other angular
bearings (69) from the gear casing.
44. Remove another floating seal (72) from the

body casing (73).
To remove them from the body casing,
strike the shaft (74) and the bearing (75)
with plastic hammer and suitable jig in
direction shown in the figure.
34-59
45. Remove the bearing (75) from the body

casing, if required.
And remove the oil seal (76) from the body
casing.
46. Remove the bearing (75) from the shaft

(74), if required.
This completes disassembly.
34-60
(2) Assembling
1. Be sure to check that all parts are clean and free from earth and dirt.
Check all O-ring, backup ring and oil seal fitted on travel unit for poor condition. When any
defect was found, replace it with new one.
Install the new floating seal.
Place the body casing on clean sheet spread on flat ground.
2. Install the oil seal in the body casing.

And install the bearing (75) on the shaft
(74).
Then, install the shaft (74) in the body
casing.
3. Place body casing on wooden block or

suitable jig directing the shaft side
downward.
Do not place the body casing directly on
flat surface to prevent shaft from damaging.
4. Using the "Jig for floating seal fitting",

install the floating seal (72) in the body
casing.
34-61
Clean and dry O-ring (rubber) and seal ring (metal) before attaching the floating seal.
Apply SAE30 engine oil or gear oil 80W-90 to the contact surface of the seal ring.
5. Apply SAE30 engine oil or gear oil

80W-90 to the contact surface (flat
surface) of the seal ring (metal).
6. Install the angular bearing (69) in the gear

casing.
7. Turn the gear casing over as shown by the

photo. Install the other angular bearings
(71) in the gear casing.
34-62
8. Using the "Jig for floating seal fitting",

install the other floating seal (70) in the
body casing. Apply SAE30 engine oil or
gear oil 80W-90 to the contact surface
(flat surface) of the seal ring (metal).

-Clean and dry O-ring (rubber) and seal ring (metal) before attaching the floating seal.
Apply SAE30 engine oil or gear oil 80W-90 to the contact surface of the seal ring.
-When joining 2 parts, use caution to prevent damage like scratch and so on to the floating seal.
9. Lift the gear casing (50) on the body

casing (73) by means of a crane as
shown in the figure. Install the gear casing
to the body casing (73).
With the ring gear placed on the body casing, there is a space left between them. This space is not a
problem because it is caused by the action of a floating seal. This space is eliminated by attaching
ring nut (68).
34-63
10. According to the following procedure,

adjust the precompression between the
bearings (69) and (71).
a.
To avoid narrow gap among the body
casing, 2 bearings, the gear casing, and
the ring nut, tighten the ring nut (68) tightly.
b.
Rotate the gear casing (50) several turn.
c.
Pull the ring nut in tangential direction with
the weight scale as shown by the photo,
and adjust the position of the ring nut
(68). During tightening or loosening of the
ring nut, the scale reading should be
adjusted within the range from 100N to
135N (22.5 lb~30.4 lb).
11. Apply an adhesive tape or a magnet plate

to cover the thread hole. Drill the new
hole at middle position between the body
casing and the ring nut as shown by the
photo.
Specification of the hole:
Hole diameter: 6.00 to 6.15 mm
(ø0.236"~ø0.242") in diameter
Hole depth: 7.0 to 7.5 mm (0.276"~0.295")
in depth
When attaching the pin (67) to the ring nut (68), new hole must be drilled on the opposite side of
the original hole. Because the ring nut position is not always the same after adjustment performed by
the procedure 10).
12. Remove the all drilling chips.

Install the pin (67) into the new hole
which is drilled at middle position between
the body casing (73) and the ring nut (68).
34-64
13. Apply the sealant "Three Bond #2403" to

the bolt (65). Install the bolt (65) and the
washer (66) in the casing. Tighten the bolt
to the specified torque 35.3±2.0 N-m
(26±1.5 lbf-ft).

14. Place the travel unit as shown by the

photo. Install the 2 steel balls (44), spring
(46), and piston (60) in the body casing.
15. Install the cam (43) into the body of the

travel unit. Push the cam several times,
and check that the motion is smooth.
16. Install the plate (42), the spring (41), and

the plate (39) in the cylinder barrel.
34-65
17. Using the press machine, push the plate

(39) to compress the spring (41). And
install the snap ring (40).
18. Install 3 pins (38) in the cylinder barrel.
19. Install the retainer ball (37) in the cylinder

barrel.
Apply clean hydraulic oil to the retainer ball
(37).
20. Install the piston assembly (35) in the

respective original holes of the retainer (34).
Apply clean hydraulic oil to the hole of
cylinder barrel and the piston assembly (35).
Install the assembly of retainers and pistons
into the original positions in the original
combinations.
34-66
21. Apply clean hydraulic oil to the cam, the

sliding surface of 9 piston shoes, and the
spline of motor shaft.
Then, lay the travel unit down, and install
the integrated cylinder barrel assembly (33)
into the shaft.

22. Apply the clean hydraulic oil to 2 friction

plates and 2 steel plates (32).
23. Install these plates in the body of travel

unit alternately. The innermost plate is the
friction plate, and the nearest plate is steel
plate.
24. Check that brake piston (26) is clean and

is free from earth and dirt. Check the
backup rings (29) (30) and O-rings (27)
(28) for possible damage. When any
irregularity or damage was detected, replace
it with new one.
Fit the backup rings (29) (30) and O-rings
(27) (28) as shown in the figure.
Apply a small amount of grease to the
backup rings and O-rings.
Be careful about the fitting positions of the
O-rings and the backup rings. (See figures)
34-67
25. Apply clean hydraulic oil to the sliding

surface of brake piston (26) of the body
casing. Using a soft head hammer, install
the brake piston (26) in to the travel unit
body.
26. Install 3 O-rings (24) (25) into the casing

body.
27. Install the bearing (23) into the motor cover.
28. Turn the motor cover over, and place it on

the wood blocks.
34-68
29. Install the spring (19) and the poppet (20)

into the motor cover. Install the O-ring (21)
in the plug (18).

30. Tighten the plug (18) to the specified

torque 65.7 N-m (48.5 lbf-ft).
31. Install the O-rings (16) in 2 plugs (15).

Put the steel ball (17) in the motor cover.

torque 19.6±1.0 N-m (14.5±0.7 lbf-ft).
34-69
33. Install the spring (13) and spool (14) in

the motor cover.

35. Apply the appropriate amount of hydraulic

oil to the spool (11), and install it in the
motor cover.
36. Tighten the cover (8) to the specified

torque 176.4 N-m (130 lbf-ft).
34-70
37. Turn the motor cover over. Install the

valve plate (22) in the original position.
Apply the appropriate amount of hydraulic
oil to the surface of the valve.

38. Apply grease to the 10 holes of the motor

cover. Install the springs (76) into the holes.
To prevent the springs (76) from falling
from holes, the grease was applied.
39. Place the motor cover (3) on the body

casing. Check if the springs (76) are not
fallen.
Tighten 8 bolts (2) to install the motor
cover.
Tighten the bolts (2) to the specified
40. Install the backup ring (6) and O-ring (7)

into the relief valve (1).
34-71
41. Tighten the relief valve (1) to the specified

42. Place the travel unit with directing the

brake side downwards as shown by the
photo. Apply the torque load to the shaft
(74), and check the value of the parking
brake torque. At the start of the rotation,
the torque should be 239 N-m (176.3
lbf-ft) or more.
43. Install each four of plates (649, bushings

(63), bearings (62), and planetary gears
(61).
44. Install the thrust plate (60) as shown by

the photo. Apply the sealant "Three Bond
#2403" to the bolt (59), and tighten 4
bolts (59). Tighten the bolts to the specified
torque 35.3±2.0 N-m (26±1.5 lbf-ft).
Next, install the sun gear (58).
34-72
45. Install 3 inner races (57) in the shaft of the

carrier (56).

46. Install the carrier (56) as shown by the

photo.
47. Install 3 bearings (55) and 3 planetary

gears (54) into the carrier (Inner race was
installed already).
Next, install the sun gear (53).
48. Install the thrust plate (52) in the carrier.

Apply the sealant "Three Bond #2403" to
the bolt (51), and tighten 3 bolts (51), and
install the plate (52) in the carrier. Tighten
the bolts to the specified torque 35.3±2.0
N-m (26±1.5 lbf-ft).
34-73
49. Check that the machined surfaces of the

gear casing (59) and the cover (49) are
clean, are free from earth and dirt and are
dried. Apply "Three Bond #1389" to the
machined surface of gear casing as shown
in the figure.
50. Attach the cover (49) to the original position

with 12 bolts (47) and 12 washers (48).
Tighten bolts to the specified torque
13.7±1.0 N-m (10.1±0.7 lbf-ft).
Fill lube oil from drain port. The optimum
oil quantity for the reduction gear is 1.35L.
Attach 2 drain plugs (77).
Fill the case of motor with hydraulic oil to prevent damage of the motor before starting operation.
34-74
㨇46. TROUBLE SHOOTING (BY ERROR CODES)㨉
46. TROUBLE SHOOTING

(BY ERROR CODES)
TABLE OF CONTENTS
46.1 JUDGMENT OF ACTUAL THING AT SITE ääääääääääääääääääääääää46-3

46.2 CLASSIFICATION OF FAILURE AND TROUBLESHOOTING ääääääääääääääää46-4
46.3 THE BLOWN FUSE OF MECHATRO CONTROLLER ääääääääääääääääääää46-5
46.4 TROUBLESHOOTING BY ERROR CODE äääääääääääääääääääääääää46-6

Book Code No. S5YT46E01
46-1
Issue Date of Issue Applicable Machines Remarks

S5YT4617E01
First Edition September, 2012 E75CSR : YT08-30001~
(NHK-EUR)
75SR-3 : YT08-30001~
(NA)
SK75SR-3 : YT07-25001~
(SE Asia & Oceania)
August, 2013 SK75SR-3E : YT08-30001~

(NA)
October, 2013 SK75SR-3E : YT08-30001~

(EUR)
Preface
Troubleshooting provides process locating for
the cause of trouble in the order that trouble
occurred. This manual describes how to solve
the specific phenomenon systematically as
early as possible. For troubleshooting
concerning the inside of equipment, refer to
troubleshooting for each manual of equipment.
Attending the field to verify actual thing.
46-2
46.1 JUDGMENT OF ACTUAL THING AT SITE
(1) Get to the site as quickly as possible.

