Cebm014201 PDF

CEBM014201
Shop
Manual
SK1026-5N
SKID STEER LOADER
SERIAL NUMBERS SK1026-5N A80001 and UP
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance
with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or
add improvements at any time without incurring any obligation to install such changes on products sold previously.
Due to continuous programs of research and development, periodic revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
July 2009 Copyright 2009 Komatsu

Printed in USA DataKom Publications Division
00-11
FOREWORD CONTENTS
12
CONTENTS 00
01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . 10-1
20 STANDARD VALUE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
30 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
40 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1
50 DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-1
90 DIAGRAMS AND SCHEMATICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
00-21 SK1026-5N
FOREWORD
The affected pages are indicated by using the following Mark Indication Action
marks. It is requested that necessary actions be taken to
these pages according to the table below. ❍ New page to be added Add
● Page to be replaced Replace
( ) Page to be deleted Discard
Mark Page Rev Mark Page Rev Mark Page Rev Mark Page Rev
● 00-1 1 ❍ 01-2 1 ● 10-17 1 ● 10-45 1
● 00-2 1 ❍ 01-3 1 ● 10-18 1 ● 10-46 1
❍ 00-2-1 1 ❍ 01-4 1 ● 10-19 1 ● 10-47 1
❍ 00-2-2 1 ❍ 01-5 1 ● 10-20 1 ● 10-48 1
❍ 00-2-3 1 ❍ 01-6 1 ● 10-21 1 ● 10-49 1
❍ 00-2-4 1 ❍ 01-7 1 ● 10-22 1 ● 10-50 1
● 00-3 1 ❍ 01-8 1 ● 10-23 1 ● 10-51 1
● 00-4 1 ❍ 01-9 1 ● 10-24 1 ● 10-52 1
● 00-5 1 ❍ 01-10 1 ● 10-25 1 ● 10-53 1
● 00-6 1 ❍ 01-11 1 ● 10-26 1 ● 10-54 1
● 00-7 1 ❍ 01-12 1 ● 10-27 1 ● 10-55 1
● 00-8 1 ● 10-28 1 ● 10-56 1
● 00-9 1 ● 10-1 1 ● 10-29 1 ● 10-57 1
● 00-10 1 ● 10-2 1 ● 10-30 1 ● 10-58 1
● 00-11 1 ● 10-3 1 ● 10-31 1 ● 10-59 1
● 00-12 1 ● 10-4 1 ● 10-32 1 ● 10-60 1
● 00-13 1 ● 10-5 1 ● 10-33 1 ● 10-61 1
● 00-14 1 ● 10-6 1 ● 10-34 1 ● 10-62 1
● 00-15 1 ● 10-7 1 ● 10-35 1 ● 10-63 1
● 00-16 1 ● 10-8 1 ● 10-36 1 ● 10-64 1
● 00-17 1 ● 10-9 1 ● 10-37 1 ● 10-65 1
● 00-18 1 ● 10-10 1 ● 10-38 1 ● 10-66 1
● 00-19 1 ● 10-11 1 ● 10-39 1 ● 10-67 1
● 00-20 1 ● 10-12 1 ● 10-40 1 ● 10-68 1
● 00-21 1 ● 10-13 1 ● 10-41 1 ● 10-69 1
● 00-22 1 ● 10-14 1 ● 10-42 1 ● 10-70 1
1 ● 10-15 1 ● 10-43 1 ● 10-71 1
❍ 01-1 1 ● 10-16 1 ● 10-44 1 ● 10-72 1
SK1026-5N WA700-3L 00-2-1 1

FOREWORD
● 10-73 1 ( ) 10-106 1 ( ) 20-28 1 ● 30-26 1
● 10-74 1 ( ) 10-107 1 ( ) 20-29 1 ● 30-27 1
● 10-75 1 ( ) 10-108 1 ( ) 20-30 1 ● 30-28 1
● 10-76 1 ( ) 10-109 1 ( ) 20-31 1 ● 30-29 1
● 10-77 1 ( ) 10-110 1 ( ) 20-32 1 ● 30-30 1
● 10-78 1 ( ) 20-33 1 ● 30-31 1
● 10-79 1 ● 20-1 1 ( ) 20-34 1 ● 30-32 1
● 10-80 1 ● 20-2 1 1 ( ) 30-33 1
● 10-81 1 ● 20-3 1 ● 30-1 1 ( ) 30-34 1
● 10-82 1 ● 20-4 1 ● 30-2 1 ( ) 30-35 1
● 10-83 1 ● 20-5 1 ● 30-3 1 ( ) 30-36 1
● 10-84 1 ● 20-6 1 ● 30-4 1 ( ) 30-37 1
● 10-85 1 ● 20-7 1 ● 30-5 1 ( ) 30-38 1
● 10-86 1 ● 20-8 1 ● 30-6 1 ( ) 30-39 1
● 10-87 1 ( ) 20-9 1 ● 30-7 1 ( ) 30-40 1
● 10-88 1 ( ) 20-10 1 ● 30-8 1 ( ) 30-41 1
● 10-89 1 ( ) 20-11 1 ● 30-9 1 ( ) 30-42 1
● 10-90 1 ( ) 20-12 1 ● 30-10 1 ( ) 30-43 1
● 10-91 1 ( ) 20-13 1 ● 30-11 1 ( ) 30-44 1
● 10-92 1 ( ) 20-14 1 ● 30-12 1 ( ) 30-45 1
● 10-93 1 ( ) 20-15 1 ● 30-13 1 ( ) 30-46 1
● 10-94 1 ( ) 20-16 1 ● 30-14 1 ( ) 30-47 1
● 10-95 1 ( ) 20-17 1 ● 30-15 1 ( ) 30-48 1
● 10-96 1 ( ) 20-18 1 ● 30-16 1 ( ) 30-49 1
● 10-97 1 ( ) 20-19 1 ● 30-17 1 ( ) 30-50 1
● 10-98 1 ( ) 20-20 1 ● 30-18 1 ( ) 30-51 1
( ) 10-99 1 ( ) 20-21 1 ● 30-19 1 ( ) 30-52 1
( ) 10-100 1 ( ) 20-22 1 ● 30-20 1 ( ) 30-53 1
( ) 10-101 1 ( ) 20-23 1 ● 30-21 1 ( ) 30-54 1
( ) 10-102 1 ( ) 20-24 1 ● 30-22 1 ( ) 30-55 1
( ) 10-103 1 ( ) 20-25 1 ● 30-23 1 ( ) 30-56 1
( ) 10-104 1 ( ) 20-26 1 ● 30-24 1 ( ) 30-57 1
( ) 10-105 1 ( ) 20-27 1 ● 30-25 1 ( ) 30-58 1
00-2-2 1 SK1026-5N
FOREWORD
( ) 30-59 1 ❍ 40-21 1 ❍ 40-54 1 ❍ 50-4 1
( ) 30-60 1 ❍ 40-22 1 ❍ 40-55 1 ❍ 50-5 1
( ) 30-61 1 ❍ 40-23 1 ❍ 40-56 1 ❍ 50-6 1
( ) 30-62 1 ❍ 40-24 1 ❍ 40-57 1 ❍ 50-7 1
( ) 30-63 1 ❍ 40-25 1 ❍ 40-58 1 ❍ 50-8 1
( ) 30-64 1 ❍ 40-26 1 ❍ 40-59 1 ❍ 50-9 1
( ) 30-65 1 ❍ 40-27 1 ❍ 40-60 1 ❍ 50-10 1
( ) 30-66 1 ❍ 40-28 1 ❍ 40-61 1 ❍ 50-11 1
( ) 30-67 1 ❍ 40-29 1 ❍ 40-62 1 ❍ 50-12 1
( ) 30-68 1 ❍ 40-30 1 ❍ 40-63 1 ❍ 50-13 1
( ) 30-69 1 ❍ 40-31 1 ❍ 40-64 1 ❍ 50-14 1
( ) 30-70 1 ❍ 40-32 1 ❍ 40-65 1 ❍ 50-15 1
❍ 40-33 1 ❍ 40-66 1 ❍ 50-16 1
● 40-1 1 ❍ 40-34 1 ❍ 40-67 1 ❍ 50-17 1
● 40-2 1 ❍ 40-35 1 ❍ 40-68 1 ❍ 50-18 1
● 40-3 1 ❍ 40-36 1 ❍ 40-69 1 ❍ 50-19 1
● 40-4 1 ❍ 40-37 1 ❍ 40-70 1 ❍ 50-20 1
● 40-5 1 ❍ 40-38 1 ❍ 40-71 1 ❍ 50-21 1
● 40-6 1 ❍ 40-39 1 ❍ 40-72 1 ❍ 50-22 1
● 40-7 1 ❍ 40-40 1 ❍ 40-73 1 ❍ 50-23 1
● 40-8 1 ❍ 40-41 1 ❍ 40-74 1 ❍ 50-24 1
● 40-9 1 ❍ 40-42 1 ❍ 40-75 1 ❍ 50-25 1
● 40-10 1 ❍ 40-43 1 ❍ 40-76 1 ❍ 50-26 1
● 40-11 1 ❍ 40-44 1 ❍ 40-77 1 ❍ 50-27 1
● 40-12 1 ❍ 40-45 1 ❍ 40-78 1 ❍ 50-28 1
● 40-13 1 ❍ 40-46 1 ❍ 40-79 1 ❍ 50-29 1
● 40-14 1 ❍ 40-47 1 ❍ 40-80 1 ❍ 50-30 1
● 40-15 1 ❍ 40-48 1 ❍ 40-81 1 ❍ 50-31 1
● 40-16 1 ❍ 40-49 1 ❍ 40-82 1 ❍ 50-32 1
● 40-17 1 ❍ 40-50 1 1 ❍ 50-33 1
● 40-18 1 ❍ 40-51 1 ❍ 50-1 1 ❍ 50-34 1
● 40-19 1 ❍ 40-52 1 ❍ 50-2 1 ❍ 50-35 1
● 40-20 1 ❍ 40-53 1 ❍ 50-3 1 ❍ 50-36 1
SK1026-5N 00-2-3 1
FOREWORD
❍ 50-37 1 ❍ 50-70 1 ❍ 90-18 1
❍ 50-38 1 ❍ 50-71 1 ❍ 90-19 1
❍ 50-39 1 ❍ 50-72 1 ❍ 90-20 1
❍ 50-40 1 ❍ 50-73 1 ❍ 90-21 1
❍ 50-41 1 ❍ 50-74 1 ❍ 90-22 1
❍ 50-42 1 ❍ 50-75 1
❍ 50-43 1 ❍ 50-76 1
❍ 50-44 1 ❍ 50-77 1
❍ 50-45 1 ❍ 50-78 1
❍ 50-46 1 ❍ 50-79 1
❍ 50-47 1 ❍ 50-80 1
❍ 50-48 1 ❍ 50-81 1
❍ 50-49 1 ❍ 50-82 1
❍ 50-50 1 ❍ 50-83 1
❍ 50-51 1 ❍ 50-84 1
❍ 50-52 1
❍ 50-53 1 ❍ 90-1 1
❍ 50-54 1 ❍ 90-2 1
❍ 50-55 1 ❍ 90-3 1
❍ 50-56 1 ❍ 90-4 1
❍ 50-57 1 ❍ 90-5 1
❍ 50-58 1 ❍ 90-6 1
❍ 50-59 1 ❍ 90-7 1
❍ 50-60 1 ❍ 90-8 1
❍ 50-61 1 ❍ 90-9 1
❍ 50-62 1 ❍ 90-10 1
❍ 50-63 1 ❍ 90-11 1
❍ 50-64 1 ❍ 90-12 1
❍ 50-65 1 ❍ 90-13 1
❍ 50-66 1 ❍ 90-14 1
❍ 50-67 1 ❍ 90-15 1
❍ 50-68 1 ❍ 90-16 1
❍ 50-69 1 ❍ 90-17 1
00-2-4 1 SK1026-5N
FOREWORD SAFETY
12
SAFETY 00
Safety Notice 00
Important Safety Notice 00
Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques
recommended and described in this manual are both effective and safe methods of operation. Some of these operations
require the use of tools specially designed for the purpose.
To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The cautions accom-
panying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first con-
sider safety, and take the necessary actions to deal with the situation.
General Precautions 00
correct places. Always keep the work area clean and
make sure that there is no dirt or oil on the floor. Smoke
Mistakes in operation are extremely dangerous. Read the only in the areas provided for smoking. Never smoke
OPERATION & MAINTENANCE MANUAL carefully while working.
BEFORE operating the machine.
Preparations for Work 00
1. Before carrying out any greasing or repairs, read all the

precautions given on the decals which are fixed to the 1. Before adding oil or making repairs, park the machine
machine. on hard, level ground, and block the wheels or tracks to
prevent the machine from moving.
2. When carrying out any operation, always wear safety
shoes and helmet. Do not wear loose work clothes, or 2. Before starting work, lower blade, ripper, bucket or any
clothes with buttons missing. other work equipment to the ground. If this is not
● Always wear safety glasses when hitting parts with a possible, insert the safety pin or use blocks to prevent
hammer. the work equipment from falling. In addition, be sure to
● Always wear safety glasses when grinding parts with a lock all the control levers and hang warning signs on
grinder, etc. them.
3. When disassembling or assembling, support the

3. If welding repairs are needed, always have a trained,
machine with blocks, jacks or stands before starting
experienced welder carry out the work. When carrying
work.
out welding work, always wear welding gloves, apron,
glasses, cap and other clothes suited for welding work..
4. Remove all mud and oil from the steps or other places
WARNING! Never modify, weld, cut, or drill used to get on and off the machine. Always use the
on any part of a ROPS handrails, ladders or steps when getting on or off the
structure. Doing so may machine. Never jump on or off the machine. If it is
weaken the structure which impossible to use the handrails, ladders or steps, use a
could lead to possible failure in stand to provide safe footing.
a rollover situation
Precautions During Work 00
1. When removing the oil filler cap, drain plug or

4. When carrying out any operation with two or more
hydraulic pressure measuring plugs, loosen them slowly
workers, always agree on the operating procedure
to prevent the oil from spurting out. Before
before starting. Always inform your fellow workers
disconnecting or removing components of the oil, water
before starting any step of the operation. Before starting
or air circuits, first remove the pressure completely from
work, hang UNDER REPAIR signs on the controls in
the circuit.
the operator's compartment.
2. The water and oil in the circuits are hot when the engine
5. Keep all tools in good condition and learn the correct
is stopped, so be careful not to get burned. Wait for the
way to use them.
oil and water to cool before carrying out any work on
the oil or water circuits.
6. Decide a place in the repair workshop to keep tools and
removed parts. Always keep the tools and parts in their
SK1026-5N 00-31
FOREWORD SAFETY
3. Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first.
4. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage.
Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or
crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by
the hoist or crane.
5. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in
position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.
6. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires.
7. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately.
Fuel or oil on the floor can cause you to slip, or can even start fires.
8. Gasoline or other fuels should never be used to clean parts. Clean part with appropriate solvents.
9. Be sure to assemble all parts again in their original places. Replace any damaged part with new parts.
• When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine
is being operated.
10. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely
careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed.
11. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as
guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed
correctly.
12. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.
13. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any
measurements.
14. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates
suddenly, so never let anyone stand at either end of the track.
15. When jump starting the machine, only use a machine of similar size and voltage. Never use a arc welder or other electrical
generating equipment to jump start the machine. Carefully review the safety and procedures for jump starting the
machine.
00-41 SK1026-5N
FOREWORD GENERAL
12
GENERAL 00
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate
understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you
understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For
ease of understanding, the manual is divided into the following sections. These sections are further divided into each main
group of components.
GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and
lubricant specification charts.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
This section explains the structure and function of each component. It serves not only to give an understanding of the
structure, but also serves as reference material for troubleshooting. In addition, this section gives the judgement standards
when inspecting disassembled parts.
STANDARD VALUE TABLE

This section explains the standard values for new machine and judgement criteria for testing, adjusting and
troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts
in troubleshooting.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at
completion of the checks and repairs.
TROUBLESHOOTING
Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component,
as well as precautions to be taken for these operations.
DIAGRAMS AND SCHEMATICS
This section has the foldout drawings for the machine.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact
your Komatsu distributor for the latest information.
SK1026-5N 00-51
FOREWORD HOW TO READ THE SHOP MANUAL
12
HOW TO READ THE SHOP MANUAL 00
Volumes 00 Revisions 00
Shop manuals are issued as a guide to carrying out repairs. Revised pages are shown at the LIST OF REVISED PAGES
They are divided as follows: between the title page and SAFETY page.
Chassis volume: Issued for every machine model Symbols 00
Engine volume: Issued for each engine series

So that the shop manual can be of ample practical use,
Electrical volume: Each issued as one to cover all models important places for safety and quality are marked with the
Attachment volume: Each issued as one to cover all models following symbols.
These various volumes are designed to avoid duplication of

information. Therefore to deal with all repairs for any model, Symbol Item Remarks
it is necessary that chassis, engine, electrical and attachment Special safety precautions are
be available. Safety necessary when performing the
work.
Distribution And Updating 00
Special technical precautions or

other precautions for preserving
Any additions, amendments or other changes will be sent to ★ Caution
standards are necessary when
your distributors. Get the most up-to-date information before
performing the work.
you start any work.
Weight of parts or systems.
Filing Method 00
Weight
Caution necessary when selecting
hoisting wire or when working
1. See the page number on the bottom of the page. File the posture is important, etc.
pages in correct order. Places that require special
2. Following examples show how to read the page number: Tightening
attention for tightening torque
Example: torque
during assembly.
10 - 3 Places to be coated with adhesives

Coat
and lubricants etc.
Item number (10. Structure and Function)
Places where oil, water or fuel
Oil, water
Consecutive page number for each item must be added, and the capacity.
Places where oil or water must be
3. Additional pages: Additional pages are indicated by a Drain drained, and quantity to be
hyphen (-) and numbered after the page number. File as drained.
in the example.
Example:
10-4
10-4-1
Added pages
10-4-2
10-5
Revised Edition Mark 00
When a manual is revised, an edition mark (bcd…) is

recorded on the bottom outside corner of the pages.
00-61 SK1026-5N
FOREWORD HOISTING INSTRUCTIONS
12
HOISTING INSTRUCTIONS 00
Hoisting 00
can result. Hooks have maximum strength at the middle
portion.
WARNING! Heavy parts (25 kg or more)
must be lifted with a hoist etc.
In the DISASSEMBLY AND
ASSEMBLY section, every
part weighing 25 kg or more is
indicated clearly with the sym-
bol.
● If a part cannot be smoothly removed from the machine

by hoisting, the following checks should be made: 3. Do not sling a heavy load with one rope alone, but sling
1. Check for removal of all bolts fastening the part to the with two or more ropes symmetrically wound on to the
relative parts. load.
2. Check for existence of another part causing interface
with the part to be removed. WARNING! Slinging with one rope may
cause turning of the load dur-
ing hoisting, untwisting of the
Wire Ropes 00
rope, or slipping of the rope

from its original winding posi-
1. Use adequate ropes depending on the weight of parts to tion on the load, which can
be hoisted, referring to the table below: result in a dangerous accident
Wire ropes
4. Do not sling a heavy load with ropes forming a wide
(Standard “Z” or “S” twist ropes without galvanizing) hanging angle from the hook. When hoisting a load with
Rope diameter Allowable load two or more ropes, the force subjected to each rope will
increase with the hanging angles. The table below
mm kN tons shows the variation of allowable load (kg) when hoist-
ing is made with two ropes, each of which is allowed to
10 9.8 1.0 sling up to 1000 kg vertically, at various hanging angles.
When two ropes sling a load vertically, up to 2000 kg of
11.2 13.7 1.4 total weight can be suspended. This weight becomes
1000 kg when two ropes make a 120° hanging angle. On
12.5 15.7 1.6 the other hand, two ropes are subject to an excessive
14 21.6 2.2 force as large as 4000 kg if they sling a 2000 kg load at a
lifting angle of 150°.
16 27.5 2.8
18 35.3 3.6
20 43.1 4.4
22.4 54.9 5.6
30 98.1 10.0
40 176.5 18.0
50 274.6 28.0
60 392.2 40.0
★ The allowable load value is estimated to be 1/6 or 1/7 of

the breaking strength of the rope used.
2. Sling wire ropes from the middle portion of the hook.
Slinging near the edge of the hook may cause the rope to
slip off the hook during hoisting, and a serious accident
SK1026-5N 00-71
FOREWORD PUSH PULL COUPLER
12
PUSH PULL COUPLER 00
WARNING! Before carrying out the following work,

release the residual pressure from the
hydraulic tank. For details, see TESTING
AND ADJUSTING, Releasing residual
pressure from hydraulic tank.
WARNING! Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows
out when the hose is disconnected. Prepare
an oil receiving container.
Type 1 00
Disconnection 00
1. Release the residual pressure from the hydraulic tank. For details,
see TESTING AND ADJUSTING, Releasing residual pressure from
hydraulic tank.
2. Hold the adapter (1) and push the hose joint (2) into the mating
adapter (3). The adapter can be pushed in about 3.5 mm. Do not hold
the rubber cap portion (4).
3. After the hose joint (2) is pushed into the adapter (3), press the
rubber cap portion (4) against the adapter until it clicks.
4. Hold the hose adapter (1) or hose (5) and pull it out. Since some
hydraulic oil flows out, prepare an oil receiving container.
Connection 00
1. Hold the hose adapter (1) or hose (5) and insert it in the mating
adapter (3), aligning them with each other. Do not hold the rubber
cap portion (4).
2. After inserting the hose in the mating adapter, pull it back to check
its connecting condition. When the hose is pulled back, the rubber
cap portion moves toward the hose about 3.5 mm. This does not
indicate an abnormality.
00-81 SK1026-5N
Type 2 00
Disconnection 00
1. Hold the mouthpiece of the tightening portion and push body (2) in
straight until sliding prevention ring (1) contacts contact surface a of
the hexagonal portion at the male end.
2. Hold in the condition in Step 1, and turn the lever (4) to the right -
clockwise.
3. Hold in the condition in Steps 1 and 2, and pull out the whole body
(2) to disconnect it.
Connection 00
1. Hold the mouthpiece of the tightening portion and push body (2) in
straight until sliding prevention ring (1) contacts surface a of the
hexagonal portion at the male end to connect it.
SK1026-5N 00-91
12
Type 3 00
Disconnection 00
1. Hold the mouthpiece of the tightening portion and push the body (2)
in straight until sliding prevention ring (1) contacts surface a of the
hexagonal portion at the male end.
2. Hold in the condition in Step 1, and push until the cover (3) contacts
surface a of the hexagonal portion at the male end.
3. Hold in the condition in Steps 1 and 2, and pull out the whole body
(2) to disconnect it.
Connection 00
1. Hold the mouthpiece of the tightening portion and push the body (2)
in straight until the slide prevention ring (1) contacts surface a of the
hexagonal portion at the male end to connect it.
00-101 SK1026-5N
FOREWORD COATING MATERIALS
12
COATING MATERIALS 00
★ The recommended coating materials prescribed in the shop manuals are listed below.
Category Code Part No. Quantity Container Main applications, features
● Used to prevent rubber gaskets, rubber
LT-1A 790-129-9030 150 g Tube
cushions and cork plugs from coming out
● Used in places requiring an immediately
effective, strong adhesive.
20 g Polyethylene ● Used for plastics (except polyethylene,
LT-1B 790-129-9050
(2 pes.) container polypropylene, tetrafluoroethylene, and
vinyl chloride), rubber, metal and
non-metal.
● Features: Resistance to heat, chemicals
Polyethylene
LT-2 09940-00030 50 g ● Used for anti-loosening and sealant
container
purposes for bolts and plugs.
Adhesive:
790-129-9060
1 kg
(Set of adhesive ● Used as adhesive or sealant for metal, glass
LT-3 Hardening Can
and hardening or plastic.
agent:
agent)
Adhesives
500 g
Polyethylene
LT-4 790-129-9040 250 g ● Used as sealant for machined holes.
container
Holtz ● Used as heat-resisting sealant for repairing
790-126-9120 75 g Tube
MH 705 engine.
● Quick hardening type adhesive.
Three
Polyethylene ● Cure time: within 5 sec. to 3 min.
bond 179-129-9140 2g
container ● Used mainly for adhesion of metals,
1735
rubbers, plastics and woods.
● Quick hardening type adhesive.
Aron- ● Quick cure type (max. strength after 30
Polyethylene
alpha 790-129-9130 50 g minutes).
container
201 ● Used mainly for adhesion of rubbers,
plastics and metals.
● Features: Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc ● Used at joint portions subject to high tem-
648-50 container
perature.
● Used as adhesive or sealant for gaskets and
LG-1 790-129-9010 200 g Tube
packing of power train case, etc.
● Features: Resistance to heat
● Used as sealant for flange surfaces and
Gasket bolts at high temperature locations; used to
sealant prevent seizure.
LG-3 790-129-9070 1 kg Can
● Used as sealant for heat resistant gasket for
at high temperature locations such as
engine pre-combustion chamber, exhaust
pipe.
SK1026-5N 00-111
FOREWORD COATING MATERIALS
Category Code Part No. Quantity Container Main applications, features

● Features: Resistance to water, oil
● Used as sealant for flange surface, thread.
● Also possible to use as sealant for flanges
LG-4 790-129-9020 200 g Tube
with large clearance.
● Used as sealant for mating surfaces of final
drive case, transmission case.
● Used as sealant for various threads, pipe
Polyethylene joints, flanges.
LG-5 790-129-9080 1 kg
container ● Used as sealant for tapered plugs, elbows,
nipples of hydraulic piping.
● Features: Silicon based, resistant to heat,
Gasket
cold.
sealant
LG-6 09940-00011 250 g Tube ● Used as sealant for flange surface, thread.
● Used as sealant for oil pan, final drive case,
etc.
● Features: Silicon based, quick hardening
type.
LG-7 09920-00150 150 g Tube ● Used as sealant for flywheel housing,
intake manifold, oil pan, thermostat hous-
ing, etc.
Three
● Used as heat-resisting sealant for repairing
bond 790-129-9090 100 g Tube
engines.
1211
● Used as lubricant for sliding parts (to
LM-G 09940-00051 60 g Can
Molybdenum
prevent squeaking).
disulphide
lubricant
● Used to prevent seizure or scuffing of the

LM-P 09940-00040 200 g Tube thread when press fitting or shrink fitting.
● Used as lubricant for linkage, bearings, etc.
SYG2-400LI
SYG2-350LI
G2-LI SYG2-400LI-A Various Various ● General purpose type
SYG2-160LI
SYGA160CNLI
SYG2-400CA
SYG2-350CA
● Used for normal temperature, light load
SYG2-400CA-A
G2-CA Various Various bearing at places in contact with water or
Grease SYG2-160CA
steam.
SYG2-
160CNCA
disulphide lubricant
Molybdenum
400 g (10 per

SYG2-400M Belows type ● Used for places with heavy load.
case)
00-121 SK1026-5N
FOREWORD STANDARD TIGHTENING TORQUE
12
STANDARD TIGHTENING TORQUE 00
Standard Tightening Torque of Bolts and Nuts 00
The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in DISASSEMBLY AND
ASSEMBLY.
Thread diameter of bolt Width across flats
mm mm Nm lbf ft
6 10 11.8 - 14.7 8.70 - 10.84
8 13 27 - 34 19.91 - 25.07
10 17 59 - 74 43.51 - 54.57
12 19 98 - 123 72.28 - 90.72
14 22 153 - 190 112.84 - 140.13
16 24 235 - 285 173.32 - 210.20
18 27 320 - 400 236.02 - 295.02
20 30 455 - 565 335.59 - 416.72
22 32 610 - 765 449.91 - 564.23
24 36 785 - 980 578.98 - 722.81
27 41 1150 - 1440 848.19 - 1062.09
30 46 1520 - 1910 1121.09 - 1408.74
33 50 1960 - 2450 1445.62 - 1807.02
36 55 2450 - 3040 1807.02 - 2242.19
39 60 2890 - 3630 2131.55 - 2677.35
Thread diameter of bolt Width across flats
mm mm Nm lbf ft
6 10 5.9 - 9.8 4.35 - 7.22
8 13 13.7 - 23.5 10.10 - 17.33
10 14 34.3 - 46.1 25.29 - 34.00
12 27 74.5 - 90.2 54.94 - 66.52
SK1026-5N 00-131
12
Tightening Torque of Hose Nuts 00
Use these torques for hose nuts.

Thread diameter Width across flat Tightening torque
Nominal No.
mm mm Nm lbf ft
02 14 19 19.6 - 29.4 14.5 - 21.7
03 18 24 29.4 - 68.6 21.7 - 50.6
04 22 27 58.9 - 98.1 44.4 - 72.4
05 24 32 107.9 - 166.7 79.6 - 123.0
06 30 36 147.1 - 205.9 108.5 - 151.9
10 33 41 147.1 - 245.1 108.5 - 180.8
12 36 46 196.2 - 294.2 144.7 - 217.0
14 42 55 245.2 - 343.2 180.9 - 253.1
Tightening Torque of Split Flange Bolts 00
Use these torques for split flange bolts.

mm mm Nm lbf ft
10 14 59 - 74 43.5 - 54.6
12 17 98 - 123 7.32 - 90.7
16 22 235 - 285 173.3 - 210.2
Tightening Torque for Flared Nuts 00
Use these torques for flared part of nut.

mm mm Nm lbf ft
14 19 24.5 ± 4.9 18.0 ± 3.6
18 24 49 ± 19.6 36.1 ± 14.4
22 27 78.5 ± 19.6 57.8 ± 14.4
24 32 137.3 ± 29.4 101.2 ± 21.6
30 36 176.5 ± 29.4 130.1 ± 21.6
33 41 196.1 ± 49 144.6 ± 36.1
36 46 245.2 ± 49 180.8 ± 36.1
42 55 294.2 ± 49 216.9 ± 36.1
00-141 SK1026-5N
12
Tightening Torques Table for O-Ring Boss Piping Joints 00
★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter Width across flat Tightening torque (Nm {lbf ft})
Norminal No.
mm mm Range Target
02 14 35 - 63 {25.81 - 46.46} 44 {32.45}
03, 04 20 84 - 132 {61.95 - 97.35} 103 {75.96}
Varies depending on
05, 06 24 128 - 186 {94.40 - 137.18} 157 {115.79}
type of connector.
10, 12 33 363 - 480 {267.73 - 354.02} 422 {311.25}
14 42 746 - 1010 {550.22 - 744.93} 883 {651.26}
Tightening Torques Table for O-Ring Boss Plugs 00
★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter Width across flat Tightening torque (Nm {lbf lb})
Norminal No.
mm mm Range Target
08 08 14 5.88 - 8.82 {4.33 - 6.50} 7.35 {5.42}
10 10 17 9.8 - 12.74 {7.22 - 9.39} 11.27 {8.31}
12 12 19 14.7 - 19.6 {10.84 - 14.45} 17.64 {13.01}
14 14 22 19.6 - 24.5 {14.45 - 18.07} 22.54 {16.62}
16 16 24 24.5 - 34.3 {18.07 - 25.29} 29.4 {21.68}
18 18 27 34.3 - 44.1 {25.29 - 32.52} 39.2 {28.91}
20 20 30 44.1 - 53.9 {32.52 - 39.75} 49.0 {36.14}
24 24 32 58.8 - 78.4 {43.36 - 57.82} 68.6 {50.59}
30 30 32 93.1 - 122.5 {68.66 - 90.35} 107.8 {79.50}
33 33 _ 107.8 - 147.0 {79.50 - 108.42} 124.4 {91.75}
36 36 36 127.4 - 176.4 {93.96 - 130.10} 151.9 {112.03}
42 42 _ 181.3 - 240.1 {133.72 - 177.08} 210.7 {155.40}
52 52 _ 274.4 - 367.5 {202.38 - 271.05} 323.4 {238.52}
Tightening Torque Table for Hoses (Taper Seal Type and Face Seal Type) 00
★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
★ Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {lbf ft}) Face seal type
type
Nominal Width
Nominal thread
size of hose across flats Thread size Root diameter (mm)
Range Target size - Threads per
(mm) (Reference)
inch, Thread series
34 - 54 {25.0 - 39.8} 44 {32.4} - 9/16 - 18UN 14.3
02 19
34 - 63 {25.0 - 46.4} 44 {32.4} 14 - -
22 54 - 93 {39.8 - 68.5} 74 {54.5} - 11/16 -16UN 17.5
03
24 59 - 98 {43.5 - 72.2} 78 57.5} 18 - -
04 27 84 - 132 {61.9 - 97.3} 103 {75.9} 22 13/16 - 16UN 20.6
05 32 128 - 186 {94.4 - 137.1} 157 {115.7} 24 1 - 14UNS 25.4
06 36 177 - 245 {130.5 - 180.7} 216 {159.3} 30 1 3/16 - 12UN 30.2
(10) 41 177 - 245 {130.5 - 180.7} 216 {159.3} 33 - -
(12) 46 197 - 294 {145.3 - 216.8} 245 {180.7} 36 - -
(14) 55 246 - 343 {181.4 - 252.9} 294 {216.8} 42 - -
SK1026-5N 00-151
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE 00
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will
help you understand WIRING DIAGRAMS.
Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.
Classification by Thickness 00
Copper wire
Nominal Cable O.D. Current rat-
Number of Dia. Of strand Cross section Applicable circuit
number (mm) ing (A)
strands (mm) (mm)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
Classification by Color and Code 00
Circuits
Priority Classi- Charging Ground Starting Lighting Instrument Signal Other
fication
Primary
Code W B B R Y G L
1
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2 White & Black & Red & Yellow & Green & Blue &
Color —
Red White White Red White White
Code WB — BY RB YB GR LR
3 White & Black & Yellow & Green &
Color — Red & Black Blue & Red
Black Yellow Black Red
Code WL — BR RY YG GY LY
Auxiliary
4 White & Red & Yellow & Green & Blue &
Color — Black & Red
Blue Yellow Green Yellow Yellow
Code WG — — RG YL GB LB
5 White & Red & Yellow & Green & Blue &
Color — —
Green Green Blue Black Black
Code — — — RL YW GL —
6 Yellow & Green &
Color — — — Red & Blue —
White Blue
00-161 SK1026-5N
FOREWORD CONVERSION TABLES
12
CONVERSION TABLES 00
Method of Using the Conversion Table 00
The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the
Conversion Table, see the example given below.
EXAMPLE
● Method of using the Conversion Table to convert from millimeters to inches.
1. Convert 55 mm into inches.
A. Locate the number 50 in the vertical column at the left side, take this as b, then draw a horizontal line from b.
B. Locate the number 5 in the row across the top, take this as c, then draw a perpendicular line down from c.
C. Take the point where the two lines cross as d. This point d gives the value when converting from millimeters to
inches. Therefore, 55 millimeters = 2.165 inches.
2. Convert 550 mm into inches.

A. The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to convert it to
55 mm.
B. Carry out the same procedure as above to convert 55 mm to 2.165 inches.
C. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to the
right) to return to the original value. This gives 550 mm = 21.65 inches.
c
Millimeters to inches 1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
d
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
b
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
SK1026-5N 00-171
12
Millimeters to Inches 1 mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound 1 kg = 2.2046 lb

0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-181 SK1026-5N
12
Liter to U.S. Gallon 1 L = 0.2642 U.S. Gal

0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon 1 L = 0.21997 U.K. Gal

0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
SK1026-5N 00-191
12
kgm to ft. lb. 1 kgm = 7.233 ft. lb.

0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.63 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-201 SK1026-5N
12
kg/cm2 to lb/in2 1 kg/cm2 = 14.2233lb/in2

0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 19324 1949 1963 1977
140 1991 2005 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
SK1026-5N 00-211
12
Temperature
Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature
reading or vise versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the
temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees,
consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the
column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8
-37.2 .35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-221 SK1026-5N
01 GENERAL
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2

Standard Machine Overall Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2
Overall Dimensions with Standard Bucket L 1880 mm (6’ 2”) and Tires (12 x 16.5) 01-2
Overall Dimensions with Bucket L 1730 mm (5’ 8’) and Tires (12 x 16.5) . . . . . . . . 01-3
Overall Dimensions With Bucket L 2030 mm (6’ 8”) and Tires (33 x 15.5 - 16.5) . . 01-3
Machine Overall Dimensions With Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 01-4
Machine Overall Dimensions with Backhoe (E35-2) . . . . . . . . . . . . . . . . . . . . . . . . . 01-4
Machine Overall Dimensions with Cold Planer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-4
Machine Overall Dimensions with Pallet Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-5
Machine Overall Dimensions with Grapple Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-5
Machine Overall Dimensions with Snow Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-6
Machine Overall Dimensions with Mixing Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-6
Machine Overall Dimensions with Sweeper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-7
Technical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-7
Total Mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-7
Bucket Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-7
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-7
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-7
Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-8
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-8
WEIGHT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-8
FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-9
Proper Selection Of Fuel, Coolant And Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-9
Lubrication with Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-10
Performing KOWA (Komatsu Oil Wear Analysis) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-11
HOMOLOGATED (HEES) SYNTHETIC BIODEGRADABLE
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-12
SPECIFIC DRIVING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-12
SK1026-5N 01-11
GENERAL TECHNICAL DATA
TECHNICAL DATA
Standard Machine Overall Dimensions

Important
• The weight of the machine increases by 200 kg (441 lb.) when this is equipped with solid tires and by 120 kg (264 lb.)
when it is equipped with additional rear counterweights.
• If the bucket is provided with teeth, the machine length increases by 100 mm (3.9 in).
Overall Dimensions with Standard Bucket L 1880 mm (6’ 2”) and Tires (12 x 16.5)
01-21 SK1026-5N
Overall Dimensions with Bucket L 1730 mm (5’ 8’) and Tires (12 x 16.5)
Overall Dimensions With Bucket L 2030 mm (6’ 8”) and Tires (33 x 15.5 - 16.5)
SK1026-5N 01-3 b
Machine Overall Dimensions With Optional Equipment

IMPORTANT
• The weight of the machine increases by 200 kg (441 lb.) when it is equipped with solid tires.
Machine Overall Dimensions with Backhoe (E35-2)
Machine Overall Dimensions with Cold Planer
01-41 SK1026-5N
Machine Overall Dimensions with Pallet Forks
Machine Overall Dimensions with Grapple Fork
SK1026-5N 01-51
Machine Overall Dimensions with Snow Blade
Machine Overall Dimensions with Mixing Bucket
01-61 SK1026-5N
Machine Overall Dimensions with Sweeper
Technical Characteristics
Total Mass
Standard machine max. total mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3690 kg (8,135 lb)
Max. total mass with bucket L 1730 (5ft.8in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3670 kg (8,091 lb)
Max. total mass with bucket L 2030 (6ft 8in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3710 kg (8,179 lb)
Max. total mass with backhoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4620 kg (10,185 lb)
Max. total mass with cold planer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4550 kg (10,031 lb)
Bucket Capacity
Standard bucket L 1880 (6ft 2in) capacity (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.415 m³ (0.54 yd.³)
Narrow bucket L 1730 (5ft 8in) capacity (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.380 m³(0.49 yd.³)
Wide bucket L 2030 (6ft 8in) capacity (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.448 m³ (0.58 yd.³)
Engine
Komatsu diesel engine model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S4D98E-2NFE
Rated power (2500 rpm EEC 80/1269) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 kW (85.8 HP)
Maximum torque (1600 rpm EEC 80/1269) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286 N•m (211 lbf ft)
Electrical System
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 V
Electrical output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 A
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . negative
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Ah-12 V
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 kW (4.02 HP)
SK1026-5N 01-71
GENERAL WEIGHT TABLE
Speed
Forward Reverse
Gears 1 2 1 2
km/h 10.5 16 10.5 16
mph 6.5 9.9 6.5 9.9
Tires
SIZE MAKE INFLATION PRESSURE
12 x 16.5, PR10 ECOMEGA 4.3 kg/cm² (61 psi)
12 x 16.5, PR10 HAULER 4.3 kg/cm² (61 psi)
12x16.5 SK01 MITAS 4.6 kg/cm² (65 psi)
12R 16.5 141A5 MICHELIN 3.8 kg/cm² (54 psi)
33 x 15.5 - 16.5 PR12 ECOMEGA 5.0 kg/cm² (71 psi)
12 x 16.5 AIR BOSS ----
WEIGHT TABLE
WARNING! This weight table is a guide for use when transporting or handling equipment components
Engine assembly - Muffler - Exhaust pipe 335 kg (739 lbs)
Radiator 38 kg (84 lbs)
Hydraulic tank (without oil) 25 kg (55 lbs)
Engine hood 18.5 kg (41 lbs)
Operator compartment (without seat) 215 kg (474 lbs)
Seat
• Standard 10 kg (22 lbs)
• With adjustable suspension 16 kg (35 lbs)
Engine-pump group 328-335 kg (723-739 lbs)
Piston pump
• Standard 91 kg (201 lbs)
• High-flow 98 kg (216 lbs)
Wheel assembly (standard only) 52 kg (115 lbs)
Control valve
• 3-spool (Standard) 21 kg (46 lbs)
• 4-spool (High-flow) 24 kg (53 lbs)
Work equipment
• Arm 480 kg (1,058 lbs)
• Lift lever 24 kg (53 lbs)
• Fulcrum lever 15 kg (33 lbs)
• Work equipment support 80 kg (176 lbs)
• Bucket 205 kg (452 lbs)
• Tilt cylinder 27 kg (60 lbs)
• Dump cylinder 16 kg (35 lbs)
01-81 SK1026-5N
GENERAL FUEL, COOLANT AND LUBRICANTS
FUEL, COOLANT AND LUBRICANTS
Proper Selection Of Fuel, Coolant And Lubricants
Ambient Temperature Capacity

Kind of
Reservoir -22 -4 14 32 50 68 86 104 122°F
fluid Specified Refill
-30 -20 -10 0 10 20 30 40 50°C
SAE 10W
SAE30
Oil 10 liters 10 liters
Engine oil pan SAE40
API CD 2.64 gal 2.64 gal
SAE 10W-30
SAE 5W-30
Hydraulic system SAE 10W

Oil 50 liters 32 liters
and hydrostatic API CD SAE 5W-30 13.2 gal 8.4 gal
transmission
Hydraulic system “HOMOLOGATED (HEES) SYNTHETIC

w/biodegradable HEES BIODEGRADABLE LUBRICANTS” on page 50 liters 32 liters
oil 01--12 13.2 gal 8.4 gal
Final
transmission case SAE 10W-30 13.5 liters 13.5 liters
(each) 3.5 gal 3.5 gal
Diesel ASTM D975 No. 2 72 liters

Fuel tank ----
fuel 19.0 gal
★
Engine cooling 15 liters

Coolant Permanent Anti-freeze Coolant ----
system 3.9 gal
★ ASTM D975 No. 1
SK1026-5N 01-91
Lubrication with Grease
Lubrication Points Consistency Type
Articulated joints NLGI 2 See note 1
NOTE (1)
The recommended lubricating grease is No. 2 multipurpose lithium grease with 3% molybdenum disulfide
(Lithio EP + Mo S2).
IMPORTANT
• When the diesel oil sulphur content is less than 0.5%, change the engine oil according to the periodic maintenance
intervals indicated in the operation and maintenance manual. If the diesel oil sulphur content exceeds 0.5%,
change the engine oil according to the following table:
Fuel sulphur content Change interval of oil in engine oil pan
0.5 to 1.0% 1/2 of regular interval
Above 1.0% 1/4 of regular interval
• When starting the engine at temperatures below 0°C (32°F), use engine oil SAE 10W, 10W-30, 5W-30, even if during the
day the temperature increases by 10°C (18°F).
• Use engine oil with CD classification; if oil with CC classification is used, reduce the engine oil change interval by a half.
• Use Komatsu genuine products whose characteristics have been specifically formulated and approved for use in the
engine, in the equipment hydraulic circuit, in the reduction gears and in the transmission.
First filling quantity: Total quantity of oil, including the oil for the components and pipes.
Oil change quantity: Quantity of oil necessary to fill the system or unit during the normal inspection and maintenance
operations.
ASTM: American Society of Testing and Materials

SAE: Society of Automotive Engineers
API: American Petroleum Institute
NLGI: National Lubricant Grease Institute
Transmission Oil GM
Engine Oil Grease LI, EP, Anti-freeze Coolant
No. Supplier Dexron II C4 Allison
API CD, CE, or CF-4 MoS2 (Permanent type)
C4
Premium multi grade Komatsu Super

Engine Oils PM701 Komatsu PM704 Grease NLGI 2
1 KOMATSU ----
SAE 10W-30 (1902) Dexron® III PM706
SAE 15W/40 ASTM D 128
01-101 SK1026-5N
Performing KOWA (Komatsu Oil Wear Analysis)

KOWA (Komatsu Oil Wear Analysis) is a maintenance service that makes it possible to prevent machine failures and
down-time. With KOWA, the oil is periodically sampled and analyzed. This enables early detection of wear of the machine
drive parts and other abnormalities.
Periodic use of KOWA makes the following possible:
• It enables the accurate understanding of the machine condition by utilizing our long experience and accumulated data
base.
• The report on the result of analysis and recommendation will be delivered to the customer soon at low cost (only the
actual expenses will be charged). Use of this service is strongly recommended.
We strongly recommend you to use this service. The oil analysis is performed at actual cost, so the cost is low, and the results
of the analysis are reported together with recommendations which will reduce repair costs and machine downtime.
KOWA Analysis Items

• Measurement of density of metal wear particles.
• This uses the latest ICP (Inductively Coupled Plasma) analyzer to
measure the density of metal wear particles in the oil.
• Measurement of particle quantity.

This uses a PQI (Particle Quantifier Index) measurer to measure the
quantity of large iron particles (larger than 5 microns) in the oil,
which enables the early detection of defect.
• Others.
Measurements are made of items such as the ratio of water in the
oil, density of the antifreeze coolant, ratio of fuel in the oil, and
dynamic viscosity, enabling a highly precise diagnosis of the
machine's health.
Oil Sampling
• Sampling interval.
• 250 hours: Engine.
• 500 hours: Other components.
• Precautions when sampling.
• Make sure that the oil is well mixed before sampling.
• Perform sampling regularly at fixed intervals.
• Do not perform sampling on rainy or windy days when water or dust can get into the oil.
For further details of KOWA, contact your Komatsu distributor.
SK1026-5N 01-111
GENERAL HOMOLOGATED (HEES) SYNTHETIC BIODEGRADABLE LUBRICANTS
HOMOLOGATED (HEES) SYNTHETIC BIODEGRADABLE

LUBRICANTS
Our machines can be filled with synthetic biodegradable hydraulic oil type HEES not of plant origin, therefore use of oils
indicated in the following table is authorized and recommended:
Supplier HEES Synthetic Biodegradable Oil
KOMATSU BO 46 G4 (KES 07.872)
• It Is not possible to mix synthetic biodegradable ooluble compounds are generated, which are deposited on the fil-
ters and clog them (the maximum concentration of ordinary oil cannot exceed 1% of the total quantity of oil).
• The synthetic biodegradable oil can be used only in the hydraulic system; it cannot be used for the endothermic
engine, the transmissions, the braking system, etc.
• Before introducing synthetic biodegradable oil into the hydraulic system, completely empty the system,
disconnecting the cylinders and all the parts that may contain ordinary oil, and replace the drain filter with a new
one. Start the engine and let it idle without using the work equipment, wait until the oil reaches a temperature of at
least 40°C (104°F), then start moving the equipment, so that all the parts of the system are filled with oil. Stop the
engine and check the oil level.
SPECIFIC DRIVING TORQUES
Item Description N•m lbf ft
Cab Rear fastening screws 98 ± 7.3 22 ± 2
Front support central screw 150 ± 7.3 34 ± 2

Engine
Rear support central screw 150 ± 7.3 34 ± 2
Front 186 ± 9.8 42 ± 2

Wheels
Rear 186 ± 9.8 42 ± 2
01-121 SK1026-5N
10 STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
12
PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Hydraulic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Flushing Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
Reduction Gearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
Operating Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
HST Pump LPV45 + 45 (Standard Flow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
HST Pump LPV45 + 45 (High Flow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
Pump Internal View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
Shuttle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
SAFETY VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
Suction Safety Valve Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
Charge Safety Valve Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29
Charge Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31
ANTI ENGINE-STALL VALVE (AS VALVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32
CONTROL VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
Standard 3-Spool Valve Port Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
Valve Sectional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
Super High-Flow 4-Spool Valve Port Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38
Valve Sectional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-39
Standard 3-spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42
Super High Flow 4-Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-48
CLOSED CENTER LOAD SENSING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-55
Pressure Compensation Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-55
Hydraulic Circuit Diagram and Names of Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-56
System Series Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-57
Self Leveling Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-58
System In Series-Parallel Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-59
Pressure Compensation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61
Dividing Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62
SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-63
Valve Group ST1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-63
SK1026-5N 10-11
STRUCTURE, FUNCTION AND
Valve Group ST2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-64

ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-65
PARTERN CHANGE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-67
Pattern Options Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70
Pattern ISO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70
Pattern Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70
R.H. PPC VALVE (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-72
Equipment Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-72
R.H. PPC VALVE (PATTERN CHANGE) (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-78
Equipment and Travel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-78
L.H. PPC VALVE (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-81
Travel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-81
L.H. PPC VALVE (PATTERN CHANGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-86
Equipment and Travel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-86
Pattern Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-87
CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-92
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-92
Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-92
WORKING EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-96
10-21 SK1026-5N
12
MEMORANDUM
SK1026-5N 10-31
PTO MAINTENANCE STANDARD
PTO
1. Disc 4. Joint
2. Flywheel 5. Pump
3. Dowel (No. 4) 6. Flywheel Cover
10-41 SK1026-5N
MAINTENANCE STANDARD PTO
Maintenance Standards
Torque Values
a. 50 N•m (37 lbf ft) c. 82 N•m (60 lbf ft)
b. 195 N•m (144 lbf ft)
SK1026-5N 10-51
POWER TRAIN MAINTENANCE STANDARD
POWER TRAIN
1. Engine 5. High-Flow Solenoid Valve 4A. Speed Increment
2. Hydraulic Pump 6. L.H. Final Drive 4B. Servo control
3. Control Valve 7. R.H. Final Drive 4C. Parking Brake
4. Solenoid Valve 8. Axle
10-61 SK1026-5N
MAINTENANCE STANDARD POWER TRAIN
Torque Values
a. 98 N•m (72 lbf ft) with Loctite 270 d. 200 N•m (148 lbf ft)
b. 29 N•m (21 lbf ft) e. 186 N•m (137 lbf ft)
c. 294 N•m (217 lbf ft)
SK1026-5N 10-71
TRANSMISSION MAINTENANCE STANDARD
TRANSMISSION
1. L.H. Final Drive
2. Front Transmission Chain
3. Rear Transmission Chain
4. Master Chain Link
10-81 SK1026-5N
MAINTENANCE STANDARD TRANSMISSION
1. Front Wheel 5. Front Transmission Chain
2. Axle Housing 6. Rear Wheel
3. Sprocket 7. Rear Transmission Chain
4. Shaft
SK1026-5N 10-91
TRANSMISSION MAINTENANCE STANDARD
Torque Values
a. 98 N•m (72 lbf ft) with Loctite 270 d. 200 N•m (148 lbf ft)
b. 29 N•m (21 lbf ft) e. 186 N•m (137 lbf ft)
c. 294 N•m (217 lbf ft)
10-101 SK1026-5N
MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
L.H. FINAL DRIVE R.H. FINAL DRIVE
a. A Port - To hydraulic pump (PA2 port) a. A Port - To hydraulic pump (PB1 port)
b. B Port - To hydraulic pump (PB2 port) b. B Port - To hydraulic pump (PA1 port)
c. PP1 Port - From solenoid valve group ST1(A Port) (2nd c. PP1 Port - From solenoid valve group ST1(A Port) (2nd
speed) speed)
d. PP2 Port - From solenoid valve group ST1 (C Port) d. PP2 Port - From solenoid valve group ST1 (C Port)
(parking brake) (parking brake)
e. DR Port - To hydraulic tank e. DR Port - To hydraulic tank
SK1026-5N 10-111
FINAL DRIVE MAINTENANCE STANDARD
1. Shaft 10. Brake Piston 19. Swash Plate 28. Plug
2. Bearing 11. Plate 20. Shaft 29. Spool
3. Bearing 12. Cylinder Block 21. Flange 30. Plug
4. Body 13. Bearing 22. Flange 31. Spring
5. Pin 14. Spring 23. Collar
6. Gear 15. Brake Piston 24. Gasket
7. Pin 16. Brake Spring 25. Plug
8. Gear 17. Bushing 26. Spring
9. Shoe 18. Retainer Plate 27. Spool
10-121 SK1026-5N
Description
The final drive motor consists of:
1. 2-speed hydraulic motor
2. Selector valve
3. Reduction gearing
Hydraulic Motor
Function
The hydraulic motor is of the axial piston type, and converts hydraulic energy supplied by the pump into rotary motion.
Operation
• The hydraulic oil arriving from the selector valve is sent on to the
valve plate (1). When the oil is sent to port “A” of the valve, it
flows into the corresponding port on the cylinder block (2) and
presses against the pistons (3).
• This pressure is converted into rotary motion by a swash plate (4)
and transmitted to shaft (5). The shaft and cylinder block have been
integrated into one piece by means of splined teeth.
• The return oil is sent to the pump through port “B”.
• Rotation in the opposite direction is achieved by sending the oil to
port “B” instead of to port “A”.
SK1026-5N 10-131
Varying the displacement
• Swash plate (4), which has two surfaces "A" and "B" on side opposite the sliding side for shoes (6), is supported by two
bearings (7) attached to the body of motor (8).
• Position of the bearings is eccentric with respect to axis of the shaft and when running at low speed, surface "A" remains
in contact with the body of the motor through pressure exerted by pistons (3) and by the force of a spring (9) mounted in
cylinder block (2).
• Angle of the swash plate is α.
• When an increase in speed is demanded, oil is sent under pressure to command piston (10). Command piston (10) moves
to the left (←) until surface "B" makes contact with the housing and the angle of the swash plate becomes β.
Displacement of the motor is reduced.
Brake
The hydraulic motor is equipped with a negative brake.

