Hyundai R160LC-7A

CONTENTS
Open index screen
SECTION 1 GENERAL
Group 1 Safety Hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1
Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-9
SECTION 2 STRUCTURE AND FUNCTION

Group 1 Pump Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1
Group 2 Main Control Valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-20
Group 3 Swing Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-43
Group 4 Travel Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-54
Group 5 RCV Lever - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-65
Group 6 RCV Pedal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-72
SECTION 3 HYDRAULIC SYSTEM

Group 1 Hydraulic Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1
Group 2 Main Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-2
Group 3 Pilot Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-5
Group 4 Single Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-13
Group 5 Combined Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-23
SECTION 4 ELECTRICAL SYSTEM

Group 1 Component Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1
Group 2 Electrical Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-3
Group 3 Electrical Component Specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-20
Group 4 Connectors 4-29
SECTION 5 MECHATRONICS SYSTEM

Group 1 Outline - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1
Group 2 Mode Selection System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-3
Group 3 Automatic Deceleration System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-6
Group 4 Power Boost System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-7
Group 5 Travel Speed Control System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-8
Group 6 Automatic Warming Up Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-9
Group 7 Engine Overheat Prevention Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-10
Group 8 Anti-Restart System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-11
Group 9 Self-Diagnostic System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-12
Group 10 Engine Control System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-17
Group 11 EPPR(Electro Proportional Pressure Reducing) Valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-19
Group 12 Monitoring System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-22
Group 13 Fuel warmer System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-33
SECTION 6 TROUBLESHOOTING
Group 1 Before Trobleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1
Group 2 Hydraulic and Mechanical System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-4
Group 3 Electrical System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-24
Group 4 Mechatronics System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-41
SECTION 7 MAINTENANCE STANDARD

Group 1 Operational Performance Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1
Group 2 Major Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21
Group 3 Track and Work Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-29
SECTION 8 DISASSEMBLY AND ASSEMBLY

Group 1 Precaution - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1
Group 2 Tightening Torque - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-4
Group 3 Pump Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-7
Group 4 Main Control Valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-29
Group 6 Travel Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-66
Group 7 RCV Lever - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-110
Group 8 Turning Joint - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-125
Group 9 Boom, Arm and Bucket Cylinder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-130
Group 10 Undercarriage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-147
Group 11 Work Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-159
SECTION 9 COMPONENT MOUNTING TORQUE

Group 1 Introduction Guide - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-1
Group 2 Engine System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-2
Group 3 Electric System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-4
Group 4 Hydraulic System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-6
Group 6 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-9
FOREWORD
1. STRUCTURE
This service 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 service 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.
SECTION 1 GENERAL
This section explains the safety hints and gives the specification of the machine and major
components.
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.
This section explains the hydraulic circuit, single and combined operation.
This section explains the electrical circuit, monitoring system and each component. It serves not only
to give an understanding electrical system, but also serves as reference material for trouble shooting.
This section explains the computer aided power optimization system and each component.
This section explains the troubleshooting charts correlating problems to causes.
This section gives the judgement standards when inspecting disassembled parts.
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.
This section shows bolt specifications and standard torque values needed when mounting
components to the machine.
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Contact your HYUNDAI distributor for the latest information.
0-1
2. HOW TO READ THE SERVICE MANUAL
Distribution and updating Revised edition mark(ΗΘΙÄ)
Any additions, amendments or other changes will When a manual is revised, an edition mark is
be sent to HYUNDAI distributors. recorded on the bottom outside corner of the
Get the most up-to-date information before you pages.
start any work.
Revisions
Filing method Revised pages are shown at the list of revised
1. See the page number on the bottom of the pages on the between the contents page and
page. section 1 page.
File the pages in correct order.
2. Following examples shows how to read the Symbols
page number. So that the shop manual can be of ample
Example 1 practical use, important places for safety and
2-3 quality are marked with the following symbols.
Item number(2. Structure and
Function) Symbol Item Remarks
Consecutive page number for
Special safety precautions are
each item.
necessary when performing the
3. Additional pages : Additional pages are work.
indicated by a hyphen(-) and number after the Safety
Extra special safety precautions
page number. File as in the example.
are necessary when performing
10 - 4 the work because it is under
10 - 4 - 1 internal pressure.
Added pages
10 - 4 - 2 Special technical precautions or
other precautions for preserving
10 - 5
ö Caution
standards are necessary when
performing the work.
0-2
3. CONVERSION TABLE
Method of using the Conversion Table
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
1. Method of using the Conversion Table to convert from millimeters to inches
Convert 55mm into inches.
(1) Locate the number 50in the vertical column at the left side, take this as ͽ, then draw a
horizontal line from ͽ.
(2) Locate the number 5in the row across the top, take this as ;, then draw a perpendicular line
down from ;.
(3) Take the point where the two lines cross as Ϳ. This point Ϳ gives the value when converting
from millimeters to inches. Therefore, 55mm = 2.165 inches.
2. Convert 550mm into inches.

(1) The number 550 does not appear in the table, so divide by 10(Move the decimal point one place
to the left) to convert it to 55mm.
(2) Carry out the same procedure as above to convert 55mm to 2.165 inches.
(3) The original value(550mm) was divided by 10, so multiply 2.165 inches by 10(Move the decimal
point one place to the right) to return to the original value.
This gives 550mm = 21.65 inches.
Millimeters to inches ; 1mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
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
Ϳ
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
ͽ
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
0-3
Millimeters to inches 1mm = 0.03937in
0 1 2 3 4 5 6 7 8 9
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 1kg = 2.2046lb
0 1 2 3 4 5 6 7 8 9
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 59.5. 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
0-4
Liter to U.S. Gallon 1˶ = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
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 6.6076 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 25.631 25.625 25.889 26.153
Liter to U.K. Gallon 1˶ = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
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 7.969 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
0-5
kgfÂm to lbfÂft 1kgfÂm = 7.233lbfÂft
0 1 2 3 4 5 6 7 8 9
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
40 289.3 396.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
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 10005.4
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 1352.6 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
0-6
kgf/cm2 to lbf/in2 1kgf / cm2 = 14.2233lbf / in2
0 1 2 3 4 5 6 7 8 9
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 2863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 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 5603 2617 2631 2646 2660 2674 2688
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
0-7
TEMPERATURE
Fahrenheit-Centigrade Conversion.
A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice
verse 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.
Á
C Á
F Á
C Á
F Á
C Á
F Á
C Á
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 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-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 35 95.0 21.1 70 158.0 51.7 125 257.0
-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 79.4 172 347.0
0-8
SECTION 1 GENERAL
Group 1 Safety Hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1

Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-9
SECTION 1 GENERAL
GROUP 1 SAFETY
FOLLOW SAFE PROCEDURE

Unsafe work practices are dangerous.
Understand service procedure before doing
work; Do not attempt shortcuts.
WEAR PROTECTIVE CLOTHING

Wear close fitting clothing and safety equipment
appropriate to the job.
13031GE01
WARN OTHERS OF SERVICE WORK

Unexpected machine movement can cause
serious injury.
Before performing any work on the excavator,
attach aÖD Do Not Operate×tag on the right side
control lever.
13031GE02
USE HANDHOLDS AND STEPS

Falling is one of the major causes of personal
injury.
When you get on and off the machine, always
maintain a three point contact with the steps and
handrails and face the machine. Do not use any
controls as handholds.
Never jump on or off the machine. Never mount
or dismount a moving machine. 13031GE03
Be careful of slippery conditions on platforms,
steps, and handrails when leaving the machine.
1-1
PREPARE FOR EMERGENCIES
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors,
ambulance service, hospital, and fire department
near your telephone.
13031GE04
PROTECT AGAINST FLYING DEBRIS

Guard against injury from flying pieces of metal
or debris; Wear goggles or safety glasses.
13031GE05
PROTECT AGAINST NOISE

Prolonged exposure to loud noise can cause
impairment or loss of hearing.
Wear a suitable hearing protective device such
as earmuffs or earplugs to protect against
objectionable or uncomfortable loud noises.
13031GE06
AVOID POWER LINES

Serious injury or death can result from contact
with electric lines.
Never move any part of the machine or load
closer to electric line than 3m(10ft) plus twice the
line insulator length.
13031GE07
1-2
KEEP RIDERS OFF EXCAVATOR
Only allow the operator on the excavator. Keep
riders off.
Riders on excavator are subject to injury such
as being struck by foreign objects and being
thrown off the excavator. Riders also obstruct
the operator's view resulting in the excavator
being operated in an unsafe manner.
13031GE08
MOVE AND OPERATE MACHINE SAFELY

Bystanders can be run over. Know the location
of bystanders before moving, swinging, or
operating the machine.
Always keep the travel alarm in working
condition. It warns people when the excavator
starts to move.
Use a signal person when moving, swinging, or
13031GE09
operating the machine in congested areas.
Coordinate hand signals before starting the
excavator.
OPERATE ONLY FORM OPERATOR'S

SEAT
Avoid possible injury machine damage. Do not
start engine by shorting across starter terminals.
NEVER start engine while standing on ground.
Start engine only from operator's seat.
13031GE26
PARK MACHINE SAFELY

Before working on the machine:
ÂPark machine on a level surface.
ÂLower bucket to the ground.
ÂTurn auto idle switch off.
ÂRun engine at 1/2 speed without load for 2 minutes.
ÂTurn key switch to OFF to stop engine.
Remove key from switch.
ÂMove pilot control shutoff lever to locked position.
ÂAllow engine to cool.
1-3
SUPPORT MACHINE PROPERLY
Always lower the attachment or implement to the
ground before you work on the machine. If you
must work on a lifted machine or attachment,
securely support the machine or attachment.
Do not support the machine on cinder blocks,
hollow tiles, or props that may crumble under
continuous load.
Do not work under a machine that is supported 13031GE10
solely by a jack. Follow recommended procedur-

es in this manual.
SERVICE COOLING SYSTEM SAFELY

Explosive release of fluids from pressurized
cooling system can cause serious burns.
Shut off engine. Only remove filler cap when
cool enough to touch with bare hands.
13031GE11
HANDLE FLUIDS SAFELY-AVOID FIRES

Handle fuel with care; It is highly flammable.
Do not refuel the machine while smoking or
when near open flame or sparks. Always stop
engine before refueling machine.
Fill fuel tank outdoors.
13031GE12
Store flammable fluids away from fire hazards.

Do not incinerate or puncture pressurized
containers.
Make sure machine is clean of trash, grease,
and debris.
Do not store oily rags; They can ignite and burn
spontaneously.
13031GE13
1-4
BEWARE OF EXHAUST FUMES
Prevent asphyxiation. Engine exhaust fumes
can cause sickness or death.
If you must operate in a building, be positive
there is adequate ventilation. Either use an
exhaust pipe extension to remove the exhaust
fumes or open doors and windows to bring
enough outside air into the area.
REMOVE PAINT BEFORE WELDING OR

HEATING
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint
is heated by welding, soldering, or using a torch.
Do all work outside or in a well ventilated area.
Dispose of paint and solvent properly.
Remove paint before welding or heating:
ÂIf you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
ÂIf you use solvent or paint stripper, remove
stripper with soap and water before welding.
Remove solvent or paint stripper containers
and other flammable material from area.
Allow fumes to disperse at least 15 minutes
before welding or heating. 13031GE14
ILLUMINATE WORK AREA SAFELY

Illuminate your work area adequately but safely.
Use a portable safety light for working inside or
under the machine. Make sure the bulb is
enclosed by a wire cage. The hot filament of an
accidentally broken bulb can ignite spilled fuel or
oil.
13031GE15
1-5
SERVICE MACHINE SAFELY
Tie long hair behind your head. Do not wear a
necktie, scarf, loose clothing or necklace when
you work near machine tools or moving parts.
If these items were to get caught, severe injury
could result.
Remove rings and other jewelry to prevent
electrical shorts and entanglement in moving
parts. 13031GE16
STAY CLEAR OF MOVING PARTS

Entanglements in moving parts can cause
serious injury.
To prevent accidents, use care when working
around rotating parts.
13031GE17
AVOID HIGH PRESSURE FLUIDS

Escaping fluid under pressure can penetrate the
skin causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
13031GE18
fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene may
result.
13031GE19
1-6
AVOID HEATING NEAR PRESSURIZED
FLUID LINES
Flammable spray can be generated by heating
near pressurized fluid lines, resulting in severe
burns to yourself and bystanders. Do not heat
by welding, soldering, or using a torch near
pressurized fluid lines or other flammable
materials.
Pressurized lines can be accidentally cut when
13031GE20
heat goes beyond the immediate flame area.
Install fire resisting guards to protect hoses or
other materials.
PREVENT BATTERY EXPLOSIONS

Keep sparks, lighted matches, and flame away
from the top of battery. Battery gas can
explode.
Never check battery charge by placing a metal
object across the posts. Use a volt-meter or
hydrometer.
Do not charge a frozen battery; It may explode.
Warm battery to 16ÁC(60ÁF). 13031GE21
PREVENT ACID BURNS

Sulfuric acid in battery electrolyte is poisonous. It
is strong enough to burn skin, eat holes in clothing,
and cause blindness if splashed into eyes.
Avoid the hazard by:
1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is
added.
4. Avoiding spilling of dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize
the acid.
3. Flush your eyes with water for 10-15
minutes. Get medical attention immediately.
If acid is swallowed:
1. Drink large amounts of water or milk.
2. Then drink milk of magnesia, beaten eggs,
or vegetable oil.
3. Get medical attention immediately. 13031GE22
1-7
USE TOOLS PROPERLY
Use tools appropriate to the work. Makeshift
tools, parts, and procedures can create safety
hazards.
Use power tools only to loosen threaded tools
and fasteners.
For loosening and tightening hardware, use the
correct size tools. DO NOT use U.S.
measurement tools on metric fasteners. Avoid
bodily injury caused by slipping wrenches. 13031GE23
Use only recommended replacement parts.(See

Parts catalogue.)
DISPOSE OF FLUIDS PROPERLY

Improperly disposing of fluids can harm the
environment and ecology. Before draining any
fluids, find out the proper way to dispose of
waste from your local environmental agency.
Use proper containers when draining fluids. Do
not use food or beverage containers that may
mislead someone into drinking from them.
DO NOT pour oil into the ground, down a drain,
or into a stream, pond, or lake. Observe 13031GE24
relevant environmental protection regulations
when disposing of oil, fuel, coolant, brake fluid,
filters, batteries, and other harmful waste.
REPLACE SAFETY SIGNS

Replace missing or damaged safety signs. See
the machine operator's manual for correct safety
sign placement.
13031GE25
LIVE WITH SAFETY

Before returning machine to customer, make
sure machine is functioning properly, especially
the safety systems. Install all guards and
shields.
1-8
GROUP 2 SPECIFICATIONS
1. MAJOR COMPONENT
Tool box Fuel tank Hydraulic tank Main pump
Engine
Radiator
Oil cooler
Tooth Bucket Turning joint Swing motor Main control valve
Arm Arm cylinder Boom Boom cylinder Cab Muffler Counterweight
Side cutter Idler

Connecting link Track roller Travel motor
Bucket cylinder Connecting rod Carrier roller Track Sprocket
1607A2SP01
1-9
2. SPECIFICATIONS
1) 5.1m(16' 9") MONO BOOM, 2.6m(8' 6") ARM
I(I') D
C
E
G
F
H
J M
K N
A B(L)
1607A2SP02
Description Unit Specification
Operating weight kg(lb) 17400(38360)

Bucket capacity(SAE heaped), standard m3(yd ) 0.70(0.92)
Overall length A 8600(28' 3")
Overall width, with 600mm shoe B 2590( 8' 6")
Overall height C 2910( 9' 7")
Superstructure width D 2475( 8' 1")
Overall height of cab E 2915( 9' 7")
Ground clearance of counterweight F 1035( 3' 5")
Engine cover height G 2295( 7' 6")
Minimum ground clearance H mm(ft-in) 460( 1' 6")
Rear-end distance I 2530( 8' 4")
Rear-end swing radius I' 2480( 8' 2")
Distance between tumblers J 3190(10' 6")
Undercarriage length K 3980(13' 1")
Undercarriage width L 2590( 8' 6")
Track gauge M 1990( 6' 6")
Track shoe width, standard N 600(24")
Travel speed(Low/high) km/hr(mph) 3.7/5.6(2.3/3.5)
Swing speed rpm 11.3
Gradeability Degree(%) 30(58)
Ground pressure(600mm shoe) kgf/cm (psi)
2
0.42(5.97)
1-10
2) 5.1m(16' 9") HYDRAULIC ADJUSTABLE BOOM, 2.6m(8' 6") ARM
I(I') D
C
E
G
F
H
J M
K N
A B(L)
1607A2SP03

Bucket capacity(SAE heaped), standard m (yd )
3
0.70(0.92)
Minimum ground clearance H mm(ft-in) 460( 1' 6")
2
0.43(6.1)
1-11
3) R160LCD-7A
I(I') D
C
E
G
F
O
Q P
H
J M
K N
A B(L)
D
1607A2SP04

Bucket capacity(SAE heaped), standard m (yd )
3 3
0.70(0.92)
Minimum ground clearance H 460( 1' 6")
mm(ft-in)
Height of blade O 645( 2' 1")
Ground clearance of blade up P 780( 2' 7")
Depth of blade down Q 520( 1' 8")
2
0.45(6.40)
1-12
3. WORKING RANGE
1) 5.1m(16' 9") MONO BOOM
A
A'
F
D
E
C
B'
B
8ft
1607A2SP05
Description 2.2m(7' 3") Arm *2.6m(8' 6") Arm 3.1m(10' 2") Arm
Max digging reach A 8690mm (28' 6") 9030mm (29' 8") 9450mm (31' 0")
Max digging reach on ground A' 8530mm (27'12") 8870mm (29' 1") 9300mm (30' 6")
Max digging depth B 5660mm (18' 7") 6060mm (19'11") 6560mm (21' 6")
Max digging depth (8ft level) B' 5440mm (17'10") 5860mm (19' 3") 6370mm (20'11")
Max vertical wall digging depth C 5140mm (16'10") 5440mm (17'10") 5730mm (18'10")
Max digging height D 8740mm (28' 8") 8870mm (29' 1") 8970mm (29' 5")
Max dumping height E 6100mm (20' 0") 6240mm (20' 6") 6380mm (20'11")
Min swing radius F 3180mm (10' 5") 3170mm (10' 5") 3180mm (10' 5")
108.6 [118.4] kN 108.6 [118.4] kN 108.6 [118.4] kN
SAE 11070 [12080] kgf 11070 [12080] kgf 11070 [12080] kgf
24410 [26630] lbf 24410 [26630] lbf 24410 [26630] lbf
Bucket digging force
124.5 [135.9] kN 124.5 [135.9] kN 124.5 [135.9] kN
ISO 12700 [13850] kgf 12700 [13850] kgf 12700 [13850] kgf
28000 [30550] lbf 28000 [30550] lbf 28000 [30550] lbf
85.2 [93.0] kN 75.0 [81.8] kN 67.4 [73.5] kN
SAE 8690 [9480] kgf 7650 [8350] kgf 6870 [7490] kgf
19160 [20900] lbf 16870 [18400] lbf 15150 [16530] lbf
Arm digging force
89.0 [97.1] kN 77.6 [84.6] kN 69.4 [75.7] kN
ISO 9080 [9910] kgf 7910 [8630] kgf 7080 [7720] kgf
20020 [21840] lbf 17440 [19030] lbf 15610 [17030] lbf
[ ] : Power boost
* : STD
1-13
2) 5.1m(16' 9") HYDRAULIC ADJUSTABLE BOOM
A
A'
F
D
E
C
B'
B
8ft
1607A2SP06
Description 2.2m(7' 3") Arm 2.6m(8' 6") Arm

Max digging reach A 8750mm (28' 8") 9110mm (29'11")
Max digging reach on ground A' 8600mm (28' 3") 8960mm (29' 5")
Max digging depth B 5460mm (17'11") 5830mm (19' 2")
Max digging depth (8ft level) B' 5350mm (17' 7") 5750mm (18'10")
Max vertical wall digging depth C 4670mm (15' 4") 5030mm (16' 6")
Max digging height D 9390mm (30'10") 9600mm (31' 6")
Max dumping height E 6680mm (21'11") 6900mm (22' 8")
Min swing radius F 3130mm (10' 3") 2970mm ( 9' 9")
108.6 [118.4] kN 108.6 [118.4] kN
SAE 11070 [12080] kgf 11070 [12080] kgf
24410 [26630] lbf 24410 [26630] lbf
Bucket digging force
124.5 [135.9] kN 124.5 [135.9] kN
ISO 12700 [13850] kgf 12700 [13850] kgf
28000 [30550] lbf 28000 [30550] lbf
85.2 [93.0] kN 75.0 [81.8] kN
SAE 8690 [9480] kgf 7650 [8350] kgf
19160 [20900] lbf 16870 [18400] lbf
Arm digging force
89.0 [97.1] kN 77.6 [84.6] kN
ISO 9080 [9910] kgf 7910 [8630] kgf
20020 [21840] lbf 17440 [19030] lbf
[ ] : Power boost
1-14
4. WEIGHT
1) R160LC-7A
Item kg lb
Upperstructure assembly 7480 16490

Main frame weld assembly 1400 3090
Engine assembly 420 930
Main pump assembly 90 200
Main control valve assembly 80 180
Swing motor assembly 250 550
Hydraulic oil tank assembly 180 400
Fuel tank assembly 140 310
Counterweight 2950 6500
Cab assembly 310 680
Lower chassis assembly 6900 15210
Track frame weld assembly 2030 4480
Swing bearing 260 570
Travel motor assembly 240 530
Turning joint 50 120
Track recoil spring 140 310
Idler 160 350
Carrier roller 20 45
Track roller 50 120
Track-chain assembly(600mm standard triple grouser shoe) 1180 2600
Front attachment assembly(5.1m boom, 2.6m arm,
3020 6660
0.7m3 SAE heaped bucket)
5.1m boom assembly 1050 2315
2.6m arm assembly 540 1190
0.7m3 SAE heaped bucket 540 1190
Boom cylinder assembly 160 350
Arm cylinder assembly 180 400
Bucket cylinder assembly 140 310
Bucket control link assembly 120 265
1-15
5. LIFTING CAPACITIES
1) ROBEX 160LC-7A
(1) 5.1m(16' 9") boom, 2.6m(8' 6") arm equipped with 0.7m3(SAE heaped) bucket, 600mm(24") triple
grouser shoe and 2950kg counterweight.
: Rating over-front : Rating over-side or 360 degree
Load radius At max. reach

Load point 1.5m(5ft) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) 7.5m(25ft) Capacity Reach
height
m(ft)
7.5m kg *3080 2940 6.33
(25ft) lb *6790 6480 (20.8)
6.0m kg *2760 *2760 *3070 2090 7.56
(20ft) lb *6080 *6080 *6770 4610 (24.8)
4.5m kg *3500 3050 2880 1710 8.28
(15ft) lb *7720 6720 6350 3770 (27.2)
3.0m kg *7360 *7360 *4940 4630 *4000 2900 *2560 1940 2630 1520 8.64
(10ft) lb *16230 *16230 *10890 10210 *8820 6390 *5640 4280 5800 3350 (28.3)
1.5m kg *7670 *7670 *6190 4250 *4570 2720 3220 1870 2560 1470 8.68
(5ft) lb *16910 *16910 *13650 9370 *10080 6000 7100 4120 5640 3240 (28.5)
Ground kg *7420 *7420 *6980 3990 4480 2590 3150 1810 2660 1520 8.42
Line lb *16360 *16360 *15390 8800 9880 5710 6940 3990 5860 3350 (27.6)
-1.5m kg *6300 *6300 *10000 7410 6990 3890 4400 2520 3000 1730 7.81
(-5ft) lb *13890 *13890 *22050 16340 15410 8580 9700 5560 6610 3810 (25.6)
-3.0m kg *9330 *9330 *9580 7530 *6480 3910 4430 2540 *3370 2230 6.75
(-10ft) lb *20570 *20570 *21120 16600 *14290 8620 9770 5600 *7430 4920 (22.1)
-4.5m kg *6950 *6950 *4610 4090
(-15ft) lb *15320 *15320 *10160 9020
Note 1. Lifting capacity are based on SAE J1097 and ISO 10567.
2. Lifting capacity of the ROBEX series does not exceed 75% of tipping load with the machine
on firm, level ground or 87% of full hydraulic capacity.
3. The load point is a hook located on the back of the bucket.
4. *indicates load limited by hydraulic capacity.
1-16
Load point 1.5m(5ft) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) Capacity Reach
height
m(ft)
7.5m kg *3400 3380 5.81

(25ft) lb *7500 7450 (19.1)
6.0m kg *3340 2300 7.16
(20ft) lb *7360 5070 (23.5)
4.5m kg *4260 *4260 *3820 3030 3120 1860 7.92
(15ft) lb *9390 *9390 *8420 6680 6880 4100 (26.0)
3.0m kg *8470 *8470 *5390 4580 *4280 2890 2830 1660 8.30
(10ft) lb *18670 *18670 *11880 10100 *9440 6370 6240 3660 (27.2)
1.5m kg *6540 4220 4640 2740 2760 1600 8.34
(5ft) lb *14420 9300 10230 6040 6080 3530 (27.4)
Ground kg *6700 *6700 7130 4010 4510 2620 2890 1680 8.06
Line lb *14770 *14770 15720 8840 9940 5780 6370 3700 (26.4)
-1.5m kg *6610 *6610 *10490 7530 7060 3950 4460 2570 3300 1930 7.42
(-5ft) lb *14570 *14570 *23130 16600 15560 8710 9830 5670 7280 4250 (24.3)
-3.0m kg *10560 *10560 *8970 7680 *6210 4010 *3380 2570 6.28
(-10ft) lb *23280 *23280 *19780 16930 *13690 8840 *7450 5670 (20.6)
-4.5m kg *5840 *5840
(-15ft) lb *12870 *12870
height
m(ft)
7.5m kg *2730 2520 6.92
(25ft) lb *6020 5560 (22.7)
6.0m kg *2640 *2640 *2760 1850 8.05
(20ft) lb *5820 *5820 *6080 4080 (26.4)
4.5m kg *3110 3080 *1940 *1940 2630 1530 8.73
(15ft) lb *6860 6790 *4280 *4280 5800 3370 (28.6)
3.0m kg *4380 *4380 *3640 2920 *2840 1940 2410 1370 9.06
(10ft) lb *9660 *9660 *8020 6440 *6260 4280 5310 3020 (29.7)
1.5m kg *9510 8060 *5730 4300 *4290 2720 3200 1850 2340 1310 9.10
(5ft) lb *20970 17770 *12630 9480 *9460 6000 7050 4080 5160 2890 (29.9)
Ground kg *8210 7460 *6710 3900 4460 2560 3120 1770 2420 1350 8.85
Line lb *18100 16450 *14790 8800 9830 5640 6880 3900 5340 2980 (29.0)
-1.5m kg *5960 *5960 *9730 7320 6940 3830 4350 2470 *2970 1730 2680 1510 8.28
(-5ft) lb *13140 *13140 *21450 16140 15300 8440 9590 5450 *6550 3810 5910 3330 (27.2)
-3.0m kg *8420 *8420 *10150 7380 *6700 3820 4340 2450 *3290 1900 7.30
(-10ft) lb *18560 *18560 *22380 16270 *14770 8420 9570 5400 *7250 4190 (24.0)
-4.5m kg *11640 *11640 *8040 7600 *5380 3930
(-15ft) lb *25660 *25660 *17730 16760 *11860 8660
1-17
(4) 5.1m(16' 9") hydraulic adjustable boom, 2.2m(7' 3") arm equipped with 0.7m3(SAE heaped) bucket,
600mm(24") triple grouser shoe and 2950kg counterweight.

height
m(ft)
6.0m kg *3390 2230 7.24
(20ft) lb *7470 4920 (23.8)
4.5m kg *3860 3020 3080 1810 7.99
(15ft) lb *8510 6660 6790 3990 (26.2)
3.0m kg *5440 4570 *4280 2880 2800 1610 8.36
(10ft) lb *11990 10080 *9440 6350 6170 3550 (27.4)
1.5m kg *6500 4190 4660 2710 *3240 1860 2730 1560 8.41
(5ft) lb *14330 9240 10270 5970 *7140 4100 6020 3440 (27.6)
Ground kg *5860 *5860 *7040 3960 4520 2590 2860 1630 8.13
Line lb *12920 *12920 *15520 8730 9960 5710 6310 3590 (24.6)
-1.5m kg *5850 *5850 *9740 7460 *6890 3900 4480 2540 3270 1890 7.50
(-5ft) lb *12900 *12900 *21470 16450 *15190 8600 9880 5600 7210 4170 (24.6)
-3.0m kg *8500 7650 *5940 3980 *2930 2530 6.37
(-10ft) lb *18740 16870 *13100 8770 *6460 5580 (20.9)

height
m(ft)
6.0m kg *3120 2010 7.66
(20ft) lb *6880 4430 (25.1)
4.5m kg 2850 1640 8.37
(15ft) lb 6280 3620 (27.5)
3.0m kg *4020 2890 *2940 1920 2600 1470 8.72
(10ft) lb *8860 6370 *6480 4230 5730 3240 (28.6)
1.5m kg *6640 *6640 *6170 4220 *4550 2700 3250 1840 2540 1420 8.77
(5ft) lb *14640 *14640 *13600 9300 *10030 5950 7170 4060 5600 3130 (28.8)
Ground kg *6650 *6650 *6880 3940 4510 2550 3180 1780 2650 1480 8.50
Line lb *14660 *14660 *15170 8690 9940 5620 7010 3920 5840 3260 (27.9)
-1.5m kg *5680 *5680 *9340 7340 *6930 3840 4440 2480 2980 1680 7.90
(-5ft) lb *12520 *12520 *20590 16180 *15280 8470 9790 5470 6570 3700 (25.9)
-3.0m kg *8890 *8890 *9150 7480 *6240 3880 *4340 2520 *2970 2180 6.86
(-10ft) lb *19600 *19600 *20170 16490 *13760 8550 *9570 5560 *6550 4810 (22.5)
-4.5m kg *6330 *6330 *4220 4080
(-15ft) lb *13960 *13960 *9300 8990
1-18
2) ROBEX 160LCD-7A
: Rating over-front : Rating over-side or 360 degree

height
m(ft)
7.5m kg *3080 *3080 6.33
(25ft) lb *6790 *6790 (20.8)
6.0m kg *2760 *2760 *3070 2210 7.56
(20ft) lb *6080 *6080 *6770 4870 (24.8)
4.5m kg *3500 3210 *3120 1820 8.28
(15ft) lb *7720 7080 *6880 4010 (27.2)
3.0m kg *7360 *7360 *4940 4870 *4000 3060 *2560 2070 2940 1630 8.64
(10ft) lb *16230 *16230 *10890 10740 *8820 6750 *5640 4560 6480 3590 (28.3)
1.5m kg *7670 *7670 *6190 4480 *4570 2890 *3340 1990 2870 1570 8.68
(5ft) lb *16910 *16910 *13650 9880 *10080 6370 *7360 4390 6330 3460 (28.5)
Ground kg *7420 *7420 *6980 4220 4980 2750 *3170 1930 2980 1630 8.42
Line lb *16360 *16360 *15390 9300 10980 6060 *6990 4250 6570 3590 (27.6)
-1.5m kg *6300 *6300 *10000 7840 *7090 4120 4900 2680 3350 1850 7.81
(-5ft) lb *13890 *13890 *22050 17280 *15630 9080 10800 5910 7390 4080 (25.6)
-3.0m kg *9330 *9330 *9580 7950 *6480 4150 *4530 2710 *3370 2380 6.75
(-10ft) lb *20570 *20570 *21120 17530 *14290 9150 *9990 5970 *7430 5250 (22.1)
-4.5m kg *6950 *6950 *4610 4320
(-15ft) lb *15320 *15320 *10160 9520
Note 1. Lifting capacity are based on SAE J1097 and ISO 10567.
2. Lifting capacity of the ROBEX series does not exceed 75% of tipping load with the machine
on firm, level ground or 87% of full hydraulic capacity.
3. The load point is a hook located on the back of the bucket.
4. *indicates load limited by hydraulic capacity.
1-19
Load point 1.5m(5ft) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) Capacity Reach
height
m(ft)
7.5m kg *3400 *3400 5.81

(25ft) lb *7500 *7500 (19.1)
6.0m kg *3340 2440 7.16
(20ft) lb *7360 5380 (23.5)
4.5m kg *4260 *4260 *3820 3190 *3370 1980 7.92
(15ft) lb *9390 *9390 *8420 7030 *7430 4370 (26.0)
3.0m kg *8470 *8470 *5390 4820 *4280 3060 3160 1770 8.30
(10ft) lb *18670 *18670 *11880 10630 *9440 6750 6970 3900 (27.2)
1.5m kg *6540 4460 *4800 2900 3090 1720 8.34
(5ft) lb *14420 9830 *10580 6390 6810 3790 (27.4)
Ground kg *6700 *6700 *7150 4250 5010 2780 3230 1790 8.06
Line lb *14770 *14770 *15760 9370 11050 6130 7120 3950 (26.4)
-1.5m kg *6610 *6610 *10490 7950 *7070 4190 4960 2740 *3610 2060 7.42
(-5ft) lb *14570 *14570 *23130 17530 *15590 9240 10930 6040 *7960 4540 (24.3)
-3.0m kg *10560 *10560 *8970 8100 *6210 4240 *3380 2730 6.28
(-10ft) lb *23280 *23280 *19780 17860 *13690 9350 *7450 6020 (20.6)
-4.5m kg *5840 *5840
(-15ft) lb *12870 *12870
height
m(ft)
7.5m kg *2730 2650 6.92
(25ft) lb *6020 5840 (22.7)
6.0m kg *2640 *2640 *2760 1970 8.05
(20ft) lb *5820 *5820 *6080 4340 (26.4)
4.5m kg *3110 *3110 *1940 *1940 *2830 1630 8.73
(15ft) lb *6860 *6860 *4280 *4280 *6240 3590 (28.6)
3.0m kg *4380 *4380 *3640 3080 *2840 2070 2700 1470 9.06
(10ft) lb *9660 *9660 *8020 6790 *6260 4560 5950 3240 (29.7)
1.5m kg *9510 8480 *5730 4530 *4290 2890 *3560 1980 2630 1410 9.10
(5ft) lb *20970 18700 *12630 9990 *9460 6370 *7850 4370 5800 3110 (29.9)
Ground kg *8210 7890 *6710 4220 *4810 2730 3490 1900 2720 1460 8.85
Line lb *18100 17390 *14790 9300 *10600 6020 7690 4190 6000 3220 (29.0)
-1.5m kg *5960 *5960 *9730 7740 *7050 4070 4850 2630 *2970 1850 3100 1630 8.28
(-5ft) lb *13140 *13140 *21450 17060 *15540 8970 10690 5800 *6550 4080 6640 3590 (27.2)
-3.0m kg *8420 *8420 *10150 7800 *6700 4050 *4750 2620 *3290 2030 7.30
(-10ft) lb *18560 *18560 *22380 17200 *14770 8930 *10470 5780 *7250 4480 (24.0)
-4.5m kg *11640 *11640 *8040 8020 *5380 4170
(-15ft) lb *25660 *25660 *17730 17680 *11860 9190
1-20

height
m(ft)
6.0m kg *3390 2360 7.24
(20ft) lb *7470 5200 (23.8)
4.5m kg *3860 3190 *3360 1920 7.99
(15ft) lb *8510 7030 *7410 4230 (26.2)
3.0m kg *5440 4810 *4280 3040 3120 1720 8.36
(10ft) lb *11990 10600 *9440 6700 6880 3790 (27.4)
1.5m kg *6500 4430 *4760 2870 *3240 1990 3050 1670 8.41
(5ft) lb *14330 9770 *10490 6330 *7140 4390 6720 3680 (27.6)
Ground kg *5860 *5860 *7040 4200 5020 2750 3200 1750 8.13
Line lb *12920 *12920 *15520 9260 11070 6060 7050 3860 (26.7)
-1.5m kg *5850 *5850 *9740 7880 *6890 4140 *4940 2710 *3340 2010 7.50
(-5ft) lb *12900 *12900 *21470 17370 *15190 9130 *10890 5970 *7360 4430 (24.6)
-3.0m kg *8500 8070 *5940 4220 *2930 2680 6.37
(-10ft) lb *18740 17790 *13100 9300 *6460 5910 (20.9)

height
m(ft)
6.0m kg *3120 2130 7.66
(20ft) lb *6880 4700 (25.1)
4.5m kg *3110 1760 8.37
(15ft) lb *6860 3880 (27.5)
3.0m kg *4020 3050 *2940 2050 2900 1580 8.72
(10ft) lb *8860 6720 *6480 4520 6390 3480 (28.6)
1.5m kg *6640 *6640 *6170 4450 *4550 2860 3600 1970 2830 1520 8.77
(5ft) lb *14640 *14640 *13600 9810 *10030 6310 7940 4340 6240 3350 (28.8)
Ground kg *6650 *6650 *6880 4180 *4930 2720 3530 1910 2950 1580 8.50
Line lb *14660 *14660 *15170 9220 *10870 6000 7780 4210 6500 3480 (27.9)
-1.5m kg *5680 *5680 *9340 7760 *6930 4080 4910 2650 *3210 1800 7.90
(-5ft) lb *12520 *12520 *20590 17110 *15280 8990 10820 5840 *7080 3970 (25.9)
-3.0m kg *8890 *8890 *9150 7900 *6240 4110 *4340 2680 *2970 2320 6.86
(-10ft) lb *19600 *19600 *20170 17420 *13760 9060 *9570 5910 *6550 5110 (22.5)
-4.5m kg *6330 *6330 *4220 *4220
(-15ft) lb *13960 *13960 *9300 *9300
1-21
6. BUCKET SELECTION GUIDE
1) GENERAL BUCKET
0.39m3 SAE 0.50m3 SAE 0.64m3 SAE 0.70m3 SAE 0.89m3 SAE 0.69m3 SAE
heaped bucket heaped bucket heaped bucket heaped bucket heaped bucket heaped bucket
Recommendation
Capacity Width 5.1m (16' 9") 5.1m (16' 9")
Weight Mono boom Hydraulic adjustable boom
SAE CECE Without With 2.0m arm 2.6m arm 3.1m arm 2.2m arm 2.6m arm
heaped heaped side cutter side cutter (7' 3") (8' 6") (10' 2") (7' 3") (8' 6")
0.39m3 0.34m3 620mm 740mm 410kg