Verify model, serial number, situation of trouble
and field, and notify person of arrival time.
(2) Verify background of trouble occurred
1. Model name and serial number
2.
Kind of attachment
Check that the combination of attachment is
proper or that the operating method is not
unreasonable.
3. Operating time by hour-meter
Verifying background of trouble occurred.
4.
History of trouble occurred and additional works.
5.
Recurrence of past trouble, or problems on the
additional works.
(3) How to diagnose trouble

1. Verify defective part
2. Make the condition of trouble again
3.
Where defective parts can not be verified,
surmise causes systematically.
4. Verify reasons for surmise
5.
Report methods, procedure, and period for
repairing to user.
Confirm the symptoms of the trouble.
(4) Explanation of the cause of trouble

1.
Explain the cause of trouble to clients. For
example, oil leak through piston is caused by
flaws on the piston rod. And the method of
using the machines should be explained so that
the same kind of trouble does not reoccur. Diagnosing fail by means troubleshooting.
2.
Treatment of damaged parts
The damaged parts to be claimed and
returned are evidence so they should be
handled with care. Protect them from entry of
water, soils, etc. into port of hydraulic unit, etc.
and return them. And also use care not to
flaw and damage those surfaces.
46-3
46.2 CLASSIFICATION OF FAILURE AND TROUBLESHOOTING
Classify failures into the following 3 types and carry out the troubleshooting.
No. Classes of failure Troubleshooting

A When error code after self-diagnosis is displayed Carry out troubleshooting according to the error code.
on gauge cluster
B When no failure is detected currently but error When it is hard to recreate the failure situation,
code after self diagnosis is remained in trouble cancel the data in the history and reproduce the
history failed situation or suppose the cause according to
the troubleshooting by error code, and then repair it.
C When error code after self diagnosis is not -Carry out troubleshooting according to instructions in
displayed or is not remained in the history Chapter 47 "TROUBLESHOOTING BY TROUBLE".
46-4
46.3 THE BLOWN FUSE OF MECHATRO CONTROLLER
If the fuse of mechatro controller has blown, the following display appears on the gauge cluster.
(1) The blown fuse of mechatro controller
a. Blown fuse 5A of mechatro controller :

"DATA COMMUNICATION ERROR" is displayed on the gauge cluster in the condition where the
controller program is not executed.
b. Blown fuse 20A of mechatro controller
The controller functions normally but the power supply applied when the controller drives the
solenoid, etc. stops.
Many error codes are displayed on the gauge cluster.
F021, F031

46-5
46.4 TROUBLESHOOTING BY ERROR CODE
When error code was displayed on the gauge cluster with the aid of self-diagnosis display function,
carry out the troubleshooting referring to applicable page in the contents of error codes.
Error Code Trouble

A015 Engine adjustment (A adjustment) is not adjusted yet or is failed.
A025 Pump propo. valve adjustment (B adjustment) is not adjusted yet or is failed.
A215 Written data of ROM adjustment data is incorrect.
A225 Writing of ROM adjustment data is incorrect.
A235 Written data of ROM hour meter data is incorrect.
A245 Writing of ROM hour meter data is incorrect.
A255 Writing of proportional valve adjustment data is incorrect.
B012 Incorrect output of boom up pressure sensor
B013 Disconnection of boom up pressure sensor
B014 Short-circuit of boom up pressure sensor
B022 Incorrect output of boom down pressure sensor
B023 Disconnection of boom down pressure sensor
B024 Short-circuit of boom down pressure sensor
B032 Incorrect output of arm out pressure sensor
B033 Disconnection of arm out pressure sensor
B034 Short-circuit of arm out pressure sensor
B042 Incorrect output of arm in pressure sensor
B043 Disconnection of arm in pressure sensor
B044 Short-circuit of arm in pressure sensor
B072 Incorrect output of swing pressure sensor
B073 Disconnection of swing pressure sensor
B074 Short-circuit of swing pressure sensor
B082 Incorrect output of swing left pressure sensor
B083 Disconnection of swing left pressure sensor
B084 Short-circuit of swing left pressure sensor
B092 Incorrect output of travel right pressure sensor
B093 Disconnection of travel right pressure sensor
B094 Short-circuit of travel right pressure sensor
B102 Incorrect output of travel left pressure sensor
B103 Disconnection of travel left pressure sensor
B104 Short-circuit of travel left pressure sensor
B172 Incorrect output of P2 optional side pressure sensor
B173 Disconnection of P2 side optional pressure sensor
B174 Short-circuit of P2 side optional pressure sensor
B222 Incorrect output of auto deceleration pressure sensor
B223 Disconnection of auto deceleration pressure sensor
B224 Short-circuit of auto deceleration pressure sensor
46-6
Error Code Trouble

C012 Incorrect output of P1 pump pressure sensor
C013 Disconnection of P1 pump pressure sensor
C014 Short-circuit of P1 pump pressure sensor
C033 Disconnection of boom head pressure sensor
C034 Short-circuit of boom head pressure sensor
C043 Disconnection of boom rod pressure sensor
C044 Short-circuit of boom rod pressure sensor
D012 Failure of output transistor ON at P1 bypass cut proportional valve
D013 Disconnection of P1 bypass cut proportional valve
D032 Failure of output transistor ON at travel straight proportional valve
D033 Disconnection of travel straight proportional valve
D062 Failure of output transistor ON at arm in high speed proportional valve
D063 Disconnection of arm in high speed proportional valve
E012 Failure of output transistor ON at P1 pump proportional valve
E013 Disconnection of P1pump proportional valve
F021 Failure of output transistor OFF and GND short of swing parking SOL valve
F023 Failure of output transistor ON and disconnection of swing parking SOL valve
F031 Failure of output transistor OFF and GND short of travel 1-2 speed SOL valve
F033 Failure of output transistor ON and disconnection of travel 1-2 speed SOL valve
G032 Overrun of speed sensor of direct input Mechatro-controller
G033 Disconnection of speed sensor of direct input Mechatro-controller
H013 Disconnection of acceleration potentio
H014 Power short-circuit of acceleration potentio
H023 Disconnection of boom angle potentio
H024 Power short-circuit of boom angle potentio
H033 Disconnection of arm angle potentio
H034 Power short-circuit of arm angle potentio
H081 Short-circuit of coolant temperature ground sensor
H091 Failure of GND short-circuit of fuel sensor
H093 Disconnection of fuel sensor
I313 Received error of cluster communication (time-out error)
K014 Adhesion of battery relay terminal
46-7
Error Code Trouble

R014 Failure of arc prevention relay of wiper motor
R024 Failure of normal rotation relay of wiper motor
R034 Failure of reverse rotation relay of wiper motor
R044 Failure of washer motor relay
R134 Failure of swing right flasher relay
R144 Failure of swing left flasher relay
R154 Failure of travel alarm relay
R164 Failure of auto idling stop relay 2
R174 Failure of engine forcible stop relay
R184 Failure of lever lock relay
Z020 Fuel type identification error
46-8
Table 46-1
Error code A015
Trouble Not yet adjusted engine or failed adjustment of engine (A adjustment)
Judging Engine adjustment is missed. Or it is impossible to set the adjusting value within the adjusting
condition range.
Symptom Deviated from the reqired value, but no problem in normal operations.
Control in the
Rotate with the default engine
event of failure
Returned in
The engine adjustment is completed normally.
normal condition
Service Screen No. 2 G-3 SPEED SET

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Checking Carry out engine adjustment (A adjustment). When "ERROR ENG" was
displayed during adjustment, refer to the section "Adjustment procedure -
Measures to be taken with the adjustment failed"
2 -Mechatro controller Check that the error is corrected after replacement of controller.
3
Table 46-2
Error code A025
Trouble Not yet adjusted engine or failed adjustment of pump proportional valve (B adjustment)
Judging Pump proportional valve adjustment is missed. Or it is impossible to set the adjusting value
condition within the adjusting range.
Symptom Deviated from the rated output, but no problem in normal operation
Control in the
Workable with the default proportional valve output.
event of failure
Returned in
The pump proportional valve adjustment is completed normally.

normal condition
Service Screen No. 9 E-1 P1 PUMP

1 -Checking Carry out pump adjustment (B adjustment).
When"ERROR PUMP" was displayed during adjustment, refer to the
section "Adjustment procedure - Measures to be taken with the
adjustment failed"
3
46-9
Table 46-3
Error code A215
Trouble The data of ROM adjustment is written incorrectly.
Judging Check adjustment data, and judge the content of memory is correct or not. (Trouble history
condition only)
Symptom No affect.
Control in the
Control at side of correct memory data.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Service Screen No.

1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3
Table 46-4
Error code A225
Trouble The data of ROM adjustment is written incorrectly.
Judging
Check adjustment data, and judge the data is correct or not.
condition
Symptom It is not normal output, but no problem in normal operation
Control in the
Control can be done by default value.
event of failure
Returned in
normal condition
Service Screen No.

2
3
46-10
Table 46-5
Error code A235
Trouble The data of ROM hourmeter is written incorrectly.
Judging
Check hourmeter memory, and judge the data is correct or not. (Trouble history only)
condition
Symptom No affect.
Control in the
Control at side of correct memory data.
event of failure
Returned in
normal condition
Service Screen No.

2
3
Table 46-6
Error code A245
Trouble The data of ROM hourmeter is written incorrectly.
Judging
Check hourmeter memory, and judge the data is incorrect.
condition
Symptom The hour meter data which was judged as error is taken as 0 Hr. No problem in normal
operation
Control in the
Normal control is available.
event of failure
Returned in
normal condition
Service Screen No.
2
3
46-11
Table 46-7
Error code A255
Trouble The data of proportional valve adjustment is written incorrectly.
Judging
Check proportional valve adjustment data, and judge the data is incorrect.
condition
Symptom It is not normal output, but no problem in normal operation
Control in the
Using fixed value of proportional valve correction data, usual control is done.
event of failure
Returned in
normal condition
Service Screen No.