• When the motor is at a stand still, or when the operator applies the brake, braking piston (1) is pushed to the left (←) by
the force of springs (2).
Friction disk (3), which has been integrated with the cylinder block by means of semicircular grooves, is compressed
between steel disks (4) and (5), which are integrated with the housing, and is then blocked. Drive shaft (6) can no longer
turn.
• When the motor is running and the operator disengages the brake, oil is sent under pressure to chamber “A”.
Force exerted by the oil is greater than the force of springs (2) and piston (1) is therefore pushed to the right (→) thus
releasing friction disk (3) and permitting rotation of cylinder block (7) (and also of the drive shaft).
10-141 SK1026-5N
Flushing Relief Valve
When oil is sent under pressure to port “A”, the oil that activated the motor returns to the pump through port “B”.
• Pressurized oil sent to port “A” is also introduced into chamber “C”. It now pushes selector valve (1) to the right (→).
This opens communication between port “B” and oil gallery “D”, which is connected to the overpressure limitation valve
(2).
• If the pressure present at port “B” exceeds the calibration value of the overpressure limitation valve (2), this valve will
open and discharge excess oil into the reduction gears.
• The valve also functions in the same way when pressurized oil is sent to port “B”. The only difference is that the selector
valve moves to the left (←), and oil gallery “D” communicates with port “A”.
SK1026-5N 10-151
Reduction Gearing
Function
This final drive motor is equipped with a one-stage epicyclic reduction gear that converts the high rotation speed and low
torque of the hydraulic motor into low speed and high torque at the swing pinion.
Operating Principle
Rotary movement of the output shaft of the motor is transmitted to gear (s1) and then to bevel gears (b1) which are integrated
with planetary gear (1). Since gear (a1) is fixed with respect to the output shaft of the hydraulic motor, the planetary gear is
obliged to turn, moving with it output shaft (2) of the reduction gearing (connected to the planetary gear by means of grooved
teething).
★ Reduction ratio of the rotation speed is described by the formula:
R= Zs1/(Zs1+Za1)
Zs1= number of sun gear teeth
Za1= number of ring gear teeth
10-161 SK1026-5N
Torque Values
a. 61.8 - 75.5 N•m (46 - 56 lbf ft) d. 167 - 196 N•m (123 - 145 lbf ft)
b. 28.4 - 31.4 N•m (21 - 23 lbf ft) e. 51.0 - 64.7 N•m (38 - 48 lbf ft)
c. 46 - 51 N•m (34 - 38 lbf ft)
SK1026-5N 10-171
HYDRAULIC PUMP MAINTENANCE STANDARD
12
HYDRAULIC PUMP
HST Pump LPV45 + 45 (Standard Flow)
10-181 SK1026-5N
MAINTENANCE STANDARD HYDRAULIC PUMP
Structure
This pump is comprised of a variable swash plate type tandem piston pumps (1), control pistons (2), suction safety valves (3),
charge safety valve (4), charge pump (5), work equipment gear pump (6), adjustment screws (7), (8), (9), AS valve (10), and
shuttle valves (11).
1. Piston pump 7. Adjustment screw (Neutral position)

2. Control piston 8. Adjustment screw (Maximum displacement)
3. Suction safety valve 9. Adjustment screw (Pump power control)
4. Charge safety valve 10. AS Valve
5. Charge pump 11. Shuttle valve
6. Work equipment pump
SK1026-5N 10-191
HST Pump LPV45 + 45 (High Flow)
10-201 SK1026-5N
Structure
This pump is comprised of a variable swash plate type tandem piston pumps (1), control pistons (2), suction safety valves (3),
charge safety valve (4), charge pump (5), work equipment gear pump (6), adjustment screws (7), (8), (9), AS valve (10), and
shuttle valves (11).
1. Piston pump 7. Adjustment screw (Neutral position)

2. Control piston 8. Adjustment screw (Maximum displacement)
3. Suction safety valve 9. Adjustment screw (Pump power control)
4. Charge safety valve 10. AS Valve
5. Charge pump 11. Shuttle valve
6. Work equipment pump
Pump Internal View
• The rotation and torque transmitted to the pump shaft is converted into hydraulic energy, and pressurized oil is discharged
according to the load.
• It is possible to change the discharge amount by changing the swash plate angle (plus, zero and minus)
1. Shaft 6. Slider 11. Main bearing

2. Case 7. Shoe 12. Spline
3. Cradle bearing 8. Piston 13. Sub bearing
4. Rocker cam 9. Cylinder block 14. Charge pump
5. Control piston 10. Valve plate 15. Work equipment pump
SK1026-5N 10-211
Structure
• Cylinder block (9) is supported to shaft (1), by spline (12), and shaft (1) is supported by the front and rear bearings (11)
and (13). The tip of piston (8) is a concave ball, and shoe (7) is caulked to it to form one complete unit. Piston (8) and shoe
(7) form a spherical bearing.
• Rocker cam (4) has flat surface “A”, and shoe (7) is always pressing against this surface while sliding in a circular
motion. There is a cradle bearing (3) between cradle and rocker cam (4) which is secured to the case. Rocker cam (4)
sways on the cradle bearing.
• Piston (8) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (9).
• The cylinder block seals the pressurized oil to valve plate (10) and carries out the relative rotation. This surface is
designed so the oil pressure balance is maintained at a suitable level. The oil inside each cylinder chamber of cylinder
block (9) is drawn in and discharged through valve plate (10).
Operation
1. Operation of Pump
● Cylinder block (9) rotates together with shaft (1), and shoe (7) slides on surface A. When this happens, rocker cam (4)
moves along cylindrical surface B, so angle α between center line X of rocker cam (4) and the axial direction of
cylinder block (9) changes. (Angle α is called the swash plate angle).
i. Center line X of rocker cam (4) maintains swash plate

angle α in relation to the axial direction of cylinder block
(9), and flat surface A moves as a cam in relation to shoe
(7). In this way, piston (8) slides on the inside of cylinder
block (9), so a difference between volumes E and F is
created inside cylinder block (9). Suction and discharge is
carried out by this difference F-E. In other words, when
cylinder block (9) rotates and the volume of chamber F
becomes smaller, the oil is discharged during that stroke.
On the other hand, the volume of chamber E becomes
larger, and as the volume becomes bigger, the oil is drawn
in (Fig. 1).
ii. If center line X of rocker cam (4) is in line with the axial
direction of cylinder block (9) (swash plate angle = 0), the
difference between volumes E and F inside cylinder block
(9) becomes 0, so the pump does not carry out any suction
or discharge of oil (Fig. 2).
10-221 SK1026-5N
iii. Center line X of rocker cam (4) maintains swash plate

angle α in relation to the axial direction of cylinder block
(9), and flat surface A moves as a cam in relation to shoe
(7). In this way, piston (8) slides on the inside of cylinder
block (9), so a difference between volumes E and F is
created inside cylinder block (9). Suction and discharge is
carried out by this difference E-F. In other words, when
cylinder block (9) rotates and the volume of chamber E
becomes smaller, the oil is discharged during that stroke.
On the other hand, the volume of chamber F becomes
larger, and as the volume becomes bigger, oil is sucked in.
If the direction of swash plate angle is changed, the
relation between discharge and suction of port PA, PB
reverse (Fig. 3).
Control of Fluid Flow
• If swash plate angle α becomes larger, the difference between

volumes E and F becomes larger and discharge amount Q
increases.
• Swash plate angle α is changed by control piston (5).
• Control piston (5) moves in a reciprocal movement (↔) according
to the signal pressure from pilot line (PPC and AS valves). This
straight line movement is transmitted through slider (6) to rocker
cam (4), which is supported by the cylindrical surface to cradle,
slides in a rotating movement in direction ( ).
• On this pump, maximum swash plate angle is ±15.8o.
• Screw A restricts to the maximum stroke of control piston (i.e.

maximum displacement of each pump). When screw A is tightened,
maximum displacement decreases, and when screw A is loosened,
maximum displacement increases. This screw should be adjusted
when the machine does not travel straight or machine maximum
speed is little bit wrong.
• Screw B is the fine adjuster of neutral position of control piston (5).
That adjustment prevents machine from creep.
SK1026-5N 10-231
Piston Control (on Non-Induction of Pilot Signal)
• If there is no pressure, control piston (5) does not move and main
pump is to a neutral condition.
Piston Control (on Induction of Pilot Signal)
• When pressurized oil which has the pressure PPA, PPB (PPA>PPB)
is led from pilot line (PPC or AS valve), control piston (5) moves
the (→) direction. Control piston (5) moves the balanced position
by spring force and pressure PPA, PPB.
• If the relation of pressure dimension of PPA, PPB is reversed (i.e.

PPA<PPB), control piston moves reversal direction.
AS valve is installed and lower pressure between AS valve output

pressure and PPC pressure is selected by shuttle valve and inducted
to control piston (see topic shuttle valve).
Shuttle Valve
1. Valve
2. Plug
3. Cover
Function
The shuttle valves are installed in the covers of the pump and are part of
the swash plate control pistons. They select the lower pressure either
travel PPC pressure or AS valve pressure, and supply the pump swash
plate with control pressure.
10-241 SK1026-5N
Torque Values
a. 147 - 186.2 N•m (108 - 137 lbf ft) c. 58.8 - 73.5 N•m (43 - 54 lbf ft)
b. 19.6 - 27.4 N•m (15 - 20 lbf ft) d. 49 - 58.8 N•m (36 - 43 lbf ft)
SK1026-5N 10-251
SAFETY VALVES MAINTENANCE STANDARD
SAFETY VALVES
Suction Safety Valve Action
1. Charge pump
2. Charge safety valve
3. Suction safety valve
3A: Valve
3B: Rod
3C: Sleeve
3D: Spring
3E: Spring
3F: Plug
4. Piston pump
5. Travel motor
Functions
There are two suction safety valves installed to each HST pump, and
they have the following functions:
★ High pressure safety valve
The valve restricts maximum pressure inside the HST circuit in
order to protect the HST circuit.
★ Suction safety valve
The valve ensures the flow of charge oil to the closed HST circuit
and prevents charge oil from flowing into the pump high pressure
side (delivery side).
10-261 SK1026-5N
MAINTENANCE STANDARD SAFETY VALVES
Acting As High Pressure Relief Valve
★ Valve at piston pump delivery side

Port A is connected to the piston pump circuit and port B is
connected to the charge circuit. The pressurized oil fills port C
through drill hole a of piston (3A). The pressurized oil at high
pressure port A fills port D through groove b between body
and valve. Poppet (3A) is in tight contact with valve seat (3C).
If abnormal pressure is generated in the circuit and oil pressure

at ports A and D reaches to the pressure set by spring (3D),
poppet (3A) is pushed to (→) direction, and oil at port A is
relieved to port B to reduce the oil pressure at port A.
Acting As Suction Safety Valve
★ When HST pump delivery is 0.

The HST circuit is closed, and the charge oil
does not flow into the HST circuit. Therefore
the charge pressurized oil from the charge
pump (1) all passes the charge safety valve
(2) and is drained to the pump case.
SK1026-5N 10-271
When HST Pump Discharges From Port PA
★ Valve at the piston pump delivery side.

When the pressure oil is discharged from port PA of the HST pump
(4), port PA becomes the high pressure side. This pressure oil at
port PA flow into port D through the groove b. When this happen,
sleeve (3C) is pushed (←) to direction, because of the difference in
area (A1>A2).
Therefore the pressure oil from charge pump is prevented from
flowing into HST pump.
★ Valve at piston pump suction side

Port PB is at low pressure because port PB is suction side and
sleeve (3C) is pushed to (→) direction to open body seat portion
because of the difference in area (A1>A2). In this way, the charge
pressure oil at port B flows into port PB through this clearance to
charge to the HST circuit.
10-281 SK1026-5N
Charge Safety Valve Action
1. Charge pump
2. Charge safety valve
2A: Valve
2B: Spring
2C: Valve seat
2D: Poppet
2E: Spring
2F: Adjustment screw
3. Piston pump
Function
There is the charge safety valve installed to the HST pump. The charge
safety valve restricts maximum pressure inside the charge circuit in
order to protect the charge circuit.
Port A is connected to the charge circuit. Port B is connected to the tank

drain circuit. The pressurized oil fills port C through orifice a in valve
(2A). Poppet (2D) is in tight contact with valve seat (2C)
SK1026-5N 10-291
If abnormal pressure is generated in the circuit or the shuttle valve of

HST motor is at neutral and the oil pressure at ports A and C reaches
the pressure set by spring (2E), poppet (2D) is pushed to (→) direction,
and oil at C is relieved to port B and pressure of the oil at C reduce.
When the pressure of the oil at port C goes down, a differential pressure
is occurred between ports A and C because of orifice a in valve (2A).
Valve (2A) is pushed to (→) direction by oil pressure at port A, and oil
at port A is relieved to port B. In this way, pressure in the charge circuit
is prevented from going any higher.
10-301 SK1026-5N
Charge Pump
1 Slide plate
2 Coupling
3 Shaft
4 Outer ring
5 Case
6 Inner rotor
7 Outer rotor
Function
• HST charge pump is built-in the HST pump
and driven with HST pump at the same time.
• Discharged oil is delivered to AS valve and
charge safety valve.
• Charge pump sucks oil from hydraulic tank.
Specifications
• Type: trochoid pump
• Theological delivery: 25 cm³/rev
Function
• Charge pump is connected to HST pump shaft by coupling (2), so inner rotor (6) and outer rotor (7) rotate.
• When inner rotor (6) and outer rotor (7) rotate, capacity of A increase and oil is sucked, and capacity of B decrease and oil
discharge.
SK1026-5N 10-311
ANTI ENGINE-STALL VALVE (AS VALVE) MAINTENANCE STANDARD
ANTI ENGINE-STALL VALVE (AS VALVE)
1. AS valve 2. Charge pump

1A: Nut 3. Orifice
1B: Screw 4. Charge safety valve
1C: Spring 5. Engine
1D: Spring
1E: Spring
1F: Valve
1G: Valve
1H: Nut
1L: Screw
Function
• The AS valve is attached on the main piston pump. It reduces pressure for pump swash plate control from charge circuit.
• The AS valve outputs pressure correspond with engine revolutions.
10-321 SK1026-5N
MAINTENANCE STANDARD ANTI ENGINE-STALL VALVE (AS VALVE)
Operation
• The oil from the charge pump (2) flows through a orifice (3) installed in the main piston pump. Oil always flows to pump
charge circuit.
• Charge pump (2) is a fixed capacity pump, so that discharge flow is proportionate to engine speed. When oil from the
charge pump (2) passes through the orifice, differential pressure is generated at port A and port B. This differential
pressure actuates the differential pressure sensing valve (1G) and produces hydraulic force F.
• Because of the hydraulic force F, the differential pressure sensing valve (1G) is moved > direction. That causes a change
in spring (1D) load. In port C, the AS valve output pressure that is balanced with spring (1C) and (1D) load is generated
by reducing charge pressure from port G. So the AS valve output pressure corresponds with charge flow that changes with
engine (5) revolution.
SK1026-5N 10-331
ANTI ENGINE-STALL VALVE (AS VALVE) MAINTENANCE STANDARD
Criteria
Standard Size Repair Limit

No. Check Item Remedy
Installed Installed Free Installed
Free Length
Length Load Length Load
38.1 mm 30 mm 52 N 41.1 N
1. Spring -
(1.50 in) (1.18 in) (11.7 lbf) (9.2 lbf)
25.9 mm 23 mm 16.7 N 13.7 N

2. Spring - Replace
(1.10 in) (0.91 in) (3.8 lbf) (3.1 lbf)
38.5 mm 34.5 mm 98 N 78.4 N

3. Spring -
(1.52 in) (1.36 in) (22.0 lbf) (17.6 lbf)
Torque Values
a. 44.1 - 53.9 N•m (33 - 40 lbf ft)
b. 34.3 - 58.8 N•m (25 - 43 lbf ft)
c. 58.8 - 78.4 N•m (43 - 58 lbf ft)
10-341 SK1026-5N
MAINTENANCE STANDARD CONTROL VALVES
CONTROL VALVES
Standard 3-Spool Valve Port Location
P1: From gear pump A3: To attachment port

T: To tank B1: To lift arm cylinder (bottom side)
Ts: To tank B2: To bucket cylinder (bottom side)
A1: To lift arm cylinder (top side) B3: To attachment port
A2: To bucket cylinder (top side)
SK1026-5N 10-351
CONTROL VALVES MAINTENANCE STANDARD
Valve Sectional Views
1. Main relief valve 8. Spool (bucket)

2. Stop plug (lift arm bottom side) 9. Spool (attachment)
3. Suction valve (bucket bottom side) 10. Flow divider
4. Plug 11. Check valve (circulating circuit)
5. Plug 12. Combination circulating valve
6. Series-parallel circuit switching valve 13. Leveling circulating valve
7. Spool (lift arm)
10-361 SK1026-5N
1. Unload valve 9. Suction valve

2. Pressure compensation valve F (lift arm) 10. Shuttle valve
3. Pressure compensation valve F (bucket) 11. Spool (bucket)
4. Pressure compensation valve F (attachment) 12. Suction valve
5. Pressure compensation valve R (attachment) 13. Shuttle valve
6. Pressure compensation valve R (bucket) 14. Spool (attachment)
7. Pressure compensation valve R (lift arm) 15. Stop plug for individual relief valve
8. Spool (lift arm)
★ F: Flow control valve
R: Pressure reducing valve
SK1026-5N 10-371
Super High-Flow 4-Spool Valve Port Location
P1: From gear pump A3: To attachment port

P2: From gear pump A4: To High-Flow port
T: To tank B1: To lift arm cylinder (bottom side)
Ts: To tank B2: To bucket cylinder (bottom side)
Pi2: From solenoid valve group ST2 (S port) B3: To attachment port
A1: To lift arm cylinder (top side) B4: To High-Flow attachment port
A2: To bucket cylinder (top side)
10-381 SK1026-5N
Valve Sectional Views
1. Main relief valve 6. Series-parallel circuit switching valve

2. Stop plug (lift arm bottom side) 7. Spool (lift arm)
3. Suction valve (bucket bottom side) 8. Spool (bucket)
4. Stop plug for individual relief valve 9. Spool (attachment)
5. Float valve 10. Spool (High-Flow)
SK1026-5N 10-391
1. Unload valve 8. Pressure compensation valve R (attachment)

2. Pressure compensation valve F (lift arm) 9. Pressure compensation valve R (bucket)
3. Pressure compensation valve F (bucket) 10. Pressure compensation valve R (lift arm)
4. Pressure compensation valve F (attachment) 11. Combination circulating valve
5. Pressure compensation valve F (High-Flow) 12. Leveling circulating valve
6. Check valve (for High-Flow joining circuit) 13. Flow divider
7. Pressure compensation valve R (High-Flow) 14. Check valve (circulating circuit)
★ F: Flow control valve
R: Pressure reducing valve
10-401 SK1026-5N
1. Pressure compensation valve F (lift arm) 12. Pressure compensation valve R (bucket)
2. Spool (lift arm) 13. Shuttle valve
3. Stop plug 14. Pressure compensation valve F (attachment)
4. Float valve 15. Spool (attachment)
5. On-Off solenoid 16. Stop plug for individual relief valve
6. Spool (float) 17. Pressure compensation valve R (attachment)
7. Pressure compensation valve F (lift arm) 18. Pressure compensation valve F (High-Flow)
8. Shuttle valve 19. Spool (High-Flow)
9. Pressure compensation valve R (bucket) 20. Pressure compensation valve R (High-Flow)
10. Spool (bucket) 21. Check valve (High-Flow joining circuit)
11. Suction valve 22. Spool (High-Flow joining)
SK1026-5N 10-411
Standard 3-spool
10-421 SK1026-5N
Torque Values
a. 11.3 ±1.5 N•m (100 ±13 lbf in)
b. 31.9 ±2.5 N•m (24 ±2 lbf ft)
c. 23.5 ±3.9 N•m (17 ±3 lbf ft)
SK1026-5N 10-431
10-441 SK1026-5N
Criteria

Free Height Installed Installed Free Installed
(Outside ∅) Length Load Height Load
Spool return spring 28.8 x 17.1 mm 26.8 mm 38.2 N 30.6 N

1. -
(lift arm) (1.13 x 0.67 in) (1.06 in) (8.6 lbf) (6.9 lbf)

2. -
(bucket) (1.04 x 0.70 in) (0.73 in) (39.7 lbf) (31.7 lbf)
Spool return spring 21.6 x 14.8 mm 10 mm 38.7 N 31.0 N

3. -
29 x 17.5 mm 25 mm 180.4 N 144.4 N

4. Spool return spring (ATT) -
(1.14 x 0.69 in) (0.98 in) (40.6 lbf) (32.5 lbf)
Replace
Spring of series - parallel 38.3 x 15.2 mm 24 mm 161.8 N 129.5 N springs if there
5. -
circuit switching valve (1.51 x 0.60 in) (0.95 in) (36.4 lbf) (29.1lbf) is damage or
deformation
32.9 x 18.2 mm 18 mm 74.0 N 59.2 N
6. Spring of unload valve -
(1.30 x 0.72 in) (0.71 in) (16.6 lbf) (13.3 lbf)
18.7 x 9.3 mm 16 mm 3.4 N 2.7 N

(0.74 x 0.37 in) (0.63 in) (0.8 lbf) (0.6 lbf)
Spring of pressure 15.4 x 6 mm 13 mm 2.5 N 2.0 N

8. compensation valve -
(0.61 x 0.24 in) (0.51 in) (0.6 lbf) (0.5 lbf)
Spring of pressure 20 x 8.4 mm 12 mm 6.9 N 5.5 N

(0.79 x 0.33 in) (0.47 in) (1.6 lbf) (1.2 lbf)
Torque Value
a. 31.9 ±2.5 N•m (24 ±2 lbf ft)
b. 53.0 ±5.9 N•m (39 ±4 lbf ft)
c. 139.7 ±22.1 N•m (103 ±16 lbf ft)
d. 22.1 ±2.5 N•m (16 ±2 lbf ft)
e. 8.3 ±1.5 N•m (74 ±13 lbf in)
SK1026-5N 10-451
10-461 SK1026-5N
Criteria

30.2 x 9.4 mm 23 mm 2.9 N 2.4 N

1. Spring of flow divider -
(1.19 x 0.37 in) (0.91 in) (0.7 lbf) (0.5 lbf)
18.5 x 3.8 mm 15.5 mm 1.1 N 0.9 N Replace

2. Spring of check valve -
(0.73 x 0.15 in) (0.61 in) (0.3 lbf) (0.2 lbf) springs if there
Spring of combination 37.5 x 16.6 mm 22.5 mm 177.5 N 142.0 N is damage or
3. - deformation
circulating valve (1.48 x 0.65 in) (0.89 in) (39.9 lbf) (31.9 lbf)
Spring of leveling 37.5 x 15.4 mm 22.5 mm 66.7 N 53.4 N

4. -
Torque Value
a. 44.1 ±4.9 N•m (33 ±4 lbf ft)
b. 53.0 ±5.9 N•m (39 ±4 lbf ft)
c. 8.3 ±1.5 N•m (74 ±13 lbf in)
SK1026-5N 10-471
Super High Flow 4-Spool
10-481 SK1026-5N
Torque Values
a. 11.3 ±1.5 N•m (100 ±13 lbf in)
b. 31.9 ±2.5 N•m (24 ±2 lbf ft)
c. 23.5 ±3.9 N•m (17 ±3 lbf ft)
SK1026-5N 10-491
10-501 SK1026-5N
Criteria


1. -
(lift arm) (1.13 x 0.67 in) (1.06 in) (8.6 lbf) (6.9 lbf)

2. -
Spool return spring 21.6 x 14.8 mm 10 mm 38.7 N 31.0 N

3. -
Replace
28 x 11.5 mm 24.5 mm 137.3 N 109.8 N springs if there
4. Spool return spring (ATT) -
(1.10 x 0.69 in) (0.97 in) (30.9 lbf) (24.7 lbf) is damage or
deformation
Spool return spring 29 x 17.6 mm 25.5 mm 131.4 N 105.1 N
5. -
(High-Flow) (1.14 x 0.69 in) (1.00 in) (29.5 lbf) (23.6 lbf)
14.7 x 4.4 mm 9.5 mm 4.9 N 3.9 N

6. Spool return spring (float) -
(0.58 x 0.17 in) (0.37 in) (1.1 lbf) (0.9 lbf)
Spring of series - parallel 38.3 x 15.2 mm 24 mm 161.8 N 129.5 N

7. -
circuit switching valve (1.51 x 0.60 in) (0.95 in) (36.4 lbf) (29.1lbf)
Torque Value
a. 90.7 ±12.3 N•m (67 ±9 lbf ft)
b. 44.1 ±4.9 N•m (33 ±4 lbf ft)
c. 8.3 ±1.5 N•m (74 ±13 lbf in)
SK1026-5N 10-511
10-521 SK1026-5N
Criteria

32.9 x 18.2 mm 18 mm 74.0 N 59.2 N

(1.30 x 0.72 in) (0.71 in) (16.6 lbf) (13.3 lbf)
18.7 x 9.3 mm 16 mm 3.4 N 2.7 N

(0.74 x 0.37 in) (0.63 in) (0.8 lbf) (0.6 lbf)
Spring of pressure 15.4 x 6 mm 13 mm 2.5 N 2.0 N

(0.61 x 0.24 in) (0.51 in) (0.6 lbf) (0.5 lbf)
Spring of pressure 20 x 8.4 mm 12 mm 6.9 N 5.5 N Replace

(0.79 x 0.33 in) (0.47 in) (1.6 lbf) (1.2 lbf) springs if there
Spring of combination 37.5 x 16.6 mm 22.5 mm 177.5 N 142.0 N is damage or
5. - deformation
Spring of leveling 37.5 x 15.4 mm 22.5 mm 66.7 N 53.4 N

6. -
Spring of series - parallel 38.3 x 15.2 mm 24 mm 161.8 N 129.5 N

7. -
circuit switching valve (1.51 x 0.60 in) (0.95 in) (36.4 lbf) (29.1lbf)
30.2 x 9.4 mm 23 mm 2.9 N 2.4 N

8. Spring of flow divider -
(1.19 x 0.37 in) (0.91 in) (0.7 lbf) (0.5 lbf)
Torque Value
a. 53.0 ±5.9 N•m (39 ±4 lbf ft)
b. 139.7 ±22.1 N•m (103 ±16 lbf ft)
c. 22.1 ±2.5 N•m (16 ±2 lbf ft)
d. 8.3 ±1.5 N•m (74 ±13 lbf in)
SK1026-5N 10-531
Criteria

13.0 x 6.5 mm 9.5 mm 2.0 N 1.6 N Replace

1. Spring of check valve -
(0.51 x 0.26 in) (0.37 in) (0.5 lbf) (0.4 lbf) springs if
there is
Spool return spring 25.7 x 11.1 mm 22 mm 66.7 N 53.4 N damage or
2. -
(High-Flow joining circuit (1.01 x 0.44 in) (0.87 in) (15.0 lbf) (12.0 lbf) deformation
Torque Values
a. 11.3 ±1.5 N•m (100 ±13 lbf in)
b. 31.9 ±2.5 N•m (24 ±2 lbf ft)
c. 77.9 ±12.3 N•m (58 ±9 lbf ft)
d. 22.0 ±2.5 N•m (16 ±2 lbf ft)
e. 34.3 ±4.9 N•m (25 ±4 lbf ft)
10-541 SK1026-5N
MAINTENANCE STANDARD CLOSED CENTER LOAD SENSING SYSTEM
CLOSED CENTER LOAD SENSING SYSTEM

Outline
• CLSS stands for Closed center Load Sensing System, and has the followings characteristics.
A. Control ability, not influenced by load.
B. Controllable digging force at a fine control range.
C. Easy simultaneous operation by spool opening proportional flow dividing function.
Pressure Compensation Control

A valve (pressure compensation valve) is installed to the inlet port side of the control valve to balance the load. When there is
compound operation of the equipment, this valve acts to make pressure difference ▲P constant for the upstream flow (inlet
port) and downstream flow (outlet port) of each spool. In this way, the flow of oil from the pump is divided in proportion to
area of opening S1 and S2 of each valve.
SK1026-5N 10-551
CLOSED CENTER LOAD SENSING SYSTEM MAINTENANCE STANDARD
Features
• The small capacity gear pump provides high flow movement because lift arm and the bucket circuit are connected in a
series circuit.
• The control valve has built in self leveling function.
• If loading pressure on the bucket goes beyond a certain value, the lift arm and the bucket circuits automatically change to
a parallel circuit to provide a strong digging force.
• The lift arm, attachment and High-flow section are connected in a parallel circuit and are provided with a pressure
compensational function in each section.
• During individual operations, attachment High-flow keeps individual demand flow rate normal. However during
compound operations, they are divided in a proportion of 1 to 9 flow rate.
Hydraulic Circuit Diagram and Names of Valves
1. Unloader valve 8. Leveling circulating valve

2. Main relief valve 9. Combination circulating valve
3. Pressure compensation valve (lift arm) 10. Flow divider
4. Pressure compensation valve (bucket) 11. Shuttle valve
5. Pressure compensation valve (attachment) 12. Check valve (circulating circuit)
6. Pressure compensation valve (High-Flow) 13. High-Flow Joining spool
7. Float valve
10-561 SK1026-5N
System Series Circuit Operation
Function
• Return flow rate from the lift arm is recirculated to the bucket.
Operation
When (lift arm raise) and (bucket dump) are operated at the same time.
• The lift arm spool (1) is at full stroke and bucket spool (2) is at half stroke.
• When this happens, notch (a) does not open, so all flow from pump supplies to the lift arm raise.
• The lift arm and bucket PPC pressure are sent through passages E and F. Then the leveling circulating valve (3) and the
combination circulating valve (4) are at full stroke.
• Return flow rate from the lift arm cylinder passes through passage A. Then it is divided and sent to passage B and C, by
the leveling circulating valve (4) and combination circulating valve (3).
• When this happens, flow divider (5) is operated as P1=P2, so flow rate (Q1, Q2) is divided to passages B and C in
proportion to the area of opening of notch (b) and (c) as expressed below.
★ Q1:Q2= (notch (b) + notch (d)): notch (C)
★ Q1= flow rate flows to B, Q2= flow rate flows to C
• Q1 passes through check valve (6) and then supplies the bucket cylinder.
SK1026-5N 10-571
Self Leveling Function
Function
When the only lever of the lift arm raise is operated, the lift arm raise and the bucket dump are worked. When this happens, the
work equipment can raise with constant bucket bottom angle. (Only the lift arm raise.)
Operation
• When the lift arm raise is operated individually.

• The lift arm spool (1) is at a full stroke position and the bucket spool is at a half stroke position.
• When this happens, notch (a) does not open, so all flow rate from the pump is supplied to the lift arm raise.
• The lift arm raise PPC pressure is then sent through passage E. When this happens the leveling circulating valve is at a
full stroke position.
• Return flow rate from the lift arm cylinder passes through passage A. Then it is divided into passages B and C, by leveling
circulating valve (3).
• When this happens, the flow divider (5) is operated as P1=P2, so flow rate (Q1, Q2) is divided to B and C in proportion
to the area of opening of notches (b) and (c) as expressed below.
★ Q1:Q2= notch (b): notch (C)
• Q1 passes through check valve (6) and then supplies the bucket cylinder.
10-581 SK1026-5N
System In Series-Parallel Circuit Operation
Function
• (1) Low bucket load: Series circuit.

• (2) High bucket load: Parallel circuit.
• Depending on bucket load, a circuit can change automatically as above.
SK1026-5N 10-591
Operation
When the (lift arm raise) and (bucket digging) are operated at the same time.
• Lift arm spool (1) and bucket spool (2) are at full stroke.
• When this happens, the bucket digging PPC pressure is sent through passage H. Then the combination circulating valve
(3) fully strokes to the right and the lift arm raise PPC pressure is sent through passage E. Then the leveling circulating
valve (4) is at full stroke to the left.
• Return flow rate from the lift arm cylinder passes through passage A. Then it is divided and sent to passage B and C, by
the leveling circulating valve (4) and the combination circulating valve (3).
• When this happens, the flow divider (5) is operated as P1=P2, so flow rate (Q1, Q2) is divided to passages B and C in
proportion to the area of opening as below expression.
★ Q1:Q2= (notch (b) + notch (d)): notch (C)
★ Q1= flow rate flows to B Q2=flow rate flows to C
• If the bucket load goes beyond a certain load, the series-parallel switching valve (7) strokes to the right. Then it passes
thorough passage G by opening notch (e). And then the spring chamber of flow divider (5) is connected to tank.
• As a result, flow divider strokes fully to the right, and P2=T Return flow rate from the lift arm is connected with tank
totally, and Q1=0L/min.
• When this happens, notch (f) of the lift arm spool and notch (a) of the bucket spool open, so the lift arm and the bucket
become parallel circuit (CLSS). And flow rate of the lift arm raise (Q3) and then bucket digging flow rate are divided as
below expression. Q3:Q4= notch (f): notch (a)
10-601 SK1026-5N
Pressure Compensation Valve
Function
During compound operations, if the load pressure becomes lower than the other actuator and the oil flow tries to increase,
compensation is received. (When this happens, the other actuator being used for compound operation (right side) is at a higher
load than the actuator on this side (left side).
Operation
• If the load pressure of the other actuator (right side) becomes higher during compound operations, the oil flow in actuator
circuit A on this side (left side) tries to increase.
• If this happens, the LS pressure PLS of the other actuator acts on spring chamber PLS1, and reducing valve (1) and flow
control valve (2) are pushed to the left in the direction of the arrow ➮.
• Flow control valve (2) throttles the area of opening between pump circuit PP and spool upstream PPA, and pressure loss
is generated between PP and PPA.
• Flow control valve (2) and reducing valve (1) are balanced in position where the difference in pressure between PLS and
PA acting on both ends of reducing valve (2) and the pressure loss between PP and PPA on both sides of flow control
valve (2) are the same.
• In this way, the pressure difference between upstream pressure PPA and down stream pressure PA of both spools used
during compound operations is the same, so the pump flow is divided in proportion to the area of opening of notch (a) of
each spool.
SK1026-5N 10-611
Dividing Function
When each section is operated individually.

★ Attachment: 60 liters/min (16 gal/min).
★ High-Flow attachment: 100 liters/min (26 gal/min).
When standard attachment and high flow attachment are operated at the same time 1:9=attachment: High-Flow.
Operation
• When each section is operated individually

• Attachment spool (1) and High-Flow spool (3) stroke fully and individually, therefore they keep demand flow rate
individually.
★ Attachment: 60 liters/min (16 gal/min).
★ High-Flow: 100 liters/min (16 gal/min).
• When attachment and High-Flow are operated at the same time.
• High-Flow attachment PPC pressure passes through passage A, is sent to retainer (2) and makes retainer (2) stroke to the
left.
• When this happens, attachment spool (1) can stroke by half.
• As a result, flow rate of attachment and High-Flow are divided as expressed below.
Attachment: High-Flow= 1:9.
• Therefore flow rate of high flow is kept.
10-621 SK1026-5N
MAINTENANCE STANDARD SOLENOID VALVE
12
SOLENOID VALVE
Valve Group ST1

Servo control - Parking Brake - 2nd. Speed
Function
1. 2nd. speed A Port - To travel motors (PP1 port)

2. Servo control B Port - To PPC valve
3. Parking brake C Port - To travel motors (PP2 port)
P Port - From hydraulic pump (E1 port)
T Port - To hydraulic tank
S Port - To accumulator
SK1026-5N 10-631
SOLENOID VALVE MAINTENANCE STANDARD
Valve Group ST2

High-Flow Control
T Port - To hydraulic tank

P1 Port - From control valve (PA3 port)
P2 Port - From control valve (PB3 port)
S Port - To control valve (Pi2 port)
10-641 SK1026-5N
MAINTENANCE STANDARD ACCUMULATOR
ACCUMULATOR
Technical Data
Servo control
• Nominal volume: 0.35 liters (21.4 in3)
• Pre-loading: 8.2 kg/cm2 (116 psi)
• Working pressure: 25.5 - 27.5 kg/cm2 (363 - 391 psi)
Function
An elastic rubber bag (1) containing nitrogen is fitted inside the accumulator to maintain oil pressure in the circuit to which the
accumulator is connected.
Operation
• When the engine is running chamber A bag (1) (containing nitrogen) is compressed by oil under pressure coming from
line B.
• If the oil under line B falls below the maximum calibration pressure (even after intensive use), the rubber bag (1) will
expand due to pressure from the nitrogen.
SK1026-5N 10-651
ACCUMULATOR MAINTENANCE STANDARD
MEMORANDUM
10-661 SK1026-5N
MAINTENANCE STANDARD PARTERN CHANGE VALVE
PARTERN CHANGE VALVE
P in 1. - From L.H. PPC valve (P4 port) P out 1. - To hydraulic pump (DA1 port)
P in 2. - From L.H. PPC valve (P1 port) P out 2. - To hydraulic pump (DA2 port)
P in 3. - From L.H. PPC valve (P3 port) P out 3. - To hydraulic pump (DB1 port)
P in 4. - From L.H. PPC valve (P2 port) P out 4. - To hydraulic pump (DB2 port)
P in 5. - From R.H. PPC valve (P1 port) P out 5. - To control valve (PA1 port)
P in 6. - From R.H. PPC valve (P2 port) P out 6. - To control valve (PB1 port)
a: 27.5 - 34.3 N•m (20 - 25 lbf ft)
SK1026-5N 10-671
PARTERN CHANGE VALVE MAINTENANCE STANDARD
10-681 SK1026-5N
1. Lever
2. Rotor
3. Valve seat
4. Ball
5. Upper cover
6. Lower cover
7. Pin lock
a: 27.5 - 34.3 N•m (20 - 25 lbf ft)

b: 11.8 - 14.7 N•m (104 - 130 lbf in)
SK1026-5N 10-691
PARTERN CHANGE VALVE MAINTENANCE STANDARD
Pattern Options Arrangement

Pattern ISO
Pattern Optional
10-701 SK1026-5N
Torque Values
a. 27.5 - 34.3 N•m (20 - 25 lbf ft)
b. 11.8 - 14.7 N•m (104 - 130 lbf in)
SK1026-5N 10-711
R.H. PPC VALVE (STANDARD) MAINTENANCE STANDARD
R.H. PPC VALVE (STANDARD)

Equipment Control
P1 port - To control valve (PA1 port) Function

P2 port - To control valve (PB1 port) P1 Lower arm
P3 port - To control valve (PA2 port) P2 Raise arm
P4 port - To control valve (PB2 port) P3 Curl bucket
P port - From solenoid valve group ST1 (B port) P4 Dump bucket
T port - To hydraulic tank
10-721 SK1026-5N
MAINTENANCE STANDARD R.H. PPC VALVE (STANDARD)
1. Spool 6. Nut
2. Metering spring 7. Joint
3. Centering spring 8. Cover
4. Piston 9. Stopper
5. Disc 10. Body
SK1026-5N 10-731
Function
1. Neutral
Ports P1 and P2 of the PPC valve are connected to drain chamber D
through fine control hole f in spool (Fig. 1)
2. During Fine Control

(Neutral ➬ Fine Control)
When piston (4) starts to be pushed by disc (5), retainer (9) is
pushed; spool (1) is also pushed by metering spring (2), and moves
down. When this happens, fine control hole f is shut off from drain
chamber D, and at almost the same time, it is connected to pump
pressure chamber PP, so pilot pressure oil from the control pump
passes through fine control hole f and goes to port P1. When the
pressure at port P1 becomes higher, spool (1) is pushed back and
fine control hole f is shut off from pump pressure chamber PP.
At almost the same time, it is connected to drain chamber D to

release the pressure at port P1. When this happens, spool (1) moves
up or down so that the force of metering spring (2) is balanced with
the pressure at port P1. The relationship in the position of spool (1)
and body (10) (fine control hole f is at a point midway between
drain hole D and pump pressure chamber PP) does not change even
if the pressure at port P1 becomes max. Therefore, metering spring
(2) is compressed proportionally to the amount of movement of the
control lever, so the pressure at port P1 also rises in proportion to
the travel of the control lever (Fig. 2).
3. During Fine Control (When The Lever Is Returned)

(fine control ➬ neutral)
When disc (5) starts to be returned, spool (1) is pushed up by the
force of centering spring (3) and the pressure at port P1. When this
happens, fine control hole f is connected to drain chamber D and
the pressure oil at port P1 is released. If the pressure at port P1
drops too far, spool (1) is pushed down by metering spring (2), and
fine control hole f is shut off from drain chamber D. At almost the
same time, it is connected to pump pressure chamber PP, and the
pump pressure is supplied until the pressure at port P1 recovers to a
pressure that corresponds to the lever position (Fig. 3).
10-741 SK1026-5N
MEMORANDUM
SK1026-5N 10-751
10-761 SK1026-5N
Criteria

Centering spring 42.4 x 15.5 mm 34 mm 9.8 N 9.2 N

1. (for P3 and P4) -
(1.67 x 0.61 in) (1.34 in) (2.2 lbf) (2.1 lbf)
Centering spring 36.6 x 15.5 mm 34 mm 17.6 N 16.5 N Replace

2. (for P1 and P2) - springs if
(1.44 x 0.61 in) (1.34 in) (4.0 lbf) (3.7 lbf)
there is
Metering spring 32.7 x 8.2 mm 25.6 mm 40.8 N 39.4 N damage or
3. -
(for P3 and P4) (1.29 x 0.32 in) (1.01 in) (9.2 lbf) (8.9 lbf) deformation
Metering spring 26.2 x 8.2 mm 25.3 mm 5.3 N 4.3 N
4. (for P1 and P2) -
(1.03 x 0.32 in) (1.00 in) (1.2 lbf) (1.0 lbf)
Torque Values
a. 112.8 ±14.7 N•m (83 ±11 lbf ft)
b. 44.1 ±4.9 N•m (33 ±4 lbf ft)
c. 13.2 ±1.5 N•m (117 ±13 lbf in)
d. 39.2 ±4.9 N•m (29 ±4 lbf ft)
SK1026-5N 10-771
R.H. PPC VALVE (PATTERN CHANGE) (OPTIONAL) MAINTENANCE STANDARD
R.H. PPC VALVE (PATTERN CHANGE) (OPTIONAL)

Equipment and Travel Control
Supply P1 - To pattern change valve (Pin 5 port) Function

Supply P2 - To pattern change valve (Pin 6 port) ISO Pattern P1 Lower arm
P3 port - To control valve (PA2 port) P2 Raise arm
P4 port - To control valve (PB2 port) P3 Curl bucket
P port - From solenoid valve group ST1 (B port) P4 Bucket dump
T port - To hydraulic tank Optional Pattern P1 R.H. Travel forward
P2 R.H. Travel reverse
P3 Curl bucket
P4 Dump bucket
10-781 SK1026-5N
MAINTENANCE STANDARD R.H. PPC VALVE (PATTERN CHANGE) (OPTIONAL)
1. Spool 6. Nut
5. Disc 10. Body
SK1026-5N 10-791
R.H. PPC VALVE (PATTERN CHANGE) (OPTIONAL) MAINTENANCE STANDARD
Function
1. Neutral
through fine control hole f in spool (Fig. 1).



10-801 SK1026-5N
MAINTENANCE STANDARD L.H. PPC VALVE (STANDARD)
L.H. PPC VALVE (STANDARD)

Travel Control
P1 port - To control valve (DA2 port) Function

P2 port - To control valve (DB2 port) P1 Travel forward
P3 port - To control valve (DA1 port) P2 Travel reverse
P4 port - To control valve (DB1 port) P3 R.H. Travel forward
P port - From solenoid valve group ST1 P4 R.H. Travel reverse
T port - To hydraulic tank
★ When acting control lever, two ports are pressurized contemporarily (i.e.: travel forward pressurize P1 and P3 ports).
SK1026-5N 10-811
L.H. PPC VALVE (STANDARD) MAINTENANCE STANDARD
1. Spool 8. Cover
2. Metering spring 9. Stopper
3. Centering spring 10. Body
4. Piston 11. Plug
5. Disc 12. Ball
6. Nut 13. Seat
7. Joint 14. Body (for shuttle valve)
10-821 SK1026-5N
Function
1. Neutral



SK1026-5N 10-831
L.H. PPC VALVE (STANDARD) MAINTENANCE STANDARD
10-841 SK1026-5N
Criteria


1. (for P out 3 and P out4) -
(1.40 x 0.61 in) (1.34 in) (2.2 lbf) (2.1 lbf) Replace
springs if
2. (for P out 1 and P out 2) - there is
(1.03 x 0.61 in) (1.34 in) (4.0 lbf) (3.7 lbf)
damage or
Metering spring 32.7 x 8.2 mm 25.3 mm 5.3 N deformation
3. - -
(for P3 and P4) (1.29 x 0.32 in) (1.00 in) (1.2 lbf)
Torque Values
a. 112.8 ±14.7 N•m (83 ±11 lbf ft)
b. 44.1 ±4.9 N•m (33 ±4 lbf ft)
c. 13.2 ±1.5 N•m (117 ±13 lbf in)
d. 13.7 ±1.0 N•m (121 ±9 lbf in)
e. 39.2 ±4.9 N•m (29 ±4 lbf ft)
SK1026-5N 10-851
L.H. PPC VALVE (PATTERN CHANGE) MAINTENANCE STANDARD
L.H. PPC VALVE (PATTERN CHANGE)

Equipment and Travel Control
P1 port - To pattern change valve (Pin 1 port) Function

P2 port - To pattern change valve (Pin 2 port) ISO Pattern P1 Travel forward
P3 port - To pattern change valve (Pin 3 port) P2 Travel reverse
P4 port - To pattern change valve (Pin 4 port) P3 L.H. Travel
P port - From solenoid valve group ST1 P4 R.H. Travel
T port - To hydraulic tank Optional Pattern P1 L.H. Travel forward
P2 L.H. Travel reverse
P3 Raise arm
P4 Lower arm
10-861 SK1026-5N
MAINTENANCE STANDARD L.H. PPC VALVE (PATTERN CHANGE)
Pattern Change
1. Spool 6. Nut
5. Disc 10. Body
SK1026-5N 10-871
Function
1. Neutral



10-881 SK1026-5N
MEMORANDUM
SK1026-5N 10-891
10-901 SK1026-5N
Criteria


1. (for P out 3 and P out4) -
(1.40 x 0.61 in) (1.34 in) (2.2 lbf) (2.1 lbf) Replace
springs if
2. (for P out 1 and P out 2) - there is
(1.44 x 0.61 in) (1.34 in) (4.0 lbf) (3.7 lbf)
damage or
Metering spring 26.2 x 8.2 mm 25.3 mm 5.3 N deformation
3. - -
(for P3 and P4) (1.03 x 0.32 in) (1.00 in) (1.2 lbf)
Torque Values
a. 112.8 ±14.7 N•m (83 ±11 lbf ft)
b. 44.1 ±4.9 N•m (33 ±4 lbf ft)
c. 13.2 ±1.5 N•m (117 ±13 lbf in)
d. 39.2 ±4.9 N•m (29 ±4 lbf ft)
SK1026-5N 10-911
CYLINDERS MAINTENANCE STANDARD
CYLINDERS
Boom
Bucket
1. Bushing 4. O-ring 7. Bushing ring 10. Piston 13. Gland nut

2. Dust seal 5. Rod 8. Bushing 11. Cylinder
3. O-ring 6. Seal 9. Nut 12. Seal
Unit: mm (in)
Cylinder Rod Piston Stroke Cylinder length Max. Cylinder length Min. Key size
Boom 40 (1.6) 65 (2.5) 690 (27.2) 1634 (64.3) 944 (37.2) 41 (1.6)
Bucket 35 (1.4) 65 (2.5) 423 (16.6) 1110 (43.7) 687 (27.0) 41 (1.6)
10-921 SK1026-5N
MAINTENANCE STANDARD CYLINDERS
MEMORANDUM
SK1026-5N 10-931
CYLINDERS MAINTENANCE STANDARD
Criteria
No. Check Item Cylinder Standard Tolerance Clerance Remedy

Minimum clerance
size Shaft Hole limit
-0.025 mm +0.105 mm
Lifting 40 mm -0.064 mm +0.135 mm 0.130 - 0.199 mm 1.0 mm
Tolerance bucket (1.58 in) (-0.001 in) (+0.004 in) (0.005 - 0.008 in) (0.039 in)
between (-0.003 in) (+0.005 in)
1. bushing and
piston rod -0.01 mm +0.072 mm
mounting pin Tilting 35 mm -0.05 mm +0.134 mm 0.082 - 0.184 mm 1.0 mm
bucket (1.38 in) (-0.0004 in) (+0.003 in) (0.003 - 0.007 in) (0.039 in)
(-0.0020 in) (+0.005 in) Replace
-0.025 mm +0.105 mm bushing
Tolerance bucket (1.58 in) (-0.001 in) (+0.004 in) (0.005 - 0.008 in) (0.039 in)
between (-0.003 in) (+0.005 in)
2. bushing and
cylinder -0.01 mm +0.072 mm
mounting pin Tilting 35 mm -0.05 mm +0.134 mm 0.082 - 0.184 mm 1.0 mm
bucket (1.38 in) (-0.0004 in) (+0.003 in) (0.003 - 0.007 in) (0.039 in)
(-0.0020 in) (+0.005 in)
-0.025 mm +0 mm
bucket (1.58 in) (-0.001 in) (+0 in) (0.001 - 0.005 in) (0.017 in)
Tolerance (-0.003 in) (+0.002 in)
between piston Replace
3.
rod and head
cylinder head -0.025 mm +0 mm
Tilting 35 mm -0.087 mm +0.039 mm 0.025 - 0.126 mm 0.426 mm
bucket (1.38 in) (-0.001 in) (+0 in) (0.001 - 0.005 in) (0.017 in)
(-0.003 in) (+0.002 in)
10-941 SK1026-5N
MAINTENANCE STANDARD CYLINDERS
Torque Values
a. 490 ±49 N•m (361 ±36 lbf ft)
b. 1127 ±112 N•m (831 ±83 lbf ft)
SK1026-5N 10-951
WORKING EQUIPMENT MAINTENANCE STANDARD
WORKING EQUIPMENT
10-961 SK1026-5N
MAINTENANCE STANDARD WORKING EQUIPMENT
Criteria
No. Check Item Standard Tolerance Clerance Remedy

Minimum clerance
size Shaft Hole limit
-0.012 mm +0.012 mm
Clearance between bushing 45 mm -0.065 mm +0.056 mm 0.024 - 0.121 mm 1.0 mm
1.
and mounting pin of lift lever (1.77 in) (-0.0005 in) (+0.0005 in) (0.001 - 0.005 in) (0.039 in)
(-0.0030 in) (+0.0022 in)
-0.01 mm +0.072 mm
2. and mounting pin of work
equipment support frame (1.38 in) (-0.0004 in) (+0.003 in) (0.003 - 0.007 in) (0.039 in)
(-0.0020 in) (+0.005 in)
-0.012 mm +0.012 mm
3. and mounting pin of fulcrum
lever (1.77 in) (-0.0005 in) (+0.0005 in) (0.001 - 0.005 in) (0.039 in)
(-0.0030 in) (+0.0022 in)
-0.012 mm +0.012 mm
4. and mounting pin of lift lever (1.77 in) (-0.0005 in) (+0.0005 in) (0.001 - 0.005 in) (0.039 in)
(-0.0030 in) (+0.0022 in)
-0.012 mm +0.012 mm
Clearance between bushing 45 mm -0.065 mm +0.056 mm 0.024 - 0.121 mm 1.0 mm Replace
5. and mounting pin of fulcrum
lever (1.77 in) (-0.0005 in) (+0.0005 in) (0.001 - 0.005 in) (0.039 in) bushing
(-0.0030 in) (+0.0022 in)
-0.01 mm +0.072 mm
Clearance between bushing
35 mm -0.05 mm +0.134 mm 0.082 - 0.184 mm 1.0 mm
6. and mounting pin bucket cyl-
(1.38 in) (-0.0004 in) (+0.003 in) (0.003 - 0.007 in) (0.039 in)
inder (bottom side)
(-0.0020 in) (+0.005 in)
-0.01 mm +0.072 mm
7. and mounting pin bucket
cylinder (head side) (1.38 in) (-0.0004 in) (+0.003 in) (0.003 - 0.007 in) (0.039 in)
(-0.0020 in) (+0.005 in)
-0.025 mm +0.105 mm
8. and mounting pin lift cylinder
(head side) (1.58 in) (-0.001 in) (+0.004 in) (0.005 - 0.008 in) (0.039 in)
(-0.003 in) (+0.005 in)
-0.025 mm +0.105 mm
9. and mounting pin lift cylinder
(bottom side) (1.58 in) (-0.001 in) (+0.004 in) (0.005 - 0.008 in) (0.039 in)
(-0.003 in) (+0.005 in)
SK1026-5N 10-971
WORKING EQUIPMENT MAINTENANCE STANDARD
MEMORANDUM
10-981 SK1026-5N
20 STANDARD VALUE TABLES
STANDARD SERVICE VALUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-2

Standard Value Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-4
SK1026-5N 20-1
STANDARD VALUE TABLES STANDARD SERVICE VALUE TABLE
STANDARD SERVICE VALUE TABLE

★ Note the following when making judgements using the standard value tables for testing, adjusting, or
troubleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine from the factory and
is given for reference. It is used as a guideline for judging the progress of wear after the machine has been operated, and as
a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the results of various
tests. It is used for reference together with the state of repair and the history of operation to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims
WARNING! When carrying out testing, adjusting, or troubleshooting, park the machine on level
ground, insert the safety pins, and use blocks to prevent the machine from moving.
WARNING! When carrying out work together with other workers, always use signals and do not let
unauthorized people near the machine.
WARNING! When checking the coolant level, always wait for the coolant to cool down. If the radiator
cap is removed when the coolant is still hot, the coolant will spurt out and cause burns.
WARNING! Be careful not to get caught in the fan, fan belt or other rotating parts.
WARNING! Be careful the hydraulic tank on this machine is pressurized, always relieve tank
pressure before removing any hydraulic components.
20-2 SK1026-5N
Standard Value Table

Engine
Machine Model SK1026-5N
Engine 4D98E-2NFE
Item Measurement Conditions Unit Standard Value Permissible Value
High idling 2685 2635 - 2760
Engine Speed rpm
Low idling 995 940 - 1050
Sudden acceleration
Exhaust gas color Bosch index -- --
At high idling speed
Air intake valve: 20°C (68°F) mm 0.20 (0.008) 0.15 - 0.25 (0.006 - 0.010)
Valve clearance Exhaust valve: 20°C (68°F) (in) 0.20 (0.008) 0.15 - 0.25 (0.006 - 0.010)
Oil temperature: 40 - 60°C (104 - 140°F) MPa 3.43 ±0.10 2.75 ±0.10
Compression {kg/cm2} {35 ±1} {28 ±1}
(SAE 30 oil)
pressure (lbf/in2) (498 ±14) (398 ±14)
(Engine speed) [rpm] [250] [250]
At high idling KPa