(0.51yd3) (0.44yd3) (24.4") (29.1") (900lb)
0.50m3 0.44m3 760mm 880mm 470kg

(0.65yd3) (0.58yd3) (29.9") (34.6") (1040lb)
0.64m3 0.55m3 920mm 1040mm 510kg

(0.84yd3) (0.72yd3) (36.2") (40.9") (1120lb)
0.70m3 0.60m3 990mm 1110mm 540kg

(0.92yd3) (0.78yd3) (39.0") (43.7") (1190lb)
0.89m3 0.77m3 1220mm 1340mm 610kg

(1.16yd3) (1.01yd3) (48.0") (52.8") (1340lb)
0.69m3 0.62m3 990mm 700kg

(0.9yd3) (0.81yd3) (39.0") - (1540lb)
: Standard bucket
: Heavy duty bucket
Applicable for materials with density of 2000kg/m3 (3370lb/yd3) or less

1-22
7. UNDERCARRIAGE
1) TRACKS
X-leg type center frame is integrally welded with reinforced box-section track frames. The design
includes dry tracks, lubricated rollers, idlers, sprockets, hydraulic track adjusters with shock
absorbing springs and assembled track-type tractor shoes with triple grousers.
2) TYPES OF SHOES
Triple grouser
Model Shapes
Shoe width mm(in) 500(20) 600(24) 700(28) 800(32)

Operating weight kg(lb) 17150(37810) 17400(38360) 17650(38910) 17900(39460)
R160LC-7A
Ground pressure kgf/cm (psi)
2
0.50(7.11) 0.42(5.97) 0.37(5.26) 0.32(4.55)
Overall width mm(ft-in) 2490(8' 2") 2590(8' 6") 2690(8'10") 2790(9' 2")
3) NUMBER OF ROLLERS AND SHOES ON EACH SIDE
Item Quantity
Carrier rollers 2EA

Track rollers 7EA
Track shoes 49EA
4) SELECTION OF TRACK SHOE

Suitable track shoes should be selected according to operating conditions.
Method of selecting shoes
Confirm the category from the list of applications in table 2, then use table 1 to select the shoe.
Wide shoes(Categories B and C) have limitations on applications. Before using wide shoes, check
the precautions, then investigate and study the operating conditions to confirm if these shoes are
suitable.
Select the narrowest shoe possible to meet the required flotation and ground pressure. Application
of wider shoes than recommendations will cause unexpected problem such as bending of shoes,
crack of link, breakage of pin, loosening of shoe bolts and the other various problems.
Table 1
Track shoe Specification Category
500mm triple grouser Option A

600mm triple grouser Standard A
700mm triple grouser Option B
800mm triple grouser Option C
1-23
Table 2
Category Applications Precautions
Rocky ground, Travel at low speed on rough ground with large obstacles such as
A river beds, boulders or fallen trees
normal soil
Normal soil, These shoes cannot be used on rough ground with large obstacles such
soft ground as boulders or fallen trees
B Travel at high speed only on flat ground
Travel slowly at low speed if it is impossible to avoid going over obstacles
Extremely soft ground Use the shoes only in the conditions that the machine sinks and it is
(Swampy ground) impossible to use the shoes of category A or B
These shoes cannot be used on rough ground with large obstacles such
C as boulders or fallen trees
Travel at high speed only on flat ground
Travel slowly at low speed if it is impossible to avoid going over obstacles
1-24
8. SPECIFICATIONS FOR MAJOR COMPONENTS
1) ENGINE
Item Specification
Model Mitsubishi D04FD-TAA

Type 4-cycle turbocharged, charge air cooled diesel engine.
Cooling method Water cooling
Number of cylinders and arrangement 4 cylinders, in-line
Firing order 1-3-4-2
Combustion chamber type Direct injection type
Cylinder bore stroke 102 130mm(4.02" 5.12")
Piston displacement 4249cc(259cu in)
Compression ratio 16.5 : 1
Rated gross horse power(SAE J1995) 126Hp at 2000rpm(94kW at 2000rpm)
Maximum torque at 1800rpm 47.7kgf m(345lbf ft)
Engine oil quantity 18.5 (4.9U.S. gal)
Dry weight 420kg(926lb)
High idling speed 2100 50rpm
Low idling speed 800 100rpm
Rated fuel consumption 170.6g/Hp hr at 2000rpm
Starting motor Mitsubishi 24V-5.0kW
Alternator Mitsubishi 24V-50A
Battery 2 12V 100Ah
2) MAIN PUMP
Item Specification
Type Variable displacement tandem axis piston pumps

Capacity 2 80cc/rev
Maximum pressure 330kgf/cm2 (4694psi) [360kgf/cm2 (5120psi)]
Rated oil flow 2 168 /min (44.4U.S. gpm/ 37.0U.K. gpm)
Rated speed 2100rpm
[ ]: Pooer boost
1-25
3) GEAR PUMP
Item Specification
Type Fixed displacement gear pump single stage

Capacity 15cc/rev
Maximum pressure 35kgf/cm2(500psi)
Rated oil flow 31.5 /min(8.3U.S. gpm/7.0U.K. gpm)
4) MAIN CONTROL VALVE
Item Specification
Type 11 spools two-block

Operating method Hydraulic pilot system
Main relief valve pressure 330kgf/cm2(4695psi)[360kgf/cm2(5120psi)]
Overload relief valve pressure 380kgf/cm2(5550psi)
[ ]: Pooer boost
5) SWING MOTOR
Item Specification
Type Two fixed displacement axial piston motor

Capacity 117.8cc/rev
Relief pressure 240kgf/cm2(3414psi)
Braking system Automatic, spring applied hydraulic released
Braking torque 56kgf m(405lbf ft)
Brake release pressure 20kgf/cm2(284psi)
Reduction gear type 2 - stage planetary
6) TRAVEL MOTOR
Item Specification
Type Variable displacement axial piston motor

Relief pressure 330kgf/cm2(4695psi)
Reduction gear type Planetary & differential type
Braking system Automatic, spring applied hydraulic released
Brake release pressure 6kgf/cm2(85psi)
Braking torque 40.6kgf m(294lbf ft)
1-26
7) REMOTE CONTROL VALVE
Item Specification
Type Pressure reducing type

Minimum 6.5kgf/cm2(92psi)
Operating pressure
Maximum 26kgf/cm2(370psi)
Lever 61mm(2.4in)
Single operation stroke
Pedal 123mm(4.84in)
8) CYLINDER
Item Specification
Bore dia Rod dia Stroke 115 80 1090mm

Boom cylinder
Cushion Extend only
Arm cylinder
Cushion Extend and retract
Bucket cylinder
Cushion Extend only
Discoloration of cylinder rod can occur when the friction reduction additive of lubrication oil spreads on
the rod surface.
Discoloration does not cause any harmful effect on the cylinder performance.
9) SHOE
Item Width Ground pressure Link quantity Overall width
Option 500mm(20") 0.50kgf/cm2(7.11psi) 49 2490mm( 8' 2")

Standard 600mm(24") 0.42kgf/cm (5.97psi)
2
49 2590mm( 8' 6")
R160LC-7A
Option 700mm(28") 0.37kgf/cm2(5.26psi) 49 2690mm( 8' 10")
Option 800mm(32") 0.32kgf/cm (4.55psi)
2
49 2790mm( 9' 2")
10) BUCKET
Capacity Tooth Width
Item
SAE heaped CECE heaped quantity Without side cutter With side cutter
STD 0.70m3(0.92yd3) 0.60m3(0.78yd3) 5 990mm(39.0") 1110mm(43.7")

0.39m (0.51yd )
3 3
0.34m (0.44yd )
3 3
3 620mm(24.4") 740mm(29.1")
0.50m3(0.65yd3) 0.44m3(0.58yd3) 4 760mm(29.9") 880mm(34.6")
R160LC-7A
OPT 0.64m (0.84yd )
3 3
0.55m (0.72yd )
3 3
5 920mm(36.2") 1040mm(40.9")
0.89m3(1.16yd3) 0.77m3(1.01yd3) 6 1220mm(48.0") 1340mm(52.8")
0.69m (0.90yd )
3 3
0.62m (0.81yd )
3 3
5 990mm(39.0") -
: Heavy duty bucket
1-27
9. RECOMMENDED OILS
Use only oils listed below or equivalent.
Do not mix different brand oil.
Ambient temperature C( F)
Capacity
Service point Kind of fluid
(U.S. gal) -20 -10 0 10 20 30 40
(-4) (14) (32) (50) (68) (86) (104)
SAE 30
SAE 10W
Engine
Engine oil 18.5(4.9)
oil pan SAE 10W-30
SAE 15W-40
Swing drive 5(1.3)

Gear oil SAE 85W-140
Final drive 3 2
(0.8 2)
Tank: ISO VG 32
Hydraulic tank Hydraulic oil 160(42.2) ISO VG 46
System:
240(63.4) ISO VG 68
ASTM D975 NO.1

Fuel tank Diesel fuel 260(68.7)
ASTM D975 NO.2
Fitting NLGI NO.1

Grease As required
(Grease nipple)
NLGI NO.2
Mixture of
Radiator antifreeze 28(7.4) Ethylene glycol base permanent type
(Reservoir tank) and water
50 : 50
SAE : Society of Automotive Engineers

API : American Petroleum Institute
ISO : International Organization for Standardization
NLGI : National Lubricating Grease Institute
ASTM : American Society of Testing and Material
1-28
Group 1 Pump Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1

Group 2 Main Control Valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-20
Group 4 Travel Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-54
Group 5 RCV Lever - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-65
Group 6 RCV Pedal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-72
GROUP 1 PUMP DEVICE
1. STRUCTURE
The pump device consists of main pump, regulator and gear pump.
Pm1 Qmax adjusting screw

Pi1 EPPR valve
a4
A3
B3
Dr Pm2 Pi2
Qmin adjusting screw Qmin adjusting screw

Regulator Regulator
Pi1 Pm1 Pm2 Pi2
Dr B3
B1
a4
a1 a2
Front pump Valve block Rear pump Gear pump
1607A2MP01
Port Port name Port size

A1 A2
a1 a2 A1,2 Delivery port SAE6000psi 3/4"
B1 Suction port SAE2500psi 2 1/2"
Dr Drain port PF 1/2 - 19
Pi1,Pi2 Pilot port PF 1/4 - 15
Pm1,Pm2 Qmax cut port PF 1/4 - 15
Pm1 Pm2
P1 EPPR port PF 1/4 - 13
Pi1 Pi2
a1,2 Gauge port PF 1/4 - 15
a3 a3 Gauge port PF 1/4 - 13
Dr P1 a4 Gauge port PF 1/4 - 14
A3 A3 Gear pump delivery port PF 1/2 - 19
B1 B3 a4
B3 Gear pump suction port PF 3/4 - 20.5
2-1
1) MAIN PUMP(1/2)
The main pump consists of two piston pumps(front & rear) and valve block.
548
535 789 732 532 531 214 702 792 901 719 124 151 152 113 406 710
808 534
724 954
953
886
717
406 04
774
111
261
127
123
710
824
251
490 212 211 153 156 157 467 313 312 114 466 885 314 141 981 271 401
728 725 983
1607A2MP02
04 Gear pump 271 Pump casing 719 O-ring

111 Drive shaft(F) 312 Valve block 724 O-ring
113 Drive shaft(R) 313 Valve plate(R) 725 O-ring
114 Spline coupling 314 Valve plate(L) 728 O-ring
123 Roller bearing 401 Hexagon socket bolt 732 O-ring
124 Needle bearing 406 Hexagon socket bolt 774 Oil seal
127 Bearing spacer 466 VP Plug 789 Back up ring
141 Cylinder block 467 VP Plug 792 Back up ring
151 Piston 490 Plug 808 Hexagon head nut
152 Shoe 531 Tilting pin 824 Snap ring
153 Set plate 532 Servo piston 885 Pin
156 Bushing 534 Stopper(L) 886 Spring pin
157 Cylinder spring 535 Stopper(S) 901 Eye bolt
211 Shoe plate 548 Pin 953 Set screw
212 Swash plate 702 O-ring 954 Set screw
214 Bushing 710 O-ring 981 Plate
251 Support 717 O-ring 983 Pin
261 Seal cover(F)
2-2
2) REGULATOR(1/2)
412 876 874 755 858

A 642 723 648 647 646 438
897 B
614
612
615
613
C
875
A 611
B
801 730 643 708 644 645 728 924 801
SECTION B-B
656 735 413 438 405 735 413 438
438
722
496 724 725 436 699 496 724 725 436
VIEW C(FRONT) VIEW C(REAR)
KR38-9C07(FR) A
KR38-9C05(RR)
1607A2MP03
P2
Pf
Pm A Delivery port 3/4"
Pi
B Suction port 2 1/2"
Pn Pilot port PF 1/4-15
Pm Qmax cut port PF 1/4-15
2-3
REGULATOR(2/2)
655 734 653 654 836 651 652 601 624 629 630 628 802
641
814
898
631
732
733
622
621 623 625 626 887 763 756 753 627
SECTION A-A
1607A2MP04
405 Hexagon socket screw 631 Sleeve, Pf 730 O-ring

412 Hexagon socket screw 641 Pilot cover 732 O-ring
413 Hexagon socket screw 642 Pilot cover (QMC) 733 O-ring
436 Hexagon socket screw 643 Pilot piston 734 O-ring
438 Hexagon socket screw 644 Spring seat (Q) 735 O-ring
496 Plug 645 Adjust stem (Q) 753 O-ring
601 Casing 646 Pilot spring 755 O-ring
611 Feed back lever 647 Stopper 756 O-ring
612 Lever (1) 648 Piston (QMC) 763 O-ring
613 Lever (2) 651 Sleeve 801 Nut
614 Fulcrum plug 652 Spool 802 Nut
615 Adjust plug 653 Spring seat 814 Snap ring
621 Compensator piston 654 Return spring 836 Snap ring
622 Piston case 655 Set spring 858 Snap ring
623 Compensator rod 656 Block cover 874 Pin
624 Spring seat (C) 699 Valve casing 875 Pin
625 Outer spring 708 O-ring 876 Pin
626 Inner spring 722 O-ring 887 Pin
627 Adjust stem (C) 723 O-ring 897 Pin
628 Adjust screw (C) 724 O-ring 898 Pin
629 Cover (C) 725 O-ring 924 Set screw
630 Lock nut 728 O-ring
2-4
3) GEAR PUMP
700 354 351 433
B3
434
311
A3
312
850
732
a3 355
710 435 361 353 307 310 308 309 434 466, 725
1607A2MP05
307 Poppet 353 Drive gear 466 Plug

308 Seat 354 Driven gear 700 Ring
309 Spring seat 355 Filter 710 O-ring
310 Spring 361 Front case 725 O-ring
311 Screw 433 Flange socket 732 O-ring
312 Nut 434 Flange socket 850 Snap ring
351 Gear case 435 Flange socket
2-5
2. FUNCTION
1) MAIN PUMP
The pumps may classified roughly into the rotary group performing a rotary motion and working as
the major part of the whole pump function: the swash plate group that varies the delivery rates: and
the valve cover group that changes over oil suction and discharge.
(1) Rotary group

The rotary group consists of drive shaft
(F)(111), cylinder block(141), piston
shoes(151,152), set plate(153), spherical
bush(156) and cylinder spring(157). 124
The drive shaft is supported by bearing 313
141
(123,124) at its both ends.
156
The shoe is caulked to the piston to from 153
151
a spherical coupling. It has a pocket to 152
relieve thrust force generated by loading 157
111
pressure and the take hydraulic balance
211
so that it slides lightly over the shoe 123
plate(211). The sub group composed by
a piston and a shoe is pressed against the
shoe plate by the action of the cylinder
spring via a retainer and a spherical bush.
Similarly, the cylinder block is pressed
against valve plate(313) by the action of 2107A2MP05
the cylinder spring.

(2) Swash plate group
The swash plate group consists of swash 531
548
plate(212), shoe plate(211), swash plate
214
support(251), tilting bush(214), tilting
pin(531) and servo piston(532). 212
The swash plate is a cylindrical part
251 211
formed on the opposite side of the sliding
surface of the shoe and is supported by
the swash support.
If the servo piston moves to the right and
left as hydraulic force controlled by the 532
regulator is admitted to hydraulic chamber
located on both sides of the servo piston,
the swash plate slides over the swash
plate support via the spherical part of the
tilting pin to change the tilting angle( )
2-7 (140-7TIER)
2-6
(3) Valve block group
The valve block group consists of valve
block(312), valve plate(313) and valve
plate pin(885).
The valve plate having two melon-shaped
ports is fixed to the valve block and feeds 312
and collects oil to and from the cylinder
block. 313 885
The oil changed over by the valve plate is
connected to an external pipeline by way
of the valve block.
Now, if the drive shaft is driven by a prime
mover(electric motor, engine, etc), it
2-8 (140-7TIER)
rotates the cylinder block via a spline
linkage at the same time. If the swash
plate is tilted as in Fig(previous page) the
pistons arranged in the cylinder block
make a reciprocating motion with respect
to the cylinder block, while they revolve
with the cylinder block.
If you pay attention to a single piston, it
performs a motion away from the valve
plate(oil sucking process) within 180
degrees, and makes a motion towards the
valve plate(or oil discharging process) in
the rest of 180 degrees. When the swash
plate has a tilting angle of zero, the piston
makes no stroke and discharges no oil.
2-7
2) REGULATOR
Regulator consists of the negative flow control, total horse power control and power shift control
function.
(1) Negative flow control
By changing the pilot pressure Pn, the
pump tilting angle(delivery flow) is
regulated arbitrarily, as shown in the
figure.
This regulator is of the negative flow
control in which the delivery flow Q
Delivery flow, Q
decreases as the pilot pressure Pn rises.
With this mechanism, when the pilot
pressure corresponding to the flow
required for the work is commanded, the
pump discharges the required flow only,
and so it does not consume the power Pilot pressure, Pn
uselessly.
2-8
① Flow reducing function
643 654 651 652 613 646
P1 CL
B(E)
874
897
C
Pi (From MCV) A
875
611
Servo piston Small diameter

Large diameter D chamber
chamber 548
531
2-10 (140-7TIER)
As the pilot pressure Pn rises, the pilot piston (643) moves to the right to a position where the
force of the pilot spring (646) balances with the hydraulic force.
The groove (A) in the pilot piston is fitted with the pin (875) that is fixed to lever 2 (613).
Therefore, when the pilot piston moves, lever 2 rotates around the fulcrum of point B [fixed by the
fulcrum plug (614) and pin (875)]. Since the large hole section (C) of lever 2 contains a
protruding pin (897) fixed to the feedback lever (611), the pin (897) moves to the right as lever 2
rotates. Since the opposing-flat section (D) of the feedback lever is fitted with the pin (548) fixed
by the tilting pin (531) that swings the swash plate, the feedback lever rotates around the fulcrum
of point D, as the pin (897) moves.
Since the feedback lever is connected with the spool (652) via the pin (874), the spool moves to
the right.
The movement of the spool causes the delivery pressure P1 to connect to port CL through the
spool and to be admitted to the large diameter section of the servo piston. The delivery
pressure P1 that is constantly admitted to the small diameter section of the servo piston moves
the servo piston to the right due to the area difference, resulting in decrease of the tilting angle.
When the servo piston moves to the right, point D also moves to the right. The spool is fitted
with the return spring (654) and is tensioned to the left at all times, and so the pin (897) is
pressed against the large hole section (C) of lever 2.
Therefore, as point D moves, the feedback lever rotates around the fulcrum of point C, and the
spool is shifted to the left. This causes the opening between the sleeve (651) and spool (652) to
close slowly, and the servo piston comes to a complete stop when it closes completely.
2-9
Flow increasing function
643 654 651 652 613 646
P1 CL
B(E)
874
897
C
Pi (From MCV)
875
611
Servo piston Small diameter

Large diameter D chamber
548
chamber
531
2-11 (140-7TIER)
As the pilot pressure Pn decreases, the pilot piston (643) moves to the left by the action of the
pilot spring (646) and causes lever 2 (613) to rotate around the fulcrum of point B. Since the pin
(897) is pressed against the large hole section (C) of lever 2 by the action of the return spring
(654) via the spool (652), pin (874), and feedback lever (611), the feedback lever rotates around
the fulcrum of point D as lever 2 rotates, and shifts the spool to the left. Port CL opens a way to
the tank port as the spool moves. This deprives the large diameter section of the servo piston of
pressure, and shifts the servo piston to the left by the discharge pressure P1 in the small
diameter section, resulting in an increase in the flow rate.
As the servo piston moves, point D also moves to the left, the feedback lever rotates around the
fulcrum of point C, and the spool moves to the right till the opening between the spool and sleeve
is closed.
2-10
Adjustment of flow control characteristic
The flow control characteristic can be
adjusted with the adjusting screw.
Adjust it by loosening the hexagon 801
924
nut(801) and by tightening(or loosening)
the hexagonal socket head screw(924).
Tightening the screw shifts the control
chart to the right as shown in the figure.
Adjusting values are shown in table.
Adjustment of flow control
characteristic 2-12 (140-7TIER)
Speed
Tightening Flow control Flow change
amount of starting amount
adjusting pressure
screw(924) change
Delivery flow, Q
amount
(min -1) (Turn) (kgf/cm2) ( /min)
2000 +1/4 +1.5 +9.5
Pilot pressure, Pn
2-11
(2) Total horsepower control
The regulator decreases the pump tilting
angle(delivery flow) automatically to limit
the input torque within a certain value with
Delivery flow, Q
a rise in the delivery pressure P1 of the
self pump and the delivery pressure P2 of
the companion pump.
(The input horsepower is constant when
the speed is constant.)
Since the regulator is of the simultaneous
Delivery pressure, (P1+P2)
total horsepower type that operates by the
sum of load pressures of the two pumps
in the tandem double-pump system, the
prime mover is automatically prevented
from being overloaded, irrespective of the
load condition of the two pumps, when
horsepower control is under way.
Since this regulator is of the simultaneous
total horsepower type, it controls the tilting
angles(displacement volumes) of the two
pumps to the same value as represented
by the following equation :
Tin = P1 q/2 + P2 q/2
= (P1+P2) q/2
The horsepower control function is the
same as the flow control function and is
summarized in the following.(For detailed
behaviors of respective parts, refer to the
section of flow control).
2-12
① Overload preventive function
621 651 652 623 612 601 625 626
P1 CL
B(E)
897
P2 P1
875
611
Large diameter Small diameter

chamber Servo piston
D chamber
2-14 (140-7TIER)
When the self pump delivery pressure P1 or the companion pump delivery pressure P2 rises, it
acts on the stepped part of the compensating piston(621). It presses the compensating rod(623)
to the right till the force of the outer spring(625) and inner spring(626) balances with the hydraulic
force. The movement of the compensating rod is transmitted to lever 1(612) via pin(875).
Lever 1 rotates around the pin(875) (E) fixed to the casing(601).
Since the large hole section(F) of lever 1 contains a protruding pin(897) fixed to the feedback
lever(611), the feedback lever rotates around the fulcrum of point D as lever 1 rotates, and then
the spool(652) is shifted to the right. As the spool moves, the delivery pressure P1 is admitted to
the large diameter section of the servo piston via port CL, causes the servo piston move to the
right, reduces the pump delivery, flow rate, and prevents the prime mover from being overloaded.
The movement of the servo piston is transmitted to the feedback lever via point D. Then the
feedback lever rotates around the fulcrum of point F and the spool is shifted to the left. The
spool moves till the opening between the spool(652) and sleeve(651) is closed.
2-13
Flow reset function
621 651 652 623 612 601 625 626
P1 CL
B(E)
897
P2 P1
875
Large diameter Small diameter

chamber Servo piston D chamber
2-15 (140-7TIER)
As the self pump delivery pressure P1 or the companion pump delivery pressure P2 decreases,
the compensating rod(623) is pushed back by the action of the springs(625 & 626) to rotate lever
1(612) around point E. Rotating of lever 1 causes the feedback lever(611) to rotate around the
fulcrum of point D and then the spool(652) to move to the left. As a result, port CL opens a way
to the tank port.
This causes the servo piston to move to the left and the pump's delivery rate to increase.
The movement of the servo piston is transmitted to the spool by the action of the feedback
mechanism to move it till the opening between the spool and sleeve is closed.
2-14
Low tilting angle(Low flow) command preferential function
As mentioned above, flow control and horsepower control tilting angle commands are transmitted
to the feedback lever and spool via the large-hole sections(C & F) of levers 1 and 2. However,
since sections C and F have the pins( 4) protruding from the large hole( 8), only the lever
lessening the tilting angle contacts the pin(897) ; the hole( 8) in the lever of a larger tilting angle
command is freed without contacting the pin(897). Such a mechanical selection method permits
preference of the lower tilting angle command of the flow control and horsepower control.
Adjustment of input horsepower
Since the regulator is of total cumulative horsepower type, adjust the adjusting screws of both the
front and rear pumps, when changing the horsepower set values. The pressure change values
by adjustment are based on two pumps pressurized at the same time, and the values will be
doubled when only one pump is loaded.
a. Adjustment of outer spring
Adjust it by loosening the hexagon
625 626 630 628
the adjusting screw C(628). Tightening
the screw shifts the control chart to the
right and increases the input
horsepower as shown in the figure.
Since turning the adjusting screw C by
N turns changes the setting of the outer
spring(625), return the adjusting stem
QI(627) by N A turns at first.(A=1.54)
802 627
Adjusting values are shown in table
2107A2MP07A
Adjustment of outer spring
Speed
Tightening Compens- Input torque
amount of ating control change
adjusting starting amount
Delivery flow, Q
screw(C) pressure
(628) change
amount
(min -1) (Turn) (kgf/cm2) (kgf m)
2000 +1/4 +17.8 +3.54
2-15
b. Adjustment of inner spring
Adjust it by loosening the hexagon nut 625 626 630 628
(802) and by tightening(or loosening)
the adjusting screw QI(627).
Tightening the screw increases the flow
and then the input horsepower as
shown in the figure.
Adjusting valves are shown in table
Adjustment of outer spring

Speed 802 627
Tightening Compens- Input torque
amount of ating control change 2107A2MP08
adjusting starting amount
screw(C) pressure
(627) change
amount
Delivery flow, Q
(min -1) (Turn) (kgf/cm2) (kgf m)
2000 +1/4 +8.5 +3.78
2-16
(3) Power shift control
621 651 652 623 612 625 626
898 P1 CL
B(E)
897
F
Pf
P2 P1
875
611
Large diameter Servo piston Small diameter

chamber D chamber
2-18 (140-7TIER)
The set horsepower valve is shifted by

varying the command current level of the
proportional pressure reducing valve
Delivery flow, Q
attached to the pump.

Only one proportional pressure reducing Pf=
valve is provided. MIN
Pf= .
However, the secondary pressure Pf MA
X.
(power shift pressure) is admitted to the
horsepower control section of each pump
regulator through the pump's internal path Delivery pressure, (P1+P2)
to shift it to the same set horsepower
level.
This function permits arbitrary setting of the pump output power, thereby providing the optimum
power level according to the operating condition.
The power shift pressure Pf controls the set horsepower of the pump to a desired level, as shown
in the figure.
As the power shift pressure Pf rises, the compensating rod(623) moves to the right via the
pin(898) and compensating piston(621).
This decreases the pump tilting angle and then the set horsepower in the same way as explained
in the overload preventive function of the horsepower control. On the contrary, the set
horsepower rises as the power shift pressure Pf falls.
2-17
(4) Adjustment of maximum and minimum flows
① Adjust it by loosening the hexagon nut 808
(808) and by tightening (or loosening) the
set screw (954). 954
The maximum flow only is adjusted
without changing other control
characteristics.
Adjustment of max flow 2-19(1) 140-7TIER
Speed
Tightening Flow change
amount of amount
adjusting screw
Delivery flow, Q
(954)
(min -1) (Turn) ( /min)
2000 +1/4 -3.2
Delivery pressure, Pn
Adjustment of minimum flow

Adjust it by loosening the hexagon nut
806
(808) and by tightening (or loosening) the
hexagonal socket head set screw (953).
953
Similarly to the adjustment of the
maximum flow, other characteristics are
not changed.
However, remember that, if tightened too 2-19(2) 140-7TIER
much, the required horsepower during

the maximum delivery pressure (or
during relieving) may increase.
Adjustment of min flow
Delivery flow, Q
Speed
Tightening Flow change
amount of amount
adjusting screw
(953)
(min -1) (Turn) ( /min)
2000 +1/4 +3.2 Delivery pressure, Pn
2-18
(5) Qmax cut control
647
The regulator regulates the
maximum delivery flow by 648
inputting the pilot pressure 723
Pm. Since this is a 2-position 642 438
control method, the
maximum delivery flow may 801
be switched in two steps by
801
turning on/off the pilot 924
pressure Pm.(The maximum
control flow cannot be
641 730 643 708 644 645 646 728
controlled in intermediate
level.)
2-4 (140-7TIER)
① Functional explanation
As shown in the figure, the pilot pressure
Pm switches the maximum flow in two
steps.
Delivery flow, Q
When the pilot pressure Pm is given, it is Pm
admitted to the lefthand side of the piston
QMC(648). The piston QMC moves the
stopper(647) and pilot piston(643) to the
right, overcoming the force of the pilot
spring(646), thereby reducing the
delivery flow of the pump. Pilot pressure, Pn
Since the adjusting screw QMC(642) is
provided with a flange, the piston QMC
stops upon contact with the flange, and
the position of the pilot piston at this time
determines the maximum flow of the
pump.
Delivery flow, Q
Adjustment of Qmax cut flow

Adjust it by loosening the hexagon
the adjusting screw QMC(642).
Tightening the screw decreases the
Qmax cut flow as shown in the figure. Pilot pressure, Pn
2-19
GROUP 2 MAIN CONTROL VALVE
1. STRUCTURE
Mark Port name Port size Tightening torque
Rs Make up for swing motor
MRV Pu Pa1 Travel left pilot port (FW)
Pb1 Travel left pilot port (BW)
A1 B1
Pc1 Travel right pilot port (BW)
T1 Pd1 Travel right pilot port (FW)
Pb21 Dr1
B2 P2 Pa20 Boom up pilot port
A2 ORV
Pa21 Boom up confluence pilot port
Pb20 Boom down pilot port
ORV Dr2
Pb21 Lock valve pilot port (Boom)
Pc2 Swing pilot port (RH)
B4
P1
Pd2 Swing pilot port (LH)
Pb3 Arm in confluence pilot port
A5 B5
ORV ORV
Pc3 Swing priority pilot port
Pa4 Option A pilot port (Breaker)
NRV2 Rs
NRV1 Pb4 Arm in regeneration cut port
Pc40 Arm in pilot port
Pc41 Lock valve pilot port (Arm) PF 1/4 3.5~3.9kgf m
VIEW A Pc42 Arm in regen-cut signal selector port (25.3~28.2lbf ft)
Pd40 Arm out pilot port
Pd41 Arm out confluence pilot port
Pa5 Bucket in pilot port
Pb5 Bucket out pilot port
Ai
Dr0 STRAIGHT STRAIGHT Pc5 Option B pilot port
TRAVEL TRAVEL
PO Pd5 Option B pilot port
TRAVEL LEFT Pb1 Pc1 TRAVEL RIGHT C1 D1 TRAVEL RIGHT Pd1 Pa1 TRAVEL LEFT Pc6 Option C pilot port
Pd6 Option C pilot port
BOOM 1 Pb20 Pc2 SWING C2 D2 SWING Pd2 Pa20 BOOM 1 PO Pilot pressure port
Pu Main relief pressure up pilot port
ARM 2 Pb3 Pc3 BOOM 2 & ORV
V3
ORV BOOM 2 & Pa21 Pd41 ARM 2 Ai Auto idle signal port
-C4 -D4
SWING PRIORITY SWING PRIORITY Dr0 Drain port (Travel straight)
A Pc42 Pb4 Dr3 Pc41 Pd40
ARM REGENERATION Pc40 ARM 1 C4 D4 ARM 1 Pa4
ARM REGENERATION Dr1 Drain port (Boom holding valve)
& OPTION-A & OPTION-A
Dr2 Drain port (Boom2 & swing priority)
Dr3 Drain port (Arm holding valve)
BUCKET Pb5 Pc5 OPTION-B C5 D5 OPTION-B Pd5 Pa5 BUCKET
Pn1 Negative control signal port (P1 port side)

PF 3/8 -
Pc6 OPTION-C C6 D6 OPTION-C Pd6 Pn2 Negative control signal port (P2 port side)
A1 Travel motor left side port (FW)

B1 Travel motor left side port (BW)
C1 Travel motor right side port (BW)
D1 Travel motor right side port (FW)
B2 Boom rod side port
C2 Swing motor port (RH)
D2 Swing motor port (LH)
B4 Option A port (Breaker) 15~18kgf m
A5 Bucket head side port PF 3/4 (109~130lbf ft)
B5 Bucket rod side port
C5 Option B port
D5 Option B port
C6 Option C port
Pn1 Pn2 D6 Option C port
P1 Pump port (P1 side)
P2 Pump port (P2 side)
A2 Boom head side port

20~25kgf m
C4 Arm head side port PF 1
D4 Arm rod side port (115~180lbf ft)
SAE3000, 1 1/2 8.5~11.5kgf m

1607A2MC01 T1 Return port (M12) (61.5~83.1lbf ft)
2-20
2
15 91 90 3 77 87 58 82 80 72 55 56 90 16,91 15 91 90 11 19 20 18 84 81 21 23 22 90 30,31
1 Housing-P1 47 Stopper-lock valve