2
3
Table 46-8
Error code B012
Trouble Boom up pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the sensor
condition after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom In case that auto acceleration is turned ON, even when control lever was shifted to neutral,
engine speed does not slow down.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on
normal condition it again.
Service Screen No. 5 B-1 BOOM RAISE

1 -Boom up pressure sensor When B012 is cancelled and other error occurs by turning starter switch
SE-3 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between boom up When B012 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-126F Check wiring for possible failure according to the wiring checking
CN-101F procedure and repair it if necessary.
46-12
Table 46-9
Error code B013
Trouble Boom up pressure sensor's wiring disconnects.
Judging
The input voltage from boom up pressure sensor is less than 0.1V.
condition
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition

1 -Boom up pressure sensor When B013 is cancelled and other error occurs after exchanging the
SE-3 connector with other sensor.
2 -Wiring between boom up When B013 is displayed after the connector is exchanged with other
pressure sensor and controller sensor.
Table 46-10
Error code B014
Trouble Boom up pressure sensor's power source is shortcut.
Judging
The input voltage from boom up pressure sensor is 4.7V or more.
condition
Control in the
Normal control
event of failure
Returned in
normal condition

1 -Boom up pressure sensor When B014 is cancelled and other error occurs after exchanging the
2 -Wiring between boom up When B014 is displayed after the connector is exchanged with other
46-13
Table 46-11
Error code B022
Trouble Boom down pressure sensor outputs error
Control in the
Normal control
event of failure
Service Screen No. 5 B-2 BOOM LOWER

1 -Boom down pressure sensor When B022 is cancelled and other error occurs by turning starter switch
2 -Wiring between boom down When B022 is displayed after turning the starter switch on after the
Table 46-12
Error code B023
Trouble Boom down pressure sensor's wiring is disconnecting.
Judging
The input voltage from boom down pressure sensor is 0.1V or less.
condition
Symptom In case that auto acceleration is turned ON, even when control lever was shifted, engine
speed dose not rise.
Control in the
Normal control
event of failure
Returned in
normal condition

1 -Boom down pressure sensor When B023 is cancelled and other error occurs after exchanging the
2 -Wiring between boom down When B023 is displayed after the connector is exchanged with other
46-14
Table 46-13
Error code B024
Trouble Boom down pressure sensor's power source is shortcut.
Judging
The input voltage from boom down pressure sensor is 4.7V or more.
condition
Control in the
Normal control
event of failure
Returned in
normal condition

1 -Boom down pressure sensor When B024 is cancelled and other error occurs by turning starter switch
2 -Wiring between boom down When B024 is displayed after turning the starter switch on after the
Table 46-14
Error code B032
Trouble Arm-out pressure sensor outputs error
Control in the
Normal control
event of failure
Service Screen No. 5 B-3 ARM OUT

1 -Arm-out pressure sensor When B032 is cancelled and other error occurs by turning starter switch
2 -Wiring between arm-out When B032 is displayed after turning the starter switch on after the
46-15
Table 46-15
Error code B033
Trouble Arm-out pressure sensor's wiring is disconnecting.
Judging
The input voltage from arm-out pressure sensor is 0.1V or less.
condition
Control in the
Normal control
event of failure
Returned in
normal condition

1 -Arm-out pressure sensor When B033 is cancelled and other error occurs after exchanging the
2 -Wiring between arm-out When B033 is displayed after the connector is exchanged with other
Table 46-16
Error code B034
Trouble Arm-out pressure sensor's power source is shortcut.
Judging
The input voltage from arm-out pressure sensor is 4.7V or more.
condition
Control in the
Normal control
event of failure
Returned in
normal condition

1 -Arm-out pressure sensor When B034 is cancelled and other error occurs by turning starter switch
2 -Wiring between arm-out When B034 is displayed after turning the starter switch on after the
46-16
Table 46-17
Error code B042
Trouble Arm-in pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the arm-in
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom Swing parking brake cannot be released during arm-in.
Control in the
The arm-in pressure is controlled to 0 MPa.
event of failure
Service Screen No. 5 B-4 ARM IN

1 -Arm-in pressure sensor When B042 is cancelled and other error occurs by turning starter switch
2 -Wiring between arm-in When B042 is displayed after turning the starter switch on after the
Table 46-18
Error code B043
Trouble Arm-in pressure sensor's wiring is disconnecting.
Judging
The input voltage from arm-in pressure sensor is 0.1V or less.
condition
Control in the

event of failure
Returned in
normal condition

1 -Arm-in pressure sensor When B043 is cancelled and other error occurs after exchanging the
2 -Wiring between arm-in When B043 is displayed after the connector is exchanged with other
46-17
Table 46-19
Error code B044
Trouble Arm-in pressure sensor's power source is shortcut.
Judging
The input voltage from arm-in pressure sensor is 4.7V or more.
condition
Control in the
event of failure
Returned in
normal condition

1 -Arm-in pressure sensor When B044 is cancelled and other error occurs by turning starter switch
2 -Wiring between arm-in When B044 is displayed after turning the starter switch on after the
Table 46-20
Error code B072
Trouble Swing right pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the swing
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom Swing parking brake does not work.
Control in the
Swing parking solenoid valve is changed to non-excitation.
event of failure
B-7 SWING
Service Screen No. 6 (Higher Pressure is selected between swing left and right, and the
diagnosis higher one is indicated.)
Screen No.
1 -Swing right pressure sensor When B072 is cancelled and other error occurs by turning starter switch
2 -Wiring between swing right When B072 is displayed after turning the starter switch on after the
46-18
Table 46-21
Error code B073
Trouble Swing right pressure sensor's wiring is disconnected.
Judging
The input voltage from swing pressure sensor is 0.1V or less.
condition
Control in the
event of failure
Returned in
normal condition
B-7 SWING
Service Screen No. 6 (Higher Pressure is selected between swing left and right, and the higher
diagnosis one is indicated.)
Screen No.

46-19
Table 46-22
Error code B074
Trouble Swing pressure sensor's power source is shortcut.
Judging
The input voltage from swing pressure sensor is 4.7V or more.
condition
Control in the
event of failure
Returned in
normal condition
B-7 SWING
Screen No.
46-20
Table 46-23
Error code B082
Trouble Swing left pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the swing
condition left pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Control in the
event of failure
B-7 SWING
Screen No.
1 -Swing pressure sensor When B082 is cancelled and other error occurs by turning starter switch
2 -Wiring between swing When B082 is displayed after turning the starter switch on after the

46-21
Table 46-24
Error code B083
Trouble Swing left pressure sensor's wiring is disconnected.
Judging
The input voltage from swing left pressure sensor is 0.1V or less.
condition
Control in the
event of failure
Returned in
normal condition
B-7 SWING
Screen No.
46-22
Table 46-25
Error code B084
Trouble Swing left pressure sensor's power source is shortcut.
Judging
The input voltage from bucket dump pressure sensor is 4.7V or more.
condition
Control in the
event of failure
Returned in
normal condition
B-7 SWING
Screen No.
Table 46-26
Error code B092
Trouble Travel right pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the travel
condition right pressure sensor after starter switch ON is in the range of 1.4V or more to less than
4.7V.
Symptom Engine speed of high idling at H mode rises to 2150 rpm.
Control in the
During parking, the 2000 rpm limitation of engine speed is not done.
event of failure
Service Screen No. 6 B-9 TRAVEL (R)

1 -Travel right pressure sensor When B092 is cancelled and other error occurs by turning starter switch
2 -Wiring between travel right When B092 is displayed after turning the starter switch on after the
46-23
Table 46-27
Error code B093
Trouble Travel right pressure sensor's wiring is disconnected.
Judging
The input voltage from Travel right pressure sensor is 0.1V or less.
condition
Control in the
event of failure
Returned in
normal condition

Table 46-28
Error code B094
Trouble Travel right pressure sensor's power source is shortcut.
Judging
The input voltage from Travel right pressure sensor is 4.7V or more.
condition
Control in the
event of failure
Returned in
normal condition

46-24
Table 46-29
Error code B102
Trouble Travel left pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the travel
condition left pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Control in the
event of failure
Service Screen No. 6 B-10 TRAVEL (L)

1 -Travel left pressure sensor When B102 is cancelled and other error occurs by turning starter switch
2 -Wiring between travel left When B102 is displayed after turning the starter switch on after the
Table 46-30
Error code B103
Trouble Travel left pressure sensor's wiring is disconnected.
Judging
The input voltage from Travel left pressure sensor is 0.1V or less.
condition
Control in the

event of failure
Returned in
normal condition

46-25
Table 46-31
Error code B104
Trouble Travel left pressure sensor's power source is shortcut.
Judging
The input voltage from Travel left pressure sensor is 4.7V or more.
condition
Control in the
event of failure
Returned in
normal condition

Table 46-32
Error code B172
Trouble P2 side option pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the P2 side
condition option pressure sensor after starter switch ON is in the range of 1.4V or more to less than
4.7V.
Symptom When the auto acceleration is ON, the engine speed does not decrease at the neutral lever
position.
Control in the
Normal control
event of failure
Service Screen No. 6 B-17 P2 OPT.

1 -P2 side option pressure When B172 is cancelled and other error occurs by turning starter switch
sensor SE-11 on after exchanging the connector with other sensor.
2 -Wiring between P2 side option When B172 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor. Check wiring for possible
CN-303F failure according to the wiring checking procedure and repair it if
CN-102F necessary.
Check wiring for possible failure according to the wiring checking
procedure and repair it if necessary.
46-26
Table 46-33
Error code B173
Trouble P2 side option pressure sensor's wiring is disconnected.
Judging
The input voltage from P2 side option pressure sensor is 0.1V or less.
condition
Symptom The selection of conflux does not work. All operation speed slows down.
Control in the
Normal control
event of failure
Returned in
normal condition

sensor on after exchanging the connector with other sensor.
SE-11 Check sensor unit for possible failure. If failure found, replace it.
Table 46-34
Error code B174
Trouble P2 side option pressure sensor's power source is shortcut.
Judging
The input voltage from P2 side option pressure sensor is 4.7V or more.
condition
Symptom The selection of conflux does not work. All operation speed slows down.
Control in the
Normal control

event of failure
Returned in
normal condition

sensor SE-11 on after exchanging the connector with other sensor.
46-27
Table 46-35
Error code B222
Trouble Auto deceleration pressure sensor outputs error
Symptom When the auto acceleration is ON, the engine speed does not decrease at the neutral lever
position.
Control in the
Normal control
event of failure
Service Screen No. 16

1 -Auto deceleration pressure When B222 is cancelled and other error occurs by turning starter switch
sensor on after exchanging the connector with other sensor.
2 -Wiring between auto When B222 is displayed after turning the starter switch on after the
deceleration pressure sensor connector is exchanged with other sensor.
and controller Check wiring for possible failure according to the wiring checking
CN-104F
Table 46-36
Error code B223
Trouble Auto deceleration pressure sensor's wiring is disconnecting.
Judging
The input voltage from auto deceleration pressure sensor is 0.1V or less.
condition
Symptom When the auto acceleration is ON, the engine speed does not increase by the lever operation.
Control in the
Normal control
event of failure
Returned in
normal condition

1 -Auto deceleration pressure When B223 is cancelled and other error occurs after exchanging the
sensor connector with other sensor.
2 -Wiring between auto When B223 is displayed after the connector is exchanged with other
deceleration pressure sensor sensor.
CN-104F
46-28
Table 46-37
Error code B224
Trouble Auto deceleration pressure sensor's power source is shortcut.
Judging
The input voltage from auto deceleration pressure sensor is 0.1V or more.
condition
Symptom When the auto acceleration is ON, the engine speed does not increase by the lever operation.
Control in the
Normal control
event of failure
Returned in
normal condition

1 -Auto deceleration pressure When B224 is cancelled and other error occurs after exchanging the
sensor connector with other sensor.
2 -Wiring between auto When B224 is displayed after the connector is exchanged with other
deceleration pressure sensor sensor.
CN-104F
Table 46-38
Error code C012
Trouble P1 pump pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the P1
condition pump pressure sensor after starter switch ON is in the range of 1.4V or more to less than
4.7V.