{mmH2O}
Crankcase pressure (coolant temperature: Min. 70°C {158°F}) -- --
(SAE15W-40 oil) (lbf/ft2)
(Oil temperature: Min. 80°C {176°F})
392 - 490
{4.0 - 5.0}
At high idling (SAE15W-40) kPa (43 - 57)
Oil pressure {kg/cm2} > 0.6 (> 8.5) ---
(lbf/in2)
392 - 490
{4.0 - 5.0}
At low idling (SAE15W-40)
(43 - 57)
> 0.6 (> 8.5)
Oil temperature All revolution range (Inside oil pan) °C (°F) Max. 120 (248) Max. 120 (248)
Fuel injection timing Before compression top dead center °(deg.) --- ---
Deflection made by finger pressure of about mm
Fan belt tension 98.1 N {about 10 kg} (22 lbf) (in) 10 (0.39) 10 - 15 (0.39 - 0.59)
Air conditioner Deflection made by finger pressure of about mm

compressor belt 10 (0.39) 10 - 15 (0.39 - 0.59)
tension 98.1 N {about 10 kg} (22 lbf) (in)
SK1026-5N 20-3
Chassis
Machine model SK1020-5N and SK1020-5NA
Category Item Measurement Conditions Unit Standard Service Limit Value

Value
Travel forward • Engine stopped Neutral Forward mm 65 (2.5) 58.5-71.5 (2.3-2.8)
• At center of lever knob (in)
Travel in reverse Neutral Reverse 65 (2.5) 58.5-71.5 (2.3-2.8)
• Reading at end of
R.H. travel travel Neutral Right 65 (2.5) 58.5-71.5 (2.3-2.8)
• Equipment on ground
L.H. travel Neutral Left 65 (2.5) 58.5-71.5 (2.3-2.8)
Raise arm Neutral Raise 65 (2.5) 58.5-71.5 (2.3-2.8)
Lower arm Neutral Lower 65 (2.5) 58.5-71.5 (2.3-2.8)
Stroke of levers and pedals
Dump bucket Neutral Dump 65 (2.5) 58.5-71.5 (2.3-2.8)

Curl bucket back Neutral Curled 65 (2.5) 58.5-71.5 (2.3-2.8)
Attachment pedal Neutral Right 20 (1.0) 15-25 (0.5-1)
Neutral Left 20 (1.0) 15-25 (0.5-1)
Travel speed Min. Max. 105 (4.1) 100-110 (3.9-4.3)
Accelerator pedal Min. Max. 40 (1.6) 30-50 (1.2-1.7)
Travel forward kg 2.0 (70.5) 1.8-2.2 (63-78)

(oz)
Travel in reverse • Engine speed: Minimum speed 2.0 (70.5) 1.8-2.2 (63-78)
R.H. travel • Oil temperature 45-55°C (113-131°F) 2.0 (70.5) 1.8-2.2 (63-78)
Operating force for control levers and pedals
L.H. travel • Instrument coupling at center of control lever 2.0 (70.5) 1.8-2.2 (63-78)
knob
Raise arm • Instrument coupling on outside edge (for control 1.8 (63) 1.5-2.1 (53-74)
Lower arm pedal) 1.8 (63) 1.5-2.1 (53-74)
Dump bucket 1.8 (63) 1.5-2.1 (53-74)
Curl bucket back 1.8 (63) 1.5-2.1 (53-74)
Attachment pedal Right 5.0 (176) 4.0-6.0 (141-212)
Left 5.0 (176) 4.0-6.0 (141-212)

Travel speed 7.5 (265) 5-10 (176-353)
• Engine speed: 1800 ± 50 rpm 196-211
Control valve 206 (2988)
• Oil temperature: 45-55°C (113-131°F) (2843-3060)
• Engine speed: 2500 ± 10 rpm

• Oil temperature: 45-55°C (113-131°F) 290-350
Travel motor 343 (4975)
• Parking brake applied (4206-5076)
• 2nd speed
Hydraulic pressure
• Engine speed: 2500 ± 10 rpm 25-29

Servo control 27 (391)
• Oil temperature: 45-55°C (113-131°F) bar (363-421)
(psi)
• Machine raised from
the ground Low idle --- ---
AS valve • Oil temperature:
45-55°C (113-131°F) Set speed --- ---
• Travel levers: neutral
• Engine speed: Max.
Unloading valve • Oil temperature: 45-55°C (113-131°F) --- ---
• Travel levers at neutral
20-4 SK1026-5N

Value
Pilot system travel 5.5 (80) 4.0-7.0 (58-111)
forward (start-up) *
Pilot and secondary circuit pressure
Pilot system travel 14.5 (210) 14-15 (203-218)

(maximum)
Pilot system travel 5.5 (80) 4.0-7.0 (58-111)
reverse (start-up) * • Engine speed: 2500 ± 10 rpm
Pilot system travel • Oil temperature: 45-55°C (113-131°F) bar
reverse (maxi- • Machine raised from the ground (psi) 14.5 (210) 14-15 (203-218)
mum)
• * Pressure of wheels at start of rotation
Pilot system travel
to right or left 14.5 (210) 14-15 (203-218)
(maximum)
Pilot system with
parking brake 5.5 (80) min. 22 (319)
disengaged
• Engine speed: Maximum
• Oil temperature: 45-55°C (113-131°F)
Engine speed (with load)
With travel pump • 2nd. speed 2600 2500-2700

• Travel lever: At full stroke
• Parking brake: Applied
• Engine speed: Maximum rpm
With travel and • 2nd. speed
equipment pump 2525 2400-2650
• Travel lever: At full stroke
• Parking brake: Applied
• Raise: At end of stroke
Total work
equipment
(Downward
movement
of bucket Max. 130 Max. 200
teeth) (5.12) (7.87)
Hydraulic drift of the work equipment
Rasing
cylinder
(Retraction) Max 15 Max. 25
Front bucket
(0.59) (0.98)
mm
(in)
• In this position, measure extension or retraction

Bucket of each cylinder, and any leakages occurring
cylinder when a load is applied to the tips of the bucket
(extension) teeth.
• Horizontal and level ground Max. 8 Max. 15
• Engine: Switched off
(0.32) (0.59)
• Take measurements as soon as the engine
stops
• Measure the variations every 5 minutes and
check the total variation after 15 mins.
SK1026-5N 20-5

Value
★ Arm
Raise Raise
Arm on 4.8 4.32 - 5.28

ground
Lower Lower
Cylinder fully • Engine speed: Maximum
extended 3.8 3.42 - 4.18
Standard
• Average Value in 3 tests sec.
★ Bucket Dump Dump
2.3 2.07 - 2.53

Cylinder fully
extended
Cylinder fully Curl Curl

Work equipment speeds
retracted
• Engine speed: Maximum 2.2 1.98 - 2.42
★ Arm
Raise Raise
3.8 3.42 - 4.18

Arm on
ground
Lower Lower
Pattern change version
Cylinder fully
extended 3.3 2.97 - 3.63
sec.
• Average Value in 3 tests
★ Bucket Dump Dump
2.4 2.07 - 2.53

Cylinder fully
extended
Cylinder fully Curl Curl

retracted
• Engine speed: Maximum 2.3 2.16 - 2.64
20-6 SK1026-5N

Value
Normal Normal
72 68 - 76
Wheel rotation
(without load) rpm With With increment
increment
111 105 - 117

• Machine raised from ground
Normal Normal
8.9 8.45 - 9.35
Travel speed sec. With

With increment
Travel
increment
• Oil temperature: 45-55°C (113-131°F) 5.8

• Wheel pressure: Min 2.8 bar (41 psi) 5.51 - 6.9
• Travel for 25 meters (27 yards) and then check
on the time needed for distance traveled.
• Check in all directions.
Max. 250
Max. 250
(Max. 9.8) (Max. 9.8)
Travel deviation mm
(in)
Value with speed
Value with
increment
★ This surface must be firn and horizontal speed
• Engine speed: Maximum increment
• Oil temperature: 45-55°C (113-131°F) Max.250 Max.250
(Max. 9.8)
• Wheel pressure: Min 2.8 bar (41 psi) (Max. 9.8)
• Travel 20 meters (21 yards) on flat ground and
then check the deviation
• Check all direction
SK1026-5N 20-7
MEMORANDUM
20-8 SK1026-5N
30 TESTING AND ADJUSTING
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-2

T-ADAPTER PROCEDURES AND KITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-3
ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4
Measuring Exhaust Smoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4
Measuring Exhaust Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4
Measuring Crankcase Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4
Measuring Boost Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4
Measuring Fuel Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4
Bleeding Air From Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4
Adjusting Engine Stop Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4
Checking Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5
Adjustment of Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6
Measurement of the Compression Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-8
Control and Adjustment of the Fan Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-9
Control and Adjustment of the Injection Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10
Checking Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-12
Adjusting the Stroke of the Accelerator Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-13
ADJUSTING PPC VALVE PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-14
Adjusting PPC Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16
ADJUSTING SERVO-CONTROL SAFETY SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17
CHAIN TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-18
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-18
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-18
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20
CALIBRATING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22
HST Valve Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22
AS Valve Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22
Travel Deviation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-24
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-26
SERVO-CONTROL POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-28
RELEAVING HYDRAULIC PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30
Elimination of Pressures in the Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30
Elimination of Pressure in the Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30
Elimination of Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30
BLEEDING HYDRAULIC CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31
Bleeding Air From the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31
Bleeding Air From the Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31
Bleeding Air From Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31
SK1026-5N 30-1
TESTING AND ADJUSTING SPECIAL TOOLS
SPECIAL TOOLS
Check or
Symbol Part number Part Name Qty Remarks
measurement item
Commercially
1 Multi-scale tachometer 1 20 to 4000 rpm
available
Engine speed A
Commercially
2 Stroboscope tachometer 1 6 to 30000 rpm
available
Commercially
Valve clearance B 1 Feeler gauge 1
available
1 Gauge set 1 Kit Yanmar

Compression gauge C
2 Adapter 1 TOL-97190080
Commercially
1 Pressure adapter 1 Thread 1/8 in.
available
Engine oil pressure D
Commercially Scale 10.2 KG/CM2
2 Pressure gauge 1
available (145 psi)
Commercially Scale 61.2 KG/CM2

1 Pressure gauge 2
available (870 psi)
Scale 407.9 KG/CM2

Commercially (5,802 psi)
2 Pressure gauge 1
available Scale 611.8 KG/CM2
(8,702 psi)
Hydraulic pressure E Scale 407.9 KG/CM2

Commercially (5,802 psi)
3 Pressure gauge 1
available Scale 10.2 KG/CM2
(145 psi)
Commercially Servo control kit 0 - 1019.7 KG/CM2

4 1
available (differential pressure) (0 - 14,504 psi)
Commercially
5 Pressure adapter 1 Thread M10
available
1 799-601-9000A T-Adapter Kit 1

T-Adapter U
2 799-601-7500 T-Adapter Kit 1
30-2 SK1026-5N
TESTING AND ADJUSTING T-ADAPTER PROCEDURES AND KITS
12
T-ADAPTER PROCEDURES AND KITS
★ For machines equipped with the weather sealing connectors these procedures must be followed in order to prevent
damage to the connector then testing a circuit for an open or a short.
★ The following KOMATSU Harness Checker Kits are available
Special Tools Required

Symbol Part No. Part Name
1 799-601-9000A T-Adapter Kit
U
2 799-601-7500 T-Adapter Kit
1. For testing circuits the T-adapters listed for the circuit should be
used.
2. When using the T-adapters it may be necessary to use the break-out

box in the kit. This allows you to check several circuits.
Remark
For testing the RC connectors, a Bosch Rexroth MA-RC1-1/10
must be used.
★ For T-adapter listing see “T-ADAPTER TABLE” on page 30-

43
SK1026-5N 30-3
TESTING AND ADJUSTING ENGINE COMPONENTS
ENGINE COMPONENTS
Remark
To tune, test and troubleshoot the following procedures you must refer to ENGINE SHOP MANUAL for tools and
proper procedures.
Measuring Exhaust Smoke
Measuring Exhaust Temperature
Measuring Crankcase Pressure
Measuring Boost Pressure
Measuring Fuel Pressure
Bleeding Air From Fuel System
Adjusting Engine Stop Solenoid
30-4 SK1026-5N
Checking Engine Speed

WARNING! When checking the engine rpm, always be very careful not to touch parts that reach high
temperatures and not to get entangled in rotating elements.
★ Check the engine speed after the following conditions have been
reached:
• Temperature of engine cooling water: 68 - 80°C (154 - 176°F).
• Oil temperature: 45 - 55°C (113 - 131°F).
1. Mount and connect the tachometer A1.
★ If the stroboscopic tachometer A2 is used, remove plug (1).
2. Start the engine and check:

• Low idling without load (accelerator lever in "minimum"
position).
• High idling without load (accelerator lever in "maximum"
position).
★ Low idling: 995 ±55 rpm
★ High idling: 2685 +75/-50 rpm
★ If the minimum and maximum speeds do not fall within

permissible limits when the engine is without load, check
position locks of the accelerator lever, and sheathing of the
accelerator well, before performing any tests under load.
(See “Adjusting the Stroke of the Accelerator Cables” on
page 30-13).
• Engine rpm with the pumps under load.
★ Only for Pattern Change version.
Check that the Pattern change valve is in "ISO" mode.
★ Max. speed with parking brake and 2nd speed inserted and
travel lever at full stroke (forward):
2500 - 2700 rpm.
★ Max. speed with parking brake and 2nd speed inserted,
travel lever at full stroke (forward) and raising arm at the
end of stroke:
2400 - 2650 rpm
★ If engine efficiency does not fall within permissible limits, have the engine checked by an authorized Yanmar
distributor.
SK1026-5N 30-5
Adjustment of Valve Clearance

1. Zero setting
A. Remove the air intake filter.
B. Remove the valve cover.
C. Remove the feedback fuel pipe.
D. Loosen the nut (1), block (3), and adjustment screw (2).
E. Operate on rocker (5) adjustment screw (4) for seat the block
on inner valve.
★ Check that the valve cap is lying flat on the valve stem and
that there is no lop-sided wear.
i. If the valve caps are damaged, replace them with new

ones.
ii. Make sure that the valve caps fit perfectly and are lying
flat on the valve stem.
iii. Tighten the adjustment screw (2) until it is seated on the
outer valve. Lock the position with the nut (1).
F. Tighten adjustment screw (2) until it seats on the outer valve.

Lock the position with nut (1).
2. Adjustment
A. Turn the drive shaft in the normal direction of rotation until the
line (1) marked as no. 1 on the flywheel is in alignment with
the reference notch (2) on the flywheel housing.
★ If the cylinder is in a compression stroke, the valves do not
move when the drive shaft is rotated slightly. If the valves
do move, rotate the drive shaft by one turn and realign the
reference marks (1) and (2).
30-6 SK1026-5N
B. Loosen the lock nut (3) and unscrew the adjustment screw (4)
by approximately 1 turn.
C. Insert feeler gauge B1 between rocker (6) and valve cap (5).
Rotate adjusting screw (4) until it rubs against feeler gauge B1.
Secure this position with nut (3).
★ After locking nut (3), check the valve clearance again.
D. Adjust clearance between valve and rockers to the following
values:
Suction valves Exhaust valves

With engine cold 0.20 mm (0.008 in) 0.20 mm (0.008 in)
E. After adjusting the No. 1 cylinder, rotate drive shaft 180° each
time and adjust the valve clearance of the other cylinders
according to the ignition sequence.
★ Ignition sequence: 1 - 3 - 4 - 2.
SK1026-5N 30-7
Measurement of the Compression Pressure

WARNING! While measuring the compression, take care not to get entangled in the cooling fan, the
alternator belt, or in other rotating parts. Check all cylinders.
★ Test conditions:
• Engine: at working temperature.
• Oil temperature: 45 - 55°C (113 - 131°F).
• Battery: fully charged.
• Valve clearance: adjusted (see “Adjustment of Valve Clearance” on page 30-6).
1. Remove the air intake filter.
2. Remove the valve cover.
3. Disconnect the connector (1) of the engine-stopping solenoid and
close the fuel cock (2).
4. Turn the engine over a few times, using the starting motor.
5. Mount the adapter C2 and connect the test pressure gauge C1.
★ Check that the seal is mounted in the adapter, and that it is
undamaged.
6. Turn the engine using the starting motor and read the compression
value.
★ Read the compression value when the pressure gauge has
stabilised.
★ While reading the compression, also check the engine rpm
using tachometer A1 or A2. If the speed does not correspond
with the control value, check it against the diagram.
7. After the reading, re-assemble valve cover, the air intake pipe and
the connector (1).
Nut that secures the nozzle: 7.84 ±0.98 N•m (69 ±9 lbf in)
High-pressure coupling: 31.85 ±2.45 N•m (24 ±2 lbf ft)
30-8 SK1026-5N
Control and Adjustment of the Fan Belt Tension

1. Checking the tension.
A. Depress the belt (1) at the centre of the section between the
alternator (2) and the pulley (3) that drives the water pump.
Check the flexion.
At a pressure of 10 kg (98 N) {22 lbf} the flexion should be
7 - 10 mm (0.28 - 0.39 in.). If this value is not found, adjust the
belt tension.
★ With a new belt the flexion should be 5 - 8 mm
(0.20 - 0.32 in.).
2. Adjusting the belt tension.

A. Loosen screws (4) that secure alternator (2).
B. Rotate alternator (2) to give belt (1) the correct tension, then
tighten screw (4).
C. Check belt (1) tension.
★ If the belt has been replaced with a new one, recheck the
tension after about 20 hours of operation.
Screw: 25 - 32 N•m (18 - 24 lbf ft)
SK1026-5N 30-9
Control and Adjustment of the Injection Timing

★ Check the injection timing of the No.1 cylinder by means of the
No.1 union of the injection pump.
★ The cylinders are numbered 1-2-3-4 counting from the flywheel
side.
★ The spark advance notches of 0°-10°-15°-20°; are also marked on
the flywheel. In order to read the intermediate values, sub-divide
the sections between the two marks into equal lengths.
1. Remove cap (1) of the flywheel casing.
2. Pass a screwdriver between the teeth and rotate the flywheel in a

counter-clockwise direction (as seen from the flywheel side) until
the 1/4 notch of the flywheel is aligned with notch (2) marked
inside the hole in the casing.
★ In this position, the piston of the No. 1 cylinder is at top dead
center (B.T.D.C.). Check that the cylinder is in a compression
stroke, i.e. that both valves are closed.
★ Once the B.T.D.C. has been ascertained, rotate the drive shaft
in a clockwise direction (seen from the flywheel side) for about
25 teeth.
3. Take off clamp (3) and disconnect all fuel delivery pipes (4) from
the injection pump.
4. Rotate the flywheel slowly in a counter-clockwise direction (seen
from the flywheel side), carefully checking the level of fuel in the
No. 1 union of the injection pump. Stop the rotation when the fuel
level starts to rise.
5. Check the position of the notches at 15° and 10° that appear in the
hole in the casing and, in function of the position, establish the true
fuel injection timing.
★ In order to determine the degrees of intermediate fuel injection
timing, sub-divide the space between 10° and 15°.
30-10 SK1026-5N
6. Rotate injection pump (5) towards the outside or towards the motor,
after having loosened pump (6) retaining nuts and screw (7).
• To BRING FORWARD the injection, rotate pump (4) towards
the outside.
• To DELAY the injection rotate pump (4) towards the cylinder
block.
★ Check the extent of movement on scale (8).
7. Lock the nuts (6) that fasten the pump to its block.
★ After adjustment of the fuel injection timing.
8. Connect fuel delivery pipes (5) to the pump and replace clamp (3).
9. Bleed any air from the fuel circuit.
SK1026-5N 30-11
Checking Engine Oil Pressure

WARNING! When measuring the engine oil pressure, take great care not to touch high-temperature
parts, or to become entangled in rotating elements.
★ Check pressure with the engine at operating temperature.

★ Low and high idle within permissible limits.
1. Start the engine and wait for it to reach operating temperature.
★ Operating temperature:
Engine coolant: 90°C (194°F)
Engine oil: 80°C (176°F)
2. Stop the engine and remove oil pressure sensor (1).
3. Mount adapter D1 and connect pressure gauge D2.

4. Start the engine and check the oil pressure at low idle (accelerator
lever in low idling position) and at high idle (accelerator lever in
high idling position).
5. Remove adapter D1 and install the oil pressure sensor (1).
30-12 SK1026-5N
Adjusting the Stroke of the Accelerator Cables

★ Conditions for the adjustment:
• Engine: stopped
• Working equipment: resting on the ground
• Cab: raised
★ If protective sheaths need to be substituted, block lever (or pedal)
side of the sheaths in an intermediate position before adjusting.
1. Place the accelerator command lever (1) in low idle position.
2. Temporarily block protective sheath (2) in an intermediate position

and block retainer (3) at approx. 1 mm (0.039 in.) from the injection
pump lever (4).
3. Put the accelerator command lever (1) into the high idle position.
4. Use nuts (7) and (8) to reset the position of injection pump lever (5)
to approx. 0.5 mm (0.020 in.) from high idle adjustment screw (6).
5. Bring the accelerator command lever back to the low idle position
and check that retainer (3) has sufficient clearance.
6. Repeat this same procedure for the accelerator pedal cable.
SK1026-5N 30-13
TESTING AND ADJUSTING ADJUSTING PPC VALVE PRESSURES
ADJUSTING PPC VALVE PRESSURES

WARNING! Before removing the valve assembly be sure to relive all hydraulic system pressure.
Disassembly and Adjustment

1. Remove the complete PPC valve assembly.
• (For details refer to “PPC VALVES” on page 30-58).
2. Lift boot (1) and mark the position of lever (2) in relation to the PPC
valve housing (3).
3. Loosen screw (4), remove washer (5) and pull out the complete handle
(6).
4. Remove joint (7) and retainer plate (8).

5. Remove boot (9) and remove O-ring (10).
6. Loosen 4 retaining screws (11) from plate (12) and remove the plate.
30-14 SK1026-5N
7. Remove stopper (13) and the seals.
★ Use a soft tool to remove.
8. Remove the complete spool (14).
9. Remove retainer (15), spring (16) and shims (17) from the spool (14).
Assembly
★ Add shims until you reach calibration value; bear in mind that 0.3 mm
(0.012 in.) thickness corresponds to a variation in pressure of about
0.6 bar (9 psi).
★ To assemble, perform the disassembly procedure in the reverse order.
★ Thoroughly clean all parts.
Cleaner: Loctite 20162
Screw: 64 to 74 N•m (47 to 55 lbf ft)
★ Press down on stoppers (13) to ease setting into place; tighten retainer plate (8) until it is properly seated and adjust the
clearance. (For details, see “Adjusting PPC Valve” on page 30-16).
Joint: 112.8 ± 14.7 N•m (83 ± 10 lbf ft)

Screws: 13.2 ± 1.5 N•m (10 ± 1.1 lbf ft)
★ Lubricate stoppers (13).
PPC Valve Rebuild Specifications

★ R.H. PPC Valve, see “Maintenance Standards” on page 10-76.
★ L.H. PPC Valve (Standard), see “Maintenance Standards” on page 10-84.
★ L.H. PPC Valve (Pattern Change), see “Maintenance Standards” on page 10-90.
SK1026-5N 30-15
Adjusting PPC Valve

WARNING! Lower the working equipment to the ground and stop the engine.
Turn the ignition key to the "I" position and move the command levers in all directions in
order to release all pressure in the hydraulic circuits.
Return the ignition key to the "O" (OFF) position and remove it.
Slowly loosen the oil-tank refuelling cap to eliminate residual pressure.
★ The clearance on the PPC valve (hand and foot) levers are adjusted as follows:
1. Slowly loosen the oil-tank cap to eliminate any residual pressure.
2. Remove cap (1).
3. Loosen nut (2) that retains disc (3).
4. Tighten disc (3) until it makes light contact with four push-rods (4).
★ During this adjustment, take care not to activate any of the
push-rods (4) individually.
5. Secure this position by tightening retaining nut (2) to the specific
torque.
Retaining nut: 113 ±15 N•m (83 ±11 lbf ft)
30-16 SK1026-5N
TESTING AND ADJUSTING ADJUSTING SERVO-CONTROL SAFETY
ADJUSTING SERVO-CONTROL SAFETY SENSOR

WARNING! Before proceeding with any adjustments, be sure all work equipment is on the ground and
there controls neutralized. Be sure the parking brake is set and the machine is on a flat
level surface. Stop the engine and remove the ignition key.
1. Lower the LH safety bar (1) and adjust the position of sensor (2) by
loosening then tightening adjustment nuts (3).
★ Distance between safety bar and sensor: 1 mm (0.039 in)
SK1026-5N 30-17
TESTING AND ADJUSTING CHAIN TENSION
CHAIN TENSION
Test
• Machine: Raised from the ground and level
• Work equipment: In road-driving position
★ Check all the wheels.
1. Position an appropriate indicator and check the wheel rotation
diameter at 600 mm (23.62 in). Make a notch “A” close to the
indicator.
2. Rotate the tire by hand in both directions and check the total
displacement of the notch. See if it remains within the permissible
limits.
★ Standard displacement: 4 mm (0.16 in)
★ Permissible displacement: 2-6 mm (0.08 - 0.24 in)
Adjustment
★ For greater clarity, the illustration shows the adjustment operations
with the tires removed. It is not necessary to remove the tires for
this adjustment.
1. Adjust screw “A” (M10 x 50, fully threaded) in until it makes
contact with the wheel hub.
2. Loosen retaining screws (1) on the wheel hub until it can move.
3. Gradually tighten screw “A” until correct tension has been restored
to the chain.
4. Tighten nuts (1).
Nuts: 200 N•m (148 lbf ft)
30-18 SK1026-5N
TESTING AND ADJUSTING HYDRAULIC SYSTEM
HYDRAULIC SYSTEM
WARNING! Before removing the plugs, release residual pressures in the circuits (for details see
“RELEAVING HYDRAULIC PRESSURE” on page 30-30) and place safety engagement
levers into their locked positions.
After having connected the pressure gauges, pressurize the tank.
★ Test conditions
• Engine: At working temperature.
• MIN and MAX. engine speeds: Within permissible limits.
• Oil temperature: 45°C - 55°C (113°F - 131°F)
Command Ports
Arm (Lower - Raise) A1 - B1
Bucket (Dump - Curled) A2 - B2
Equipment (R.H. - L.H.) A3 - B3
SK1026-5N 30-19
TESTING AND ADJUSTING HYDRAULIC PUMP
HYDRAULIC PUMP
Checking Working Pressure of Travel HST Charge Valve
• Engine: High idle
• Hydraulic Oil temperature: 45-55°C (113-131°F)
• Safety bar: Raised
WARNING! Do not activate the travel lever.
1. Remove plugs (1) and (2) and install the two pressure adapters E5.
2. Connect pressure gauges E1 61.2 kg/cm2 (870 psi), start the engine
and accelerate to high idle.
3. Check to see if the pressure is within permissible limits.
• Use the lower of the two pressure values taken.
• Normal pressure: 25.5 - 29.6 kg/cm2 (363-421 psi)
4. Remove the pressure adapters and install the plugs (1) and (2).
Plugs: 19.6 - 27.4 N•m (15 - 20 lbf ft)
Checking Working Pressure Of The AS Valve

• Engine: High idle
• Hydraulic oil temperature: 45-55°C (113-131°F)
• Safety bar: Lowered
• Machine: Raised from the ground
1. Remove plug (1) and install pressure adapter E5.
2. Connect pressure gauge E1 61.2 kg/cm2 (870 psi) and start the
engine. Allow engine to idle at (1100 rpm).
3. Push the travel lever full stroke forward and read the pressure.
4. Repeat the readings with the engine at a working speed of (2800 ±
30 rpm).
5. Remove the pressure adapter and install plug (1).
Plugs: 19.8 - 27.4 N•m (15 - 20 lbf ft)
30-20 SK1026-5N
TESTING AND ADJUSTING HYDRAULIC PUMP
12
MEMORANDUM
SK1026-5N 30-21
TESTING AND ADJUSTING CALIBRATING VALVE
12
CALIBRATING VALVE
HST Valve Calibration
1. Loosen nut (1), be careful not to move adjustment screw (2).
2. Adjust the working pressure of the HST valve as follows:
• To INCREASE pressure, turn screw (2) in a
CLOCKWISE direction.
• To REDUCE pressure, turn screw (2) in a
COUNTER-CLOCKWISE direction.
★ One complete turn of screw (2) varies the pressure by

15.8 kg/cm2 (225 psi).
3. Tighten nut (1) and check to see if the working pressure remains
within permissible limits.
Nut: 58.8-78.5 N·m (44-58 lbf ft)
AS Valve Calibration
Pressure Adjustment Made at Low Idle
1. Loosen nut (1), and adjust the working pressure of the AS valve
(with the engine at low idle), proceed as follows:
3.44 kg/cm2 (49 psi)
2. Tighten nut (1) and check to be sure the working pressure remains
Nut: 34.3-58.8 N·m (25-43 lbf ft)
30-22 SK1026-5N
Pressure Adjustment At Working Pressure
1. Loosen nut (3),. and adjust the working pressure of the AS valve
(with the engine at working pressure), proceeding as follows:
2.0 kg/cm2 (28.4 psi).
2. Tighten nut (3) and check to see if the working pressure remains
Nut: 34.3-58.8 N·m (25-43 lbf ft)
SK1026-5N 30-23
Travel Deviation Check

• Engine: At maximum speed
• Hydraulic oil temperature: 45-55°C (113-131°F)
★ Drive the machine onto solid, level ground.
Checking the Deviation

1. Position the boom and bucket in their travelling positions.
★ Boom lowered and bucket fully curled.
2. Bring the engine up to maximum rpm.
3. Push the travel lever to full stroke forward.
4. Travel for 5 metres (5.5 yds), then measure the deviation of the
machine over the next 20 metres (22 yds).
5. Check the deviation also in reverse gear and while accelerating in
both directions.
30-24 SK1026-5N
Adjusting the Deviation
1. Select the adjustment screw to be re-set:
Travel Deviation Screw

Forwards Left A1
Forwards Right A2
Reverse Left B1
Reverse Right B2
2. Loosen the nut (1) and tighten the screw (2).

• A 60o turn of the screw (2) will reduce the deviation by about
500 mm (20 in).
3. Tighten the nut (1).
Nut: 26.5-32.4 N·m (20-24 lbf ft)
SK1026-5N 30-25
TESTING AND ADJUSTING CONTROL VALVE
CONTROL VALVE
Special Tools
Commercially
1 Pressure gauge 2 Scale 61.2 kg/cm2 (870 psi)
available
Commercially Scale 407.9 kg/cm2 (5802 psi)

2 Pressure gauge 1
available Scale 611.8 kg/cm2 (8702 psi)
Hydraulic pressure E Commercially Scale 407.9 kg/cm2 (5802 psi)

3 Pressure gauge 1
available Scale 10 kg/cm2 (145 psi)
Commercially Servo control kit

4
available (differential pressure)
1 0 - 1019.7 kg/cm2 (0 - 14504 psi)
Commercially
5 Pressure adapter 1 Thread M10
available
1. Operating Pressure (Unloading Valve)
A. Remove plug (1) and install a pressure adapter.
B. Connect pressure gauge E3, 10.2 kg/cm2 (145 psi).
C. Start the engine and bring it up to a high idle with all levers in
neutral position.
D. Check the pressure.
★ Normal pressure: 4.9 kg/cm2 (70 psi)
★ Take care do not operate the equipment levers.
★ The unloading valve cannot be re-adjusted. If the pressure
differs from the normal value, the valve must be replaced.
2. Operating pressures of the working equipment

A. Remove plug (1) and install a pressure adapter.
B. Connect a pressure gauge E2 407.9 kg/cm2 or 611.8 kg/cm2
(5,802 or 8,702 psi).
C. Start the engine and bring it up to high idle.
D. Check the pressure for each movement of the lever at the end
of its stroke and with the pressure stabilized.
★ To check pressure of the work equipment, push the piston
to the end of its stroke.
30-26 SK1026-5N
TESTING AND ADJUSTING CONTROL VALVE
Valve Adjustment
★ The unloading valve cannot be re-adjusted, only replaced.
Adjustment Of Main Relief Valve
1. If the pressures measured for the working equipment and machine
travel do not fall within normal values, adjust the main relief valve
(1) as follows:
★ Loosen lock nut (2) and rotate the adjusting screw (3).
• To INCREASE pressure, turn in a CLOCKWISE
direction.
• To DECREASE pressure, turn in a
COUNTERCLOCKWISE direction.
★ Each turn of the adjusting screw (3) varies the pressure by
about 56.1 kg/cm2 (798 psi).
2. Lock the nut (2).
Nut: 69 ± 10 N·m (51 ± 7 lbf ft)
★ After adjustment, check the adjustment of the main relief valve

with the same procedures as used for the measurements.
SK1026-5N 30-27
TESTING AND ADJUSTING SERVO-CONTROL POWER SUPPLY
SERVO-CONTROL POWER SUPPLY

WARNING! Before removing the cap to measure the pressure, release the residual pressures from
the circuits. Put the safety device engagement levers into their locked position.
After connecting the pressure gauge, pressurize the tank. For details see “RELEAVING
HYDRAULIC PRESSURE” on page 30-30.
• Engine: At working temperature.
Checking Pressure of the Servo-Controls

1. Disconnect the delivery line (1) and install a tee and a adapter;
reconnect the line (1).
2. Connect pressure gauge E1 61.2 kg/cm2 (870 psi).
3. Start the engine and bring it up to 2500 rpm with all levers in
neutral position.
4. Lower the safety bars and check the pressure.
• Normal pressure: 27.5 ±2 bar (392 ±29 psi)
Test Pressure of the Travel Pilot System

• Machine raised from the ground.
1. Disconnect the line (1) of the actuator to be tested, install a union
tee and a pressure adapter, and then reconnect the line (1).
★ During travel in one direction, two actuators are activated.
Always check both pressures:
Action involved
Action
A1 A2 B1 B2
FORWARD ❍ ❍
REVERSE ❍ ❍
RIGHT ❍ ❍
LEFT ❍ ❍
2. Connect pressure gauge E1, 61.2 kg/cm2 (870 psi).

3. Lower the cab and sit in the driving seat.
4. Start the engine and bring it up to working speed of about 2500 rpm
with all levers in neutral position.
5. Lower the safety bar, slowly activate the travel lever in the direction
of the test to be performed, then check the following conditions:
• Pressure as the wheels start to turn.
• Pressure with the levers at full stroke.
★ Normal pressures:
• When the wheels start to turn:
4.1 - 7.1 kg/cm2 (58 - 102 psi)
• With levers at full stroke:
14.3 - 15.3 kg/cm2 (203 - 218 psi)
30-28 SK1026-5N
TESTING AND ADJUSTING SERVO-CONTROL POWER SUPPLY
Parking Brake System Pressure Check
1. Disconnect the brake control hose (1); connect a “T” fitting and a
pressure tap and reconnect the hose.
2. Connect pressure gauge E1, 61.2 kg/cm2 (870 psi).
3. Lower the cab and sit down in the drivers seat.
4. Start the engine and bring it up to operating speed (2500 rpm) with
all the levers in neutral position.
5. Lower the safety bars; operate the parking brake control and check
the pressure.
★ Parking brake pressure:
• Normal: Minimum 25.5 kg/cm2 (363 psi)
• Minimum: 25.5 kg/cm2 (363 psi)
SK1026-5N 30-29
TESTING AND ADJUSTING RELEAVING HYDRAULIC PRESSURE
RELEAVING HYDRAULIC PRESSURE

WARNING! Before any work is to be performed on the hydraulic system it is important to remember to
lower all work equipment to the ground, neutralize and lock the controls and relieve any
hydraulic pressure in the hydraulic tank. Be sure all work is performed on a flat level
surface and the parking brake is set.
Elimination of Pressures in the Hydraulic Circuits

1. Rest the working equipment on the ground and stop the engine.
2. Turn the ignition key to the position “I” and, with safety bars lower, move the control lever in all directions to release all
pressure in the main hydraulic circuits and servo-controls.
3. Return the ignition key to the position “O” (OFF) and remove the key.
4. Place a (Do Not Operate) tag on the ignition switch.
Elimination of Pressure in the Tank

★ The hydraulic oil tank is sealed and pressurized.
★ When hydraulic lines are to be removed or disconnected for repairs,
or when caps are removed, tank pressure must be relieved using the
following procedures:
1. Rest the work equipment on the ground and stop the engine.
2. Slowly loosen the hydraulic oil-refill cap (1) in order to release the
residual pressure.
Elimination of Pressure
1. This operation should be performed every time the hydraulic tank
cap is removed for installation of equipment or hydraulic lines are
removed.
2. Start the engine and position the machine as in the figure.
3. Stop the engine, loosen the tank cap (1) and then close it again.
★ This operation lets air into the tank when the level of the
remaining oil is at minimum.
4. Start the engine and lower the working equipment to the ground.
30-30 SK1026-5N
TESTING AND ADJUSTING BLEEDING HYDRAULIC CIRCUITS
BLEEDING HYDRAULIC CIRCUITS

Bleeding Air From the Pump
1. Loosen and remove the cap (1) from the pump body (2).
2. Pour hydraulic oil through the hole until the entire casing is full.
3. Replace the cap (1).
★ After filling the casing, start the engine and allow it to run at
low idling for about 10 minutes before proceeding to bleed the
air from the circuits.
Bleeding Air From the Cylinders

1. Start the engine and let it run at low idle for about 5 minutes.
2. Lower and raise the boom 4 to 5 times.
★ Lower and raise the piston of the boom up to about the end of
its stroke. Care must be taken to avoid pressurizing the circuits.
3. Bring the engine up to high idle and repeat the operations described
in procedure 2. Return the engine to low idle and operate the piston
through its entire stroke until it reaches max. pressure in both
directions.
Bleeding Air From Optional Equipment

1. This method must be used for all the optional equipment, unless
otherwise indicated.
★ Each time optional equipment is installed, operate the
equipment repeatedly, with the engine at low idle, until all air
has been completely eliminated from the system.
Procedures for bleeding air from hydraulic circuits

1 2 3 4 5
Starting Pressurized Starting
Pumps Cylinders
engine tank tasks
• Replacing hydraulic oil ❍ ❍ ❍ ❍ ❍
• Replacing or cleaning filters ❍ ❍ ❍ ❍
• Repairs to any pumps ❍ ❍ ❍ ❍ ❍
• Repair of control valve ❍ ❍ ❍ ❍
• Repair of hydraulic cylinders
❍ ❍ ❍ ❍
• Replacing hydraulic cylinders
• Repair of travel motor
❍ ❍ ❍ ❍ ❍
• Removal of any hydraulic lines
SK1026-5N 30-31
TESTING AND ADJUSTING BLEEDING HYDRAULIC CIRCUITS
MEMORANDUM
30-32 SK1026-5N
40 TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-4

SEQUENCE OF EVENTS IN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-6
PRECAUTIONS WHEN PERFORMING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-7
Precautions When Handling Electrical Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-8
Handling Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-13
Points to Remember When Troubleshooting Electrical Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-14
Points to Remember When Handling Hydraulic Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-15
CHECKS BEFORE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-17
Using Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-18
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-19
T-ADAPTER TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-43
TRAVEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-46
Motor does not move (The supplied pressure is enough.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-46
Revolution Speed is Late . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-46
Abnormal Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-46
Oil Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-46
Excessive Heat Generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-46
Does Not Change to Second Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-47
Does Not Return to First Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-47
Standard for Parts Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-47
Hydraulic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-47
Reduction Gear Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-48
AIR CONDITIONING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50
Environmental Impact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50
Basic Air Conditioning System (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50
Operator Cab Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-51
Principles of Refrigeration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-51
Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-51
The Act of Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-52
The Refrigeration Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-52
Air Conditioner System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-53
Compressor (Refrigerant Pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-53
Service Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-53
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-53
Receiver-Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-53
Thermostatic Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-54
Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-54
Electrical Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-55
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-55
Compressor Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-55
Safety Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-56
System Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-57
R-134A Refrigerant Containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-57
Service Tools And Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-58
Recovery/recycle Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-58
Leak Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-59
Service Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-59
SK1026-5N 40-1
TROUBLESHOOTING
Vacuum Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-59
Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60
Installing Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-61
Purging Air from Service Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-62
Adding Refrigerant to the System (Without a Charging Station) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-63
Stabilizing the AC System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-63
Adding Refrigerant and Stabilizing the System (With a Recovery/Recycling Station) . . . . . . . . . . . . . . . . . 40-64
Recovering and Recycling the Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-64
Performing the Recovery Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-64
Performing the Recycling Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-65
Evacuating and Charging the AC System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-65
System Performance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-66
System Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-67
Electronic Leak Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-67
Tracer Dyes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-67
Soap and Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-67
System Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-68
Hoses and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-68
Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-68
Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-68
Receiver-Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-68
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-68
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-69
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-69
Checking Compressor Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-69
Evacuating The System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70
Troubleshooting - Air Conditioning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-72
Pre-Diagnosis Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-72
Preparing for Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-72
Preliminary Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-72
System Performance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-72
Diagnosis of Gauge Readings and System Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-73
Troubleshooting by Manifold Gauge Set Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-74
Preventive Maintenance Schedule for A/C System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80
40-2 SK1026-5N
TROUBLESHOOTING
MEMORANDUM
SK1026-5N 40-3
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLE-
POINTS TO REMEMBER WHEN TROUBLESHOOTING
WARNING! Stop the machine in a level place, and check that the safety pin, blocks, and parking
brake are securely fitted.
WARNING! When performing the operation with two or more workers, keep strictly to the agreed
signals, and do not allow any unauthorized person to come near.
WARNING! If the radiator cap is removed when the engine is hot, hot coolant may spurt out and
cause burns, so wait for the engine to cool down before starting troubleshooting.
WARNING! Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
WARNING! When disconnecting wiring, always disconnect negative (-) terminal of the battery first.
WARNING! When removing the plug or cap from a location which is under pressure from oil, coolant,
or air, always release the internal pressure first. When installing measuring equipment,
be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to perform repairs swiftly, and to prevent reoccurrence
of the failure.
When performing troubleshooting, an important point is to understand the structure and function of the machine. However,
a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the
failure that would produce the reported symptoms.
1. When performing troubleshooting, do not hurry to disassemble the components. If components are disassembled
immediately after a failure occurs:
• Parts that have no connection with the failure or other unnecessary parts will be disassembled.
• It will become impossible to find the cause of the failure.
• It will also cause a waste of man hours, parts, or oil and grease. At the same time, it will also lose the confidence of
the user or operator. For this reason, when performing troubleshooting, it is necessary to perform thorough prior
investigation and to perform troubleshooting in accordance with the fixed procedure.
2. Points to ask the user or operator.
A. Have any other problems occurred apart from the problem that has been reported?
B. Was there anything strange about the machine before the failure occurred?
C. Did the failure occur suddenly, or were there problems with the machine condition before this?
D. Under what conditions did the failure occur?
E. Had any repairs been carried out before the failure? When were these repairs carried out?
F. Has the same kind of failure occurred before?
40-4 SK1026-5N
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLE-
3. Check before troubleshooting.
A. Check the oil level.
B. Check for any external leakage of oil from the piping or hydraulic equipment.
C. Check the travel of the control levers.
D. Check the stroke of the control valve spool.
E. Other maintenance items can be checked externally, so check any item that is considered to be necessary.
4. Confirming the failure.
A. Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the
method of operation, etc.
★ When operating the machine to reenact the troubleshooting symptoms, do not perform any investigation or
measurement that may make the problem worse.
5. Troubleshooting.
A. Use the results of the investigation and inspection in Steps 2 - 4 to narrow down the causes of the failure, then use the
troubleshooting flowchart to locate the position of the failure exactly.
B. The basic procedure for troubleshooting is as follows.
i. Start from the simple points.
ii. Start from the most likely points.
iii. Investigate other related parts or information.
6. Measures to remove root cause of failure.
A. Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again.
B. To prevent this, always investigate why the problem occurred. Then, remove the root cause.
SK1026-5N 40-5
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLE-
SEQUENCE OF EVENTS IN TROUBLESHOOTING
40-6 SK1026-5N
TROUBLESHOOTING PRECAUTIONS WHEN PERFORMING MAIN-
PRECAUTIONS WHEN PERFORMING MAINTENANCE

To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur,
correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out. This section deals particularly
with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives
sections on 'Handling electric equipment' and 'Handling hydraulic equipment' (particularly hydraulic oil).
SK1026-5N 40-7
Precautions When Handling Electrical Equipment

1. Handling wiring harnesses and connectors.
Wiring harnesses consist of wiring connecting one component to
another component, connectors used for connecting and
disconnecting one wire from another wire, and protector or tubes
used for protecting the wiring. Compared with other electrical
components fitted in boxes or cases, wiring harnesses are more
likely to be affected by the direct effects of rain, water, heat, or
vibration. Furthermore, during inspection and repair operations
they are frequently removed and installed again, so they are likely
to suffer deformation or damage. For this reason, it is necessary to
be extremely careful when handling wiring harnesses.
2. Main failures occurring in wiring harness.
A. Faulty contact of connectors (faulty contact between male and

female).
Problems with faulty contact are likely to occur because the
male connector is not properly inserted into the female
connector, or because one or both of the connectors is
deformed or the position is not correctly aligned, or because
there is corrosion or oxidation of the contact surfaces.
B. Defective compression or soldering of connectors.

The pins of the male and female connectors are in contact at
the compressed terminal or soldered portion, but there is
excessive force on the wiring, and the plating peels to cause
improper connection or breakage.
C. Disconnections in wiring.
If the wiring is held and tugged and the connectors are pulled
apart, or components are lifted with a crane with the wiring
still connected, or a heavy object hits the wiring, the crimping
compression of the connectors to the wire may be loosened, or
the soldering may be damaged, or the wiring may be broken.
40-8 SK1026-5N
D. High pressure water entering a connector.
The connector is designed to make it difficult for water to enter
(drip-proof structure), but if high-pressure water is sprayed
directly on the connector, water may enter the connector
depending on the direction of the water jet.
The connector is designed to prevent water from entering, but
if water does enter, it is difficult for it to be drained. Therefore,
if water should get into the connector, the pins will be
short-circuited by the water, so if any water gets in,
immediately dry the connector or take other appropriate action
before passing electricity through it.
E. Oil, grease or dirt stuck to connector.

If oil or grease are stuck to the connector and an oil film is
formed on the mating surface between the male and female
pins, the oil will not let the electricity pass, and this will cause
a defective contact.
If there is oil or grease or dirt stuck to the connector, wipe it off
with a dry cloth or blow dry with air, and spray it with a
contact restorer.
★ When wiping the mating portion of the connector, be
careful not to use excessive force or deform the pins.
★ If there is water or oil present, it will increase the
contamination of the points, so clean with air until all
water and oil has been removed.
SK1026-5N 40-9
3. Removing, installing, and drying connectors and wiring harnesses.
A. Disconnecting connectors.
i. Hold the connectors when disconnecting.

When disconnecting the connectors, hold the connectors
and not the wires. For connectors held by a screw, loosen
the screw fully, then hold the male and female connectors
in each hand and pull apart. For connectors which have a
lock stopper, press down the stopper with your thumb and
pull the connectors apart.
★ Never try to pull apart with one hand
ii. When removing the connectors from the clips, pull the
connector in a parallel direction to the clip.
★ If the connector is twisted to the left and right or up
and down, the housing may break.
iii. When disconnecting male and female connectors, release

the lock and pull in parallel with both hands.
★ Never try to pull apart with one hand.
iv. Action to take after removing connectors.

After removing any connector, cover it with a vinyl bag to
prevent any dust, dirt, oil, or water from getting in the
connector portion.
40-10 SK1026-5N
B. Connecting connectors.
i. Check the connector visually.

• Check that there is no oil, dirt, or water stuck to the
connector pins (mating portion).
• Check that there is no deformation, faulty contact,
corrosion, or damage to the connector pins.
• Check that there is no damage or breakage to the
outside of the connector.
★ If there is any oil, water, or dirt stuck to the connector,
wipe it off with a dry cloth. If any water has gotten
inside the connector, warm the inside of the wiring
with a dryer, but be careful not to make it too hot as
this will cause short circuits.
★ If there is any damage or breakage, replace the
connector.
ii. Assemble the connector securely.

Align the position of the connector correctly, then insert it
securely.
For connectors with a lock stopper:
Push in the connector until the stopper clicks into position.
iii. Correct any protrusion of the boot and any misalignment

of the wiring harness.
For connectors fitted with boots, correct any protrusion or
the boot. In addition, if the wiring harness is misaligned,
or the clamp is out of position, adjust it to its correct
position.
★ When blowing with dry air, there is danger that the oil
in the air may cause improper contact, so clean with
properly filtered air.
iv. When the wiring harness clamp of the connector has been
removed, always return it to its original condition and
check that there is no looseness of the clamp.
C. Connecting connectors (DT type connector).

Since the DT 8-pole and 12-pole DT type connectors have two
latches respectively, push them in until they click 2 times.
• Male connector (1), Female connector (2).
• Normal locking state (Horizontal): a, b, d
• Incomplete locking state (Diagonal): c
SK1026-5N 40-11
D. Drying wiring harness.
If there is any oil or dirt on the wiring harness, wipe it off with
a dry cloth. Avoid washing it in water or using steam. If the
connector must be washed in water, do not use high pressure
water or steam directly on the wiring harness. If water gets
directly on the connector, do as follows:
i. Disconnect the connector and wipe off the water with a

dry cloth.
★ If the connector is blown dry with air, there is the risk
that oil in the air may cause a faulty contact, so avoid
blowing with air.
ii. Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dryer to dry the
connector.
★ Hot air from the dryer can be used, but be careful not
to make the connector or related parts too hot, as this
will cause deformation or damage to the connector.
iii. Perform a continuity test on the connector.

After drying, leave the wiring harness disconnected and
perform a continuity test to check for any short circuits
between pins caused by water.
★ After completely drying the connector, spray it with
contact restorer and reassemble.
40-12 SK1026-5N
Handling Control Box

1. The control box contains a microcomputer and electronic control
circuits.
★ This controls all of the electronic circuits on the machine, so be
extremely careful when handling the control box.
2. Do not open the cover of the control box unless necessary.
3. Do not place objects on top of the control box.
4. Cover the control connectors with tape or a vinyl bag.
5. Do not leave the control box in a place where it is exposed to rain.
6. Do not place the control box on oil, water, or soil, or in any hot
place, even for a short time.
★ Place it on a suitable dry stand.
7. Precautions when performing arc welding.

★ When performing arc welding on the body, disconnect all
wiring harness connectors connected to the control box. Fit an
arc welding ground close to the welding point.
SK1026-5N 40-13
Points to Remember When Troubleshooting Electrical Circuits

1. Always turn power OFF before disconnecting or connecting connectors.
2. Before performing troubleshooting, check that all the related connectors are properly inserted.
★ Disconnect and connect the related connectors several times to check.
★ Check each individual wire on the connector suspected of the problem by performing a pull test on the wire insert.
3. Always connect any disconnected connectors before going on to the next step.
★ If power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated.
4. When performing troubleshooting of circuits (measuring the voltage, resistance, continuity or current), move the related
wiring and connectors several times and check that there is no charge in the reading of the tester.
★ If there is any charge, there is probably defective contact in that circuit.
5. When checking a single diode circuit:

★ Isolate the diode from the circuit.
★ Using a digital volt ohm meter, in the Ohms mode, check the
polarity of the diode as shown in the illustration. Reversing the
meter leads, you should have a reading in one direction only.
★ Electrical flow should be negative (-) to positive (+) only, red
lead positive and black lead negative.
6. When checking a dual diode circuit:

★ Isolate the diode from the circuit.
★ Using a digital volt ohm meter, in the Ohms mode, check the
polarity of the diode as shown in the illustration. Reversing the
meter leads, you should have a reading in one direction only.
★ Electrical flow should be negative (-) to positive (+) only, red
lead positive and black lead negative.
7. Always be aware of what you are measuring. Voltage, Ohms or

Amps. Always use caution when measuring a circuit.
★ When measuring voltage, be sure the meter is set in the voltage
range, AC or DC and above the voltage value you are
measuring.
★ When measuring ohms, be sure the circuit is dead and has (no
voltage) in it before you take any readings. Be sure the meter is
set in the proper ohms range.
★ When measuring Amps, be sure your meter is rated for the
amount of amps you will be measuring. Failure to follow these
procedures may damage your equipment or possibly cause
injury. Always study the operators manuel for the meter you
will be using.
40-14 SK1026-5N
Points to Remember When Handling Hydraulic Equipment

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material)
in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary
to be particularly careful.
1. Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot
of dust.
2. Disassembly and maintenance work in the field.

If disassembly or maintenance work is carried out on hydraulic
equipment in the field, there is danger of dust entering the
equipment. It is also difficult to confirm the performance after
repairs, so it is desirable to use unit exchange. Disassembly and
maintenance of hydraulic equipment should be carried out in a
specially prepared dust proof workshop, and the performance
should be confirmed with special test equipment.
3. Seal or cover all openings of disconnected piping.

After any piping or equipment is removed, the openings should be
sealed with caps, tape, or vinyl bags to prevent any dirt or dust from
entering. Never leave any openings opened or blocked with a rag,
this could cause particles or dirt to get into the system. Drain all oil
into a container and not unto the ground and be sure to follow the
proper environmental regulation for any disposal of oil.
4. Do not let any dirt, or dust get in during refilling operations.