A A 2 Housing-P2 48 Spool-regen selector
3 Spool-straight travel 49 Spring-regeneration
B B 4 Spool-travel 1 50 Stopper-regeneration
51 5 Spool-travel 2 51 Piston-cut off
73 78 78 73 C C 6 Spool-swing 52 Poppet-signal
32,74 7 Spool-boom 1 53 Spring-signal
D D
8 Spool-swing priority 54 Plug
E E 9 Spool-boom 2 55 Orifice-signal
10 Spool-arm 2 56 Coin type filter
72 80 19 20 18 84 18 20 19 24 50 48 69 49 90 76 57 12 68 19 20 18 84 81 21 23 22 90 91 16
F F 11 Spool-arm 1 57 Orifice-plug
A - A(STRAIGHT-TRAVEL & SUPPLY) E - E(ARM 1 & ARM REGENERATION /BREAKER)
12 Spool-arm regeneration 58 Plug
15 91 90 26 4 81 21 84 18 20 19 26 90 16,91 15 91 90 26 13 19 20 18 84 81 21 70 83 26 90 16,91 & breaker 59 Plug
G G
13 Spool-option B 60 Plug
14 Spool-bucket 61 Plug-orifice
HOUSING P2 SIDE 15 Cover-pilot A 62 Poppet-negative control
16 Cover-pilot B1 63 Coin type filter
80 72 72 80 1 17 Cover-Pilot B2 64 Spring seat
18 Plug 65 Spring-negative control
19 Poppet 1-check valve 66 Piston-negative control
A A
20 Spring-check valve 67 Socket-negative control
B B 21 Plug 68 Plug
15,91 90 5 18 84 52 53 54 75 68 90 91 16 15,91 90 25 14 19 20 18 84 81 21 23 22 25 90 91 16
22 Poppet 2-check valve 69 Plug
C C 23 Spring-check valve 70 Plug
B - B(TRAVEL RIGHT & LEFT) F - F(OPTION-B & BUCKET)
24 Main relief valve 71 Plug
17 91 90 6 84 18 20 19 90 16,91 15 91 90 26 92 19 20 18 84 81 21 70 83 26 90 16,91
D 25 Cover 72 Plug
26 Plug 73 Plug
E E 27 Plug 74 Socket head bolt
28 Lock valve kit A 75 O-ring
F F 29 Lock valve kit B 76 O-ring
30 Socket head bolt 77 O-ring
G G 31 Block-Holding valve 78 O-ring
32 Block-Regeneration 79 O-ring
33 C-ring 80 O-ring
80 72 34 Poppet-lock valve 81 O-ring
67 66 85 65 64 62 63 63 62 64 65 85 66 67 HOUSING P1 SIDE 35 Restrictor-lock valve 82 O-ring
91,15 25 90 7 22 23 21 81 84 18 20 19 90 30,31
36 Spring-lock valve pilot 83 O-ring
C - C(SWING & BOOM 1) G - G(OPTION-C & NEGATIVE CONTROL) 37 Guide-poppet 84 O-ring
17 91 25 90 8 80 72 81 59 87 77 70 83 9 90 25 17,91 86 76 38 Poppet-pilot 85 O-ring
ITEM 29
39 Seat-poppet 86 Back-up ring
81 81 31 40 Piston 1 87 Back-up ring
21 60
ITEM 28 41 43 41 Guide-piston 88 Back-up ring
34 35 36 37 38 40 82 42 Spring1-lock valve 89 Back-up ring
71
43 Piston 2 90 O-ring
78 44 Sleeve 91 Socket head bolt
73
45 Spool-lock valve 92 Spool-option C
59 61
81 81 46 Spring 2-lock valve
33 84 39 77,87
47 79 79 69 77 44 76 42 45 46
88 78 86 76 88 78 86 76
LOCK VALVE - B KIT 89 87
(BOOM & ARM)
91,15 90 27 10 72 80 22 23 21 81 21 23 22 25 90 91 16 LOCK VALVE - A KIT(BOOM & ARM)
D - D(SWING PRIORITY & BOOM 2 & ARM 2) 1607A2MC02
2-21
2. HYDRAULIC CIRCUIT
Pn1 Pn2
C6
D6
Pc6
OPTION-C
Pd6
B5
A5
C5
D5
Pb5
OPTION-B Pc5
Pd5 Pa5
(DOZER) BUCKET
C4
D4
Pb3 B4
DR3
Pc42
Pc41
Pc40 Pb4 OPTION-A &
Pd40 Pa4 ARM
ARM 1 Pd41 REGENERATION
Pc42
V3
BOOM 2 & Pc3

SWING DR2 Pb3
Pa21 Pd41 ARM 2
PRIORITY
B2
C2 A2
D2
Pb21
DR1
Pc2 Pb20
Pd2 Pa20
SWING
Pa21 BOOM 1
C1 B1
D1 A1
Pc1 Pb1
Pd1 Pa1 TRAVEL(LH)
TRAVEL(RH)
DR0
STRAIGHT P0
TRAVEL
BLOCK Ai T1
P1 P2 Pu(Pz)
1407A2MC04A
2-22
3. FUNCTION
1) CONTROL IN NEUTRAL FUNCTION
(1) P1 SIDE
Straight travel spool P2 port Tank port T1
B B
P1 port
P1 Bypass passage P1 Parallel passage
SECTION A-A
P1 Bypass passage
TRAVEL A A
STRAIGHT
TRAVEL(RH)
SWING
BOOM 2 &
SW PRIORITY
ARM 1
OPTION-B
OPTION-C
Tank passage
SECTION B-B
1607A2MC12A
The hydraulic fluid from pump A1 flows into the main control valve through the inlet port "P1", pass the
straight travel spool, into the P1 bypass passage and P1 parallel passage.
The hydraulic fluid from the pump A1 is directed to the tank through the bypass passage of spools :
travel right, swing, boom 2 & swing priority, arm 1, option "B" and option "C", and the negative relief
valve with the tank passage.
2-23
(2) P2 SIDE
Straight travel spool P2 port Tank port T1
B B
SECTION A-A
P2 Bypass passage
A A
TRAVEL(LH)
BOOM 1
ARM 2
ARM REGEN
& OPTION-A
BUCKET
Tank passage
P2 Negative relief valve P1 Negative relief valve

SECTION B-B
1607A2MC11
The hydraulic fluid from pump A2 flows into the main control valve through the inlet port "P2", pass the
travel straight spool, into the P2 bypass passage and P2 parallel passage.
The hydraulic fluid from the pump A2 is directed to the tank through the bypass passage of spools :
travel left, boom 1, arm 2, arm regeneration & option A and bucket, the negative relief valve, tank
passage, and the tank port "T1"
2-24
2) EACH SPOOL OPERATION
(1) TRAVEL OPERATION
① Travel forward operation
P1 Bypass passage
A1 B1
From RCV
TRAVEL RIGHT
Pd1
Pa1
TRAVEL LEFT
From RCV
Tank passage
C1 D1
P2 Bypass passage
1607A2MC17A
Travel backward operation
P1 Bypass passage
A1 B1
From RCV
Pc1
TRAVEL RIGHT
Pb1
TRAVEL LEFT
From RCV
Tank passage
C1 D1
P2 Bypass passage
1607A2MC18A
During the travel operation, the hydraulic fluid of the pump A2 is supplied to the travel motor and the
hydraulic fluid of the pump A1 is supplied to the other travel motor.
The pilot pressure from the pilot control valve is supplied to the spring side of pilot port (pa1, pd1).
And it shifts travel right and left spools in the left direction against springs. Hydraulic fluid from the
pump A1 flow into the travel right spool through the bypass passage and hydraulic fluid from the pump
A2 flow into the travel left spool through the bypass passage.
Then they are directed to the each travel motor through port A1 and D1. As a result, the travel motors
turn and hydraulic fluid returns to the tank passage through the travel spools.
In case of the opposite operation, the operation is similar.
2-25
(2) TRAVEL
TR STRAIGHT FUNCTION
P1 Parallel passage P2 port

P1 Bypass passage Orifice
Check valve
Straight travel
spool
P1 port
1607A2MC19A
This function keeps straight travel in case of simultaneous operation of other actuators (boom, arm,
bucket, swing) during a straight travel.
① During travel only :
The hydraulic fluid of the pump A2 is supplied to the travel motor and the pump A1 is supplied to
the other motor.
Thus, the machine keep travel straight.
The other actuator operation during straight travel operation :
When the other actuator spool (s) is selected under straight travel operation, the straight travel
spool is moved.
The hydraulic fluid from pump A2 is supplied actuator through P2 and P1 parallel pass and travel
motors through orifice at side of straight travel spool.
The hydraulic oil fluid from pump A1 is supplied to travel motors (left/right).
Therefore, the other actuator operation with straight travel operation, hydraulic oil fluid from pump
A2 is mainly supplied to actuator, and the hydraulic oil fluid form pump A1 is mainly supplied to
travel motors (left/right).
Then the machine keeps straight travel.
2-26
(3) BOOM OPERATION
① Boom up operation
P2 Bypass passage
Tank passage
Boom 1 spool Holding valve
From RCV
Boom summation B2 A2
passage P2 Parallel passage
Cylinder rod side Cylinder head side
P1 Parallel passage Arm summation passage

P1 Bypass passage
Swing priority
spool Boom 2 spool
From RCV
Arm 2 spool
Boom summation passage Check
1607A2MC24A
During boom up operation, the pilot pressure from RCV is supplied into the port Pa20 and shift the
boom1 spool in the left direction. The hydraulic oil fluid from pump A2 is entered P2 parallel passage
and then passes through the load check valve and boom holding valve then flows into the port A2.
Following this it flows into the head side of the boom cylinder.
(In this case, the boom holding valve is free flow condition)
At the same time the pilot pressure through the port Pa21 shifts the boom 2 spool. The hydraulic oil
fluid from pump A1 entered boom summation passage via the P1 parallel passage, the swing priority
spool, the boom 2 spool, arm2 spool and the check. The flows combine in passage and are directed
to port A2 and head side of boom cylinder.
The flow from rod side of the boom cylinder return to the boom 1 spool through the port B2. There
after it is directed to the hydraulic oil tank through the tank passage.
2-27
Boom down operation
P2 Bypass passage
Tank passage
Boom 1 spool
Holding valve
From RCV
B2 A2
P2 Parallel passage
Cylinder rod side Cylinder head side
1607A2MC26
During the boom lowing operation, the pilot pressure from RCV is supplied to the port Pb20 and shift
the boom 1 spool in the right direction.
The hydraulic fluid from the pump A2 enters the parallel passage and is directed to the port B2
through the load check valve. Following this, it flows into the rod side of the boom cylinder.
The return flow from the head side of the boom cylinder returns to the boom 1 spool through the port
A2 and boom holding valve. Thereafter it is directed to the hydraulic oil tank through tank passage.
For details of the boom holding valve, see page 2-36.
2-28
(4) BUCKET OPERATION
① Bucket roll in operation
Tank passage P2 Bypass passage
Bucket spool
Check 2
From RCV
B5 A5
Check 1
P2 Parallel passage
Cylinder head side

Cylinder rod side
1607A2MC34A
Bucket roll out operation
P2 Bypass passage
Tank passage
Bucket spool
Check 2
From RCV
B5 A5
Check 1
P2 Parallel passage
Cylinder head side

Cylinder rod side
1607A2MC35
2-29
① Bucket roll in operation
During the bucket roll in operation, the pilot pressure from RCV is supplied to port Pa5 and shift
the bucket spool in the left direction.
The hydraulic fluid from pump A2 entered P2 parallel passage and is directed to the port A5
through the check 1.
At the same time, the hydraulic fluid from P2 bypass passage is directed to the port A5 through
the check 2.
Following this it flows into the head side of the bucket cylinder.
The return flow from the rod side of the bucket cylinder returns to the bucket spool through the
port B5. Thereafter it is directed to the hydraulic oil tank through the tank passage.
Bucket roll out operation
In case of the bucket roll out operation, the operation is similar
Bucket operation with arm or boom operation
When combined operation, mostly same as above but the fluid from bypass passage is empty.
So only the fluid from parallel passage is supplied to the bucket cylinder. Also, parallel passage
is installed the orifice for supplying the fluid from pump to the boom or the arm operation prior to
the bucket operation.
2-30
(5) SWING OPERATION
① Swing left operation
Tank passage Swing spool

C2 D2
From RCV

1607A2MC32
Swing right operation
Tank passage
C2 D2
Swing spool
From RCV

1607A2MC33
The pilot pressure from the RCV is supplied to the Pd2 and shift the swing spool in left direction. The
hydraulic fluid from pump A1 flows into swing spool through the parallel passage. Then it is directed to
swing motor through the port D2. As the result, swing motor turns and flow from the swing motor
returns to the hydraulic oil tank through the port C2, swing spool and the tank passage .
In case of swing right operation, the operation is similar.
2-31
(6) ARM OPERATION
① Arm roll in operation
Cylinder head side Cylinder rod side

Arm summation passage
P1 Parallel passage
Arm 1 spool
C4 D4
Piston C
Selector spool
Arm regeneration
cut pilot pressure Tank passage
Arm roll in
pilot pressure
Arm regeneration P1 Bypass passage
& breaker spool

Boom 2 spool
Arm 2 spool
Arm roll in
pilot pressure
From RCV

1607A2MC21
Arm roll in operation :

During arm roll in operation the pilot pressure from the RCV is supplied to the port Pc40 and Pb3
and shifts arm 1 spool and arm 2 spool in the right direction.
The hydraulic oil from the pump A1 flows into the arm cylinder head side through P1 parallel
passage, the load check valve and the port C4.
At same time, the hydraulic fluid from the pump A2 flows into the arm summation passage through
parallel passage, the check valve, the arm 2 spool and the boom 2 spool. Then it entered the arm
cylinder head side with hydraulic fluid from arm 1 spool.
2-32
Arm regeneration :
The return flow from the arm cylinder rod side is pressurized by self weight of arm and so, returns
to port D4. The pressurized oil returning to port D4 enters the arm regeneration & breaker spool
through the arm holding valve and the arm 1 spool. It is suppled the arm cylinder head through
internal passage. This is called the arm regeneration function.
The amount of regeneration fluid are changed by movement of the arm regeneration & breaker
spool.
A few fluid after P1 parallel passage is push piston "C" through the notch of arm regeneration spool
and selector spool. At this time, the selector spool is opened by pilot pressure from RCV.
Then, the arm regeneration spool shift to right side and flow to tank pass increases and
regeneration flow decreases. Therefore, pressure of arm cylinder head increases, then, arm
regeneration flow decreases.
Furthermore, the arm regeneration cut pressure is supplied to port and arm regeneration spool is
move into the right direction fully. The flow from the arm cylinder rod is returned to the hydraulic oil
tank and regeneration function is not activated.
2-33
Arm roll out operation
Cylinder head side Cylinder rod side

P1 Parallel passage
Arm 1 spool
C4 D4
Tank passage
Arm roll out

pilot pressure
From RCV
P1 Bypass passage
Spool bypass notch

Boom 2 spool
Arm 2 spool From RCV
Arm roll out

pilot pressure
1607A2MC23
During arm roll out operation the pilot pressure from RCV is supplied to the port Pd40 and the
Pd41 and shifts arm 1 spool and arm 2 spool in the right direction.
The hydraulic fluid from pump A1 flows into arm1 spool through the parallel passage. Then it
enters into the arm cylinder rod side through the load check valve, bridge passage, arm holding
valve and the port D4.
Some of the hydraulic fluid from pump A1 bypassed through bypass notch.
The rest of hydraulic fluid from pump A2 flows into the arm summation passage through P2
parallel passage the check valve arm 2 spool and boom 2 spool.
Then it enters into the arm cylinder rod side with the fluid from the arm 1 spool.
The return flow from the arm cylinder head side returns to the hydraulic tank through the port C4
the arm 1 spool and tank passage.
2-34
(7) SWING PRIORITY FUNCTION
Swing priority spool Path "A" P1 Parallel passage
Swing priority
pilot pressure
From RCV Boom 2 spool
Arm 2 spool
1607A2MC27
During swing priority operation, the pilot pressure is supplied to the port Pc3 and shift swing priority
spool in the right direction.
The hydraulic fluid from P1 parallel passage flows into the parallel passage of arm 1 side through
swing priority spool and the passage "A" and also flows into the boom 2 spool.
Due to shifting of the swing priority spool, the fluid from pump A1 flows to swing side more then next
spools to make the swing operation most preferential.
2-35
(8) HOLDING VALVE OPERATION
① Holding operation
14072SF30
At neutral condition, the pilot piston chamber is connected to drain port through the pilot port.
And the piston "B" is supported with spring "B" and the pressured fluid from actuator entered to inside
of the holding valve through the periphery hole of check, crevice of the check and the plug and the
periphery hole of plug.
Then, this pressured oil pushed the poppet to the poppet seat and the check to the seat of body.
So the hydraulic fluid from actuator is not escaped and the actuator is not moved.
2-36
Release holding operation
TANK PATH PISTON "A" PILOT PISTON CHAMBER
SPRING POPPET SPRING "B" PISTON "B"
CHECK
SPRING "C"
PLUG
SOCKET SPOOL
POPPET SEAT
PILOT PORT
ACTUATOR PORT FOR RELEASE
DRAIN PORT HOLDING VALVE
14072SF31
The pilot pressure is supplied to the pilot port for release holding valve and shifts the piston "B" in the
left direction against the spring "B", and shifts the poppet in the left direction through piston "B" and
piston "A" against spring "B" and shifts the spool in the left side.
At same time, the return fluid from actuator returns to the drain port through the periphery hole of
check, crevice of the check and the plug, the periphery hole of the plug, in side of holding valve,
crevice of the poppet and the poppet seat, the periphery hole of the poppet seat, crevice of the socket
and spool and inside of spool.
When the poppet is opened, pressure of inside of holding valve is decreased and the return fluid from
actuator returns to the tank passage through the notch of spool.
2-37
(9) NEGATIVE RELIEF VALVE CONTROL
Negative Tank passage P2 Bypass passage P1 Bypass passage end

control valve
Bucket spool
Tank passage
P2 negative P1 negative
relief valve relief valve
Negative Orifice Pn2 port Pn1 port
control spring
1607A2MC28
When no function is being actuated on P2 side, the hydraulic fluid from the pump A2, flows into the
tank passage through the bypass passage and orifice. The restriction caused by this orifice thereby
pressurizes. This pressure is transferred as the negative control signal pressure Pn2 to the pump A2
regulator.
It controls the pump regulator so as to minimize the discharge of the pump A2.
The bypass passage is shut off when the shifting of one or more spools and the flow through bypass
passage became zero. The pressure of negative control signal become zero and the discharge of the
pump A2 become maximum.
The negative control pressure reaches to the set level, the hydraulic fluid in the passage pushes open
negative control valve and escapes into the return passage.
For the pump A1 the same negative control principle.
2-38
(10) OPERATION OF MAIN RELIEF VALVE
The main relief valve is fitted to the straight travel valve block and functions as follows :
① The pressurized oil passes through the orifice (A) of the plunger is filled up in chamber A of the
inside space, and seats the plunger against the housing securely.
Socket Chamber A Piston A Poppet Hole A Spring Piston B
Housing Tank
passage
T
Plunger Orifice A
1607A2MC36
When the pressure at (P) becomes equal to the set pressure of the spring the hydraulic oil
passes through the piston (A) pushes open the poppet and flows to tank passage (T) through the
hole (E).
Piston A Poppet Spring

Orifice B
Tank
passage
T Hole E
1607A2MC37
2-39
Opening the poppet causes the pressure in chamber A to fall and the plunger to open. As
the result the pressurized oil at port P runs into tank passage (T).
Plunger Poppet
Tank
passage
T
1607A2MC38
High pressure setting pilot signal (Pu) : ON

When the power boost switch is ON, the pilot pressure enters through hole A.
It pushes the piston (B) in the left direction to increase the force of the spring and change the
relief set pressure to the high pressure.
Hole A Spring Piston B
Housing Tank
passage
T
1607A2MC36A
2-40
(11) OPERATION OF PORT RELIEF VALVE
① Function as relief valve
The pressurized oil passes through the piston A and orifice is filled up in chamber A of the
inside space and seat the plunger against the socket and the socket against the housing
securely.
Piston A Socket Chamber A Poppet Spring
Housing
Tank
passage Plunger Orifice A
T
1607A2MC39
When the pressure at port P becomes equal to the set pressure of the spring, the pressurized
oil pushes open the poppet flows to tank passage (T) through hole E.
Tank passage Orifice B Poppet Hole E Spring

T
Housing
1607A2MC40
2-41
Opening of the poppet causes the pressure in chamber A to fall and the plunger to open. As
the result the pressurized oil at port P runs into tank passage (T).
Tank passage Chamber A Poppet

T
Housing
Tank
passage Plunger
T
1607A2MC41
Make-up function
When negative pressure exists at port P, the oil is supplied through tank passage (T). When the
pressure at tank passage (T) becomes higher than that at port P, the socket moves in the right
direction. Then, sufficient oil passes around the socket from tank passage (T) to port P and fills
up the space.
Tank passage Socket Poppet

T
Housing
Tank
passage
T
1607A2MC42
2-42
GROUP 3 SWING DEVICE
1. STRUCTURE
Swing device consists swing motor, swing reduction gear.
Swing motor include mechanical parking valve, relief valve, make up valve and time delay valve.
Reduction gear Grease port(PT 1/4) Swing motor Gear oil filling port(PT 1/4) PA A B PB
Gear oil drain port(PT 1/2) SH PG Time delay valve Mu Dr Oil gauge port(PT 1/4)
1607A2SM01
A Main port SAE PF 3/4

B Main port SAE PF 3/4
SH Dr Drain port PF 1/2
Mu Make up port PF 1
PG
PG Brake release port PF 1/4
dr
SH Brake pilot port PF 1/4
PA,PB Gage port PF 1/4
PA PB
Mu
A(cw) B(ccw)
Hydraulic circuit
2-43
1) SWING MOTOR
117 121 118 114 706 707 702 712 472 106 994 469 488 355 351 052 841
438
432 X X
A 303
106
748
471
A 747
443
444
304
468
487
746
101
433
491
745
437
124 451
301 401 051 993

131
122 123 113 116 111 744 742 031 743 058 060 053 054
464 485
059
057
056
055
SECTION A-A SECTION X-X

17W72SM02
031 Brake valve 122 Shoe 471 O-ring

051 Relief valve 123 Retainer 472 O-ring
052 Reactionless valve assy 124 Shoe plate 485 O-ring
053 Valve 131 Valve plate 487 O-ring
054 Block 301 Casing 488 O-ring
055 Plug 303 Casing 491 Oil seal
056 Back up ring 304 Front cover 702 Piston
057 O-ring 351 Plunger 706 O-ring
058 Plug 355 Spring 707 O-ring
059 O-ring 401 Hexagon socket bolt 712 Brake spring
060 O-ring 432 Snap ring 742 Friction plate
101 Drive shaft 433 Snap ring 743 Separate plate
106 Spacer 437 Snap ring 744 Plug
111 Cylinder block 438 Snap ring 745 Plug
113 Bushing 443 Roller bearing 746 Plug
114 Spring 444 Roller bearing 841 Hexagon socket bolt
116 Push rod 451 Spring pin 993 Plug
117 Spacer 464 Plug 994 Plug
118 Spacer 468 Plug
121 Piston 469 Plug
2-44
2) REDUCTION GEAR
25 37 36 13 3 35 34 5 2 30 29 6 7 10 9 11 18 19 26 31
28
27
38
33 32 1 8 14 12 23 15 16 21 17 20 24 22 39
17W72SM03
1 Casing 15 Planet gear 2 28 Stop ring

2 Drive shaft 16 Pin 2 29 Plug
3 Spacer 17 Spring pin 30 Plug
5 Roller bearing 18 Sun gear 2 31 Socket bolt
6 Oil seal 19 Carrier 1 32 Gauge pipe
7 Roller bearing 20 Side plate 1 33 Gauge bar
8 Thrust plate 21 Pin 1 34 Cover plate
9 Carrier 2 22 Needle cage 35 Hexagon bolt
10 Stop ring 23 Bushing 2 36 Lock plate
11 Ring gear 24 Planet gear 1 37 Hexagon bolt
12 Knock pin 25 Lock washer 38 Stop ring
13 Pinion gear 26 Side plate 3 39 Side plate 2
14 Thrust washer 27 Sun gear 1
2-45
2. FUNCTION
1) ROTARY PART
When high pressurized oil enters a cylinder through port(a), which is the inlet of balance plate(131),
hydraulic pressure acting on the piston causes axial force F. The pressure force F works via the
piston(121) upon the return plate(123) which acts upon the swash plate(124) via an hydrostatic
bearing. Force F1 perpendicular to swash plate(124) and force F2 perpendicular to cylinder center.
Being transferred to the cylinder block(111) through piston, force F2 causes rotational moment at
surroundings of cylinder.
Since cylinder block has 9 equidistantly arrayed pistons, rotational torque is transmitted to cylinder
shaft in order by several pistons connected to the inlet port of high pressurized oil. When the
direction of oil flow is reversed, rotational direction of cylinder is also reversed. Output torque is
given by the equation.
pÝq F
T= , q=ZÂAÂPCDÂtanɾ, F1 = , F2=F tanɾ, S=PCDÝtanɾ
2ӕ COSɾ
Where p : Effective difference of pressure(kgf/cm2)
q : Displacement(cc/rev)
T : Output torque(kgfÂcm)
Z : Piston number(9EA)
A : Piston area(cm2)
ɾ: Tilting angle of swash plate(degree)
S : Piston stroke(cm)
Low High
pressure oil pressure oil
F1 F2
131
124 123 121 111
R290SM05(2)
2-46
2) MAKE UP VALVE
In the system using this type of motor, there is no counter balance functioning valve and there
happens the case of revolution exceeding hydraulic supply of motor. To prevent the cavitation
caused by insufficient oil flow there is a make up valve to fill up the oil insufficiency.
A make up valve is provided immediately before the port leading to the hydraulic oil tank to secure
feed pressure required when the hydraulic motor makes a pumping action. The boost pressure
acts on the hydraulic motor's feed port via the make up valve.
Pressurized oil into the port B, the motor rotate counterclockwise.
If the plunger of MCV moves neutral position, the oil in the motor is drain via left relief valve, the
drain oil run into motor via right make up valve, which prevent the cavitation of motor.
A B
29072SM09
2-47
3) RELIEF VALVE
3
5
1 Body
2 O-ring
4 3 Plug
15 4 O-ring
11 5 Back up ring
6 Plunger
14
7 Piston
13 7 8 Spring
9 Seat spring
9
12 10 Seat
2 11 Sleeve
12 Adjust plug
1
13 O-ring
14 Back up ring
8
15 Nut
10
29072SM03
(1) Construction of relief valve

The valve casing contains two cartridge type relief valves that stop the regular and reverse
rotations of the hydraulic motor. The relief valves relieve high pressure at start or at stop of swing
motion and can control the relief pressure in two steps, high and low, in order to insure smooth
operation.
(2) Function of relief valve

Figure illustrates how the pressure acting P P=pressure, T=time
on the relief valve is related to its rising PS
process. Here is given the function, 4
referring to the figure following page.
P1 3
T
1
29072SM05
2-48
Η Ports (P,R) at tank pressure.
A1 m 6 7
8 A2
29072SM04
Θ When hydraulic oil pressure(PÝA1) reaches the preset force(FSP) of spring(8), the plunger (6)
moves to the right as shown.
P1ÝA1 = Fsp + P1ÝA2
Fsp
P1=
A1 - A2
P=P1
8
29072SM06
2-49
Ι When the pressure of chamber g reaches the preset force(Fsp) of spring(8), the piston(7) moves
right and stop the piston(7) hits the end of body.
m 6 7 f g
P=P2
P=P1
8
29072SM07
Κ When piston(7) hits the end of body, it stops moving to the right any further. As the result, the
pressure in chamber(g) equals(Ps).
PsÝA1 = Fsp + PsÝA2
Fsp
Ps =
A1 - A2
m 6 7 g
P=Ps
P=P1
8
29072SM08
2-50
4) BRAKE SYSTEM
(1) Control valve swing brake system
This is the brake system to stop the swing motion of the excavator during operation.
In this system, the hydraulic circuit is throttled by the swing control valve, and the resistance
created by this throttling works as a brake force to slow down the swing motion.
Work Deceleration Stop
A B A B A B
MCV MCV MCV
MCV A, B opened MCV A, B throttled MCV A, B closed
210-7 2-48(1)
(2) Mechanical swing parking brake system

The mechanical swing parking brake system is installed to prevent the upper structure from
swinging downhill because of its own weight when the excavator is parked on a slope since it
completely eliminates the hydraulic drift of swing motion while the excavator is on a slop, work can
be done more easily and safely.
Η Brake assembly
Circumferential rotation of separate
plate(743) is constrained by the groove
located at casing(301). When housing
is pressed down by brake spring(712)
712
through friction plate(742), separate
plate(743) and brake piston(702), friction 702
force occurs there.
743
Cylinder(111) is constrained by this
friction force and brake acts, while brake 742
releases when hydraulic force exceeds 111 Groove
spring force. 301
17W72SM04
111 Cylinder 712 Brake spring

301 Casing 742 Friction plate
702 Brake piston 743 Separate plate
2-51
Θ Operating principle
a. When the swing control lever(1) is set to the swing position, the pilot oil go to the swing control
valve(2) and to SH of the time delay valve(3) via the shuttle valve(4), this pressure move
spool(5) to the leftward against the force of the spring(8), so pilot pump charged oil(P3) goes to
the chamber G.
This pressure is applied to move the piston(702) to the upward against the force of the
spring(712). Thus, it releases the brake force.
5
712
G SH
702
8
1 Swing control lever

2 Swing control valve(MCV) 12
3 Time delay valve
P3
4 Shuttle valve
5 Spool
8 Spring 2 2
702 Brake piston 4
712 Brake spring
17W72SM05
2-52
b. When the swing control lever(1) is set the neutral position, the time delay valve(3) shifts the
neutral position and the pilot oil blocked chamber G.
Then, the piston(702) is moved lower by spring(712) force and the return oil from the chamber
G is drain.
5
712
G SH
702
8
1 Swing control lever

2 Swing control valve(MCV)
3 Time delay valve
4 Shuttle valve P3
702 Brake piston
712 Brake spring
2 2
4
17W72SM06
2-53
GROUP 4 TRAVEL DEVICE
1. CONSTRUCTION
Travel device consists travel motor and gear box.
Travel motor includes brake valve, parking brake and high/low speed changeover mechanism.
2 Speed control port(P) Parking brake release

gauge port(P3) Oil fill port(PT 1/2)
D1
P1 A
P3
P2 B
D2
Oil level check port(PT 1/2)
Drain port(PT 1/2)
Pressure gauge port(P1,P2)
1607A2TM01
Hi Low
RED
A Main port SAE 5000psi 1"
D1 D2
P1 P2 B Main port SAE 5000psi 1"
P3 P1, P2 Gauge port PT 1/4
P
P3 Gauge port PT 1/8
D1, D2 Drain port PT 1/2
P 2 speed control port PF 1/4
A B
Hydraulic circuit
2-54
1) BASIC STRUCTURE
14072SF62
2-55
2) STRUCTURE
14072SF61
1 Hub 25 Needle bearing 106 Shoe 151 Roller 219 O-ring 355 O-ring
2 Spindle 27 Parallel pin 107 Retainer plate 161 Piston 2 220 Piston seal 357 RO plug
3 Carrier 28 O-ring 108 Thrust ball 162 Shoe 2 301 Rear flange 358 O-ring
4 Ring gear A 29 O-ring 109 Timing plate 167 Pivot 323 Spool 359 O-ring
5 Ring gear B 30 PT plug 110 Washer 171 Parallel pin 324 Plug 363 Spool 2
6 Cluster gear 31 Floating seal 111 Collar 193 Spring 325 Stopper 366 Spring
7 Sun gear 32 Socket bolt 112 Piston 201 Valve 326 Plug 368 Steel ball
8 Coupling gear 33 Spring washer 113 Spring 202 Sleeve 327 Valve 379 Filter
9 Cluster shaft 34 Parallel pin 114 Spring 203 Spring retainer 328 Spring 380 Plug
12 Distance piece 35 Socket bolt 115 Friction plate 204 Plug 330 Spring 381 Piston
13 Cover 36 Steel ball 116 Mating plate 205 Shim 336 O-ring 382 Plug
14 Thrust collar 40 O-ring 132 Oil seal 206 Spring 337 O-ring 383 O-ring
15 Ring 42 Parallel pin 135 O-ring 208 O-ring 341 Parallel pin 384 O-ring
17 Pin 102 Main shaft 139 O-ring 209 O-ring 343 Socket bolt 385 Steel ball
19 Coupling 103 Swash plate 145 Snap ring 210 O-ring 346 PT plug 397 Orifice
20 Thrust plate 104 Cylinder block 149 Ball bearing 211 Back-up ring 352 RO plug 398 PT plug
23 Seal ring 105 Piston 150 Ball bearing 217 Back-up ring 354 PT plug 399 Name plate
24 Ball bearing
2-56
2. FUNCTION
1) HYDRAULIC MOTOR
(1) Rotary group
Y1
301 104 105 102 F3

F3
ri
F3
Y2 F3
P
F2
F3 A P
F1
α
109 103
25032TM04
The pressurized oil delivered from the hydraulic pump flows to rear flange(301) of the motor,
passes through the brake valve mechanism, and is introduced into cylinder block(104) via timing
plate(109). This oil constructively introduced only to one side of Y1-Y2 connecting the upper and
lower dead points of stroke of piston(105). The pressurized oil fed to one side in cylinder
block(104) pushes each piston(105, four or five) and generates a force(F kg = P kg/cm2ÝA cm2).
This force acts on swash plate(103), and is resolves into components (F2 and F3) because swash
plate(103) is fixed at an angle(ɷÁ ) with the axis of drive shaft(102). Redial component(F3)
generates respective torques(T = F3Ýri) for Y1-Y2. This residual of torque(T = F3Ýri) rotates
cylinder block(104) via piston(105). Cylinder block(104) is spline-coupled with drive shaft(102).
So the drive shaft(102) rotates and the torque is transmitted.
2-57
(2) Brake valve
Η Brake released(Starting / Running)
When the pressurized oil supplied from
port , the oil opens valve(327) and
flows into port at the suction side of
hydraulic motor to rotate motor. At the
same time, the pressurized oil passes 112
through pipe line ͽ from a small hole in
spool(323) and flows into chamber ;. P
The oil acts on the end face of
spool(323) which is put in neutral position 328 323 a b
by the force of spring(328), thus causing
D E C
spool(323) to side to the left. When
spool(323) slides, port on the passage
at the return side of hydraulic motor,
which is closed by the spool groove
during stoppage, connected with port
at the tank side and the return oil from 327
the hydraulic motor runs into the tank. In

consequence, the hydraulic motor
rotates. Moreover, sliding of spool(323)
causes the pressurized oil to flow into
B A Drain
ports .
The pressurized oil admitted into port
activates piston(112) of the parking brake
to release the parking brake force. (For 25032TM05
details, refer to description of the parking
brake.) When the pressurized oil is
supplied from port , spool(323) move
reversely and the hydraulic motor also
rotates reversely.
2-58
Θ Brake applied(Stopping / Stalling)
When the pressurized oil supplied from
port is stopped during traveling, no
hydraulic pressure is applied and
spool(323) which has slid to the left will
D C
return on the right(Neutral) via stopper
(325) by the force of spring(328). g 381
At the same time, the hydraulic motor will
rotate by the inertia even if the f
pressurized oil stopped, so the port D of 201
the motor will become high pressure. 323
This pressurized oil goes from chamber
΂ to chamber ΃ through the left-hand 325
valve(201).
328
When the oil enters chamber ΃, the
piston(381) slids to the right so as not to
rise the pressure, as shown in the figure. 327
Meanwhile, the left-hand valve(201) is 330
pushed open by the pressurized oil in
port D. B A
Therefore, the pressurized oil in port D
flows to port C at a relatively low
pressure, controlling the pressure in port 25032TM06
D and preventing cavitation in port C.