Symptom The P1 pump operability becomes poor.
Control in the
Normal control
event of failure
Service Screen No. 7 C-1 PUMP P1

1 -P1 pump pressure sensor When C012 is cancelled and other error occurs by turning starter switch
2 -Wiring between P1 pump When C012 is displayed after turning the starter switch on after the
46-29
Table 46-39
Error code C013
Trouble P1 pump pressure sensor's wiring is disconnected.
Judging
The input voltage from P1 pump pressure sensor is 0.1V or less.
condition
Symptom All operation speed slows down.
Control in the
P1 pump pressure is controlled to 25 MPa.
event of failure
Returned in
normal condition

Table 46-40
Error code C014
Trouble P1 pump pressure sensor's power source is shortcut.
Judging
The input voltage from P1 pump pressure sensor is 4.7V or more.
condition
Control in the
event of failure
Returned in
normal condition

46-30
Table 46-41
Error code C022
Trouble P2 pump pressure sensor outputs error.
4.7V.
Control in the
Normal control
event of failure

Table 46-42
Error code C023
Judging
condition
Control in the
event of failure
Returned in
normal condition

46-31
Table 46-43
Error code C024
Judging
condition
Control in the
event of failure
Returned in
normal condition

Table 46-44
Error code C033
Trouble Boom head pressure sensor's wiring is disconnected.
Judging
The input voltage from boom head pressure sensor is 0.1V or less.
condition
Symptom Over load alarm function does not actuate.
Control in the
Normal control
event of failure
Returned in
normal condition
Service Screen No. 7 C-3 BOOM-HEAD

1 -Boom head pressure sensor When C033 is cancelled and other error occurs by turning starter switch
2 -Wiring between boom head When C033 is displayed after turning the starter switch on after the
46-32
Table 46-45
Error code C034
Trouble Boom head pressure sensor's power source is shortcut.
Judging
The input voltage from boom head pressure sensor is 4.7V or more.
condition
Symptom Over load alarm function does not actuate.
Control in the
Normal control
event of failure
Returned in
normal condition
Service Screen No. 7 C-3 BOOM-HEAD

1 -Boom head pressure sensor When C034 is cancelled and other error occurs by turning starter switch
2 -Wiring between boom head When C034 is displayed after turning the starter switch on after the
Table 46-46
Error code C043
Trouble Boom rod pressure sensor's wiring is disconnected.
Judging
The input voltage from boom rod pressure sensor is 0.1V or less.
condition
Symptom Indication load value of High-reach crane becomes abnormal.
Control in the
Normal control

event of failure
Returned in
normal condition
Service Screen No. 7 C-4 BOOM-ROD

1 -Boom rod pressure sensor When C043 is cancelled and other error occurs by turning starter switch
2 -Wiring between boom rod When C043 is displayed after turning the starter switch on after the
46-33
Table 46-47
Error code C044
Trouble Boom rod pressure sensor's power source is shortcut.
Judging
The input voltage from boom rod pressure sensor is 4.7V or more.
condition
Symptom Indication load value of High-reach crane becomes abnormal.
Control in the
Normal control
event of failure
Returned in
normal condition
Service Screen No. 7 C-4 BOOM-ROD

1 -Boom rod pressure sensor When C044 is cancelled and other error occurs by turning starter switch
2 -Wiring between boom rod When C044 is displayed after turning the starter switch on after the
Table 46-48
Error code C082
Trouble P3 pump pressure sensor outputs error
4.7V.
Control in the
Normal control
event of failure

46-34
Table 46-49
Error code C083
Judging
condition
Control in the
event of failure
Returned in
normal condition

Table 46-50
Error code C084
Judging
condition
Control in the

event of failure
Returned in
normal condition

46-35
Table 46-51
Error code D012
Trouble P1 bypass cut proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Option conflux can not be done.
Control in the
Normal control
event of failure
Returned in
normal condition
Service Screen No. 8 D-1 P1 UN-LOAD (BP-CUT)

1 -P1 bypass cut proportional When D012 is cancelled and other error occurs by turning starter switch
valve on after exchanging the connector with other sensor.
PSV-18 Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between P1 bypass cut When D012 is displayed after turning the starter switch on after the
Table 46-52
Error code D013
Trouble P1 bypass cut proportional valve's wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 100mA or less, judging is not done.)
Symptom Option conflux can not be done.
Control in the
Normal control
event of failure
Returned in
normal condition
Service Screen No. 8 D-1 P1 UN-LOAD (BP-CUT)

1 -P1 bypass cut proportional When D013 is cancelled and other error occurs by turning starter switch
2 -Wiring between P1 bypass cut When D013 is displayed after turning the starter switch on after the
46-36
Table 46-53
Error code D032
Trouble Travel straight proportional valve and output transistor ON are failure.
Judging
condition
Symptom Travel deviation occurs by combined operation of travel and attachment.
Control in the
Set Travel straight proportional valve output to 0mA.
event of failure
Returned in
normal condition
Service Screen No. 8 D-3 S-TRAVEL

1 -Travel straight proportional When D032 is cancelled and other error occurs by turning starter switch
PSV-C Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between Travel straight When D032 is displayed after turning the starter switch on after the
proportional valve and controller connector is exchanged with other sensor.
Table 46-54
Error code D033
Trouble Travel straight proportional valve's wiring is disconnected.
Symptom Travel deviation occurs by combined operation of travel and attachment.
Control in the
Set Travel straight proportional valve output to 0mA.

event of failure
Returned in
normal condition
Service Screen No. 8 D-3 S-TRAVEL

1 -Travel straight proportional When D033 is cancelled and other error occurs by turning starter switch
PSV-C Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between Travel straight When D033 is displayed after turning the starter switch on after the
46-37
Table 46-55
Error code D062
Trouble Arm-in spool 2 proportional valve and output transistor ON are failure.
Judging condition The feed-back value from proportional valve is 1000mA or more.
Symptom Operability of combined operation with arm-in becomes poor.
Control in the
Set Arm-in spool 2 proportional valve output to 0mA.
event of failure
Returned in
normal condition
Screen No. 8 D-6 ARM IN-2-SPEED
Service diagnosis
Screen No.
checking screen
Screen No.
1 -Arm-in spool 2 proportional When D062 is cancelled and other error occurs by turning starter switch
2 -Wiring between Arm-in spool 2 When D062 is displayed after turning the starter switch on after the
Table 46-56
Error code D063
Trouble Arm-in spool 2 proportional valve's wiring is disconnected.
Judging condition The feed-back value from proportional valve is 100mA or less.
(If output is 100mA or less, judging is not done.)
Symptom Operability of combined operation with arm-in becomes poor.
Control in the
Set Arm-in spool 2 proportional valve output to 0mA.
event of failure
Returned in
normal condition
Screen No. 8 D-6 ARM IN-2-SPEED
Service diagnosis
Screen No.
checking screen
Screen No.
1 -Arm-in spool 2 proportional When D063 is cancelled and other error occurs by turning starter switch
2 -Wiring between Arm-in spool 2 When D063 is displayed after turning the starter switch on after the
46-38
Table 46-57
Error code E012
Trouble P1 pump proportional valve and output transistor ON are failure.
Judging
condition
Control in the Set proportional valve output rate of P1 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Service Screen No. 9 E-1 PUMP P1

1 -P1 pump proportional valve When E012 is cancelled and other error occurs by turning starter switch
PSV-P1 on after exchanging the connector with other sensor.
When replacing of connector is executed, turn off power source once.
2 -Wiring between P1 pump When E012 is displayed after turning the starter switch on after the

46-39
Table 46-58
Error code E013
Trouble P1 pump proportional valve's wiring is disconnected.
Control in the
Set proportional valve output rate of P1 pumps to 0mA.
event of failure
Service Screen No. 9 E-1 PUMP P1

1 -P1 pump proportional valve When E013 is cancelled and other error occurs by turning starter switch
PSV-P1 on after exchanging the connector with other sensor.
2 -Wiring between P1 pump When E013 is displayed after turning the starter switch on after the
46-40
Table 46-59
Error code F021
Trouble Swing parking solenoid valve and output transistor OFF are failure, and grounding is
short-circuit.
Judging
The feed-back signal is grounding level while exciting command is output.
condition
Symptom Swing parking is not available.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is 24V level while exciting command is output.
normal condition
Service Screen No. 3 F-2 SWING-BRAKE

1 -Swing parking solenoid valve When F021 is cancelled and other error occurs by exchanging the
SV-1 connector for other solenoid valve. Check solenoid valve unit for
possible failure. If failure found, replace it.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 -Wiring between swing parking When F021 is displayed after the connector is exchanged with other
solenoid valve and controller solenoid valve.
Table 46-60
Error code F023
Trouble Swing parking solenoid valve and output transistor ON are failure, and disconnection.
Judging
The feed-back signal is 24V level while exciting command is not output.
condition
Symptom Swing parking is not available or is leaving available.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is grounding level while exciting command is output.
normal condition
Service Screen No. 3 F-1 POWER BOOST

1 -Swing parking solenoid valve When F023 is cancelled and other error occurs by exchanging the
SV-1 connector for other solenoid valve.
2 -Wiring between swing parking When F023 is displayed after the connector is exchanged with other
46-41
Table 46-61
Error code F031
Trouble Travel 1, 2 speed solenoid valve and output transistor OFF are failure, and grounding is
short-circuit.
Judging condition The feed-back signal is grounding level while exciting command is output.
Symptom Travel 2 speed is not obtainable.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is 24V level while exciting command is output.
normal condition
Screen No. 3 F-3 1/2-TRAVEL
Service diagnosis
Screen No.
checking screen
Screen No.
1 -Travel 1, 2speed solenoid valve When F031 is cancelled and other error occurs by exchanging the
2 -Wiring between travel 1, 2speed When F031 is displayed after the connector is exchanged with other
Table 46-62
Error code F033
Trouble Travel 1, 2 speed solenoid valve and output transistor ON are failure, and disconnection.
Judging condition The feed-back signal is 24V level while exciting command is not output.
Symptom Travel 2 speed is not obtainable or is keeping 1 speed.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is grounding level while exciting command is not output.
normal condition
Screen No. 3 F-3 1/2-TRAVEL
Service diagnosis
Screen No.
checking screen
Screen No.
1 -Travel 1, 2speed solenoid valve When F033 is cancelled and other error occurs by exchanging the
2 -Wiring between travel 1, 2speed When F033 is displayed after the connector is exchanged with other
46-42
Table 46-63
Error code G032
Trouble Mechatro controller direct input speed sensor is overrun.
Judging
Engine rpm input is 3000rpm or more. (Only trouble history)
condition
Symptom Operate without problem.
Control in the
Engine speed slows down to 0 rpm.
event of failure
Returned in
normal condition
Service Screen No. 2 G-3 MEAS 1 (for mechatro controller)

1 -Engine speed sensor Measure the resistance between terminals of speed sensor.
SE-13 Normal value: 1.6 to 2.0 kilo-ohms
2 -Wiring between engine Check wiring for possible failure according to the wiring checking
speed sensor and controller procedure and repair it if necessary.
CN-136F Especially check wiring for false disconnection and noise included.
CN-106F
(Controller is broken by only applying power to grounding of signal.)
Table 46-64
Error code G033
Trouble Mechatro controller direct input speed sensor, Disconnection
Judging
Voltage of alternator is 12V or more, and speed sensor indicates excess low engine rpm.
condition
Symptom Operate without problem.
Control in the
Normal control

event of failure
Returned in
normal condition
Service Screen No. 2 G-3 MEAS 1 (for mechatro controller)

1 -Engine speed sensor Measure the resistance between terminals of speed sensor.
SE-13 Normal value: 1.6 to 2.0 kilo-ohms
2 -Wiring between engine Check wiring for possible failure according to the wiring checking
speed sensor and controller procedure and repair it if necessary.
CN-136F
CN-106F
(Controller is broken by only applying power to grounding of signal.)
46-43
Table 46-65
Error code H013
Trouble Accel potentiometer is disconnected.
Judging
The input voltage from accel potentiometer is 0.1V or less.
condition
Symptom LOW idling is fixed.
Control in the
LOW idling is fixed.
event of failure
Returned in
normal condition
Service Screen No. 2 H-1 ACCEL VOLT.