Be careful not to let any dirt or dust get in when refilling with
hydraulic oil. Always keep the oil filler and the area around it clean,
and also use clean pumps and oil containers. If an oil cleaning
device is used, it is possible to filter out the dirt that has collected
during storage, so this is an even more effective method.
SK1026-5N 40-15
5. Change hydraulic oil when the temperature is high.
When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the
circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible
of the old hydraulic oil must be drained out. (Do not drain the oil from the hydraulic tank; but drain the oil from the filter
and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and
will shorten the life of the hydraulic oil.
6. Flushing operations.
After disassembling and assembling the equipment, or changing the
oil, use flushing oil to remove the contaminants, sludge, and old oil
from the hydraulic circuit.Normally, flushing is carried out twice:
primary flushing is carried out with flushing oil, and secondary
flushing is carried out with the specified hydraulic oil.
7. Cleaning operations.
After repairing the hydraulic equipment (pump, control valve, etc.)
or when running the machine, perform oil cleaning to remove the
sludge or contaminants in the hydraulic oil circuit.The oil cleaning
equipment is used to remove the ultra fine (about 3µ) particles that
the filter built into the hydraulic equipment cannot remove, so it is
an extremely effective device.
40-16 SK1026-5N
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING

Item Judgement Value Action
1. Check fuel level - Add fuel
Lubricating oil, coolant
2. Check for impurities in fuel - Drain

3. Check oil level in hydraulic oil tank - Add oil
4. Check oil filter (Hydraulic, HST) - Replace
5. Check brake oil level - Add oil
6. Check engine oil level inside oil pan - Add oil
7. Check coolant level - Add coolant
8. Check dust indicator for clogging - Clean or replace
9. Check play of steering wheel Max. 80 mm (3.15 in) Adjust
10. Check emergency steering - Repair
Air, Hydraulic, Mechanical equipment
Air charge or
11. Check tire inflation pressure and damage -
replace
Before Starting Checking Item
Tightening torque
12. Check loosening of hub nut (See DISASSENBLY AND Tighten
ASSEMBLY)
13. Check effect of foot brake - Adjust
14. Check effect of parking brake - Adjust or repair
15. Check effect of emergency brake - Adjust or repair
16. Check operation of steering - Adjust or repair
17. Check direction of rear view mirror and under mirror - Adjust
18. Check effect of exhaust gas color and sound - Adjust or repair
19. Check effect retarder brake - Adjust or repair
20. Check effect body mounting rubber - Replace
21. Check sound of horn - Repair
22. Check flashing of lamps - Repair or replace
Electrical equipment
23. Check operation of gauge when during operation - Adjust or repair

24. Check operation of monitor panel - Adjust or repair
25. Check operation of machine monitor system - Adjust or repair
26. Check for missing central warning lamps - Repair or replace
27. Check for looseness, corrosion of battery terminal, wiring - Tighten or clean
28. Check for looseness, corrosion of alternator terminal, wiring - Tighten or clean
29. Check for looseness, corrosion of starting motor terminal,
- Tighten or clean
wiring
30. Check for abnormal noise, smell - Repair
31. Check for oil leakage - Repair
32. Perform air bleeding - Bleed air
33. Check battery voltage (Engine stopped) 24 V Charge or replace
Others Checking Item
34. Check battery electrolyte level - Add

35. Check for discolored, burnt, exposed wiring - Replace
36. Check for missing wiring clamps, hanging wire - Repair
37. Check for water leakage on wiring (Pay particular attention
- Dry
to water leaking on connectors or terminals)
38. Check for blown, corroded fuses - Replace
39. Check alternator voltage (Engine running at 1/2 throttle or After running for several minutes:
Replace
above) 28.5 - 29.5V
40. Check sound of actuation of battery relay (When starting - Replace
switch is turned ON, OFF)
SK1026-5N 40-17
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
Using Troubleshooting Charts

1. Categories of troubleshooting codes.
★ If the machine monitor displays a failure code, the name of the controller is also displayed at the same time, so the
troubleshooting codes are categorized according to the name of each controller. (This may also includes some failure
codes for the electrical system that are not displayed)
★ Failures of the hydraulic and mechanical system that the machine monitor cannot display are categorized as H mode.
Failure code System for troubleshooting
HST Troubleshooting of HST controller system
MON Troubleshooting of machine monitor system
E Troubleshooting of electrical system
H Troubleshooting of hydraulic, mechanical system
Engine Troubleshooting of engine (see 102 Series engine shop manual)
2. Procedure for troubleshooting.

★ If a problem occurs on the machine, or if any problem is felt, perform troubleshooting as follows.
A. When failure code is displayed on machine monitor.

If a failure code is displayed on the machine monitor at the same time as the problem occurs, check the content of the
display, then go to the applicable troubleshooting for the failure code.
B. If no failure code is displayed on the machine monitor but the failure is recorded in memory.
If it is impossible to check the failure code display on the machine monitor when a problem occurs, use the
troubleshooting history display function in the service mode of the machine monitor to check if there is a failure code.
If a failure code is recorded, it is probable that it is the cause, so go to the applicable troubleshooting for the failure
code.
C. If no failure code is displayed and no failure history is recorded.

If it is impossible to check the failure display on the machine monitor when a problem occurs, and there is also no
failure code recorded in the troubleshooting history display function in the service mode of the machine monitor, it is
probable that are problem has occurred in the hydraulic or mechanical system or in the electrical system that the
controller cannot detect. In such a case, check the condition of the failure carefully, then go to the applicable
troubleshooting for the failure.
40-18 SK1026-5N
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

★ The terms male and female refer to the pins, while the terms male housing and female housing refer to the mating portion
of the housing.
★ Deuscht connector has marks of pin numbers on the wiring harness side.
X Type Connector
Number
of Pins T-adapter Part
Male (Female housing) Female (Male housing) Number
1 Part number: 08055-00181 Part number: 08055-00191 799-601-7010
2 799-601-7020
Part number: 08055-00282 Part number: 08055-00292
3 799-601-7030
4 799-601-7040

Terminal part number: 79A-222-3370 Terminal part number: 79A-222-3390
• Wire size: 0.85 • Wire size: 0.85
— —
• Quantity: 20 pieces • Quantity: 20 pieces
• Grommet: black • Grommet: black
Terminal part number: 79A-222-3380 Terminal part number: 79A-222-3410
— —
• Grommet: red • Grommet: red
SK1026-5N 40-19
SWP Type Connector

Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number
6 799-601-7050
8 799-601-7060
12 799-601-7310
14 799-601-7070
40-20 SK1026-5N
SWP Type Connector

Number of
Number
16 799-601-7320

Terminal part number: Terminal part number:
— —
• Grommet: black • Grommet: black
Terminal part number: Terminal part number:
— —
• Grommet: red • Grommet: red
SK1026-5N 40-21
M Type Connector
Number of
Number
1 Part number: 08056-00171 Part number: 08056-00181 799-601-7080
2 799-601-7090
3 799-601-7110
4 799-601-7120
6 799-601-7130
40-22 SK1026-5N
8 799-601-7340
SK1026-5N 40-23
S Type Connector
Number of
Number
8 799-601-7140
10 (white) 799-601-7150
12 (white) 799-601-7350
16 (white) 799-601-7330
40-24 SK1026-5N
S Type Connector
Number of
Number
10 (blue) —
— —
12 (blue) 799-601-7160
16 (blue) 799-601-7170
SK1026-5N 40-25
MIC Type Connector

Number of
Number
Body part number: 79A-222-2640 Body part number: 79A-222-2630
7 —
(Quantity: 5 pieces) (Quantity: 5 pieces)
11 (Quantity: 5 pieces) (Quantity: 5 pieces) —
5 799-601-2710

9 799-601-2950

13 799-601-2720

40-26 SK1026-5N
MIC Type Connector

Number of
Number
17 799-601-2730

21 799-601-2740

— —
SK1026-5N 40-27
AMP040 Type Connector

Number of
Number
8 799-601-7180
Housing part number: 79A-222-3430

—
(Quantity: 5 pieces)
12 799-601-7190
— Housing part number: 79A-222-3440

16 799-601-7210
Housing part number: 79A-222-3450

—
20 799-601-7220
— Housing part number: 79A-222-3460

★ Terminal part number: 79A-222-3470 (for all numbers of pins).
40-28 SK1026-5N
AMP070 Type Connector

Number of
Number
10 799-601-7510
— Part number: 08195-10210
12 799-601-7520
— Part number: 08195-12210
14 799-601-7530
— Part number: 08195-14210
18 799-601-7540
— Part number: 08195-18210
SK1026-5N 40-29
20 799-601-7550
— Part number: 08195-20210
L Type Connector
Number of
Pins T-adapter Part
Male (Female housing) Female (Male housing) Number
2 —
— —
PA Type Connector
Number of
Number
9 —
— —
40-30 SK1026-5N
BENDIX (MS) Type Connector

Number of
Number
10 799-601-3460
— —
SK1026-5N 40-31
KES1 Automobile Type Connector

Number of
Number
2 —
Part number: 08027-10210 (Natural color) Part number: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 —
4 —
08027-10420 (Black) 08027-10470 (Black)
6 —
08027-10620 (Black) 08027-10670 (Black)
40-32 SK1026-5N
KES1 Automobile Type Connector

Number of
Number
8 —
08027-10820 (Black) 08027-10870 (Black)
SK1026-5N 40-33
Connector for relay (Socket)

Number of
Number
5 799-601-7360
— —
6 799-601-7370
— —
Type F Type Connector

(shell size T-adapter Part
code) Pin (Male terminal) Body (Female terminal)
Number
4 —
— —
40-34 SK1026-5N
★ The pin No. is also marked on the connector (electric wire insertion end)
Type HD30 Series connector

code) Body (plug) Body (receptacle)
Number
Pin (male terminal) Pin (female terminal)
799-601-9210
Part number: 08191-11201, 08191-11202 Part number: 08191-14101, 08191-14102

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
(1) Pin (female terminal) Pin (male terminal)
799-601-9210

08191-11205, 08191-12206 08191-13105, 08191-13106
799-601-9220

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9220

08191-22205, 08191-22206 08191-23105, 08191-23106
SK1026-5N 40-35

Number
799-601-9230
18-20 Part number: 08191-31201, 08191-31202 Part number: 08191-34101, 08191-34102

799-601-9230

799-601-9240

799-601-9240
40-36 SK1026-5N

Number
799-601-9250

799-601-9250

799-601-9260

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260

08191-62205, 08191-62206 08191-63105, 08191-63106
SK1026-5N 40-37

Number
799-601-9270

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270

08191-72205, 08191-72206 08191-73105, 08191-73106
799-601-9280
Part number: 08191-81201, 08191-81202, Part number: 08191-84101, 08191-84102,

08191-81203, 08191-81204, 08191-84103, 18191-84104,
24-22 08191-81205, 08191-80206 08191-84105, 08191-84106
799-601-9280
Part number: 08191-82201, 08191-82202, Part number: 08191-83101, 08191-83102,

08191-82203, 08191-82204, 08191-83103, 18191-83104,
08191-82205, 08191-82206 08191-83105, 08191-83106
40-38 SK1026-5N

Number
799-601-9290

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
799-601-9290

08191-92205, 08191-92206 08191-93105, 08191-93106
SK1026-5N 40-39
DT Series connector
Number
Body (plug) Body (receptacle)
Number
2 799-601-9020
Part number: 08192-12200 (normal type) Part number: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
4 799-601-9040
6 799-601-9050
40-40 SK1026-5N
DT Series connector
Number
Number
8GR: 799-601-9060
8B: 799-601-9070
8 8G: 799-601-9080
8BR: 799-601-9080
Part number: 08192-1820 T (normal type) Part number: 08192-1810 T (normal type)
08192-2820 T (fine wire type) 08192-2810 T (fine wire type)
12GR: 799-601-9110
12B: 799-601-9120
10 12G: 799-601-9130
12BR: 799-601-9140
Part number: 08192-1920 T (normal type) Part number: 08192-1910 T (normal type)
08192-2920 T (fine wire type) 08192-2910 T (fine wire type)
SK1026-5N 40-41
DTM Series connector
Number
Number
2 799-601-9010
DTHD Series connector

Number
Number
1 —
Part number: 08192-31200 (Contact size #12) Part number: 08192-31100 (Contact size #12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
40-42 SK1026-5N
TROUBLESHOOTING T-ADAPTER TABLE
T-ADAPTER TABLE
★ The part Nos. of the T-adapter boxes and T-adapters are shown in the columns and those of the wiring harness checker
assemblies are shown in the lines.
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Port No. Connector type Pin No.
—
799-601-2600 For measuring box Econo-21P O O O O O O
799-601-3100 For measuring box MS-37P O
799-601-3200 For measuring box MS-37P O
799-601-3300 For measuring box Econo-24P O
799-601-3360 Plate For MS box
799-601-3410 BENDIX(MS) 24P O O
799-601-3420 BENDIX(MS) 24P O O
799-601-3430 BENDIX(MS) 17P O O
799-601-3440 BENDIX(MS) 17P O O
799-601-3450 BENDIX(MS) 5P O O
799-601-3460 BENDIX(MS) 10P O O
799-601-3510 BENDIX(MS) 5P O O
799-601-3520 BENDIX(MS) 14P O O
799-601-3530 BENDIX(MS) 19P O O
799-601-2910 BENDIX(MS) 14P O O
799-601-3470 CASE O
799-601-2710 MIC 5P O O O O
799-601-2720 MIC 13P O O O O
799-601-2730 MIC 17P O O O O O O O
799-601-2740 MIC 21P O O O O O O O
799-601-2950 MIC 9P O O O O
799-601-2750 ECONO 2P O O
799-601-2760 ECONO 3P O O
799-601-2770 ECONO 4P O O
799-601-2780 ECONO 8P O O
799-601-2790 ECONO 12P O O
799-601-2810 DLI 8P O O
799-601-2820 DLI 12P O O
799-601-2830 DLI 16P O O
799-601-2840 Extension cable O O O
799-601-2850 CASE O
799-601-7010 X 1P O O
799-601-7020 X 2P O O O O
799-601-7030 X 3P O O O O
799-601-7040 X 4P O O O O
799-601-7050 SWP 6P O O O
799-601-7060 SWP 8P O O O
799-601-7310 SWP 12P O
SK1026-5N 40-43
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
799-601-7070 SWP 14P O O
799-601-7320 SWP 16P O
799-601-7080 M 1P O O
799-601-7090 M 2P O O O O
799-601-7110 M 3P O O O O
799-601-7120 M 4P O O O O
799-601-7130 M 6P O O O O
799-601-7340 M 8P O
799-601-7140 S 8P O O O O
799-601-7150 S 10P-White O O O O
799-601-7160 S 12P-Blue O O O
799-601-7170 S 16P-Blue O O O O
799-601-7330 S 16P-White O
799-601-7350 S 12P-White O
799-601-7180 AMP040 8P O
799-601-7190 AMP040 12P O O
799-601-7210 AMP040 16P O O O O
799-601-7220 AMP040 20P O O O O
799-601-7230 Short connector X-2 O O O O
799-601-7240 Case O O
799-601-7270 Case O
799-601-7510 070 10P O
799-601-7520 070 12P O
799-601-7530 070 14P O
799-601-7540 070 18P O
799-601-7550 070 20P O
799-601-7360 Relay connector 5P O
799-601-7370 Relay connector 6P O
799-601-7380 JFC connector 2P O
799-601-9010 DTM 2P O O
799-601-9020 DT 2P O O
799-601-9030 DT 3P O O
799-601-9040 DT 4P O O
799-601-9050 DT 6P O O
799-601-9060 DT 8P-Gray O O
799-601-9070 DT 8P-Black O O
799-601-9080 DT 8P-Green O O
799-601-9090 DT 8P-Blown O O
799-601-9110 DT 12P-Gray O O
799-601-9120 DT 12P-Black O O
799-601-9130 DT 12P-Green O O
799-601-9140 DT 12P-Blown O O
799-601-9210 HD30 18-8 O O
799-601-9220 HD30 18-14 O O
40-44 SK1026-5N
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
799-601-9230 HD30 18-20 O O
799-601-9240 HD30 18-21 O O
799-601-9250 HD24 24-9 O O
799-601-9260 HD30 2-16 O O
799-601-9270 HD30 24-21 O O
799-601-9280 HD30 24-23 O O
799-601-9290 HD30 24-31 O O
799-601-9310 Plate For HD30 O O O
799-601-9320 For measuring box For DT, HD O O O
799-601-9330 Case O
799-601-9340 Case O
799-601-9350 DEUTSCH 40P O
799-601-9360 DEUTSCH 24P O
799-601-9410 For NE, G sensor 2P O
799-601-9420 For boost pressure, 3P O

fuel
799-601-9430 PVC socket 2P O
AMP 2-963215-1
799-601-9710 AMP 2-963217-1 16P O
for HST controller
AMP 2-963215-1
799-601-9720 AMP 2-963217-1 16P O
for HST controller
AMP 2-1437285-2
799-601-9730 AMP 2-1437285-8 26P O
for HST controller
SK1026-5N 40-45
TROUBLESHOOTING TRAVEL MOTOR
TRAVEL MOTOR
Motor does not move (The supplied pressure is enough.)

Possible Reasons Countermeasures
Burned inner parts

Hydraulic motor Replace the hydraulic motor assembly
Too much internal leakage
Reduction gear Damage to the gears Replace the body kit, carrier 1 kit, shaft kit
Overload Remove the overload.
Revolution Speed is Late

Hydraulic pump Faulty operation Inspect the hydraulic pump
Burned inner parts

Hydraulic motor Replace the hydraulic motor assembly
Too much internal leakage
Abnormal Noise
Hydraulic motor Damage to sliding parts Replace the hydraulic motor assembly
Damage to the gears

Reduction gear Replace the body kit, carrier 1 kit, shaft kit
Damage to bearings
Output shaft Damage to the gears surface Replace the body kit
Oil Leakage
Damage to O-Rings Replace the O-Rings

Hydraulic motor body gasket
Loose bolts Retighten the loose bolts
Damage to O-Rings Replace the O-Rings

Reduction gear body gasket
Loose bolts Retighten the loose bolts
Output shaft Damage to oil seal Replace the body kit
Excessive Heat Generation

Hydraulic motor Burned or damaged sliding parts Replace the hydraulic motor assembly
Damage to the gears

Reduction gear Replace the body kit, carrier 1 kit, shaft kit
Damage to the bearings
40-46 SK1026-5N
Does Not Change to Second Speed

Faulty operation of the hydraulic equipment except the hydraulic motor Inspect the hydraulic equipment
Hydraulic motor Damage to sliding parts Inspect the hydraulic motor
Hydraulic valve Spools do not stroke Inspect the valve assembly
Does Not Return to First Speed

Faulty operation of the hydraulic equipment except the hydraulic motor Inspect the hydraulic equipment
Hydraulic motor Damage to sliding parts Inspect the hydraulic motor
Hydraulic valve Spools do not stroke Inspect the valve assembly
Standard for Parts Inspection

Hydraulic Motor
Part Extent of Damage Inspection Standard Action
Replace the hydraulic

Shaft Excessive wear of the spline section Worn depth: 25 μm or more
motor assembly
Excessive wear to the sliding surface Replace the cylinder

Cylinder barrel Worn depth: 20 μm or more
of the valve plate barrel kit
Excessive wear to the sliding surface Replace the cylinder

Valve plate Worn depth: 20 μm or more
of the cylinder barrel barrel kit
Play of piston and shoe:

Replace the cylinder
Piston shoe Wear of joint section 0.3mm (0.012 in) or more by hand
barrel kit
operation
Excessive wear to the sliding surface Replace the swash

Swash plate Worn depth: 0.1 μm or more
of the shoe plate
Other
Damage, excessive rust Replace each part
(screw, etc.)
SK1026-5N 40-47
Reduction Gear Section

Part Extent of Damage Inspection Standard Action
Pitching area 5% or more of the gear

surface.
Replace the body

Internal gear Excessive wear of the surface
kit
Replace carrier 1
Carrier 1 Damage to spline section By visual
kit
Pitching area 5% or more of the gear

surface.
Replace carrier 1
Excessive wear of the surface
kit and shaft kit
b1 Gear Shaft
By visual pitching, flaking
Replace carrier 1
Excessive wear of the bearing surface
kit
Replace carrier 1
Ring Excessive wear of the bearing surface
kit
Replace carrier 1
Roller Excessive wear of the bearing surface
kit
Other Replace each

Damage, excessive rust
(screw, etc.) part
40-48 SK1026-5N
MEMORANDUM
SK1026-5N 40-49
TROUBLESHOOTING AIR CONDITIONING SYSTEM
AIR CONDITIONING SYSTEM

Environmental Impact
★ Environmental studies have indicated a weakening of the earth’s protective Ozone (O3) layer in the outer stratosphere.
Chloro-flouro-carbon compounds (CFC’s), such as R-12 refrigerant (Freon ®), commonly used in mobile equipment air
conditioning systems, has been identified as a possible contributing factor to the Ozone depletion. Consequently,
legislative bodies in more than 130 countries have mandated that the production and distribution of R-12 refrigerant be
discontinued after 1995. Therefore, a more “environmentally-friendly” hydro-flouro-carbon (HFC) refrigerant, commonly
identified as HFC-134a, is being used in most current mobile air conditioning systems. Additionally, the practice of
releasing either refrigerant to the atmosphere during the charging/recharging procedure is now prohibited.
★ These new restrictions require the use of new equipment and new procedures which are significantly different from those
traditionally used in air conditioning service techniques. The use of new equipment and techniques allows for complete
recovery of refrigerants, which will not only help to protect the environment, but through the “re-cycling” of refrigerant
will preserve the physical supply, and help to reduce the cost of the refrigerant.
Basic Air Conditioning System (Typical)
40-50 SK1026-5N
1. Blower Switch 7. Evaporator 13. Magnetic Clutch
2. Thermostatic Switch 8. Expansion Valve 14. Compressor Drive Pulley
3. Battery Supply 9. Suction Line 15. Receiver/Dryer
4. Circuit breaker 10. Test gauges & Manifold 16. Discharge Line
5. Blower 11. Compressor 17. Condenser
6. Temperature Sensor 12. Refrigerant Container
Operator Cab Air Conditioning

Utility and construction vehicles have unique characteristics of vibration, shock-loading, operator changes, and climate
conditions that present different design and installation problems for Air Conditioning systems. Off-highway equipment, in
general, is unique enough that normal automotive or highway vehicle engineering is not sufficient to provide the reliability to
endure the various work cycles encountered.
The cab tightness, insulation, and isolation from heat sources is very important to the efficiency of the system. It is advisable to
close all vents, even the intakes of pressurization systems, when there are high humidity conditions.
The general cleanliness of the system and components is important. Dust or dirt collected in the condenser, evaporator, or air
filters decreases the system’s cooling capacity.
The compressor, condenser, evaporator units, hoses and fittings must be installed clean, tight, and be capable of withstanding
the strain and abuse they are subjected to on off-highway vehicles.
Equipment downtime costs are high enough to encourage service areas to perform preventative maintenance at regular
intervals on vehicle air conditioning systems. (Cleaning, checking belt tightness, and operation of electrical components).
Principles of Refrigeration
A brief review of the principles of air conditioning is necessary to relate the function of components and technique of
troubleshooting and the corrective action necessary to put the A/C unit into top operating efficiency.
Too frequently, the operator and serviceman over-look the primary fact that no A/C system will function properly unless it is
operated within a completely controlled cab environment. The circulation of air must be a directed flow. The cab must be
sealed against seepage of ambient air. The cab interior must be maintained for cleanliness, dust, and dirt which if picked up in
the air system, will clog the intake side of the evaporator coil.
Air Conditioning
Air conditioning is a form of environmental control. As applied to the cab, it refers to the control of temperature, humidity,
cleanliness, and circulation of air. In the broad sense, a heating unit is as much an air conditioner as is a cooling unit. The term
“Air Conditioner” is commonly used to identify an air cooling unit. To be consistent with common usage, the term “Air
Conditioner” will refer to the cooling unit utilizing the principles of refrigeration; sometimes referred to as the evaporator unit.
SK1026-5N 40-51
The Act of Cooling

• There is no process for producing cold; there is only heat removal.
• Heat is always drawn toward cold objects. This principle is the basis for the operation of a cooling unit. As long as one
object has a temperature lower than another, this heat transfer will occur.
• Temperature is the measurement of the intensity of heat in degrees. The most common measuring device is a thermometer.
• All objects have a point at which they will turn to vapor. Water boiling is the most common example of heating until vapor
is formed. Boiling is a rapid form of evaporation. Steam is a great deal hotter than boiling water. The water will not
increase in temperature once brought to a boil. The heat energy is used in the vaporization process. The boiling point of a
liquid is directly affected by pressure. By changing pressure, we can control the boiling point and temperature at which a
vapor will condense. When a liquid is heated and vaporizes, the gas will absorb heat without changing pressure. This gas
is in a superheated condition.
• Reversing the process, when heat is removed from water vapor, it will return to the liquid state. Heat from air is attracted
to a cooler object. Usually the moisture in the cooled air will condense on the cooler object.
• Refrigerant - Only R-134a should be used in the new mobile systems which are designed for this refrigerant.
The Refrigeration Cycle

In an air conditioning system, the refrigerant is circulated under pressure through the five major components in a closed
circuit. At these points in the system, the refrigerant undergoes predetermined pressure and temperature changes.
The compressor (refrigerant pump) takes in low pressure heat laden refrigerant gas through the suction valve (low side), and as
its name indicates, pressurizes the heat laden refrigerant and forces it through the discharge valve (high side) on to the
condenser.
Ambient air, passing through the condenser removes the heat from the circulating refrigerant resulting in the conversion of the
refrigerant from gas to liquid.
The liquid refrigerant moves on to the filter-receiver drier where impurities are filtered out, and moisture removed. This
component also serves as the temporary storage unit for the liquid refrigerant.
The liquid refrigerant, still under high pressure, then flows to the expansion valve. This valve meters the amount of refrigerant
entering the evaporator. As the refrigerant passes through the valve, it becomes a low temperature, low pressure liquid and
saturated vapor.
The remaining low pressure liquid immediately starts to boil and vaporize as it approaches the evaporator. This causes the
refrigerant to become cold. The hot, humid air of the cab is pulled through the evaporator by the evaporator blower. Since the
refrigerant is colder than the air, it absorbs the heat from the air producing cool air which is pushed back into the cab. The
moisture in the air condenses upon movement into the evaporator and drops into the drain pan from which it drains out of the
cab.
The cycle is completed when the heated low pressure gas is again drawn into the compressor through the suction side.
This simplified explanation of the principles of refrigeration does not call attention to the fine points of refrigeration
technology. Some of these will be covered in the following discussions of the components, controls, and techniques involved
in preparing the unit for efficient operation.
40-52 SK1026-5N
Air Conditioner System Components

Compressor (Refrigerant Pump)
The compressor separates the low pressure and the high pressure sides of the system. It concentrates the refrigerant returning
from the evaporator (low side) creating a temperature much higher than the outside air temperature. The high temperature
differential between the refrigerant and the outside air is necessary to aid rapid heat flow in the condenser from the hot
refrigerant gas to much cooler outside air.
To create high pressure concentration, the compressor draws in refrigerant from the evaporator through the suction valve and
during compression strokes, forces it out through the discharge valve to the condenser. The pressure from the compressor
action moves the refrigerant through the condenser, receiver-drier and connecting hoses to the expansion valve.
The compressor is driven by the engine through a v-belt driving an electrically operated clutch mounted on the compressor
drive shaft.
Service Valves
Quick-connect hose end fittings with integral service valves attach to system service ports for servicing the unit. A manifold
gauge set is connected into the system at the service valve ports and all procedures, such as discharging, evacuating and
charging the system, are performed through the service valves.
Condenser
The condenser receives the high pressure, high temperature refrigerant vapor from the compressor and condenses it to high
pressure, hot liquid.
It is designed to allow heat movement from the hot refrigerant vapor to the cooler outside air. Cooling of refrigerant changes
the vapor to liquid. Heat exchange is accomplished using cooler air flowing through the condenser. Condenser cooling can be
with ram air provided by vehicle movement and sometimes aided by electric or hydraulic fans or by using the air movement
provided by the radiator fan.
Ram air condensers depend upon the vehicle movement to force a large volume of air past the fins and tubes of the condenser.
The condenser is usually located in front of the radiator or on the roof of the vehicle.
Condensing of refrigerant is the change of state of refrigerant from a vapor to a liquid. The action is affected by the pressure of
refrigerant in the coil and air flow through the condenser. Condensing pressure in an A/C system is the controlled pressure of
the refrigerant which affects the temperature at which it condenses to liquid, giving off large quantities of heat in the process.
The condensing point is sufficiently high to create a wide temperature differential between the hot refrigerant vapor and the air
passing over the condenser fins and tubes. This difference permits rapid heat transfer from the refrigerant to ambient air.
Receiver-Drier
The receiver-drier is an important part of the air conditioning system. The drier receives liquid refrigerant from the condenser
and removes any moisture and foreign matter present which may have entered the system. The receiver section of the tank is
designed to store extra refrigerant until it is needed by the evaporator. Storage of this refrigerant is temporary and is dependent
on the demand of the expansion valve.
A desiccant is a solid substance capable of removing moisture from gas, liquid or solid. It is held in place within the receiver
between two screens, which also act as strainers. Sometimes it is simply placed in a metal mesh or wool felt bag. Filtering is
accomplished by a separate strainer screen on the pickup tube.
SK1026-5N 40-53
Some systems may utilize an accumulator instead of a receiver-drier. If an accumulator is used, an expansion (fixed-orifice)
tube is used instead of the thermostatic expansion valve described below. When used, the expansion tube is located inside the
inlet tube of the evaporator and is used to restrict, but still allow a continuous flow of refrigerant to the evaporator coil.
Thermostatic Expansion Valve

The thermostatic expansion valve controls the amount of refrigerant entering the evaporator coil. Both internally and
externally equalized valves are used.
The expansion valve is located near the inlet of the evaporator and provides the functions of throttling, modulating, and
controlling the liquid refrigerant to the evaporator coil.
The refrigerant flows through a restriction creating a pressure drop across the valve. Since the expansion valve also separates
the high side of the system from the low side, the state of the refrigerant entering the valve is warm to hot high pressure liquid;
exiting it is low pressure liquid and gas. The change to low pressure allows the flowing refrigerant to immediately begin
changing to gas as it moves toward the evaporator.
The amount of refrigerant metered into the evaporator varies with different heat loads. The valve modulates from wide open to
the nearly closed position, seeking a point between for proper metering of the refrigerant.
As the load increases, the valve responds by opening wider to allow more refrigerant to pass into the evaporator. As the load
decreases, the valve reacts and allows less refrigerant into the evaporator. It is this controlling action that provides the proper
pressure and temperature control in the evaporator.
The externally equalized expansion valve is controlled by both the temperature of the power element bulb and the pressure of
the liquid in the evaporator.
Some systems may use an internally equalized, block type expansion valve. With this type valve, the refrigerant leaving the
evaporator coil is also directed back through the valve so the temperature of the refrigerant is monitored internally rather than
by a remote sensing bulb.
Remark
It is important that the sensing bulb, if present, is tight against the output line and protected from ambient
temperatures with insulation tape.
Evaporator
The evaporator cools and dehumidifies the air before it enters the cab. Cooling a large area requires that large volumes of air
be passed through the evaporator coil for heat exchange. Therefore, a blower becomes a vital part of the evaporator assembly.
It not only draws heat laden air into the evaporator, but also forces this air over the evaporator fins and coils where the heat is
surrendered to the refrigerant. The blower forces the cooled air out of the evaporator into the cab.
Heat exchange, as explained under condenser operation, depends upon a temperature differential of the air and the refrigerant.
The greater the temperature differential, the greater will be the amount of heat exchanged between the air and the refrigerant.
A high heat load condition, as is generally encountered when the air conditioning system is turned on, will allow rapid heat
transfer between the air and the cooler refrigerant.
The change of state of the refrigerant in and going through the evaporator coil is as important as that of the air flow over the
coil.
All or most of the liquid that did not change to vapor in the expansion valve or connecting tubes boils (expands) and vaporizes
immediately in the evaporator, becoming very cold. As the process of heat loss from the air to the evaporator coil surface is
taking place, any moisture (humidity) in the air condenses on the cool outside surface of the evaporator coil and is drained off
as water.
At atmospheric pressure, refrigerant boils at a point lower than water freezes. Therefore, the temperature in the evaporator
must be controlled so that the water collecting on the coil surface does not freeze on and between the fins and restrict air flow.
40-54 SK1026-5N
The evaporator temperature is controlled through pressure inside the evaporator, and temperature and pressure at the outlet of
the evaporator.
Electrical Circuit
The air conditioner’s electrical circuit is fed from an accessory circuit and is fused with a 30-ampere fuse or circuit breaker.
The blower control is a switch which provides a range of blower speeds from fast to slow. When the blower switch is turned
on, current is fed to the thermostat. Once the blower is turned on, fan speeds may be changed without affecting the thermostat
sensing level.
The thermostat reacts to changing temperatures which cause electrical contacts to open and close. The thermostat has a
capillary tube extended into the evaporator coil to sense temperature.
When the contacts are closed, current flows to the clutch field and energizes the clutch, causing the crankshaft to turn which
starts the refrigeration cycle. When the temperature of the evaporator coil drops to a predetermined point, the contacts open
and the clutch disengages.
When the clutch is disengaged, the blower remains at the set speed. After the evaporator temperature rises about twelve
degrees above the cutout point, the contacts in the thermostat close and the refrigeration cycle resumes.
Thermostat
An electromagnetic clutch is used on the compressor to provide a means of constant temperature control of the cab. The clutch
is controlled by a thermostat in the evaporator which is set initially by the driver to a predetermined point. Coil temperature is
then maintained by the cycling action of the clutch.
The thermostat is simply a thermal device which controls an electrical switch. When warm, the switch is closed; when cold, it
is open. Most thermostats have a positive OFF position as a means to turn the clutch OFF regardless of temperature.
The bellows type thermostat has a capillary tube connected to it which is filled with refrigerant. The capillary tube is attached
to the bellows inside of the thermostat. Expansion of the gases inside the capillary tube exerts pressure on the bellows, which
in turn closes the contacts at a predetermined temperature.
Compressor Clutch
An electromagnetic clutch is used in conjunction with the thermostat to disengage the compressor when it is not needed, such
as when a defrost cycle is indicated in the evaporator, or when the system is turned off.
The stationary field clutch is the most desirable type since it has fewer parts to wear out. The field is mounted to the
compressor by mechanical means depending on the type field and compressor. The rotor is held on the armature by a bearing
and snap rings. The armature is mounted on the compressor crankshaft.
When no current is fed to the field, there is no magnetic force applied to the clutch and the rotor is free to rotate on the
armature, which remains stationary on the crankshaft.
When the thermostat or switch is closed, current is fed to the field. This sets up a magnetic force between the field and
armature, pulling it into the rotor. When the armature becomes engaged with the rotor, the complete unit rotates while the field
remains stationary. This causes the compressor crankshaft to turn, starting the refrigeration cycle.
When the switch or thermostat is opened, current is cut off. The armature snaps back out and stops while the rotor continues to
turn. Pumping action of the compressor is stopped until current is again applied to the field. In addition, safety switches in the
compressor clutch electrical circuit control clutch operation, disengaging the clutch if system pressures are abnormal.
SK1026-5N 40-55
Safety Switches
TrinaryTM Switch
The TrinaryTM switch performs three distinct functions to monitor and control refrigerant pressure in the system. This switch is
installed between the condenser and expansion valve, usually on the receiver-drier. The switch functions are:
• The low-pressure switch prevents compressor operation if the refrigerant has been lost or the ambient temperature is too
low. Low ambient temperature results in very low system pressure.
• The mid-range function actuates the engine fan clutch if installed.
• The high-range pressure function disengages the compressor clutch if system pressure is too high.
The switch functions will automatically reset when the system pressure returns to normal.
40-56 SK1026-5N
System Servicing
Servicing an air conditioning system really means closely monitoring refrigerant flow. For this reason, the following
procedures deal extensively with the proper use, handling, care and safety factors involved in the R-134a refrigerant quality
and quantity in an air conditioning system.
Because the refrigerant in an air conditioning system must remain pressurized and sealed within the unit to function properly,
safety is a major consideration when anything causes this pressurized, sealed condition to change. The following warnings are
provided here to alert service personnel to their importance BEFORE learning the correct procedures. Read, remember, and
observe each warning before beginning actual system servicing.
Remark
If the owner operates a fleet with some vehicles using R-12 and others using R-134a refrigerant, it is
essential that servicing tools that come into contact with the refrigerant (gauge sets, charging equipment,
recycle/recovery equipment etc.) be dedicated to one type refrigerant only, to prevent cross contamination.
WARNING! Federal regulations prohibit venting R-12 and R134a refrigerant into the atmosphere. An SAE and UL
approved recovery/recycle station must be used to remove refrigerant from the AC system.
Refrigerant is stored in a container on the unit for recycling, reclaiming, or transporting. In addition,
technicians servicing AC systems must be certified, they have been properly trained to service the
system.
WARNING! Although accidental release of refrigerant is a remote possibility when proper procedures are followed,
the following warnings must be observed when servicing AC systems:
• Provide appropriate protection for your eyes (goggles or face shield) when working around
refrigerant.
• A drop of the liquid refrigerant on your skin will produce frostbite. Wear gloves and exercise
extreme care when handling refrigerant.
• If even the slightest trace of refrigerant enters in your eye, flood the eye immediately with cool
water and seek medical attention as soon as possible.
• Ensure sufficient ventilation whenever refrigerant is being discharged from a system, keeping in
mind refrigerant is heavier than air and will seek low areas of the shop.
• When exposed to flames or sparks, the components of refrigerant change and become deadly
phosgene gas. This poison gas will damage the respiratory system if inhaled. NEVER smoke in
area where refrigerant is used or stored.
• Never direct steam cleaning hose or torch in direct contact with components in the air conditioning
system. Localized heat can raise the pressure to a dangerous level.
• Do not heat or store refrigerant containers above 120° F (49° C).
• Do not flush or pressure test the system using shop air or another compressed air source. Certain
mixtures of air and R-134a refrigerant are combustible when slightly pressurized. Shop air supplies
also contain moisture and other contaminants that could damage system components.
R-134A Refrigerant Containers

Two basic, readily available containers are used to store R-134a: the 30
or 60 pound (13.6 or 27.2 kg) bulk canisters.
Always read the container label to verify the contents are correct for the
system being serviced. Note the containers for R-134a are painted light
blue.
1. 30 Pound (13.6 kg) Cylinder

2. 60 Pound (27.2 kg) Cylinder
SK1026-5N 40-57
Service Tools And Equipment

Recovery/recycle Station
Whenever refrigerant must be removed from the system, a dual purpose
station performs both recovery and recycle procedures which follows
the new guidelines for handling used refrigerant.
★ Recovered refrigerant can then be recycled to reduce contaminants,
and reused in the same machine or fleet.
Remark
To be re-sold, the gas must be “reclaimed” which leaves
it as pure as new, but requires equipment normally too
expensive for all but the largest refrigeration shops.
Equipment is also available to just remove or extract the refrigerant.

Extraction equipment does not clean the refrigerant, it is used to recover
the refrigerant from an AC system prior to servicing.
To accomplish this, the recovery/recycle station separates the oil from

the refrigerant and filters the refrigerant multiple times to reduce
moisture, acidity, and particulate matter found in a used refrigerant.
WARNING! Mixing different types of refrigerant will

damage equipment. Dedicate one
recovery/recycle station to each type of
refrigerant processing to avoid equipment
damage.
WARNING! DISPOSAL of the gas removed requires

laboratory or manufacturing facilities.
Remark
Test equipment is available to confirm refrigerant in the system is actually the type intended for the system
and has not been contaminated by a mixture of refrigerant types.
Remark
Recycled equipment must meet certain standards as published by the Society of Automotive Engineers
and carry a UL approved label. Basic principals of operation remain the same for all machines, even if
details of operation differ somewhat.
40-58 SK1026-5N
Leak Detector
The electronic detector is very accurate and safe. It is a small
hand-held device with a flexible probe used to seek refrigerant
leaks. A buzzer, alarm or light will announce the presence of
even the smallest leak.
Remark
Electronic leak detectors are available for use
only with R-12 or only with R-134a.
Service Valves
Because an air conditioning system is a sealed system, two service
valves are provided on the compressor to enable diagnostic tests, system
charging or evacuation. Connecting applicable hoses from the manifold
gauge set to the compressor service valves enables each of these to be
readily performed. New and unique service hose fittings have been
specified for R-134a systems. Their purpose is to avoid accidental
cross-mixing of refrigerants and lubricants with R-12 based systems.
Service ports on the system are quick disconnect type with no external
threads. They do contain a Schrader type valve. The low side fitting has
a smaller diameter than the high side attachment.
1. System Service Port Fitting

2. Quick Connect
3. Service Hose Connection
Remark
Protective caps are provided for each service valve. When not being used these caps should be in place to
prevent contamination or damage to the service valves.
Vacuum Pump
The vacuum pump is used to completely evacuate all of the refrigerant,
air, and moisture from the system by deliberately lowering the pressure
within the system to the point where water turns to a vapor (boils) and
together with all air and refrigerant is with-drawn (pumped) from the
system. Normally the vacuum pump is only used when a system has
completely lost its refrigerant charge.
SK1026-5N 40-59
Manifold Gauge Set

A typical manifold gauge set has two screw type hand valves to control
access to the system, two gauges and three hoses. The gauges are used
to read system pressure or vacuum. The manifold and hoses are for
access to the inside of an air conditioner, to remove air and moisture,
and to put in, or remove, refrigerant from the system. Shutoff valves are
required within 12 inches (304.8 mm) of the hose end(s) to minimize
refrigerant loss.
A gauge set for R-134a will have a blue hose with a black stripe for the
low side, a red hose with a black stripe for the high side, and a yellow
hose with a black stripe for the utility (center) hose. Hoses use a 1/2 in.
ACME female nut on the gauge end. Special quick disconnect couplings
are normally combined with a shutoff valve on the high and low side
hoses. The free end of the center hose contains a 1/2 in. ACME female
nut and a shutoff device within 12 inches (304.8 mm) of the hose end.
These special hoses and fittings are designed to minimize refrigerant
loss and to preclude putting the wrong refrigerant in a system.
Remark
When hose replacement becomes necessary, the new hoses must be marked “SAE J2916 R-134a”.
Functions of the manifold gauge set are included in many of the commercially available recovery or recovery/ recycle stations.
Low Side Gauge
The Low Side Gauge, registers both vacuum and pressure. The vacuum side of the scale is calibrated from 0 to 30 inches (0 to
762 mm) of mercury (in. Hg). The pressure side of the scale is calibrated to 150 psi (10.6 kg/cm²).
WARNING! Never open the hand valve to the high side at anytime when the air conditioning system is
operating. High side pressure, if allowed, may rupture charging containers and potentially
cause personal injury.
High Side Gauge
The High Side Gauge is used to measure pressure only on the discharge side of the compressor. The scale is calibrated from
0 to 500 psi (0 to 35.3 kg/cm²).
40-60 SK1026-5N
Installing Manifold Gauge Set
WARNING! Shut off engine. DO NOT attempt to

connect servicing equipment when the
engine is running.
Before attempting to service the air conditioning system, a visual

inspection of both the engine and system components is recommended.
Particular attention should be paid to the belts, hoses, tubing and all
attaching hardware plus the radiator cap, fan clutch, and thermostat.
Inspect both the condenser and radiator for any obstructions or potential
contamination. Minimize all possibilities for error or malfunction of
components in the air conditioning system.
1. Be sure all valves on the manifold are closed all the way (turn them
clockwise).
2. Check the hose connections on the manifold for tightness.
3. Locate the low and high side system service fittings and remove
their protective caps.
4. Connect two service hoses from the manifold to the correct service
valves on the compressor. (High side to compressor discharge valve
and low side to compressor suction side.) Do not open service valves at this time.
This gauge hook-up process will be the same, regardless of the gauge set being installed. Whether it is a recovery station or
individual gauges, the connections are the same. The procedures performed next will vary depending what type of equipment
is being used. If a recovery/recycling station is being used, complete servicing can be accomplished. Using only a set of
gauges will limit the servicing to only adding refrigerant or observing pressures.
SK1026-5N 40-61
Purging Air from Service Hoses
The purpose of this procedure is to remove all air trapped in the hoses prior to actual system testing. Environmental regulations
require that all service hoses have a shutoff valve within 12 inches (304.8 mm) of the service end. These valves are required to
ensure only a minimal amount of refrigerant is lost to the atmosphere. R-134a gauge sets have a combination quick disconnect
and shutoff valve on the high and low sides.
The center hose also requires a valve. Initial purging is best accomplished when connected to recovery or recycle equipment.
With the center hose connected to the recovery station, service hoses connected to the high and low sides of the system, we can
begin purging.
The manifold valves and service valves should be closed. Activating the vacuum pump will now pull any air or moisture out of
the center hose. This will require only a few minutes of time. The hose is the only area that is being placed in a vacuum and
this will not require a lengthy process. Closing the valve will then insure the hose is purged.
It is now safe to open the other manifold valves.
40-62 SK1026-5N
Adding Refrigerant to the System (Without a Charging Station)

1. After determining that the system is low and requires additional refrigerant perform the following procedures. Connect the
center hose from the manifold gauge set to the refrigerant dispensing valve on the container.
2. Start the engine and set the idle at 1200 to 1500 RPM and then turn on the air conditioning.
3. Open the refrigerant dispensing valve on the container and then the low pressure hand valve on the manifold. This will
allow the refrigerant to enter the system as a gas on the low pressure or suction side of the compressor. The compressor
will pull refrigerant into the system.
4. Continue adding refrigerant until the gauge reads in the normal range. Gauge readings will fluctuate as the compressor
cycles on and off. Pressures within the air conditioning system vary with ambient temperature. A normal pressure range is
defined as follows:
Low side 15 - 30 psi (1.1 - 2.1 kg/cm²)
High side 170 - 300 psi (12.0 - 21.1 kg/cm²)
5. When the gauges show a normal reading, close the hand valve on the refrigerant container.
Stabilizing the AC System
WARNING! During this stabilization period, do not open hand valves on manifold for any reason.
Equipment damage and personal injury may result.
1. Start the engine and return to an idle speed of 1200 to 1500 rpm. Turn on the air conditioner.
2. After a performance check of the control functions, blower speeds and air flow, set the AC system controls to maximum
cooling and blower speed on high. All windows must be closed. If the cab temperature is hot, open the windows long
enough to allow the hot air to move out of the cab.
3. Run the engine and air conditioner about 5 minutes for the system to stabilize.
4. If humidity is high it will be necessary to place a fan in front of the AC condenser to help air flow across the condenser.
This helps to stabilize the system by simulating normal operating conditions.
5. It is then possible to observe the gauge readings and the temperature coming out of the air ducts with a thermometer.
Remark
If low refrigerant is indicated by lower than normal pressure readings, add refrigerant to enable adequate
system testing.
SK1026-5N 40-63
Adding Refrigerant and Stabilizing the System (With a Recovery/Recycling

Station)
When using a recovery/recycling station the procedure is the same as previously described. The difference is that instead of
just opening the refrigerant container the refrigerant should be added 0.5 to 1 pound (0.23 to 0.45 kg) at a time. After each
instance of adding the refrigerant, pause long enough to observe the gauge reading to determine if the system is full. Again
using the pressures that were mentioned above.
WARNING! Do not open high side hand valve. High side system pressure is greater than refrigerant
container. Serious personal injury may result if the container explodes.
WARNING! Use hand valve to regulate low side reading during charging. DO NOT EXCEED 40 psi
(2.8 kg/cm²) maximum. Exceeding this pressure may cause compressor failure.
Recovering and Recycling the Refrigerant

Draining the Oil from the Previous Recovery Cycle
1. Place the power switch and the controller on the recovery unit in the OFF position.
2. Plug in the recovery station to the correct power source.
3. Drain the recovered oil through the valve marked OIL DRAIN on the front of the machine.
4. Place the controller knob in the ON position. The low pressure gauge will show a rise.
5. Immediately switch to the OFF position and allow the pressure to stabilize. If the pressure does not rise to between 5 psi
and 10 psi (0.35 and 0.70 kg/cm²), switch the controller ON and OFF again.
6. When the pressure reaches 5 to 10 psi (0.35 to 0.70 kg/cm²), open the OIL DRAIN valve, collect the oil in an appropriate
container, and dispose of container as indicated by local, state or Federal Regulation.
Remark
The oil is not reusable, due to contaminants absorbed during its previous use.
Performing the Recovery Cycle
1. Be sure the equipment being used is designed for the refrigerant you intend to recover.
2. Observe the sight glass oil level. Having drained it, it should be zero.
3. Check the cylinder refrigerant level before beginning recovery to make sure you have enough capacity.
4. Confirm that all shut-off valves are closed before connecting to the AC system.
5. Attach the appropriate hoses to the system being recovered.
6. Start the recovery process by operating the equipment as per the manufacturer’s instructions.
7. Continue extraction until a vacuum exists in the AC system.
8. If an abnormal amount of time elapses after the system reaches 0 psi (0 kg/cm²) and does not drop steadily into the
vacuum range, close the manifold valves and check the system pressure. If it rises to 0 psi (0 kg/cm²) and stops, there is a
major leak.
40-64 SK1026-5N
9. Check the system pressure after the recovery equipment stops. After five minutes, system pressure should not rise above
“0” gauge pressure. If the pressure continues to rise, restart and begin the recovery sequence again. This cycle should
continue until the system is void of refrigerant.
10. Check the sight glass oil level to determine the amount of oil that needs to be replaced. (The amount of oil that was lost
during the recovery cycle must be replaced back into the system).
11. Mark the cylinder with a RECOVERED (red) magnetic label to reduce the chance of charging a system with
contaminated refrigerant. Record the amount of refrigerant recovered.
Performing the Recycling Procedure

The recovered refrigerant contained in the cylinder must undergo the recycle procedure before it can be reused. The recycle or
clean mode is a continuous loop design and cleans the refrigerant rapidly. Follow equipment manufacturer’s instructions for
this procedure.
Evacuating and Charging the AC System

Evacuate the system once the air conditioner components are repaired or replacement parts are secured, and the AC system is
reassembled. Evacuation removes air and moisture from the system. Then, the AC system is ready for the charging process,
which adds new refrigerant to the system.
Evacuating the System
1. Attach the high and low side hoses to the appropriate connections.
2. Start the vacuum pump and run it for five minutes.
3. Check the gauge readings for five minutes. If the gauge needle moves up, the system is not sealed. The vacuum that was
just created did not hold, air and moisture are being sucked into the system by that same vacuum.
4. Tighten any loose connections. Re-start the pump, and open the hand valves on the gauges again. Repeat the vacuum test.
5. If the leak has been repaired, run the vacuum pump for at least an hour to remove any moisture from the system.
Remark
The moisture must turn to gas before the pump can pull it out. The moisture takes time to boil away, so that it can be
drawn out of the system. The vacuum pump can draw most of the air out quickly, but a deep vacuum requires more
time; the deeper the vacuum the more time required.
Charging the AC System
When adding a full charge of refrigerant, it is possible to put it in as a gas or as a liquid. Adding refrigerant as a liquid is faster
but can damage the compressor if not done correctly. The procedure used, and where the refrigerant is added in the AC system
makes a difference. When using refrigerant as a liquid, never add more than two thirds of system requirements as a liquid.
Finish charging the system using gas.
SK1026-5N 40-65
System Performance Test

This test is performed to establish the condition of all components in the system. Observe these conditions during testing:
1. Start engine and operate at 1200 to 1500 RPM.
2. Place fan in front of condenser to simulate normal ram air flow and allow system to stabilize.
3. Place a thermometer in air conditioning vent closest to evaporator.
4. Evaluate the readings obtained from the gauges to see if they match the readings for the ambient temperature.
5. As preliminary steps to begin checkout of the system, perform the following:
A. Close all windows and doors to the cab.
B. Set air conditioning system at maximum cooling and blower speed operation.
C. Readings on the two manifold gauges should be within normal range, adjust for ambient temperature.
D. Compare evaporator discharge air temperature reading to see if it matches the recommended temperature for the
ambient temperature and gauge readings obtained.
E. Carefully feel the hoses and components on the high side. All should be warm-hot to the touch. Check the inlet and
outlet of receiver-drier for even temperatures, if outlet is cooler than inlet, a restriction is indicated.
WARNING! Use extreme caution when placing hands on high side components and hoses. Under
certain conditions these items can be extremely hot.
F. Feel the hoses and components on the low side. They should be cool to the touch. Check connections near the
expansion valve, inlet side should be warm and cold-cool on the outlet side.
G. If these conditions are met, the system is considered normal. Shut down engine. Remove gauges and install the caps
on the service valves.
40-66 SK1026-5N
System Leak Testing
WARNING! Use extreme caution leak testing a system while the engine is running.
In its natural state, refrigerant is a harmless, colorless gas, but when combined with an
open flame, it will generate toxic fumes (phosgene gas), which can cause serious injuries
or death.
Refrigerant leaks are probably the most common cause of air conditioning problems, resulting from improper or no cooling, to
major internal component damage. Leaks most commonly develop in two or three places. The first is around the compressor
shaft seal, often accompanied by an indication of fresh refrigerant oil. If a system is not operated for a while (winter months),
the shaft seal may dry out and leak slightly. The centrifugal force of the clutch pulley spinning can also cause the problem.
When the system is operated and lubricant wets the seal, the leak may stop. Such leaks can often be located visually, or by
feeling with your fingers around the shaft for traces of oil. (The R-134a itself is invisible, odorless, and leaves no trace when it
leaks, but has a great affinity for refrigerant oil.)
A second common place for leaks is the nylon and rubber hoses where they are crimped or clamped to the fittings, or where
routing allows abrasion. Other threaded joints or areas where gaskets are used should be visually and physically examined.
Moving your fingers along the bottom of the condenser and evaporator, particularly near the drain hole for the condensate will
quickly indicate the condition of the evaporator. Any trace of fresh oil here is a clear indication of a leak.
Usually, a 50% charged system is enough to find most leaks. If the system is empty, connect manifold gauge set to the system
and charge at least one (1) lb. (0.45 kg) of refrigerant into the system.
Remark
The refrigerant is heavier than air and will move down when it leaks. Apply pickup hose or test probe on
the undersurface of all components to locate leak.
Electronic Leak Detector

As the test probe is moved into an area where traces of refrigerant are present, a visual or audible announcement indicates a
leak. Audible units usually change tone or speed as intensity changes.
Tracer Dyes
Tracer dyes are available that can be added to the system as refrigerant is added. The system is then operated to thoroughly
circulate the dye. As refrigerant escapes, it leaves a trace of the dye at the point of leakage, which is then detected using an
ultraviolet light (black light), revealing a bright fluorescent glow.
Soap and Water

Soap and water can be mixed together and applied to system components. Bubbles will appear to pinpoint the specific location
of leaks. After determining the location or source of leak(s), repair or replace leaking component(s).
Remark
The length of the hose will affect the refrigerant capacity. When replacing hoses, always use the same
hose length, if possible.
SK1026-5N 40-67
System Repair
WARNING! Before system assembly, check the compressor oil level and fill to manufacturer
specifications.
WARNING! All of the service procedures described are only performed after the system has been
discharged. Never use any lubricant or joint compound to lubricate or seal any AC
connections.
The following service and repair procedures are not any different than typical vehicle service work. However, AC system
components are made of soft metals (copper, aluminum, brass, etc.). Comments and tips that follow will make the job easier
and reduce unnecessary component replacement.
Remark
To help prevent air, moisture or debris from entering an open system, cap or plug open lines, fittings or
components and lubricant containers until connected and as soon as they are disconnected.
Keep all connections clean (also caps and plugs used) so debris can’t enter accidentally.
Hoses and Fittings