When the piston(381) reaches the stroke
end, the pressure in chamber ΃ and ΂
increase and the left-hand valve(201)
closes again, allowing the oil pressure in
port D to increase further. Then, the
right-hand valve(201) opens port C with
pressure higher than that machine relief
set pressure.
In this way, by controlling the pressure in
port D in two steps, the hydraulic motor is
smoothly braked and brought to a stop.
2-59
Ι Braking effect on downhill travel
If the machine traveling downhill with a
relatively small supply of high pressure
oil to its travel motors should start
coasting, the same braking effect as the
one described above would automatically 112
occur.
In the coasting condition, the motor is
P
driven, instead of driving the track, from
the ground and sucks high pressure oil 328 323 a b
in.
In other words, the motor tends to draw D E C
more high pressure oil than is being
supplied.
Under this condition, port A goes
negative to pull oil out of chamber ;
through oil way ͽ, moving back the 327
spool(323) rather rapidly.
The clearance on the left then becomes
smaller to throttle the outgoing oil more
than before, thereby obstructing the
pumping action of the motor. B A Drain
As in stopping the machine, pressure will
build up in port D to make it harder to
drive the motor from the ground: This is
25032TM07
the braking action.
2-60
(3) Parking brake
Η Running
113 112 a 116 115 104
When the pressurized oil is supplied from
the brake valve, the spool of brake valve
in the hydraulic motor assembly actuates
to open the passage to the parking brake
and the pressurized oil is introduced into
cylinder chamber ͽ which is composed
of the spindle of reduction gear assembly
and piston(112). When the hydraulic
pressure reaches 6kgf/cm2(0.59Mpa) or
more, it overcomes the force of spring
(113) and shifts piston(112). With shift
of piston(112), no pressing force is
applied to mating plate(116) and friction
plate (115) and the movement of friction
plate (115) becomes free, whereby the
brake force to the cylinder in the hydraulic
motor assembly is released.
25032TM08
Θ Stopping
When the pressurized oil from the brake
113 112 a 116 115 104
valve is shut off and the pressure in
cylinder chamber ͽ drops 6kgf/cm 2
(0.59Mpa) or less, piston(112) will return
by the force of spring(113).
Piston(112) is pushed by this force of
spring(113), and mating plate(116) and
friction plate(115) in free condition are
pressed against the spindle of reduction
gear assembly.
The friction force produced by this
pressing stops rotation of the cylinder
block(104) and gives a braking torque
40.6kgfÂm(398NÂm) to the hydraulic
motor shaft.
Note that oil control through a proper oil
passage ensures smooth operation.
25032TM08
2-61
(4) High/low speed changeover mechanism
Η At low speed - At pilot pressure of less than 20kgf/cm2(1.96Mpa)
Pilot pressure
P
A B
366
363 θ1 Spindle
103 Support
C 161
a
Motor
case
Drain
25032TM09
When the pilot pressure is shut off from port , valve(363) is pressed upward by the force of
spring(366), the pressurized oil supply port is shut off, and oil in chamber ͽ is released into
the motor case through the valve(363). Consequently, swash plate(103) is tilted at a maximum
angle(ɾ1) and the piston displacement of hydraulic motor becomes maximum, thus leading to
low-speed operation.
Θ At high speed - At pilot pressure of 20kgf/cm2(1.96Mpa) or more
Pilot pressure
P
A B
366
b
363 θ2
Spindle
103
Support
C 161
a
Motor
case
Drain
25032TM10
When a pilot pressure supplied from port (At a pressure of 20kgf/cm2(1.96Mpa) or more), the
pressure overcomes the force of spring(366) and valve(363) is pressed downward. The
pressurized oil supply port is then introduced into chamber ͽ through the valve(363). Piston
(161) pushes up swash plate(103) until it touches side ; of the spindle. At this time, swash
plate(103) is tilted at a minimum angle(ɾ2) and the piston displacement of hydraulic motor
becomes minimum, thus leading to high-speed operation.
2-62
2) REDUCTION GEAR
(1) Function
Planetary gear mechanism
The reduction gear unit consists of a
combination of simple planetary gear
mechanism and differential gear
mechanism. This mechanism reduce the
high speed rotation from the hydraulic
motor and convert it into low speed, high
torque to rotate the hub(or case), which in
turn rotates the sprocket.
(2) Operating principle
Η Upon rotation of the sun gear (S) via the
input shaft, the planetary gear (P)
engages with the fixed ring gear (R)
while rotating on its axis.
Rotation around the fixed ring gear (R) is
transmitted to the carrier (K).
RÂP2
i1 = 1+
SÂP1 14072SF63A
Θ With rotation of the carrier (K), the Differential gear mechanism

planetary gears (P1) and (P2) rotate
around the fixed ring gear(R).
When a proper difference in number of
teeth is given between (P1) and (R) and
between (P1) and (P2), a difference in
rotation is produced on the gear (D)
because the gears (P1) and (P2) are on
the same axis.
1
i2 =
RÂP2
1 -
DÂP1
14072SF63B
2-63
Ι Upon rotation of the sun gear (S) via the Combination of planetary gear mechanism and
input shaft, planetary motion is given differential gear mechanism
among the gears (S), (P1) and (R) and
rotation of the gear (P1) around another
gear causes the carrier (K) to rotate.
This carrier rotation gives differential
motion among the gears (R), (P1), (P2)
and (D) to rotate the ring gear (D). The
motor then rotates since the ring gear (D)
is connected to the hub (case) of the
motor.
RÂP2
1 +
SÂP1
i = i1 Ý i2 =
RÂP2
1 -
DÂP1
14072SF63C
2-64
GROUP 5 RCV LEVER
1. STRUCTURE
The casing has the oil inlet port P(Primary pressure) and the oil outlet port T(Tank). In addition the
secondary pressure is taken out through ports 1, 2, 3 and 4 provided at the bottom face.
23.3
VIEW B
19
25
Single
operation Simultaneous
operation
Handle bending direction

(No. push rod direction)
4
P
1
T 3
2
30
30
VIEW A
A
Port LH RH Port size
P Pilot oil inlet port Pilot oil inlet port

P T
T Pilot oil return port Pilot oil return port
1 Left swing port Bucket out port
PF 1/4
2 Arm in port Boom down port
3 Right swing port Bucket in port
4 Arm out port Boom up port
1 3 2 4
Hydraulic circuit
2507A2RL01
2-65
CROSS SECTION
The construction of the pilot valve is shown in the attached cross section drawing. The casing has
vertical holes in which reducing valves are assembled.
The pressure reducing section is composed of the spool(5), spring(7) for setting secondary pressure,
return spring(10), stopper(9), spring seat(8) and shim(6). The spring for setting the secondary
pressure has been generally so preset that the secondary pressure is 5 to 20.5kgf/cm2(Depending on
the type). The spool is pushed against the push rod(15) by the return spring.
When the push rod is pushed down by tilting the handle, the spring seat comes down simultaneously
and changes setting of the secondary pressure spring.
1 Case 11 Plug 21 Adjusting nut

2 Plug 12 Rod seal 22 Lock nut
3 Plug 13 O-ring 23 O-ring
4 O-ring 14 Push rod 24 Handle bar
5 Spool 15 Push rod 25 Nut
6 Shim 16 Plate 26 Boot
7 Spring 17 Bushing 27 Handle assembly
8 Spring seat 18 Joint assembly 28 Spring
9 Stopper 19 Swash plate 29 Spring seat
10 Spring 20 Boot
2-66
CROSS SECTION
27
25
26
24
22
18
21
19
15
14
20 16
12 11
17 9
29
13
28
8
6
7
10
23 5
1 3
2 4
Port 1,3 Port 2,4
2507A8RL01
2-67
2. FUNCTIONS
1) FUNDAMENTAL FUNCTIONS
The pilot valve is a valve that controls the spool stroke, direction, etc of a main control valve. This
function is carried out by providing the spring at one end of the main control valve spool and
applying the output pressure(Secondary pressure) of the pilot valve to the other end.
For this function to be carried out satisfactorily, the pilot valve is composed of the following
elements.
(1) Inlet port(P) where oil is supplied from hydraulic pump.
(2) Output ports(1, 2, 3 & 4) to apply pressure supplied from inlet port to ends of control valve spools.
(3) Tank port(T) necessary to control the above output pressure.
(4) Spool to connect output port to inlet port or tank port.
(5) Mechanical means to control output pressure, including springs that work on the above spools.
2) FUNCTIONS OF MAJOR SECTIONS
The functions of the spool(5) are to receive the supply oil pressure from the hydraulic pump at its
port P, and to change over oil paths to determine whether the pressure oil of port P is led to output
ports 1, 2, 3 & 4 or the output port pressure oil to tank port T.
The spring(7) works on this spool to determine the output pressure.
The change the deflection of this spring, the push rod(14,15) is inserted and can slide in the
plug(11).
For the purpose of changing the displacement of the push rod through the switch plate(19) and
adjusting nut(22) are provided the handle(27) that can be tilted in any direction around the fulcrum
of the universal joint(18) center.
The spring(10) works on the case(1) and spring seat(29) and tries to return the push rod(14,15) to
the zero-displacement position irrespective of the output pressure, securing its resetting to the
center position.
This also has the effect of a reaction spring to give appropriate control feeling to the operator.
2-68
3) OPERATION
The operation of the pilot valve will be described on the basis of the hydraulic circuit diagram shown
below and the attached operation explanation drawing.
The diagram shown below is the typical application example of the pilot valve.
5 6
3
1
3
P T
2 4
2-70
1 Pilot valve 3 Main pump 5 Hydraulic motor

2 Pilot pump 4 Main control valve 6 Hydraulic cylinder
2-69
(1) Case where handle is in neutral position
28
10
P
5
1 3
2507A2RL02
The force of the spring(28) that determines the output pressure of the pilot valve is not applied to
the spool(5). Therefore, the spool is pushed up by the spring(10) to the position of port(1, 3) in
the operation explanation drawing. Then, since the output port is connected to tank port T only,
the output port pressure becomes equal to tank pressure.
2-70
(2) Case where handle is tilted
14
1 3
2507A2RL03
When the push rod(14) is stroked, the spool(5) moves downwards.

Then port P is connected with port(1) and the oil supplied from the pilot pump flows through
port(1) to generate the pressure.
When the pressure at port(1) increases to the value corresponding to the spring force set by tilting
the handle, the hydraulic pressure force balances with the spring force. If the pressure at port(1)
increases higher than the set pressure, port P is disconnected from port(1) and port T is
connected with port(1). If it decreases lower than the set pressure, port P is connected with
port(1) and port T is disconnected from port 1.
In this manner the secondary pressure is kept at the constant value.
Besides, in some type, when the handle is tilted more than a certain angle, the upper end of the
spool contacts with the inside bottom of the push rod and the output pressure is left to be
connected with port P.
2-71
GROUP 6 RCV PEDAL
1. STRUCTURE
The casing(Spacer) has the oil inlet port P(Primary pressure), and the oil outlet port T(Tank). In
addition the secondary pressure is taken out through ports 1,2, 3 and 4 provided at the bottom face.
ä12.4ä
12.4
1 2
3 4
14072SF73A
Port Port Port size
P Pilot oil inlet port

T Pilot oil return port
T 1 Travel(LH, Forward)
PF 1/4
P 2 Travel(LH, Backward)
3 Travel(RH, Forward)
1 23 4
Hydraulic circuit 4 Travel(RH, Backward)
2-72
CROSS SECTION
The construction of the RCV pedal is shown in the below drawing. The casing has vertical holes in
which reducing valves are assembled.
The pressure reducing section is composed of the spool(8), spring(6) for setting secondary pressure,
return spring(10), stopper(9), and spring seat(7). The spring for setting the secondary pressure has
been generally so preset that the secondary pressure is 5 to 19 kgf/cm2 (depending on the type).
The spool is pushed against the push rod(14) by the return spring.
When the push rod is pushed down by tilting pedal, the spring seat comes down simultaneously and
changes setting of the secondary pressure spring.
27 31 30 29 28 33
32 25,26
24
23 3
22 36
14 15
16
21 17
13 18
12
19
11
20
9
5 6
4 7
10
3 8
37 1 35 34 2
14072SF70
1 Body(1) 14 Push rod 27 Cam

2 Body(2) 15 Spring pin 28 Bushing
3 Plug 16 Seal 29 Cam shaft
4 Plug 17 Steel ball 30 Set screw
5 Spring seat 18 Spring 31 Set screw
6 Spring 19 Plate 32 Nut
7 Spring seat 20 Snap ring 33 Bellows
8 Spool 21 Plug 34 Space
9 Stopper 22 O-ring 35 O-ring
10 Spring 23 Rod seal 36 O-ring
11 Rod guide 24 Dust seal 37 Bolt
12 O-ring 25 Cover
13 Snap ring 26 Bolt
2-73
2. FUNCTION
1) FUNDAMENTAL FUNCTIONS
The pilot valve is a valve controls the spool stroke, direction, etc of a main control valve. This
function is carried out by providing the spring at one end of the main control valve spool and
applying the output pressure(Secondary pressure) of the pilot valve to the other end.
For this function to be carried out satisfactorily, the pilot valve is composed of the following
elements.
(1) Inlet port(P) where oil is supplied from hydraulic pump.
(2) Output port(1, 2, 3 & 4) to apply pressure supplied from inlet port to ends of control valve spools.
(3) Tank port(T) necessary to control the above output pressure.
(4) Spool to connect output port to inlet port tank port.
(5) Mechanical means to control output pressure, including springs that work on the above spools.
2) FUNCTIONS OF MAJOR SECTIONS
The functions of the spool(8) are to receive the supply oil pressure from the hydraulic pump at its
port P, and to change over oil paths to determine whether the pressure oil of port P is led to output
ports 1, 2, 3 & 4 or the output spool to determine the output pressure.
The spring(6) works on this spool to determine the output pressure.
The change the deflection of this spring, the push rod(14) is inserted and can slide in the plug(21).
For the purpose of changing th displacement of the push rod through the cam(27) and adjusting
nut(32) are provided the pedal that can be tilted in any direction around the fulcrum of the cam(27)
center.
The spring(10) works on the casing(1) and spring seat(7) and tries to return the push rod(14) to the
zero-displacement position irrespective of the output pressure, securing its resetting to the center
position.
This also has the effect of a reaction spring to give appropriate control feeling to the operator.
2-74
3) OPERATION
The operation of the pilot valve will be described on the basis of the hydraulic circuit diagram shown
below ant the attached operation explanation drawing.
The diagram shown below is the typical application example of the pilot valve.
5 6
3
1
2
2 4
2-76 (140-7 TIER)
1 Pilot valve 3 Main pump 5 Hydraulic motor

2 Pilot pump 4 Main control valve 6 Hydraulic cylinder
2-75
(1) Case where pedal is in neutral position
T 8
10
P
1 2
14072SF74
The force of the spring(6) that determines the output pressure of the pilot valve is not applied to
the spool(8). Therefore, the spool is pushed up by the spring(10) to the position of port 2 in the
operation explanation drawing. Then, since the output port is connected to tank port T only, the
output port pressure becomes equal to tank pressure.
2-76
(2) Case where pedal is tilted
14
1 2
14072SF75
When the push rod(14) is stroked, the spool(8) moves downwards.

Then port P is connected with port 1, and the oil supplied from the pilot pump flows through port 1
to generate the pressure.
When the pressure at port 1 increases to the value corresponding to the spring force set by tilting
the handle, the hydraulic pressure force balances with the spring force. If the pressure at port 1
increases higher than the set pressure, port P is disconnected from port 1 and port T is connected
with port 1. If it decreases lower than the set pressure, port P is connected with port 1 and port T
is disconnected from port 1.
In this manner the secondary pressure is kept at the constant value.
Besides, in some type, when the handle is tilted more than a certain angle, the upper end of the
spool contacts with inside bottom of the push rod and the output pressure is left to be connected
with port P.
2-77
Group 1 Hydraulic Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1

Group 2 Main Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-2
Group 3 Pilot Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-5
Group 4 Single Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-13
Group 5 Combined Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-23
GROUP 1 HYDRAULIC CIRCUIT
3 42 40 10 11 8 9
SH DR4 31
39 41
41
B
Pn2 Rs Pn1 2
PG
C
DB
R/PIPE "R4" C6 44 30 30
D6 43 E
Pc6
PA PB 45
C 25
Pd6 Pi1
DR5
37 V2
B5
C5 37 A5 33 32
Pb5 dr7
D5 Pc5
A(cw) B(ccw)
11 Main
Main pump
Pd5 Pa5
pump
22 Main
Main control
control valve
valve
4 C4
33 Swing
Swing motor
motor
L/H RED RED R/H D4 DR3
B4 44 Travel
Travelmotor
motor
D2 D2 35 36 Pc40
Pc41 Pb4 55 RCV
RCV lever(LH)
lever(LH)
D1
66 RCV
RCV lever(RH)
D1 Pa4
P1 P2 P2 P1 Pd40 lever(RH)
P3 P P P3
Pc42 77 RCV
RCV pedal
pedal
V3 88 Boom
Boom cylinder(LH)
cylinder(LH)
Pc3
Pb3 99 Boom
Boom cylinder(RH)
cylinder(RH)
Backward
Backward
DR2
1010 Arm
Arm cylinder
Forward
Forward
Pa21 Pd41 cylinder

1111 Bucket
Bucket cylinder
cylinder
C2
B2 1212 Turning
Turningjointjoint
B A B A D2
Pb21 A2
1313 Check
Check valve
valve
1414 Check
Check valve
DR1
Pc2 Pb20 valve
Pd2 Pa20
1515 Hydraulic
Hydraulic tank tank
12 E 1616 Oil
Oilcooler
cooler
F C1
P Dr
D
B
B1
1717 Air
Airbreather
breather
D1 Pc1 Pb1 A1
C
A Pd1 Pa1 1818 Bypass
Bypass valvevalve
25
Pk
S/Motor"DB" 1919 Strainer
Strainer
38 DR0 25 2020 Spin
Spin filter
filter
P0 2121 Line filter
Line filter
Ai T1
24
2222 Solenoid
Solenoid valvevalve
P1 P2 Pz 2323 Accumulator(Option)
Accumulator(option)
2424 Pressure
Pressure switch
switch
Pd6 Pc6 27 2525 Pressure
Pressure switch(Option)
switch(option)
5 6 2626 Terminal
Terminal
SWING ARM BUCKET BOOM 7 TRAVEL 34 DOZER 2727 Last
Last guard
guard filter
filter
3030 Boom
Boom safety
safety valve(Option)
valve(option)
3131 Arm safety
Arm safety valve(Option)
valve(option)
27 3232 Pressure switch(Option)
Pressure switch(option)
(1) (3) (2) (4) (3) (1) (2) (4)
(1) (2) 13 a1 A1 A2 a2 1 3333 Shut off
Shut off valve(Option)
valve(option)
SH
Pd5 Pc5 Dr#, T
14 3434 RCV lever(Dozer,
RCV lever(Dozer, option)
option)
(2) (1) (4) (3) 27 3535 Dozer cylinder(LH,
cylinder(LH, option)
option)
Pb1 Pa1 Pc1 Pd1 16 Dozer
26 B A D E G F H J
3636 Dozer cylinder(RH,
Dozer cylinder(RH, option)
option)
Pc2 Pd2 Pd40 Pc40 Pa5 Pb5 Pa20 Pb20
17
MCV "Pn2"
Pi1 Pi2
MCV "Pn1" 3737 Port relief valve(option)
Port relief valve(Option)
Pm1 Pm2
MCV T/Joint PUMP PUMP MCV 23 3838 Breaker pedal(Option)
Breaker pedal(option)
18 15
P1
22 "Pb4" "Pk" "Pm1" "Pm2" "Pz"
20 3939 Accumulator(option)
Accumulator(Option)
A5 A4 A3 A2 A1
4040 Accumulator(option)
Accumulator(Option)
P4 S/Motor "PG"
ENG
19 Dr a3 4141 Stop valve(Option)
Stop valve(option)
P3 MCV "P0"
P2 B1 B3 A3 4242 2 way selector valve(Option)
2 way selector valve(option)
R/PIPE T 21 4343 Port relief valve(option)
"R10" P1 Port relief valve(Option)
4444 Port relief
Port relief valve(Option)
valve(option)
1607A3HC01
4545 2 way shuttle valve(option)
2 way shuttle valve(Option)
3-1
GROUP 2 MAIN CIRCUIT
The main hydraulic circuit consists of suction circuit, delivery circuit, return circuit and drain circuit.
The hydraulic system consists of one main pump, one control valve, one swing motor, four cylinders
and two travel motors.
The swash plate type variable displacement axial piston pump is used as the main pump and is
driven by the engine at ratio 1.0 of engine speed.
1. SUCTION AND DELIVERY CIRCUIT
To cylinders To motors
Main control valve To oil cooler
To hydraulic oil tank
Main pump
Suction filter
Hydraulic oil tank
3-02 (140-7 TIER)
The pumps receive oil from the hydraulic tank through a suction filter. The discharged oil from the
pump flows into the control valve and goes out the tank ports.
The oil discharged from the main pump flows to the actuators through the control valve.
The control valve controls the hydraulic functions.
The return oil from the actuators flows to the hydraulic tank through the control valve and the oil
cooler.
3-2
2. RETURN CIRCUIT
Check valve(2)
Full flow filter Oil cooler 1.5kgf/cm 2
Main control valve Actuators
Check valve(1)
3.0kgf/cm 2
Bypass relief valve

1.5kgf/cm 2
21073CI01
All oil returned from each actuator returns to the hydraulic tank through the control valve.
The bypass check valves are provided in the return circuit.
The setting pressure of bypass check valves are 1.5kgf/cm2(21psi) and 3.0kgf/cm2(43psi). Usually, oil
returns to the hydraulic tank from the left side of control valve through oil cooler.
When oil temperature is low, viscosity becomes higher and flow resistance increases when passing
through the oil cooler. When the oil pressure exceeds 3.0kgf/cm2(43psi), the oil returns directly to the
hydraulic tank, resulting in the oil temperature being raised quickly at an appropriate level.
When the oil cooler is clogged, the oil returns directly to the hydraulic tank through bypass check valve(1).
The full-flow filter and bypass relief valve are provided in the hydraulic tank.
The oil returned from right and left side of control valve is combined and filtered by the full-flow filter. A
bypass relief valve is provided in the full-flow filter.
When the filter element is clogged, the bypass relief valve opens at 1.5kgf/cm2(21psi) differential pressure.
3-3
3. DRAIN CIRCUIT
Travel motor Swing motor
Main
Return line pump
Turning
joint
dr2 ~ dr8
Return filter
Hydraulic Spin filter

oil tank
dr1
Check valve
1.5kgf/cm 2
16073CI02
Besides internal leaks from the motors and main pump, the oil for lubrication circulates. The main
pump drain oil have to be fed to the hydraulic tank passing through spin filter.
When the drain oil pressure exceed 1.5kgf/cm2(21psi), the oil returns to the hydraulic tank directly.
1) TRAVEL MOTOR DRAIN CIRCUIT

Oil leaked from the right and left travel motors comes out of the drain ports provided in the
respective motor casing and join with each other. These oils pass through the turning joint and
return to the hydraulic tank after being filtered by spin filter.
2) SWING MOTOR DRAIN CIRCUIT
Oil leaked from the swing motor returns to the hydraulic tank passing through a return filter with oil
drained from the travel circuit .
3) MAIN PUMP DRAIN CIRCUIT
Oil leaked from main pump returns to the hydraulic tank passing through spin filter.
3-4
GROUP 3 PILOT CIRCUIT
Remote control valve Remote control valve

RCV pedal (RH lever)
(LH lever)
Safety lock
solenoid valve Swing parking brake
Control valve
Travel speed solenoid valve
Max flow cut off solenoid valve
Power boost solenoid valve
Swing priority solenoid valve

Line filter
Main pump
Relief valve
35kgf/cm2
Pilot pump
Suction filter
3-05 (140-7 TIER)
The pilot circuit consists of suction circuit, delivery circuit and return circuit.
The pilot pump is provided with relief valve, receives the oil from the hydraulic tank through the
suction filter.
The discharged oil from the pilot pump flows to the remote control valve through line filter, EPPR
valve, solenoid valve assemblies, swing parking brake, main control valve and safety lock solenoid
valve.
3-5
1. SUCTION, DELIVERY AND RETURN CIRCUIT
ARM BUCKET BOOM

CYLINDER CYLINDER CYLINDER
TRAVEL MOTOR
Pn2 Rs Pn1
C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET
C4
D4 B4
DR3
Pc41 Pb4
Pc40
Pa4
Pd40
ARM 1
SWING MOTOR Pc42
ARM
V3 REGEN
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
TRAVEL(LH) TRAVEL(RH)
P0
TRAVEL T1
P2 P1 Pz
FRONT REAR
Dr#, T PUMP PUMP
(2) (1) (4) (3) PILOT
Pb1 Pa1 Pc1 Pd1 PUMP
SW AM BK BM
Pb4 Pk Pm1 Pm2 Pz
A5 A4 A3 A2 A1
PG
(1) (3) (2) (4) (3) (1) (2) (4) P4 (S/Motor)
P3 P0(MCV) HYDRAULIC TANK
sh P2
B A D E G F H J T P1
Pc2 Pd2 Pd40 Pc40 Pa5 Pb5 Pa20 Pb20 LINE FILTER
1607A3HC02
The pilot pump receive oil from the hydraulic tank. The discharged oil from the pilot pump flows to
the safety solenoid valve through the line filter. The oil is filtered by the line filter. The pilot relief valve
is provided in the pilot pump for limiting the pilot circuit pressure.
The oil filtered by line filter flows remote control valve through safety solenoid valve.
The return oil flow into the hydraulic tank.
3-6
2. SAFETY VALVE(SAFETY LEVER)
ARM BUCKET BOOM

TRAVEL MOTOR
Pn2 Rs Pn1
C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET
C4
D4 B4
DR3
Pc41 Pb4
Pc40
Pa4
Pd40
ARM 1
SWING MOTOR Pc42
ARM
V3 REGEN
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
TRAVEL T1
P2 P1 Pz
FRONT REAR
Dr#, T PUMP PUMP
(2) (1) (4) (3) PILOT
SW AM BK BM
SAFETY
SOLENOID
Pb4 Pk Pz VALVE
Pm1 Pm2
LEVER UP
A5 A4 A3 A2 A1
PG
(1) (3) (2) (4) (3) (1) (2) (4) P4 (S/Motor)
sh P2
LEVER DOWN
1607A3HC03
When the lever of the safety solenoid valve is moved upward, oil flows into the remote control valve
through solenoid valve and line filter.
When the lever of the safety solenoid valve is moved upward, oil does not flow into the remote control
valve, because of the blocked port.
3-7
3. ARM REGENERATION SYSTEM
ARM BUCKET BOOM

TRAVEL MOTOR
Pn2 Rs Pn1
C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET
C4
D4 B4
DR3
Pc41 Pb4
Pc40
Pa4
Pd40
ARM 1
SWING MOTOR Pc42
ARM
V3 REGEN
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
TRAVEL T1
P2 P1 Pz
FRONT REAR
Dr#, T PUMP PUMP
(2) (1) (4) (3) PILOT
SW AM BK BM
Pb4 Pk Pm1 Pm2 Pz
A5 A4 A3 A2 A1
PG
(1) (3) (2) (4) (3) (1) (2) (4) P4 (S/Motor)
SH
P2
1607A3HC04
Then the heavy duty mode switch on the cluster is pushed ON, the arm regeneration solenoid valve
is deactivated and the arm regeneration spool is returned to neutral position.
Then, the arm regeneration function is activated and arm operation speed is increased.
3-8
4. TRAVEL SPEED CONTROL SYSTEM
ARM BUCKET BOOM
CONTROL PISTON
PILOT VALVE
TRAVEL MOTOR
L/H RED RED R/H
Pn2 Rs Pn1
C6
D6
Pc6
Pd6
OPTION
B5
B A B A
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET
Pk
C4
Dr
D4 B4
DR3
Pc41 Pb4
Pc40
Pa4
Pd40
SWING MOTOR ARM 1
Pc42
ARM
V3 REGEN
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
TRAVEL T1
P2 P1 Pz
FRONT REAR
Dr#, T PUMP PUMP
(2) (1) (4) (3) PILOT
SW AM BK BM
Pb4 Pk Pm1 Pm2 Pz
A5 A4 A3 A2 A1
P4 PG
(1) (3) (2) (4) (3) (1) (2) (4) (S/Motor)
sh P2
B A D E G F H J T
P1
1607A3HC05
When the travel speed switch is pushed, the travel speed solenoid valve is actuated and the
discharged oil from the pilot pump flows to the Pk port of pilot valve in the travel motors.
As a result, the control piston is pushed by the main oil flow, thus the displacement is minimized.
When the travel speed switch is pushed once more, the travel speed solenoid valve is return to
original position by the force of spring, the hydraulic oil of Pk port returns to the hydraulic tank.
As a result, the control piston is returned by the main oil flow, thus the displacement is maximized.
3-9
5. MAIN RELIEF PRESSURE CHANGE SYSTEM
ARM BUCKET BOOM
TRAVEL MOTOR
Pn2 Rs Pn1
C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET
C4
D4 B4
DR3
Pc41 Pb4
Pc40
Pa4
Pd40
ARM 1
SWING MOTOR Pc42
ARM
V3 REGEN
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
TRAVEL T1
P2 P1 Pz
FRONT REAR
Dr#, T PUMP PUMP
(2) (1) (4) (3) PILOT
SW AM BK BM
Pb4 Pk Pz
Pm1 Pm2
A5 A4 A3 A2 A1
PG
(1) (3) (2) (4) (3) (1) (2) (4) P4 (S/Motor)
sh P2
1607A3HC06
When the power boost switch on the left control lever is pushed ON, the power boost solenoid valve
is actuated, the discharged oil from the pilot pump flows into Pz port of the main relief valve of main
control valve; then the setting pressure of the main relief valve is raised from 330kgf/cm2 to 360kgf/cm2
for increasing the digging power. And even when pressed continuously, it is canceled after 8
seconds.
3-10
6. MAX FLOW CUT OFF SYSTEM
ARM BUCKET BOOM

TRAVEL MOTOR
Pn2 Pn1
C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET
C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pa4
Pd40
ARM 1
SWING MOTOR Pc42
ARM
V3 REGENERATION
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
TRAVEL
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
(2) (1) (4) (3) T1
Pb1 Pa1 Pc1 Pd1
Pz
SW AM BK BM
a1 P1 P2 a2
Dr#, T
(1) (3) (2) (4) (3) (1) (2) (4)
sh
B A D E G F H J MCV "Pn2" MCV "Pn1"

Pm1 Pm2
Pc2 Pd2 Pd40 Pc40 Pa5 Pb5 Pa20 Pb20
Pb4 Pk Pm1 Pm2 Pz
A5 A4 A3 A2 A1
M
Dr a3
PG
P4 (S/Motor)
P2
T P1
LINE FILTER
1607A3HC07
When the breaker operation mode is selected on the cluster, max flow cut off solenoid valve actuates
automatically.
Thus pilot pressure(Pm1,2) is sent to the regulator and pump discharge volume is decreased.
3-11
7. SWING PARKING BRAKE RELEASE
ARM BUCKET BOOM
TRAVEL MOTOR
Pn2 Rs Pn1
C6
D6
Pc6
Pd6
OPTION
B5
SWING MOTOR
C5 A5
D5 Pb5
SH Pc5
Pd5 Pa5
OPTION BUCKET
PG
C4
D4 B4
DR3
Pc41 Pb4
Pc40
Pa4
Pd40
Mu ARM 1
Pc42
ARM
V3 REGEN
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
A(cw) B(ccw) B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
TRAVEL T1
P2 P1 Pz
FRONT REAR
Dr#, T PUMP PUMP
(2) (1) (4) (3)
Pb1 Pa1 Pc1 Pd1 PILOT
PUMP
SW AM BK BM
Pb4 Pk Pm1 Pm2 Pz
A5 A4 A3 A2 A1
PG
(1) (3) (2) (4) (3) (1) (2) (4) P4 (S/Motor)
SH
P2
1607A3HC08
When the swing control lever is tilted, the pilot oil flow into SH port of shuttle valve, this pressure
move spool so, discharged oil from pilot valve flow into PG port.
This pressure is applied to swing motor disc, thus the brake is released.
When the swing control lever is set in the neutral position, oil in the swing motor disc cylinder is
drained, thus the brake is applied.
3-12
GROUP 4 SINGLE OPERATION
1. BOOM UP OPERATION
ARM BUCKET BOOM
TRAVEL MOTOR
Pn2 Rs Pn1
C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET
C4
D4 B4
DR3
Pc41 Pb4
Pc40
Pa4
Pd40
SWING MOTOR ARM 1
Pc42
ARM
V3 REGEN
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
T1
P2 P1 Pz
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
1607A3HC10
When the right control lever is pulled back, the boom spools in the main control valve are moved to
the up position by the pilot oil pressure from the remote control valve.
The oil from the front and rear pump flows into the main control valve and then goes to the large
chamber of boom cylinders. At the same time, the oil from the small chamber of boom cylinders
returns to the hydraulic oil tank through the boom spool in the main control valve. When this
happens, the boom goes up. The excessive pressure in the boom cylinder bottom end circuit is
prevented by relief valve. When the boom is up and the control lever is returned to neutral position,
the circuit for the holding pressure at the bottom end of the boom cylinder is closed by the boom
holding valve. This prevents the hydraulic drift of boom cylinder.
3-13
2. BOOM DOWN OPERATION
ARM BUCKET BOOM

TRAVEL MOTOR
Pn2 Rs Pn1
C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET
C4
D4 B4
DR3
Pc41 Pb4
Pc40
Pa4
Pd40
SWING MOTOR ARM 1
Pc42
ARM
V3 REGEN
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
T1
P2 P1 Pz
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
1607A3HC11
When the right control lever is pushed forward, the boom spools in the main control valve are moved
to the down position by the pilot oil pressure from the remote control valve.
The oil from the rear pump flows into the main control valve and then goes to the small chamber of
boom cylinders. At the same time, the oil from the large chamber of boom cylinders returns to the
hydraulic tank through the boom spool in the main control valve.
When the down speed of boom is faster, the oil returned from the large chamber of boom cylinder
combines with the oil from the rear pump, and flows into the small chamber of the cylinder.
This prevents cylinder cavitation by the negative pressure when the rear pump flow can not match
the boom down speed. And the excessive pressure in the boom cylinder rod end circuit is prevented
by the relief valve.
3-14
3. ARM ROLL IN OPERATION
ARM BUCKET BOOM

TRAVEL MOTOR
Pn2 Rs Pn1
C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET
C4
D4 B4
DR3
Pc41 Pb4
Pc40
Pa4
Pd40
SWING MOTOR ARM 1
Pc42
ARM
V3 REGEN
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
T1
P2 P1 Pz
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
1607A3HC12
When the left control lever is pulled back, the arm spools in the main control valve are moved the to
roll in position by the pilot oil pressure from the remote control valve.
The oil from the front and rear pump flows into the main control valve and then goes to the large
chamber of arm cylinder.
At the same time, the oil from small chamber of arm cylinder returns to the hydraulic oil tank through
the arm spool in the main control valve. When this happens, the arm rolls in.
The cavitation which will happen to the bottom of the arm cylinder is also prevented by the make-up
valve in the main control valve.
3-15
4. ARM ROLL OUT OPERATION
ARM BUCKET BOOM

TRAVEL MOTOR
Pn2 Rs Pn1
C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET
C4
D4 B4
DR3
Pc41 Pb4
Pc40
Pa4
Pd40
SWING MOTOR ARM 1
Pc42
ARM
V3 REGEN
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
T1
P2 P1 Pz
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
1607A3HC13
When the left control lever is pushed forward, the arm spool in the main control valve are moved to
the roll out position by the pilot oil pressure from the remote control valve.
The oil from the front and rear pump flows into the main control valve and then goes to the small
chamber of arm cylinder.
At the same time, the oil from the large chamber of arm cylinder returns to the hydraulic oil tank
through the arm spool in the main control valve. When this happens, the arm rolls out.
The cavitation which will happen to the rod of the arm cylinder is also prevented by the make-up
3-16
5. BUCKET ROLL IN OPERATION
ARM BUCKET BOOM