1 -Accel potentiometer Measure the resistance between terminals of speed sensor. 1.6 to 2.4
SE-16 kilo-ohms
Turn the potentiometer and measure resistance between signal and GND.
2 -Wiring between accel Check wiring for possible failure according to the wiring checking
potentiometer and controller procedure and repair it if necessary.
CN-402F
CN-102F
Table 46-66
Error code H014
Trouble Accel potentiometer's power source is shortcut.
Judging
The input voltage from accel potentiometer is 4.7V or more.
condition
Symptom LOW idling is fixed.
Control in the
LOW idling is fixed.
event of failure
Returned in
normal condition
Service Screen No. 2 H-1 ACCEL VOLT.

1 -Accel potentiometer Measure the resistance between terminals of accel potentiometer.
SE-16 1.6 to 2.4 kilo-ohms
CN-402F
CN-102F
46-44
Table 46-67
Error code H023
Trouble Boom angle potentiometer's wiring is disconnected.
Judging
The input voltage from boom angle potentiometer is 0.1V or less.
condition
Symptom Indications of rating load and working radius of High-reach crane become abnormal.
Control in the
Normal control
event of failure
Returned in
normal condition
Service Screen No. 12 H-2 BOOM

1 -Boom angle potentiometer Measure the resistance between terminals of boom angle potentiometer.
Normal value: 0 to all resistance (4.0 to 6.0) kilo-ohms
CN-702F
CN-103F
Table 46-68
Error code H024
Trouble Boom angle potentiometer's power source is shortcut.
Judging
The input voltage from boom angle potentiometer is 0.1V or less.
condition
Control in the
Normal control
event of failure
Returned in
normal condition
Service Screen No. 12 H-2 BOOM

1 -Boom angle potentiometer Measure the resistance between terminals of boom angle potentiometer.
2 - Wiring between boom angle Check wiring for possible failure according to the wiring checking
CN-702F
CN-103F
46-45
Table 46-69
Error code H033
Trouble Arm angle potentiometer's wiring is disconnected.
Judging
The input voltage from arm angle potentiometer is 0.1V or less.
condition
Control in the
Normal control
event of failure
Returned in
normal condition
Service Screen No. 12 H-3 ARM

1 -Arm angle potentiometer Measure the resistance between terminals of arm angle potentiometer.
2 -Wiring between arm angle Check wiring for possible failure according to the wiring checking
CN-703F
CN-103F
Table 46-70
Error code H034
Trouble Arm angle potentiometer's power source is shortcut.
Judging
The input voltage from arm angle potentiometer is 0.1V or less.
condition
Control in the
Normal control
event of failure
Returned in
normal condition
Service Screen No. 2 H-3 ARM

1 -Arm angle potentiometer Measure the resistance between terminals of arm angle potentiometer.
2 -Wiring between arm angle Check wiring for possible failure according to the wiring checking
CN-703F
CN-103F
46-46
Table 46-71
Error code H081
Trouble Grounding of coolant temperature sensor is short-circuited.
Judging
The input voltage from coolant temperature sensor is 0.1V or less.
condition
Symptom The water temperature is fixed to 20 degrees C.
Control in the
Normal control
event of failure
Returned in
normal condition
Service Screen No. 2 G-5 The lower side of water temperature meter on gauge cluster is fixed.
1 -Coolant temperature sensor Measure the resistance between terminals.
SE-14 20 degrees C 10 ohms to 878 ohms
2 -Wiring between coolant Check wiring for possible failure according to the wiring checking
temperature sensor and procedure and repair it if necessary.
controller
F-14
CN-104
Table 46-72
Error code H091
Trouble Fuel sensor grounding is short-circuited.
Judging
The input voltage from fuel sensor is 0.1V or less.
condition
Symptom Warning for low fuel level is indicated.
Control in the
Fuel level becomes 0%.

event of failure
Returned in
normal condition
Service Screen No. 10 H-9 FUEL LEVEL

1 - Fuel sensor potentiometer Move fuel sensor and measure the resistance between terminals of fuel
SE-15 sensor.
EMPTY 95 ohms to FULL 5 ohms
2 -Wiring between fuel Check wiring for possible failure according to the wiring checking
sensor and controller procedure and repair it if necessary.
CN-152F
CN-104F
46-47
Table 46-73
Error code H093
Trouble Fuel sensor's wiring is disconnection.
Judging
The input voltage from fuel sensor is 4.7V or more.
condition
Symptom Warning for low fuel level is indicated.
Control in the
Fuel level becomes 0%.
event of failure
Returned in
normal condition
Service Screen No. 10 H-9 FUEL LEVEL

1 - Fuel sensor potentiometer Move fuel sensor and measure the resistance between terminals of fuel
SE-15 sensor.
EMPTY 95 ohms to FULL 5 ohms
2 -Wiring between fuel Check wiring for possible failure according to the wiring checking
sensor and controller procedure and repair it if necessary.
CN-152F
CN-104F
Table 46-74
Error code I313
Trouble Reception of cluster communication is abnormal. (Time-out error)
Judging
Reception from gauge cluster can not receive correctly.
condition
Symptom Switch operation of gauge cluster can not be done.
Control in the
Keep the condition after immediately key-on is operated.
event of failure
Returned in
normal condition
Service Screen No.

1 -Wiring between gauge cluster Check wiring for possible failure according to the wiring checking
and controller procedure and repair it if necessary.
CN-600F
CN-101F
46-48
Table 46-75
Error code K014
Trouble Battery relay contact welded
Judging The power 24V is continuously supplied to controller for 40 seconds or more while the key
condition switch ON signal turned OFF
Symptom The power on the battery relay secondary side does not turn OFF even if the key switch is
turned OFF.
Control in the
Normal control with key switch OFF
event of failure
Returned in Turn key switch ON.
normal condition Or when the power supply 24V to mechatro controller is stopped
Service Screen No. 4 K-1 AIS RELAY 2

diagnosis Screen No. 4 K-3 KEY SWITCH OFF
1 -Battery relay Turn key switch off and disconnect the connector (CN-256F) on the
R-1 battery relay coil. If 24V power lives on battery relay secondary side,
CN-256F check on battery relay for failure and replace it if failed.
2 -Auto idle stop relay 2 Turn off the key switch, and remove the connector (CN-256F) on the
R-24 battery relay coil side. If power of battery relay on secondary side falls,
-Alternator relay remove either auto idling stop relay 2 or alternator relay.
R-28 The failure may be occurred in case where the power falls after the
relay was removed, and therefore check on the relay unit and replace it
with new one if failed.
3 -Wiring between auto idle stop When K014 is left displayed with the relay removed
relay/alternator relay and Check that no power 24V is produced on relay (-) line according to the
controller wiring checking procedure and replace it if necessary.
CN-109F, CN2-1 When no failure found after checking on wiring and K014 is left displayed
-Fuse & relay box Replace fuse/relay box.
E-1

46-49
46-50

46-51
46-52

46-53
46-54
Table 46-86
Error code Z020
Trouble Fuel type identification error.
Judging Identification value from the fuel type identification sensor equals to the value of kerosene or
condition less for 10th consecutive time.
Symptom Without proper procedures, the engine fails.
Control in the
Control the engine as usual.
event of failure
Returned in When the value from the fuel type identification sensor equals to the value of diesel oil, it
normal condition automatically returns to normal condition.
Service Screen No. Result of fuel type identification can be checked from Merit.
1 -Fuel Check the sub tank which has the fuel type identification sensor and if
water accumulation is found, drain the water.
2 -Fuel Replace the fuel to the specified fuel(diesel oil).
3 -Fuel type identification sensor Replace the fuel type identification sensor and check if the error
condition is changed to normal condition.

46-55
㨇47. TROUBLESHOOTING (BY TROUBLE)㨉
47. TROUBLESHOOTING
(BY TROUBLE)
TABLE OF CONTENTS
47.1 HYDRAULIC SYSTEM ääääääääääääääääääääääääääääääääää47-3

47.2 ELECTRIC SYSTEMS ääääääääääääääääääääääääääääääääää47-24
47.2.1 WIRING CHECKING PROCEDURE ääääääääääääääääääääääääää47-24
47.2.2 TROUBLEääääääääääääääääääääääääääääääääääääää47-27
47.3 ENGINE RELATED TROUBLESHOOTING äääääääääääääääääääääääää47-30

Book Code No. S5<747E01
47-1

S5YT4717E01
First Edition September, 2012 E75CSR : YT08-30001~
(NHK-EUR)
75SR-3 : YT08-30001~
(NA)
SK75SR-3 : YT07-25001~
(SE Asia & Oceania)
August, 2013 SK75SR-3E : YT08-30001~

(NA)
October, 2013 SK75SR-3E : YT08-30001~

(EUR)
47-2
47.1 HYDRAULIC SYSTEM
Preface:
The troubleshooting for the failures shown below is explained here.
Identify the failure and trouble and carry forward the troubleshooting in order of the failure item number.
(1) All controls do not function/slow

(2) Engine down/stalled
(3) Move at lever neutral position
(4) Poor fine operability
(5) When auto deceleration function is ON and lever is in neutral, engine rpm dose not decrease.
When the lever is operated, engine rpm dose not increase.
(6) Slow boom up, insufficient power
(7) Slow boom down, insufficient power for lifting up body
(8) Slow arm in, insufficient power
(9) Slow arm out, insufficient power
(10) Slow bucket digging, insufficient power
(11) Slow bucket dumping, insufficient power
(12) Slow dozer up, insufficient power
(13) Slow dozer down, insufficient power for lifting up body
(14) Swing operation not functioned/slow
(15) Noise during swing operation
(16) Swing on a slope drifts when control lever is in neutral position
(17) Swing drifts when swing operation is stopped
(18) Slow travel speed/weak
(19) Travel deviation
(20) Travel 1st/2nd speed not changed
(21) Travel parking on a slope is not held
(22) Travel does not run straightly when both crawlers and attachment operated simultaneously.
(23) Slow breaker (crusher) operation, weak power
(24) Option selector valve malfunction: not switched to breaker circuit
(25) Option selector valve malfunction: not switched to nibbler (crusher) circuit