When replacing hoses, be sure to use the same type and ID hose you removed. When hoses or fittings are shielded or clamped
to prevent vibration damage, be sure these are in position or secured.
Lines
Always use two wrenches when disconnecting or connecting AC fittings attached to metal lines. You are working with copper
and aluminum tubing which can kink or break easily. Tube O-ring type fittings require only 18 ft. lbs. (24.4 N.m) {2.5 kgf.m}
of torque for correct sealing. When grommets or clamps are used to prevent line vibration, be certain these are in place and
secured.
Expansion Valve
When removing the expansion valve from the system, remove the insulation, clean the area and disconnect the line from the
receiver-drier. Detach the capillary (bulb) and external equalizer tube (if present) from their mounting locations. Remove the
expansion valve from the evaporator inlet. Expansion valve service is limited to cleaning or replacing the filter screen. If this is
not the problem, replace the valve. Secure the capillary and equalizer, if used, to clean surfaces and replace or attach any
insulating material.
Receiver-Drier
The receiver-drier can not be serviced or repaired. It should be replaced whenever the system is opened for any service. If the
receiver-drier has a pressure switch to control the clutch, it should be removed and installed on the new unit.
Thermostat
A thermostat can be stuck open or closed due to contact point wear or fusion. The thermostat temperature sensing element
(capillary tube) may be broken or kinked closed and therefore unable to sense evaporator temperature.
When thermostat contact points are stuck open or the sensing element can not sense temperature in the evaporator, the clutch
will not engage (no AC system operation). Causes are a loss of charge in the capillary tube or a kink, burned thermostat contact
or just no contact. When troubleshooting, bypass the thermostat by hot wiring the clutch coil with a fused lead. If the clutch
engages, replace the thermostat.
Thermostat contact points may be fused (burned) closed and the clutch will not disengage. Causes are a faulty switch that
could be due to fatigue. The thermostat must be replaced. When the clutch will not disengage you may also note that
condensate has frozen on the evaporator fins and blocked air flow. There will also be below normal pressure on the low side of
the system. Side effects can be compressor damage caused by oil accumulation (refrigeration oil tends to accumulate at the
coolest spot inside the system) and lower than normal suction pressure that can starve the compressor of oil.
40-68 SK1026-5N
Clutch
Clutch problems include electrical failure in the clutch coil or lead wire, clutch pulley bearing failure, worn or warped clutch
plate or loss of clutch plate spring temper. Defective clutch assembly parts may be replaced or the whole assembly replaced. If
the clutch shows obvious signs of excessive heat damage, replace the whole assembly.
The fast way to check electrical failure in the lead wire or clutch coil is to hot wire the coil with a fused lead. This procedure
enables you to bypass clutch circuit control devices.
Clutch pulley bearing failure is indicated by bearing noise when the AC system is off or the clutch is not engaged. Premature
bearing failure may be caused by poor alignment of the clutch and clutch drive pulley. Sometimes it may be necessary to use
shims or enlarge the slots in the compressor mounting bracket to achieve proper alignment.
Excessive clutch plate wear is caused by the plate rubbing on the clutch pulley when the clutch is not engaged or the clutch
plate slipping when the clutch coil is energized. A gap that is too small or too large between the plate and clutch pulley or a
loss of clutch plate spring temper are possible causes. The ideal air gap between the clutch pulley and the clutch plate is 0.022
to 0.057 in. If the gap is too wide, the magnetic field created when the clutch coil is energized will not be strong enough to pull
and lock the clutch plate to the clutch pulley.
Compressor
The compressor can fail due to shaft seal leaks (no refrigerant in the system), defective valve plates, bearings, other internal
parts or problems associated with high or low pressure, heat or lack of lubrication. Be sure the compressor is securely mounted
and the clutch pulley is properly aligned with the drive pulley.
Use a mechanic’s stethoscope to listen for noises inside the compressor.
Checking Compressor Oil Level

Every air conditioning system and compressor depends on refrigeration oil for lubrication and safe operation.
Refrigerant oil is a synthetic oil very susceptible to high levels of water absorbtion. Always be sure the oil is an approved type
for use in the air conditioner compressor.
Refrigerant oil, under normal circumstances inside the sealed system, cannot go anywhere, and there is no need to check the
oil at such times. Always keep a cap on an oil container except when in use. Moisture is quickly absorbed by the oil.
Whenever a system is opened for service, the compressor oil level should be checked and clean refrigeration oil added as
required by the manufacturer’s specifications (usually located on compressor).
SK1026-5N 40-69
Evacuating The System
WARNING! Do not use the air conditioning compressor as a vacuum pump or the compressor will be
damaged.
Evacuating the complete air conditioning system is required in all new system installations, and when repairs are made on
systems requiring a component replacement (system opened), or a major loss of refrigerant has occurred. All these conditions
will require that a vacuum be pulled using a vacuum pump that completely removes any moisture from the system.
Once properly evacuated, the system can be recharged again.
Using a pump to create a vacuum in the air conditioning system effectively vaporizes any moisture, allowing the water vapor
to be easily drawn out by the pump. The pump does this by reducing the point at which water boils (212°F {100° C}) at sea
level with 15 psi {1.05 kg/cm²}). In a vacuum, water will boil at a lower temperature depending upon how much of a vacuum
is created.
As an example, if the ambient air outside the vehicle is 75°F (23° C) at sea level, by creating a vacuum in the system so that the
pressure is below that of the outside air (in this case, at least 29.5 inches {749.3 mm} of vacuum is needed), the boiling point
of water will be lowered to 72°F (22° C). Thus any moisture in the system will vaporize and be drawn out by the pump if the
pump is run for approximately an hour. The following steps indicate the proper procedure for evacuating all moisture from the
heavy duty air conditioning systems.
Remark
Lower the vacuum requirement 1 inch (25.4 mm) for every 1000 feet (304.8 m) above sea level at your
location.
1. With the manifold gauge set still connected (after discharging the
system), connect the center hose to the inlet fitting of the vacuum
pump. Then open the low side hand valves to maximum.
2. Open the discharge valve on the vacuum pump or remove the dust
cap from the discharge outlet. Turn the pump on and watch the low
side gauge. The pump should pull the system into a vacuum (if not,
the system has a leak).
3. Run the pump for five minutes and close the hand valves and shut
off the pump.
4. Observe gauge reading and wait 10 minutes. Reading should not

vary more than 1-2 inch (25.4-50.8 mm) hg. After waiting, if more
vacuum is lost than this, a serious leak is indicated and the system
must be recharged, leak tested, repaired and evacuated.
5. Turn on pump, open hand valves and continue evacuation for at

least one hour.
1. Low Pressure Hand Valve
2. High Pressure Hand Valve
3. Vacuum Pump
Remark
If system has excessive amounts of moisture, 60 minutes evacuation may not be sufficient since the water
must turn to a vapor to be drawn out of the system. If it has been verified that no system leaks exist and
gauge readings increase after 1 hour, extend the evacuation time to ensure total moisture removal.
6. Close the manifold hand valves and turn off vacuum pump, watching the low side gauge reading. If vacuum remains for a
few minutes, the system is ready for charging.
Remark
If using a recycling and charging machine, the vacuum pump is built into the unit. Separate hook-up is not
required.
40-70 SK1026-5N
MEMORANDUM
SK1026-5N 40-71
Troubleshooting - Air Conditioning System

Pre-Diagnosis Checks
If the system indicates insufficient cooling, or no cooling, the following points should be checked before proceeding with the
system diagnosis procedures.
Preparing for Diagnosis

Successfully servicing an air conditioning system, beyond the basic procedures outlined in the previous section, requires
additional knowledge of system testing and diagnosis.
A good working knowledge of the manifold gauge set is required to correctly test and diagnose an air conditioning system. An
accurate testing sequence is usually the quickest way to diagnose an internal problem. When correctly done, diagnosis
becomes an accurate procedure rather than guesswork.
• Compressor Belt - Must be tight, and aligned.
• Compressor Clutch - The clutch must engage. If it does not, check fuses, wiring, and switches.
• Oil Leaks - Inspect all connection or components for refrigeration oil leaks (especially in the area of the compressor
shaft). A leak indicates a refrigerant leak.
• Electrical Check - Check all wires and connections for possible open circuits or shorts. Check all system fuses.
• Cooling System - Check for correct cooling system operation. Inspect the radiator hoses, heater hoses, clamps, belts,
water pump, thermostat and radiator for condition or proper operation.
• Radiator Shutters - Inspect for correct operation and controls, if equipped.
• Fan and Shroud - Check for proper operation of fan clutch. Check installation of fan and shroud.
• Heater/Water Valve - Check for malfunction or leaking.
• System Ducts and Doors - Check the ducts and doors for proper function.
• Refrigerant Charge - Make sure system is properly charged with the correct amount of refrigerant.
Remark
Some systems use different safety devices in the compressor circuit to protect the compressor. Check the
thermal fuse, low pressure cutout switch, high pressure cutout switch, or trinary pressure switch if
equipped.
Preliminary Steps
The following steps outline the correct procedures necessary to prepare the vehicle and the system for testing and diagnosis:
1. Correctly connect the manifold gauge set to the system. Refer to the connection and purging procedures outlined in this
section.
2. Run the engine with the air conditioning system on for five to ten minutes to stabilize the system.
3. With the engine and the system at normal operating temperature, conduct a Performance Test.
System Performance Test

This test is performed to establish the condition of all components in the system. Observe these conditions during testing:
1. Start engine and operate at 1200 to 1500 RPM.
2. Place fan in front of condenser to simulate normal ram air flow and allow system to stabilize.
3. Place a thermometer in air conditioning vent closest to evaporator.
4. Evaluate the readings obtained from the gauges to see if they match the readings for the ambient temperature.
40-72 SK1026-5N
As preliminary steps to begin checkout of the system, perform the following:
A. Close all windows and doors to the cab.
B. Set air conditioning system at maximum cooling and blower speed operation.
C. Readings on the two manifold gauges should be within normal range, adjust for ambient temperature.
D. Compare evaporator discharge air temperature reading to see if it matches the recommended temperature for the
ambient temperature and gauge readings obtained.
E. Carefully feel the hoses and components on the high side. All should be warm-hot to the touch. Check the inlet and
outlet of receiver-drier for even temperatures, if outlet is cooler than inlet, a restriction is indicated.
WARNING! Use extreme caution when placing hands on high side components and hoses. Under
certain conditions these items can be extremely hot.
F. Feel the hoses and components on the low side. They should be cool to the touch. Check connections near the
expansion valve, inlet side should be warm and cold-cool on the outlet side.
G. If these conditions are met, the system is considered normal. Shut down engine. Remove gauges and install the caps
on the service valves.
Diagnosis of Gauge Readings and System Performance

The following Troubleshooting Chart lists typical malfunctions encountered in air conditioning systems. Indications and or
problems may differ from one system to the next. Read all applicable situations, service procedures, and explanations to gain a
full understanding of the system malfunction. Refer to information listed under “Suggested Corrective Action” for service
procedures.
SK1026-5N 40-73
12
Troubleshooting by Manifold Gauge Set Readings
Possible Causes Suggested Corrective Action
Trouble: Insufficient Cooling
Indications:
• Low side pressure LOW.
Check for leaks by perfoming leak test.
• High side pressure LOW.
• Discharge air is only slightly cool.
1. Charge system.
No leaks found:
2. Performance test system.
1. If a leak is present at a connection, tighten and add

refrigerant as required.
2. If a system component needs to be replaced, recover all
refrigerant from the system. Replace the defective part,
Leaks found: then check the compressor oil level; refill compressor oil
as necessary.
3. Evacuate the system.
4. Charge system with new / recycled refrigerant.
5. Check A/C operation and do system performance test.
Trouble: Little or No Cooling
Indications: 1. Add refrigerant (make sure system has at least 50% of its
• Low side pressure VERY LOW. normal amount) and leak test system.
• High side pressure VERY LOW. 2. It may be necessary to use a jumper wire to enable the
• Discharge air warm compressor to operate, if the compressor has shut down
• No bubbles observed in sight glass, may show oil due to faulty pressure sensing switch.
streaks. 3. If a leak is present at a connection, tighten the
• Pressure sensing switch may have compressor clutch connection, then add refrigerant as required.
disengaged. 4. If a system component needs to be replaced, recover all
• Refrigerant excessively low; leak in system. refrigerant from the system. Replace the defective part,
then check the compressor oil level; refill compressor oil
as necessary.
5. Evacuate system.
Extremely Low Refrigerant Charge in the System
Indications:
• Low side pressure LOW.
• High Side Pressure LOW.
• Air from vents in the cab seems warm. If there is a low
pressure switch in the system, it may have shut off the Check for leaks by performing leak test.
compressor clutch.
Extremely low or no refrigerant in the system. There may be

a leak in the system.
1. Add refrigerant to the system (at least half of the normal

No leaks found: full charge amount).
2. Performance test system.
40-74 SK1026-5N
1. If a leak is present at a connection, tighten the

connection, then add refrigerant as required.
2. It may be necessary to use a jumper wire to enable the
compressor to operate, if the compressor has shut down
due to faulty pressure sensing switch.
3. If a system component needs to be replaced, recover all
Leaks found:
refrigerant from the system. Replace the defective part,
then check the compressor oil level; refill compressor oil
as necessary.
4. Evacuate system.
Air and/or Moisture in the System
Indications: Repair Procedure:

• Gauge Reading - Low Side Normal. Test for leaks, especially around the compressor shaft
• High Side Normal. seal area. When the leak is found, recover refrigerant
• Air and/or Moisture in the System. from the system and repair the leak. Replace the
• Gauge Reading - Low Side Normal. receiver-drier or accumulator because the desiccant
• High Side Normal. maybe saturated with moisture. Check the compressor
and replace any refrigerant oil lost due to leakage.
Cause: Evacuate and recharge the system with refrigerant, then
• Air and/or moisture in the system. check AC operation and performance.
• The air from the vents in the cab is only slightly cool. In
a cycling type system with a thermostatic switch, the
switch may not cycle the clutch on and off, so the low
pressure gauge will not fluctuate.
Excessive Air and/or Moisture in the System

• Gauge Reading- Low Side High. Test for leaks, recover refrigerant from the system and
• High Side High. repair the leak. Depending on the type of system, replace
• Air from the vents in the cab is only slightly cool. the receiver-drier or accumulator. Check and replace any
compressor oil lost due to leakage. Evacuate and
Cause- System contains excessive air and/or moisture. recharge the system, then check AC operation and
performance.
SK1026-5N 40-75
Expansion Valve Stuck or Plugged
Indications: Test:
• Gauge Reading - Low Side Low or Vacuum. Warm diaphragm and valve body with your hand, or very
• High Side High. carefully with a heat gun. Activate system and watch to
• Air from vents in the cab is only slightly cool. see if the low pressure gauge rises.
• The expansion valve body is frosted or sweating.
Next, carefully spray a little nitrogen, or any substance
Cause: below 32° F (0° C), on the capillary coil (bulb) or valve
• An expansion valve malfunction could mean the valve diaphragm. The low side gauge needle should drop and
is stuck in the closed position. read at a lower (suction) pressure on the gauge. This
• The filter screen is clogged (block expansion valves do indicates the valve was part way open and that your
not have filter screens). action closed it. Repeat the test, but first warm the valve
• Moisture in the system has frozen at expansion valve diaphragm or capillary with your hand. If the low side
orifice. gauge drops again, the valve is not stuck.
• Sensing bulb is not operating.
Repair Procedure:
If the sensing bulb is accessible, perform the following test. Inspect the expansion valve screen (except block type
If not then proceed to the Repair Procedure. valves). To do this, remove all refrigerant from system.
Disconnect the inlet hose fitting from the expansion
valve. Remove, clean and replace the screen, then
reconnect the hose. Replace the receiver-drier. Then
evacuate and recharge the system with refrigerant, and
check AC operation and performance. If the expansion
valve tests did not cause the low pressure gauge needle
to rise and drop, and if the other procedure described did
not correct the problem, the expansion valve is defective.
Follow the procedure for component replacement.
Expansion Valve Stuck Open
Indications: Test:
• Gauge Reading- Low Side High. Operate the AC system on it’s coldest setting for a few
• High Side Normal. minutes. Carefully spray a little nitrogen or other cold
• Air from vents in cab is warm or only slightly cool. substance, on the capillary tube coil (bulb) or head of the
valve. The low pressure (suction) side gauge needle
Cause: should now drop on the gauge. This indicates the valve
• Expansion valve is stuck open and/or the capillary tube has closed and is not stuck open. Repeat the test, but
(bulb) is not making proper contact with the evaporator first warm the valve diaphragm by warming with hands.
outlet tube. If the low side gauge shows a drop again, the valve is not
• Liquid refrigerant may be flooding evaporator making it stuck. Clean the surfaces of the evaporator outlet and the
impossible for the refrigerant to vaporize and absorb capillary coil or bulb. Make sure the coil or bulb is
heat normally. securely fastened to the evaporator outlet and covered
• In vehicles where the expansion valve sensing bulb is with insulation material. Operate the system and check
accessible, check the capillary tube for proper mounting performance.
and contact with the evaporator outlet tube.
• Perform the following test if the valve is accessible. If it Repair Procedure:
is not, proceed to the Repair Procedure. If the test did not result in proper operation of expansion
valve, the valve is defective and must be replaced.
Recover all refrigerant from the system and replace the
expansion valve and the receiver-drier. Evacuate and
recharge the system with refrigerant, then check AC
operation and performance.
40-76 SK1026-5N
System High Pressure Side Restriction

• Gauge Reading- Low Side Low. After you locate the defective component containing the
• High Side Normal to High. restriction, recover all of the refrigerant. Replace the
• Air from vents in the cab is only slightly cool. defective component and the receiver-drier. Evacuate
• Look for sweat or frost on high side hoses and tubing, and recharge the system with refrigerant, then check AC
and frost appearing right after the point of restriction. operation and performance.
The hose may be cool to the touch near the restriction.
Cause:
• There could be a kink in a line, or other restriction in the
high side of the system.
Compressor Malfunction

• Gauge Reading- Low Side High. If the belt is worn or loose, replace or tighten it and
• High Side Low. recheck system performance and gauge readings. If
• The compressor may be noisy when it operates. inspection of the compressor is required, all refrigerant
must be recovered and the compressor disassembled to
Cause: the point that inspection can be performed. Replace
• Defective reed valves or other compressor defective components or replace the compressor.
components. If particles of desiccant are found in the compressor,
• If the compressor is not noisy, there may be a worn or flushing system will be required. It will also be necessary
loose compressor clutch drive belt. to replace the receiver-drier. Always check oil level in the
compressor, even if a new unit has been installed. Rotary
compressors have a limited oil reservoir. Extra oil must
be added for all vehicle installations.
Tighten all connections and evacuate the system.
Recharge the air conditioner with refrigerant and check
the system operation and performance.
Condenser Malfunction or System Overcharge

• Gauge Reading- Low Side High. Inspect the condenser for dirt, bugs or other debris and
• High Side High. clean if necessary. Be sure the condenser is securely
• The air from the vents in the cab may be warm. mounted and there is adequate clearance (about 1-1/2
• The high pressure hoses and lines will be very hot. inches {38.1 mm}) between it and the radiator. Check the
• Check the engine cooling system components, fan and radiator pressure cap and cooling system, including the
drive belt, fan clutch operation, and radiator shutter. fan, fan clutch, drive belts and radiator shutter assembly.
Replace any defective parts and then recheck the AC
Cause: system operation, gauge readings and performance. If
• Condenser is not functioning correctly or there may be the problem continues, the system may be overcharged.
an overcharge of refrigerant inside the system. Recover the system refrigerant slowly until low and high
• Another possibility is lack of air flow through condenser pressure gauges read below normal.
fins during testing. Then add refrigerant until pressures are normal. Add
• Engine cooling system component malfunction can another 1/4 to 1/2 pound (0.11 to 0.23 kg) of refrigerant
cause high pressure by blocking air flow and recheck AC system operation, gauge readings and
(radiator shutter) or not providing air flow (fan clutch) in performance. If the gauge readings do not change, all of
sufficient quantity. the refrigerant should be recovered and the system
flushed. The condenser may be partially blocked -
replace condenser. Also replace the receiver-drier or
accumulator. Evacuate the system and check operation
and performance.
SK1026-5N 40-77
Thermostatic Switch Malfunction

• Gauge Reading- Low Side Normal. Replace the thermostatic switch. When removing the old
• High Side Normal. thermostat, replace it with one of the same type. Take
• Low side gauge needle may fluctuate in a very narrow care in removing and handling the thermostat and thin
range compared to a normal range. capillary tube attached to it. Do not kink or break the
• Compressor clutch may be cycling on and off more tube.
frequently than it should. Position new thermostat capillary tube at or close to the
• Low side gauge needle may fluctuate in an above same location and seating depth between the evaporator
normal range as the clutch cycles. This may be an coil fins as the old one. Connect the electrical leads.
indication that the thermostat is set too high.
A new thermostat may have been installed incorrectly.
Cause - The thermostat switch is not functioning properly or

at all.
40-78 SK1026-5N
MEMORANDUM
SK1026-5N 40-79
Preventive Maintenance Schedule for A/C System

Model and Serial Number:
____________________________________________________________________________________________________
Site Unit Number: _____________________________________________________________________________________
Date:_______________________________ Hour Meter:_________________________________________
Last Maintenance Check:________________________________________________________________________________
Name of Service person:_________________________________________________________________________________
Remark
Compressor should be run at least 5 minutes (40° F {4° C}) minimum ambient temperature) every month,
in order to circulate oil and lubricate components.
Maintenance Interval
Component (Months)
3 6 12 Done
Compressor
Check noise level •
Check clutch pulley •
Check oil level •
Run system 5 minutes •
1 Check belt tension: 80 - 100 lbf (356 - 445 N) (11.1 - 13.8 kgf.m) V-belt •
Inspect shaft seal (leakage) •
Check mounting bracket (tighten bolts) •
Check alignment of clutch w/crankshaft pulley (within 0.06 in. {1.5 mm}) •
Perform manifold gauge check •
Verify clutch is engaging •
Condenser
Clean dirt, bugs, leaves, etc. from coils (w/compressed air) •

2
Verify engine fan clutch is engaging (if equipped) •
Check inlet/outlet for obstructions or damage •
Receiver - Drier
3 Check inlet line from condenser (should be hot to touch) •
Replace if system is opened •
Expansion Valve
4 Inspect capillary tube (if used) for leakage, damage, or
•
looseness)
40-80 SK1026-5N
Maintenance Interval
Component (Months)
3 6 12 Done
Evaporator
Clean dirt bugs, leaves, etc. from fins (w/compressed air) •

5
Check solder joints on inlet/outlet tubes for leakage •
Inspect condensate drain •
Other (Components)
Check discharge lines (hot to touch) •
Check suction lines (cold to touch) •
Inspect fittings, clamps, and hoses •

6
Check thermostatic switch for proper operation •
Outlets in cab: 40° F - 50° F (4° C - 10° C) temperature •
Inspect electrical connections •
Operate all manual controls through full function •
SK1026-5N 40-81
MEMORANDUM
40-82 SK1026-5N
50 DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-4

Removal and Installation of Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-4
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-4
Disassembly and Assembly of Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-5
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-5
PRECAUTIONS DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-8
Precautions When During Removal Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-8
Precautions When Performing Installation Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-9
Precautions When Completing the Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-9
Other Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10
CONNECTOR REPAIR PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-11
Stripping Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-11
Wire Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-11
Contact Terminal Removal (HD30 Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-12
Crimping Contact Terminal (HD30 Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-13
Insertion of Contact Terminal (HD30 Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-14
Contact Terminal Removal (DT Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-15
Crimping Contact Terminal (DT Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-16
Insertion of Contact Terminal (DT Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-17
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-19
Engine Front Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-19
Engine Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-19
Engine Rear Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-19
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-19
Engine Assembly - Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-23
Valve Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-25
Nozzle Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-26
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-26
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-29
SK1026-5N 50-1
DISASSEMBLY AND ASSEMBLY TABLE OF CONTENTS
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-32
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-33
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-33
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-34
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-34
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-34
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-35
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-35
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-35
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-36
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-36
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-36
ENGINE HOOD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-37
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-37
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-37
OPERATOR’S CAB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-38
Tilting the Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-38
Lowering the Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40
Removing the Cab Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41
Installing the Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-43
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-44
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-44
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-44
AIR CLEANER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-45
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-45
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-45
MUFFLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-46
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-46
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-47
RADIATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-48
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-48
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-49
FUEL TANK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-51
HYDRAULIC PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-52
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-52
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-54
GEAR PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-55
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-55
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-55
ENGINE-PUMP COUPLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-56
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-56
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-56
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-57
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-57
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-57
50-2 SK1026-5N
DISASSEMBLY AND ASSEMBLY TABLE OF CONTENTS
PPC VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-58

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-58
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-58
CAB HEATER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-61
WHEEL HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-62
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-62
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-63
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-64
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-65
FINAL DRIVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-66
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-66
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-67
CYLINDER ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-68
Lift Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-68
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-68
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-69
Bucket Cylinder Asssembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-71
Disassembly of the Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-72
Assembly of the Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-74
Assembly of the Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-74
Piston Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-75
Piston Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-75
Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-76
WORK EQUIPMENT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-78
Removal of the Complete Work Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-78
Installation of the Complete Work Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80
Removal of the Fulcrum Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-81
Installation of the Fulcrum Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-81
Removal of the Lift Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-82
Installation of the Lift Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-83
Removal of the Work Equipment Support Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-84
Installation of the Work Equipment Support Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-84
SK1026-5N 50-3
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS SECTION
HOW TO READ THIS SECTION

Removal and Installation of Assemblies
Special Tools
• Special tools which are deemed necessary for removal or installation of parts are described as A1,•••X1 etc. and their
part names, part numbers and quantities are described in the special tool list.
• Also the following information is described in the special tool list.
A. Necessity
■: Special tools that cannot be substituted and should always be used (installed).
●: Special tools that will be useful if available and are substitutable with commercially available tools.
B. Distinction of new and existing special tools

N: Tools newly developed for this model. They respectively have a new part number.
R: Tools with upgraded part numbers. They are remodeled from already available tools for other models.
Blank: Tools already available for other models. They can be used without any modification.
C. Circle mark ❍ in sketch column:

The sketch of the special tool is presented in the section of "Sketches of special tools".
This mark means part No. of special tools starting with 79*T-***-**** and that they can not be
supplied from Komatsu in Japan (i.e. locally made parts).
Removal
• The [Removal] section contains procedures and precautions for implementing the work, expertise, and the amount of oil
or coolant to be drained.
• General tools that are necessary for removal are described as [1], [2]•••etc. and their part names, part numbers and
quantities are not described.
• Various symbols used in the Removal Section are explained and listed below.
WARNING! This mark indicates safety-related precautions that must be followed when
implementing the work.
★ : Instructions or precautions for work

[*1] :This mark shows that there are instructions or precautions for installing parts.:
This mark shows the amount of oil or coolant to be drained.
Weight of part or component.
Installation
• Except where otherwise instructed, installation of parts is done in the reverse order of removal.
• Instructions and precautions for installing parts are shown with [*1] mark in the Installation Section, identifying which
step the instructions are intended for.
• General tools that are necessary for installation are described as [1], [2]•••etc. and their part names, part numbers and
• Marks shown in the Installation Section stand for the following.
WARNING! Precautions related to safety in execution of work.
50-4 SK1026-5N
★ :This mark gives guidance or precautions when doing the procedure.
Type of coating material.
Tightening torque.
Quantity of oil or coolant to be added.
Sketches of special tools

• Various special tools are illustrated for the convenience of local manufacture.
Disassembly and Assembly of Assemblies

Special Tools
• Special tools which are deemed necessary for disassembly or assembly of parts are described as A1,•••X1 etc. and their
part names, part numbers and quantities are described in the special tool list.
• Also the following information is described in the special tool list.
A. Necessity
■ : Special tools that cannot be substituted and should always be used (installed).
• : Special tools that will be useful if available and are substitutable with commercially available tools.
B. Distinction of new and existing special tools

N : Tools newly developed for this model. They respectively have a new part number.
R : Tools with upgraded part numbers. They are remodeled from already available tools for other models.
Blank : Tools already available for other models. They can be used without any modification.
C. Circle mark ❍ in sketch column:

• The sketch of the special tool is presented in the section of "Sketches of special tools".
• This mark means part No. of special tools starting with 79*T-***-**** and that they can not be supplied from
Komatsu in Japan (i.e. locally made parts).
Disassembly
• In Disassembly section, the work procedures, precautions and expertise for performing those procedures, and quantity of
the oil and coolant drained are described.
• General tools that are necessary for disassembly are described as [1], [2]•••etc. and their part names, part numbers and
• The meanings of the symbols used in Disassembly section are as follows.
WARNING! This mark indicates safety-related precautions that must be followed when implementing
the work.
★ Instructions or precautions for work
Quantity of oil or coolant drained.
Assembly
• In Assembly section, the work procedures, precautions and expertise for performing those procedures, and quantity of the
oil and coolant added are described.
• General tools that are necessary for assembly are described as [1], [2]•••etc. and their part names, part numbers and
SK1026-5N 50-5
• The meanings of the symbols used in Assembly section are as follows.
WARNING! Precautions related to safety in execution of work.
★ : This mark gives guidance or precautions when doing the procedure.
Type of coating material.
Tightening torque.
Quantity of oil or coolant to be added.
Sketches of special tools

• Various special tools are illustrated for the convenience of local manufacture.
50-6 SK1026-5N
MEMORANDUM
SK1026-5N 50-7
DISASSEMBLY AND ASSEMBLY PRECAUTIONS DURING OPERATION
PRECAUTIONS DURING OPERATION

★ Be sure to follow the general precautions given below when performing removal or installation (disassembly or assembly)
of units.
Precautions When During Removal Work

• If the coolant contains antifreeze, dispose of it correctly.
• After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
• When draining oil, prepare a container of adequate size to catch the oil.
• Confirm the match marks showing the installation position, and make match marks in the necessary places before removal
to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting them.
• Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
• Check the number and thickness of the shims, and keep in a safe place.
• When raising components, be sure to use lifting equipment of ample strength.
• When using forcing screws to remove any components, tighten the forcing screws alternately.
• Before removing any unit, always clean the surrounding area and fit a cover to prevent any dust or dirt from entering after
removal.
• Precautions when handling piping during disassembling
★ Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1. Hoses and tubes using sleeve nuts
Nominal Plug (nut end) Sleeve nut (elbow end) Use the two items below as a set
number
02 07376-50210 07221-20210 (Nut), 07222-00210 (Plug)
03 07376-50315 07221-20315 (Nut), 07222-00312 (Plug)
04 07376-50422 07221-20422 (Nut), 07222-00414 (Plug)
05 07376-50522 07221-20522 (Nut), 07222-00515 (Plug)
06 07376-50628 07221-20628 (Nut), 07222-00616 (Plug)
10 07376-51034 07221-21034 (Nut), 07222-01018 (Plug)
12 07376-51234 07221-21234 (Nut), 07222-01219 (Plug)
2. Split flange type hoses and tubes

Nominal Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3. If the part is not under hydraulic pressure, the following corks can be used:
Dimensions
Nominal number Part Number
D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
50-8 SK1026-5N
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
Precautions When Performing Installation Work

• Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
• Install the hoses without twisting or interference.
• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pin or lock plate securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with two or three
drops of adhesive.
• When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage,
then coat uniformly with gasket sealant.
• Clean all parts, and correct any damage, dents, burrs, or rust.
• Coat rotating parts and sliding parts with engine oil.
• When press-fitting parts, coat the surface with anti-friction compound (LM-P).
• After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
• When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely.
• When using eye bolts, check that there is no deformation or deterioration, screw them fully, and align the direction of
the hook.
• When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
Precautions When Completing the Operations

• If the coolant has been drained, tighten the drain valve, and add coolant to the specified level. Run the engine to circulate
the coolant through the system. Then check the coolant level again.
• If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to
circulate the oil through the system. Then check the oil level again.
• If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been removed for repair, bleed
air from the system after reassembling the parts.
★ For details, see “BLEEDING HYDRAULIC CIRCUITS” on page 30-31.
• Add the specified amount of grease (molybdenum disulfide grease) to the work equipment related parts.
SK1026-5N 50-9
Other Precautions
• To maintain performance of the machine and to prevent failures, it is particularly important to pay attention to the degree
of cleanliness of oil in the hydraulic circuits. When adding or changing the oil, or when replacing the filters, check that the
oil container and area around the filler of the hydraulic tank are clean.
• To keep the hydraulic circuits clean and to protect hydraulic equipment, be careful of the following when disassembling or
assembling:
★ Before disassembling, wash the machine. Be particularly careful to completely clean the area that is to be
disassembled.
★ Do not let dirt or dust get into the hydraulic circuits when disassembling or assembling.
★ Perform thorough flushing of the parts, and be particularly careful to do this thoroughly for the circuits or parts that
have failed.
★ When disassembling or after flushing, always mask the openings of the piping or hydraulic equipment completely.
★ Do not use seal tape for the thread of plug mounts or connections.
• If any internal part of the hydraulic equipment breaks, disassemble and clean all the hydraulic equipment and circuits to
remove any dirt or pieces from the circuit. If any parts of the hydraulic circuits are disassembled and assembled, always
thoroughly flush the hydraulic circuits.
• When changing oil in the hydraulic tank, or when removing the piston pump or piston pump piping, always bleed the air
before starting the engine to prevent seizure of the pump. For details, see “Bleeding Air From the Pump” on page 30-31.
Remark
After replacing or flushing the hydraulic tank oil, filter element, or strainer, or when removing and installing
any hydraulic cylinder, hydraulic pump or any other hydraulic equipment or work equipment piping, always
bleed the air as follows after completion of installation.
1. Run the engine at low idling, and extend and retract the steering, bucket, and lift arm cylinders 4 - 5 times without going
to the end of this stroke. (Stop approximate 100 mm (4 in.) before the end of the stroke.)
★ If the engine is run at high speed from the start, or the cylinders are operated to the end of its stroke, the air inside the
cylinder will cause damage to the piston packing.
2. Operate the steering, bucket, and lift arm cylinders 3 - 4 times to the end of the stroke, then stop the engine and bleed
the air from the plugs at the top of the hydraulic tank filter.
3. Raise the engine speed and repeat Step B to bleed the air. Repeat this procedure until no more air comes out from the
plugs.
4. After completing bleeding the air, tighten the plugs.
Plug: 11.3 ±1.5 N·m (100 ±13 lbf in)
5. After repair or long storage, follow the same procedure.
50-10 SK1026-5N
DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES
CONNECTOR REPAIR PROCEDURES

These steps outline the proper repair procedures for the HD30 and DT type wire connectors. Failure to follow these procedures
may result in a failed contact situation in the electrical circuit or damage to the connector or wiring harness.
Stripping Insulation
After obtaining the proper terminal size for the wire gauge you will be using in the connector repair, remove all damaged or
corroded sections of the wire being repaired referring to the table below.
Deutsch Terminal Part Number Wire Gauge Range Strip Length: mm (in)
0460 - 202 - 20141 20 AWG 3.96 - 5.53 (0.156 - 0.218)

0462 - 201 - 20141 20 AWG 3.96 - 5.53 (0.156 - 0.218)
0460 - 202 - 16141 16, 18 and 20 AWG 6.35 - 7.92 (0.250 - 0.312)
0462 - 201 - 16141 16, 18 and 20 AWG 6.35 - 7.92 (0.250 - 0.312)
0460 - 215 - 16141 14 AWG 6.35 - 7.92 (0.250 - 0.312)

0462 - 209 - 16141 14 AWG 6.35 - 7.92 (0.250 - 0.312)
0460 - 204 - 12141 12 and 14 AWG 5.64 - 7.21 (0.222 - 0.284)

0462 - 203 - 12141 12 and 14 AWG 5.64 - 7.21 (0.222 - 0.284)
0460 - 204 - 08141 8 and 10 AWG 10.92 - 12.47 (0.430 - 0.492)

0462 - 203 - 08141 8 and 10 AWG 10.92 - 12.47 (0.430 - 0.492)
0460 - 204 - 0490 6 AWG 10.92 - 12.47 (0.430 - 0.492)

0462 - 203 - 04141 6 AWG 10.92 - 12.47 (0.430 - 0.492)
Using wire insulation strippers, remove only the measured amount of

insulation from the wire according to the size contact terminal listed in
the "Strip Length" above.
Wire Inspection
After stripping insulation from wire, inspect wire strands for:
• Corrosion, straightness and uniformity
• Broken or nicked wire strands are unexcitable and may cause high
resistance in the circuit.
• Do not twist or wrap the wire strands as this may cause wire strand
breakage during the crimping process.
SK1026-5N 50-11
Contact Terminal Removal (HD30 Type)

1. Obtain the correct removal tool according to the wire size used in
the connector.
2. With the rear insert part of the connector facing you, snap the
removal tool over the wire of the contact terminal you will be
removing.
Remark
Using a removal tool that is too large or too small will hinder
wire removal and may damage the connector or removal
tool. Always use the correct removal tool size for the wire
gauge you are servicing.
3. In a straight line, carefully slide the removal tool along the wire and
into the grommet until a contact resistance is felt.
Remark
Do not pull on the wire or twist the tool when inserting
removal tool into the grommet. Damage to tool or connector
may result.
4. Once tool is fully inserted into the connector, carefully pull the
removal tool and contact terminal-wire out of the connector.
5. If contact terminal-wire will not come out, remove tool and reinsert
removal tool again.
50-12 SK1026-5N
Crimping Contact Terminal (HD30 Type)

1. After insulation has been stripped from wire and contact terminal is
ready for crimping, raise selector knob on Crimp Tool #HDT48-00
and rotate until arrow is aligned with wire size to be crimped.
2. Loosen locknut, turn adjusting screw in until it stops.
3. Insert contact terminal with barrel up. Turn the adjusting screw
counterclockwise until contact terminal surface is flush with
indenter cover. Tighten locknut.
4. Insert wire into contact terminal. Be sure the contact terminal is

centered between indicators.
5. Close crimp tool handle until crimp cycle is completed.
6. Release the tool handle and remove the crimped contact terminal.
7. Using the inspection hole in the contact terminal inspect the

crimped contact terminal to ensure that all strands are in the
crimped barrel.
Remark
The tool must be readjusted for each type/size of contact. Use
Crimp tool HDT04-08 for size 8 and 4 contacts.
SK1026-5N 50-13
Insertion of Contact Terminal (HD30 Type)

1. Grasp contact terminal approximately 25.2 mm (1 in) behind the
crimped barrel.
2. Hold connector with rear grommet facing you.

3. Insert completed contact terminal straight into connector grommet
until a positive stop is felt.
4. Once contact terminal is in connector, a slight tug will confirm that

the contact terminal is properly locked in place.
5. For unused wire cavities, insert sealing plugs for full environmental
sealing.
50-14 SK1026-5N
Contact Terminal Removal (DT Type)

1. Remove wedge lock using needle nose pliers or a hooked shaped
wire.
2. Pull the wedge lock straight out and save for reinstallation.
3. To remove the contact terminal gently pull the wire backwards

while at the same time releasing the locking finger by pushing it
away from the terminal with a small screwdriver.
4. Hold the rear seal grommet in place and pull the contact terminal
out of the connector.
SK1026-5N 50-15
Crimping Contact Terminal (DT Type)

1. After the insulation has been stripped from the wire and contact
terminal is ready for crimping, raise selector knob on Crimp Tool
#HDT48-00 and rotate until arrow is aligned with wire size to be
crimped.
2. Loosen locknut, turn adjusting screw in until it stops.
3. Insert the contact terminal with barrel up. Turn adjusting screw
counterclockwise until contact terminal surface is flush with
indenter cover. Tighten locknut.
4. Insert wire into contact terminal. Be sure the contact terminal is

centered between indicators.
5. Close crimp tool handle until crimp cycle is completed.
6. Release the tool handle and remove the crimped contact terminal.
7. Using the inspection hole in the contact terminal inspect the

crimped contact terminal to ensure that all strands are in the
crimped barrel.
Remark
The tool must be readjusted for each type/size of contact. Use
Crimp tool HDT04-08 for size 8 and 4 contacts.
50-16 SK1026-5N
Insertion of Contact Terminal (DT Type)

1. Grasp the crimped contact terminal approximately 25.2mm (1 in)
behind the crimped barrel.
2. Hold the connector with the rear grommet facing you and insert the
completed wire into the connector.
3. Push the contact terminal straight into the connector until a "click"
is felt. A slight tug will confirm that the contact terminal is properly
locked in place.
4. Once all contact terminals are in place, insert the wedge lock with
the arrow pointing toward exterior locking mechanism. The wedge
lock will snap into place. Rectangular wedges are not oriented and
may fit either way.
Remark
As the connector receptacle is shown - use the same
procedures for a plug.
SK1026-5N 50-17
MEMORANDUM
50-18 SK1026-5N
DISASSEMBLY AND ASSEMBLY ENGINE
ENGINE
Remark
For disassembly and assembly of the following components, see the ENGINE SHOP MANUAL.
Engine Front Seal

Engine Oil Cooler
Engine Rear Seal
Thermostat
SK1026-5N 50-19
Engine Assembly - Complete

Remark
For disassembly and assembly of the engine assembly, see the ENGINE SHOP MANUAL.
Removal
1. Tilt the cab until it is resting on a support.
(For details, see “Tilting the Cab” on page 30-38). [*1]
2. Remove the battery. (For details, see “BATTERY” on page 30-44).

3. Drain the engine coolant, hydraulic oil, and fuel.
Engine Coolant: max. 15 liters (4 gal)

Hydraulic Oil: max. 50 liters (13 gal)
Diesel Fuel: max. 72 liters (20 gal)
4. Remove the radiator assembly.

(For details, see “RADIATOR ASSEMBLY” on page 30-48). [*2]
5. Remove the cover on control unit (1), loosen nuts (2) and
disconnect control unit (3) from the frame.
6. Disconnect connectors X10 (4), X01 (5), X42 (6) and X02 (7) that
connect control unit (1) to the engine and frame wiring harness.
7. Loosen fastener (8) and remove the pre-heater fuse (9).
50-20 SK1026-5N
8. Disconnect fuel level sensor (11) and connector (10).
With Heating System

9. Loosen fastener (12) and remove clamp (13).
10. Remove clamps (14).
11. Disconnect the heating system supply (15) and return (16) hoses
from the engine and drain any engine coolant from the hoses.
★ Mark the lines to avoid mixing them up during reassembly.
12. Remove clamp (17), disconnect line (19) and connector (20) from
tank (18).
SK1026-5N 50-21
13. Disconnect throttle cable (22) from engine (21).
14. Disconnect the sensor connector on the accelerator cable support.
15. Disconnect delivery (25) and return (26) lines from container (23)
and filter (24).
16. Disconnect lines (28), (29) and (30) from pump (27).
17. Disconnect pipes (31), (32), (33) and (34) from the pump.
50-22 SK1026-5N
18. Attach a hoist and tackle to the engine assembly and apply slight
tension to the cables.
19. Loosen the four nuts (35) that secure the engine and remove the
complete assembly. [*3]
Engine Assembly: 335 kg (739 lb)
Installation
• To install, reverse removal procedure. [*1]
1. Adjust the accelerator cables.
(For details, see “Adjusting the Stroke of the Accelerator Cables” on page 30-13)
2. Fill the hydraulic oil tank up to maximum level. [*2]
3. While filling the tank, bleed the air from the pump.
(For details, see “Bleeding Air From the Pump” on page 30-31).
Hydraulic oil: approx. 32 liters (8.5 gal)
4. Fill the cooling system up to maximum level.
Coolant liquid: approx. 15 liters (4 gal)
5. Fill the fuel tank and bleed the air from the system.
(For details, see “Bleeding Air From Fuel System” on page 30-4).
6. Start the engine to circulate the oil and coolant and check for leaks.
7. Stop the engine, check the levels and, if necessary, top them off.
8. Bleed the air from the hydraulic circuits and pressurize the tank.
(For details, see “BLEEDING HYDRAULIC CIRCUITS” on page 30-31).
[*3]
Engine nuts: 80 N·m (60 lbf ft)
SK1026-5N 50-23
Valve Cover
Removal
WARNING! Disconnect the negative terminal cable (-)
from the battery.
1. Remove the air filter (1).

(For detail see “AIR CLEANER ASSEMBLY” on page 30-45).
2. Loosen the screws (2) and remove the clamp (3).

3. Remove the screw (4) that secure the level oil rod (5).
4. Loosen the screws (6) that secure the support (7) and remove it.
With heating system

5. Remove the clamp (9) screw (8) and move the pipes.
6. Remove the high-pressure pipes (10).[*1]
50-24 SK1026-5N
7. Loosen two screws (11), remove the four centering bushings (12)
and valve cover (13). [*2]
Installation
• To install, reverse the removal procedure.
[*1]
High-pressure pipe union: 19.6 - 24.5 N•m (15 - 18 lbf ft)
[*2]
★ Check the condition of cover gasket and if necessary replace it.
SK1026-5N 50-25
Nozzle Holder
Remark
For disassembly and assembly of the nozzle holder, see the ENGINE SHOP MANUAL.
Removal
(For detail see “AIR CLEANER ASSEMBLY” on page 30-45).
2. Remove the valve cover (1).
(For detail see “Valve Cover” on page 30-24).
3. Loosen the five screws (1) and remove the fuel pipe (2). [*1]
★ Take care to not damage the five gaskets (3).
4. Loosen the screws (4) and remove the four bracket (5). [*2]
5. Remove the nozzle (6).
Installation
To install, reverse the removal procedure.
[*1]
Screw (1): 7.8 - 9.8 N•m (67 - 87 lbf in)
[*2]
Screws (4): 22.6 - 28.4 N•m (200 - 251 lbf in) {17 - 21 lbf ft}
50-26 SK1026-5N
Fuel Injection Pump

Remark
For disassembly and assembly of the fuel injection pump, see the ENGINE SHOP MANUAL.
Removal
WARNING! Disconnect the negative terminal cable
(-) from the battery. Close the cock of the
water separator to prevent fuel leakage.
1. Remove radiator group.

(For details, see “RADIATOR ASSEMBLY” on page 30-48).
2. Disconnect connector (1) and accelerator cable (2). [*1]

(For details, see “AIR CLEANER ASSEMBLY” on page 30-45).
4. Disconnect from injection pump (4) fuel feeding pipes (5), return
pipes (6), feedback pipe (7) and the coolant pipes (8) and (9).
5. Disconnect high pressure pipes (10) from injection pump (4). [*2]
6. Disconnect injection pump (4) lubricating pipe (11).
SK1026-5N 50-27
7. Remove fan (12) and cover (13). [*3]
8. Loosen and remove nut (14) and lock washer (15) of pump driving
gear. [*4]
★ Be careful not let nut (14) and lock washer drop in the housing.
9. Remove pump (4) driving gear (15).

★ Before removing pump driving gear, mark position compared
to idling gear.
★ For removal, use a puller (X1) and tighten its screws (X2)
directly in the gear (15).
★ During removal be careful not let key drop (16) in the housing.
10. Loosen nuts (17) (No. 3). [*5]
50-28 SK1026-5N
11. Loosen screws (18) (No. 3) and remove injection pump (4) with
O-rings (19). [*6]
Installation
★ Check accelerator stroke lever. (For details, see “Adjusting the Stroke of the Accelerator Cables” on page 30-13).
[*1]
[*2]
High pressure pipe: 19.6 - 24.5 N•m (15 - 18 lbf ft)
[*3]
Cover surface: liquid gasket
Screw: 22.6 - 28.4N•m (17 - 21 lbf ft)
★ Align marks among gears before to install pump and nut. [*4]
Nut: 113 - 123 N•m (83 - 91 lbf ft)
★ Check fuel injection timing. [*5]

(For details, see “Control and Adjustment of the Injection Timing” on page 30-10).
[*6]
Screw: 22.6 - 28.4N•m (17 - 21 lbf ft)
SK1026-5N 50-29
Cylinder Head
Remark
For disassembly and assembly of the cylinder head, see the ENGINE SHOP MANUAL.
Removal
(-) from the battery.
★ Drain the engine coolant. [*1]
Coolant: Maximum 15 liters (4 U.S. gal)
1. Remove the water pump.

(For details, see “Water Pump” on page 30-33ª).
2. Remove the air filter (1) and the bracket (2).

(For details, see “AIR CLEANER ASSEMBLY” on page 30-45).
3. Remove the muffler (2).
(For details, see “MUFFLER ASSEMBLY” on page 30-46).
4. Loosen the screws (4) and remove the complete filter (5).
5. Remove the valve cover (6).
6. Remove the nozzle (7). [*2]
7. Disconnect the pre-heater cable (8).
50-30 SK1026-5N
8. Remove the rocker-arm shaft (8).[*2]
★ Loosen the lock nuts and unscrew the valve tappets by 2-3
turns. [*3]
9. Take out the rocker-arm control rods (9).
10. Take out the screws (10) in the sequence indicated and remove the
complete cylinder head (11).[*4]
★ The cylinder head gasket (12) must be substituted every time it
is dismantled.
SK1026-5N 50-31
Installation
[*1]
1. Fill up the cooling circuit.
Coolant: approx. 15 liters (4 U.S. gal)
2. Start the engine to circulate the liquid through all circuits. Stop the engine and check the level.
3. Pressurize the hydraulic tank and bleed air from the hydraulic circuits.
[*2]
Second step:
Screw: 22.6 - 28.4 N•m (17 - 21 lbf ft)
[*3]
★ Adjust valve clearance. (For details, see “Adjustment of Valve Clearance” on page 30-6).
[*4]
★ Raise the cylinder head, keeping it horizontal, and place it on the
gasket without shifting anything.
★ Lubricate the screw-threads with engine oil.
★ Tighten screws in two steps in the sequence given. (See illustration
on the right).
First step:
Screw: 49.0 - 58.8 N•m (36 - 43 lbf ft)
Second step:
Screw: 103.1 - 112.9 N•m (76 - 83 lbf ft)
50-32 SK1026-5N
Water Pump
Remark
For disassembly and assembly of the cylinder head, see the ENGINE SHOP MANUAL.
Removal
(-) from the battery.
★ Drain the engine coolant. [*1]
Coolant: Maximum 15 liters (4 U.S. gal)
1. Remove the radiator (1).

(For details, see “RADIATOR ASSEMBLY” on page 30-48).
2. Loosen screws (2), remove fan (3) and spacer (4).

Loosen the alternator drive belt and disengage the circulation pump
pulley. [*2]
3. Loosen screws (5) and remove the complete pump (6) and gasket
(7). [*3]
Installation
• To install, reverse removal procedure.
[*1]
1. Fill up the coolant circuit.
2. Start the engine and idle for a few minutes; re-check the coolant
level again and add coolant if necessary before replacing radiator
cap.
[*2]
★ Adjust the belt tension. (For details, see “Control and Adjustment of the Fan Belt Tension” on page 30-9).
Fan screws: 22.6 - 28.4 N•m (17 - 21 lbf ft)
[*3]
★ A new gasket (7) must be fitted each time the pump is removed.
Pump screws: 22.6 - 28.4 N•m (17 - 21 lbf ft)
SK1026-5N 50-33
Starter Motor
Remark
For disassembly and assembly of the starter motor, see the ENGINE SHOP MANUAL.
Removal
1. Tilt the cab and secure it in its safety position. (For details, see
“Tilting the Cab” on page 30-38.)
2. Remove battery (1). (For details, see “BATTERY” on page 30-44).
3. Disconnect all cables (2) and (3).
Remark
Do not allow the starter motor to hang from the cables,
damage to the cables may result.
4. Loosen the bolts (4) and remove the starting motor (5).
Installation
50-34 SK1026-5N
Turbocharger
Remark
For disassembly and assembly of the turbocharger, see the ENGINE SHOP MANUAL.
Removal
1. Remove the muffler.
(For details see “MUFFLER ASSEMBLY” on page 30-46).
2. Loosen clamps (1), (2) and disconnect intake hose (4) and supply
hose (5) from turbocharger (3).
3. Loosen fitting (6) and disconnect upper lubrication pipe (7) from
turbocharger (3).
★ Seals (8) must be replaced at each disassembly.
4. Loosen clamp (9) and remove the lower lubrication pipe (10).
5. Loosen nuts (11) and remove the turbocharger (3).

★ Seal (12) must be replaced at each disassembly.
Installation
SK1026-5N 50-35
Alternator
Remark
For disassembly and assembly of the alternator, see the ENGINE SHOP MANUAL.
Removal
1. Tilt the cab and secure it in its safety position. (For details, see
“Tilting the Cab” on page 30-38.)
2. Remove battery (1). (For details, see “BATTERY” on page 30-44).
3. Disconnect the cable (1) and (2), then connectors (3).
4. Loosen fasteners (4) and (5) to allow the alternator to move freely.
5. Remove fan belt (6) from the pulley and remove the alternator (7).
Installation
• Adjust the tension of the fan-belt. (For details, see “Control and Adjustment of the Fan Belt Tension” on page 30-9).
50-36 SK1026-5N
DISASSEMBLY AND ASSEMBLY ENGINE HOOD ASSEMBLY
ENGINE HOOD ASSEMBLY

Removal
WARNING! Before proceeding with any removal or disassembly procedures, be sure all work
equipment is on the ground and there controls neutralized. Be sure the parking brake is
set and the machine is on a flat level surface. Be sure the engine is in the OFF position
and the battery negative (-) terminal is disconnected.
1. Remove the retaining fasteners (1) from hinges (2) and (3).
2. While lifting the hood, remove the retaining nut (4) from the shock
strut (5). [*1]
Engine hood: 18.5 kg (41 lbs)
Installation
1. To install, reverse removal procedure. [*1]
2. Check and centre the lock engagement.
SK1026-5N 50-37
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB ASSEMBLY
OPERATOR’S CAB ASSEMBLY

Tilting the Cab
1. Completely raise the work equipment and secure them in their
safety positions.
2. Loosen the four fasteners (1) and remove the foot-rest (2).
Remark
Only if the engine or the complete pump are to be
removed, remove the engine hood. For removal details
see “ENGINE HOOD ASSEMBLY” on page 30-37.
With Front Door

3. Loosen fasteners (3), remove bracket (4) and close the front door.
4. Loosen the fasteners (5) (two to each side) and raise the cab as far
as the safety cables allow. [*1]
5. Insert the safety pin
★ If the engine or pump are to be removed, proceed as follows:

• Disconnect the four lines (6) on the RH side, two servo-control
supply-lines (7), and four lines (8) on the LH side.
• To disconnect the lines, remove retainer (9), completely push
line (6) inside union (10) and extract the line (6).
• Mark the lines to avoid mixing them up during reassembly.
[*2]
50-38 SK1026-5N
6. Disconnect cable (12) from the accelerator lever and from the
engine (11).
With Heating System

7. Drain engine coolant from the system and disconnect the washer
hose from the washer tank.
8. Loosen the fastener (13) and remove clamp (14).
9. Remove the clamps (15).
10. Disconnect the heating system supply (16) and return (17) hoses
from the engine.
• Mark the lines to avoid exchanging them during reassembly.
11. Attach the cab (18) to a hoist. Be sure the hook and straps are in
place
SK1026-5N 50-39
12. Remove pin (19) and the washers (20).
13. Remove the safety pin.
14. Push cab (18) gently towards ”its at rest” position to relieve tension
on the safety cables (21), and disconnect them from the pins (22).
WARNING! Apply a slight tension to the hoist-tackle

chains to prevent the cab from moving
unexpectedly.
15. Tilt the cab (18) slowly until the distance between the centers of the
hooks (23) is 1100 mm (43 in).
★ The distance of 1100 mm (43 in) corresponds to the maximum
stretch of the dumper hooks.
16. Remove pins (22) from the dumper hooks (23).
17. Position a stand “A”, about 1200 mm (48 in) high, and tilt the cab
(18) until it is resting on the stand.
★ Make sure that the connecting cables between the cab and the
engine are not being strained.
Lowering the Cab

• To lower the cab back into position, reverse the procedures.
[*1]
Fasteners: 98 ±7.3 N•m (72 ±5 lbf ft)
• Connect all the fluid lines.