TRAVEL MOTOR
Pn2 Rs Pn1
C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET
C4
D4 B4
DR3
Pc41 Pb4
Pc40
Pa4
Pd40
SWING MOTOR ARM 1
Pc42
ARM
V3 REGEN
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
T1
P2 P1 Pz
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
1607A3HC14
When the right control lever is pulled left, the bucket spool in the main control valve is moved to the
roll in position by the pilot oil pressure from the remote control valve.
The oil from the rear pump flows into the main control valve and then goes to the large chamber of
bucket cylinder.
At the same time, the oil from the small chamber of bucket cylinder returns to the hydraulic oil tank
through the boom spool in the main control valve. When this happens, the bucket rolls in.
The cavitation which will happen to the bottom of the bucket cylinder is also prevented by the make-
up valve in the main control valve.
3-17
6. BUCKET ROLL OUT OPERATION
ARM BUCKET BOOM

TRAVEL MOTOR
Pn2 Rs Pn1
C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET
C4
D4 B4
DR3
Pc41 Pb4
Pc40
Pa4
Pd40
SWING MOTOR ARM 1
Pc42
ARM
V3 REGEN
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
T1
P2 P1 Pz
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
1607A3HC15
When the right control lever is pushed right, the bucket spool in the main control valve is moved to
the roll out position by the pilot oil pressure from the remote control valve.
The oil from the rear pump flows into the main control valve and then goes to the small chamber of
bucket cylinder.
At the same time, the oil from the large chamber of bucket cylinder returns to the hydraulic oil tank
through the bucket spool in the main control valve. When this happens, the bucket rolls out.
The cavitation which will happen to the rod of the bucket cylinder is also prevented by the make-up
3-18
7. SWING OPERATION
TRAVEL MOTOR ARM BUCKET BOOM

Pn2 Rs Pn1
C6
D6
Pc6
Pd6
OPTION
B5
SWING MOTOR
C5 A5
D5 Pb5
SH Pc5
Pd5 Pa5
OPTION BUCKET
PG
C4
dr
D4 B4
DR3
Pc41 Pb4
Pc40
Pa4
Pd40
Mu ARM 1
ARM Pc42
V3 REGEN
Pc3
Pa21 DR2 Pb3
Pd41
BOOM 2 ARM 2
A(cw) B(ccw) B2
C2
D2 Pb21 A2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
TRAVEL T1
P2 P1 Pz
FRONT REAR
Dr#, T PUMP PUMP
(2) (1) (4) (3)
Pb1 Pa1 Pc1 Pd1 PILOT
PUMP
SW AM BK BM
Pb4 Pk Pm1 Pm2 Pz
A5 A4 A3 A2 A1
PG
(1) (3) (2) (4) (3) (1) (2) (4) P4 (S/Motor)
SH
P2
1607A3HC10
When the left control lever is pushed left or right, the swing spool in the main control valve is moved
to the left or right swing position by the pilot oil pressure from the remote control valve.
The oil from the front pump flows into the main control valve and then goes to the swing motor.
At the same time, the return oil from the swing motor returns to the hydraulic oil tank through the
swing spool in the main control valve. When this happens, the superstructure swings to the left or
right. The swing parking brake, make up valve and the overload relief valve are provided in the swing
motors. The cavitation which will happen to the swing motor is also prevented by the make up valve
in the swing motor itself.
3-19
SWING CIRCUIT OPERATION
SWING MOTOR DEVICE

PARKING BRAKE
BRAKE RELEASE VALVE
SH
BRAKE OFF
PG
BRAKE ON
dr
MAKE UP VALVE
PA PB
Mu(MAKE UP PORT)
MOTOR BRAKE VALVE
A(cw) B(ccw)
TO / FROM MAIN CONTROL VALVE

1607A3HC16A
1) MOTOR BRAKE VALVE

Motor brake valve for the swing motor limits to cushion the starting and stopping pressure of swing
operation.
2) MAKE UP VALVE
The make up valves prevent cavitation by supplying return oil to the vacuum side of the motor.
3) PARKING BRAKE
In case that the parking, of the machine at slope is required during operation, there is the danger of
involuntary swing caused by the self weight of the machine. The brake is connected to prevent this
involuntary swing.
PARKING BRAKE "OFF" OPERATION
The parking brake is released by the pilot pressure oil from the pilot pump.
When the left control lever placed in the swing position, the pilot pressure at the shuttle valve is
transferred to the brake release valve and the brake release valve is change over. Then the pilot
pressure lift the brake piston and release the parking brake.
PARKING BRAKE "ON" OPERATION
When the control lever placed in the neutral position, the pressure of the pilot oil passage down.
Then the brake release valve returned to the neutral position and the oil is returned from the brake
piston to the tank. And the brake is set to 'ON".
BYPASS VALVE
This bypass valve absorbs shocks produced as swing motion stops and reduced oscillation cause
by swing motion.
3-20
8. TRAVEL FORWARD AND REVERSE OPERATION
ARM BUCKET BOOM

TRAVEL MOTOR
L/H RED RED R/H
Pn2 Rs Pn1
C6
D6
Pc6
Pd6
OPTION
B A B A
B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
Pk
OPTION BUCKET
Dr
C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pa4
Pd40
SWING MOTOR ARM 1
ARM Pc42
V3 REGEN
Pc3
Pa21 DR2 Pb3
Pd41
BOOM 2 ARM 2
B2
C2
D2 Pb21 A2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
TRAVEL T1
P2 P1 Pz
FRONT REAR
Dr#, T PUMP PUMP
(2) (1) (4) (3) PILOT
SW AM BK BM
Pb4 Pk Pm1 Pm2 Pz
A5 A4 A3 A2 A1
P4 PG
(1) (3) (2) (4) (3) (1) (2) (4) (S/Motor)
sh P2
B A D E G F H J T
P1
1607A3HC17
When the travel levers are pushed forward or reverse position, the travel spools in the main control
valve are moved to the forward or reverse travel position by the pilot oil pressure from the remote
control valve. The oil from the both pumps flows into the main control valve and then goes to the
both travel motors through the turning joint. The return oil from both travel motors returns to the
hydraulic oil tank through the turning joint and the travel spools in the main control valve. When this
happens, the machine moves to the forward or reverse.
3-21
TRAVEL CIRCUIT OPERATION
TRAVEL MOTOR DEVICE
LH RH
RED RED
B A B A
OVERLOAD TURNING COUNTER BALANCE

RELIEF VALVE JOINT VALVE
Pk
dr
TO/FROM MAIN CONTROL VALVE
1607A3HC17A
Valves are provided on travel motors to offer the following functions.

1) COUNTER BALANCE VALVE
When stopping the motor of slope descending, this valve to prevent the motor over run.
2) OVERLOAD RELIEF VALVE
Relief valve limit the circuit pressure below 365kgf/cm2 to prevent high pressure generated at at time
of stopping the machine. Stopping the motor, this valve sucks the oil from lower pressure passage
for preventing the negative pressure and the cavitation of the motor.
3-22
GROUP 5 COMBINED OPERATION
1. OUTLINE
ARM BUCKET BOOM
TRAVEL MOTOR
Pn2 Rs Pn1
C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET
C4
D4 B4
DR3
Pc41 Pb4
Pc40
Pa4
Pd40
SWING MOTOR ARM 1
Pc42
ARM
V3 REGEN
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
Ai
T1
P2 P1 Pz
HYDRAULIC TANK STRAIGHT

TRAVEL FRONT REAR PILOT
SPOOL PUMP PUMP PUMP
1607A3HC20
The oil from the front and rear pump flows through the neutral oil passage, bypass oil passage and
confluence oil passage in the main control valve. Then the oil goes to each actuator and operates
them. Check valves and orifices are located on these oil passage in the main control valve. These
control the oil from the main pumps so as to correspond to the operation of each actuator and
smooth the combined operation.
STRAIGHT TRAVEL SPOOL
This straight travel spool for straight travel is provided in the main control valve.
If any actuator is operated when traveling, the straight travel spool is pushed to the right by the pilot
oil pressure.
Consequently, the left and right travel oil supply passage are connected, and equivalent amount of oil
flows into the left and right travel motors. This keeps the straight travel.
3-23
2. COMBINED SWING AND BOOM OPERATION
ARM BUCKET BOOM

TRAVEL MOTOR
Pn2 Rs Pn1
C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET
C4
D4 B4
DR3
Pc41 Pb4
Pc40
Pa4
Pd40
SWING MOTOR ARM 1
Pc42
ARM
V3 REGEN
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
T1
P2 P1 Pz
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
1607A3HC21
When the swing and boom functions are operated, simultaneously the swing spool and boom spools
in the main control valve are moved to the functional position by the pilot oil pressure from the remote
control valve.
The oil from the front pump flows into the swing motor through swing spool and the boom cylinder
through boom 2 spool.
The oil from the rear pump flows into the boom cylinders through the boom 1 spool.
The superstructure swings and the boom is operated.
3-24
3. COMBINED SWING AND ARM OPERATION
ARM BUCKET BOOM

TRAVEL MOTOR
Pn2 Rs Pn1
C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET
C4
D4 B4
DR3
Pc41 Pb4
Pc40
Pa4
Pd40
SWING MOTOR ARM 1
Pc42
ARM
V3 REGEN
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
T1
P2 P1 Pz
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
1607A3HC22
When the swing and arm functions are operated, simultaneously the swing spool and arm spools in
the main control valve are moved to the functional position by the pilot oil pressure from the remote
control valve.
The oil from the front pump flows into the swing motor through swing spool and the arm cylinder
through arm 1 spool.
The oil from the rear pump flows into the arm cylinder through the arm 2 spool.
The superstructure swings and the arm is operated.
3-25
4. COMBINED SWING AND BUCKET OPERATION
ARM BUCKET BOOM

TRAVEL MOTOR
Pn2 Rs Pn1
C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET
C4
D4 B4
DR3
Pc41 Pb4
Pc40
Pa4
Pd40
SWING MOTOR ARM 1
Pc42
ARM
V3 REGEN
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
T1
P2 P1 Pz
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
1607A3HC23
When the swing and bucket functions are operated, simultaneously the swing spool and bucket spool
control valve.
The oil from the front pump flows into the swing motor through the swing spool.
The oil from the rear pump flows into the bucket cylinder through the bucket spool.
3-26
5. COMBINED SWING, BOOM, ARM AND BUCKET OPERATION
ARM BUCKET BOOM

TRAVEL MOTOR
Pn2 Rs Pn1
C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET
C4
D4 B4
DR3
Pc41 Pb4
Pc40
Pa4
Pd40
SWING MOTOR ARM 1
Pc42
ARM
V3 REGEN
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
T1
P2 P1 Pz
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
1607A3HC24
When the swing, boom, arm and bucket functions are operated, simultaneously each spool in the
main control valve is moved to the functional position by the pilot oil pressure from the remote control
valve.
The oil from the front pump flows into the swing motor, boom cylinders and arm cylinder through the
swing spool, boom 2 spool, arm 1 spool, and the parallel and confluence oil passage.
The oil from the rear pump flows into the boom cylinders, arm cylinder and bucket cylinder through
the boom 1 spool, arm 2 spool, bucket spool and the parallel and confluence oil passage.
The superstructure swings and the boom, arm and bucket are operated.
3-27
6. COMBINED SWING AND TRAVEL OPERATION
ARM BUCKET BOOM

TRAVEL MOTOR
Pn2 Rs Pn1
C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET
C4
D4 B4
DR3
Pc41 Pb4
Pc40
Pa4
Pd40
SWING MOTOR ARM 1
Pc42
ARM
V3 REGEN
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
T1
P2 P1 Pz
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
1607A3HC25
When the swing and travel functions are operated, simultaneously the swing spool and travel spools
control valve and straight travel spool is pushed to the right by the pilot oil pressure from the pilot
pump.
The oil from the front pump flows into the swing motor through the swing spool. The oil from the rear
pump flows into the travel motor through the RH travel spool and the LH travel spool via the straight
travel spool.
The superstructure swings and the machine travels straight.
3-28
7. COMBINED BOOM AND TRAVEL OPERATION
ARM BUCKET BOOM

TRAVEL MOTOR
Pn2 Rs Pn1
C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET
C4
D4 B4
DR3
Pc41 Pb4
Pc40
Pa4
Pd40
SWING MOTOR ARM 1
Pc42
ARM
V3 REGEN
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
T1
P2 P1 Pz
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
1607A3HC26
When the boom and travel functions are operated, simultaneously the boom spools and travel spools
control valve and the straight travel spool is pushed to the right by the oil pressure from pilot pump.
The oil from the front pump flows into the boom cylinders through the boom 2 spool and boom 1
spool via the parallel and confluence oil passage in case boom up operation. The oil from the rear
pump flows into the travel motors through the RH travel spool and the LH travel spool via the straight
travel spool.
3-29
8. COMBINED ARM AND TRAVEL OPERATION
ARM BUCKET BOOM

TRAVEL MOTOR
Pn2 Rs Pn1
C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET
C4
D4 B4
DR3
Pc41 Pb4
Pc40
Pa4
Pd40
SWING MOTOR ARM 1
Pc42
ARM
V3 REGEN
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
T1
P2 P1 Pz
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
1607A3HC27
When the arm and travel functions are operated, simultaneously the arm spools and travel spools in
the main control valve are moved to the functional position by the pilot oil pressure from the remote
control valve and the straight travel spool is pushed to the right by the oil pressure from pilot pump.
The oil from the front pump flows into the arm cylinders through the arm 1 spool and arm 2 spool via
the parallel and confluence oil passage. The oil from the rear pump flows into the travel motors
through the RH travel spool and the LH travel spool via the straight travel spool.
The arm is operated and the machine travels straight.
3-30
9. COMBINED BUCKET AND TRAVEL OPERATION
ARM BUCKET BOOM

TRAVEL MOTOR
Pn2 Rs Pn1
C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET
C4
D4 B4
DR3
Pc41 Pb4
Pc40
Pa4
Pd40
SWING MOTOR ARM 1
Pc42
ARM
V3 REGEN
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
T1
P2 P1 Pz
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
1607A3HC28
When the bucket and travel functions are operated, simultaneously the bucket spool and travel
spools in the main control valve are moved to the functional position by the pilot oil pressure from the
remote control valve, and the straight travel spool is pushed to the right by the oil pressure from pilot
pump. The oil from the front pump flows into the bucket cylinder through the bucket spool via the
confluence oil passage. The oil from the rear pump flows into the travel motors through the RH travel
spool and the LH travel spool via the straight travel spool of the control valve.
The bucket is operated and the machine travels straight.
3-31
Group 1 Component Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1

Group 2 Electrical Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-3
Group 3 Electrical Component Specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-20
Group 4 Connectors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-29
GROUP 1 COMPONENT LOCATION
1. LOCATION 1
25
24
23
27
B
A
28
C
Switch 22
panel 21
29 20
19
30
18
17
16
1
2
3
4
5
TA
HYU
NDA
I
15
1 Electric box
2 20A
SPARE
SPARE
RE
CAB
10A 10A 20A 10A
SPARE
HOLDER
LAMP
SPARE
10A
FUSE
CABIN
LAMP
LAMP SPARE
5A
BEACON
10A
WORK
F/PUMP
& HEATER
10A 10A 20A
LAMP FUEL
KEY AC
5A
HEAD
20A
3
START
5A
MOTOR SOLENOID
LAMP HONE
20A
WIPER 2
5A
BOOM
LIGHT
5A
SOL. SOLENOID
CIGAR
& HEATER
5A
SAFETY 1
5A
AC
10A
PANEL - HEAT SOLENOID

5A
MOTOR PRE
5A
SWITCH
5A
WIPER
RY
5A
CUT-OFF TRAVEL
5A
CONVERTOR HONE
10A 20A
FUEL
PANEL
-2
10A
SWITCH RY
CLUSTER CR
COMP
AC RY
5A
C/RADIO
-7 ETHER
3
RY CR
POWER - 36
CR
- 35
CR
RY
SAFETY
-5
CR
4 14
CN-47
13
5 CN-19&19A
CN-19B
CN-92A
CN-92B
9 12
CN-16&16A
8 CN-16B
7 11
6 10
1607A4EL01
1 Horn switch 11 Fuse box 21 Preheat switch

2 Breaker operation switch 12 RS232 serial connector 22 Travel alarm switch
3 Cluster 13 J1939 serial connector 23 Cab light switch
4 Cigar lighter 14 Machine control unit 24 Heated seat switch
5 Hour meter 15 Prolix resistor 25 Breaker selection switch
6 Safety lever 16 Cassette radio 26 Beacon switch
7 Power max switch 17 Speaker 27 Accel dial
8 One touch decel switch 18 Main light switch 28 Start switch
9 Air conditioner switch 19 Wiper switch 29 Overload switch
10 Master switch 20 Washer switch 30 Quick clamp switch
4-1
2. LOCATION 2
1 4
ON
3 1 5
OF
F
CAB BOOM
7
8
2
9
10
1
11
12
1607A4EL02
1 Lamp 7 Pressure sender

2 Fuel sender 8 Heater relay
3 Fuel filler pump 9 Alternator
4 Beacon lamp 10 Travel alarm buzzer
5 Air cleaner switch 11 Battery
6 Horn 12 Battery relay
4-2
GROUP 2 ELECTRICAL CIRCUIT
V 118 5W 104
5R 105
ECU
POWER RY POWER RY 3L 103
5R 123
5R 105
FUSE BOX
123
116
5W 104
5W 115
AC COMP RY 60R 60B
87a 87 85
87a 87 85
30 86
30 86
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
1
2
3
4
5
6
7
8
9
R/DRYER HORN RY
5R
5R
87a 87 85
30A
10A
30A
30A
10A
10A
10A
CASSETTE RADIO 10A
10A
10A
10A
30A
10A
20A
20A
20A
10A
20A
10A
20A
10A
10A
10A
10A
10A
30A
CS-74
30 86
20A
5A
CN-60
CR-45
CN-95
CR-35
BATTERY
Pa
2
1
87a
87a
87a 87 85
2
1
30 86
12V X 2
30
86
85
2
1
30
87
86
85
87
FUEL FILLER P/P
CN-29
CIGAR LIGHTER
SWITCH PANEL
FUEL WARMER
CR-7
WIPER MOTOR
BEACON LAMP
87a
AC& HEATER
CONVERTOR
AC& HEATER
30
86
SAFETY SOL
85
87
ROOM LAMP
WORK LAMP
CABIN LAMP
SOLENOID 1
SOLENOID 3
HEAD LAMP
2
1
START KEY
START,ALT
Or
3L
Or
PRE-HEAT
W
CR-2
W
B
V
B
CLUSTER
87a
WIPER+
30
86
TRAVEL
85
87
CPU B+
FUSIBLE LINK
CN-36
HORN
G12
G11
18E
24A
103
118
106 G
101 G
V
L
L
18
24
ECU
CPU
ECU
CR-1
106
4A
4E
85
Br
Br
G
Y
G21 B
GW
RW
5A
10 GrW
22
98
2 2RW
TO:STARTER "B" TERM.
66 2RW
15 ROr
2G
Gr
Gr
Or
Gr
Gr
2L
Gr
Or
Br
Br
W
5
9
110 R
G
109 R
Y
100 V
Y
108 L
L
MASTER SW
18
99
56
77
78
90
21
88
87
86
97
83
20
19
41
8
NO.
1
DESTINATION CN-11
4
5
1 AC CONTROLLER GND 1
B 111 BATT RY
2B 127
2 BLOWER MOTOR GND 2 DO-3
2L 4 9E G
3 AC 24V 3 2
2R 102 G23 B
4 NC 4 1
2RW 66
5 AIR-CON 5 DIODE
G 101
6 AC COMP 6
7 AC CONDENSOR FAN 7 9A G
DO-2
R 6F 2
8 ILLUMINATION 8 92 V
1
AIR CON HARNESS DIODE
NO. DESTINATION CN-10 9 G
DO-1
V 100 2
1 CASSETTE RADIO 24V 1 16A W
R 6E 1
2 ILLUMINATION 2
3 NC 3 DIODE
2B G1
4 GND 4 CN-25
G83 B
5 NC 5 1
Y 99 22A G
6 CASSE&ROOM LAMP B+ 6 2
J1 J2
7 NC 7 HORN
B 112 G82 B
8 CASSETTE GND 8 1 SERVICE TOOL J1 ECU J2
9 NC 9 22 G
2
Intake Manifold press(gnd)

G 96
Intake Manifold press(sig)
Intake Manifold press(5V)

10 BEACON LAMP 10 CN-20
Or 89
Pump Solenoid(Return)
11 CABIN LIGHT 11
Key Switch ON Signal
Accel Dial Power(5V)
Fuel Rail Press(gnd)

CN-61
Fuel Rail Press(gig)

12 NC
Battery Power B+
Pump Solenoid(sig)
Fuel Rail Press(5v)

12
Coolant Temp (sig)

Temp Sensor(gnd)
Air Heater Ry(gnd)
G61
Crank Speed (sig)

B
Crank Speed (5V)

Battery Power B+
Battery Power B+
Battery Power B+
Battery Power B+
Battery Power -
1 M
CAN A+(j1939)
Boost Temp (sig)

Cam Speed (sig)
CAN A-(j1939)
Battery Power -
Battery Power -
CABIN HARNESS
Battery Power -
Battery Power -
Battery Power -
Accel Dial(gnd)
41 G
Oil Press (gnd)

Throttle Return
Throttle Power
Throttle Signal
Injector2(high)
Accel Dial(sig)
Injector3(high)
Injector4(high)
Injector1(high)
Oil Press (sig)

2
Oil Press (5V)

Data Link +
Data Link -
SWG Return
Injector2(Lo)
Injector3(Lo)
Injector4(Lo)
Injector1(Lo)
SWG2(W/L)
SWG3(W/L)
CAN Shield
Data Link +
Data Link -
NO. DESTINATION CN-9 FUEL PUMP
Shield
CAN A+
B G3
CAN A-
1
SWG1
1 HORN SW Y 98
nc
nc
2 HORN SW 2
3 CR-62
CN-94
3
CN-93
NC
CN-14
Br 81 1A Or
4 INT. SIG 4 30
43
57
40
54
34
42
10
16
15
26
58
35
57
37
42
43
56
39
47
55
38
46
51
40
48
20
52
10
00
52
24
21
33
53
35
00
63
64
34
53
23
22
25
G
H
B
C
E
A
F
13
J
B
9
3
2
1
8
7
8
7
5 95 Gr 87a 87 85
5 ACCEL DIAL(-) W 25 86
6 124 G
6 ACCEL DIAL(SIG)
RW
GrW
87
BrW
SH
GOr
ROr
RW
RW
RW
RW
BW
BW
BW
BW
VW
YW
11
LW
GOr
G
V
B
G14
Gr
Or
Or
B
Br
Br
W
W
7
R
Y
S
35A B
35E B
35F B
35G B
35H B
Y
B
7 ACCEL DIAL(+)
L
85
8
71A
72A
73A
8 30 86
35J
SPARE SW
2G
49
50
2A
2E
87a
2F
73
72
71
62
15
54
65
43
42
53
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
2H
49
50
9
8
7
6
5
4
3
2
1
BRAEKER RY
CN-8
CN-66
ENGINE HARNESS
1 SPARE SW 1 124 G
2 SPARE SW 2 G52 B
2 CN-171
*2 2RW
2B
Y 97 1 1 R
3 BEACON LAMP 24V 3
2 B
27 Rail Press Sensor(5v)
G 96 BREAKER SOL
*35
4 BEACON LAMP SIG 4
3 Y
19 Rail Press Sensor(gnd)
Or 1
5 BRAKER SW 24V 5 30 Rail Press Sensor(sig)
6 BRAKER SIG 6
Gr 95
B
CL-4 4 R
25 Boost Press Sensor(5V)
G62 5 B
7 SPARE SW 7 1 17 Boost Press Sensor(gnd)
6 R 6 Or
8 SPARE SW 8 2 35 Boost Press Sensor(sig)
2B
Br 17 7 R
9 START KEY (START SIG) 9 HEAD LAMP 8 B
26 Oil Press Sensor(5V)
R 93
10 START KEY (ACC) 10 18 Oil Press Sensor(gnd)
35
V 92 9 G
11 START KEY (BR) 11
10 V
36 Oil Press Sensor(sig)
W 18A
12 START KEY (COM) 12 22 Coolant Temp Sensor(sig)
71E
72E
CR-13 11 Br
21 Boost Temp Sensor(sig)
88 Gr
CN-7 30 12 B
16 Temp Sensor(gnd)
RW 117 117 RW 87a 87 85 13 L
1 1
G
HEAD LIHGT SIG
V
86 6 Crank Speed Sensor(5V)
V 91 6 R 14 Y
2 WORK LIHGT SIG 2 87 32 Crank Speed Sensor(sig)
CN-99
W 82 G13 B 13A L
3 WIPER DRIVE SIG 3 85
A
B
C
7 Cam Speed Sensor(5V)
4 NC 4 87a 30 86 15 G
L 108 33 Cam Speed Sensor(sig)
5 SW PANEL 24V 5 16 Or
B
HEAD LAMP RY
A
Or 89 37 Injector1(high)
6 CABIN LIGHT SIG 6 17 Br
Gr 88A CN-12 CL-5 RESISTOR 18 GOr
14 Injector1(Lo)
7 HEAD LIHGT 24V 7 G81 B B 2 2 B 38 Injector4(high)
Y 87 2 1 19 YW
8 WORK LIHGT 24V 8 91 V
1
V 1 1 V 13 Injector4(Lo)
L 79 2 20 VW
9 WASHER SIG 9 40 Injector3(high)
B G4 21 BW
10 GND 10 WORK LAMP 4 Injector3(Lo)
OrW 28 22 W
11 TRAVEL ALARM SIG 11 2A B
39 Injector2(high)
RW 86 1 23 LW
12 CABIN LIGHT 24V 12 1A V 3 Injector2(Lo)
2 24 BrW
13 NC 13 9 Pump Solenoid(sig)
14 NC 14 CL-6 25 GrW
10 Pump Solenoid(Return)
15 NC 15
RH CONSOLE HARNESS CN-16B
B 42
CN-125 1 1
Y 99A W 43
1 1 2 2
114 R R 93 Gr 53
2 2 3 3
B 126 BW 54
3 3 4 4
R Or 24 BW 65
114 5 5
4 4
6 6
GPS CONN.
13 B B 29
1 1
25 W W 32
2 2
11 GOr GOr 30
3 3
59 BW
4 4
59 BW
5 5
6 6
NO. DESTINATION CN-6
Or1E CN-16 CN-16A CN-140
1 QUICK COUPLING SW 24V 1
102
Y 102 Y
2 QUICK COUPLING SW 2 2
84
L/W G53 B
3 OVERLOAD SW 3 1
G 46
4 OVERLOAD SW 4 QUICK CLAMP
GrW 10
5 WIPER MOTOR 24V 5
B G2
6 GND 6
Gr 83
7 CIGARLIGHTER 24V 7
R 6A CD-14
8 CIGARLIGHTER ILL. 8 1F Y
W 82 2 Pa
9 WIPER DRIVE SIG 9 2F G
Br 81 1
10 INT. SIG 10 CD-31
V 80
11 WASHER PUMP 11 84 LW
2 CN-55 CD-13
Pa 19A Y 1 1E Y
12 NC 12 G84 B 2 Y
2 Pa
1 125 G G 2 2E G
1 1
CN-5
L 79 OVERLOAD PS CD-12
1 WASHER SIG 1
1A Y
2 NC 2 CN-81 2 Pa
Br77 G 2A G
3 CLUSTER 24V 3 125
2 1
R 110 V
4 WIPER MOTOR CONT. 4 51 1 CD-11
Gr 78
5 CONVERTOR 24V 5 1 Y
6 HOUR METER SIG 6
WOr 61 CN-98 TRAVEL BZ 2 G
2 Pa
Or 8 C B 1
7 HOUR METER 24V 7 72F G
SH 70 B
8 SHIELD 8 71F V
B 113 A A
9 CLUSTER GND 9
Y 68
10 CLUSTER SERIAL+ (RX) 10 RESISTOR
L 69
11 CLUSTER SERIAL- (TX) 11
CR-23 CN-45
12 NC 12 CN-2
G41 B B 1 1 B M
12
12
NC
NC
13
14 CN-22 94 BOr
1
BOr 2 2 BOr M
GrW 2
12 NC 10A 16 W W 3
15 2 M 3
80 V
1 21A Gr Gr 4 START RY B+
RH SIDE HARNESS CN-75 107 G
4
G 5 STARTER
WASHER PUMP G42
5
1A
FROM BATT.RY
57 Y B B
2 6
NO. DESTINATION CN-4 75 L
1
85 VW
7
VW 6
TO PRE-HEAT RY CN-74
B G6 10 8R
1 POWER MAX SW 1 8 B+
2 POWER MAX SW 2
Y 34 EPPR V/V U
B G7 9 ~
3 O/T DECEL SW 3 10 3 W 3
Gr 45 1 I
4 O/T DECEL SW 4 9 R G
11 2 R
5 NC 5 12
B G5 ALTERNATOR
6 SAFETY SW (Com) 6 DO-4
7 SAFETY SW (NC) 7 9 R
8 SAFETY SW (NO) 8
G 76 ENGINE HARNESS 4 Gr
2
1
CN-1
TO START MOTOR
LH CONSOLE HARNESS 14 RW
1
R 1 DIODE
CN-68 2
CR-24
G 76 15R
1 47 B B 2 5 G
R 109 3
2 38 W W 3
4 15R
39 Br Br 4
SAFETY SOL 5
40 V V 5
6 PRE-HEAT RY PRE HEATER
CN-19B
B G15
1 CN-28
Y 67 6 VW
2 1
L
CN-19 CN-19A L
AC COMP
75 48
WOr 37A
1 1
57 Y Y 52
2 2
20A
107
62
20
90A
WOr 37
94
17
21
44
G51
GW 58
GW 90
44
26A
CN-92A CN-92
12E
BOr
GW
BW
2G
Gr
Br
G
L
L
2G
B
Y/W
CR-46
CR-36
CR-5
B
87
30
85
87a
86
87
87
30
30
85
85
87a
86
87a
86
ADJUDT BOOM AUTO-IDLE PS
CN-15 CN-15
2A
1A
2E
R 1E
CN-96
W 3
2
BR 4
R 1
V 5
4
3
2
1
85 87 87a
85 87 87a
85 87 87a
2
1
B
R
B
B
86 30
86 30
86 30
BW 122
GW 121
VW 120
119
52
CD-44
CD-43
CD-42
8A
W 32
YOr 26
34
OrW 28
RW 14
47
W 16
W 38
Br 39
40
Gr 45
BrW 31
36
29
GOr 30
LW 33
12
ROr 27
GrW 55
BrW 60
LOr 63
WOr 61
GW 58
Gr 56
48
WOr 37
W 64
GOr 51
46
71
72
73
23
68
69
70
67
8E
G16
1
2
3
1
2
3
1
2
3
FUEL WARMER
SH
12H
31
GY
SH
G
G
Y
B
Y
Y
L
L
Or
12F
12A
Or
26
W
W
G
R
R
27
G
R
FUEL WARMER RY
7
12
33
PRE HEAT RY ANTI-RESTART RY

BrW
CN-51
CN-50
55
63
60
3
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
12J
YOr
CN-47
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
119
120
121
122
36
GND
3E
3A
GND
GND
64
19
ROr
24V
24V
24V
SIG
B
SIG
SIG
2
1
CD-37
LW
CD-16
GrW
FUEL LEVEL SENSOR

BrW
BOOM PRIORITY SOL

LOr
GND(PRES.SENSOR)
TRAVEL SPEED SOL

HYD TEMP SENDOR
CD-7
24V(PRES.SENSOR)
W
2
1
TRAVEL ALARM SW
R
R
Y
B
L
GW
VW
BW
CD-1
ANTI-RESTART RY
WATER LEVEL SW
PUMP3 PS PUMP2 PS PUMP1 PS

1
2
AIR CLEANER SW
POWER MAX SOL
PROGRAM DUMP
B
TRAVEL BUZZER
POWER MAX SW
GND (POT&DIAL)
BATTERY 24V(+)
ACCEL DIAL SIG
C 1
2
CN-133
CN-137
MAX FLOW SOL

1
2
OVERLOAD SIG
CN-126
TRAVEL OIL PS
GND (SENSOR)
FUEL WARMER
1
1
2
P1 PRESS SIG.
P2 PRESS SIG.
P3 PRESS SIG.
O/T DECEL SW
PUMP EPPR(+)
5V (POT&DIAL)
CN-70
PUMP EPPR(-)
CN-88
HOUR-METER
CD-2
CD-10
DATA SHIELD
WORKING PS
RESISTOR
RS232 (GND)
DATA LINK+
Pa
GND (MAIN)
Pa
DATA LINK-
SERIAL-RX
3
4
1
ALT LEVEL
2
SERIAL-TX
POWER IG
1
2
RS232 (+)
RS232 (-)
HYD TEMP CN-92