47-3
(1) All controls do not function/slow

No. Sections Contents/normal value Corrective action, others
1 Safety lever lock Check that the Measure both terminals of Check solenoid unit for
switching solenoid is solenoid connector. 24V by pushing possible failure.
switched correctly the lever down, 0V by pushing it Check harness for
up possible failure.
2 Solenoid valve for Measure About 0MPa by pushing the lever Replace solenoid valve
safety lock lever pressure of up, and 3MPa or more by push it
solenoid A1 port down.
3 Pilot line filter Disassemble and Check filter for clogging Clean filter
check it visually
4 Pilot gear pump Measure pilot Check that it is 3MPa or more in Check gear pump and the
primary pressure high idling relief valve for possible
at gear pump failure
5 Multi control valve Change position Since all are blocked due to poor
(in case that switching performance, check that
travel is operable) the lever select pattern is set to
the proper position.
6 Main relief pressure Check set -See Service Diagnosis Data List Measure the relief
pressure Operation No.2 Boom up full lever pressure actually
& relief
Check that pump pressure is Replace
26MPa or more in boom up full
lever, high idling and H mode
operation.
7 Pump regulator Visual check When removing, free from Replace
abnormal resistance against sliding.
Free from abnormal damage on
outside of regulator.
Spring free from breakage and
damage.
8 Pump Visual check When removing, inside parts Replace
(cylinder block, piston, valve plate,
shaft, etc.) are free from abnormal
resistance against sliding and
abnormal damage.
(2) Engine down/stalled

Spring free from breakage.
2 Pump Visual check When removing, inner parts Replace
abnormal damage.
47-4
(3) Move at lever neutral position

1 Remote control Measure the Check that targeted pilot pressure Check remote control
pressure targeted remote is 0MPa. valve
control pressure
directly
2 Remote control Check targeted Check that spool is free from Replace
valve remote control abnormal damage and Spring is
valve free from breakage.
3 Main spool Check targeted Check that spool is free from Replace
spool visually abnormal damage and Spring is
free from breakage.
4 Over load relief Check targeted Free from dust entered in port Replace
valve spool visually relief valve. Seat is free from
abnormality
5 Lock valve poppet Check targeted Seat is free from abnormality Replace
(in case of boom poppet visually
and arm)
6 Lock valve selector Exchange lock Check that the trouble is reversed Replace
(in case of boom valve selector of
and arm) boom/arm and
boom/arm
7 Holding valve spool Check that Free from abnormal resistance Replace
for boom smooth sliding of against sliding. Do not pull spool out of
(* In case that spool in sleeve sleeve forcibly.
this machine
equips the boom
H/V)
8 Holding valve Check targeted Filter free from abnormal Replace
relief valve for spool visually contamination
boom
(* In case that
this machine
equips the boom
H/V)
9 Cylinder Check targeted Make sure of no problem of seals Replace cylinder or seals
cylinder visually by disassembling and investigation

(4) Poor fine operability
1 Main spool Check targeted Free from abnormal damage and Replace
spool visually spring breakage
2 Slow return check Visual check Check that slow return valve
valve of pilot line installed on pilot line is free from
dust entered.
47-5
(5) When auto deceleration function is ON and lever is in neutral, engine rpm dose not
decrease. When the lever is operated, engine rpm dose not increase.
1 Pilot pressure Carry out Service At full lever position : Replace the targeted
sensor Diagnosis to ATT and Swing operations are to pilot pressure sensor
check the targeted be 3.0 MPa, and other operations
pilot secondary are to be 2.1 MPa or more.
pressure.
47-6
(6) Slow boom up, insufficient power

1 Boom up pressure Carry out service -See Service Diagnosis Data List Check and replace
sensor diagnosis Operation No.2 boom up full lever pressure sensor
and relief Check remote control
valve
2 Pilot secondary Measure directly Check that pressure is 3.0MPa or Check remote control
pressure remote control more in boom up full lever and valve
pressure of high idling operation When equipped with
boom up (pa8 multi control valve, check
port) it while changing lever
pattern
4 Lock valve poppet Visual check Free from abnormal resistance Replace
<Trouble> against sliding. (Check on the casing for
Pump pressure is Free from abnormal damage on damage)
high. outside of valve
5 Holding valve for Visual check Free from abnormal resistance Replace
boom (poppet) against sliding. (Check on the casing for
(* In case that Free from abnormal damage on damage)
this machine outside of valve
equips the boom
H/V)
<Trouble>
Pump pressure is
high.
6 Boom spool Visual check Free from abnormal resistance Replace
<Trouble> against sliding. (Check on the casing for
Pump pressure is Spring is free from breakage. damage)
high.
7 Check boom Visual check Free from abnormal resistance Replace spool assembly
spool for against sliding. (Check on the casing for
recirculation Spring is free from breakage. damage)
<Trouble>
Pump pressure is
low.
8 Main relief valve Check set Operation : Boom up full lever Replace
<Trouble> pressure from and relief 26MPa or more
Relief pressure is P1(P2) port on
low. pump
9 Over load relief Visual check Pressure is 26MPa or more in When only relief
valve (Head side) boom up full lever and high idling. pressure of boom up is
<Trouble> Free from dust entered in over low, replace valve
Relief pressure is load relief valve. Seat is free from
low. abnormality
47-7
(7) Slow boom down/insufficient power for lifting up body

1 Boom down Carry out service -See Service Diagnosis Data List Check and replace
pressure sensor diagnosis Operation No.3 boom down full pressure sensor
lever and relief Check remote control
valve
2 Pilot secondary Measure remote Check that pressure is 3.0MPa or Check remote control
pressure control pressure more in boom down full lever and valve
of boom down high idling operation When equipped with
directly (pb8 port) multi control valve, check
it while changing lever
pattern.
3 Remote control valve Check targeted Check that spool is free from Replace
remote control abnormal damage and Spring is
4 Lock valve poppet Visual check When removing, free from Replace
<Trouble> abnormal resistance against sliding. (Check on the casing for
Boom down is low. Free from abnormal damage on damage)
outside of valve
5 Holding valve Visual check When removing, free from Replace
(poppet) abnormal resistance against sliding. (Check on the casing for
(* In case that Free from abnormal damage on damage)
this machine outside of valve
equips the boom

H/V)
<Trouble>
Boom down is
slow.
6 Boom spool Visual check When removing, free from Replace
Boom down is slow. Free from abnormal damage on damage)
outside of valve
Spring is free from breakage.
7 Check boom spool Visual check Free from abnormal resistance Replace
for recirculation against sliding. (Check on the casing for
<Trouble> Spring is free from breakage. damage)
Machine can not
be lifted by
supporting with
boom.
8 Main relief valve Measure pump Operation : Boom up full lever Replace
<Trouble> pressure from and relief 26MPa or more
Relief pressure is P1(P2) port on
low. pump
9 Over load relief Visual check Free from dust entered in port Replace
valve relief valve.
<Trouble> Seat is free from abnormality
Machine can not
be lifted by
supporting with
boom.
47-8
(8) Slow arm in, insufficient power

1 Arm in pressure Carry out service -See Service Diagnosis Data List Check and replace
sensor diagnosis Operation No.5 arm in full lever pressure sensor
valve
pressure pilot secondary more in arm in full lever and high valve
pressure of arm idling operation When equipped with
in (pb5 port) multi control valve, check
pattern
<Trouble> pressure of and relief 26MPa
Relief pressure is pump from P1(P2)
low. port
5 Over load relief Visual check Pressure is 26MPa or more in When only relief
valve (Head side) arm in and relief. pressure of arm in is
Pump pressure is load relief valve.
low. Seat is free from abnormality
6 Arm spool Visual check When removing, free from Replace
high. outside of spool.
7 Check arm spool Visual check Free from abnormal resistance Replace
for recirculation against sliding. (Check on the casing for
<Trouble> Spring is free from breakage. damage)
Arm in is slow.
8 Check lock valve Visual check Free from abnormal resistance Replace
poppet against sliding. (Check on the casing for
<Trouble> Free from abnormal damage on damage)
Pump pressure is outside of poppet.
high.
9 Arm pressure Visual check Free from abnormal resistance Replace
compensation valve against sliding. (Check on the casing for
Spring is free from breakage. damage)
47-9
(9) Slow independent arm out (in the air)

1 Arm out pressure Carry out service -See Service Diagnosis Data List Check and replace
sensor diagnosis Operation No.4 arm out full lever pressure sensor
valve
2 Remote control Measure directly Check that pressure is 3.0MPa or Check remote control
valve remote control more in arm out full lever and high valve
pressure of arm idling operation When equipped with
out (pa5 port) multi control valve, check
pattern
<Trouble> pressure of and relief 26MPa or more
low. port
5 Over load relief Visual check (Rod Pressure is 26MPa or more in When only relief
valve side) arm out and relief. pressure of arm out is
Pump pressure is load relief valve. Seat is free from
low. abnormality
6 Arm spool Visual check When removing, free from Replace
high. outside of spool
7 Check arm spool Visual check Free from abnormal resistance Replace
for recirculation against sliding.
<Trouble> Spring is free from breakage.
Pump pressure is
low.
8 Check lock valve Visual check Free from abnormal resistance Replace
poppet against sliding. (Check on the casing for
Pump pressure is outside of poppet
high.
9 Arm pressure Visual check Free from abnormal resistance Replace
compensation valve against sliding. (Check on the casing for
Spring is free from breakage. damage)
47-10
(10) Bucket digging is slow

1 Bucket digging Carry out service -See Service Diagnosis Data List Check and replace
pressure sensor diagnosis Operation No.6 bucket digging full pressure sensor
valve
pressure remote control more in bucket digging full lever valve
pressure of bucket and high idling operation When equipped with
digging (pb7 port) multi control valve, check
pattern
low. port
5 Bucket spool Visual check When removing, free from Replace
6 Over load relief Check targeted Free from dust entered in over Replace
valve spool visually load relief valve.
Seat is free from abnormality.