• Check to be sure all connections are correct.
★ Adjust the stroke of the accelerator lever cable. (For details,
see “Adjusting the Stroke of the Accelerator Cables” on page 30-13).
[*2]
• Fill the cooling system.
• Start the engine to circulate the coolant. Stop the engine and check the level.
50-40 SK1026-5N
Removing the Cab Assembly

1. Remove the work equipment. (For details, see “WORK EQUIP-
MENT SYSTEM” on page 30-78).
2. Loosen four nuts (1) and tilt the rear panel (2) towards the front of
the machine.
3. Disconnect connectors (3) from the cab cabling (4) and release the
engine cable (5) from its retaining clamps.
4. Tilt the cab. (For details, see“Tilting the Cab” on page 30-38).
5. Disconnect the four lines (6) on the RH side, the two servo-control
feed-lines (7) and the four lines (8) on the LH side.
★ To disconnect the lines, remove the retainer (9) push line (6)
completely inside the union (10) and extract line (6).
★ Mark all hoses to avoid any mix-up during reassembly. [*1]
6. Pull out the cab cable (5).
SK1026-5N 50-41
With Front Door
7. Loosen fastener (11) and remove clamp (12).
8. Remove clamps (13) that secure the lines.
9. Disconnect the heating systems supply (14) and return (15) hoses
★ Mark the hoses to avoid mixing them during installation.
10. Remove clamp (16) and disconnect the line (18) from washer tank
(17).
11. Disconnect the accelerator lever cable (20) from the engine (19).
[*2]
50-42 SK1026-5N
12. Connect the cab (21) to hoist and tackle.
13. Remove the safety pins (22) and the washers (23).
14. Push the cab slightly towards its “at rest” position to relieve the
strain on the safety cables (24), and disconnect the cables from the
pins (25).
WARNING! Apply a slight tension to the hoist-tackle

chains to prevent the cab from moving
unexpectedly.
15. Tilt the cab (21) slowly until the distance between the centres of the
hooks is 1100 mm (43 in)
★ The distance of 1100 mm (43 in) corresponds to the maximum
stretch of the hooks.
16. Remove the pins (25) from the hooks (26).
17. Loosen nuts (27) and remove the fasteners (28) and washers (29).
18. Remove the complete cab assembly (21).
Installing the Cab

1. To install, reverse removal procedure.
• Install nuts (9) on the hoses and connect the pipes by
pushing them fully into their seats. [*1]
• Check the connections.
2. Adjust the accelerator lever cable. (For details, see “Adjusting the
Stroke of the Accelerator Cables” on page 30-13). [*2]
3. Fill up the cooling system.
• Start the engine to circulate the coolant and check for leaks.
• Stop the engine, check the levels and, if necessary, top them off.
SK1026-5N 50-43
DISASSEMBLY AND ASSEMBLY BATTERY
BATTERY
WARNING! When handling batteries always wear
personal protective equipment including
face shield, rubber gloves and apron.
Never allow an open flame or smoke
around batteries, explosive gasses may
be present.
Removal
1. Loosen screws (1) and remove cover (2).
2. Disconnect the negative cable (-) (3) first and the positive cable (+)
(4) next from the battery (5) in that sequence.
3. Loosen the nuts (6) that secure battery clamp (7) and remove the tie
rods (8) of the battery support.
★ Disconnect battery clamp (7)
4. Tilt battery clamp (7) towards the front of the machine and lift out
and remove the battery (5).
Installation
• To replace, reverse removal procedure.
50-44 SK1026-5N
DISASSEMBLY AND ASSEMBLY AIR CLEANER ASSEMBLY
AIR CLEANER ASSEMBLY

Removal
WARNING! Disconnect the battery’s negative end cable (–).
1. Loosen the clamp (1) and remove the suction elbow (2).
2. Disconnect the connector (3).
3. Loosen the clamps (4) and remove the manifold (5).

4. Loosen the screws (6) and remove the complete air filter (7).
Installation
SK1026-5N 50-45
DISASSEMBLY AND ASSEMBLY MUFFLER ASSEMBLY
MUFFLER ASSEMBLY
Removal
1. Loosen clamp (1) and remove inlet hose (2).
2. Remove heat shield (3) and remove fasteners (4).

3. Remove fasteners (5) and shield (6).
4. Loosen and remove bolt (7) that secures muffler (8).
5. Remove four nuts (9) that secure muffler (8) to turbocharger (10).
50-46 SK1026-5N
DISASSEMBLY AND ASSEMBLY MUFFLER ASSEMBLY
6. Remove muffler (8).
★ A new gasket (11) should be installed each time the muffler is
removed.
Installation
SK1026-5N 50-47
DISASSEMBLY AND ASSEMBLY RADIATOR ASSEMBLY
RADIATOR ASSEMBLY
Removal
1. Completely raise the working equipment and tilt the cab. (For
details, see “Tilting the Cab” on page 30-38). [*1]
2. Drain the hydraulic oil.
Hydraulic oil: max. 32 liters (8.5 gal)
3. Drain the coolant:
Coolant: max. 15 liters (4 gal)
4. Disconnect hose (2) from the pump (1).

5. Open the coolant drainage cock (3) on the radiator.
6. Disconnect the wire (4) from the hydraulic-oil filter.

7. Loosen the clamp (5) and disconnect the coolant delivery line (6).
8. Disconnect the coolant return line (7). [*2]
9. Attach the radiator group (8) to hoist and tackle and apply a slight
tension to the cables.
10. Loosen the fasteners (9) and raise the radiator group (8) until the
lower supports are free.
11. Move assembly way away from the frame.

12. Disconnect the back-up alarm connector (10).
13. Disconnect the lines (11) and (12) and remove the complete
assembly (8).
50-48 SK1026-5N
DISASSEMBLY AND ASSEMBLY RADIATOR ASSEMBLY
Installation
[*1]
★ To install, reverse removal procedure.
1. Fill the hydraulic oil to maximum level.
Hydraulic oil: approx. 32 liters (8.5 gal)
2. Fill the coolant to maximum level.
Coolant: approx. 15 liters (4 gal)
3. Start the engine to circulate the oil and coolant, and check for leaks.
[*2]
4. Stop the engine, check the levels and, if necessary, top them off.
Fasteners: 190 N•m (80 lbf ft)
5. Pressurizes the tank and bleed the air from all circuits.
SK1026-5N 50-49
DISASSEMBLY AND ASSEMBLY FUEL TANK ASSEMBLY
FUEL TANK ASSEMBLY

Removal
★ Drain the fuel.
Fuel: max 72 liters (20 gal)
1. Remove fasteners (1) and loosen the fastener (2), leaving them in
place.
2. Loosen fastener (3) and remove the support (4).
With Front Door

3. Remove the washer tank (5).
4. Disconnect the return (7) line from filter (6) and the delivery line
(9) from bottle (8).
5. Loosen fastener (10) that secure the front bracket
50-50 SK1026-5N
DISASSEMBLY AND ASSEMBLY FUEL TANK ASSEMBLY
6. Loosen fastener (12) that secure the rear bracket (13).
7. Disconnect wire connector (14) from the level sensor.
8. Raise the tank (15) and move it towards the front of the machine.
Installation
SK1026-5N 50-51
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP ASSEMBLY
HYDRAULIC PUMP ASSEMBLY

Removal
WARNING! Fully raise the work equipment and tilt the cab. (For details, see “Tilting the Cab” on page
30-38).
★ Drain the hydraulic oil.
1. Disconnect pipes (2), (3) and (4) from pump (1).

★ Mark all lines to avoid mixing them up during reassembly.
2. Disconnect lines (5), (6), (7), and (8) from the pump.
3. Disconnect the servo-control pressure sensor connectors (9) and

disconnect support (10) from the engine (11).
50-52 SK1026-5N
4. Attach the pump (1) to a hoist tackle and apply a slight tension to
the cables.
5. Loosen the eight fasteners (12) and remove the pump (1) complete
with bell housing (13). [*1]
Pump: 98 kg (216 lb)
6. Loosen fastener (14) and disconnect pump (1) from bell housing
(13). [*2]
SK1026-5N 50-53
Installation
[*1]
Flange screws: 80 N•m (59 lbf ft)
Flange screws: Loctite 262
Pump shaft: Litio EP MS2 NLGI2
[*2]
Pump screws: 195 N•m (144 lbf ft)
Pump screws: Loctite 262
1. Fill the tank up to maximum level.
2. Bleed the air from the pump. (For details, see “Bleeding Air From the Pump” on page 30-31).
3. Fill the coolant to maximum level.
4. Start the engine to circulate the oil and check that there are no leaks.
5. Stop the engine, check the levels and, if necessary, top them up.
6. Bleed the air from the hydraulic circuits and pressurizes the tank. (For details, see “Bleeding Air From the Cylinders” on
page 30-31 and “Bleeding Air From Optional Equipment” on page 30-31).
50-54 SK1026-5N
DISASSEMBLY AND ASSEMBLY GEAR PUMP ASSEMBLY
GEAR PUMP ASSEMBLY

Removal
1. Fully raise the working equipment and tilt the cab. (For details, see
“Tilting the Cab” on page 30-38).
2. Drain the hydraulic oil.
3. Disconnect from pump (1) the suction line (2) and (3) (one for the
normal version, two for the HIGHFLOW version).
4. Loosen the two fasteners (4) and remove the pump (1) complete
with the O-ring (5).
Installation
Fasteners: 59-74 N•m (44-55 lbf ft)
SK1026-5N 50-55
DISASSEMBLY AND ASSEMBLY ENGINE-PUMP COUPLING
ENGINE-PUMP COUPLING
Removal
1. Fully raise the working equipment and tilt the cab. (For details, see
“Tilting the Cab” on page 30-38).
2. Remove the pump. (For details, see “HYDRAULIC PUMP
ASSEMBLY” on page 30-52).
Half-coupling On Pump
3. Loosen dowel (1) that secures the coupling (2). [*1]
★ Heat the dowel at 85-100°C (185-212°F) temperature.
4. Remove the pump coupling (2).
★ Use an extractor if necessary.
Half-coupling On Flywheel
5. Remove fastener (3) and the flange (4). [*2]
Installation
[*1]
Coupling fastener: Loctite 262
Coupling fastener: 195 N•m (144 lbf ft)
[*2]
Flange fastener: Loctite 262
Flange fastener: 50 N•m (37 lbf ft)
1. Fill the tank up to maximum level bleed the air from piston pump and pressurize the tank. (For details, see “Bleeding Air
From the Pump” on page 30-31).
2. Start the engine to circulate the oil and check for leaks.
3. Stop the engine, check the levels and, if necessary, top them up.
50-56 SK1026-5N
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
CONTROL VALVE
Removal
WARNING! Fully raise the working equipment and tilt the cab. (For details, see “Tilting the Cab” on
page 30-38).
WARNING! Release residual pressures from all hydraulic circuits and the tank. (For details, see
“Elimination of Pressure” on page 30-30).
★ Drain the hydraulic oil.
1. Disconnect from control valve (1) servo-control lines (2), delivery

lines to the actuators, and the delivery and return lines (3).
2. Loosen three fasteners (4) and remove the control valve (1).
Control valve: max. 24 kg (53 lbs)
Installation
1. To install, reverse removal procedure.
Control valve screws: 35 N•m (26 lbf ft)
2. Fill the hydraulic oil tank up to maximum level.
3. Start the engine and run at low idle to circulate the oil throughout the system.
4. Pressurize the tank and bleed the air from all circuits.
(For details, see “Bleeding Air From the Pump” on page 30-31).
SK1026-5N 50-57
DISASSEMBLY AND ASSEMBLY PPC VALVES
PPC VALVES
Removal
1. Lower the working equipment until it is resting on the ground, stop
the engine and remove the ignition key.
2. Release residual pressures from all circuits and from the tank.
With Front Door

3. Remove the heater assembly. Raise the box cover (1) disconnect the
connectors (2) and remove the cover (1).
4. Disconnect the protective sleeve (3).

★ Take care not to damage the frame (4).
5. Loosen the four fasteners (5) and remove the casing (6).
6. Take out the three fasteners (7) and disconnect the PPC valve (8)
from the support (9).
7. Disconnect the six lines (10) from the PPC valve and plug the ends
to prevent entry of impurities.
★ Check and mark the lines to avoid mixing them up during
re-assembly.
Installation
Left Hand PPC Valve
Position
P T P1 P2 P3 P4
M S A R L R
White White Yellow Yellow Blue Blue
Right Hand PPC Valve
Position
P T P1 P2 P3 P4
M S D S C A
White White Red Red Yellow Yellow
• If the unions are removed from the PPC valves, make sure that a
union with a filter is mounted at the “P” inlet.
• Check the positions for the line connections carefully.
50-58 SK1026-5N
DISASSEMBLY AND ASSEMBLY PPC VALVES
MEMORANDUM
SK1026-5N 50-59
DISASSEMBLY AND ASSEMBLY CAB HEATER ASSEMBLY
CAB HEATER ASSEMBLY

Removal
WARNING! Disconnect the negative terminal cable (-)
from the battery.
1. Loosen the fastener (1) and remove the clamp (2).

2. Remove the hose retainer clamp (3).
3. Disconnect the heating systems supply (4) and return (5) hoses
★ Mark the hoses to avoid mixing them up during reassembly.
4. Loosen the fastener (6) and remove the front part of the air intake
line (7).
5. Remove the upper retaining fastener (8) from the heater assembly.
50-60 SK1026-5N
DISASSEMBLY AND ASSEMBLY CAB HEATER ASSEMBLY
6. Remove the lower retaining screws (9) from the heater assembly.
7. Rotate the heater assembly (10) towards the inside of the machine
and remove the retainer clamp (11) from the washer pipe (12).
8. Disconnect the connector (13) and remove the heater assembly (10)
together with the supply and return hoses.
Installation
1. Fill the cooling system with engine coolant.
2. Start the engine to let the coolant circulate.
3. Stop the engine and top off.
SK1026-5N 50-61
DISASSEMBLY AND ASSEMBLY WHEEL HUB ASSEMBLY
WHEEL HUB ASSEMBLY

Removal
1. Place the machine on blocks that are high enough to raise the
wheels off the ground, and fully raise the working equipment.
2. Loosen the nuts (1) and take off the tire (2). [*1]
3. Loosen the drain plug (3) in order to drain the chain and gearing
lube oil.
Gear-box oil: max. 15.5 liters (4.1 gal)
4. To facilitate oil drainage, remove the vent plug (4).
5. Loosen the nuts (5) and take off the cover (6). [*2]
★ Check condition of seal (7) and install a new one if necessary.
50-62 SK1026-5N
6. Start the engine and allow the pinion (8) to turn slowly until the
master links (9) are both positioned on the upper section of the
chain.
7. Remove the pins (10) and pull out the master link (9). [*3]
8. Turn the wheel hub (11) to release it from the chain.

9. Attach the complete hub assembly (11) to a hoist and tackle and
apply a slight tension to the cables.
10. Loosen the nuts (12) and remove the hub (11). [*4]
Hub: 61 kg (135 lb)
11. Check the condition of the O-ring and replace it if necessary.
Installation
[*1]
Nuts: 186 ±9.8 N•m (137 ±7 lbf ft)
[*2]
[*3]
1. Make sure that the master link is in the correct position with respect
to the pinion.
2. Adjust the tension of the chains.
(For details, see “CHAIN TENSION” on page 30-18).
3. Fill the oil up to maximum level.
Transmission oil: max. 13.5 liters (3.6 gal)
[*4]
SK1026-5N 50-63
Disassembly
1. Remove the wheel hub (1).
(For details, see “Removal” on page 30-62).
2. Place the wheel hub (1) in a vice and loosen the fastener (2). [*1]
3. Remove the disk (3) and the shims (4). [*2]
★ Make a note of the number and positions of the shims (4).
4. Remove the sprocket gear (5).

★ Make a note of which way the sprocket gear (5) is facing with
respect to the hub (1)
5. Position the wheel hub (1) beneath a press and slowly extract the
axle shaft (6) until it is released from the inner ring (7).
★ Place the wheel hub (1) on two supports “A” about 520 mm
(20.4 in) high.
6. Remove the inner bearing (7).
7. Proceed with the removal of the axle shaft (6) until it is fully
removed from the bearing (8). [*3]
50-64 SK1026-5N
8. Place the hub (1) in a vice and extract the seal ring (9).
9. Mount a new seal ring (9) each time the hub is dismantled.
10. Extract the outer rings (7) and (8). [*4]
Assembly
[*1]
Fastener: 294 N·m (217 lbf ft)
[*2]
1. Take the existing measurement “X” between the axle shaft (6) and
the ring bevel gear (5).
2. Calculate the thickness of shims that should be inserted between the
disc (3) and the ring bevel gear (5) using the following formula:
S=X-Z
• S = the shim pack
• X = the measurement taken
• Z = residual clearance [0.05-0.125]
★ For example: clearance measured X = 0.570 Addition of two shims of 0.2 and one of 0.1
3. Check that the measurement X lies within the permissible limits.
[*3]
4. Grease bearings (7) and (8).
Bearings: Litio EP NLGI 2
[*4]
5. Grease the lip of the seal ring (9).
Seal ring: Litio EP NLGI 2
SK1026-5N 50-65
DISASSEMBLY AND ASSEMBLY FINAL DRIVE ASSEMBLY
FINAL DRIVE ASSEMBLY

Removal
1. Disconnect the gearing chains (1) from the final drive (2).
(For details, see“WHEEL HUB ASSEMBLY” on page 30-62).
2. Remove the complete hydraulic pump. (For details, see
“HYDRAULIC PUMP ASSEMBLY” on page 30-52).
3. Disconnect from the final drive (2) the supply pipes (3), the speed
increment pipe (4) and the drainage pipe (5).
★ Cap all lines to prevent entry of impurities.
4. Attach the final drive (2) to some type of hoist and tackle and apply
a slight tension to the chains.
5. Loosen the 10 fastener (6) and remove the complete final drive
assembly (2). [*1]
★ Check the condition of the O-ring (7) and replace it with a new
one if necessary.
Final drive assembly: 68 kg (150 lb)
50-66 SK1026-5N
DISASSEMBLY AND ASSEMBLY FINAL DRIVE ASSEMBLY
Installation
Grease the O-ring. [*1]
O-ring: Litio EP NLGI 2
Fasteners: 120 N•m (89 lbf ft)
Fasteners: Loctite 270
SK1026-5N 50-67
DISASSEMBLY AND ASSEMBLY CYLINDER ASSEMBLIES
CYLINDER ASSEMBLIES
Lift Cylinder Assembly
Removal
WARNING! Lower the working equipment until it is resting on the ground. Release residual pressures
from all circuits. (For details, see “Elimination of Pressure” on page 30-30).
1. Remove all the working equipment. (For details see, “Removal of

the Complete Work Equipment” on page 30-78).
2. Remove the lift lever. (For details see “Removal of the Lift Lever”
on page 30-82).
3. Loosen the screws (1) and remove the front bracket (2) retaining
the plate (3).
4. Push the cylinder (4) towards the front of the machine, loosen the
screws (5), remove the rear bracket (6) retaining the plate (3) and
remove the plate.
5. Loosen the 4 screws (7) and remove the lower lock.
50-68 SK1026-5N
6. Remove the clamps (9); disconnect the hoses (10) from the fittings
(11).
★ Mark the hoses for position to avoid mixing them during
installation.
★ Plug the hoses (10) and fittings (11) to prevent foreign material
and dirt from entering.
7. Connect the cylinder (4) to a hoist, tension the belt, loosen the
screw (12) and remove the pin (13). [*1], [*2]
8. Remove the cylinder (4) together with the hoses (10).
Installation
[*1]
Bushing inner side: Lithium EP MS2 NLGI2
Pin retaining screws: 49 N•m (36 lbf ft)
[*2]
WARNING! When the positions of hole and pin line up, idle the engine. Do not insert fingers into the
holes to check alignment.
1. Start the engine and bleed air from the cylinder. (For details see “Bleeding Air From the Cylinders” on page 30-31).
★ When air bleeding is complete, check the oil level in the tank.
SK1026-5N 50-69
Bucket Cylinder Asssembly

Removal
WARNING! Lower work equipment and rest the
equipment support frame on the ground.
1. Remove pin (1) and fully retract the piston rod (2). [*1], [*2]
★ Make a note as to the position of the adjustments and given
clearance.
2. Disconnect lines (4) and (5) from the cylinder (3).

★ Cap the lines to prevent entry of impurities.
3. Remove pin (6) and lift off cylinder (3). [*1], [*3]
★ Make a note as to the position of the adjustments in relation to
the given clearance.
50-70 SK1026-5N
Installation
WARNING! When aligning the positions between the hole and the pin, do not insert fingers into the
[*1]
Inside the bushings: Lithium EP MS2 NLGI 2
Pin screws: 49 N•m (36 lbf ft)
[*2]
1. Insert the removed shims and, if necessary, add more until the
residual clearance is about 1 mm (0.039 in).
[*3]
2. Insert the removed shims and, if necessary, add more until the
residual clearance is about 1 mm (0.039 in).
3. Start the engine and bleed the air from the cylinder. (For details, see
“Bleeding Air From the Cylinders” on page 30-31).
★ After bleeding the air, check the level of oil in the tank
SK1026-5N 50-71
Disassembly of the Cylinder Assembly

1. Take off the guard (1) from both sides of the cylinder and from the
piston rod.
★ Make sure the tube unions are not plugged.
2. Place cylinder (2) on apparatus “A”. Install cylinder in tool “B”,

having the same bushing diameter.
3. Attach special wrench “C” (adjusted to fit the cylinder) to head (3)
and apply dynamometric tool “D”.
4. Unscrew head (3) and completely remove it from the cylinder (2).
50-72 SK1026-5N
5. Raise the cylinder, and hook the piston rod to the mobile group of
tool “A”.
6. Extract the piston rod assembly (4) from the cylinder.
7. Remove cylinder (2) and the piston rod assembly.
8. Lock the complete piston rod (4) onto apparatus “A”.

9. Attach wrench “E” to lock nut (5) of piston (6), and using the
dynamometric tool with a multiplier “D”, remove the nut.
★ Socket wrench measurement: 41 mm
10. Take all the parts and remove all the seals, guard rings and guide
rings.
★ The seals, guard rings, and guide rings cannot be re-used,
always replace with new seals and rings.
SK1026-5N 50-73
Assembly of the Cylinder Assembly

★ Be careful not to damage the seals and sliding surfaces.
★ Prepare each individual component before commencing with the
final assembly.
Assembly of the Cylinder Head

1. Position guard ring (7), and using a press and push rod “F”, press it
into the head (3).
★ Carefully check the orientation.
2. Install snap ring (8).

3. Using tool “G”, install the lip-seal (9).
★ Be sure the lips face is properly seated into the cylinder.
4. Install O-ring (10), the anti-extrusion ring (11), and O-ring (12) on
to the cylinder head (3).
50-74 SK1026-5N
Piston Assembly
1. Using tool “H”, install the piston seal. Install in sequence rubber
ring (13), outer seal (14), and anti-extrusion rings (15).
2. Install the guide ring (16).

3. Install gasket (14) to the piston (6), placing them on a press and
using the calibrating ring “J” attach and adjust the piston diameter.
Piston Rod Assembly

1. Using a press and tool “B” adjusted to the diameter, insert bushing
(17) into piston rod (4).
2. Insert support “K” beneath the piston rod.
3. Install pilot boss “L” set to the diameter onto the outside of the
piston rod.
4. Slide head (3) onto the piston rod (4).
5. Remove pilot boss “L” from the outside of the piston rod.
SK1026-5N 50-75
6. Install the complete piston (6).
7. Install nut (5) that secures the piston and tighten it with socket
wrench “E” and the dynamometric tool with a multiplier “D”.
Nut: Loctite 262
Nut: 1127 ±112 N•m (831 ±83 lbf ft)
Cylinder Assembly
1. Set tools “A” onto apparatus “B”.
2. Position bushing (20) and install it onto cylinder (2).
★ Leave the cylinder in position, ready for the next assembly
operation.
3. Lubricate the threading and the first part of cylinder (2).
Cylinder: Lithium EP NLGI 2
4. Place the two halves of tool “M”, set to the diameter, onto the end
of cylinder (2).
50-76 SK1026-5N
5. Install the piston rod group (4) onto tool “A” and raise the movable
part up to the end of its stroke.
6. Position cylinder (2) into a vertical position and guide the piston
into tool “M”.
7. Lower the apparatus supporting piston rod (4) in order to insert the
piston into the cylinder liner (2).
8. Remove tool “M” from the cylinder and then lower apparatus “A”
even further, until head (3) and the piston rod reach the cylinder.
9. Place cylinder (2) in position for installing the head (3).
10. Insert the head (3) into the cylinder and screw it in by hand for a
few turns.
11. Attach special wrench “C” to the impact tool “D” and screw head
(3) into the cylinder.
Gland Nut: 490 ±49 N•m (361 ±36 lbf ft)
12. Install guard rings (1) on both sides of the cylinder and piston rod.
SK1026-5N 50-77
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT SYSTEM
WORK EQUIPMENT SYSTEM

WARNING! Before proceeding with any removal or disassembly procedures, be sure all of the work
equipment is on the ground and the controls neutralized. Be sure the parking brake is set
and the machine is on a flat level surface. Be sure the engine is in the OFF position and
the battery is disconnected. Release hydraulic tank pressure.
Removal of the Complete Work Equipment

HIGH-FLOW and SUPER HIGH-FLOW version only
1. Disconnect power socket (1) and electrical harness from arm (2).
2. Disconnect hoses (3) and (4).

★ Mark the pipes for position to avoid mixing them during
installation.
★ Plug hoses (3) (4) and pipes (5), (6) to prevent dirt and foreign
material from entering.
3. Connect the complete arm (1) to a hoist and tension the cables.
★ Cable length: approximately 2 m (6.5 ft)
50-78 SK1026-5N
4. Remove snap ring (7) and 6 shims (8).
5. Loosen screw (10) and remove pin (11).
★ Check for a damaged seal (9), replace if necessary.
6. Introduce wooden shims "A" between lift lever (12) and fulcrum
lever (13).
7. Lift the arm until the tool holder frame fulcrum pin and arm
fulcrum pin line up.
8. Loosen screw (14), remove pin (15) and remove the work
equipment.
Work equipment (without bucket): 600 kg (1,323 lbs)
★ Check for damaged seals (16); replace if necessary.

★ Check and note position the of shims. [*1], [*2]
SK1026-5N 50-79
Installation of the Complete Work Equipment


[*1]
Bushing inner side: Lithium EP MS2 NLGI2
Pin screws: 49 N•m (36 lbf ft)
[*2]
★ Introduce shims between arm and frame until residual clearance is
less than 1 mm (0.039 in).
1. Start the engine and bleed the air from the cylinder. (For details, see
“Bleeding Air From the Cylinders” on page 30-31).
★ After bleeding the air, check the level of oil in the tank
50-80 SK1026-5N
Removal of the Fulcrum Lever

WARNING! Before proceeding with any removal or
disassembly procedures, be sure all of
the work equipment is on the ground and
the controls neutralized. Be sure the
parking brake is set and the machine is
on a flat level surface. Be sure the engine
is in the OFF position and the battery is
disconnected. Release hydraulic tank
pressure.
1. Remove the complete work equipment. (For details see “Removal

of the Complete Work Equipment” on page 30-78).
2. Connect lever (1) to a hoist and slightly add tension to the cable.
3. Remove bolt (2), then remove lock pin (3) and fulcrum lever (1).
Fulcrum lever: 15 kg (33 lbs)
★ Check for any damage to seals (4), replace if necessary.

★ Check and note position of the shims. [*1], [*2]
Installation of the Fulcrum Lever

[*1]
Bushing inner side: Lithium EP MS2 NLGI 2
Lock pin bolt: 49 N•m (36 lbf ft)
[*2]
★ Introduce shims between the fulcrum lever and frame until the
residual clearance is less than 1 mm (0.039 in).
SK1026-5N 50-81
Removal of the Lift Lever

WARNING! Before proceeding with any removal or disassembly procedures, be sure all of the work
equipment is on the ground and the controls neutralized. Be sure the parking brake is set
and the machine is on a flat level surface. Be sure the engine is in the OFF position and
the battery is disconnected. Release hydraulic tank pressure.
1. Remove the complete work equipment. (For details see “Removal

of the Complete Work Equipment” on page 30-78).
2. Introduce a pin into the center hole on lift lever (1), connect a hoist
and add slight tension to the cables.
3. Remove bolt (2) and lock pin (3). [*1]
4. Hoist lift lever (1) until the center hole on the lever and the fulcrum
hole on the frame line up.
50-82 SK1026-5N
5. Remove bolt (4) and lock pin (5) and remove lift lever (1).
Lift lever: 24 kg (53 lbs)
★ Check for any damaged seals (6) and replace if necessary.

★ Check and note position of the shims. [*1], [*2]
Installation of the Lift Lever

[*1]
Lock pin bolt: 49 N•m (36 lbf ft)
[*2]
★ Introduce shims between the lift lever and frame until the residual
clearance is less than 1 mm (0.039 in).
SK1026-5N 50-83
Removal of the Work Equipment Support Frame

1. Lower the working equipment until the supporting frame is lying
flat on some blocks "A".
2. Remove the pins (1) and retract the cylinder piston rods (2).
Check and make a note of the positions of the adjustments to a
given clearance. [*1], [*2]
3. Remove the pins (3) and take off the complete working equipment
support frame (4). [*2]
Equipment support frame: 80 kg (176 lbs)
Installation of the Work Equipment Support Frame

[*1]
★ Insert the removed shims and if necessary add more until the residual clearance is less than 3 mm.
[*2]
WARNING! When aligning the positions between the hole and the pin, run the engine at loe idle.
ATTENTION! DO NOT insert fingers into the holes to check alignment.
50-84 SK1026-5N
90 DIAGRAMS AND SCHEMATICS
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-3

Hydraulic Circuit (Road Specification) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-3
Hydraulic Circuit (Standard + Pattern Change) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-4
Hydraulic Circuit (Super-Flow + Float + Pattern Change). . . . . . . . . . . . . . . . . . . . . . . . . 90-5
Hydraulic Circuit (Standard + Float + Pattern Change) . . . . . . . . . . . . . . . . . . . . . . . . . . 90-6
Hydraulic Circuit (Standard + Float) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-7
Hydraulic Circuit (High-flow + Float) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-8
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-9

Electrical Diagram (Engine Line) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-9
Electrical Diagram (Frame Line - Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-10
Electrical Diagram (Frame Line - Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-11
Electrical Diagram (Cab Line - Standard) (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-12
Electrical Diagram (Cab Line - Standard) (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-13
Electrical Diagram (Cab Line - Optional) (1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-14
Electrical Diagram (Top-Cab Light Line - Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-17
Electrical Diagram (Top-Cab Light Line - Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-18
Electrical Diagram (Rear Light Line) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-19
Electrical Diagram (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-20
Electrical Diagram (Optional) (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-21
Electrical Diagram (Optional) (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-22
SK1026-5N 90-1 1
12
90-21 SK1026-5N
HYDRAULIC CIRCUIT (ROAD HOMOLOGATION)

PPC VALVE L.H. PPC VALVE R.H.
Ø16t=2 Ø12.71=3700 (13/16-16 ORFS)
P1 P2 P4 P3
T
Ø16t=2 Ø12.71=3700 (13/16-16 ORFS)
P
LIFT ARM CYLINDER L.H.
Ø6.51=400 (1/2-20 JIC)
100 100
MESH P1 P2 P3 P4 MESH
Ø9.51=1200 (13/16-16 ORFS)

PORT PORT PORT PORT
Ø9.51=1850 (13/16-16 ORFS) A3 1 3 2 4
B3
Ø101=520 (9/16-18 JIC)
Ø101=520 (9/16-18 JIC)
Ø101=520 (9/16-18 JIC)
Ø101=520 (9/16-18 JIC)

Ø6.41=435 (1/2-20 JIC)
Ø6.41=435 (1/2-20 JIC)

Ø6.41=435 (1/2-20 JIC)
Ø6.41=435 (1/2-20 JIC)

LIFT ARM CYLINDER R.H. PORT PORT
PB3 PA3 Ø6.51=400 (1/2-20 JIC)
Ø6.51=600 (9/16-18 JIC)
Ø6.51=680 (9/16-18 JIC)
Ø6.41=435 (1/2-20 JIC)

Ø6.41=435 (1/2-20 JIC)
Ø6.41=435 (1/2-20 JIC)
Ø6.41=435 (1/2-20 JIC)

Ø9.51=1200 (13/16-16 ORFS)
Ø9.51=1850 (13/16-16 ORFS)

A2
PORT B2
PB2
Ø6.41=1500 (1/2-20 JIC)
BUCKET DUMP BUCKET CURL
BUCKET CYLINDER L.H. PORT
PA2
Ø101=1050 (9/16-18 JIC)
Ø101=1050 (9/16-18 JIC)

Ø9.51=530 (13/16-16 ORFS)
PORT
Ø9.51=530 (13/16-16 ORFS) PB1
LIFT ARM A1
RAISE
BUCKET CYLINDER R.H. B1
Ø6.41=1500 (1/2-20 JIC)
PORT Ø6.41=950 (1/2-20 JIC)

Ø9.51=530 (13/16-16 ORFS)
PA1
LIFT ARM Ø6.41=950 (1/2-20 JIC)
Ø9.51=530 (13/16-16 ORFS) LOWER
UNLOAD VALVE
TRAVEL MOTOR L.H.

DR RELIEF VALVE
20.6MPa A B C
(210kg/cm 2 )
PORT
Ø6.41=650 (1/2-20 JIC)
Ø6.41=650 (1/2-20 JIC)

Ø6.41=950 (1/2-20 JIC)
Ø6.41=850 (1/2-20 JIC)

P
RED PORT
TS SV1 SV2 SV3
Ø0.5 P
HYDRAULIC CIRCUIT DIAGRAM PORT
T T
Ø12.71=1950 (13/16-16 ORFS)

Ø12.71=1950 (13/16-16 ORFS)
Ø16t=2 Ø12.71=3700 (13/16-16 ORFS)
Ø16t=2 Ø12.71=3700 (13/16-16 ORFS)
Ø19.1=1100 (1”3/16-12 ORFS)
Ø6.41=1550
(9/16-18 JIC)
PP2 A B PP1 PA1 DA1 DB1 DB2 DA2 PA2 P4
Ø15.91=1100 (1”3/16-12 ORFS)

Ø6.51=600
(9/16-18 JIC) Ø15.91=1100 (1”3/16-12 ORFS)
Ø7.3
Ø6.51=500 Ø15.91=1100 (1”3/16-12 ORFS) +40cm 2 /rev +40cm 2 /rev
(9/16-18 JIC) E
Ø15.91=1100 (1”3/16-12 ORFS)
ENGINE
B A S4D98E-2NFE
PP1 PP2 84.2/2500 PS/rpm
(61.9/2500 Kw/rpm
PB1 T5 PB2 S3 S4
Ø24.6~26.21=1000
Ø9.5=1150 (9/16-18 JIC)
Ø32.1=620
Ø19.11=900 (1”5/8-12 JIC)
(1”1/16-12 JIC) Ø9.51=1000 (9/16-18 JIC)
Ø6.51=350 (9/16-18 JIC)
Ø6.51=680 (9/16-18 JIC)
RED
Ø191=1650 Ø16 Ø191=1450
(1”1/16-12 JIC) t2 (1”5/16-12 JIC)
TRAVEL MOTOR R.H. DR

Ø9.51=1300 (9/16-18 JIC) Ø25.41=430
(1”5/16-12 JIC)
Ø191=850
Ø9.51=1300 (9/16-18 JIC) (1”1/16-12 JIC) Ø42
CVSM0362
SK1026-5 Turbo 90-3j

HYDRAULIC CIRCUIT (STANDARD + PATTERN CHANGE)

Ø16t=2 Ø12.71=3700 (13/16-16 ORFS)
T
Ø16t=2 Ø12.71=3700 (13/16-16 ORFS)
P
Ø6.51=400 (1/2-20 JIC)
100 100
P1 P2 P3 P4 MESH P1 P2 P3 P4 MESH
Ø9.51=1200 (13/16-16 ORFS)
Ø9.51=1850 (13/16-16 ORFS) A3

B3
Ø101=520 (9/16-18 JIC)
Ø101=520 (9/16-18 JIC)
Ø101=520 (9/16-18 JIC)
Ø101=520 (9/16-18 JIC)

Ø6.41=435 (1/2-20 JIC)
Ø6.41=435 (1/2-20 JIC)
Ø6.41=435 (1/2-20 JIC)
Ø6.41=435 (1/2-20 JIC)

Ø6.41=435 (1/2-20 JIC)
Ø6.41=435 (1/2-20 JIC)
Ø6.41=435 (1/2-20 JIC)
Ø6.41=435 (1/2-20 JIC)

Ø6.51=600 (9/16-18 JIC)
Ø6.51=680 (9/16-18 JIC)

PB3 PA3 Ø6.51=400 (1/2-20 JIC)
Ø9.51=1200 (13/16-16 ORFS)
Ø9.51=1850 (13/16-16 ORFS)

A2
PORT B2
PB2
BUCKET DUMP BUCKET CURL Ø6.41=1500 (1/2-20 JIC)
Ø101=1050 (9/16-18 JIC)

Ø101=1050 (9/16-18 JIC)
PA2
Ø9.51=530 (13/16-16 ORFS)

PORT
Ø9.51=530 (13/16-16 ORFS) PB1
LIFT ARM A1
RAISE
PORT
Ø9.51=530 (13/16-16 ORFS)
PA1
LIFT ARM
Ø9.51=530 (13/16-16 ORFS) LOWER
Ø6.41=950 (1/2-20 JIC)
UNLOAD VALVE
TRAVEL MOTOR L.H. ISO PATTERN (KOMATSU)

DR RELIEF VALVE OUTPUT INPUT
20.6MPa
(210kg/cm 2 )
PORT
P Ø6.41=650 (1/2-20 JIC) P4 OUT P4 IN
RED PORT
TS
Ø6.41=850 (1/2-20 JIC) P3 OUT P2 IN
Ø0.5
HYDRAULIC CIRCUIT DIAGRAM PORT Ø6.41=650 (1/2-20 JIC) P2 OUT P1 IN
T
Ø6.41=950 (1/2-20 JIC) P1 OUT P3 IN
Ø12.71=1950 (13/16-16 ORFS) Ø6.41=1500 (1/2-20 JIC) P5 OUT P5 IN

Ø12.71=1950 (13/16-16 ORFS)
Ø16t=2 Ø12.71=3700 (13/16-16 ORFS) Ø6.41=950 (1/2-20 JIC) P6 OUT P6 IN
Ø16t=2 Ø12.71=3700 (13/16-16 ORFS)
Ø19.1=1100 (1”3/16-12 ORFS) P4 OUT P4 IN
P3 OUT P2 IN
Ø6.41=1550
(9/16-18 JIC)
P2 OUT P1 IN
PP2 A B PP1 PA1 DA1 DB1 DB2 DA2 PA2 P4
P1 OUT P3 IN
P5 OUT P5 IN
33.2 cm 2 /rev
Ø15.91=1100 (1”3/16-12 ORFS)
28 cm 2/rev
Ø6.51=600 P6 OUT P6 IN
(9/16-18 JIC) Ø15.91=1100 (1”3/16-12 ORFS)
OPTION PATTERN (CASE)

Ø7.3
(9/16-18 JIC) E
Ø15.91=1100 (1”3/16-12 ORFS)
ENGINE
B A S4D98E-2NFE
PP1 PP2 84.2/2500 PS/rpm
(61.9/2500 Kw/rpm
SV1 SPEED SV2 PPC SV3 BRAKE
A B C
PB1 T5 PB2 S3 S4
Ø24.6~26.21=1000
Ø32.1=620 P
(1”5/8-12 JIC)
Ø9.5=1150 (9/16-18 JIC)
T
Ø19.11=900
(1”1/16-12 JIC) Ø9.51=1000 (9/16-18 JIC)
Ø6.51=350 (9/16-18 JIC)
Ø6.51=680 (9/16-18 JIC)
RED
Ø191=1650 Ø16 Ø191=1450
(1”1/16-12 JIC) t2 (1”5/16-12 JIC)

Ø9.51=1300 (9/16-18 JIC) Ø25.41=430
(1”5/16-12 JIC)
Ø191=850
Ø9.51=1300 (9/16-18 JIC) (1”1/16-12 JIC) Ø42
CVSM0363

HYDRAULIC CIRCUIT (SUPER-FLOW + FLOAT + PATTERN CHANGE)
FEMALE 1/2
Ø16 t=2 Ø12.71=3700 (13/16-16 ORFS)
PORT 2 LS PRESSURE PORT

RIGHT SIDE
FRONT ARM MALE 1/2 PPC VALVE L.H. PPC VALVE R.H.
Ø16 t=2 Ø12.71=3700 (13/16-16 ORFS) T
Ø6.51=400 (1/2-20 JIC)

HI-FLOW ATT.
Ø0.5
MALE 3/4
100 100
Ø20 t=2 Ø16 (5/8) 1=3700 (1”14 ORFS) A4 P1 P2 P3 P4 MESH P1 P2 P3 P4 MESH
CONNECTOR
CN-B B4
FEMALE 3/4
LEFT SIDE Ø20 t=2 Ø16 (5/8) 1=3700 (1”14 ORFS)
FRONT ARM
PORT
Ø101=520 (9/16-18 JIC)
Ø101=520 (9/16-18 JIC)
Ø101=520 (9/16-18 JIC)
Ø101=520 (9/16-18 JIC)

Ø6.41=435 (1/2-20 JIC)
Ø6.41=435 (1/2-20 JIC)
Ø6.41=435 (1/2-20 JIC)
Ø6.41=435 (1/2-20 JIC)

FEMALE 1/2
Ø6.41=435 (1/2-20 JIC)

Ø6.41=435 (1/2-20 JIC)
Ø6.41=435 (1/2-20 JIC)
Ø6.41=435 (1/2-20 JIC)

P1
Ø6.51=600 (9/16-18 JIC)
Ø6.51=680 (9/16-18 JIC)

Ø16 t=2 Ø12.71 (1/2) 1=3700 (1”1/16-12 JIC-3/16 ORFS) CONNECTOR
CN-A
LIFT ARM CYLINDER L.H. A3
B3
PORT PORT Ø6.51=400 (1/2-20 JIC)
Ø9.51=1200 (13/16-16 ORFS) PB3 PA3
Ø101=1050 9/16-18 JIC)
Ø101=1050 (9/16-18 JIC)
Ø6.41=950 (9/16-18 JIC)

Ø9.51=1850 (13/16-16 ORFS)
LIFT ARM CYLINDER R.H.

A2
PORT
PB2 B2
Ø9.51=1200 (13/16-16 ORFS) Ø6.41=1500 (1/2-20 JIC)
Ø9.51=1850 (13/16-16 ORFS) PORT
PA2
BUCKET CYLINDER L.H.
PORT
Ø9.51=530 (13/16-16 ORFS) PB1
LIFT ARM A1
Ø9.51=530 (13/16-16 ORFS) RAISE B1
BUCKET CYLINDER R.H. ARM FLOAT
Ø6.41=950 (1/2-20 JIC)
Ø9.51=530 (13/16-16 ORFS)
Ø9.51=530 (13/16-16 ORFS)

ISO PATTERN (KOMATSU)
UNLOAD VALVE OUTPUT INPUT
CONNECTOR
TRAVEL MOTOR L.H. 12V CN-A
DR P4 OUT P4 IN
Ø6.41=650 (1/2-20 JIC)
PORT
PORT PA1
Ø6.41=850 (1/2-20 JIC) P3 OUT P2 IN
RED P
LIFT ARM
PORT LOWER
Ø6.41=650 (1/2-20 JIC) P2 OUT P1 IN
TS
Ø0.5 Ø6.41=950 (1/2-20 JIC) P1 OUT P3 IN
HYDRAULIC CIRCUIT DIAGRAM PORT Ø6.41=1500 (1/2-20 JIC) P5 OUT P5 IN

T
RELIEF VALVE
20.6MPa Ø6.41=950 (1/2-20 JIC) P6 OUT P6 IN
(210kg/cm 2 )
P4 OUT P4 IN
Ø12.71=1950 (13/16-16 ORFS) Ø19.1=1100 (1”3/16-12 ORFS) P3 OUT P2 IN

Ø12.71=1950 (13/16-16 ORFS)
Ø16t=2 Ø12.71=3700 (13/16-16 ORFS)
P2 OUT P1 IN
Ø16t=2 Ø12.71=3700 (13/16-16 ORFS)
Ø12.71=1350 (1”-14 ORFS) P1 OUT P3 IN
PP2 A B PP1 PA1 DA1 DB1 DB2 DA2 PA2 P4 P5
P5 OUT P5 IN
P6 OUT P6 IN
Ø15.91=1100 (1”3/16-12 ORFS)
33.2 cm 2 /rev
23.7 cm 2 /rev
28 cm 2/rev
Ø6.51=600
Ø15.91=1100 (1”3/16-12 ORFS)
(9/16-18 JIC) OPTION PATTERN (CASE)
Ø6.51=500 Ø15.91=1100 (1”3/16-12 ORFS) Ø7.3

(9/16-18 JIC) +40cm 2 /rev +40cm 2 /rev
Ø15.91=1100 (1”3/16-12 ORFS) E
PP1 B A PP2
ENGINE
Ø6.41=1550 S4D98E-2NFE
(9/16-18 JIC) 84.2/2500 PS/rpm
(61.9/2500 Kw/rpm
PB1 T5 PB2 S3 S4 S5
(1”5/16-12 JIC)
(1”5/8-12 JIC)
Ø25.41=800
Ø32.1=620
Ø24.6~26.21=1000 SV1 SPEED SV2 PPC SV3 BRAKE
A B C
Ø9.5=1150 (9/16-18 JIC)
Ø9.51=1000 (9/16-18 JIC)

Ø19.11=900 Ø6.51=350 (9/16-18 JIC)
(1”1/16-12 JIC) P
Ø6.51=680 (9/16-18 JIC)
T
Ø191=1650 Ø16 Ø191=1450
RED
(1”1/16-12 JIC) t2 (1”5/16-12 JIC)
Ø25.41=430
TRAVEL MOTOR R.H. DR (1”5/16-12 JIC)
Ø191=850
Ø9.51=1300 (9/16-18 JIC) (1”1/16-12 JIC)
Ø42
Ø9.51=1300 (9/16-18 JIC)
CVSM0364

HYDRAULIC CIRCUIT (STANDARD + FLOAT + PATTERN CHANGE)

FEMALE 1/2
Ø16t=2 Ø12.71=3700 (13/16-16 ORFS)
T
RIGHT SIDE
FRONT ARM MALE 1/2
P
Ø16t=2 Ø12.71=3700 (13/16-16 ORFS)
LIFT ARM CYLINDER L.H. Ø6.51=400 (1/2-20 JIC)
LS PRESSURE PORT 100 100

P1 P2 P3 P4 MESH P1 P2 P3 P4 MESH
PRESSURE
Ø9.51=1200 (13/16-16 ORFS) CHECK PORT P
Ø9.51=1850 (13/16-16 ORFS) A3

B3
Ø101=520 (9/16-18 JIC)
Ø101=520 (9/16-18 JIC)
Ø101=520 (9/16-18 JIC)
Ø101=520 (9/16-18 JIC)

Ø6.41=435 (1/2-20 JIC)
Ø6.41=435 (1/2-20 JIC)
Ø6.41=435 (1/2-20 JIC)
Ø6.41=435 (1/2-20 JIC)

Ø6.41=435 (1/2-20 JIC)
Ø6.41=435 (1/2-20 JIC)
Ø6.41=435 (1/2-20 JIC)
Ø6.41=435 (1/2-20 JIC)

Ø6.51=600 (9/16-18 JIC)
Ø6.51=680 (9/16-18 JIC)

PB3 PA3 Ø6.51=400 (1/2-20 JIC)
Ø9.51=1200 (13/16-16 ORFS)
Ø9.51=1850 (13/16-16 ORFS)

A2
PORT B2
PB2
Ø6.41=1500 (1/2-20 JIC)
Ø101=1050 (9/16-18 JIC)

Ø101=1050 (9/16-18 JIC)
PA2
Ø9.51=530 (13/16-16 ORFS)

PORT
Ø9.51=530 (13/16-16 ORFS) PB1
LIFT ARM A1
RAISE
ARM FLOAT
Ø9.51=530 (13/16-16 ORFS)
Ø9.51=530 (13/16-16 ORFS)
Ø6.41=950 (1/2-20 JIC)
UNLOAD VALVE
CONNECTOR
12V CN-A
TRAVEL MOTOR L.H. ISO PATTERN (KOMATSU)
DR OUTPUT INPUT
PORT PA1
PORT
P Ø6.41=650 (1/2-20 JIC) P4 OUT P4 IN
RED
PORT LIFT ARM LOWER
TS Ø6.41=850 (1/2-20 JIC) P3 OUT P2 IN
Ø0.5
Ø6.41=650 (1/2-20 JIC) P2 OUT P1 IN
T
Ø6.41=950 (1/2-20 JIC) P1 OUT P3 IN
RELIEF VALVE
20.6MPa Ø6.41=1500 (1/2-20 JIC) P5 OUT P5 IN
(210kg/cm 2 )
Ø6.41=950 (1/2-20 JIC) P6 OUT P6 IN
Ø19.1=1100 (1”3/16-12 ORFS) P4 OUT P4 IN
Ø12.71=1950 (13/16-16 ORFS)

P3 OUT P2 IN
Ø12.71=1950 (13/16-16 ORFS)
Ø16t=2 Ø12.71=3700 (13/16-16 ORFS)
P2 OUT P1 IN
Ø16t=2 Ø12.71=3700 (13/16-16 ORFS) PA1 DA1 DB1 DB2 DA2 PA2 P4
PP2 A B PP1
P1 OUT P3 IN
P5 OUT P5 IN
33.2 cm 2 /rev
Ø15.91=1100 (1”3/16-12 ORFS)
28 cm 2/rev
Ø6.51=600 P6 OUT P6 IN
(9/16-18 JIC) Ø15.91=1100 (1”3/16-12 ORFS)
OPTION PATTERN (CASE)

Ø7.3
(9/16-18 JIC) E
Ø15.91=1100 (1”3/16-12 ORFS)
ENGINE
B A S4D98E-2NFE
PP1 PP2 84.2/2500 PS/rpm
Ø6.41=1550
(9/16-18 JIC) (61.9/2500 Kw/rpm
A B C
PB1 T5 PB2 S3 S4
Ø24.6~26.21=1000
Ø32.1=620 P
(1”5/8-12 JIC)
Ø9.5=1150 (9/16-18 JIC)
T
Ø19.11=900
(1”1/16-12 JIC) Ø9.51=1000 (9/16-18 JIC)
Ø6.51=350 (9/16-18 JIC)
Ø6.51=680 (9/16-18 JIC)
RED
Ø191=1650 Ø16 Ø191=1450
(1”1/16-12 JIC) t2 (1”5/16-12 JIC)

Ø9.51=1300 (9/16-18 JIC) Ø25.41=430
(1”5/16-12 JIC)
Ø191=850
Ø9.51=1300 (9/16-18 JIC) (1”1/16-12 JIC) Ø42
CVSM0365

HYDRAULIC CIRCUIT (STANDARD + FLOAT)

FEMALE 1/2
Ø16t=2 Ø12.71=3700 (13/16-16 ORFS) P1 P2 P4 P3
T
RIGHT SIDE
FRONT ARM MALE 1/2
P
Ø16t=2 Ø12.71=3700 (13/16-16 ORFS)
LIFT ARM CYLINDER L.H. Ø6.51=400 (1/2-20 JIC)
LS PRESSURE PORT 100 100

MESH P1 P2 P3 P4 MESH
PRESSURE
Ø9.51=1200 (13/16-16 ORFS) CHECK PORT P
PORT PORT PORT PORT
Ø9.51=1850 (13/16-16 ORFS) A3 1 3 2 4
B3
Ø101=520 (9/16-18 JIC)
Ø101=520 (9/16-18 JIC)
Ø101=520 (9/16-18 JIC)
Ø101=520 (9/16-18 JIC)

Ø6.41=435 (1/2-20 JIC)
Ø6.41=435 (1/2-20 JIC)
Ø6.41=435 (1/2-20 JIC)
Ø6.41=435 (1/2-20 JIC)

PB3 PA3 Ø6.51=400 (1/2-20 JIC)
Ø6.51=600 (9/16-18 JIC)
Ø6.51=680 (9/16-18 JIC)
Ø6.41=435 (1/2-20 JIC)

Ø6.41=435 (1/2-20 JIC)
Ø6.41=435 (1/2-20 JIC)
Ø6.41=435 (1/2-20 JIC)

Ø9.51=1200 (13/16-16 ORFS)
Ø9.51=1850 (13/16-16 ORFS)

A2
PORT B2
PB2
Ø6.41=1500 (1/2-20 JIC)
PA2
Ø9.51=530 (13/16-16 ORFS) Ø101=1050

PORT (9/16-18 JIC) Ø101=1050
Ø9.51=530 (13/16-16 ORFS) PB1 (9/16-18 JIC)
LIFT ARM A1
RAISE
ARM FLOAT
Ø9.51=530 (13/16-16 ORFS)
Ø9.51=530 (13/16-16 ORFS) Ø6.41=1500 (1/2-20 JIC)
UNLOAD VALVE
CONNECTOR
12V CN-A
TRAVEL MOTOR L.H.
DR
PORT PA1
PORT
P
RED
PORT LIFT ARM LOWER
TS
Ø0.5
T
RELIEF VALVE Ø101=850 Ø101=950 Ø101=650 Ø101=650
20.6MPa (9/16-18 JIC) (9/16-18 JIC) (9/16-18 JIC) (9/16-18 JIC)
(210kg/cm 2 )
Ø19.1=1100 (1”3/16-12 ORFS)
Ø12.71=1950 (13/16-16 ORFS)

Ø12.71=1950 (13/16-16 ORFS)
Ø16t=2 Ø12.71=3700 (13/16-16 ORFS)
Ø16t=2 Ø12.71=3700 (13/16-16 ORFS) PA1 DA1 DB1 DB2 DA2 PA2 P4
PP2 A B PP1
33.2 cm 2 /rev
Ø15.91=1100 (1”3/16-12 ORFS)
28 cm 2/rev
Ø6.51=600
(9/16-18 JIC) Ø15.91=1100 (1”3/16-12 ORFS)
Ø7.3
(9/16-18 JIC) E
Ø15.91=1100 (1”3/16-12 ORFS)
ENGINE
B A S4D98E-2NFE
PP1 PP2 84.2/2500 PS/rpm
Ø6.41=1550
(9/16-18 JIC) (61.9/2500 Kw/rpm
A B C
PB1 T5 PB2 S3 S4
Ø24.6~26.21=1000
Ø32.1=620 P
(1”5/8-12 JIC)
Ø9.5=1150 (9/16-18 JIC)
T
Ø19.11=900
(1”1/16-12 JIC) Ø9.51=1000 (9/16-18 JIC)
Ø6.51=350 (9/16-18 JIC)
Ø6.51=680 (9/16-18 JIC)
RED
Ø191=1650 Ø16 Ø191=1450
(1”1/16-12 JIC) t2 (1”5/16-12 JIC)