TRAVEL BOOM POWER MAX AIR WATER LEVEL WORK PS
GND
Pa
FUEL LEVEL RS232 CONN

NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
PRIORITY MAX FLOW CLEANER SW
CPU CONTROLLER 1607A4CI01
4-3
ELECTRIC CIRCUIT(2/2)
CS-26A
Gr 5A CS-5
2 B 8
CS-54 1 CN-21
Gr 18A Y 9
B G2 1 OVERLOAD SW
10 10 2
3 1 WIPER CUT SW QUICK CLAMP SW
9 L 7A 10
R
2
8
7
9
BREAKER SW
8
2
HORN SW
9
1
9 2
RH HARNESS
CS-53
CN-142 Gr 12
8 CS-26 13 GOr 5 3 I
8 Gr 18 A + R 4A
6 7 1 12 W 4
2 B 19 Gr 5 B S CN-9 NO. DESTINATION 4 G 8
6 2 11 B 8 B 5
7 Or 20 C - 1 1 GND 9
2A B
10
L
10
5
6
5 5 BREAKER SW 9 Y 6 M 2 6
CS-50
CS-67
1 ACCEL DIAL 2 2 HORN RELAY
Or
4 32 BrW
10
3
7
2
6
1
4
5
8
9
10
3
7
2
6
1
4
5
8
9
3 3 FUEL WARMER
3 10 Br
11
Gr 14 4 4 WIPER CONTROLLER WIPER MOTOR
11
LW
2 B
Or
Or
Gr
Or
G
5 CPU CONTROLLER
B
L 7 5
Y
B
1 12 W
6 6 CPU CONTROLLER
G1
1A
G2
2A
SPARE SW 13 GOr
7
6
4
7 7 CPU CONTROLLER CN-141
CS-23 14 Gr
G 8
B G1 8 8 NC FEED BACK 1
9 10 10 W 1
G 6A MOTOR DRIVE SIG 2 CN-17
9 CN-8 L 9
15 G MOTOR DRIVE- 3 1
8 1 1 NC 10 1 9
8 7 L R W W
MOTOR DRIVE+ 4 2
6 7 2 2 NC B 2 2 B B G3
2 Y 16 16 Y GND 5 3
6 3 3 FUSE GrW 3 3 GrW GrW 3
7 6 G VCC 6 4
5 5 4 4 BEACON LAMP 4 R 29
1 17 Or CONTINUE 24V 7
R 4 R
CN-156
5 5 FUSE 5
4 5 V 11 G9 B
18 Gr WASHER P/P 8
V 5 6
V
2
3 6 6 BRAKER SOL L 6 6 L L 13 1F Gr
G 6 19 B WASHER SIG. 9 7 1
2 7 7 NC Br 7 7 Br Br 10
20 Or INT. SIG 10 8 AIR SEAT
1 8 8 FUSE Or 11
21 Br WIPER CUT SW 11
BEACON LAMP SW 9 9 SAFETY RELAY
22 R N.C 12
10 10 POWER RELAY Gr 12
CS-27 23 V FEED BACK 13 CN-6 NO. DESTINATION
11 DIODE(DO-2)
9 10 10
B G3
24 W
11
12 12 FUSE WIPER MOTOR CONTROLLER
WIPER MOTOR HARNESS 4 Or
1 1 FUSE
Gr 5A 2 Y
9 2 2 QUICK CLAMP SOL
G 15 5 LW
8 CN-7
8 25 R 3 3 OVERLOAD PS
6 7 1 1 HEAD LAMP 6 G
2 4 V 4 4 CPU CONTROLLER
2 2 WORK LAMP 3 GrW
6 CL-2 5 5 FUSE
7 Or 17 26 W
G5
5 3 3 WIPER CONTROLLER B G1 B
5 27 Br 6 6 GND
1 Or 17E 4 4 CPU CONTROLLER Gr 1 1 Gr
4 7 7 FUSE
Or 17F 28 L
8 8 R
3 5 5 FUSE R
3 Or 8 8 ILLUMINATION
2 6 6 CABIN LIGHT 9 W
GY 5 29 Gr 9 9 SWITCH PANEL
1 7 7 FUSE CIGARLIGHT 10 Br
2 Y 10 10 SWITCH PANEL
8 8 FUSE 11 V
BREAKER SW 30 L CN-48 11 11 WASHER PUMP
9 9 WIPER CONTROLLER Or 16 12 GW
CS-84 G1 B 12 12 CPU CONTROLLER
+ -
10 GND
9 10 10
B G5
31 OrW
10
h WOr 15 CS-52
Gr 1E
BrW 32A 11 11 CPU CONTROLLER 10
9 1 R 9 10 G 28
12 12 FUSE HOUR METER 9
8 33 LW LOr 23
8 13 13 SEAT HEATER 8
2
6 7 34 G
14 14 SPARE CN-138
Gr 14
8
6 7
RH SIDE HARNESS
6 24V A 2 B 24
7 Or 17A 15 15 NC 24V B G6 6
5 5 GND B 7 B G8
1 Or 22 5 5
4 12V 12V C 1
CS-2 4
3 24 W
H0 I
1
DC/DC CONVERTER 3
2 23 V L 12
BrW 32 2 CN-5
0, I
1 2
22 R G 28 13 L
4 1 1 1 SWITCH PANEL
H
FUEL WARMER SW 3 CN-139
Or 22 ECONO SW 2 2 NC
BR ACC
4 1
B
2 2 17 Br
CS-82 21 Br G7 3 3 FUSE
B G6 5 3 B
10 10 1 29 R
9 LW 33A 4 4 FUSE
6
9 14 Gr
5 FUSE
ST C
5 5
8 6
12V SOCKET 15 WOr
8 6 6 CPU CONTROLLER
6 7 START KEY SW 16 Or
2 Y 16A CN-56 17
7 7 FUSE
6 CN-116 RR Br 21 SH
7 1A R POWER IG(24V) 1 8 8 CPU CASE EARTH
5 5 17 CABIN LIGHT 24V B 18 18 B
1 1 R GND 2 9 9 GND
4 16 CABIN LIGHT 24V Y 19 19 Y
10 Br RX 3 10 10 CPU CONTROLLER
3 15 INT. SIG L 20 20 L
LW 33 31 OrW TX 4 11 11 CPU CONTROLLER
2 14 TRAVEL ALARM 23 LOr
G4 B CLUSTER 12 12 NC
1 13 GND 24 B
30 L 13 13 NC
HEAT SEAT SW 12 WASHER SIG
2A Y 14 14 NC
CS-83 11 WORK LIGHT 24V
B G7 2 Y 15 15 NC
10 10 WORK LIGHT 24V
9 10 29 Gr
G 34A 9 HEAD LIHGT 24V
9
3A Or
8 8 CABIN LIGHT OUT
8 3 Or
6 7 7 CABIN LIGHT OUT
2 28 L
6 6 POWER 24V
7 Y 16E 27 Br
5 5 5 PRE-HEAT
1 26 W
4 4 WIPER MOTOR DRIVE
4A V
3 3 WORK LIGHT OUT
4 V
2 2 WORK LIGHT OUT
G 34 25 R
1 1 HEAD LIGHT OUT
INLET M/ACT TEMP M/ACT MODE(D/FOOT) MODE(VENT) RESISTOR RELAY(HI) RELAY(M2)
SPARE SW SWITCH PANEL
2 7 2 7 BLOWER
1 4 1 4
3 M M 3 M M
3
7
1
7
Lo 1
4
ML 2
MH 3
5 5
M
CN-24
Hi
4
2
2
BW 12
5
6
7
5
6
7
5
6
7
1
2
3
4
5
6
7
1
2
3
4
1
2
3
4
1
2
3
4
2
Gr 11 CS-1
1
2
3
4
1
2
1
1
4
4
2
3
2
3
8 Gr
GW
WR
BW
WB
BG
BG
GB
GB
GL
YB
LR
LB
Y
Y
SPEAKER-RH
YBr
YW
LG
YW
BG
RY
RY
2B
YB
CN-23
L
20A
L
9A
9B
21
22
17
20
18
19
23
24
25
16
15
BOr 10
2 DOOR SW
36A
26
35
27
33A
9
32
36
6B
6A
Or
29
33
36
28
35
1
SPEAKER-LH
CL-1
8 Gr
CN-27 1 CS-29
4 Y B 1
N.C 1 2 1
BW 12 Y 2
S.R- 2 ROOM LAMP 2
S.R- 3 CN-4 NO. DESTINATION
BOr 10 POWER MAX SW 1 B
S.L- 4 1 1 GND
2 Y
S.L- 5 CN-10 NO. DESTINATION CS-19 2 2 CPU CONROLLER
1 V B 3 3 B
N.C 6 1 1 FUSE 1 3 3 GND CN-11 NO. DESTINATION
R 2 2 R Gr 4 4 Gr
ILL+ 7 2 2 ILLUMINATION 2 4 4 CPU CONROLLER 1,2 BR
Gr 11 1 1 GND(CONTROLLER)
S.R+ 8 3 3 5 5 NC 32 2B
3 2B
ONE TOUCH DECEL SW G B 2 2 GND(BLOWER)
S.R+ 9 4 4 GND 6 6 GND 6 RY
RW 16 CS-4 6 V 3 3 FUSE(IG)
ACC 10 5 5 Or 5 7 7 NC 10 RW
Y 4A 4 Y B C A 7 G 4 4 MCU
B+ 11 6 6 FUSE V 6 8 8 SAFETY SOL 33 2R
Or 9 B 5 5 FUSE(Battery)
S.L+ 12 7 7 G 7 30 LW
6 6 DPS(COMPRESSOR)
S.L+ 13
5 B
8 8 GND A C LH HARNESS 31 LY
7 7 CONDENSOR FAN
B 5 SAFETY SW 5 G
GND 14 9 9 8 8 ILLUMINATION
6 G
10 10 BEACON SW
CN-143 7 Or
R1 1
L 14 11 11 SWITCH PANNEL AIR CON HARNESS
Y 13 12 12
R2 2
WB 15
BW 16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
GB 10
1
BR 2
RW 3
RW 4
5
RY 6
8
9
CASSETTE RADIO CS-20
CABIN HARNESS
GW
BrR
WR
YBr
5
LW
15 Or
BG
BG
BG
GB
9
BR
8
GL
YB
LG
YB
LR
LB
LY
G
G
Y
B
CN-144
1.25LgB
1.25G
NC 1
10
11
12
13
14
15
16
17
18
10
11
12
13
14
14
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
R1 2
L CL-9
7 Or SAFETY SW
NC 3 2
Y 13 3 B
TEMP MOTOR ACT(+)
DUCT SENSOR(GND)
1
TEMP MOTOR ACT(-)
BLOWER RELAY(M1)
BLOWER RELAY(M2)
COMPRESSOR(DPS)
BLOWER RELAY(LO)
1
2
MODE M/ACT(FOOT)
R2 4
INLET MOTOR(REC)
BLOWER RELAY(HI)
INLET MOTOR(FRE)
MODE M/ACT(PBR)
REVERSE FAN SIG

MODE M/ACT(DEF)
TEMP M/ACT(PBR)
MOTOR ACT(REF)
CONDENSER FAN
CABIN LIGHT
DUCT SENSOR(+)
MODE M/ACT(M+)
MODE M/ACT(M-)
NC 5
RW 16
ILLUMINATION
24V OUTPUT 6 CL-8
BATTERY(+)
BATTERY(+)
V 1 7A Or
POWER IG
IG 24V INPUT 7 2
NC 8 3A B DUCT
2A 1 SENSOR
GND
GND
R
9
NC
NC
NC
NC
NC
ILLUMINATION
NC 10 CL-7
B 5A 6 G
GND 11 AC & HEATER CONTROLLER
3B B M
NC 12
REMOCONE BEACON LAMP
1607A4CI02
4-4
MEMORANDUM
4-5
1. POWER CIRCUIT
The negative terminal of battery is grounded to the machine chassis through master switch.
When the start switch is in the OFF position, the current flows from the positive battery terminal as
shown below.
1) OPERATING FLOW
Battery Battery relay Fusible link CN-60 Master switch CS-74
Fuse box No.1 l/conn CN-8(12) Start switch CS-2(1)
Power relay CR-35(30)]
ECU power relay CR-45(30)
Fuse box No.2 I/conn CN-10(6) Room lamp CL-1(2) Door switch CS-1
Cassette radio CN-27(11)
Fuse box No.3 l/conn CN-11(4) AC & Heater controller CN -116(10)
l/conn CN-11(5) AC & Heater controller CN -116(3, 4)
Relay(Hi, M2)
Fuse box No.4 ECU earth CN -93(7, 8, 15, 16)
Fuse box No.5 I/conn CN - 5(4) I/conn CN -17(5) Wiper motor controller
CN-141(7)
Wiper motor CN-21(4)
Fuse box No.6 CPU controller CN-50(7)
I/conn : Intermediate connector
2) CHECK POINT
Engine Start switch Check point Voltage
① - GND (Battery 1EA) 10~12.5V

- GND (Battery 2EA) 20~25V
OFF OFF
- GND (Battery 2EA) 20~25V
- GND (Fusible link) 20~25V
GND : Ground
4-6
W CR-45
30
Or 87a 87 85
86
ECU
V
87
CN-10 B
CN-27 85
1
N.C 1 87a 30 86
POWER RY
2
S.R- 2 W CR-35
3 30
S.R- 3 Or 87a 87 85
4 86
S.L- 4 3L
5 87
5
Y Y B
S.L- 85
6
N.C 6 87a 30 86
POWER RY
7
ILL+ 7 8
POWER CIRCUIT
S.R+ 8 9
S.R+ 9 10
CN-36
W START KEY 30A
ACC 10 11 1
CASSETTE RADIO
Y Y ROOM LAMP 10A
B+ 11 12 2
12 2RW AC& HEATER 30A
S.L+ 3
S.L+ 13 3L ECU 30A
4
5R
CN-8
GY
GY
Y
GND 14 R WIPER+ 10A
1 5
Gr CPU B+ 10A
3L
2
1
6
CL-1
3 CLUSTER 10A
7
4
CS-1
CS-2 CASSETTE RADIO 10A
8
DOOR SW
5
6 CONVERTOR 10A
ROOM LAMP
5
ST C
6 9
RW
RW
RW
RW
6 SWITCH PANEL 10A
7 10
5 CPU 10A
7
8
1
2
3
9
3 8
15
16
10
42
34
54
2 11
BR ACC
1 4 9 5A
ECU
ECU
CN-93
R R 12 V
START KEY SW
H
4 3 10
FUEL WARMER 30A
13
0, I
2 11
W W START, ALT 20A
1 12 14
H 0 I
4-7
WIPER MOTOR 10A
15
Accel Dial(sig)
HEAD LAMP 20A

Accel Dial(gnd)
Battery Power -
Battery Power -
Battery Power -
Battery Power -
Battery Power -
16
Battery Power B+
Battery Power B+
Battery Power B+
Battery Power B+
CN-116 CN-11 WORK LAMP 20A
RW 17
BATTERY(+) 3
RW 1 CABIN LAMP 20A
BATTERY(+) 4 18
GB 2 BEACON LAMP 10A
REVERSE FAN SIG 10 19
3
AC & HEATER CONTROLLER 2RW AC& HEATER 20A
20
5W
4
2RW HORN 10A
5 21
1 2 1
R 6 CIGAR LIGHTER 20A
2 22
7 PRE-HEAT 10A
3 23
8 10A
3 4 4 TRAVEL
24
1 2 1 SOLENOID 1 10A
R 25
2
3
CR-1
CN-5 SAFETY SOL 10A

26
3 1
SOLENOID 3 10A
BATT RY
3 4 4 27
RELAY(M2) RELAY(HI)
2
CN-17 FUEL FILLER P/P 30A
3 28
CN-21 1 29 R R
FUSE BOX
4
3 1 2
2
5
2 3
60R
6 CS-74
5 3 4 5R
R R 7 2
4 5
1
2
1
2
4 8 5R
1
CS-74
CN-95
CN-60
5 6
FUSIBLE LINK
9
6 2 6 7
M
MASTER SW
10
(12VX2)
5R
5R
5W
BATTERY
5W
8
4
11
CN-50
WIPER MOTOR 12 GY
BATTERY 24V(+) 7
60B
CN-141 13
1
R CPU CONTROLLER
CONTINUE 24V 7 14
1607A4EL03
WIPER MOTOR CONTROLLER 15
2. STARTING CIRCUIT
1) OPERATING FLOW
Battery(+) terminal Battery relay CR-1 Fusible link CN-60 Master switch CS-74
Fuse box No.1 I/conn CN-8(12) Start switch CS-2(1)
(1) When start key switch is in ON position
Start switch ON CS-2(2) I/conn CN-8(11) Battery relay CR-1
Battery relay operating (All power is supplied with the electric component)
Start switch ON CS-2(3) I/conn CN-8(10) Power relay CR-35(86) (87)
Fuse box No.10
(2) When start key switch is in START position
Start switch START CS-2(5) I/conn CN-8(9) Anti-restart relay CR-5(86) (87)
l/conn CN-2(2) Start relay CR-23
2) CHECK POINT
① - GND(Battery)
- GND(Start key)
- GND(Battery relay M4)
OPERATING START - GND(Starter B+) 20~25V
- GND(Starter M)
- GND(Start relay)
- GND(Battery relay M8)
GND : Ground
4-8
W CR-45
30
Or 87a 87 85
86
ECU
V
87
CN-8 B
85
1 87a 30 86
POWER RY
2 W CR-35
3 30
Or 87a 87 85
4 86
CS-2 3L
5 87
6 B
5 85
ST C
6
87a 30 86
POWER RY
6 7
BR
3 5 8
2 BR
B
1
BR ACC
4 9
R R CN-36
START KEY SW
H
4 3 10
V V W START KEY 30A
STARTING CIRCUIT
0, I
2 11
W W ROOM LAMP 10A
1 12 2
H0 I
AC& HEATER 30A
3
ECU 30A
4
5R
2
WIPER+ 10A
5
CPU B+ 10A
3L
6
CLUSTER 10A
7
CASSETTE RADIO 10A
8
CN-50 CONVERTOR 10A
W/OR 9
ANTI-RESTART RY 11
SWITCH PANEL 10A
CN-51 10
W 10A
ALT LEVEL 9 CPU CONTROLLER CPU
11
CPU CONTROLLER ECU 5A V
B W/OR 12
FUEL WARMER 30A
W
13
Gr
B/OR
CN-92A CN-92 BW START, ALT 20A
14
WIPER MOTOR 10A
4-9
2
5
4
1
9
8
7
6
3
12
11
10
15
CN-2
Gr HEAD LAMP 20A
BR
16
B/OR
W/OR
WORK LAMP 20A
W
Gr
17
B/OR
87 CABIN LAMP 20A
85
86
30
18
87a
CR-5
BEACON LAMP 10A

19
3
AC& HEATER 20A
20
5W
30 86
87a 87 85
HORN 10A
CR-1
21
CIGAR LIGHTER 20A
ANTI-RESTART RY
22
BATT RY
7
PRE-HEAT 10A
23
TRAVEL 10A
24
1
SOLENOID 1 10A
R
G
B
V
25
Gr
B/OR
60R
SAFETY SOL 10A

26
10A
1
SOLENOID 3
2
2
1
1
1
2
2
27
6
DO-2
DO-3
DO-4
DO-1
FUEL FILLER P/P 30A
28
DIODE
DIODE
DIODE
DIODE
FUSE BOX
(12VX2)
BATTERY
CR-23
CS-74
START RY
5R
60B
2
1
2
1
2
R
W
8R
5R
CS-74
1
CN-95
CN-60
5
FUSIBLE LINK
MASTER SW
1
2
5R
5R
5W
4
5W
I
B+
R
B+
CN-45
CN-74
STARTER
M
1607A4EL04
G
U
ALTERNATOR
~3
3. CHARGING CIRCUIT
When the starter is activated and the engine is started, the operator releases the key switch to the ON
position.
Charging current generated by operating alternator flows into the battery through the battery relay
(CR-1).
The current also flows from alternator to each electrical component and controller through the fuse box.
1) OPERATING FLOW
(1) Warning flow
Alternator "I" terminal I/conn CN-2(3) CPU alternator level CN-51(9)
Cluster charging warning lamp(Via serial interface)
(2) Charging flow

Alternator "B+" terminal Battery relay(M8) Battery(+) terminal
Fusible link CN-60 Master switch CS-74
Fuse box
2) CHECK POINT
① - GND(Battery voltage)
- GND(Battery relay)
Run ON - GND(Alternator B+ terminal) 20~30V
- GND(Alternator I terminal)
- GND(CPU)
GND : Ground
4-10
SERIAL-TX
ALT LEVEL
SERIAL-RX
CLUSTER
TX
RX
GND
CN-5
POWER IG(24V)
1 CN-36
CPU CONTROLLER
2 30A
9
START KEY
30
29
1
RR
CN-50
CN-51
3 ROOM LAMP 10A
2
L
30A
Y
4 AC& HEATER
W
3
4
3
2
1
5
5 ECU 30A
CHARGING CIRCUIT
CN-56
4
5R
6 WIPER+ 10A
5
L
Y
7 CPU B+ 10A
6
SH SH CLUSTER
8 10A
7
9 CASSETTE RADIO 10A
8
Y Y
10 CONVERTOR 10A
9
L L 10A
11 SWITCH PANEL
10
12 CPU 10A
11
13 ECU 5A
12
14 FUEL WARMER 30A
13
15 START, ALT 20A
14
WIPER MOTOR 10A
15
W
HEAD LAMP 20A
16
WORK LAMP 20A
2
3
5
4
1
17
9
8
7
6
12
11
10
CN-2
CABIN LAMP 20A
4-11
18
BEACON LAMP 10A
W
19
B/OR
AC& HEATER 20A
20
5W
HORN 10A
CR-1
21
CIGAR LIGHTER 20A
22
BATT RY
2 PRE-HEAT 10A
23
TRAVEL 10A
24
1
SOLENOID 1 10A
25
G
W
60R
SAFETY SOL 10A

26
10A
1
SOLENOID 3
B
27
B/OR
DO-1
FUEL FILLER P/P 30A
28
DIODE
FUSE BOX
(12VX2)
BATTERY
CR-23
CS-74
START RY
5R
60B
4
1
2
1
2
5R
W
8R
1
CS-74
CN-60
CN-95
3
MASTER SW
FUSIBLE LINK
1
2
5R
5R
5W
5W
R
B+
B+
CN-45
CN-74
STARTER
M
G
U
ALTERNATOR
~3
1607A4EL05
4. HEAD AND WORK LIGHT CIRCUIT
1) OPERATING FLOW
Fuse box (No.16) I/conn CN-7(7) Switch panel CN-116(9)
Fuse box (No.17) I/conn CN-7(8) Switch panel CN-116(10,11)
(1) Head light switch ON
Head light switch ON CN-116(1) l/conn CN-7(1)] Head light relay CR-13(86) (87)
Head light ON CL-4(2)
l/conn CN-10(2) Cassette radio & Remote controller illumination ON CN-27(7), CN-144(9)
l/conn CN-11(8) AC & Heater controller illumination ON 5
l/conn CN-6(8) Cigarlight CL-2
(2) Work light switch ON
Work light switch ON CN-116(2,3) l/conn CN-7(2) l/conn CN-12(1)
Work light ON CL-5(2), CL-6(2)
2) CHECK POINT
① - GND(Fuse box)
- GND(Switch power input)
STOP ON 20~25V
- GND(Switch power output)
- GND(Head light relay)
- GND(Head light)
- GND(Fuse box)
STOP ON - GND(Switch power input) 20~25V
GND(Switch power output)
- GND(Work light)
GND : Ground
4-12
CN-11
1
GND 1 CN-36
2
GND 2 START KEY 30A
3 1
BATTERY(+) 3
4 ROOM LAMP 10A
S.L-
S.L-
ILL+
S.R-
S.R-
S.L+
S.L+
2
B+
4
N.C
N.C
BATTERY(+)
S.R+
S.R+
ACC
GND
G 5 30A
ILLUMINATION 5 AC& HEATER
6 3
8
9
7
6
5
4
3
2
1
POWER IG 6 ECU 30A
14
13
12
11
10
7 4
CN-27
NC 7 R
WIPER+ 10A
CASSETTE RADIO
8
R
DUCT SENSOR(+) 8 5
CPU B+ 10A
DUCT SENSOR(GND) 9 6
REVERSE FAN SIG 10 CLUSTER 10A
7
NC 11 CASSETTE RADIO 10A
CN-144 CN-10 8
NC 12
NC 1 1 CONVERTOR 10A
NC 13 R 9
AC & HEATER CONTROLLER

R1 2 2
NC 14 SWITCH PANEL 10A
NC 3 3 10
CPU 10A
R2 4 4 11
NC 5 5 ECU 5A
12
24V OUTPUT 6 6 FUEL WARMER 30A
IG 24V INPUT 7 13
7
20A
1 START, ALT
NC 8 8 14
ILLUMINATION 9 WIPER MOTOR 10A
9
HEAD AND WORK LAMP CIRCUIT
15
NC 10 10 GY HEAD LAMP 20A
16
REMOTE CONTROLLER
GND 11 11
Y WORK LAMP 20A
NC 12 12 17
3
CABIN LAMP 20A
18
BEACON LAMP 10A
CN-116 19
6
R
HEAD LIGHT OUT 1 AC& HEATER 20A
R 20
WORK LIGHT OUT 2 CN-7 HORN 10A
R R 21
WORK LIGHT OUT 3 1
V CIGAR LIGHTER 20A
4-13
WIPER MOTOR DRIVE 4 2 22
PRE-HEAT 10A
PRE-HEAT 5 3 23
POWER 24V 6 4 TRAVEL 10A
24
8 2
CABIN LIGHT OUT 7 5 10A
SOLENOID 1
CABIN LIGHT OUT 8 6 25
GY GY SAFETY SOL 10A
HEAD LIHGT 24V 9 7 26
Y Y
WORK LIGHT 24V 10 8 SOLENOID 3 10A
Y 27
WORK LIGHT 24V 11 9 FUEL FILLER P/P 30A
SWITCH PANEL
28
WASHER SIG 12 10
FUSE BOX
GND 13 11
B
V
7
9
TRAVEL ALARM 14 12
INT. SIG 15
CABIN LIGHT 24V 16
1
2
CABIN LIGHT 24V 17

CN-12
CN-6
1
2
4
3
4
CL-2 5
6
RW
R
B
5
7
V
B
V
B
R R
Gr
B
8
9
CIGAR LIGHT
1
2
1
2
1
2
87
85
86
30
10
87a
CL-4
CL-6
CL-5
CR-13
11
12
HEAD LAMP
30 86
87a 87 85
WORK LAMP
HEAD LAMP RY
2107A4EL06
5. BEACON LAMP AND CAB LIGHT CIRCUIT
1) OPERATING FLOW
Fuse box (No.19) I/conn CN-8(3) Beacon lamp switch CN-23(6)
Fuse box (No.18) I/conn CN-7(12) Switch panel CN-116(16, 17)
(1) Beacon lamp switch ON
Beacon lamp switch ON CS-23(2) Switch lndicator lamp ON CS-23(9)
l/conn CN-8(4) l/conn CN-10(10)
Beacon lamp ON CL-7
(2) Cab light switch ON
Cab light switch ON CN-116(7, 8) I/conn CN-7(6) I/conn CN-10(11)
Cab light ON CL-8(2), CL-9(2)
2) CHECK POINT
① - GND(Fuse box)
STOP ON 20~25V
- GND(Beacon lamp)
- GND(Fuse box)
STOP ON 20~25V
- GND(Cab light)
GND : Ground
4-14
CN-116
HEAD LIGHT OUT 1 CN-7
WORK LIGHT OUT 2 1
WORK LIGHT OUT 3 2
WIPER MOTOR DRIVE 4 3
7
PRE-HEAT 5 4
POWER 24V 6 5
CN-36
OR OR
CABIN LIGHT OUT 7 6 START KEY 30A
OR 1
CABIN LIGHT OUT 8 7 ROOM LAMP 10A
2
HEAD LIHGT 24V 9 8
AC& HEATER 30A
WORK LIGHT 24V 10 9 3
ECU 30A
WORK LIGHT 24V 11 10 4
SWITCH PANEL
WASHER SIG 12 11 WIPER+ 10A
R 5
GND 13 12 10A
CPU B+
6
6
TRAVEL ALARM 14
CLUSTER 10A
INT. SIG 15 CN-10 7
R CASSETTE RADIO 10A
CABIN LIGHT 24V 16 1
R 8
CABIN LIGHT 24V 17 2 CONVERTOR 10A
9
3
SWITCH PANEL 10A
4 10
CPU 10A
5 11
6 ECU 5A
12
7 30A
FUEL WARMER
8 13
START, ALT 20A
BEACON LAMP AND CAB LAMP CIRCUIT
9 14
G
10 WIPER MOTOR 10A
OR 15
11 20A
HEAD LAMP
5
12 16
WORK LAMP 20A
4-15
4
17
8
R CABIN LAMP 20A
G
B
B
B
18
OR
OR
Y BEACON LAMP 10A
19
1
2
8
7
2
20A
2
AC& HEATER
CL-7
20
CL-9
CL-8
HORN 10A
21
M
1
CIGAR LIGHTER 20A

22
CAB LIGHT
CAB LIGHT
5
6
10
PRE-HEAT 10A
23
BEACON LAMP
3
7
9
2
6
1
4
5
8
10
TRAVEL 10A
24
CS-23
BEACON LAMP SW
SOLENOID 1 10A
Y
B
G
G
25
SAFETY SOL 10A
26
SOLENOID 3 10A
CN-8 27
3
2
1 FUEL FILLER P/P 30A
28
2
FUSE BOX
Y
3
G
4
5
6
7
8
9
10
11
12
2107A4EL07
6. WIPER AND WASHER CIRCUIT
1) OPERATING FLOW
(1) Key switch ON
Fuse box (No.12) I/conn [CN-7(5)] Switch panel [CN-116(6)]
Fuse box (No.4) I/conn [CN-5(4)] I/conn [CN-17(5)] Wiper motor controller [CN-141(7)]
Wiper motor [CN-21(4)]
Fuse box (No.14) I/conn [CN-6(5)] l/conn [CN-17(4)] Wiper motor controller [CN-141(6)]
Washer pump [CN-22(2)]
(2) Wipe switch ON : 1st step(Intermittent)
Wiper switch ON [CN-116(15)] I/conn[CN-9(4)] I/conn[CN-6(10)] I/conn[CN-17(8)]
Wiper motor controller [CN-141(10) (3)] Wiper motor intermittently operating [CN-21(6)]
(3) Wiper switch ON : 2nd step(Low speed)
Wiper switch ON [CN-116(4)] I/conn [CN-7(3)] I/conn [CN-6(9)] I/conn[CN-17(2)]
Wiper motor controller [CN-141(2) (4)] Wiper motor operating [CN-21(2)]
(4) Washer switch ON
Washer switch ON [CN-116(12)] I/conn [CN-7(9)] I/conn [CN-5(1)] I/conn [CN-17(7)]
Wiper motor controller [CN-141(9) (8)] I/conn [CN-17(6)] I/conn [CN-6(11)]
Washer operating [CN-22(1)]
Wiper switch ON [CN-116(4)] I/conn [CN-7(3)] I/conn [CN-6(9)] I/conn[CN-17(2)]
Wiper motor controller [CN-141(2) (4)] Wiper motor operating [CN-21(2)]
(5) Auto parking(When switch OFF)
Switch OFF [CN-116(4)] Wiper motor parking position by wiper motor controller
2) CHECK POINT
① - GND(Fuse box)
24V
STOP ON 0~5V
- GND(Wiper Power input)
- GND(Wiper power output) 24V
- GND(Wiper motor) 0 or 24V
GND : Ground
4-16
CN-9
1
2
3
CN-36
BR 30A
4 START KEY
1
5 ROOM LAMP 10A
2
6 30A
1
AC& HEATER
7 3
CN-116 ECU 30A
8 4
3
HEAD LIGHT OUT 1 V WIPER+ 10A
5
WORK LIGHT OUT 2
CPU B+ 10A
WORK LIGHT OUT 3 CN-7 6
W CLUSTER 10A
WIPER MOTOR DRIVE 4 1 7
CASSETTE RADIO 10A
1
PRE-HEAT 5 2
L W 8
POWER 24V 6 3 CONVERTOR 10A
CABIN LIGHT OUT
9
7 4
L L SWITCH PANEL 10A
CABIN LIGHT OUT 8 5 10
HEAD LIHGT 24V 9 CPU 10A
6 11
2
WASHER CONTROL CIRCUIT
WORK LIGHT 24V 10 7 ECU 5A

12
WORK LIGHT 24V 11 8 30A
SWITCH PANEL
L L FUEL WARMER
WASHER SIG 12 9 13
START, ALT 20A
GND 13 10 14
3
TRAVEL ALARM 14 11 GY/W WIPER MOTOR 10A
BR 15
INT. SIG 15 12 HEAD LAMP 20A
WORK LAMP 20A
1
CABIN LAMP 20A

18
3
CN-5 BEACON LAMP 10A
L
1 19
AC& HEATER 20A
2 20
4-17
CS-53 10A
OR 3 HORN
6
V 21
CN-21 4 CIGAR LIGHTER 20A
22
3 1 5
R PRE-HEAT 10A
2 6 23
GY 10A
TRAVEL
WIPER CUT SW
5 3 7 24
R
4 8 SOLENOID 1 10A
4 G 25
5 9
L SAFETY SOL 10A
6 2 6 10 26
M
WIPER MOTOR
SOLENOID 3 10A
11 27
12 FUEL FILLER P/P 30A
4
28
FUSE BOX
CN-141
G
FEED BACK 1 CN-6
W
MOTOR DRIVE SIG 2 CN-17 1
L
MOTOR DRIVE- 3 1 2
R W W
MOTOR DRIVE+ 4 2 3
B B B
GND 5 3 4
GY/W GY/W GY/W GY/W
VCC 6 4 5
R R R
CONTINUE 24V 7 5
V
6
V V V
GY/W
WASHER P/P 8 6 7
L L L
WASHER SIG. 9 7 8
2
BR BR BR BR
INT. SIG 10 8 9
CN-22
OR BR
M
WIPER CUT SW 11 10
V
N.C 12 11
WIPER MOTOR CONTROLLER

GY
12
WASHER PUMP
FEED BACK 13
2107A4EL08
-
+
S
ACCEL DIAL
A
B
C
CN-142
B
W
G/OR
8
7
6
5
4
3
1
2
CN-9
CN-36
START KEY 30A
1
6
5
4
3
2
1
ROOM LAMP 10A
CONTROLLER CIRCUIT
2
AC& HEATER 30A
3
6
5
4
3
2
1
ECU 30A
4
CN-16 CN-16A
WIPER+ 10A
5
B
W
G/OR
CN-51 GY CPU B+ 10A
B 6
GND (POT&DIAL) 20 CLUSTER
G/OR
10A
5V (POT&DIAL) 21 7
CASSETTE RADIO 10A
NC 22 8
W CONVERTOR
ACCEL DIAL SIG 23 10A
9
FUEL LEVEL SENSOR 24 SWITCH PANEL 10A
10
NC 25
OR CPU 10A
NC 26 11
ECU 5A
NC 32 12
NC 33 FUEL WARMER 30A
13
HYD TEMP SENDOR 34 20A
START, ALT
4-18
14
CN-50 WIPER MOTOR 10A
FUEL HEAT 6 15
GR HEAD LAMP 20A
BATTERY 24V(+) 7 16
BR
PUMP EPPR(-) 8 WORK LAMP 20A
CPU CONTROLLER
17
NC 9 20A
CABIN LAMP
10
18
PROGRAM DUMP
BEACON LAMP 10A
ANTI-RESTART RY 11 19
12 AC& HEATER 20A
NC 20
NC 23 HORN 10A
OR 21
POWER IG 24
CIGAR LIGHTER 20A
GND (MAIN) 28 22
PRE-HEAT 10A
SERIAL-TX 29 23
SERIAL-RX 30 TRAVEL 10A
24
GND 31 SOLENOID 1 10A
25
RS232 (+) 32
SAFETY SOL 10A
RS232 (-) 33 26
10A
1
2
RS232 (GND) 34 SOLENOID 3
27
NC 35 FUEL FILLER P/P 30A
Or 28
1
1
2
2
PUMP EPPR(+) 36
FUSE BOX
CN-19B
CN-19 CN-19A
B
Or
Br
Or
Br
Or
1
2
CN-47
OR 8E
CN-75
1
EPPR VLV
OR 59
2
RESISTOR
1607A4EL09
Pa
h
CD-10
TX
RX
GND
CLUSTER
-
+
CN-48
L
B
POWER IG(24V)
HOUR METER
OR
W/OR
RR
MONITORING CIRCUIT
AIR CLEANER PRESSURE SW

4
3
2
1
CN-56
L
Y
B
BR
CD-2
B
1
LW
2
FUEL LEVEL
CN-51
WORKING PS 1
POWER MAX SW 2
TRAVEL ALARM SW 3
NC 4
NC 5
NC 6
24V(PRES.SENSOR) 7
GND(PRES.SENSOR) 8
ALT LEVEL 9
P1 PRESS SIG. 10
P2 PRESS SIG. 11
P3 PRESS SIG. 12
TRAVEL OIL PS 13
O/T DECEL SW 14
WATER LEVEL SW 15
L
AIR CLEANER SW 16
NC 17
NC 18
NC 19
GND (POT&DIAL) 20
5V (POT&DIAL) 21
NC 22
CPU CONTROLLER
ACCEL DIAL SIG 23
L/W
FUEL LEVEL SENSOR 24
NC 25
NC 26
NC 27
CN-36
L
Y
B
SH
28
OR
NC
BR
W/OR
START KEY 30A

NC 29 1
NC 30 ROOM LAMP 10A
B 2
GND (SENSOR)
2
5
4
1
9
8
7
6
3
31
12
11
10
AC& HEATER 30A

CN-5
NC 32 3
ECU 30A
NC 33 4
L
Y
B
BR
OR
WIPER+
SH
HYD TEMP SENDOR 34 10A

W/OR
5
NC 35 CPU B+ 10A
NC 36 6
CLUSTER 10A
CN-50 7
CASSETTE RADIO 10A
BOOM PRIORITY SOL 1 8
MAX FLOW SOL CONVERTOR 10A
2
9
POWER MAX SOL 3 SWITCH PANEL 10A
W/OR 10
HOUR-METER 4
CPU 10A
NC 5 11
4-19
ECU 5A
FUEL HEAT 6 12
BATTERY 24V(+) 7 FUEL WARMER(OPT) 30A
13
PUMP EPPR(-) 8
START 20A
NC 9 14
B/W WIPER MOTOR 10A
PROGRAM DUMP 10 15
ANTI-RESTART RY 11 HEAD LAMP 20A
16
NC 12 WORK LAMP 20A
TRAVEL SPEED SOL 13 17
CABIN LAMP 20A
NC 14 18
NC 15 BEACON LAMP 10A
19
TRAVEL BUZZER 16 AC & HEATER 20A
NC 17 20
HORN 10A
A
NC 18 21
CN-98
NC 19 CIGAR LIGHTER 10A