47-11
(11) Bucket dump is slow

1 Bucket dump Carry out service -See Service Diagnosis Data List Check and replace
pressure sensor diagnosis Operation No.7 bucket dump full pressure sensor
valve
2 Pilot secondary Measure directly Check that pressure is 3.0 MPa Check remote control
pressure remote control or more in bucket dump full lever valve
pressure of bucket and high idling operation When equipped with
dump (pa7 port) multi control valve, check
pattern
low. port
5 Bucket spool Visual check When removing, free from Replace
Both P1, P2 Free from abnormal damage on damage)
pressures are high. outside of spool
47-12
(12) Slow dozer up, insufficient power

1 Dozer pressure Carry out service -See Service Diagnosis Data List Check and replace
sensor diagnosis Operation No.11 Dozer up full lever pressure sensor
valve
pressure remote control more in dozer up full lever and valve
pressure of high idling operation
dozer up (pb11
port)
<Trouble> pressure of and relief 26MPa
low. port
5 Dozer spool Visual check When removing, free from Replace

47-13
(13) Slow dozer down, insufficient power for lifting up body

1 Dozer pressure Carry out service -See Service Diagnosis Data List Check and replace
sensor diagnosis Operation No.12 Dozer down full pressure sensor
valve
pressure remote control more in dozer down full lever and valve
pressure of high idling operation
dozer down (pa11
port)
4 Dozer spool Visual check When removing, free from Replace
Both P1, P2 Free from abnormal damage on damage)
pressures are high. outside of spool
low. port
47-14
(14) Swing does not move/slow

1 Swing pressure Carry out service -See Service Diagnosis Data List Check and replace
sensor diagnosis Operation No.8 Swing full lever and pressure sensor
in operation Check remote control
valve
pressure remote control more in boom up full lever and valve
pressure of swing high idling operation When equipped with
(Swing right pa3, multi control valve, check
Swing left pb3) it while changing lever
pattern
3 Swing parking Carry out service No.3 F-2 SWING-BRAKE Check swing pressure
brake solenoid diagnosis Lever neutral: COMP ON, MEAS sensor
ON Check harness
Swing: COMP OFF, MEAS OFF
Measurement of Lever neutral: 0MPa Replace solenoid valve
solenoid valve A2 In operation: 3MPa or more
port
5 Swing spool Visual check When removing, free from Replace
6 Swing relief valve Check set Operation : Swing full lever and Reset or replace
<Trouble> pressure relief 24.5MPa or more
Relief pressure is
low.
7 Swing motor Visual check Inner parts (cylinder block, piston, Replace
valve brake etc) are to be Free
from abnormal resistance against
sliding.
outside of brake plate etc.
8 Swing reduction Take sample oil Sampling oil does not include a Disassemble and inspect
gear oil from swing lot of metal powder. reduction gear
reduction gear
drain
9 Swing reduction Visual check Tooth surface is not worn Replace
abnormally and is not chipped.
47-15
(15) Noise occurred at swing operation

ON Check harness
Swing: COMP OFF, MEAS OFF
port
2 By-pass check Visual check When removing, free from Replace
valve abnormal resistance against sliding.
(Sound of Spring is free from breakage.
cavitation at
stopping)
3 Swing motor Visual check Disassemble and inspect abnormal Replace
Brake valve/friction wear and scuffing
plate)
4 Swing motor piston Visual check When removing, free from Replace
5 Swing reduction Take sample oil Sampling oil does not include a Disassemble and inspect
gear oil from swing lot of metal powder. reduction gear
reduction gear
drain.
6 Swing reduction Visual check Tooth surface has no abnormally Replace
worn and chipped.
(16) Swing drifts on a slope while swing control lever is in neutral position
1 Swing pressure Carry out service -Engine stop & starter key ON Check and replace
sensor diagnosis All pilot low pressure sensors are pressure sensor
within range of 0 to 0.1MPa.
ON Check harness
Swing: COMP OFF, MEAS OFF Check parking brake
release switch
port
4 Swing motor Visual check Disassemble and inspect abnormal Replace
(Brake valve/friction wear and scuffing
plate)
5 Parking brake Visual check Piston and friction plate do not Replace
have abnormal resistance against
sliding
Free from spring damage
47-16
(17) Swing drifts at stopping

1 Swing pressure Carry out service -Engine stop & starter key ON Replace pressure sensor
sensor diagnosis All pilot low pressure sensors are
within range of 0 to 0.1MPa.
2 Swing relief valve Check set Operation : Swing full lever and Reset or replace
<Trouble> pressure relief 24.5MPa or more
Relief pressure is
low.
3 Anti-reaction valve Visual check Free from dirt entering Clean or replace
Sliding part should be free from
foreign matter entering, abnormal
damage and wear.
5 Swing motor Visual check Inner parts (cylinder block, piston, Replace
valve brake etc) are to be Free
from abnormal resistance against
sliding.

47-17
(18) Travel speed is slow/poor

1 Travel right and left Carry out service No.9,10 B-9, B-10 Check and replace
pressure sensor diagnosis Operation : Travel right full lever pressure sensor
and idling Check remote control
Operation : Travel left full lever valve
and idling
2 Secondary pressure Measure the pilot Check that the secondary Check remote control
of pilot proportional valve secondary pressures of travel right (left), valve
valve pressure directly forward (reverse) full lever and high
idling operation
Pressure : 3.0MPa or more
Check sealing ability of shuttle
valve and entry of dust in orifice
4 Travel spool Visual check When removing, free from Replace
5 Travel motor relief Check set Check pump pressure is 29MPa Lock travel motor and
valve pressure or more in right and left travel relieve oil, and identify
levers full lever (relief operation at which travel motor is
locked crawler belt) and high idling lower in relief pressure.
And lower pressure
motor is failed.
6 Travel motor Visual check Inner parts (piston, cylinder block, Replace
valve plate, brake valve spool) are
to be free from abnormal
resistance against sliding.
7 Parking brake in Visual check When removing, free from Replace
travel motor abnormal resistance against sliding.
No sticking on friction plate and
separator plate.
8 Travel reduction Take sample oil Sampling oil does not include a Disassemble and inspect
gear oil from travel lot of metal powder. reduction gear
reduction gear
drain
9 Travel reduction Visual check Tooth surface is not worn Replace
47-18
(19) Travel deviation

1 Travel right and left Carry out service No.9,10 B-9, B-10 Check and replace
pressure sensor diagnosis Operation : Travel right full lever pressure sensor
and idling Check remote control
Operation : Travel left full lever valve
and idling
2 Secondary pilot Measure directly Check that pressure is 2.1MPa or Check remote control
valve remote control more in travel right (left), forward valve
pressure of travel (reverse) full lever and high idling
right and left operation
valve remote control abnormal damage and spring is
valve free from breakage. Check sealing
ability of shuttle valve and entry
of dust in orifice
4 Right and left Exchange right for Check the direction of deflection If the direction is
travel spool left travel spool changed, replace the
spool. If the direction is
not changed, inspect a
pressure compensation
valve for right/left travel
and travel unit.
5 Travel spool Visual check of When removing, free from Replace
<Trouble> targeted spool abnormal resistance against sliding. (Check on the casing for
6 Travel motor relief Check set Check pump pressure is 26MPa Lock travel motor and
valve pressure or more in right and left travel relieve oil, and identify
levers full lever (relief operation at which travel motor is
locked crawler belt) and high idling lower in relief pressure.
And lower pressure
motor is failed.
7 Travel motor Visual check Inner parts (piston, cylinder block, Replace
valve plate, brake valve spool) are
to be free from abnormal
resistance against sliding.
8 Travel reduction Take sample oil Sampling oil does not include a Disassemble and inspect
gear oil from travel lot of metal powder. reduction gear
reduction gear
drain
9 Travel reduction Visual check Tooth surface is not worn Replace
damage.
47-19

11 Pump Visual check When removing, inside parts Replace
abnormal damage.
(20) Travel 1, 2 speed cannot be switched

(In case of the traveling under heavy loading (for example traveling on a slope or traveling on a soft
ground), the speed may sometimes does not change from 1st to 2nd because this machine equips the
function of automatic speed change.)

1 Travel 1, 2 speed Carry out service Switch Travel 1, 2 speed to 2nd Check pressure sensor
switching solenoid diagnosis speed No.3 F-3 1/2-TRAVEL Check harness
Lever neutral COMP OFF, MEAS Check Travel 1, 2 speed
OFF switch on gauge cluster
Travel operation COMP ON, MEAS
ON
Measure A3 port Lever neutral: 0MPa Replace solenoid valve
pressure on In operation: 3MPa or more
solenoid valve
2 1, 2 speed Visual check Check that spool is free from Replace
switching spool in abnormal damage and Spring is (Check on the casing for
travel motor free from breakage. damage)
3 1, 2 speed Visual check Free from entry of dust Remove dust or replace
switching orifice in
travel motor
4 Tilting piston in Visual check Free from abnormal wear on piston Replace
travel motor and seal (Check on the casing for
damage)
(21) Machine does not stay on a slope in traveling

1 Pilot pressure Carry out service -Engine stop & starter key switch Check pressure sensor
sensor diagnosis is ON and replace as necessary
Targeted pilot low pressure sensor Check remote control
is in range of 0 to 0.1MPa valve
3 Parking brake in Visual check When removing, free from Replace
travel motor abnormal resistance against sliding.
damage.
4 Orifice of passage Visual check Free from entry of dust Remove dust or replace
for parking brake
in travel motor
47-20
(22) Machine does not travel straight in simultaneous operation of traveling and attachment
1 Actual measuring Carry out service No.8 D-3 S-TRAVEL is should be -Check voltage of low
current value of diagnosis COMP 730mA and MEAS 700 to pressure sensor other
travel straight 760mA in both travel full lever than travel sensor-In
proportional valve and in boom up full lever at high case where the reading is
idling largely differed from the
actually measured value,
check proportional valve
and controller for possible
failure.
2 Secondary pressure Measure directly Check secondary pressure is within Replace proportional valve
of travel straight the proportional range of 1.8 to 2.2MPa in both
proportional valve valve secondary travel full lever and in boom up full
pressure lever at high idling
3 Travel straight spool Visual check When removing, free from Replace
abnormal resistance against sliding (Check on the casing side
Free from abnormal damage, etc for damage)
on outside surface

47-21
(23) Breaker works slowly and power is poor

1 Breaker pressure Carry out service -See Service Diagnosis Data List Check and replace
sensor diagnosis Operation No.13, No.14 in full lever pressure sensor
valve
2 Secondary pressure Measure directly Check pressure is 2.1MPa or Check the ermote control
of proportional valve the proportional more in breaker attachment full valve
valve secondary lever and high idling operation
pressure of N&B
3 Remote control Check targeted Check sealing ability of shuttle Replace
valve remote control valve and entry of dust in orifice.
valve
4 Actual measuring Carry out service -See Service Diagnosis Data List -Check voltage of low
current value of diagnosis Operation No.13 P2 side OPT full pressure sensor other
travel straight lever & relief than sensor for optional
proportional valve attachment
-In case where the
reading is largely differed
from the actually
measured value, check
proportional valve and
controller for possible
failure.
5 Secondary pressure Measure directly Check that travel straight secondary Replace proportional valve
of travel straight the proportional pressure is 2.7MPa or more in
proportional valve valve secondary optional attachment full lever and
pressure at the high idling operation
ports A5 (travel
straight) of 7
sections solenoid
block
6 P1 by-pass cut Visual check Check that spool is free from Clean or replace
valve abnormal damage and spring is
<Trouble> free from breakage
Only P1 pressure
is low.
7 Relief pressure Check set Operation of breaker full lever and Reset or replace
pressure relief
(Set value of factory shipment is
26MPa.)
8 Travel straight spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against sliding (Check on the casing side
P1 pressure is Free from abnormal damage, etc for damage)
high. on outside surface
9 Spool for optional Visual check When removing, free from Replace
attachment abnormal resistance against sliding. (Check on the casing for
Pump pressure is outside of spool.
high. Spring is free from breakage.
47-22

valve spool visually load relief valve
(24) Selector valve malfunctions: Breaker circuit is not obtained.