Ø9.51=1300 (9/16-18 JIC) Ø25.41=430
(1”5/16-12 JIC)
Ø191=850
Ø9.51=1300 (9/16-18 JIC) (1”1/16-12 JIC) Ø42
CVSM0366

HYDRAULIC CIRCUIT (HIGH-FLOW + FLOAT)

S
PPC VALVE L.H.
T
Ø6.51=670 (9/16-18 JIC) P1 P2 P4 P3
PPC VALVE R.H.
PORT 2 LS PRESSURE PORT
P P
PRESSURE
CHECK PORT P T
PORT P12 Ø4.71=450 (1/2-20 JIC) P

100
HI-FLOW ATT. MESH
100
P1 P2 P3 P4 MESH
A3 PORT PORT PORT PORT
Ø4.71=1570
(1/2-20 JIC)
MALE 3/4 Ø6.51=400 (1/2-20 JIC)
B3 1 3 2 4
Ø20 t=2 Ø16 (5/8) 1=3700 (1”14 ORFS)
PORT PORT Ø6.51=400 (1/2-20 JIC)

FEMALE 3/4 PB3 PA3
LEFT SIDE Ø20 t=2 Ø16 (5/8) 1=3700 (1”14 ORFS)
FRONT ARM
Ø101=520 (9/16-18 JIC)
Ø101=520 (9/16-18 JIC)

Ø6.41=435 (1/2-20 JIC)
Ø6.41=435 (1/2-20 JIC)
Ø6.41=435 (1/2-20 JIC)
Ø6.41=435 (1/2-20 JIC)

Ø101=520 (9/16-18 JIC)
Ø101=520 (9/16-18 JIC)

Ø6.51=600 (9/16-18 JIC)
Ø6.51=680 (9/16-18 JIC)
Ø6.41=435 (1/2-20 JIC)

Ø6.41=435 (1/2-20 JIC)
Ø6.41=435 (1/2-20 JIC)
Ø6.41=435 (1/2-20 JIC)

FEMALE 1/2
Ø16 t=2 Ø12.71 (1/2) 1=3700 (1”1/16-12 JIC-3/16 ORFS) CONNECTOR
CN-A
A2
PORT
PB2 B2
Ø6.41=1500 (1/2-20 JIC)
PORT
PA2
Ø6.41=1500 (1/2-20 JIC)

Ø9.51=1200 (13/16-16 ORFS)
Ø9.51=1850 (13/16-16 ORFS)
Ø101=1050 9/16-18 JIC)
Ø101=1050 (9/16-18 JIC)

PORT
LIFT ARM CYLINDER R.H. PB1
LIFT ARM A1
RAISE
B1
Ø9.51=1200 (13/16-16 ORFS)
ARM FLOAT
Ø9.51=1850 (13/16-16 ORFS)
BUCKET CYLINDER L.H.
Ø9.51=530 (13/16-16 ORFS) UNLOAD VALVE

CONNECTOR
Ø9.51=530 (13/16-16 ORFS) 12V CN-A
PORT
BUCKET CYLINDER R.H. PORT PA1
P
PORT LIFT ARM LOWER
TS
Ø9.51=530 (13/16-16 ORFS)
Ø101=650 (9/16-18 JIC)

Ø0.5
Ø9.51=530 (13/16-16 ORFS)
T
RELIEF VALVE
TRAVEL MOTOR L.H. 20.6MPa
(210kg/cm 2 )
DR
RED
Ø12.71=1950 (13/16-16 ORFS)
Ø12.71=1950 (13/16-16 ORFS) Ø101=850 (9/16-18 JIC)
Ø16t=2 Ø12.71=3700 (13/16-16 ORFS)
Ø16t=2 Ø12.71=3700 (13/16-16 ORFS)
Ø12.71=1350 (1”-14 ORFS) Ø101=950 (9/16-18 JIC)
Ø101=650 (9/16-18 JIC)
Ø19.1=1100 (1”3/16-12 ORFS)
PP2 A B PP1 PA1 DA1 DB1 DB2 DA2 PA2 P4 P5
Ø15.91=1100 (1”3/16-12 ORFS)
33.2 cm 2 /rev
23.7 cm 2 /rev
cm 2/rev
Ø6.51=600
(9/16-18 JIC) Ø15.91=1100 (1”3/16-12 ORFS)
28
Ø6.51=500 Ø15.91=1100 (1”3/16-12 ORFS) Ø7.3
(9/16-18 JIC) +40cm 2 /rev +40cm 2 /rev
Ø15.91=1100 (1”3/16-12 ORFS) E
PP1 B A PP2
ENGINE
Ø6.41=1550 S4D98E-2NFE
(9/16-18 JIC) 84.2/2500 PS/rpm
(61.9/2500 Kw/rpm
PB1 T5 PB2 S3 S4 S5
(1”5/16-12 JIC)
(1”5/8-12 JIC)
Ø25.41=800
Ø32.1=620
Ø24.6~26.21=1000 SV1 SPEED SV2 PPC SV3 BRAKE
A B C
Ø9.5=1150 (9/16-18 JIC)
Ø9.51=1000 (9/16-18 JIC)

Ø19.11=900 Ø6.51=350 (9/16-18 JIC)
(1”1/16-12 JIC) P
Ø6.51=680 (9/16-18 JIC)
T
Ø191=1650 Ø16 Ø191=1450
RED
(1”1/16-12 JIC) t2 (1”5/16-12 JIC)
Ø25.41=430
TRAVEL MOTOR R.H. DR (1”5/16-12 JIC)
Ø191=850
Ø9.51=1300 (9/16-18 JIC) (1”1/16-12 JIC)
Ø42
Ø9.51=1300 (9/16-18 JIC)
CVSM0367

ELECTRICAL DIAGRAM (ENGINE LINE)
R-N2.5
X01
V1 K02 K03 4
M2.5
X01
SAFETY RELAY 3
POWER K01 86 87 R4
X01
BOX 2
R4
R-B1
85 30 X01
G1
R1
N1
1
SOLENOID
X03 X03 X03 X03 X06 X06 X07 X07 X07 X07 XS1 XS1 X08 X08 X08 X08 N4 RELAY
GND. 5 AIR FILTER FUEL-STOP FUEL LEVEL BACK-UP
86 85 30 87 I - 4 3 2 1 A B 1 3 5 6 X03 SWITCH PREHEATING SOLENOID SENSOR ALARM
R-N2.5 XS R4 S25 R1 X13 X17 X29
R-N1.5
R-N1.5
R-N1.5
X02
M-V1
M-V1
R-G1
S-N1
L/B1
L/B1
B2.5
I
TO FRAME LINE OPT/STD

N1
N1
N1
B2
B1
L-R1
X02
SAFETY RELAY
R10
-
R-N1.5
X08 ENGINE OIL
X10 PERSURE SWITCH
13 S31
X10
12
R2.5
X10 SAFETY RELAY
11 XS1
R-V1
X10
B1 10
X10
9 INSULATOR
S1 XS
X10
8
C-N1
X10
7
C-L1 ENGINE STOP
X10 TIMER
S-G1 6
X10 X07 STOP LIGHT
5 PRESSURE SWITCH 2
X10 X20
4 DIODE
B-N1
X10 X06
3 GROUND
R-G1
X10
1
ENGINE COOLANT GND
8
2
2 BACK-UP
9
R10
3
TEMPERATURE
10
GND. B-G1
4
X10 FRAME SENSOR PRESSURE SWITCH 2
5
11
6
1 CABLE
1
1 X18 X23
2
7
13
1
X10
XF X28
+ FRAME
STOP LIGHT
CABLE
S31 PRESSURE SWITCH 2
FG1 X01
80A p>
HA3 - FRAME
START (+50) X21
CABLE BACK-UP
GROUND
X02 XM FUEL PRESSURE SWITCH 1
GND5 PUMP
XF GENERATOR X22
X11 X14
2 X29 X29
2 1
HYDRAULIC
Z-N1
OIL FILTER
N1
SWITCH
R10 R10
S26
GENERATOR
G2
R-N1.5
R-G1
R-G1
C-N1
S-G1
S-N1
B-N1
R-V1
M2.5
Z-N1
C-L1
L-R1
L-R1
L-R1
B2.5
R50 POWER (+30)

N2
N1
N1
N1
N1
S1
B2
CONNECT WITH XS
1 2 1 3 3 1 2 - + 1 2 1 C A - + 1 1 2 1 2 1 2 1 2
XS*
G1 +
1
X09 X11 X11 X11 X13 X13 X13 X14 X14 X15 X16 X16 X17 X17 X18 X18 X19 X20 X20 X21 X21 X22 X22 X23 X23
1 STARTER GENERAL
R-1.5
MOTOR FUSE (50A)

N2.5
B2.5
12Vcc XB XM R1 R2 R3
M2 S25 S26 S27 S28 S29 S30 XB FG1
M1 50 G2 D+ Y0 M
M 30
G W p> p> p> p> p> p>
- 3
t
U
N50
31
COMPONENTS
FG1 General Fuse 80A X06 Diode 2 Way Connector
G1 Battery 100Ah X07 Pool Solenoid Timer 4 Way Connector
G2 Generator X08 Safety Relay 6 Way Connector
GND C8 Ground Terminal X09 C6 Generator Terminal
GND5 C6 Ground Terminal X10 Frame Line Mark 13 Way Connector
HA3 Back-Up Alarm X11 Generator 3 Way Connector
K01 Fuel Solenoid Valve Relay X13 Fuel Pool-Stop Solenoid 3 Way Connector
K02 Fuel Pull Solenoid Valve Timer 1 Second X14 Fuel Pump 2 Way Connector
K03 Safety Relay X15 Preheating Start C6 Terminal
M1 Starter Motor X16 Air Filter Blocked Switch 2 Way Connector
M2 Fuel Pump X17 Fuel Level Sender 3 Way Connector
R1 Preheating Starter X18 Engine Water Temperature Sender 2 Way Connector
R2 Fuel Level Sender X19 Hydraulic Oil Filter Blocked Switch C5 Terminal
R3 Engine Water Temperature Sender X20 Stop Light Pressure 1 Switch 2 Way Connector
S25 Air Filter Blocked Switch X21 Stop Light Pressure 2 Switch 2 Way Connector
S26 Hydraulic Oil Filter Blocked Switch X22 Back-Up Pressure 1 Switch 2 Way Connector
S27 Stop Lights Pressure Switch X23 Back-Up Pressure 2 Switch 2 Way Connector
S28 Stop Lights Pressure Switch X28 Engine Min. Pressure Switch Terminal
S29 Back-Up Alarm Pressure Switch X29 Back-Up Alarm 2 Way Connector
S30 Back-Up Alarm Pressure Switch XB C8 Start Motor Terminal
S31 Engine Oil Min. Pressure Switch XF General Fuse 2 Way Connector
V1 Diode 1A XM C4 Start Motor Terminal
X01 Frame Line 3 Way Connector XS Safety Relay 2 Way Connector
X02 2 Way Connector XS1 Insulator
X03 Fuel Solenoid Relay Connector Y0 Stop Fuel Solenoid Valve CVSM0352

ELECTRICAL DIAGRAM (FRAME LINE - STANDARD)
X01.1 R-N2.5 M1
X48 TO
1 TO
X01.1 4 M2.5 M-V1 ENGINE CABLE
X48 CABIN CABLE
X01.1 3 2
X46 X01.1
R4 R-V1 TO
X48
2 3 ENGINE CABLE
X01.1 R4 L-G1
X48 X02.1
1 4 TO
ENGINE CABLE
8 9
1 2
X10.1
10
3
R-N2.5
4 5
X46
11 1
GND. 5 4 TO
M2.5
2 13
6 7
X46 CABIN CABLE
3
R4 X47
X02.1 X46
2
R4
FROM ENGINE LINE STD/OPT
X02.1 I L-R1.5
X46
1
- GND 5
X10.1 R-N1.5
X10.1 13 R-N1.5
X45
TO CABIN LINE EURO/USA STD.

X10.1 12 R1 V-N1 13
X45
X10.1 11 12
8 9 10
1 2 3
M-B1
X45 TO
X10.1 10 11
B1 L-R1.5 CABIN CABLE GND 2
4
X45
X45
11 12 13
5 6 7
X10.1 9 10
S1 B1
X45
X10.1 8 C-N1 M-N1
9
X45
X10.1 7 8
C-L1 R-G1
X45
X10.1 6 S-G1 S1
7
X45
X10.1 5 C-N1
6
X45
X10.1 4 B-N1 C-L1 5
X45 PPC SAFETY
X10.1 3 4
R-G1 S-G1 PRESSURE SWITCH
X45
1
X10.1 2 3 X32
2
B-G1 B-N1
X45 TO
3
5
1 2 CABIN CABLE
B-G1
X45 X48 BRAKE PRESSURE
1 SWITCH
X37
PPC SERV. VALVE 2nd SPEED VALVE BRAKE VALVE

X33 X36 X35
N4
X32A
X47
2
N4
X47 FLOAT VALVE
1
X34
N2.5
M-B1
M-N1
M-V1
L-G1
V-N1
M1
R1
N1
N1
N1
N1
1 1 1 2 1 2 1 2 1 2 1
X33 X33 X34 X34 X35 X35 X36 X36

COMPONENTS
X32 X32A X37
S32 S33
Y1 Y2 Y6 Y3 GND 2 C8 Ground Terminal
p> p>
GND 5 C6 Ground Terminal
S32 PPC Safety Pressure Switch
GND. 2 S33 Brake Valve Pressure Switch
X01.1 Engine Line 4 Way Connector
X32 PPC Safety Pressure Switch 1 Way Connector
X32A PPC Safety Pressure Switch 1 Way Connector
X33 PPC Valve 2 Way Connector
X34 Float Valve 2 Way Connector
X35 Brake Valve 2 Way Connector
X36 Second Speed Valve 2 Way Connector
X37 Brake Pressure Switch 1 Way Connector
X45 Cabin Line 13 Way Connector
X47 Ground 2 Way Connector
Y1 PPC Valve
Y2 Float Valve
Y3 Second Speed Valve
Y6 Brake Valve
CVSM0353
SK1026-5 Turbo 90-10j

ELECTRICAL DIAGRAM (FRAME LINE - OPTIONAL)
TO
ENGINE CABLE
X42
TO
X01.1 ENGINE CABLE
4
R-N2.5 M1 5
X48
1 2
X01.1
3
1 TO
X01.1 4 M2.5 M-V1 TO
X48 CABIN CABLE ENGINE CABLE
2 TO
X01.1 3 R4 R-V1 X46 ENGINE CABLE X43 TO
X48
2 3 X41 ENGINE CABLE
X01.1 R4 L-G1
X48 X02.1
1 4 TO
ENGINE CABLE
8 9
1 2
X10.1
10
N4
3
R-N2.5
4 5
X46
11 1
GND. 5 4 TO
M2.5
2 13
6 7
X46 CABIN CABLE
3
R4 X47
X02.1 X46
2
R4
X02.1 I X46
TO ENGINE LINE STD/OPT
L-R1.5 1
- GND. 5
X10.1 R-N1.5
X10.1 13 R-N1.5
X45
X10.1 12 R2.5 V-N1 13
X45
X10.1 11 12
TO CABIN LINE EURO/USA STD
8 9 10
1 2 3
RV.1 M-B1
X45 TO
X10.1 10 11
B1 L-R1.5 CABIN CABLE GND. 2
4
X45
X45
11 12 13
5 6 7
X10.1 9 10
S1 B1
X45
X10.1 8 C-N1 M-N1
9
X45
X10.1 7 8
C-L1 R-G1 GND. 1
X45
X10.1 6 S-G1 S1
7
X45
X10.1 5 C-N1
6
X45
X10.1 4 B-N1 C-L1 5
X45 PPC SAFETY
PRESSURE
1
X10.1 3 4
4
R-G1 S-G1
2
X45 TO SWITCH
3
X32
5
X10.1 2 3 CABIN CABLE
B-G1 B-N1
X45 X48
1 2
B-G1
X45
1
C-B1
X41
4 1 PPC SERV. BRAKE
C1 7
2
VALVE 2nd VALVE
X41 8 3
4
SPEED
3 9
HI-FLOW HI-FLOW X35 BRAKE
V-B1 10
5
6
X32A X33 VALVE PRESSURE
(POWER BOX ATTACH. LINE)
X41 11 MOMENTARY DETENT

2 X36 VALVE VALVE SWITCH
V1 C-B1 TO
X41 X49 CABIN CABLE X40 X39 X37
1 11
C1 X49
X49
10 FLOAT
N1.5 V-B1
X42 X49 VALVE
5 9
X42
L-R1.5 V1
X49
X34
4 8
A-N1 A-N1
X42 X49
3 7
A-B1 A-B1
X42 X49
2 6
A-G1 A-G1
X42 X49
1 5
Z-N1
X49
4
AV1
X49
S- N1.5 3
S-N1.5
X43 X49
1 2
L-R1.5
X49 COMPONENTS
1
GND. 1 C8 Ground Terminal

N4
X47 GND. 2 C8 Ground Terminal
N4 2 GND. 5 C6 Ground Terminal
X47
1 X01.1 Engine Line 4 Way Connector
X32 PPC Safety Pressure Switch 1 Way Connector
X32A PPC Safety Pressure Switch 1 Way Connector
X33 PPC Valve 2 Way Connector
X34 Float Valve 2 Way Connector
N2.5
X35 Brake Valve 2 Way Connector
X36 Second Speed Valve 2 Way Connector
X37 Brake Pressure Switch 1 Way Connector
X39 High-Flow Detent Valve 2 Way Connector
X40 High-Flow Momentary Valve 2 Way Connector
M-N1
M-V1
M-B1
L-G1
V-N1
Z-N1
A-V1
R2.5
X41
M1
Stabilizer 5 Way Connector

N1
N1
N1
N1
N1
N1
1 1 1 2 1 2 1 2 1 2 1 2 1 2 1 X42 Attachment 5 Way Connector

X43 ENPI Valve 1 Way Connector
X32 X32A X33 X33 X34 X34 X39 X39 X40 X40 X35 X35 X36 X36 X37
S32 GND. 2 GND. 1 S33 X46 Cabin Line 4 Way Connector
Y1 Y2 Y5 Y4 Y6 Y3
p> p> X47 Ground Cabin Line 2 Way Connector
Y1 PPC Valve
Y2 Float Valve
Y3 Second Speed Valve
Y4 Reverse Hi- Flow Momentary Valve
Y5 Super-Flow Detent Valve
Y6 Brake Valve
CVSM0354
SK1026-5 Turbo 90-11j

ELECTRICAL DIAGRAM (CAB LINE - STANDARD) (1 of 2)
H-R1
HA1 LEFT LEVER RIGHT LEVER
+ G1.5
R-N2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
S13 S14 S15
R2.5
X50 -
BRAKE P.B. IN L/B1
X52 X53 1 1 1 1 1 1 1
H-R2.5
1 1 1 1
X50 23
M2.5
HI SPEED P.B. IN A/B1
K04
B1
1 1 X64 X66 X68 X70 X72 X74 X76 85 87
X56 X58 X60 X62
R-N0.5
R-N0.5
X50 22
V/B0.5
L/G0.5
L/G0.5
FLOAT P.B. IN L/G1
R/N1
Z-B1
OFF ACC
21 R1 ST R1 ACC BR R2 C
SAF. BAR. SWITCH IN X50 C/N1 FU11 FU10 FU09 FU08 FU07 FU06 FU05 FU04 FU03 FU02 FU01 86 30 X83 X83 X83 X83 X84 X84 X84
20
SEAT SWITCH IN X50 C-B1 30A 7.5A 7.5A 10A 10A 10A 15A 7.5A 15A 3A 3A
POWER SUPPLY +12V X50 19 H-R1 S10 B

X89 X89 X89 X89 1 2 3 11 1 3 11
X57 X59 X61 X63 X65 X67 X69 X71 X73 X75 X77 X78 X79
X50 18
B-R1
B/R1
A/B1
N1
B-R1
L/G1
EV BRAKE OUT H-L1
N1
17 S12 1 1 1 1 1 1 1 1 1 1 1
1 1 85 86 30 87
STOP ENGINE OUT X50 R-N1.5
BRAKE LIGHT OUT X50 16 S/N1 S11
M-N1
B-N1
B-R1
B-R1
H/R1
N1
ELECTRONIC UNIT
H/R1
B-R1
A-R1.5
G/R1
G-N1
G-N1
R-N2.5
R-G1
L-R1.5
H/R1
H-R1.5
G1
+ -
SAF. BAR. LED OUT X50 15 B/N1
R4
14
SEAT LED OUT X50 G/N1 X55 X55
X54 X54 X54
13
WARNING LED OUT X50 M/B1
C A B 2 1
12
FLOAT OUT X50 B-N1
N1
H-R1
C-B1
H-R1
C/N1
BUZZER OUT (-) X50 11 Z-B1
G/R1 X85
10
Hi-SPEED OUT X50 M-B1 9
A-R1.5 X85
9 1
GROUND X50 N1.5
8 1 9
HORN OUT X50 C1 1 0
X50 7
START SIGN IN B1
6
+12V HORN X50 H-R1.5
5
S01 5 10
HORN PUSH B. IN X50 B/R1 A-G1.5 X85
4 5
PPC SAF. SWITCH IN X50 L-G1 N1 X85
X50 3 10
EV PPC OUT V-N1
2
BUZZER OUT (+) X50 R/N1
1
K06
G/R1 X86
G1.5 9 X86
8
H-N1 X86
1
1 6 9
1
X48.1 M1 0 2
1
X48.1 M-V1
X48.1 2
S02 3 2 10
X48.1 3 L-G1 H-R1.5 X86
4 3
H-R1 X86
N1 2 X86
10
X44 86
X46.1 R-N2.5
M1 X44 87a
4
X46.1 M2.5 S/N1 X87
X46.1 3 R4 H-R1
6
X87
K14 86 87a 87
3
X46.1 2 R4
FROM FRAME LINE STANDARD
1 15/1 30/3 L/6

85 30 0 1
X45.1 R-N1.5 H-L1 X44 30

13
X45.1 V-N1 X44 85 49/4 30b/2 R/7
12
B-G1 S08
X45.1 M-B1 L/B1 X87
11
X45.1 L-R1.5 H-R1 2
X87
10 7
X45.1 B1
9
X45.1 M-N1
8
X45.1 R-G1
7
X45.1 S1 G/R1 X88
6 9
X45.1 C-N1 H/R1 X88
5 1
X45.1 C-L1
4 1 9
X45.1 S-G1 1 0
3
X45.1 B-N1
2
X45.1 B-G1 S07 5 10
1
H-G1 X88
N1 5
X47.1 X88
2 10
X47.1 N4
1
A-G1.5
M-N1
G-N1
M-V1
M-B1
G-N1
H-G1
C-N1
H-R1
S-G1
B-G1
M/B1
G/N1
H-N1
H-N1
B-N1
B/N1
Z-B1
C-L1
H0.5
N1.5
M1
N1
C1
B1
S1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10 11
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X81
X81
X81
X81
X81
X81
X81
X81
X82
X82
X82
X82
X82
X82
X82
X82
X82
X82
X82
P1
CONTROL PANEL (UNIDECK) GND. 3
TO TOP CAB IN LINE STD.
CVSM0355A
SK1026-5 Turbo 90-12j
ELECTRICAL DIAGRAM (CAB LINE STANDARD) (2 of 2)
PARKING
SAFETY CONTROL BOX RELAY
X50 K14 FLOAT RELAY
BUZZER FUSE BOX SOCKET
X52-X53 CIGARETTE X56-X77 K04
CONTROL PANEL (EXTERNAL VIEW) INTERNAL CONECTION CONTROL PANEL LIGHTER
X78-X79 01171077
X80-15
X80-16
X80-12
X80-14
X80-11
X80-8
+ FROM
L1 L2 L3 L4 L5 C2 C3 FRAME LINE
X48.1
4
1
FUEL WATER TEMP.
2
LEVEL INDICATOR
1
H F
3
L1 L2 L3 L4 L5
C2
C1 00000 00 h PROXIMITY
BAR 3 WAY
C E X54
C1 FROM
HOUR COUNTER C3 FRAME LINE
DL1 DL2 DL3 X46.1

X80-6 L6 L7 L8 L9 L10
P
LEFT LEVER
X81-3
X81-4
X81-2
X81-5
X81-6
X81-7
X81-8
X81-1
STARTING RIGHT LEVER X83
1
SWITCH X84
8
2
9
S10
11 4 3
10
L6 L7 L8 L9 L10 DL2 DL1 DL3 X80-9
X80-2 X80-3
13 6 5
FROM
12
7
FRAME LINE
X45.1
SAFETY SEAT
SWITCH
GROUND
X47.1 X55
REAR FRONT
WIRE WIRE GROUND WORK LIGHTS WORK LIGHTS
POS. PIN FUNCTION SIGNAL COLOR POS. PIN FUNCTION SIGNAL COLOR GND. 3 SWITCH SWITCH CONTROL
1
2 PANEL
7
8
3
4 X85 X86
9
10
5
6 X80
X80-1 X80-9 INTERNAL LIGHTS (+LUCI) POSITIVE G-N1 11
C2 X80-2 FUEL LEVEL INDICATOR ohm B-N1 X80-10 BUZZER NEGATIVE Z-B1 CABIN LINE
X82 BRAKE BEACON LIGHT
C3 X80-3 WATER TEMPERATURE INDICATOR ohm C-N1 L5 X80-11 HYDRAULIC OIL FILTER LAMP NEGATIVE S-G1 CONTROL
PANEL BUTTON SWITCH
X80-4 PREHEATING LAMP X81 X87 X88
+50 START SIGNAL +50 B1 L2 X80-12 POSITIVE M1
GND. X80-5 GROUND GND. X80-13
GND. X80-6 GROUND GND. N1 L4 X80-14 AIR FILTER LAMP NEGATIVE C-L1
X80-7 L1 X80-15 GENERATOR LAMP NEGATIVE S1
COMPONENTS
+15 X80-8 POWER SUPPLY (+12V) +15 H-R1 L3 X80-16 ENGINE OIL PRESSURE LAMP NEGATIVE B-G1 GND3 C6 Ground Terminal X54 Proximity Bar 3 Way Connector
FU01 Fuse 3A Left Side Lights X55 Safety Seat Switch 3 Way Connector
FU02 Fuse 3A Control Panel Lights X56 Fuse 1 Way Connector
FU03 Fuse 15A Horn, Front Work Lights X57 Fuse 1 Way Connector
FU04 Fuse 7.5A Switch Lights X58 Fuse 1 Way Connector
FU05 Fuse 15A Rear Work Light X59 Fuse 1 Way Connector
FU06 Fuse 10A Lever Switch Power Supply, Float X60 Fuse 1 Way Connector
WIRE WIRE FU07 Fuse 10A Current Intake 12V, Beacon Light X61 Fuse 1 Way Connector
POS. PIN FUNCTION SIGNAL COLOR POS. PIN FUNCTION SIGNAL COLOR FU08 Fuse 10A Control Panel, Electronic Unit, Fuel Shut Off, Safety Bar Proximity, Seat Safety Switch and Brake Switch X62 Fuse 1 Way Connector
FU09 Fuse 7.5A Back-Up Alarm X63 Fuse 1 Way Connector
DL3 X81-1 SAFETY BAR OPEN LED NEGATIVE B/N1 L9 X81-5 DIRECTION LAMP POSITIVE L-N1 FU10 Fuse 7.5A Fuel Pump, Safety Engine Relay, Generator X64 Fuse 1 Way Connector
FU11 Fuse 30A Pull Solenoid, PPC Safety Pressure Switch X65 Fuse 1 Way Connector
L8 X81-2 FLOAT LAMP POSITIVE M-N1 L10 X81-6 LOW BEAM LAMP POSITIVE H0.5 HA1 Warning Buzzer X66 Fuse 1 Way Connector
L6 X81-3 PARKING BRAKE LAMP NEGATIVE M-V1 DL1 X81-7 WARNING LED NEGATIVE M/B1 K04 Float Relay X67 Fuse 1 Way Connector
K06 Electronic Unit X68 Fuse 1 Way Connector
L7 X81-4 SECOND SPEED LAMP POSITIVE M-B1 DL2 X81-8 SEAT LED NEGATIVE G/N1 K14 Brake Relay X69 Fuse 1 Way Connector
P1 Control Panel X70 Fuse 1 Way Connector
S01 Rear Work Lights Switch X71 Fuse 1 Way Connector
S02 Panel Lights and Low Beam Lights Switch X72 Fuse 1 Way Connector
S07 Beacon Light Switch X73 Fuse 1 Way Connector
S08 Brake Switch X74 Fuse 1 Way Connector
S10 Starting Switch X75 Fuse 1 Way Connector
S11 Safety Seat Switch X76 Fuse 1 Way Connector
S12 Bar PNP Safety Sensor X77 Fuse 1 Way Connector
S13 Horn Push Button X78 Current Intake 1 Way Connector
S14 Second Speed Push Button X79 Current Intake 1 Way Connector
S15 Float Push Button X80 Control Panel 16 Way Connector
X44 Brake Relay Connector X81 Control Panel 8 Way Connector
X45.1 From Frame Line 13 Way Connector X82 Lights Line 11 Way Connector
X46.1 From Frame Line 4 Way Connector X83 Left Lever 12 Way Connector
X47.1 From Frame Line 2 Way Ground Connector X84 Right Lever 12 Way Connector
X48.1 From Frame Line 5 Way Connector X85 Rear Work Lights SWF Switch
X50 Electronic Unit 23 Way Connector X86 Panel and Front Lights SWF Switch Connector
X52 Buzzer 1 Way Connector X87 Brake Switch Connector
X53 Buzzer 1 Way Connector X88 Beacon Light Switch Connector
X89 Float Relay Connector
CVSM0355B
SK1026-5 Turbo 90-13j

ELECTRICAL DIAGRAM (CAB LINE OPTIONAL) (1 of 3)
H-R1
HA1 G1.5
+
TO TOP CAB IN LINE OMOLOG./STD
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
R-N2.5
R2.5
- K04 K95 1 2 3 4 5 6 7 8 9 10 11
BRAKE P.B. IN X50 L/B1
X52 X53 1 1 1 1 1 1 1 85 87a 87
H-R2.5
X82
X82
X82
X82
X82
X82
X82
X82
X82
X82
X82
1 1 1 1 85 87
X50 23
M2.5
HI SPEED P.B. IN A/B1
B1
1 1 X64 X66 X68 X70 X72 X74 X76
X56 X58 X60 X62
X50 22
H-N1
A1
L1
G1
G-N1
R/N1
H-N1
A-G1.5
C1
N1.5
H-G1
FLOAT P.B. IN L/G1
R/N1
Z-B1
OFF ACC 85 30
R1 ACC BR R2 C 86 30
21 R1 ST
SAF. BAR. SWITCH IN X50 C/N1 FU11 FU10 FU09 FU08 FU07 FU06 FU05 FU04 FU03 FU02 FU01
20 X95 X95 X95 X95
SEAT SWITCH IN X50 C-B1 30A 7.5A 7.5A 10A 10A 10A 15A 7.5A 15A 3A 3A
X89 X89 X89 X89
POWER SUPPLY +12V X50 19 H-R1 S10 B
X57 X59 X61 X63 X65 X67 X69 X71 X73 X75 X77 86 85 30 87a
EV BRAKE OUT X50 18 H-L1
X78 X79 85 86 30 87
R-V1
S12
L-R1
M1
N1
17 1 1 1 1 1 1 1 1 1 1 1 1 1
STOP ENGINE OUT X50 R-N1.5
X50 16
M-N1
B-N1
B-R1
B-R1
S/N1 S11
H/R1
B-R1
A-R1.5
G/R1
G-N1
G-N1
BRAKE LIGHT OUT
R-N2.5
R-G1
L-R1.5
H/R1
H/R1
N1
+ -
SAF. BAR. LED OUT X50 15 B/N1
R4
14
SEAT LED OUT X50 G/N1 X55 X55
X54 X54 X54
13
C A B 2 1
12
FLOAT OUT X50 B-N1
N1
H-R1
C-B1
H-R1
C/N1
10
Hi-SPEED OUT X50 M-B1
9
GROUND OUT X50 N1.5
8 G/R1 X85
HORN OUT X50 C1
9
7 A-R1.5 X85
START SIGN IN X50 B1 1
6
+12V HORN X50 H-R1.5 1 9
5 1 0
HORN PUSH B. IN X50 B/R1
4
PPC SAF. SWITCH IN X50 L-G1
EV PPC OUT X50 3

V-N1
S01 5 10
2 G-N1.5 X85
BUZZER OUT (+) X50 R/N1 5
1 N1 X85
K06 10
G/R1 X86
G1.5 9 X86
8
H-N1 X86
1
X48.1 M1 1 6 9
1
0 2
X48.1 1 M-V1
X48.1 2 R-V1
X48.1 3
L-G1 S02 3 2 10
4 H-R1.5 X86
3
H-R1 X86
N1 2 X86
10
X46.1 86 X44
R-N2.5
4 X44
X46.1 M2.5 M1 87a
S/N1 X87
X46.1 3 R4
K14 86 87a 87 H-R1
6
X87
X46.1 2 R4 3
FROM FRAME LINE OPTION
1
85 30 15/1 30/3 L/6
0 1
X45.1 R-N1.5 H-L1 30 X44
13
X45.1 V-N1 X44
B-G1 85
49/4 30b/2 R/7
X45.1
12
M-B1
S08
11 L/B1 X87
X45.1 L-R1.5
H-R1 2
10 X87
X45.1 B1
7
X45.1 9 M-N1
8
X45.1 R-G1
7
X45.1 S1 G/R1 X88
6 9
X45.1 C-N1 H/R1 X88
5 1
X45.1 C-L1
4 1 9
X45.1 S-G1 1 0
3
X45.1 B-N1
2
X45.1 B-G1
S07 5 10
1
H-G1 X88
N1 5
X47.1 X88
2 10
X47.1 N4
1
M-N1
G-N1
M-V1
M-B1
C-N1
H-R1
S-G1
B-G1
M/B1
G/N1
B-N1
B/N1
Z-B1
C-L1
H0.5
M1
N1
B1
S1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8
A-R1.5
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X81
X81
X81
X81
X81
X81
X81
X81
L-R1.5
L-R1.5
G/R1
H/R1
B-R1
R-V1
R/N1
B/R1
L-N1
L/G1
A/B1
N1.5
N1
A1
L1
= Parts are Not Includes in the Wiring
P1
CONTROL PANEL (UNIDECK) GND. 3
CONTINUED ON PAGE 90-15 (CVSM0356B)
CVSM0356A
SK1026-5 Turbo 90-14j

RELAYS UNIT
K12 K08 K09 K11

86 87a 87 85 30 85 30 86 87
85 30 86 87 86 87 85 30
K10
K07 K13
FROM PAGE 90-14 (CVSM0356A) 85 30
+
R CL(T)
53M
53S
86 87
31
15
T
-(53S)
H/R1
L-N1
B-R1
L1
A1
R-V1
L/G1
L-R1.5
A/B1
L-R1.5
B/R1
R/N1
N1
N1.5
A-R1.5
G/R1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
X90.1
K05
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
A-V1
C/B1
L-R1.5
A/N1
L-N1
A/V1
R/N1
R-V1
L/N1
Z-N1
N1.5
A-N1
V/B1
L/R1
A-G1
Z/N1
A-B1
A-R1.5
A1 X104
2
L1 X104
1
0
S03 1 2
1 2
54
A/N1 X104
54
N1 X105
A/N1 10 X105
5
G/R1 X105
8
H/R1 X105
2
S09 2 8 5 10
1 0
4 6 3 1 7
L/R1 X105
4
A1 X105
L1 3 X105
1
G/R1 X105
X49.1 7
C-B1
X49.1 11 C1 G/R1 X106
9
X49.1 10 V-B1 V-B1 X106
7
X49.1 9 V1
V1 X106
1
X49.1 8 A-N1 S05
0 1 7 9
X49.1 7 A-B1 1 2
X49.1 6
A-G1
B-R1
B-R1
A-N1
B/R1
C/B1
Z-N1
A-B1
A/B1
V/B1
L/G1
A/V1
Z/N1
L/N1
A-G1
N1
N1
X49.1 5 Z-N1
L-R1.5
1 2 3 4 5 6 11 1 2 3 4 5 6 7 8 9 11 3 10
G/R1
S-N1
X49.1 4
N1
AV1 L-R1.5 X106
X49.1 3 S-N1 5 1 9 10 3
X83
X83
X83
X83
X83
X83
X83
X84
X84
X84
X84
X84
X84
X84
X84
X84
X84
N1 X106
X49.1 2 L-R1.5 10
LEFT LEVER RIGHT LEVER
R-N0.8
R-N0.8
A-G0.5
A-N0.5
A-B0.5
A-B0.5
Z-N0.5
V/B0.8
L/G0.8
A/V0.8
Z/N0.8
V/B0.8
L/G0.8
A/V0.8
Z/N0.8
1
N0.8
N0.8
G/R1 X107
SWITCH EV ENPI C-B1 9 X107
7
C1 X107
1
0 S06 1 7 9
1 2
3 10
S13 S14 S36 S37 HL1 S15 S38 HL2 S39 HL3 S40 HL4 HL5
L-R1.5 X107
N1 3
X107
10
CVSM0356B
SK1026-5 Turbo 90-15j

BUZZER
FROM X52-X53
FRAME LINE PARKING STOP LIGHT OFF
X49.1 SAFETY CONTROL BOX RELAY RELAY
7 X50 K14 FLOAT RELAY S K95 COMAND UNIT
9
8
1 CURRENT INTAKE SOCKET RELAY
2 FUSE BOX
SOLDER JOINT 10 4
11 5
3
X78-X79 X56-X77 K04 K90
6
SAL ENPI VALVE
11 10 9 8 7 6 5 4 3 2 1
SWITCH
21 20 19 18 17
01171077
X91
CONTROL PANEL (EXTERNAL VIEW) INTERNAL CONECTION CONTROL PANEL

FROM
16 15 14 13 12
FRAME LINE
X80-15
X80-16
X80-12
X80-14
X80-11
X80-8
+ X48.1
4
1
L1 L2 L3 L4 L5 C2 C3
2
1
3
FUEL WATER TEMP. PROXIMITY
LEVEL INDICATOR BAR 3 WAY
H F
L1 L2 L3 L4 L5 X54
C2 FROM
C1 00000 00 h FRAME LINE
X46.1
C E
RIGHT LEVER
C1 X84
C3 LEFT LEVER
HOUR COUNTER
DL1 DL2 DL3 STARTING X83
1
SWITCH
8
2
X80-6 L6 L7 L8 L9 L10
9
S10
11 4 3
10
P
X81-3
X81-4
X81-2
X81-5
X81-6
X81-7
X81-8
X81-1
13 6 5
FROM
12
7
FRAME LINE
X45.1 HAZARD
L6 L7 L8 L9 L10 DL2 DL1 DL3 X80-9
SWITCH
X80-2 X80-3
X105
LEFT STAB. SWITCH
SAFETY SEAT
SWITCH X106
GROUND X55
X47.1
FRONT
WORK LIGHTS
SWITCH
REAR STAB. DX SWITCH
GROUND X86
WORK LIGHTS X107
1
GND. 3 SWITCH CONTROL
2
3 PANEL
7
8 4 X85
9
10
5
6 X80
WIRE WIRE
11
POS. PIN FUNCTION SIGNAL COLOR POS. PIN FUNCTION SIGNAL COLOR CABIN LINE
X82 BRAKE
DIRECTION LIGHTS CONTROL
X80-1 X80-9 INTERNAL LIGHTS (+LUCI) POSITIVE G-N1 SWITCH PANEL BUTTON
X104 X81 X87 BEACON LIGHT SWITCH
C2 X80-2 FUEL LEVEL INDICATOR ohm B-N1 X80-10 BUZZER NEGATIVE Z-B1
X88
C3 X80-3 WATER TEMPERATURE INDICATOR ohm C-N1 L5 X80-11 HYDRAULIC OIL FILTER LAMP NEGATIVE S-G1
+50 X80-4 START SIGNAL +50 B1 L2 X80-12 PREHEATING LAMP POSITIVE M1
GND. X80-5 GROUND GND. X80-13 COMPONENTS
GND3 C6 Ground Terminal S01 Rear Work Lights Switch X59 Fuse 1 Way Connector X104 Direction Lights Switch Connector
X80-7 L1 X80-15 GENERATOR LAMP NEGATIVE S1
FU01 Fuse 3A Left Side Lights, Plate Light S02 Panel Lights and Low Beam Lights Switch X60 Fuse 1 Way Connector X105 SWF Hazard Connector
+15 X80-8 POWER SUPPLY (+12V) +15 H-R1 L3 X80-16 ENGINE OIL PRESSURE LAMP NEGATIVE B-G1 FU02 Fuse 3A Control Panel Lights, Right Side Lights S03 Direction Lights Switch X61 Fuse 1 Way Connector X106 Stabilizer Push Button Connector
FU03 Fuse 15A Horn, Low Beam or Front Work Lights S05 Up-Down Left Stabilizer Button X62 Fuse 1 Way Connector X107 Stabilizer Push Button Connector
FU04 Fuse 10A Switch Lights, Direction Lights S06 Up-Down Right Stabilizer Button X63 Fuse 1 Way Connector
FU05 Fuse 15A Rear Work Light, Stop Light S07 Beacon Light Switch X64 Fuse 1 Way Connector
FU06 Fuse 10A Lever Switch Power Supply, Float S08 Brake Switch X65 Fuse 1 Way Connector
FU07 Fuse 10A Current Intake 12V, Hazard, Beacon Light S09 Hazard Switch X66 Fuse 1 Way Connector
FU08 Fuse 10A Control Panel, Electronic Unit, Fuel Shut Off, S10 Starting Switch X67 Fuse 1 Way Connector
WIRE WIRE Safety Bar Proximity, Seat Safety Switch and Brake Switch S11 Safety Seat Switch X68 Fuse 1 Way Connector
POS. PIN FUNCTION SIGNAL COLOR POS. PIN FUNCTION SIGNAL COLOR FU09 Fuse 10A Back-Up Alarm, Attachment 3 Way, Hi-Flow, S12 Bar PNP Safety Sensor X69 Fuse 1 Way Connector
Stabilizer, ENPI Valve S13 Horn Push Button X70 Fuse 1 Way Connector
DL3 X81-1 SAFETY BAR OPEN LED NEGATIVE B/N1 L9 X81-5 DIRECTION LAMP POSITIVE L-N1 FU10 Fuse 7.5A Fuel Pump, Safety Engine Relay, Generator S14 Second Speed Push Button X71 Fuse 1 Way Connector
FU11 Fuse 30A Pull Solenoid, PPC Safety Pressure Switch S15 Float Push Button X72 Fuse 1 Way Connector
L8 X81-2 FLOAT LAMP POSITIVE M-N1 L10 X81-6 LOW BEAM LAMP POSITIVE H0.5 HA1 Warning Buzzer S36 Reverse Hi-Flow Momentary Push Button X73 Fuse 1 Way Connector
X81-3 DL1 X81-7 WARNING LED NEGATIVE M/B1 HL1 Super-Flow LED Diode S37 Super-Flow Detent Push Button X74 Fuse 1 Way Connector
L6 PARKING BRAKE LAMP NEGATIVE M-V1
HL2 “C” Way LED Diode S38 “C” Way Push Button X75 Fuse 1 Way Connector
L7 X81-4 SECOND SPEED LAMP POSITIVE M-B1 DL2 X81-8 SEAT LED NEGATIVE G/N1 HL3 “A” Way LED Diode S39 “A” Way Push Button X76 Fuse 1 Way Connector
HL4 “B” Way LED Diode S40 “B” Way Push Button X77 Fuse 1 Way Connector
HL5 Optional LED Diode X44 Parking Brake Relay Connector X78 Current Intake 1 Way Connector
K04 Float Relay X45.1 From Frame Line Mark 13 Way Connector X79 Current Intake 1 Way Connector
K05 Relays Box (Without Relays) X46.1 From Frame Line 4 Way Connector X80 Control Panel 16 Way Connector
K06 Electronic Unit X47.1 Ground 2 Way Connector X81 Control Panel 8 Way Connector
K07 “B” Way Relay X48.1 From Frame Line Mark 5 Way Connector X82 Lights Line 11 Way Connector
K08 “A” Way Relay X49.1 From Frame Line Mark 11 Way Connector X83 Left Lever 12 Way Connector
K09 “C” Way Relay X50 Safety Control Box 23 Way Connector X84 Right Lever 12 Way Connector
K10 Super-Flow Detent Step By Step Relay X52 Buzzer 1 Way Connector X85 Rear Work Lights SWF Switch
K11 Reverse Hi-Flow Momentary Relay X53 Buzzer 1 Way Connector X86 Panel and Front Lights SWF Switch Connector
K12 Stop Lights Relay X54 Proximity Bar 3 Way Connector X87 Brake Push Button Connector
K13 Flasher Unit X55 Safety Seat Switch 2 Way Connector X88 Beacon Light Switch Connector
K14 Brake Relay X56 Fuse 1 Way Connector X89 Float Relay Connector
K95 Stop Light Relay X57 Fuse 1 Way Connector X90 Relays Box 21 Way Connector
P1 Control Panel X58 Fuse 1 Way Connector X91 ENPI Valve SWF Connector
CVSM0356C
SK1026-5 Turbo 90-16j

ELECTRICAL DIAGRAM (TOP-CAB LIGHT LINE STANDARD)
REAR RIGHT REAR LEFT

WORKING LIGHT WORKING LIGHT
= Parts are not included on the wiring H11 H10
B
A A B
X82.1 H-G1
11
X82.1 N1.5
10
X82.1 C1
9
X82.1 A-G1
FROM CABIN LINE
8
X82.1 H-N1 FRONT LEFT
7 WORKING LIGHT
X82.1 H-N1 H4
GND. 4
6
9 8 7
3 2 1
X82.1
FROM
5 DASHBOARD
A B
X82.1 CABLE
6 5 4
4 X82.1
11 10
X82.1
X82.1 3
2
X82.1
1
1 2 1 2 A B A B 2 1
HORN
X108 X108 X109 X109 X110 X110 X111 X111 XP1 XP1A CURRENT
INTAKE (12V) HA 2
XP1
H-N1
N1
H-N1
N1
A-G1
N1
A-G1
N1
N1
H-G1
B A
GROUND
GND. 4
FRONT RIGHT
WORKING LIGHT
H6
HORN
GROUND
GND. 6 GND. 6
X113 H1
H4 H6 H10 H11
M
HA2
COMPONENTS
GND. 4 C6 Ground Terminal

GND. 6 C8 Horn Ground Terminal
H1 Beacon Light
H4 Left Front Work Lamp
H6 Right Front Work Lamp
H10 Left Rear Work Light
H11 Right Rear Work Light
HA2 Horn
X82.1 From Cabin Line 11 Way Connector
X108 Left Front Light 2 Way Connector
X109 Right Front Light 2 Way Connector
X110 Left Rear Work Lights 2 Way Connector
X111 Right Rear Work Lights 2 Way Connector
X113 Horn 1 Way Connector
XP1 12V Socket, Beacon Light 1 Way Connector
XP1A 12V Socket, Beacon Light 1 Way Connector
CVSM0357
SK1026-5 Turbo 90-17j

ELECTRICAL DIAGRAM (TOP-CAB LIGHT LINE -OPTIONAL)
REAR LEFT
WORKING LIGHT
H10
G1
TO REAR LIGHT LINE
X130 REAR RIGHT

7 WORKING LIGHT
R-N1.5
X130 H11 FRONT LEFT
6 G-N1 A B
LIGHT
X130 H5
5
A1
X130 REAR LIGHT
4 CONNECTOR
B
N1.5 A
X130 = Parts are not included on the wiring X130
3
X130
2
5 6
1
L1
X130
2
FRONT LEFT
3
1
7
4
MAIN BEAM
H4
X82.1 H-G1
11
X82.1
A
N1.5
B
10
X82.1 C1
9 8 7
3 2 1
9 FROM
X82.1 A-G1 DASHBOARD
FROM CABIN LINE
8 CABLE
6 5 4
X82.1 H-N1 X82.1
11 10
7
X82.1 H-N1
6
X82.1 R-N1.5
5
X82.1 G-N1
GND. 4
4
X82.1 G1
3
X82.1 L1
2
X82.1 A1 HORN
1 HA 2
CURRENT
INTAKE (12V)
A B 1 1 1 A B 1 1 1 A B A B 1 1
XP1
1
B A
X113 X108 X108 X115 X116 X117 X109 X109 X118 X119 X120 X110 X110 X111 X111 XP1 XP1A GROUND
GND. 4 FRONT RIGHT
LIGHT
H-N1
N1
L1
G1
N1
N1
H-N1
G-N1
A1
N1
A-G1
N1
A-G1
N1
N1
H-G1
FRONT RIGHT
H7
MAIN BEAM
HORN H6
GROUND
GND. 6
GND. 6
HA2
H5 H7 H1
L
58L
58R
H4 H6 H10 H11
M
COMPONENTS
31
31
H8 Left Rear Lamp

H9 Right Rear Lamp
H12 Plate Light
X121 Rear Traffic Lights 1 Way Connector
X129 Plate Light Connector
X129.1 Plate Light Connector
X130.1 Cabin Line 7 Way Female Connector
X131 2 Way DT Male Connector
X131.1 2 Way DT Female Connector
X132 7 Way Male Connector
X132.1 7 Way Female Connector
CVSM0358
SK1026-5 Turbo 90-18j

ELECTRICAL DIAGRAM (REAR LIGHT LINE)
REAR LEFT
WORKING LIGHT
H10
REAR RIGHT
WORKING LIGHT
H11 FRONT LEFT
A B
LIGHT
= Parts are not included on the wiring H5
REAR LIGHT B
CONNECTOR A
X130
5 6
1
2
FRONT LEFT
3
7
4
MAIN BEAM
H4
X130.1 G1 X132 X132.1 G1
FROM CABIN LINE
X130.1 7 X132.1 7
R-N1.5 X132
A
B
X130.1 G-N1 6 X132.1 6 G-N1
X132
9 8 7
5 X132.1 5
3 2 1
X130.1 A1 X132 A1 FROM
X130.1 4 4 DASHBOARD
N1.5 X132 X132.1
CABLE
6 5 4
X130.1 3 X132.1 3 X82.1
11 10
X132
2 2
X130.1 L1 X132 X132.1 L1
1 1
X131
X131
1 2
HORN
HA 2
1 2
X131.1
X131.1
CURRENT
INTAKE (12V) B A
XP1 GROUND
FRONT RIGHT
GND. 4 LIGHT
G1
N1
FRONT RIGHT
H7
1 2 1 1 1 1 1 1 1 1
MAIN BEAM
HORN H6
X121 X122 X123 X124 X115 X116 X117 GROUND
GND. 6
X129.1
X129
N1
L1
G1
R-N1
R-N1
G-N1
A1
N1
G1
N1
H8 H9
L
58L
54
54
58R
H12
COMPONENTS
31
31
H8 Left Rear Lamp

H9 Right Rear Lamp
H12 Plate Light
X129 Plate Light Connector
X129.1 Plate Light Connector
X130.1 Cabin Line 7 Way Female Connector
X131 2 Way DT Male Connector
X131.1 2 Way DT Female Connector
X132 7 Way Male Connector
X132.1 7 Way Female Connector
CVSM0359
SK1026-5 Turbo 90-19j

ELECTRICAL DIAGRAM (STANDARD)

H-R1
HA1
+ G1.5 S13 S14 S15
S13
R-N2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
S14
R2.5
K14, X18 X13
X50 -
BRAKE P.B. IN L/B1
H-R2.5
X52 X53 1 1 1 1 1 1 1 1 1 1 1
R-N0.5
R-N0.5
V/B0.5
L/G0.5
L/G0.5
M2.5
X50 23
1 2 HI SPEED P.B. IN A/B1 K04
B1
1 1 X56 X58 X60 X62 X64 X66 X68 X70 X72 X74 X76 85 87
22
FLOAT P.B. IN X50 L/G1
R/N1
Z-B1
X83 X83 X83 X83 X84 X84 X84
3 SAF. BAR. SWITCH IN X50
21
C/N1
OFF ACC
R1 ACC BR R2 C FU11 FU10 FU09 FU08 FU07 FU06 FU05 FU04 FU03 FU02 FU01
R1 ST 86 30
20 30A 7.5A 7.5A 10A 10A 10A 15A 7.5A 15A 3A 3A 1 2 3 11 1 3 11
SEAT SWITCH IN X50 C-B1
K08 K07
B-R1
L/G1
B-R1
B/R1
A/B1
N1
X50 19
POWER SUPPLY +12V H-R1 S10 X89 X89 X89 X89
N1
18 B X57 X59 X61 X63 X65 X67 X69 X71 X73 X75 X77
X78 X79
1 2 3 1 2 EV BRAKE OUT X50 H-L1
85 86 30 87
17 1 1 1 1 1 1 1 1 1 1 1 1 1
STOP ENGINE OUT X50 R-N1.5 S12
4 5 6 3 4 BRAKE LIGHT OUT X50 16
S/N1
H/R1
N1
M-N1
B-N1
B-R1
B-R1
ELECTRONIC UNIT
H-R1.5
H/R1
B-R1
A-R1.5
G/R1
G-N1
G-N1
G1
R-N2.5
R-G1
L-R1.5
H/R1
SAF. BAR. LED OUT X50 15
B/N1
S11
R4
+ -
14
SEAT LED OUT X50 G/N1
13 X54 X54 X54 X55 X55
= Parts are not included on the wiring = Parts are not included on the wiring 12
WIRE POSITIONING ON CONNECTOR FLOAT OUT X50 B-N1 C A B 2 1
11
(WIRE SIDE VIEWING WIRING) X50 Z-B1
N1
H-R1
C-B1
H-R1
BUZZER OUT (-)
C/N1
G/R1 X85
10 9
Hi-SPEED OUT X50 M-B1 A-R1.5 X85
9 1
GROUND X50 N1.5
8 1 9
HORN OUT X50 C1 1 0
X50 7
START SIGN IN B1
6
+12V HORN X50 H-R1.5
R-N2.5 X01 X01.1 R-N2.5 S01 5 10
5
4 4 HORN PUSH B. IN X50 B/R1 A-G1.5 X85
M2.5 X01 X01.1 M2.5
X50 4 5
3 3 PPC SAF. SWITCH IN L-G1 N1 X85
R4 X01 X01.1 R4
V1 K02 K03 EV PPC OUT X50 3
V-N1 10
2 2
R4 X01 X01.1 R4 2
86 87 SAFETY RELAY BUZZER OUT (+) X50 R/N1
POWER K01 1 1
1
BOX K06
R-B1
N4
85 30
G1
R1
N1
N4 G/R1 X86
X03 X03 X03 X03 X06 X06 X07 X07 X07 X07 XS1 XS1 X08 X08 X08 X08
GND. 5 GND. 5 9
G1.5 X86
H-N1 8 X86
86 85 30 87 I - 4 3 2 1 A B 1 3 5 6
XS X02.1 1
R-N2.5
R-N1.5
R-N1.5
R-N1.5
R4 X02
M-V1
M-V1
R-G1
S-N1
L/B1
L/B1
B2.5
I I 1 6 9
N1
N1
N1
X02.1
B2
B1
L-R1 X02 L-R1.5
1
M1 X48 X48.1 M1 0 2
R10
- -
M-V1 1 1
R-N1.5 X10 X10.1 R-N1.5 X48 X48.1 M-V1
13 13 X10.1 2 2 X48.1
X10 R-V1 X48 S02 3 2 10
12 12 3 3
X10.1 R2.5 L-G1 X48 X48.1 L-G1 H-R1.5 X86
R2.5 X10
4 4 H-R1 3 X86
11 11
R-V1 X10 X10.1 R-V1
N1 2 X86
10 10
B1 X10 X10.1 B1 R-N2.5 X46 X46.1 R-N2.5 10
9 9 X10.1 H-L1 X44 86
S1 X10 S1 4 4 X46.1
M2.5 X46 M2.5
8 8 M1 X44 87a
C-N1 X10 X10.1 C-N1 3 3
R4 X46 X46.1 R4 S/N1 X87
7 7 X10.1 2 6
C-L1 X10 C-L1 2 X46.1 H-R1 X87
R4 X46 R4 K14 86 87a 87
6 6 X10.1 3
S-G1 X10 S-G1 1 1
5 5 X10.1 15/1 30/3 L/6
X10 0 1
85 30
4 4 X10.1
B-N1 X10 B-N1
R-N1.5 X45 X45.1 R-N1.5 H-L1 X44 30
3 3 X10.1
R-G1 X10 R-G1 13
2 2 X10.1 V-N1 X45 13 X45.1 V-N1 B-G1 X44 85 S08 49/4 30b/2 R/7
R10
GND. B-G1 X10 B-G1 12 X45.1