22
A
B
C
OVERLOAD SIG 20 PRE-HEAT 10A

RESISTOR
NC 21 23
TRAVEL 10A
NC 22
V
24
G
NC 23 SOLENOID 1 10A
25
POWER IG 24 SAFETY SOL 10A
V
DATA LINK+ 25 26
G SOLENOID 3 10A
DATA LINK- 26 27
SH
DATA SHIELD 27 FUEL FILLER P/P 30A
28
GND (MAIN) 28
FUSE BOX
Y
SERIAL-TX 29
L
SERIAL-RX 30
GND 31
R
RS232 (+) 32
G
RS232 (-) 33
B 35 2B CN-14
RS232 (GND) 34
J nc
NC 35 H nc
PUMP EPPR(+) 71A V
36 G CAN A+
72A G
F CAN A-
49 L
E Data Link -
50 Y
D Data Link +
73A SH
C Shield
35J B
B Battery Power -
2H RW
SERVICE TOOL
A Battery Power B+
CN-126 CN-93
B 49 L
1 24 Data Link -
G 50 Y
2 CN-99 23 Data Link +
R V 71E 73 S
3
A A 22 CAN Shield
G 72E 72 G
RS232
B/W B 21 CAN A-
4 71 V
B C 20 CAN A+
CONNECTOR
33 Throttle Return
RESISTOR
53 Throttle Signal
ECU
43 Throttle Power
57 Air Heater Ry(gnd)
40 Key Switch ON Signal
35 SWG Return
00 SWG3(W/L)
00 SWG2(W/L)
J1
52 SWG1
54 Accel Dial(sig)
34 Accel Dial(gnd)
42 Accel Dial Power(5V)
*35 2B 35A B
10 Battery Power -
35E B
9 Battery Power -
35F B
3 Battery Power -
35G B
2 Battery Power -
35H B
1 Battery Power -
*2 2RW 2A RW
16 Battery Power B+
2E RW
15 Battery Power B+
2F RW
8 Battery Power B+
2G RW
7 Battery Power B+
1607A4EL11
1
2
8
7
9
B
SIG
SIG
SIG
24V
24V
24V
GND
GND
GND
CS-26
A
CS-26A
C
2
1
R
G
2
1
2
1
R
R
G
G
W
2
1
W
W
5
6
CS-29
CS-19
SAFETY SW
10
POWER MAX
A
B
C
BREAKER SW
BREAKER SW
1
2
3
1
2
3
1
2
3
Y
B
PUMP2 PRESS
PUMP3 PRESS
B
PUMP1 PRESS
Gr
Gr
Gr
Gr
GR
3
9
2
1
4
5
8
CS-4
6
7
10
CD-44
CD-43
CD-42
CS-27
V
G
OR
ONE TOUCH DECEL
B
B
B
V
BR
W
B
RW
RW
RW
BREAKER PEDAL SW
GR
OR
GR
OR
CD-6
BR/W
1
PS
Pa B
2
TRAVEL
CS-20
SAFETY SW
B
CD-7
B
1
PS
Pa Y
2
WORK
ELECTRIC CIRCUIT FOR HYDRAULIC
V
B
B
Y
B
G
GR
CS-50
OR
1
G
6
4
1
8
7
5
2
2
CN-4
CD-2 3
V
W
B
R/W
BR
4
C
B
B
Y
B
1
GR
L/W B 1
2 5 5
FUEL
L/W 7
LEVEL
3
6
4
1
5
2
6
OVERLOAD SW
CN-1
CD-1 2
B 7 6
o 8
C 1 8
B
V
R/OR
W
HYD
OR
BR
2
R/W
TEMP
GY 10 9
10
CN-51
Y/OR
WORKING PS 1
Y
POWER MAX SW 2
TRAVEL ALARM SW 3
NC 4
NC 5
NC 6
R/W
24V(PRES.SENSOR) 7
B
GND(PRES.SENSOR) 8
ALT LEVEL 9
W
P1 PRESS SIG. 10
BR
P2 PRESS SIG. 11
V
P3 PRESS SIG. 12
BR/W
TRAVEL OIL PS 13
GR
O/T DECEL SW 14
WATER LEVEL SW 15
AIR CLEANER SW 16
NC 17
NC 18
NC 19
GND (POT&DIAL) 20
5V (POT&DIAL) 21
NC 22
ACCEL DIAL SIG 23
L/W
FUEL LEVEL SENSOR 24
G
B
GY
OR
LW
CY
NC 25
NC 26
NC 27
2
2
5
4
1
9
8
7
5
9
8
7
6
4
1
6
3
12
11
10
12
11
10
4-20
CN-8
CN-6
NC 28
NC 29
B
G
LW
CY
GY
OR
NC 30
B
GND (SENSOR) 31
NC 32
NC 33 CN-36
R/OR
HYD TEMP SENDOR 34 START KEY 30A
1
NC 35
ROOM LAMP 10A
NC 36 2
AC& HEATER 30A
CN-50 3
GR/W ECU 30A
BOOM PRIORITY SOL 1 4
BR/W
MAX FLOW SOL 2 WIPER+ 10A
L/OR 5
POWER MAX SOL 3 CPU B+ 10A
6
CPU CONTROLLER
HOUR-METER 4
CLUSTER 10A
NC 5 7
CASSETTE RADIO 10A
FUEL HEATER 6 8
BATTERY 24V(+) 7 CONVERTOR 10A
9
PUMP EPPR(-) 8 SWITCH PANEL 10A
NC 9 10
CPU 10A
PROGRAM DUMP 10 11
ANTI-RESTART RY 11 ECU 5A
12
NC 12 FUEL WARMER 30A
W 13
TRAVEL SPEED SOL 13
START, ALT 20A
NC 14 14
WIPER MOTOR 10A
NC 15 15
G/OR
TRAVEL BUZZER 16 HEAD LAMP 20A
16
NC 17 WORK LAMP 20A
NC 18 17
CABIN LAMP 20A
NC 19 18
G
OVERLOAD SIG 20 BEACON LAMP 10A
19
NC 21 AC& HEATER 20A
20
NC 22
HORN 10A
NC 23 21
GY CIGAR LIGHTER 20A
POWER IG 24 22
J1939 DATA LINK+ 25 PRE-HEAT 10A
23
J1939 DATA LINK- 26 Y 10A
TRAVEL
J1939 DATA SHIELD 27 24
R SOLENOID 1 10A
GND (MAIN) 28 25
SERIAL-TX 29 R SAFETY SOL 10A
26
SERIAL-RX 30 OR SOLENOID 3 10A
27
GND 31
FUEL FILLER P/P 30A
RS232 (+) 32 28
FUSE BOX
RS232 (-) 33
RS232 (GND) 34
NC 35
PUMP EPPR(+) 36
CN-70
W
1
Y
2
CN-133
GR/W
V
B
Gr
Or
1
R
TRAVEL BOOM
2
R
G
Y
B
87
85
G/OR
86
30
L/W
87a
CN-88
GY
L/OR
CN-62
1
1
2
1
2
2
1
R
1
2
PRIORITY1 MAX
2
CN-81
CN-68
CD-31
POWER
30 86
CN-66
87a 87 85
BREAKER RY
CN-137
Pa
BR/W
1
TRAVEL BZ
SAFETY SOL
R
BREAKER SOL
MAX
2
OVERLOAD PS
FLOW
1607A4EL10
GROUP 3 ELECTRICAL COMPONENT SPECIFICATION
Part name Symbol Specifications Check
Check specific gravity

12V 80Ah 1.280 over : Over charged
Battery
(2EA) 1.280 ~ 1.250 : Normal
1.250 below : Recharging
Rated load Check coil resistance(M4 to M4)

24V Normal : About 50
Battery relay
100A(continuity) Check contact
1000A(30seconds) Normal :
CR-1
Check contact
Preheat relay 24V 200A Normal : 0.942
(For terminal 1-GND)
CR-24
6
5
4
3
2
1
B Check contact
1
I ,O B-BR : 24V 1A OFF : (For each terminal)

Start key B-ACC : 24V 10A
ON : 0 (For terminal 1-3 and 1-2)
B-ST : 24V 40A
I I OH START : 0 (For terminal 1-5)
6
5
3
2
CS AC B H
CS-2
A A
B Check resistance A-B
Resistor 4W
C B 120
CN-98 CN-99
CN-99 CN-174
4-21
Pressure switch
(For working, 2 3~6kgf/cm2 Check contact
Pa
overload, auto 1 (N.O TYPE) Normal
idle)
CD-7 CD-31 CD-37
Check resistance
Pre heater 24V 200A
0.25~0.12
CN-80
C 1 Check resistance
Temperature
- 50 C : 804
sensor
2 80 C : 310
(Hydraulic)
CD-8 100 C : 180
CD-1
Pressure : Check contact

Air cleaner Pa 635mmH2O High level :
pressure switch
(N.O TYPE) Low level : 0
CD-10
Check resistance
Full : 50 6/12 : 350
2 11/12 : 100 5/12 : 400
10/12 : 150 4/12 : 450
Fuel sender 1 -
9/12 : 200 3/12 : 500
8/12 : 250 2/12 : 550
CD-2 7/12 : 300 1/12 : 600
Empty warning : 700
3 4 4 Check resistance
3 Normal : About 200
Relay
2 24V 20A (For terminal 1-3)
(Air con)
1 2 1 0
Mi M2 (For terminal 2-4)
CR-46
4-22
30
86
87a 87 85
Check resistance
87
Normal : About 160
85
Relay 30 86
24V 16A (For terminal 85-86)
87a
CR-2 CR-5 CR-7 0 (For terminal 30-87a)

CR-13 CR-35 CR-36 (For terminal 30-87)
CR-45 CR-46 CR-62
1
Check resistance
Solenoid valve 2 24V 1A Normal : 15~25
(For terminal 1-2)
CN-66 CN-68
CN-66 CN-68 CN-70
CN-70
CN-88 CN-133
CN-88 CN-133 CN-137
CN-137
CN-140
2
Check resistance
EPPR valve 700mA Normal : 15~25
1
(For terminal 1-2)
CN-75
1
Check resistance
Resistor 50 20W 5% Normal : 50
2
CN-47
1
Check resistance
Speaker 2 20W Normal : A few
CN-23(LH)
CN-24(RH)
10 9 8 7 6 5 4 3 2 1 Check contact
10 6 5
Normal
ON : 0 (For terminal 1-5, 2-6)
Switch (For terminal 5-7, 6-8)
24V 8A
(Locking type) OFF : (For terminal 1-5, 2-6)
9 8 2 7 1
0 (For terminal 5-7, 6-8)
CS-23 CS-27 CS-50 CS-52
CS-54 CS-82 CS-83 CS-84
4-23
Check resist
Normal : About 5k
(For terminal A-C)
A + Check voltage
Accel dial B S - Normal : About 5V
C - (For terminal A-C)
CN-142 : 2~4.5V
(For terminal C-B)
8
2
7
9
1
I
Check disconnection
Normal : 1.0
Switch ON : 0 (For terminal 1-5, 2-6)
24V 8A
5
10
(Quick clamp) (For terminal 5-7, 6-8)
OFF : (For terminal 1-5, 6-8)
3
10
2
6
1
4
5
8
9
0 (For terminal 5-7, 6-8)

CS-67
2
Head lamp, 24V 65W
(H3 Type) Check disconnection
Work lamp,
1 24V 10W Normal : 1.2
Room lamp,
Cab lamp (Room lamp) : A few (Room lamp)
CL-1 CL-4 CL-5
CL-6 CL-8 CL-9
21V 70W Check disconnection

Beacon lamp M (H1 type) Normal : A few
CL-7
CL-7
-
1 M 24V 10A Check resistance

Fuel filler pump
35 /min Normal : 1.0
2
CN-61
Check operation
1
Supply power(24V) to terminal
Hour meter h 16~32V
2 No.2 and connect terminal No.1
and ground
CN-48
4-24
1 Check operation
DC22~28V Supply power(24V) to each
Horn 2 2A
terminal and connect ground.
CN-20 CN-25
Check contact
2 3 1
Normal : 0 (For terminal 1-2)
2 24V 15A (For terminal 1-3)
Safety switch 1
(N.C TYPE)
Operating : (For terminal 1-2)
3
1 0 (For terminal 1-3)
CS-4
CS-4
Safety switch 2, 24V Check contact

Wiper cut switch (N.O TYPE) Normal : 0 (One pin to ground)
CS-20
CS-53
1
P Check contact
Receiver dryer 24V 2.5A
2 Normal :
CN-29
CN-29
N.C 1
2
S.R- 3
4
S.L- 5
N.C 6
7
8
Check voltage
Cassette radio S.R+ 9
24V 2A 20~25V
10
11
12 (For terminal 10-14, 11-14)
S.L+ 13
14
CN-27
Washer pump Check contact

24V 3.8A
Normal : 10.7 (For terminal 1-2)
CN-22
4-25
3 1
2
5 3
4 Check disconnection
Wiper motor 4
5
24V 2A
Normal : 7 (For terminal 2-6)
6 M 2 6
CN-21
A 24V
DC/DC 24V 24V (A-B)
B GND 12V 3A
Converter 12V (B-C)
C 12V 12V
CN-138
Check coil resistance

Normal : About 1M
Cigar lighter 24V 5A 1.4W Check contact
Normal :
Operating time : 5~15sec
CL-2
CL-2
B+
U
~ Mitsubishi Check contact
3
Alternator 1 I 24V 50A Normal : 0 (For terminal B+-I)
2 R G
Normal : 24~27.5V
CN-74
M
M
Mitsubishi Check contact
Starter
24V 5.0kW Normal : 0.1
B+
CN-45
Check contact
Travel alarm 24V 0.5A
Normal : 5.2
CN-81
4-26
1
Aircon Check contact
24V 79W
compressor Normal : 13.4
CN-28
Check contact
Start relay 24V 300A
CR-23
1 M Check resistance
Blower motor 24V 9.5A
2
1 Lo 1 Check resistance
2 MH 3 Normal : 1.12 (For terminal 4-2)
Aircon resistor -
3 ML 2 2.07 (For terminal 2-3)
4 Hi 4 3.17 (For terminal 3-1)
Check resistance
Duct sensor 2 1 C OFF Normal : 0 (For terminal 1-2),
(Switch) 4 C ON the atmosphere temp :
1
Over 4 C
Check resistance
Door switch 24V 2W
Normal : About 5M
CS-1
CS-1
4-27
Switch
(Power max, 1 Check resistance
one touch 24V 6A
decel, horn, 2 Normal :
breaker) CS-5 CS-19
CS-26 CS-29
3 24V
Transducer 0bar : 1V(For terminal 1-2)
2 SIG
(Pump 1, 2) 500bar
1 GND 500bar : 5V(For terminal 1-2)
CD-42 CD-43
3 24V
Transducer 0bar : 1V(For terminal 1-2)
(Pump 3) 2 SIG 50bar
50bar : 5V(For terminal 1-2)
1 GND
CD-44
Check disconnection
2
Fusible Normal : 0
link 60A
(Connect ring terminal and check
1
resist between terminal 1 and 2)
CN-60 CN-95
Master switch Check disconnection

6-36V
Normal : 0.1
CS-74
4-28
GROUP 4 CONNECTORS
1. CONNECTOR DESTINATION
Connector No. of Connector part No.
number Type Destination
pin Female Male
CN-1 AMP 6 I/conn(Engine harness-Frame harness) S816-006002 S816-106002
CN-2 AMP 12 I/conn(Engine harness-Frame harness) S816-012002 S816-112002
CN-4 AMP 8 I/conn(Frame harness-Console harness LH) S816-008002 S816-108002
CN-5 AMP 15 I/conn(Frame harness-Side harness RH) 2-85262-1 368301-1
CN-6 AMP 12 I/conn(Frame harness-Side harness RH) S816-012002 S816-112002
CN-7 AMP 15 I/conn(Frame harness-Console harness RH) 2-85262-1 368301-1
CN-8 AMP 12 I/conn(Frame harness-Console harness RH) S816-012002 S816-112002
CN-9 AMP 8 I/conn(Frame harness-Console harness RH) S816-008002 S816-108002
CN-10 DEUTSCH 12 I/conn(Frame harness-Cab harness) DT06-12S DT04-12P
CN-11 DEUTSCH 8 I/conn(Frame harness-Aircon harness) DT06-8S -
CN-12 DEUTSCH 2 I/conn(Frame harness-Boom wire harness) DT06-2S-EP06 DT04-2P
CN-14 DEUTSCH 9 Service tool HD10-9-96P -
CN-15 AMP 2 Auto idle pressure S816-002002 S816-102002
CN-16 AMP 6 Emergency engine speed control S816-006002 S816-106002
CN-17 DEUTSCH 8 I/conn(Wiper harness) DT06-8S DT04-8P
CN-19 AMP 2 Emergency CPU controller S816-002002 S816-102002
CN-20 MOLEX 2 Horn 36825-0211 -
CN-21 AMP 6 Wiper motor 925276-0 -
CN-22 KET 2 Washer pump MG640605 -
CN-23 KET 2 Speaker-LH MG610070 -
CN-24 KET 2 Speaker-RH MG610070 -
CN-25 MOLEX 2 Horn 36825-0211 -
CN-27 AMP 14 Cassette radio 173852 -
CN-28 MWP 1 Aircon compressor NMWP01F-B -
CN-29 KET 2 Receiver dryer MG640795 -
CN-36 DEUTSCH 3 Fuse box 21N8-20041 -
+
CN-45 RING-TERM - Start motor B S820-414000 -
CN-47 FASTEN 2 Resistor S810-002202 -
CN-48 AMP 2 Hour meter GP890469 -
CN-50 AMP 36 CPU controller 3441111-1 -
CN-51 AMP 36 CPU controller 3441111-1 -
CN-55 AMP 2 I/conn(Frame harness-Travel alarm PS) S816-002002 S816-102002
CN-56 DEUTSCH 4 Cluster - DT04-4P-E004
CN-60 YAZAKI 2 Fusible link 21N4-01320 7122-4125-50
CN-61 DEUTSCH 2 Fuel filler pump DT06-2S-P01 -
4-29
pin Female Male
CN-66 DEUTSCH 2 Breaker solenoid DT06-2S-P012 DT04-2P-E004
CN-68 DEUTSCH 2 Safety solenoid DT06-2S-P012 DT04-2P-E004
CN-70 DEUTSCH 2 Travel solenoid DT06-2S-P012 DT04-2P-E004
CN-74 RING-TERM - Alternator "l" terminal - S820-105000
CN-75 AMP 2 EPPR valve S816-002002 -
CN-80 RING-TERM - Glow plug S820-306000 -
CN-81 DEUTSCH 2 Travel buzzer solenoid DT06-2S-P012 DT04-2P-E004
CN-88 DEUTSCH 2 Power max solenoid DT06-2S-P012 -
CN-92 SWF 1 Emergency engine starting connector S814-001100 S814-101100
CN-93 DELPHI 64 ECU(J1) 15488668 -
CN-94 DELPHI 64 ECU(J2) 15488668 -
CN-95 KET 2 Fusible link 21N4-01311 S813-130200
CN-96 DELPHI 4 Fuel warmer 2-967325-3 -
CN-98 DEUTSCH 3 Resistor DT06-3S-P012 DT04-3P-EP10
CN-99 DEUTSCH 3 Resistor DT06-3S-P012 DT04-3P-EP10
CN-116 PA 17 Switch panel S811-017002 -
CN-125 Econoseal J 4 GPS connector S816-004002 S816-104002
CN-126 DEUTSCH 4 RS 232 connector DT06-4S-P012 DT04-4P-E004
CN-133 DEUTSCH 2 Boom prioity solenoid DT06-2S-P012 DT04-2P-E004
CN-137 DEUTSCH 2 Max flow solenoid DT06-2S-P012 DT04-2P-E004
CN-138 DEUTSCH 3 DC/DC Converter DT06-3S-P012 DT04-3P
CN-139 DEUTSCH 2 12V socket - DT04-2P-E004
CN-140 DEUTSCH 2 Quick clamp DT06-2S-P012 DT04-2P-E004
CN-141 AMP 13 Wiper motor controller 172498-1 DT04-3P-EP10
CN-142 DEUTSCH 3 Accel dial DT06-3S-P012 -
CN-143 KET 2 Cassette radio(With remocon) S816-002002 -
CN-144 AMP 12 Remocon-cassette radio 174045-2 -
CN-156 AMP 2 Air seat S816-002002 -
CN-171 DEUTSCH 40 I/conn(ECU-Engine harness) DRC18-40SAE -
Relay
CR-1 RING-TERM - Battery relay - S820-208002
CR-2 - 5 Horn relay - -
CR-5 - 5 Anti restart relay - -
CR-7 - 5 Aircon compressor relay - -
CR-13 - 5 Head lamp relay - -
CR-23 KET 2 Start relay S814-002001 S814-102001
CR-24 RING-TERM - Preheat relay S822-014000 -
CR-35 - 5 Power relay - -
CR-36 - 5 Preheat relay - -
4-30
pin Female Male
CR-45 - 5 ECU power relay - -
CR-46 FASTEN 4 Fuel warmer relay S810-004202 -
CR-62 FASTEN 4 Breaker relay S810-004202 -
Switch
CS-1 SHUR 1 Door switch S822-014004 S822-114004
CS-2 WP 6 Start key switch S814-006000 -
CS-4 DEUTSCH 3 Safety switch DT06-3S -
CS-5 DEUTSCH 2 Horn switch - DT04-2P-E004
CS-19 DEUTSCH 2 One touch decel switch - DT04-2P-E004
CS-20 AMP 1 Safety switch S822-014002 -
CS-23 SWF 10 Beacon lamp switch SWF 593757 -
CS-26 DEUTSCH 2 Breaker switch DT06-2S-P012 -
CS-26A AMP 2 Breaker pedal switch S816-002002 S816-102002
CS-27 SWF 10 Breaker switch SWF 593757 -
CS-29 DEUTSCH 2 Power max switch DT06-2S-P012 -
CS-50 SWF 10 Overload switch SWF 593757 -
CS-52 SWF 10 Econo switch SWF 593757 -
CS-53 AMP 1 Wiper cut switch S822-014002 -
CS-54 SWF 10 Spare switch SWF 593757 -
CS-67 SWF 10 Quick clamp switch SWF 593757 -
CS-74 AMP 2 Master switch S813-030201 -
CS-82 SWF 10 Heat switch SWF 593757 -
CS-83 SWF 10 Spare switch SWF 593757 -
CS-84 SWF 10 Fuel warmer switch SWF 593757 -
Light
CL-1 KET 2 Room lamp MG 610392 -
CL-2 AMP 1 Cigar light S822-014002 -
CL-4 DEUTSCH 2 Head lamp - DT04-EP-E004
CL-5 DEUTSCH 2 Work lamp-LH - DT04-2P
CL-6 DEUTSCH 2 Work lamp-RH - DT04-2P
CL-7 SHUR 1 Beacon lamp S822-014004 -
CL-8 DEUTSCH 2 Cab light-LH DT04-2S DT04-2P-E005
CL-9 DEUTSCH 2 Cab light-RH DT04-2S DT04-2P-E005
Sensor, sendor
CD-1 AMP 2 Hydraulic oil temp sender 85202-1 -
CD-2 DEUTSCH 2 Fuel sender DT06-2S-EP06 -
CD-7 KET 2 Working pressure switch MG640795 -
CD-10 RING-TERM - Air cleaner switch - S820-104002
CD-11 RING-TERM 2 Travel alarm pressure switch - -
4-31
pin Female Male
CD-12 KET 2 Travel alarm pressure switch - -
CD-16 KET 2 Water level sender S814-002100 -
CD-42 AMP 3 Pump pressure 1 S816-003002 -
4-32
2. CONNECTION TABLE FOR CONNECTORS
1) PA TYPE CONNECTOR
No. of
pin Receptacle connector(Female) Plug connector(Male)
2 5 1 3
1 3 2 5
S811-005002 S811-105002
3 7 1 4
1 4 3 7
S811-007002 S811-107002
4 9 1 5
1 5 4 9
S811-009002 3S811-109002
5 11 1 6
11
1 6 5 11
S811-011002 S811-111002
4 - 33
No. of
Receptacle connector(Female) Plug connector(Male)
pin
6 13 1 7
13
1 7 6 13
S811-013002 S811-113002
8 1 9
17
17
1 9 8 17
S811-017002 S811-117002
1 21
1 11
21
1 11 1 21
S811-021002 S811-121002
4 - 34
2) J TYPE CONNECTOR
No. of
pin
1 1
2
2 12
S816-002001 S816-102001
2 3 1
3 1 2
S816-003001 S816-103001
3 1 4 2
4 2 3 1
S816-004001 S816-104001
8 5 2
6 3 1
8 5 2 6 3 1
S816-008001 S816-108001
4 - 35
3) SWP TYPE CONNECTOR
No. of
pin
1 1
S814-001000 S814-101000
2 1
1 2
S814-002000 S814-102000
3 1
2 1 23
S814-003000 S814-103000
2 4
1 3
1 3 2 4
S814-004000 S814-104000
4 - 36
No. of
pin Receptacle connector(Female) Plug connector(Male)
3 6
1 4
1 4 3 6
S814-006000 S814-106000
4 8
1 5
1 5 4 8
S814-008000 S814-108000
4 12
1 9
12
4 12
1 9
S814-012000 S814-112000
3 14
1 11
14
1 11 3 14
S814-014000 S814-114000
4 - 37
4) CN TYPE CONNECTOR
No. of
pin
1 1
S810-001202 S810-101202
2 2
1 1
S810-002202 S810-102202
3 2
1 2 1 3
S810-003202 S810-103202
2 4 1 3
1 3 2 4
S810-004202 S810-104202
4 - 38
No. of
pin
3 6 1 4
1 4 3 6
S810-006202 S810-106202
4 8 1 5
1 5 4 8
S810-008202 S810-108202
4 - 39
5) 375 FASTEN TYPE CONNECTOR
No. of
pin
1 2 1 2
S810-002402 S810-102402
6) AMP ECONOSEAL CONNECTOR

No. of
pin
12
1
1 13
24
36
36 25
13 12
24
25 36
344111-1 344108-1
7) AMP TIMER CONNECTOR

No. of
pin
85202-1
4 - 40
8) AMP 040 MULTILOCK CONNECTOR
No. of
pin
12 1 6
7 12
174045-2
9) AMP 070 MULTILOCK CONNECTOR

No. of
pin
14 1 6
7 14
173852
10) AMP FASTIN - FASTON CONNECTOR

No. of
pin
3 1
6 4
1
4 6 3
480003-9
925276-0
4 - 41
11) KET 090 CONNECTOR
No. of
pin
1
2
MG610070
12) KET 090 WP CONNECTORS

No. of
pin
1
2
MG640605
2 1
MG640795
4 - 42
13) KET SDL CONNECTOR
No. of
pin
14
6
14
MG610406
4 - 43
14) DEUTSCH DT CONNECTORS
DT 06 - 3S -
Modifications(See below)
Number of contacts(P : Pin, S : Socket)
04 : Receptacle, 06 : Plug
Deutsch connetors
Modification
E003 : Standard end cap - gray
E004 : Color of connector to be black
E005 : Combination - E004 & E003
EP04 : End cap
EP06 : Combination P012 & EP04
P012 : Front seal enhancement - connectors color to black for 2, 3, 4 & 6pin
No. of
pin
1 2 2 1
2
DT06-2S DT04-2P
2 1 1 2
3 3
DT06-3S DT04-3P
4 1 1 4
3 2 2 3
DT06-4S DT04-4P
4 - 44
No. of
pin
6 1 1 6
4 3 3 4
DT06-6S DT04-6P
4 5 5 4
1 8 1
8
DT06-8S DT04-8P
6 7 7 6
12
1 12 12 1
DT06-12S DT04-12P
4 - 45
15) MOLEX 2CKTS CONNECTOR
No. of
pin
1 2
35215-0200
35215-0200
16) ITT SWF CONNECTOR

No. of
pin
2
10
1 10
9
SWF593757
17) MWP NMWP CONNECTOR

No. of
pin
1
1
NMWP01F-B
4 - 46
18) ECONOSEAL J TYPE CONNECTORS
No. of
pin
S816-001002 S816-101002
1 2 2 1
S816-002002 S816-102002
S816-003002 S816-103002
S816-004002 S816-104002
4 - 47
No. of
pin
S816-006002 S816-106002
S816-008002 S816-108002
10
S816-010002 S816-110002
12
S816-012002 S816-112002
4 - 48
No. of
pin
15
368301-1 2-85262-1
19) METRI-PACK TYPE CONNECTOR

No. of
pin
12040753
20) DEUTSCH HD30 CONNECTOR

No. of
pin
J K
K J
B
23
N T
A B
F
F Q N
Q A
HD36-24-23SN HD34-24-23PN
4 - 49
21) DEUTSCH DRC CONNECTOR
No. of
pin
5 6
1 1 2 3 4 5 6 7 8 9 10
10
11 11 15 16 20 20
12 25 26 30
31 32 33 34 35 36 37 38 39 40
31 40
35 36
40
DRC18-40SAE
22) DEUTSCH SERVICE TOOL CONNECTOR

No. of
pin
C
D
E
A
9
F
B
G
H J
HD10-9-96P
23) DELPHI CONNECTOR

No. of
pin
3 2
2-967325-3
4 - 50
24) DEUTSCH SERVICE TOOL CONNECTOR
No. of
pin
8
1 16
33
41
9 40
17
64
25
48
24
32
49
57 56
64 15488668
4 - 51
Group 1 Outline - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1

Group 2 Mode Selection System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-3
Group 3 Automatic Deceleration System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-6
Group 4 Power Boost System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-7
Group 5 Travel Speed Control System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-8
Group 6 Automatic Warming Up Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-9
Group 7 Engine Overheat Prevention Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-10
Group 8 Anti-Restart System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-11
Group 9 Self-Diagnostic System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-12
Group 10 Engine Control System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-17
Group 11 EPPR(Electro Proportional Pressure Reducing) Valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-19
Group 12 Monitoring System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-22
Group 13 Fuel warmer System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-33
GROUP 1 OUTLINE
The NEW CAPO(Computer Aided Power Optimization) system controls engine and pump mutual power
at an optimum and less fuel consuming state for the selected work by mode selection, auto-
deceleration, power boost function, etc. It monitors machine conditions, for instance, engine speed,
coolant temperature, hydraulic oil temperature, and hydraulic oil pressure, etc.
It consists of a CPU controller, a cluster, an accel actuator, an EPPR valve, and other components. The
CPU controller and the cluster protect themselves from over-current and high voltage input, and
diagnose malfunctions caused by short or open circuit in electric system, and display error codes on the
cluster.
Engine control system

Pump control system
Mode selection system Work mode selection
User mode system(M, U)
Auto deceleration system
Power boost system
Travel speed control system Travel speed control system
Automatic warming up system
Engine overheat prevention system

NEW CAPO
SYSTEM
Max flow control system
Anti-restart system
Controller & cluster protection
Self-diagnostic system Open-short diagnosis & error code display
ECU Fault code display
Machine condition monitoring
Machine monitoring system
Electric signal monitoring
One touch deceleration system
Arm regeneration system
5-1
SYSTEM DIAGRAM
Travel motor
Regulator
Auto deceleration pressure switch
Main control valve
Extra C
Extra B Bucket Arm regen CO

(Dozer) solenoid valve
Extra A &
Arm 1
Arm regen
Power boost
Boom 2 Arm 2 solenoid valve
Sw/Priority
Swing Boom 1 Travel speed

solenoid valve
Travel(LH) Travel(RH)
Max flow CO
Straight solenoid valve
Travel Main relief
valve
Engine
P1 P2
ECU
Main pump Pilot pump
Max flow
Hyd temp
CO valve
sensor
CAN +
CAN -
GND
EPPR valve
Power boost
button
Horn One touch
decel button
Option
button
RH control LH control Hyd temperature signal

lever lever signal
signal Drive signal
Drive signal
CPU controller Drive signal
Drive signal
Accel dial signal CN-92
Normal
Resistor
Emergency
Normal Emergency
Accel dial
(optional)
Serial Communication(-)
Drive signal
Serial Communication(+)
Prolix
Resistor
Pressure switch signal
Cluster
1607A5MS01
5-2
GROUP 2 MODE SELECTION SYSTEM
1. POWER MODE SELECTION SYSTEM
Main control valve
Engine
ECU
Max flow
CO valve
CAN +
CAN -
GND
EPPR valve
Work mode switch signal
Power mode switch signal CPU controller
User mode switch signal Accel dial signal CN-92

Normal
Emergency
Normal Emergency Accel dial

(optional)
CN-47
Drive signal
Prolix
Resistor
2107A5MS02
Mode selection system(Micro computer based electro-hydraulic pump and engine mutual control
system) optimizes the engine and pump performance.
The combination of 2 power modes(H, S) and accel dial position(10 set) makes it possible to use the
engine and pump power more effectively corresponding to the work conditions from a heavy and
great power requesting work to a light and precise work.
Engine rpm Power shift by EPPR valve

Ver 3.1(STD) Ver 4.1(OPT) Ver 3.1(STD) Ver 4.1(OPT)
Mode Application
Current Pressure Current Pressure
Unload Load Unload Load
(mA) (kgf/cm2) (mA) (kgf/cm2)
M Maximum power 2100 50 2000 2100 50 2000 219 30 4 160 0
H High power 1900 50 1800 2000 50 1900 219 30 10 219 4
S Standard power 1800 50 1700 1900 50 1800 322 30 10 350 12
AUTO DECEL Engine deceleration 1000 100 - 1000 100 - 700 30 35 700 30 35
One touch decel Engine quick deceleration 850 100 - 850 100 - 700 30 35 700 30 35
KEY START Key switch start position 850 100 - 850 100 - 700 30 35 700 30 35
5-3
2. WORK MODE SELECTION SYSTEM
3 work modes can be selected for the optional work speed of the machine operation.
Main control valve
Extra C
Extra B Bucket
(Dozer)
Extra A &
Arm 1 Arm regen CO
Arm regen
solenoid valve
Boom 2 Arm 2
S/Priority
Swing Boom 1 Power boost

solenoid valve
Straight Max flow CO

Main relief solenoid valve
Travel
valve
Engine
ECU
Max flow
CO valve Hyd temp
sensor
CAN +
CAN -
GND
EPPR valve
Hyd temperature signal

Drive signal
CPU controller Drive signal
Drive signal
Accel dial signal CN-92
Normal
Emergency
Normal Emergency Accel dial

(optional)
Serial Communication(-)
Drive signal
Serial Communication(+)
Prolix
Resistor
Cluster
1607A5MS03
1) HEAVY DUTY WORK MODE

Boom and arm operation speed faster than general work mode.
2) GENERAL WORK MODE
When key switch is turned ON, this mode is selected and swing operation speed is faster than
heavy duty work mode.
3) BREAKER OPERATION MODE
It sets the pump flow to the optimal operation of breaker by activating the max flow cut-off solenoid.
Work mode Swing priority solenoid Max flow cut-off solenoid

Heavy duty OFF OFF
General ON OFF
Breaker OFF ON
5-4
3. USER MODE SELECTION SYSTEM
An operator can change the engine and pump power and memorize it for his preference.
Mode Operation
High idle rpm, auto decel rpm

U
EPPR pressure can be modulated and memorized separately
HOW TO MODULATE THE MEMORY SET

1) Each memory mode has a initial set which are
mid-range of max engine speed, auto decel rpm,
ACCEL
and EPPR valve input current.
DECEL
2) High idle rpm, auto decel rpm, EPPR pressure

EPPR
can be modulated and memorized separately in
the U-mode. 2507A4OP08
Refer to the page 5-30 for set of user mode.