1 N&B selector spool Check the Does the lever switched correctly Replace
switching (Check on the casing for
damage)
2 N&B selector spool Visual check When removing, free from Replace
abnormal resistance against sliding. (Check on the casing for
Free from abnormal damage on damage)
outside of spool.
(25) Selector valve malfunctions: Nibbler circuit is not obtained.

1 N&B selector spool Check the Does the lever switched correctly. Replace
switching (Check on the casing side
for damage)
2 N&B selector spool Visual check When removing, free from Replace
abnormal resistance against sliding. (Check on the casing side
Free from abnormal damage on for damage)
outside of valve.

47-23
47.2 ELECTRIC SYSTEMS
47.2.1 WIRING CHECKING PROCEDURE

Check for continuity between connector terminals, presence or absences of short-circuit with other
wires, and presence or absences of short-circuit with machine body grounding.
(1)
Checking for disconnection between connectors.
(When both ends measurement is easy because
of short distance between connectors,)
Measure the resistance using tester.
Pull out opposite connector first.
When the resistance is zero (0), it is in normal
condition.
(When both ends measurement is difficult

because of long distance between connectors,)
Where the resistance is zero (0), if the
terminal on one side is connected to frame
body grounding with jumper wire, it is in normal
condition.
The resistance is 1M-ohm or more when the
terminal on one side is not connected to frame
body grounding with jumper wire, it is in normal
condition.
(2)
Checking for presence or absence of
short-circuit with machine body
When the resistance is 1M-ohm or more, it is
in normal condition.
(3)
Checking for presence or absence of
short-circuit between wirings.
When the resistance is 1M-ohm or more, it is
in normal condition.
47-24
(4)
Checking connector terminal for contact
Insert male terminal into female terminal unit,
and then check that the inserting force is
equivalent to other female terminals.
If looseness is there, replace the female
terminal with new one.
Clean the dirt terminal.
Do not insert the male terminal the thickness differs. It may cause loose connection.
(5)
Caution which should be paid in measuring voltage
When measuring the power supply to electric equipment at connector position with the grounding
terminal contained inside of connector, measure the voltage between grounding inside of connector and
power terminal.
When measuring the voltage between frame body grounding and power source, the disconnection of
wiring to grounding inside of connector cannot be identified.
Since the voltage may vary between with connector connected and with connector not connected.
Measure the voltage with each connector connected whenever possible.
(6)
Checking the general view of connector
a. Check the terminal crimped condition.

Pull one electric cable with the about 3kg
force, and make sure that the cable does
not come out of the terminal.
When came out, replace the terminal and
crimp it again.
b. Check connector for imperfect insertion
Check that all top ends form a line on the
same position as seen from the connector
engaged side.

When moved along, push it in further
through wire inserting hole.
c. Check connector for intruding of water.
Pull out the connector and check that the
inside is free from intruding of water.
When water intruding is found, check
rubber plug for damage and also that the
sealing is fitted properly.
47-25
(7)
When abnormality occurs at intervals
When the abnormality situation can not be reoccurred during checking operation, try the following
operations.
a. Check that variable of display exists or not on the service diagnosis screen while shaking the
harness or giving shock by operating the machine.
b. Check that variables of resistance and voltage exist or not using tester while shaking the harness.
c. Turn starter switch on and apply electricity continuously, and check it again after the temperature
of wiring and equipment was raised.
(8)
Checking on body grounding
Check attaching bolts of grounding terminal for
loosening.
And also check that there is no loose
connection due to corrosion.
There are multiple groundings like centralized

grounding box shown in the figure and battery
grounding, engine grounding, horn grounding
fixed together with horn, body grounding
placed on attaching section of boom working
light.
47-26
47.2.2 TROUBLE
(1) Engine does not stop.
(2) "CPU DATA COMMUNICATION ERROR" is displayed on multi display.
(3) Auto accel does not actuate. (The engine speed does not automatically slow down.)
(4) Auto accel does not actuate. (The engine speed does not automatically speed up.)
(5) Wiper does not function.

47-27
(1) Engine does not stop.

1 Starter key switch Check signal of No.4 K-3 Key switch Check continuity between
starter key switch OFF at starter key switch OFF terminals of starter switch
ON by carrying position using tester
out service ON at starter key switch ON
diagnosis. position
2 Engine forcible When OFF is No.4 K-3 Key switch Check on engine forcible
stop relay displayed with OFF at starter key switch OFF stop relay
the starter switch position
OFF, then pull out ON at starter key switch ON
R-25 engine position
forcible stop
relay and carry
out the service
diagnosis.
3 Wiring Voltage between 0V when starter switch is OFF Check harness
line No.762 Check diode D-9
among starter between starter switch
switch, engine and auto idling stop relay
forcible stop relay, 1
mechatro
controller and the
body grounding
(2) "CPU DATA COMMUNICATION ERROR" is displayed on multi display.

1 Fuse No.1 fuse (5A) Not blown fuse Check harness
Replace fuse
2 Mechatro controller Accel control Engine speed varies according to Check mechatro
accel potentiometer operation. controller and replace as
(Use remote control because the necessary
auto accel function is working.)
3 Wiring Transmission See "WIRING CHECKING Repair wiring
circuit line PROCEDURE"
No.770 from
mechatro
controller to
gauge cluster
4 Gauge cluster Gauge cluster Replace gauge cluster
(3) Auto accel does not actuate. (The engine speed does not automatically slow down).
1 Gauge cluster Indication of auto Mark "Display/not display" for auto Replace gauge cluster
accel accel switches by auto accel switch
operation on gauge cluster.
2 Low pressure Service diagnosis Each control pressure of No.5, Check low pressure sensor
sensor No,6 is in the range of 0~0.1MPa
at control lever neutral position.
47-28
(4) Auto accel does not actuate. (The engine speed does not automatically speed up.)
1 Low pressure Service diagnosis Each control pressure of No.5, Check low pressure sensor
sensor No.6, No.16 is raised with control
lever operated.
(5) Wiper does not function

47-29
47.3 ENGINE RELATED TROUBLESHOOTING
47-30

47-31
47-32

47-33
㨇51. ENGINE㨉
51. ENGINE
PREFACE

This service manual explains the single engine. Note that this manual is edited without modification by
based on the service manual of ISUZU MOTORS, Ltd.
Book Code No. S5YT51E0
51-1
㨇51. ENGINE㨉

S5YT5117E01
First Edition October, 2012 E75CSR : YT08-30001~
(NHK-EUR)
August, 2013 SK75SR-3E : YT08-30001~

(NA)
SK85CS-3E : LF08-05501~
(NA)
October, 2013 SK75SR-3E : YT08-30001~

(EUR)
SK85CS-3E : LF08-05501~
(EUR)
S5YT5117E02
Revision November, 2013 E75CSR : YT08-30001~
(NHK-EUR)
75SR-3 : YT08-30001~
(NA)
SK75SR-3E : YT08-30001~
(NA)
SK85CS-3E : LF08-05501~
(NA)
SK75SR-3E : YT08-30001~
(EUR)
51-2
4LE2
TIER 4/STAGE Ⅲ B
EXHAUST EMISSION STANDARDS
WORKSHOP MANUAL
ENGINE
FOREWORD
This manual describes the service procedures for the 4LE2 diesel engine (Tier 4/Stage Ⅲ B compatible).
The contents of this manual are current at the date of issue, but may differ slightly from your engine due to specification changes
or other modifications made thereafter.
This manual consists of the following sub-sections.

Publication No. Publication Name Sub-sections
IDE-2650 ENGINE 0 Introduction
14A Service Information Guide
15B Maintenance Information
15C Functional Inspection
15D Sympton
15E DTC Information
1A Engine Control
1B Mechanical
1C Fuel System
1D Cooling
1E Lubrication
1F Induction
1G Exhaust
1H Aux. Emission Control Devices
1J Electrical
– Wiring Diagram
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Sk75sr-3e S5yt0023e02 Shop Manual - Part3

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Sk75sr-3e S5yt0023e02 Shop Manual - Part3

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㨇34.

(4) Press fitting of master pin

Press fitting of master pin

(5) Adjusting crawler tension (See right Fig.)

Adjusting crawler tension

34.1.2.4 MAINTENANCE STANDARDS

34.1.2.5 TOOLS AND JIGS

34.1.3 UPPER ROLLER

Upper roller assy

Installing upper roller (1)

Construction of upper roller

34.1.3.5 DISASSEMBLY AND ASSEMBLY

Removing snap ring (9), cover (4), O-ring (7),

4. Removing O-ring (7)

Extruding shaft (2)

7. Removing floating seal (6).

Taking out floating seal (6)

8. Removing floating seal (6).

Removing floating seal (6)

9. Removing bushing (5)

Pushing in bushing (5)

1. Pressing the bushing (5).

Pushing in bushing (5)

2. Installing floating seals (6).

3. Inserting shaft (2).

5. Installing O-ring (7).

34.1.3.6 MAINTENANCE STANDARD

34.1.3.7 TOOLS AND JIGS

34.1.4 LOWER ROLLER (TRACK ROLLER)

Lower roller assy

(2) Where crawler is installed

Construction of lower roller

34.1.4.5 DISASSEMBLY AND ASSEMBLY

Drawing out collar fixing pin (4)

3. Removing collar (7), O-ring (6)

Removing shaft (2), collar (7), O-ring (6)

5. Removing collar (7), O-ring (6)

7. Removing floating seal (5)

Removing floating seal (5)

8. Removing bushing (3)

Extruding bushing (3)

2. Press fitting bushing (3)

3. Press fitting collar (7)

5. Attach floating seal (5) to roller side

Inserting roller (1)

7. Installing O-ring (6)

Installing O-ring (6), collar (7)

10. Filling oil

34.1.4.6 MAINTENANCE STANDARD

Lower roller (Track roller)

34.1.4.7 TOOLS AND JIGS

34.1.5 FRONT IDLER (IDLER ADJUSTER ASSY)

Front idler assy

Removing and installation the front idler

Keep away from the front side of front idler.

(4) Where idling assy (1) has to be separated

-The separated idler assy (1) should be

Separating idler assy (1) from idler adjuster

34.1.5.3 IDLER ASSY

34.1.5.3.2 REMOVING AND INSTALLING

3. Removing collar (3)

Removing collar (3)

4. Removing collar (3) from shaft (2)