1 1 M-B1 X45 12 M-B1 L/B1 X87
1 1 11 11
L-R1.5 X45 X45.1 L-R1.5 H-R1 2
XF X87
X28
+ B1 X45
10 10
X45.1 B1 7
S31 9 9
FG1
80A p>
HA3 - M-N1 X45 X45.1 M-N1
8 8 X45.1 R-G1
R-G1 X45
7 G/R1 X88
XF S1 X45 7 X45.1 S1
H/R1 9 X88
2 X29 X29 6 6
C-N1 X45 X45.1 C-N1
1
2 1 C-L1 5 5 X45.1 C-L1
X45 1 9
Z-N1
4 4 1 0
N1
S-G1 X45 X45.1 S-G1
3 3
R10 R10 B-N1 X45 X45.1 B-N1
2 2 S07 5 10
B-G1 X45 X45.1 B-G1
1 1 H-G1 X88
R-N1.5
N1 5 X88
R-G1
R-G1
C-N1
S-G1
S-N1
B-N1
R-V1
M2.5
Z-N1
C-L1
L-R1
L-R1
L-R1
B2.5
R50 10
N2
N1
N1
N1
N1
S1
B2
N4 X47 X47.1 N4
1 2 1 3 3 1 2 - + 1 2 1 C A - + 1 1 2 1 2 1 2 1 2
2 2 X47.1 N4
G1 N4 X47
+ X09 X11 X11 X11 X13 X13 X13 X14 X14 X15 X16 X16 X17 X17 X18 X18 X19 X20 X20 X21 X21 X22 X22 X23 X23 1 1
1 1
R-1.5
G-N1
C-N1
H-R1
S-G1
B-G1
N2.5
B-N1
B2.5
M-N1
Z-B1
C-L1
M-V1
M-B1
M/B1
G/N1
B/N1
R1 R2 R3
H0.5
12Vcc XB XM
M1
N1
M2
B1
S1
S25 S26 S27 S28 S29 S30
A-G1.5
M1 50 G2 D+ Y0 M
G-N1
H-G1
H-N1
H-N1
M
N1.5
30 G W p> p> p> p> p> p> 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8
G1
C1
- 3
t INTERNAL CONECTION CONTROL PANEL
N50
U CONTROL PANEL (EXTERNAL VIEW) 1 2 3 4 5 6 7 8 9 10 11
X80-15
X80-16
X80-12
X80-14
X80-11
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X81
X81
X81
X81
X81
X81
X81
X81
31
X80
X80-8
X82
X82
X82
X82
X82
X82
X82
X82
X82
X82
X82
+
L1 L2 L3 L4 L5 C2 C3
ENGINE PARTS P1
GND. 3
L1 L2 L3 L4 L5 CONTROL PANEL (UNIDECK)
FUEL WATER TEMP.
LEVEL INDICATOR
N2.5
H F
1 2 3 4 5 6 7 8 9 10 11
M-B1
M-V1
M-N1
L-G1
V-N1
R2.5
C2
M1
N1
N1
C1
N1
N1
00000 00 h
DESCRIPTION
X82.1
X82.1
X82.1
X82.1
X82.1
X82.1
X82.1
X82.1
X82.1
X82.1
H-G1 X82.1
NAME SUPP. TYPE QTY. 1 1 1 2 1 2 1 2 1 2 1
C E
= Parts are not included on the wiring
X32 X32A X33 X33 X34 X34 X35 X35 X36 X36 X37 C1
H-N1
H-N1
A-G1
DESCRIPTION
N1.5
C3
FG1 General Fuse 80A CIAM 163028 HOUR
NAME SUPP. TYPE QTY.
C1
1 S32 S33 COUNTER
Y1 Y2 Y6 Y3 DL1 DL2 DL3
G1 Battery 100Ah FIAMM (KUE) L5 600 103 086 (37C-06-11110) 1 p> p> X80-6
L6 L7 L8 L9 L10
G2 Generator YANMAR (DENSO) 129423-77200 1 P
S07 Beacon Light Switch C1AM 106AA008 (KUE 885081160) 1
X81-3
X81-4
X81-2
X81-5
X81-6
X81-7
X81-8
X81-1
GND C8 Ground Terminal * * 1 GND. 2 X80-2 X80-3 S08 Brake Switch C1AM 0A003455 (KUE 37A-06-11410) 1
GND5 C6 Ground Terminal * * 1 S10 Starting Switch 1
L6 L7 L8 L9 L10 DL2 DL1 DL3 X80-9
HA3 Back-Up Alarm CIAM (KUE) 0A001357 (312612100) 1 S11 Safety Seat Switch 1
K01 Fuel Solenoid Valve Relay MATSUSHITA (KUE) CB1aH (885071022) 1 S12 Bar PNP Safety Sensor SAIET E-A1TMU/3AP (KUE 37A-06-11250) 1
K02 Fuel Pull Solenoid Valve Timer 1 Second 1 S13 Horn Push Button 1
K03 Safety Relay YANMAR (KUE) 119802-77200 1 S14 Second Speed Push Button 1 1 2 1 2 A B A B 2 1 GND. 4
WIRE WIRE
M1 Starter Motor YANMAR 123900-77010 1 POS. PIN FUNCTION SIGNAL COLOR POS. PIN FUNCTION SIGNAL COLOR S15 Float Push Button 1
M2 Fuel Pump YANMAR 129612-52100 1 X44 Brake Relay Connector 1 X108 X108 X109 X109 X110 X110 X111 X111 XP1 XP1A
R1 Preheating Starter YANMAR 129100-77500 1 X80-1 X80-9 INTERNAL LIGHTS (+LUCI) POSITIVE G-N1
X45.1 From Frame Line 13 Way Connector AMP * 1
R2 Fuel Level Sender COBO (KUE) 29-0419-0000 (37A-04-11140)
H-N1
N1
H-N1
N1
A-G1
N1
A-G1
N1
N1
H-G1
1 C2 X80-2 FUEL LEVEL INDICATOR ohm B-N1 X80-10 BUZZER NEGATIVE Z-B1 X46.1 From Frame Line 4 Way Connector DEUTSCH DTP04-4P 1
R3 Engine Water Temperature Sender YANMAR (KUE) (7861-92-3320) 1 C3 X80-3 WATER TEMPERATURE INDICATOR ohm C-N1 L5 X80-11 HYDRAULIC OIL FILTER LAMP NEGATIVE S-G1 X47.1 From Frame Line 2 Way Ground Connector DEUTSCH DTP04-2P 1
S25 Air Filter Blocked Switch DONALDSON (KUE) X770317 (37A-06-11960) 1 X48.1 From Frame Line 5 Way Connector AMP * 1
+50 X80-4 START SIGNAL +50 B1 L2 X80-12 PREHEATING LAMP POSITIVE M1 X113 GND. 6
S26 Hydraulic Oil Filter Blocked Switch FMDI (KUE) 11716/1 (885261034) 1 X50 Electronic Unit 23 Way Connector AMP * 1
H1
GND. X80-5 GROUND GND. X80-13
S27 Stop Lights Pressure Switch FMDI (KUE) 11717.70 (37A-06-11680) 1 X52 Buzzer 1 Way Connector AMP * 1 H4 H6 H10 H11
S28 Stop Lights Pressure Switch FMDI (KUE) 11717.70 (37A-06-11680) 1 GND. X80-6 GROUND GND. N1 L4 X80-14 AIR FILTER LAMP NEGATIVE C-L1 M
X53 Buzzer 1 Way Connector AMP * 1
S29 Back-Up Alarm Pressure Switch FMDI (KUE) 11717.70 (37A-06-11680) 1 X80-7 L1 X80-15 GENERATOR LAMP NEGATIVE S1 X54 Proximity Bar 3 Way Connector DEUTSCH * 1 HA2
S30 Back-Up Alarm Pressure Switch FMDI (KUE) 11717.70 (37A-06-11680) 1 X55
S31 Engine Oil Min. Pressure Switch YANMAR *
+15 X80-8 POWER SUPPLY (+12V) +15 H-R1 L3 X80-16 ENGINE OIL PRESSURE LAMP NEGATIVE B-G1 Safety Seat Switch 3 Way Connector DEUTSCH * 1 WIRING COLORS
1 X56 Fuse 1 Way Connector AMP * 1
V1 Diode 1A CIAM 1A1N4007 1 X57 Fuse 1 Way Connector AMP * 1
A LIGHT BLUE
X01 Frame Line 3 Way Connector * * 1 WIRE WIRE X58 Fuse 1 Way Connector AMP * 1
POS. PIN FUNCTION SIGNAL POS. PIN FUNCTION SIGNAL B WHITE
X02 2 Way Connector * * 1 COLOR COLOR X59 Fuse 1 Way Connector AMP * 1
C ORANGE
X03 Fuel Solenoid Relay Connector * * 1 X60 Fuse 1 Way Connector AMP * 1
DL3 X81-1 SAFETY BAR OPEN LED NEGATIVE B/N1 L9 X81-5 DIRECTION LAMP POSITIVE L-N1 G YELLOW
X61 Fuse 1 Way Connector AMP * 1
H GRAY
L8 X81-2 FLOAT LAMP POSITIVE M-N1 L10 X81-6 LOW BEAM LAMP POSITIVE H0.5
X62 Fuse 1 Way Connector AMP * 1
L BLUE
X06 Diode 2 Way Connector * * 1 L6 X81-3 PARKING BRAKE LAMP NEGATIVE M-V1 DL1 X81-7 WARNING LED NEGATIVE M/B1
X63 Fuse 1 Way Connector * 1
X07 Pool Solenoid Timer 4 Way Connector * * 1
AMP
NAME DESCRIPTION SUPP. TYPE QTY. M BROWN
L7 X81-4 SECOND SPEED LAMP POSITIVE M-B1 DL2 X81-8 SEAT LED NEGATIVE G/N1 X64 Fuse 1 Way Connector AMP * 1
N BLACK
X08 Safety Relay 6 Way Connector SUMITOMO 6195-0021 1 X65 Fuse 1 Way Connector AMP * 1
R RED
X09 C6 Generator Terminal * * 1 X66 Fuse 1 Way Connector AMP * 1 GND. 4 C6 Ground Terminal AMP * 1
X10 Frame Line Mark 13 Way Connector * * 1 NAME DESCRIPTION SUPP. TYPE QTY. X67 Fuse 1 Way Connector * 1 GND. 6 C8 Horn Ground Terminal AMP * 1 S PINK
AMP V GREEN
X11 Generator 3 Way Connector SUMITOMO 6189-0442 1 NAME DESCRIPTION SUPP. TYPE QTY. X68 Fuse 1 Way Connector AMP * 1 H1 Beacon Light CIAM (KUE) 110450 (885111118) 1
Z VIOLET
GND 2 C8 Ground Terminal * * 1
X69 Fuse 1 Way Connector * 1 H4 Left Front Work Lamp COBO (KUE) 05-531-000 (885111132) 1
AMP
X13 Fuel Pool-Stop Solenoid 3 Way Connector DEUTSCH DT06-35 1 GND 5 C6 Ground Terminal 1
X70 H6 Right Front Work Lamp COBO (KUE) 05-531-000 (885111132) 1
FU01 Fuse 3A Left Side Lights 1 Fuse 1 Way Connector AMP * 1 EXAMPLE:
X14 Fuel Pump 2 Way Connector * * 1 S32 PPC Safety Pressure Switch FMDI (KUE) 11717.75 (37A-06-11670) 1
X71 H10 Left Rear Work Light COBO (KUE) 05-531-000 (885111132) 1
FU02 Fuse 3A Control Panel Lights 1 Fuse 1 Way Connector AMP * 1
X15 Preheating Start C6 Terminal * * 1 S33 Brake Valve Pressure Switch FMDI (KUE) * 1
X72 H11 Right Rear Work Light COBO (KUE) 05-531-000 (885111132) 1 G/V = YELLOW/GREEN
FU03 Fuse 15A Horn, Front Work Lights 1 Fuse 1 Way Connector AMP * 1
X16 Air Filter Blocked Switch 2 Way Connector AMP MINI TIMER 1 X01.1 Engine Line 4 Way Connector DEUTSCH DTP04-4P 1
X73 HA2 Horn CIAM (KUE) 112001 (885100005) 1 (TRANSVERSE MARKED)
FU04 Fuse 7.5A Switch Lights 1 Fuse 1 Way Connector AMP * 1
X17 Fuel Level Sender 3 Way Connector * * 1 X02.1 Engine Line 2 Way Connector * * 1
X74 X82.1 From Cabin Line 11 Way Connector AMP * 1 YELLOW GREEN
FU05 Fuse 15A Rear Work Light 1 Fuse 1 Way Connector AMP * 1
X18 Engine Water Temperature Sender 2 Way Connector * * 1 X10.1 Engine Line 13 Way Connector * * 1
X75 X108 Left Front Light 2 Way Connector PACKARD * 1
FU06 Fuse 10A Lever Switch Power Supply, Float Fuse 1 Way Connector AMP * 1
X19 Hydraulic Oil Filter Blocked Switch C5 Terminal * * 1 X32 PPC Safety Pressure Switch 1 Way Connector AMP SUPERSEAL 1
X76 X109 Right Front Light 2 Way Connector PACKARD * 1
FU07 Fuse 10A Current Intake 12V, Beacon Light 1 Fuse 1 Way Connector AMP * 1
X20 Stop Light Pressure 1 Switch 2 Way Connector DEUTSCH DT06-2S 1 X32A PPC Safety Pressure Switch 1 Way Connector AMP SUPERSEAL 1
X77 X110 Left Rear Work Lights 2 Way Connector DEUTSCH * 1
FU08 Fuse 10A Control Panel, Electronic Unit, Fuel Shut Off, 1 Fuse 1 Way Connector AMP * 1
X21 Stop Light Pressure 2 Switch 2 Way Connector DEUTSCH DT06-2S 1 X33 PPC Valve 2 Way Connector * * 1
X78 Current Intake 1 Way Connector * 1 X111 Right Rear Work Lights 2 Way Connector DEUTSCH * 1
Safety Bar Proximity, Seat Safety Switch and Brake Switch AMP G-V = YELLOW-GREEN
X22 Back-Up Pressure 1 Switch 2 Way Connector DEUTSCH DT06-2S 1 X34 Float Valve 2 Way Connector * * 1
X79 X113 Horn 1 Way Connector AMP * 1
FU09 Fuse 7.5A Back-Up Alarm 1 Current Intake 1 Way Connector AMP * 1 (LONGITUDINAL COLORS)
X23 Back-Up Pressure 2 Switch 2 Way Connector DEUTSCH DT06-2S 1 X35 Brake Valve 2 Way Connector * * 1
X80 XP1 12V Socket, Beacon Light 1 Way Connector AMP * 1
FU10 Fuse 7.5A Fuel Pump, Safety Engine Relay, Generator 1 Control Panel 16 Way Connector AMP * 1
X28 Engine Min. Pressure Switch Terminal * * 1 X36 Second Speed Valve 2 Way Connector * * 1 XP1A 12V Socket, Beacon Light 1 Way Connector AMP * 1 YELLOW GREEN
FU11 Fuse 30A Pull Solenoid, PPC Safety Pressure Switch 1 X81 Control Panel 8 Way Connector AMP * 1
X29 Back-Up Alarm 2 Way Connector * * 1 X37 Brake Pressure Switch 1 Way Connector * * 1
X82
GND3 C6 Ground Terminal AMP * 1 Lights Line 11 Way Connector AMP * 1
X45 Cabin Line 13 Way Connector * * 1
X83
HA1 Warning Buzzer 1 Left Lever 12 Way Connector DEUTSCH DT04-12P,DT06-12-S 1
XB C8 Start Motor Terminal * * 1 X46 Cabin Line 4 Way Connector DEUTSCH DTP-06-4S 1
X84
K04 Float Relay C1AM 157061 (KUE 88507 1043) 1 Right Lever 12 Way Connector DEUTSCH DT04-12P,DT06-12-S 1
XF General Fuse 2 Way Connector * * 1 X47 Ground 2 Way Connector DEUTSCH DTP06-2S 1
X85
K06 Electronic Unit C1AM 01171077 (KUE885070046) 1 Rear Work Lights SWF Switch SWF * 1
XM C4 Start Motor Terminal * * 1 X48 Cabin Line 5 Way Connector * * 1
X86
K14 Brake Relay C1AM * 1 Panel and Front Lights SWF Switch Connector SWF * 1
XS Safety Relay 2 Way Connector SUMITOMO 6195-0060 1 Y1 PPC Valve HYDRAFORCE * 1
X87
P1 Control Panel UNIDECK 04610027 (KUE 37A-54-14291) 1 Brake Switch Connector PNEUTRON * 1
XS1 Insulator * * 1 Y2 Float Valve HYDRAFORCE * 1
X88
S01 Rear Work Lights Switch C1AM 106AA008 (KUE 885081159) 1 Beacon Light Switch Connector SWF * 1
Y0 Stop Fuel Solenoid Valve YANMAR 129005-77950 1 Y3 Second Speed Valve HYDRAFORCE * 1
X89
S02 Panel Lights and Low Beam Lights Switch C1AM 106AA018 (KUE 885081160) 1 Float Relay Connector 1
Y6 Brake Valve HYDRAFORCE * 1 CVSM0360
SK1026-5 Turbo 90-20j

A01
A02
A03
A04
A05
A06
A07
A08
A09
NAME DESCRIPTION SUPP. TYPE QTY. A10
A11
GND. 4 C6 Ground Terminal AMP 1
A12
GND. 6 C8 Horn Ground Terminal AMP 1
HA2 Horn CIAM 112001 (KUE 885100005) 1
H1 Beacon Light CIAM 110450 (KUE 885111118) 1 A13
H4 Left Low Beam COBO (KUE 885111133) 1
H5 Left Side Lght COBO (KUE 885110036) 1 A14
A B 1 1 1 A B 1 1 1 1 1 1 1 1 1 1 1 1 1 A B A B 1 1
H6 Right Low Beam COBO (KUE 885111133) 1 A15
K14, X18 X13 H7 Right Side Light COBO (KUE 885111135) 1 HA1
A16
C1
H8 Left Rear Lamp COBO (KUE 885111135) 1 + A17
X108 X108 X115 X116 X117 X109 X109 X118 X119 X120 X121 X122 X123 X124 X125 X126 X127 X128 X129 X130 X110 X110 X111 X111 XP1 XP1A
1 2 H9 Right Rear Lamp COBO (KUE 885111134) 1
H-N1
N1
L1
G1
N1
N1
H-N1
G-N1
A1
N1
N1
L1
G1
R/N1
R/N1
G-N1
A1
N1
G1
N1
A-G1
N1
A-G1
N1
N1
H-G1
H10 Left Rear Work Light COBO 05-531-000 (KUE 885111132) 1 X113 X50 23 L/B1
-
H-R2.5
R-N2.5
BRAKE P.B. IN
3 H11 X52 X53
M2.5
Right Rear Work Light COBO 05-531-000 (KUE 885111132) 1 IN X50 22 A/B1
HI SPEED P.B.
B1
H12 Plate Light COBO 02224-600 (KUE 885110052) 1 1 1
H1 FLOAT P.B. IN X50 21 L/G1 OFF ACC
58L
R
X82.1
58R
58L
54
58R
K08 K07
54
R
11 Way Connector AMP 1
R/N1
Z-B1
HA2 SAF. BAR. SWITCH IN X50 20 C/N1 R1 ST R1 ACC BR R2 C
X108 & X109 Front Low Beam 2 Way Connector PACKARD 1 H4 H5 H6 H7 H8 H9 H12 H10 H11
1 2 3 1 2 X110 & X111 Rear Work Lights 2 Way Connector PACKARD 1 M SEAT SWITCH IN X50 19 C-B1
X113 Horn 1 Way Connector AMP 1 POWER SUPPLY +12V X50 18 H-R1 S10
4 5 6 3 4 B
X115, X116 & X117 Front Traffic Lights 1 Way Connector AMP 1 EV BRAKE OUT X50 17 H-L1
31
31
31
X118, X119 & X120
31
Front Traffic Lights 1 Way Connector AMP 1 STOP ENGINE OUT X50 16 R-N1.5 S12
X121, X122, X123 & X124 Rear Traffic Lights 1 Way Connector AMP 1 GND. 6
BRAKE LIGHT OUT X50 15 S/N1
ELECTRONIC UNIT
X125, X126, X127 & X128 Rear Traffic Lights 1 Way Connector AMP 1 X50 S11
SAF. BAR. LED OUT 14 B/N1
R4
XP1 & XP1A 12V Socket, Beacon Light 1 Way Connector AMP 1
+ -
WIRE POSITIONING ON CONNECTOR SEAT LED OUT X50 13 G/N1

(WIRE SIDE VIEWING WIRING) WARNING LED OUT X50 M/B1 X54 X54 X54 X55 X55
12
FLOAT OUT X50 11 B-N1 C A B 2 1
N1
H-R1
C-B1
H-R1
C/N1
GND. 4 GND. 5 C6 GROUND TERMINAL Hi-SPEED OUT X50 9 M-B1 A18
= Parts are not included GROUND X50 8 N1.5 A19
on the wiring X129-X130 Plate Light Connection HORN OUT X50 7 C1
A20
KUE 37C-06-11312 A21
= Parts are not included on the wiring START SIGN IN X50 6 B1
X01 X01.1 R-N2.5

XP1-XP1A Current Intake 12V. Beacon Light +12V HORN X50 5 H-R1.5
R-N2.5
4 HORN PUSH B. IN X50 4 B/R1 A22
M2.5 X01 4 X01.1 M2.5
V1 3 PPC SAF. SWITCH IN X50 3 L-G1 A23
K02 K03 R4 X01 3 X01.1 R4
EV PPC OUT X50 2 V-N1
86 87 X01 2
2
POWER K01 SAFETY RELAY R4 X01.1 R4
OUT (+) X50 1 R/N1
BUZZER
1 1
BOX
R-B1
85 30
G1
R1
N1
N4 K06 A24
X03 X03 X03 X03 X06 X06 X07 X07 X07 X07 XS1 XS1 X08 X08 X08 X08 N4
GND. 5 GND. 5
A25
86 85 30 87 I - 4 3 2 1 A B 1 3 5 6
XS R4 X02 X02.1
R-N2.5
R-N1.5
R-N1.5
R-N1.5
R-G1
S-N1
B2.5
M-V1
M-V1
I I
L/B1
L/B1
L-R1 X02 X02.1 L-R1.5

N1
B1
A26
N1
N1
B2
- M1 X48 X48.1 M1
-
R10
M-V1 X48 1 1 X48.1 M-V1 A27

R-N1.5 X10 X10.1 R-N1.5
13 13 X10.1 R-V1 X48
2 2 X48.1 R-V1
X10 A28
12 12 L-G1 3 3 X48.1 L-G1
R2.5 X10 X10.1 R2.5 X48
11 11 4 4 A29
R-V1 X10 X10.1 R-V1
10
B1 X10 10 X10.1 B1 R-N2.5 X46 X46.1 R-N2.5 X44 86 A30
9 9 X10.1
S1 4 4
S1 X10 M2.5 X46 X46.1 M2.5
M1 X44 87a A31
8 8
X10.1 C-N1 3 3
C-N1 X10 R4 X46 X46.1 R4
7 X10.1
C-L1 X10 7 C-L1
R4 2 2
X46.1 R4 K14 86 87a 87
X46
6 6 X10.1 S-G1 1
S-G1 X10 1
X10 5 5 X10.1
85 30
4 4 X10.1
B-N1 X10 B-N1
H-L1 X44 30
R-N1.5 X45 X45.1 R-N1.5
3 3 X10.1
R-G1 X10 R-G1
13
V-N1 X45 13 X45.1 V-N1 B-G1 X44 85
R10
2 2 X10.1
B-G1 X10 B-G1 12
M-B1 X45 12 X45.1 M-B1
1 1 1
1 GND. X45 11 11 X45.1 L-R1.5
L-R1.5 A32
XF X28 + B1 X45
10 10 X45.1 B1
S31 9
FG1 HA3 - M-N1 X45 9 X45.1 M-N1
80A p> A33
R-G1 8 8 X45.1 R-G1
X45 A34
S1 X45 7 7 X45.1 S1
XF X29 X29
2 C-N1 X45 6 6 X45.1 C-N1
2 1 C-L1 X45 5 5 X45.1 C-L1
Z-N1
4 4
N1
S-G1 X45 X45.1 S-G1

B-N1 3 3 X45.1 B-N1
R10 R10 X45
2 2 X45.1 B-G1
B-G1 X45
1 1
R-N1.5
A35
R-G1
R-G1
C-N1
S-G1
S-N1
B-N1
R-V1
M2.5
Z-N1
C-L1
L-R1
L-R1
L-R1
B2.5
R50 N4 X47 X47.1 N4

N2
N1
N1
N1
N1
S1
B2
A36
1 2 1 3 3 1 2 - + 1 2 1 C A - + 1 1 2 1 2 1 2 1 2 N4 2 2 X47.1 N4
X47 A37
G1 + 1 1
1 X09 X11 X11 X11 X13 X13 X13 X14 X14 X15 X16 X16 X17 X17 X18 X18 X19 X20 X20 X21 X21 X22 X22 X23 X23 A38
1
X49 X49.1 C-B1
R-1.5
C-B1
N2.5
B2.5
12Vcc XB XM R1 R2 R3 A39
M2 S25 S26 S27 S28 S29 S30 C1 X49 11 11 X49.1 C1
M1 50 G2 D+ Y0 M A40
M 30 G W p> p> p> p> p> p>
V-B1 X49 10 10 X49.1 V-B1
- 3
t V1 X49 9 9 X49.1 V1
N50
U
A-N1 X49 8 8 X49.1 A-N1
31
A-B1 X49 7 7 X49.1 A-B1
A-G1 X49 6 6 X49.1 A-G1
ENGINE PARTS
G-N1
C-N1
H-R1
S-G1
B-G1
B-N1
M-N1
M-V1
M-B1
Z-B1
C-L1
M/B1
G/N1
B/N1
L-N1
H0.5
Z-N1 X49 5 5 X49.1 Z-N1
M1
N1
B1
S1
4 4
N2.5
A-V1 X49 X49.1 A-V1

S-N1.5 X49 3 3 X49.1 S-N1.5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8
L-R1.5 X49 2 2 X49.1 L-R1.5
1 1
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X80
X81
X81
X81
X81
X81
X81
X81
X81
M-N1
M-V1
M-B1
L-G1
Z-N1
A-V1
V-N1
R2.5
M1
N1
N1
N1
N1
N1
N1
1 1 1 2 1 2 1 2 1 2 1 2 1 2 1 P1
CONTROL PANEL (UNIDECK)
X32 X32A X33 X33 X34 X34 X39 X39 X40 X40 X35 X35 X36 X36 X37
S32 S33
Y1 Y2 Y5 Y4 Y6 Y3
p> p>
A41
X41 S-N1.5
X41 L-R1.5
X41 A-G1
X41 C-B1
X41 A-N1
X41 A-B1
X41 V-B1
X41 N1.5
GND. 2 GND. 1 KUE 37C-06-11331 A42
NAME DESCRIPTION SUPP. TYPE QTY.
X41 C1
X41 V1
A43
A44
FG1 General Fuse 80A CIAM 163028 1 A45
G1 Battery 100Ah FIAMM (KUE) L5 600 103 086 (37C-06-11110) 1 A46
G2 Generator YANMAR (DENSO) 129423-77200 1 A47
GND C8 Ground Terminal * * 1 KUE 37A-06-11460
GND5 C6 Ground Terminal * * 1 a c A48
A49
HA3 Back-Up Alarm CIAM (KUE) 0A001357 (312612100) 1 DESCRIPTION
NAME SUPP. TYPE QTY. b WAY A50
K01 Fuel Solenoid Valve Relay MATSUSHITA (KUE) CB1aH (885071022) 1
A51
N1.5
N1.5
R1.5
A-N1.5
A-B1.5
A-G1.5
K02 Fuel Pull Solenoid Valve Timer 1 Second YANMAR (KUE) 1
X121 Attachment 8 Way Connector DEUTSCH HD34 18-8PN 1
X121
H
WAY A
K03 Safety Relay YANMAR (KUE) 119802-77200 1
M1 Starter Motor YANMAR 1
X121 Nut DEUTSCH 114020-90 1
A
X121
G C
A-B1.5
M2 Fuel Pump YANMAR 129612-52100 1
X121 Washer DEUTSCH 114021 1 B N1.5
X121
F “B” Way Attachment C D E (-)
X121 Male Pin DEUTSCH D460-204-12141 6 X121
R1 Preheating Starter YANMAR 129100-77500 1
X121 Plug DEUTSCH HDC36-18 1 C A-G1.5 X121
E Ground
(+12V) B A
R2 Fuel Level Sender COBO (KUE) 29-0419-0000 (37A-04-11140) 1 D “A” Way Attachment H G F
R3 Engine Water Temperature Sender YANMAR (KUE) (7861-92-3320) 1
X8 5 Way Female Mark II Connector CIAM (AMP) 125216 1 A-N1.5 X121
C “C” Way Attachment KEY
S25 Air Filter Blocked Switch DONALDSON (KUE) X770317 (37A-06-11960) 1
X8 Male Pin CIAM (AMP) 120072 5 R1.5 X121
B +15 WAY
S26 Hydraulic Oil Filter Blocked Switch FMDI (KUE) 11716/1 (885261034) 1 RIGHT LEVER N1.5 X121
A Ground
B
S27 Stop Lights Pressure Switch FMDI (KUE) 11717.70 (37A-06-11680) 1
S28 Stop Lights Pressure Switch FMDI (KUE) 11717.70 (37A-06-11680) 1
S29 Back-Up Alarm Pressure Switch FMDI (KUE) 11717.70 (37A-06-11680) 1
S30 Back-Up Alarm Pressure Switch FMDI (KUE) 11717.70 (37A-06-11680) 1
S31 Engine Oil Min. Pressure Switch YANMAR * 1
V1 DESCRIPTION SUPP. TYPE QTY. NAME DESCRIPTION SUPP. TYPE QTY.
Diode 1A CIAM 1A1N4007 1 NAME
X01 Frame Line 3 Way Connector * * 1
X02 2 Way Connector * * 1 X107 Stabilizer Push Button Connector SWF 1
X03 Fuel Solenoid Relay Connector * *
GND. 1 C8 Ground Terminal AMP * 1 NAME DESCRIPTION SUPP. TYPE QTY. NAME DESCRIPTION SUPP. TYPE QTY. X44 Parking Brake Relay Connector BOSCH 1 WIRING COLORS
1 GND. 2 C8 Ground Terminal AMP * 1
X45.1 From Frame Line Mark 13 Way Connector AMP 1
GND. 5 C6 Ground Terminal AMP * 1 FU01 Fuse 3A Left Side Lights 1 K13 Flasher Unit CIAM 00105013 (KUE 885151012) 1
X46.1 From Frame Line 4 Way Connector DEUTSCH DTP04-4P 1 LIGHT BLUE
A
S32 PPC Safety Pressure Switch 1 Way Connector FMDI 11717.75 (37A-06-11670) 1 FU02 Fuse 3A Control Panel Lights 1 K14 Brake Relay CIAM 157061 (KUE 885071043) 1
X47.1 Ground 2 Way Connector DEUTSCH DTP04-2P 1 WHITE
X06 Diode 2 Way Connector * * 1 B
S33 Brake Valve Pressure Switch FMDI (KUE) * 1 FU03 Fuse 15A Horn, Front Work Lights 1 K95 Stop Lights Relay CIAM 157061 (KUE 885071043) 1
X48.1 From Frame Line Mark 6 VIE Connection 1
X07 Pool Solenoid Timer 4 Way Connector * * 1 AMP C ORANGE
X01.1 Engine Line 4 Way Connector DEUTSCH DTP04-4P 1 FU04 Fuse 7.5A Switch Lights 1 P1 Control Panel UNIDECK 04810027 (KUE 37A-54-14291) 1
X49.1 From Frame Line Mark 11 VIE Connector 1
X08 Safety Relay 6 Way Connector SUMITOMO 6195-0021 1 AMP G YELLOW
X02.1 Engine Line 2 Way Connector AMP * 1 FU05 Fuse 15A Rear Work Light 1 S01 Rear Worklights Switch CIAM 106AA008 (KUE 885081160) 1
X50 Safety Control Box 23 Way Connector 1
X09 C6 Generator Terminal * * 1 AMP H GRAY
X10.1 Engine Line 13 Way Connector AMP * 1 FU06 Fuse 10A Lever Switch Power Supply, Float S02 Panel Lights and Low Beam Lights Switch CIAM 106AA018 (KUE 885081159) 1
X52 Buzzer One Way Connector 1
X10 Frame Line Mark 13 Way Connector * * 1 AMP L BLUE
X32 PPC Safety Pressure Switch 1 Way Connector AMP SUPERSEAL 1 FU07 Fuse 10A Current Intake 12V, Beacon Light 1 S03 Direction Lights Switch CIAM 116003 (KUE 885081161) 1
X53 Buzzer One Way Connector 1
X11 Generator 3 Way Connector SUMITOMO 6189-0442 1 AMP M BROWN
X32A PPC Safety Pressure Switch 1 Way Connector AMP SUPERSEAL 1 FU08 Fuse 10A Control Panel, Electronic Unit, Fuel Shut Off, 1 S05 Up-Down Left Stabilizer Button CIAM 108AA002 (KUE885081163) 1
X54 Proximity Bar 3 Way Connector 1
DEUTSCH N BLACK
X33 PPC Valve 2 Way Connector DEUTSCH DT06-2S 1 Safety Bar Proximity, Seat Safety Switch and Brake Switch S06 Up-Down Right Stabilizer Button CIAM 108AA002 (KUE885081163) 1
X55 Safety Seat Switch 3 Way Connector 1
X13 Fuel Pool-Stop Solenoid 3 Way Connector DEUTSCH DT06-35 1 DEUTSCH R RED
X34 Float Valve 2 Way Connector DEUTSCH DT06-2S 1 FU09 Fuse 7.5A Back-Up Alarm 1 S07 Beacon Light Switch CIAM 106AA008 (KUE 885081160) 1
X56 Through X60 Fuse 1 Way Connector 5
X14 Fuel Pump 2 Way Connector * * 1 AMP S PINK
X35 Brake Valve 2 Way Connector DEUTSCH DT06-2S 1 FU10 Fuse 7.5A Fuel Pump, Safety Engine Relay, Generator 1 S08 Brake Switch CIAM 0A003455 (KUE 37A-06-11411) 1
X15 Preheating Start C6 Terminal * * 1 AMP V GREEN
X36 Second Speed Valve 2 Way Connector DEUTSCH DT06-2S 1 FU11 Fuse 30A Pull Solenoid, PPC Safety Pressure Switch 1 S09 Hazard Switch CIAM 106AA014 (KUE 885081162) 1
X16 Air Filter Blocked Switch 2 Way Connector AMP MINI TIMER 1 AMP Z VIOLET
X37 Brake Pressure Switch 1 Way Connector AMP * 1 GND. 3 C6 Ground Terminal SWF 1 S10 Starting Switch 1
X71 Through X75 Fuse 1 Way Connector AMP 5
X17 Fuel Level Sender 3 Way Connector * * 1 X39 Hight Flow Detent Valve 2 Way Connector DEUTSCH * 1 HA1 Warning Buzzer 1 S11 Safety Seat Switch 1
X76 & X77 Fuse 1 Way Connector AMP 2 EXAMPLE:
X18 Engine Water Temperature Sender 2 Way Connector * * 1 X40 Hight Flow Momentary Valve 2 Way Connector DEUTSCH * 1 HL1 Super Flow LED Diode 1 S12 Bar PNP Safety Sensor SAIET E-A1TMU3AP (KUE 37A-06-1250) 1
X78 & X79 Current Intake 1 Way Connector AMP 2
X19 Hydraulic Oil Filter Blocked Switch C5 Terminal * * 1 G/V = YELLOW/GREEN
X41 Stabilizer 5 Way Connector AMP * 1 HL2 “C” Way LED Diode 1 S13 Horn Push Button 1
X80 Control Panel 16 Way Connector AMP 1 (TRANSVERSE MARKED)
X20 Stop Light Pressure 1 Switch 2 Way Connector DEUTSCH DT06-2S 1 X42 1 S14 Second Speed Push Button 1
Attachment 5 Way Connector AMP * HL3 “A” Way LED Diode 1
X21 Stop Light Pressure 2 Switch 2 Way Connector DEUTSCH DT06-2S 1 X81 Control Panel 8 Way Connector AMP 1 YELLOW GREEN
X43 ENPI Valve 1 Way Connector AMP * 1 HL4 “B” Way LED Diode 1 S15 Float Push Button 1
X82 Lights Line 11 Way Connector 1
X22 Back-Up Pressure 1 Switch 2 Way Connector DEUTSCH DT06-2S 1 AMP
X45 Cabin Line 13 Way Connector AMP * 1 HL5 Optional LED Diode 1 S32 PPC Safety Pressure Switch FMDI (KUE) 11717.75 (37A-06-11670) 1
X83 Left Lever 12 Way Connector DT04-12P, DT06-12S 1
X23 Back-Up Pressure 2 Switch 2 Way Connector DEUTSCH DT06-2S 1 DEUTSCH
X46 Cabin Line 4 Way Connector DEUTSCH DTP06-4S 1 K04 Float Relay C1AM 01170922 (KUE 885070040) 1 S33 Brake Valve Pressure Switch FMDI (KUE) 11717.15 (885411439) 1
X84 Right Lever 12 Way Connector DT04-12P, DT06-12S 1
X28 Engine Min. Pressure Switch Terminal * * 1 DEUTSCH
X47 Ground 2 Way Connector DEUTSCH DTP06-2S 1 K05 Relays Box (Without Relays) C1AM 122010 (KUE 885411196) 1 S36 Reverse HI-Flow Momentary Push Button 1
X85 Rear Work Lights SWF Switch 1 G-V = YELLOW-GREEN
X29 Back-Up Alarm 2 Way Connector * * 1 SWF
X48 Cabin Line 5 Way Connector AMP * 1 K06 Electronic Unit C1AM 01171077 (KUE 885070046) 1 S37 Super-Flow Detent Push Button 1
X86 Panel & Front Lights SWF Switch Connector 1 (LONGITUDINAL COLORS)
SWF
X49 Cabin Line 11 Way Connector AMP * 1 K07 “B” Way Relay KUE 885071044 1 S38 “C” Way Push Button 1
X87 Brake Switch Connector 1
XB C8 Start Motor Terminal * * 1 PNEUTRON
Y1 PPC Valve HYDRAFORCE * 1 K08 “A” Way Relay KUE 885071044 1 S39 “A” Way Push Button 1
X88 Beacon Light Switch Connector 1 YELLOW GREEN
XF General Fuse 2 Way Connector * * 1 SWF
Y2 Float Valve HYDRAFORCE * 1 K09 “C” Way Relay KUE 885071044 1 S40 “B” Way Push Button 1
X89 Float Relay Connector 1
XM C4 Start Motor Terminal * * 1 BOSCH
Y3 Second Speed Valve HYDRAFORCE * 1 K10 Super-Flow Detent Step By Step Relay CIAM 01170923 (KUE 37A-06-11430 1 X104 Direction Lights Switch Connector 1
X90 Relays Box 21 Way Connector 1
XS Safety Relay 2 Way Connector SUMITOMO 6195-0060 1 AMP
Y4 Reverse HI-Flow Momentary Valve HYDRAFORCE * 1 K11 Reverse HI-Flow Momentary Relay CIAM 157061 (KUE 885071043) 1 X105 SWF Hazad Connector SWF 1
X91 ENPI Valve SWF Connector 1
XS1 Insulator * * 1 CEMBRE
Y5 Super-Flow Detent Valve HYDRAFORCE * 1 K12 Stop Lights Relay CIAM 157061 (KUE 885071043) 1 X106 Stabilizer Push Button Connector SWF 1
X95 Stop Light Relay Connector 1
Y0 Stop Fuel Solenoid Valve YANMAR 129005-77950 1 AMP
Y6 Brake Valve HYDRAFORCE * 1
CVSM0361A
SK1026-5 Turbo 90-21j

A01
G/R1 X85
A02 9
A03 A-R1.5 X85
A04 1
A05 1 9
1 0
A06
A07
S01 5 10
A08
A09 A-G1.5 X85
A10 5
N1 X85
A11 10
A12
GND. 4
X82.1 G-N1
10 X82.1 H-G1
X82.1 H-N1
X82.1 H-N1
X82.1 A-G1
X82.1 R/N1
A13
X82.1 N1.5
G/R1 X86
X82.1 G1
X82.1 C1
X82.1 A1
X82.1 L1
G1.5 X86 9
A14
8
A15 H-N1 X86
H-R1
A16 KUE 37A-06-11391 1
11
7
1
2
3
4
5
6
8
9
A17 G1.5 1 6 9
1
0 2
R-N2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
H-R2.5
R2.5
H-G1 X82 10
11
L1 X82 1
G1 X82 2
G-N1 X82 3
R/N1 X82 4
H-N1 X82 5
H-N1 X82 6
A-G1.5 X82 7
C1 X82 8
9
S02 3 2 10
1 1 1 1 1 1 1 1 1 1 1 K04 85 87
A1 X82
N1.5 X82
86 87a 87 H-R1.5 X86
K95
X56 X58 X60 X62 X64 X66 X68 X70 X72 X74 X76 3
H-R1 X86
86 30 2
FU11 FU10 FU09 FU08 FU07 FU06 FU05 FU04 FU03 FU02 FU01 N1 X86
85 30
30A 7.5A 7.5A 10A 10A 10A 15A 7.5A 15A 3A 3A 10
X89 X89 X89 X89
X78 X79
X57 X59 X61 X63 X65 X67 X69 X71 X73 X75 X77 86 85 30 87a
1 1 85 86 30 87
1 1 1 1 1 1 1 1 1 1 1
X95 X95 X95 X95
H/R1
N1
M-N1
B-N1
B-R1
B-R1
M1
N1
L-R1
R-V1
H-R1.5
H/R1
B-R1
A-R1.5
G/R1
G-N1
G-N1
G1
R-N2.5
R-G1
L-R1.5
H/R1
S/N1 X87
6
H-R1 X87
3
15/1 30/3 L/6
0 1
A18
A19 R/7
S08 49/4 30b/2
A20
L/B1 X87
A21
2
H-R1 X87
7
A22
A23
G/R1 X88
9
A24 H/R1 X88
1
A25 1 9
1 0
A26 S07 5 10
H-G1 X88
A27 5
N1 X88
A28
10
A29
A30
A31
RELAYS UNIT
K12 88 87a 87 K08 85 30 K09 85 30 K11 86 87
85 30 86 87 86 87 85 30
A32
A33
A34
KUE 37A-06-11363
K07 85 30 K10
K13 +
R CL (T)
53M
53S
86 87
31
15
T
- (53S)
A35
A36
A37
A38
A39
A40
A1 X104 2
L1 X104 1
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
X90
K05 0 1 2
1 2
GND. 3
10
12
13
14
15
16
17
18
19
20
21
11
S03 54
1
2
3
4
5
6
7
8
9
A/N1 X104 54
A-R1.5
L-R1.5
A-G1
R/N1
R-V1
A-N1
A-V1
C/B1
A/N1
Z-N1
Z-N1
A-B1
L-N1
A/V1
V/B1
L/N1
N1.5
L/R1
N1 X105 10
A/N1 X105 5
A41 G/R1 X105 8

A42 H/R1 X105 2
A43
A44 2 8 5 10
A45 1 0
A46
A47
S09
A48
4 6 3 1 7
A49
L/R1 X105 4
A50
A1 X105 3
A51
L1 X105 1
G/R1 X105 7
INTERNAL CONECTION CONTROL PANEL G/R1 X106 9

CONTROL PANEL (EXTERNAL VIEW) V-B1 X106 7
V1 X106 1
X80-15
X80-16
X80-12
X80-14
X80-11
L1 L2 L3 L4 L5 C2 C3 X80-8 0
+ 1 2 1 7 9
H F L1 L2 L3 L4 L5
FUEL WATER TEMP.
LEVEL INDICATOR
S05 3 10
C1 00000 00 h C2
L-R1.5 X106 3
C E
N1 X106 10
C1
HOUR C3
COUNTER
DL1 DL2 DL3
X80-6
P L6 L7 L8 L9 L10 G/R1 X107 9
C-B1
X81-3
X81-4
X81-2
X81-5
X81-6
X81-7
X81-8
X81-1
X107 7
X80-2 X80-3
C1 X107 1
L6 L7 L8 L9 L10 DL2 DL1 DL3 X80-9
0
1 2 1 7 9
WIRE WIRE
POS. PIN FUNCTION SIGNAL COLOR POS. PIN FUNCTION SIGNAL COLOR S05 3 10
L-R1.5 X107 3
B-R1
B/R1
C/B1
Z-N1
A/B1
A-G1
L/N1
B-R1
A-N1
A-B1
V/B1
L/G1
A/V1
Z/N1
X80-1 X80-9 INTERNAL LIGHTS (+LUCI) POSITIVE
N1
G-N1
N1
N1 X107 10
C2 X80-2 FUEL LEVEL INDICATOR ohm B-N1 X80-10 BUZZER NEGATIVE Z-B1 1 2 3 4 5 6 11 1 2 3 4 5 6 7 8 9 11
C3 X80-3 WATER TEMPERATURE INDICATOR ohm C-N1 L5 X80-11 HYDRAULIC OIL FILTER LAMP NEGATIVE S-G1
+50 X80-4 START SIGNAL +50 L2 X80-12 PREHEATING LAMP POSITIVE HL3 HL2
B1 M1
X83
X83
X83
X83
X83
X83
X83
X84
X84
X84
X84
X84
X84
X84
X84
X84
X84
GND. X80-5 GROUND GND. X80-13 HL4
S-N1.5
L-R1.5
HL1
G/R1
R-N0.8
V/B0.8
L/G0.8
A/V0.8
Z/N0.8
A-B0.6
N0.8
R-N0.8
V/B0.8
L/G0.8
A/V0.8
Z/N0.8
A-B0.5
A-G0.5
A-N0.6
Z-N0.6
N0.8
N1
X80-7 L1 X80-15 GENERATOR LAMP NEGATIVE S1 5 1 9 10
S13 S38 S15
+15 X80-8 POWER SUPPLY (+12V) +15 H-R1 L3 X80-16 ENGINE OIL PRESSURE LAMP NEGATIVE B-G1 S14
X91
X91
X91
X91
S36 S39 S40
S37
WIRE WIRE SWITCH EV ENPI

POS. PIN FUNCTION SIGNAL COLOR POS. PIN FUNCTION SIGNAL COLOR
DL3 X81-1 SAFETY BAR OPEN LED NEGATIVE B/N1 L9 X81-5 DIRECTION LAMP POSITIVE L-N1 S13 S14 S36 S37 HL1 S15 S38 HL2 S39 HL3 S40 HL4 HL5
L8 X81-2 FLOAT LAMP POSITIVE M-N1 L10 X81-6 LOW BEAM LAMP POSITIVE H0.5
L6 X81-3 PARKING BRAKE LAMP NEGATIVE M-V1 DL1 X81-7 WARNING LED NEGATIVE M/B1
L7 X81-4 SECOND SPEED LAMP POSITIVE M-B1 DL2 X81-8 SEAT LED NEGATIVE G/N1 LEFT LEVER RIGHT LEVER
CVSM0361B
SK1026-5 Turbo 90-22j

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CEBM014201

SERIAL NUMBERS SK1026-5N A80001 and UP

July 2009 Copyright 2009 Komatsu

10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . 10-1

20 STANDARD VALUE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1

30 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1

50 DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-1

90 DIAGRAMS AND SCHEMATICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1

● Page to be replaced Replace

( ) Page to be deleted Discard

● 00-1 1 ❍ 01-2 1 ● 10-17 1 ● 10-45 1

● 00-2 1 ❍ 01-3 1 ● 10-18 1 ● 10-46 1

❍ 00-2-1 1 ❍ 01-4 1 ● 10-19 1 ● 10-47 1

❍ 00-2-2 1 ❍ 01-5 1 ● 10-20 1 ● 10-48 1

❍ 00-2-3 1 ❍ 01-6 1 ● 10-21 1 ● 10-49 1

❍ 00-2-4 1 ❍ 01-7 1 ● 10-22 1 ● 10-50 1

● 00-3 1 ❍ 01-8 1 ● 10-23 1 ● 10-51 1

● 00-4 1 ❍ 01-9 1 ● 10-24 1 ● 10-52 1

● 00-5 1 ❍ 01-10 1 ● 10-25 1 ● 10-53 1

● 00-6 1 ❍ 01-11 1 ● 10-26 1 ● 10-54 1

● 00-7 1 ❍ 01-12 1 ● 10-27 1 ● 10-55 1

● 00-8 1 ● 10-28 1 ● 10-56 1

● 00-9 1 ● 10-1 1 ● 10-29 1 ● 10-57 1

● 00-10 1 ● 10-2 1 ● 10-30 1 ● 10-58 1

● 00-11 1 ● 10-3 1 ● 10-31 1 ● 10-59 1

● 00-12 1 ● 10-4 1 ● 10-32 1 ● 10-60 1

● 00-13 1 ● 10-5 1 ● 10-33 1 ● 10-61 1

● 00-14 1 ● 10-6 1 ● 10-34 1 ● 10-62 1

● 00-15 1 ● 10-7 1 ● 10-35 1 ● 10-63 1

● 00-16 1 ● 10-8 1 ● 10-36 1 ● 10-64 1

● 00-17 1 ● 10-9 1 ● 10-37 1 ● 10-65 1

● 00-18 1 ● 10-10 1 ● 10-38 1 ● 10-66 1

● 00-19 1 ● 10-11 1 ● 10-39 1 ● 10-67 1

● 00-20 1 ● 10-12 1 ● 10-40 1 ● 10-68 1

● 00-21 1 ● 10-13 1 ● 10-41 1 ● 10-69 1

● 00-22 1 ● 10-14 1 ● 10-42 1 ● 10-70 1

1 ● 10-15 1 ● 10-43 1 ● 10-71 1

❍ 01-1 1 ● 10-16 1 ● 10-44 1 ● 10-72 1

SK1026-5N WA700-3L 00-2-1 1

● 10-73 1 ( ) 10-106 1 ( ) 20-28 1 ● 30-26 1

● 10-74 1 ( ) 10-107 1 ( ) 20-29 1 ● 30-27 1

● 10-75 1 ( ) 10-108 1 ( ) 20-30 1 ● 30-28 1

● 10-76 1 ( ) 10-109 1 ( ) 20-31 1 ● 30-29 1

● 10-77 1 ( ) 10-110 1 ( ) 20-32 1 ● 30-30 1

● 10-78 1 ( ) 20-33 1 ● 30-31 1

● 10-79 1 ● 20-1 1 ( ) 20-34 1 ● 30-32 1

● 10-80 1 ● 20-2 1 1 ( ) 30-33 1

● 10-81 1 ● 20-3 1 ● 30-1 1 ( ) 30-34 1

● 10-82 1 ● 20-4 1 ● 30-2 1 ( ) 30-35 1

● 10-83 1 ● 20-5 1 ● 30-3 1 ( ) 30-36 1

● 10-84 1 ● 20-6 1 ● 30-4 1 ( ) 30-37 1

● 10-85 1 ● 20-7 1 ● 30-5 1 ( ) 30-38 1

● 10-86 1 ● 20-8 1 ● 30-6 1 ( ) 30-39 1

● 10-87 1 ( ) 20-9 1 ● 30-7 1 ( ) 30-40 1

● 10-88 1 ( ) 20-10 1 ● 30-8 1 ( ) 30-41 1

● 10-89 1 ( ) 20-11 1 ● 30-9 1 ( ) 30-42 1

● 10-90 1 ( ) 20-12 1 ● 30-10 1 ( ) 30-43 1

● 10-91 1 ( ) 20-13 1 ● 30-11 1 ( ) 30-44 1

● 10-92 1 ( ) 20-14 1 ● 30-12 1 ( ) 30-45 1

● 10-93 1 ( ) 20-15 1 ● 30-13 1 ( ) 30-46 1

● 10-94 1 ( ) 20-16 1 ● 30-14 1 ( ) 30-47 1

● 10-95 1 ( ) 20-17 1 ● 30-15 1 ( ) 30-48 1

● 10-96 1 ( ) 20-18 1 ● 30-16 1 ( ) 30-49 1