LCD segment vs parameter setting
Segment ACCEL DECEL EPPR SYSTEM MENU
( ) (rpm) (rpm) (mA)

1 1650 Low idle(800) 137 Monitoring Diagnosis Management
2 1700 850 192 Settings Display User Mode
3 1750 900 235 User mode icon

4 1800 950 281
5 1850 Decel rpm(1000) 329
6 1900 1050 379 ACCEL
DECEL
7 1950 1100 428
EPPR
8 2000 1150 478

9 2050 1200 528
10 2100 1250 638
2507A4OP05
5-5
GROUP 3 AUTOMATIC DECELERATION SYSTEM
1607A5MS04
1. WHEN AUTO DECEL LAMP ON

If all the work equipment control levers including swing and travel levers are at neutral for at least 4
seconds, CPU controller sends throttle command to ECU to reduce the engine speed to 1000rpm. As
the result of reducing the engine speed, fuel consumption and noise are effectively cut down during
non-operation of the control levers.
When the Auto decel lamp is turned off by pressing the switch or any control lever is operated, the
reduced engine speed rises upto the speed set before deceleration in a second.
Engine rpm
Accel dial set rpm
1000 rpm
Max Max
4sec 1.5sec 1.5sec
Lever Lever Time

neutral operation
2107A5MS05
2. WHEN AUTO DECEL LAMP OFF

The engine speed can be set as desired using the engine speed switch, and even if the control levers
are neutral, the engine speed is not reduced.
ö Auto decel function can be activated when accel dial position is over 4.
5-6
GROUP 4 POWER BOOST SYSTEM
Main control valve
Extra C
Extra B Bucket
(Dozer)
Arm 1 Extra A &

Arm regen
Boom 2 Arm 2
Sw/Priority
Swing Boom 1
Straight
Travel Main relief Power boost
valve solenoid valve
Engine
ECU
Max flow
CO valve
CAN +
-
GND
CAN
EPPR valve
Power boost
button
LH control
lever
Power boost button signal

Drive signal
Mode switch signal Drive signal

CPU controller
1607A5MS06
When the power boost switch on the left control lever knob is pushed ON, the maximum digging
power is increased by 10%.
When the power set is at M, H or S and the power boost function is activated, the power boost
solenoid valve pilot pressure raises the set pressure of the main relief valve to increase the digging
power.
Power boost switch
Description
OFF ON
H or S H
Power set
M M
Main relief valve set pressure 330kgf/cm 2
360kgf/cm2
Time of operation Even when pressed continuously,

- it is canceled after 8 sec.
Default - Power boost solenoid valve : OFF
5-7
GROUP 5 TRAVEL SPEED CONTROL SYSTEM
Travel motor
Main control valve
Extra C
Extra B Bucket
(Dozer) Regulator Regulator
Extra A &
Arm 1
Arm regen
Boom 2 Arm 2
S/Priority
Swing Boom 1
Straight
Travel
Travel spped
solenoid valve
Engine
Max flow
CO valve
EPPR valve
Travel speed switch signal Drive signal

CPU controller
1607A5MS07
Travel speed can be switched manually by pressing the travel speed switch on the cluster.
Travel speed Lamp
Speed Operation
solenoid valve on cluster
Lo OFF Turtle Low speed, high driving torque in the travel motor
Hi ON Rabbit High speed, low driving torque in the travel motor
ö Default : Turtle(Lo)
5-8
GROUP 6 AUTOMATIC WARMING UP FUNCTION
Engine
ECU
Max flow
CO valve
CAN +
-
GND
CAN
EPPR valve
Drive signal
Overheat warning signal
CPU controller
Cluster
1607A5MS09
1. CPU controller receives engine coolant temperature from the ECU, and if the coolant temperature is
less than 30 C, it increases the engine speed from key start rpm to 1000rpm. At this time the mode
does not change.
2. In case of the coolant temperature increases up to 30 C, the engine speed is decreased to key start
speed. And if an operator changes mode set during the warming up function, the CPU controller
cancels the automatic warming up function.
3. LOGIC TABLE
Description Condition Function

- Coolant temperature : S mode)
- Mode : Default(S
Actuated Less than 30 C(After engine run) - Warming up time : 10 minutes(Max)
- Accel dial position is under 3 - Warming up lamp : ON
- Coolant temperature : Above 30 C - Default mode

- Warming up time : Above 10 minutes - Default mode
- Changed mode set by operator - Changed mode
Canceled - Increase engine speed by rotating accel
dial clockwise
If any of the above conditions is
applicable, the automatic warming up
function is canceled
Warming up lamp - Coolant temperature : Above 30 C - Warming up lamp : OFF
5-9
GROUP 7 ENGINE OVERHEAT PREVENTION FUNCTION
Engine
ECU
Max flow
CO valve
CAN +
-
GND
CAN
EPPR valve
Drive signal
Overheat warning signal
CPU controller
Cluster
1607A5MS09
1. CPU controller receives engine coolant temperature from the ECU and when the engine coolant boils
up to 110Á C, it sends overheat warning signal to the cluster and decrease the engine speed same as
accel dial 7 position.
2. If the coolant temperature drops less than 100ÁC, the CPU controller returns the mode to the mode
set before. And if mode set is changed during the function, the CPU controller cancels the function.
Even if the overheat prevention function is canceled by mode change, the overheat warning lamp
turns OFF only when the coolant temperature is less than 100Á C.
3. LOGIC TABLE
Description Condition Function
- Coolant temperature : Above 110Á

C - Engine rpm drop to accel dial 7 position
Actuated
- Accel dial set : Above 8 - Overheat warning lamp & buzzer : ON
- Coolant temperature : Less than 100ÁC - Return to the mode and accel dial set before
- Changed mode set by operator - Hold on the changed set
Canceled ö If any of the above conditions is
applicable, engine overheat prevention
function is canceled
Overheat warning lamp - Coolant temperature : Less than 100Á

C - Overheat warning lamp : OFF
5-10
GROUP 8 ANTI-RESTART SYSTEM
Engine
Starter
Start safety relay
Drive signal
CPU controller
CN-92A
CN-92B
21075MS10
1. ANTI-RESTART FUNCTION
After 10 seconds from the engine starts to run, CPU controller turns off the start safety relay to protect
the starter from inadvertent restarting.
2. When a replacement or taking-off of the CPU controller is needed, connect CN-92A and CN-92B to
ensure the engine start without the CPU controller.
5-11
GROUP 9 SELF-DIAGNOSTIC SYSTEM
1. OUTLINE
When any abnormality occurs in the NEW CAPO system caused by electric parts malfunction and by
open or short circuit, the CPU controller diagnoses the problem and sends the error codes to the
cluster and also stores them in the memory.
2. CURRENT ERROR DISPLAY
(Error display)
(Recorded error delete)
5-12
3. ERROR CODES TABLE
Error code No. Description
1 Short circuit in accel actuator system

2 Potentiometer circuit is shorted to Vcc(5V) or battery +
3 Short circuit in pump EPPR valve system
4 Short circuit in boom down EPPR valve system
5 Short circuit in travel speed solenoid system
6 Short circuit in power boost solenoid system
7 Short circuit in max flow solenoid system
10 Short circuit in hour-meter system
11 Accel dial circuit is shorted to Vcc(5V) or battery +
12 P1 pressure sensor circuit is shorted to power supply(24V) line
13 P2 pressure sensor circuit is shorted to power supply(24V) line
14 P3 pressure sensor circuit is shorted to power supply(24) line
15 Boom down pressure circuit is shorted to power supply(24V) line
16 Accel actuator circuit is open or shorted to ground
17 Potentiometer circuit is open or shorted to ground
18 Pump EPPR valve circuit is open or shorted to ground
19 Boom down EPPR valve circuit is open or shorted to ground
20 Travel speed solenoid circuit is open or shorted to ground
21 Power boost solenoid circuit is open or shorted to ground
22 Max flow solenoid circuit is open or shorted to ground
25 Hour-meter circuit is open or shorted to ground
26 Accel dial circuit is open or shorted to ground
27 P1 pressure sensor circuit is open or shorted to ground
30 Boom down pressure sensor circuit is open or shorted to ground
31 Engine preheater circuit is open or shorted to ground
32 Travel alarm buzzer circuit is open or shorted to ground
33 Alternator circuit is open or shorted to ground
34 Controller input voltage is below 18V
35 Controller input voltage is over 38V
36 Communication error with cluster
37 Engine speed sensor circuit is open or shorted to ground
38 Anti-restart relay circuit is open or shorted to ground
39 Accel actuator does not stop at a target position
40 There is more than 500rpm difference between target speed and actual speed
5-13
Error code No. Description
41 Hydraulic oil temperature sensor circuit is shorted to ground

42 Fuel level sensor circuit is shorted to ground
43 Coolant temperature sensor circuit is shorted to ground
44 Boom up pressure sensor circuit is shorted to power supply(24V) line
45 Hydraulic oil temperature sensor circuit is open or shorted to battery +
46 Fuel level sensor circuit is open or shorted to battery +
47 Coolant temperature sensor circuit is open or shorted to battery +
48 Boom up pressure sensor circuit is open or shorted to ground
49 Engine preheater circuit is shorted to battery +
51 Heavy duty work solenoid circuit is open or shorted to ground
56 Travel alarm buzzer circuit is shorted to battery +
58 Heavy duty work solenoid circuit is shorted to battery +
5-14
4. ENGINE FAULT CODE INFORMATION
SPN FMI Fault code No. Description
91 2 SPN91-FMI2 Throttle Position Sensor Data Erratic, Intermittent, or Incorrect
3 SPN91-FMI3 (Secondary) Throttle Position Sensor Voltage Above Normal or Shorted High
4 SPN91-FMI4 (Secondary) Throttle Position Sensor Voltage Below Normal or Shorted Low
8 SPN91-FMI8 (Secondary) Throttle Position Sensor Abnormal Frequency or Period
12 SPN91-FMI12 (Secondary) Throttle Position Sensor Bad Device or Component
100 1 SPN100-FMI1 Engine Oil pressure Low-Warning
2 SPN100-FMI2 Engine Oil Pressure Low-Derate
3 SPN100-FMI3 Engine Oil Pressure Sensor Voltage Above Normal or Shorted High(Shutdown)
4 SPN100-FMI4 Engine Oil Pressure Sensor Voltage Below Normal or Shorted Low
10 SPN100-FMI10 Engine Oil Pressure Sensor 5V Supply Connection Open Circuit
105 1 SPN105-FMI1 Inlet Manifold Air Temp High-Warning
2 SPN105-FMI2 Inlet Manifold Air Temp High-Derate
3 SPN105-FMI3 Inlet Manifold Air Temp Sensor Voltage Above Normal or Shorted High
4 SPN105-FMI4 Inlet Manifold Air Temp Sensor Voltage Below Normal or Shorted Low
106 3 SPN106-FMI3 Inlet Manifold Pressure Sensor Voltage Above Normal or Shorted High
4 SPN106-FMI4 Inlet Manifold Pressure Sensor Voltage Below Normal or Shorted Low
10 SPN106-FMI10 Inlet Manifold Pressure Sensor 5V Supply Connection Open Circuit
110 1 SPN110-FMI1 Engine Coolant Temp High-Warning
2 SPN110-FMI2 Engine Coolant Temp High-Derate
3 SPN110-FMI3 Engine Coolant Temp Sensor Voltage Above Normal or Shorted High(Shutdown)
4 SPN110-FMI4 Engine Coolant Temp Sensor Voltage Below Normal or Shorted Low
157 3 SPN157-FMI3 Fuel Rail Pressure Sensor Voltage Above Normal or Shorted High
4 SPN157-FMI4 Fuel Rail Pressure Sensor Voltage Below Normal or Shorted Low
158 2 SPN158-FMI2 Keyswitch Data Erratic, Intermittent, or Incorrect
168 0 SPN168-FMI0 ECU Battery Power Excessive
1 SPN168-FMI1 ECU Battery Power Low
2 SPN168-FMI2 ECU Battery Power Intermittent
190 1 SPN190-FMI1 Engine Overspeed - Warning
8 SPN190-FMI8 Speed/Timing Sensor Abnormal Signal Frequency
558 2 SPN558-FMI2 (Secondary) Throttle Position Sensor Idle Validation Switch
630 2 SPN630-FMI2 Customer or System Parameters Data Incorrect
631 2 SPN631-FMI2 Engine Software Data Incorrect
637 11 SPN637-FMI11 Primary to Secondary Engine Speed Signal Calibration Fault
639 9 SPN639-FMI9 SAE J1939 Data Link Abnormal Update
646 5 SPN646-FMI5 Turbo Wastegate Solenoid Current Low
6 SPN646-FMI6 Turbo Wastegate Solenoid Current High
651 5 SPN651-FMI5 Cylinder #1 Injector Current Low
öSPN : Suspect Parameter Number
FMI : Failure Mode Identifier
5-15
SPN FMI Fault code No. Description
651 6 SPN651-FMI6 Cylinder #1 Injector Current High
7 SPN651-FMI7 Cylinder #1 Injector Not Responding
6 SPN652-FMI6 Cylinder #2 Injector Current High
676 5 SPN676-FMI5 Glow Plug Start Aid Relay Current Low
6 SPN676-FMI6 Glow Plug Start Aid Relay Current High
678 3 SPN678-FMI3 ECU 8V DC Supply Voltage Above Normal or Shorted High
4 SPN678-FMI4 ECU 8V DC Supply Voltage Below Normal or Shorted Low
723 8 SPN723-FMI8 Secondary Engine Speed Sensor Abnormal Signal Frequency
1079 3 SPN1079-FMI3 5V Sensor DC Supply Voltage Above Normal or Shorted High
4 SPN1079-FMI4 5V Sensor DC Supply Voltage Below Normal or Shorted Low
1188 7 SPN1188-FMI7 Turbo Wastegate Not Responding
1347 5 SPN1347-FMI5 Fuel Rail Pump Output Current Low
6 SPN1347-FMI6 Fuel Rail Pump Output Current High
7 SPN1347-FMI7 Fuel Rail Pump Output Not Responding
öSPN : Suspect Parameter Number
FMI : Failure Mode Identifier
5-16
GROUP 10 ENGINE CONTROL SYSTEM
1. CPU CONTROLLER AND ECU (Engine control unit)
1
2
3
HYUN
4 DAI
5
TA
-94
CN
20A
SPARE
SPARE
RE
CAB
10A
SPARE
HOLDER
10A 10A 20A

LAMP
10A
SPARE
FUSE
CABIN
LAMP
LAMP SPARE
5A
10A
BEACON
WORK
F/PUMP
& HEATER
10A 10A 20A

LAMP FUEL
KEY AC
5A
20A
HEAD 3
START
5A
MOTOR SOLENOID
20A
LAMP HONE
WIPER 2
5A
-93
BOOM
LIGHT
5A
SOL. SOLENOID
CIGAR
& HEATER
5A
SAFETY 1
5A
AC
10A
PANEL - HEAT SOLENOID
5A
MOTOR PRE
5A
SWITCH
5A
WIPER
RY
5A
CUT-OFF TRAVEL
5A
20A
FUEL
CONVERTOR HONE
PANEL
-2
10A
RY
10A
SWITCH
CLUSTER CR
COMP
AC RY
5A
C/RADIO
-7 ETHER
RY CR
POWER - 36
CR
- 35
CR
CN
RY
SAFETY
-5
CR
1607A5MS11
2. CPU CONTROLLER ASSEMBLY

1) Remove four pieces of bolt(3) of electric box(2).
2) Disconnect 2 connectors from CPU controller.
3) Remove 6 pieces of screw and open the cover of CPU controller.
4) Inspection : Check PCB(Printed Circuit Board)
(1) If any damage is found, replace CPU controller assembly.
(2) If not, but CAPO system does not work please report it to HHI dealer or A/S department.
5-17
3. EXCHANGE METHOD OF THE ROM
1) Disassemble the ash tray(2).
2) Disassemble the wiper motor cover(3).
3) Disassemble the cluster(1).
21075MS12
4) Loosen the screws(6EA) located back of

the cluster.
5) Then you can open the upper case of the
cluster easily.
21075MS13
6) Install the new ROM.(Be careful of direction

and assemble the cluster in the reverse
order to removal).
21075MS14
5-18
GROUP 11 EPPR VALVE
1. COMPOSITION OF EPPR VALVE

EPPR(Electro Proportional Pressure Reducing) valve consists of electro magnet and spool valve
installed at main hydraulic pump.
1) ELECTRO MAGNET VALVE
Receive electric current from CPU controller and move the spool proportionally according to the
specific amount of electric current value.
2) SPOOL VALVE
Is the two way direction control valve for pilot pressure to reduce hydraulic pump flow.
When the electro magnet valve is activated, pilot pressure enters into flow regulator of hydraulic pump.
So, pump flow decreases to prevent engine stall.
3) PRESSURE AND ELECTRIC CURRENT VALUE FOR EACH MODE
Pressure Electric current Engine rpm
Mode
kgf/cm2
psi (mA) (At accel dial 10)
M 4Ü3 57 Ü 40 219 Ü 30 2100 Ü 50

Standard H 10 Ü 3 142 Ü 40 219 Ü 30 2000 Ü 50
(Ver : 3.1)
S 10 Ü 3 142 Ü 40 322 Ü 30 1900 Ü 50
M 0Ü3 0 Ü 40 160 Ü 30 2100 Ü 50
Option
H 4Ü3 57Ü 40 219 Ü 30 2100 Ü 50
(Ver : 4.1)
S 12 Ü 3 170 Ü 40 350 Ü 30 2000 Ü 50
ø 19 Ü 3 275 Ü 40 440 Ü 30 -
ø Manually operated condition when prolix switch is selected emergency position.
2. HOW TO SWITCH THE VERSION(3.1Ĉ 4.1) ON THE CLUSTER

You can switch the EPPR valve pressure set by selecting the version(3.1 Ĉ 4.1).
- Dual mode
ÂChanging the MCU mode
5-19
2. OPERATING PRINCIPLE
1) STRUCTURE
6 7
2 3 4 5
1
5-22(1) 140-7 TIER
1 Sleeve 4 O-ring 6 Solenoid valve

2 Spring 5 O-ring 7 Connector
3 Spool
P Pilot oil supply line(Pilot pressure)

P A
T Return to tank
T
A Secondary pressure to flow regulator at hydraulic pump
2) AT H MODE
Pressure line is blocked and A oil returns to tank.
P A
T P T
3) AT S MODE
Secondary pressure enters into A.
P A
T P T
A
5-22(2) 140-7 TIER
5-20
3. EPPR VALVE CHECK PROCEDURE Spec : 200~550mA
1) CHECK ELECTRIC VALUE AT EPPR
VALVE CN-75
Multimeter
(1) Start engine.
(2) Set S-mode and cancel auto decel mode.
(3) Position the accel dial at 10. EPPR valve
(4) If tachometer show approx 1800Ü50rpm,
disconnect one wire harness from EPPR
valve.
Main pump
(5) Install multimeter as figure.
(6) Check electric current at bucket circuit
relief position.
2107A5MS12
2) CHECK PRESSURE AT EPPR VALVE

Spec : 2~25kgf/cm2(30~350psi)
(1) Remove plug and connect pressure
gauge as figure. Pressure adjusting
screw locknut
ÂGauge capacity : 0 to 40-50kgf/cm2 Pilot pressure
CN-75
supply line
(0 to 580-725psi)
(2) Start engine.
(3) Set S-mode and cancel auto decel mode.
(4) Position the accel dial at 10. EPPR valve
(5) If tachometer show approx 1800Ü50rpm,

check pressure at relief position of bucket Main pump
circuit by operating bucket control lever.

(6) If pressure is not correct, adjust it.
(7) After adjust, test the machine. 2107A5MS13
5-21
GROUP 12 MONITORING SYSTEM
1. OUTLINE
Monitoring system consists of the monitor part and switch part.
The monitor part gives warnings when any abnormality occurs in the machine and informs the
condition of the machine.
Various select switches are built into the monitor panel, which act as the control portion of the machine
control system.
2. CLUSTER
1) MONITOR PANEL
RPM display
Clock display
Fuel gauge
Hyd oil temp gauge
Engine coolant temp gauge
CPU controller
Air cleaner warning lamp check warning lamp
Power max pilot lamp
Engine oil pressure warning lamp Preheat pilot lamp
Battery charging warning lamp Warming up pilot lamp
Overload warning lamp

Decel pilot lamp
Engine check warning lamp
Work mode switch
Power mode switch
Travel speed switch

User mode switch
Buzzer stop switch

Auto deceleration switch Select switch
2507A5MS10
5-22
2) CLUSTER CHECK PROCEDURE
(1) Start key : ON
① Check monitor initial 5 seconds
a. All lamps light up.
b. Buzzer sound.
Check monitor after 5 seconds : Indicate cluster version and machine condition
a. Cluster program version : 1.00 Indicates program version 1.00 for 5 seconds.
b. Tachometer : 0rpm
c. Fuel gauge : All light up below appropriate level
d. Hydraulic oil temperature gauge : All light up below appropriate level
e. Engine coolant temperature gauge : All light up below appropriate level
f. Warning lamp
During start key ON the engine oil pressure lamp and battery charging lamp go on, but it is not
abnormal.
When engine coolant temperature below 30 C, the warming up lamp lights up.
Indicating lamp state
a. Work mode selection : General work
b. Power mode selection : S mode
c. User mode selection : No LED ON
d. Auto decel LED : ON
e. Travel speed pilot lamp : Low(Turttle)
(2) Start of engine
① Check machine condition
a. Tachometer indicates at present rpm
b. Gauge and warning lamp : Indicate at present condition.
When normal condition : All warning lamp OFF
c. Work mode selection : General work
d. Power mode selection : S mode
e. User mode selection : No LED ON
f. Auto decel LED : ON
g. Travel speed pilot lamp : Low(Turttle)
When warming up operation
a. Warming up lamp : ON
b. 10 seconds after engine started, engine speed increases to1000rpm(Auto decel LED : ON)
Others same as above ①
When abnormal condition
a. The lamp lights up and the buzzer sounds.
b. If BUZZER STOP switch is pressed, buzzer sound is canceled but the lamp light up until
normal condition.
5-23
3. CLUSTER CONNECTOR
No. Signal Input / Output
1 Power IG(24V) Input(20~32V)

Cluster
2 GND Input(0V)
3 Serial-(RX) Input(Vpp=12V)
4 Serial+(TX) Output(Vpp=4V)
1 4
2 3
21075MS16
5-24
2) LCD main operation display
Default screen
Default screen Option screen
Option screen 1 Time display
2 2
1 1 2 RPM display
4
4
5
3 Hydraulic oil temperature gauge
3 3
5 4 Fuel level gauge
1607A3CD02A 1607A3CD02B 5 Engine coolant temperature gauge
(1) Time display
① This displays the current time.
Refer to the page 5-29 to set time for details.
1607A3CD02C
(2) RPM display

① This displays the engine rpm.
1607A3CD02C
(3) Hydraulic oil temperature gauge

12th step
① This gauge indicates the temperature of hydraulic oil in 12 step
gauge.
1st step : Below 30 C(86 F)
2nd~10th step : 30-105 C(86-221 F)
1st step 11th~12th step : Above 105 C(221 F)
1607A3CD02D
The gauge between 2nd and 10th steps illuminates when
operating.
Keep idling engine at low speed until the gauge between 2nd
and 10th steps illuminates, before operation of machine.
When the gauge of 11th and 12th steps illuminates, reduce the
load on the system. If the gauge stays in the 11th~12th steps,
stop the machine and check the cause of the problem.
(4) Fuel level gauge
1st step ① This gauge indicates the amount of fuel in the fuel tank.
Fill the fuel when the 1st step or fuel icon blinks in red.
If the gauge illuminates the 1st step or fuel icon blinks in
red even though the machine is on the normal condition,
check the electric device as that can be caused by the poor
1607A3CD02E
connection of electricity or sensor.
(5) Engine coolant temperature gauge
12th step
① This gauge indicates the temperature of coolant in 12 step
gauge.
1st step : Below 30 C(86 F)
2nd~10th step : 30-105 C(86-221 F)
1st step
11th~12th step : Above 105 C(221 F)
1607A3CD02F
The gauge between 2nd and 10th steps illuminates when
operating.
Keep idling engine at low speed until the gauge between 2nd
and 10th steps illuminates, before operation of machine.
When the gauge of 11th and 12th steps illuminates, turn OFF
the engine, check the radiator and engine.
5-25
3) Warning of main operation screen
(1) Warning display
① Engine coolant temperature
- This lamp blinks and the buzzer sounds
when the temperature of coolant is over
the normal temperature 105 C 221 F) .
- Check the cooling system when the lamp
blinks.
Fuel level
when the level of fuel is below 38
(10.0U.S. gal).
- Fill the fuel immediately when the lamp
blinks.
Hydraulic oil temperature
- This warning lamp operates and the
buzzer sounds when the temperature of
hydraulic oil is over 105 C 221 F) .
- Check the hydraulic oil level when the
lamp blinks.
- Check for debris between oil cooler and
radiator.
All gauge
when the all gauge is abnormal.
- Check the each system when the lamp
blinks.
Communication error
- Communication problem between CPU
controller and cluster makes the lamp
blinks and the buzzer sounds.
- Check if any fuse for CPU burnt off.
If not check the communication line
between them.
(2) Pop-up icon display
No Switch Selected mode Display No Switch Selected mode Display
1 Work mode General work 3 Auto
Light ON
switch mode deceleration
switch
Heavy duty
Light OFF
work mode
Breaker 4 Travel speed

Low speed
operation mode control
2 Power mode High power

switch High speed
work mode
Standard power
work mode
5-26
4) LCD
SYSTEM MENU
1 : LCD
Monitoring Diagnosis Management
1 : Escape,
Settings Display User Mode 2
Return to the previous menu
3 : Down/Left Direction
4 : Up/Right Direction
2 5 : Select(Enter)
4 Activate the currently chosen item
3 5
2507A4OP95B
(1) Main menu
1 2 3 4
1 : Menu information
: Monitoring
2 Equipment, Switch, Output
: Diagnosis
3 Current error, Recorded error
5 6 7 4 : Maintenance
2507A4OP94
: Settings
5 Time set Dual mode
System lock(Reserved)
: Display
6
Operation skin, Brightness, Language
7 : User mode
5-27
(2) Display map
① Monitoring
Diagnosis
a. Protocol type 1
(Error display)
(Recorded error delete)
5-28
b. Protocol type 2
- If there are more than 2 error codes, each one can be displayed by pressing or
switch respectively.
- 3 error codes (①SPN200200, FMI06, SPN6789, FMI04, 345) display.
① No change
Maintenance
Setting
a. Time set
: Adjusting
: Setting
b. System lock - Reserved
5-29
c. Dual mode
- Changing the MCU mode
Display
a. Operation skin
b. Brightness
c. Language
User mode
Usermode(U) is not selected.
: Adjusting : Adjusting : Adjusting

: Setting : Setting : Setting
5- 30
5) Warning and pilot lamp
(1) Engine oil pressure warning lamp
① This lamp blinks and the buzzer sounds after starting the
engine because of the low oil pressure.
If the lamp blinks during engine operation, shut OFF engine
immediately. Check oil level.
21073CD07
(2) Air cleaner warning lamp

① This lamp blinks and the buzzer sounds when the filter of air
cleaner is clogged.
Check the filter and clean or replace it.
21073CD08
(3) CPU controller check warning lamp

① If any fault code is received from CPU controller, this lamp
blinks and the buzzer sounds.
Check the communication line between CPU controller and
cluster.
21073CD10
(4) Battery charging warning lamp

① This lamp blinks and the buzzer sounds when the starting
switch is ON, it is turned OFF after starting the engine.
Check the battery charging circuit when this lamp blinks during
engine operation.
21073CD13
(5) Overload warning lamp

① When the machine is overload, the overload warning lamp
blinks during the overload switch is ON.
21073CD15
5- 31
(6) Engine check warning lamp
① This lamp blinks and the buzzer sounds when the
communication between CPU controller and ECU on the
engine is abnormal, or if any fault code received from ECU.
Check the communication line between them.
If the communication line is OK, then check the fault code on
29073CD10 the cluster
(7) Power max pilot lamp

① The lamp will be ON when pushing power max switch on the
LH RCV lever.
21073CD11
(8) Decel pilot lamp

① Operating auto decel or one touch decel makes the lamp ON.
The lamp will be ON when pushing one touch decel switch on
the LH RCV lever.
21073CD17
(9) Warming up pilot lamp

① This lamp is turned ON when the coolant temperature is below
30 C 86 F).
The automatic warming up is cancelled when the engine
coolant temperature is above 30 C, or when 10 minutes have
passed since starting.
21073CD18
(10) Preheat pilot lamp

① Turning the start key switch ON position starts preheating in
cold weather.
Start the engine as this lamp is OFF.
21073CD12
5-32
CN-8 CR-45
1 18E W
30
93A Or 87a 87 85
ECU
2 86
3 2 V
87
G45 B
4 85
POWER RY
30 86
5 87a
6
5
ST C
CS-2 6
18 W
CR-35
6
minutes.
7 30
5 8 93 R 87a 87 85
3 86
2
BR ACC
1 4 103 3L
9
mechanism.
87
temperature.
2. OPERATION
R 22 R 125 G42 B
3) Current : 15A
H
4 3 10 85
POWER RY
30 86
0, I
2 11 87a
W 24 W 18A
START KEY SW
1 12
1. SPECIFICATION
H 0 I
2) Power : 350Ü50W
CN-36
3. ELECTRIC CIRCUIT
CN-50 18 W START KEY 30A
1
BOOM PRIORITY SOL 1 ROOM LAMP 10A
2
MAX FLOW SOL 2
AC& HEATER 30A
POWER MAX SOL 3 3
1) Operating voltage : 24Ü4V
HOUR-METER 4 54 2L ECU 30A

4
5R
103
ENG PREHEATER 5 WIPER+ 10A
5
FUEL WARMER 6
CPU B+ 10A
3L
56 Gr
105
BATTERY 24V(+) 7 6
CLUSTER 10A
reduce the current as low as 1.5A.

PUMP EPPR(-) 8 7
NC 9 CASSETTE RADIO 10A
8
PROGRAM DUMP 10 CONVERTOR 10A
ANTI-RESTART RY 11 9
SWITCH PANEL 10A
ACCEL ACT(+) 12 10
TRAVEL SPEED SOL 13 CPU 10A
11
T/M OIL LAMP 14
ECU 5A V 2
BRAKE FAIL LAMP 15 12
30A
GROUP 13 FUEL WARMER SYSTEM
41 G FUEL WARMER
RW
RW
RW
RW
TRAVEL BUZZER 16 13
PRE-HEAT SW 17 START, ALT 20A
14
7
8
1
2
3
9
5-33
15
16
10
42
34
40
NC 18
So, fuel is protected from overheating by this

warmer and engine may be started in 1~2
controlled without thermostat according to fuel
warmer heater senses the fuel temperature to

3) If the fuel starts to flow, ceramic-disk in the fuel
2) At the first state, the 15A current flows to the fuel
1) The current of fuel warmer system is automatically
WIPER MOTOR 10A
ECU
PARKING SW 15
CN-93
19
HEAD LAMP 20A
OVERLOAD SIG 20 16
ENG.OIL FILTER SW 21 WORK LAMP 20A
CPU CONTROLLER
17
NC 22 20A
CABIN LAMP
ACCEL ACT(-) 23 18
10A
Accel Dial(gnd)
Battery Power -
Battery Power -
Battery Power -
BEACON LAMP
Battery Power -
Battery Power -
POWER IG 24 19
Battery Power B+
Battery Power B+
Battery Power B+
Battery Power B+
CAN_H 25 AC& HEATER 20A

Key switch ON signal
20
5W
CAN_L 26 HORN 10A
CAN_SHIELD 27
21
104
CIGAR LIGHTER 20A
GND (MAIN) 28 22
SERIAL-TX 29 PRE-HEAT 10A
23
SERIAL-RX 30 TRAVEL 10A
GND 24
31
SOLENOID 1 10A
RS232 (+) 32 25
CR-1
RS232 (-) 33 SAFETY SOL 10A
26
RS232 (GND) 34 SOLENOID 3 10A
BATT RY
NC
27
35
FUEL FILLER P/P 30A
PUMP EPPR(+) 36 28
FUSE BOX
CR-46
CS-74
60R
86 30 87a
GW 58 5R
85 2
1
2
1
2
2G 44 5R
87
1
CS-74
GW 90A
CN-60
CN-95
86
85 87 87a GW 90
Prefilter
30
MASTER SW
(12VX2)
5R
5R
FUSIBLE LINK
BATTERY
74
5W 115
5W 104
CN-96
116
2L 117
60B
Fuel warmer
1
2B G11
2
3
2507A5MS12
1607A5MS14
FUEL WARMER RY FUEL WARMER
Group 1 Before Troubleshooting 6-1

Group 2 Hydraulic and Mechanical System 6-4
Group 3 Electrical System 6-24
Group 4 Mechatronics System 6-40
GROUP 1 BEFORE TROUBLESHOOTING
1. INTRODUCTION
When a trouble is occurred in the machine, this section will help an operator to maintain the machine
with easy.
The trouble of machine is parted Hydraulic & Mechanical system, Electrical system and Mechatronics
system. At each system part, an operator can check the machine according to the troubleshooting
process diagram.
Hydraulic &
GROUP 2
Mechanical part
Electrical part GROUP 3
Troubles occur
Mechatronics
GROUP 4
part
2 digit See page

(Machine) 5-13
Fault codes
displayed on
monitor display
10~12 digit See page
(Engine) 5-15
6-1
2. DIAGNOSING PROCEDURE
To carry out troubleshooting efficiently, the following steps must be observed.
STEP 1. Study the machine system

Study and know how the machine is operating,
how the system is composing, what kinds of
function are installed in the machine and what
are specifications of the system components by
the machine service manual.
Especially, deepen the knowledge for the related
parts of the trouble.
13031SH02
STEP 2. Ask the operator

Before inspecting, get the full story of
malfunctions from a witness --- the operator.
1) How the machine is used and when it is
serviced?
2) When the trouble was noticed and what
work the machine was doing at that time?
3) What is the phenomenon of the trouble?
Was the trouble getting worse, or did it
come out suddenly for the first time?
4) Did the machine have any troubles
previously? If so, which parts were repaired
13031SH03
before.
STEP 3. Inspect the machine

Before starting troubleshooting, check the
machine for the daily maintenance points as
shown in the operator's manual.
And also check the electrical system including
batteries, as the troubles in the electrical system ON THE
INSPECTION
such as low battery voltage, loose connections
and blown out fuses will result in malfunction of
6-2(3) 140-7
the controllers causing total operational failures
of the machine.
6-2
STEP 4. Inspect the trouble actually on the
machine
In case that some trouble cannot be confirmed,
obtain the details of the malfunction from the
operator.
Also, check if there are any in complete
connections of the wire harnesses are or not.
6-3(1) 140-7
STEP 5. Perform troubleshooting

According to where the trouble parts are
located, hydraulic & mechanical system part or
electrical system part or mechatronics system
part, perform troubleshooting the machine refer
to the each system part's troubleshooting
process diagram.
13031SH05
STEP 6. Trace a cause

Before reaching a conclusion, check the most
suspectible causes again. Try to trace what the
real cause of the trouble is.
Make a plan of the appropriate repairing

procedure to avoid consequential malfunctions.
6-3(3) 140-7
6-3
GROUP 2 HYDRAULIC AND MECHANICAL SYSTEM
1. INTRODUCTION
1) MACHINE IN GENERAL
(1) If even a minor fault is left intact and operation is continued, a fatal failure may be caused, entailing
a large sum of expenses and long hours of restoration.
Therefore when even a small trouble occurs, do not rely on your intuition and experience, but look
for the cause based on the troubleshooting principle and perform maintenance and adjustment to
prevent major failure from occurring. Keep in mind that a fault results from a combination of
different causes.
(2) The following lists up commonly occurring faults and possible causes with this machine. For the
troubleshooting of the engine, refer to the coming troubleshooting and repair.
(3) When carrying out troubleshooting, do not hurry to disassemble the components.
It will become impossible to find the cause of the problem.
(4) Ask user or operator the following.
Η Was there any strange thing about machine before failure occurred?
Θ Under what conditions did the failure occur?
Ι Have any repairs been carried out before the failure?
(5) Check before troubleshooting.
Η Check oil and fuel level.
Θ Check for any external leakage of oil from components.
Ι Check for loose or damage of wiring and connections.
6-4
2. DRIVE SYSTEM
1) UNUSUAL NOISE COMES OUT OF PUMP CONNECTION
Cause Remedy
YES
Coupling element Disassemble
is broken. and repair.
Remove dust plug
under engine
flywheel and
YES
check if rubber Replace hub or
pieces or particles retighten
are not present. Coupling hub setscrew.
spline is worn or
NO hub fastening
setscrew is slack.
If hydraulic pump or engine is
suspected as a culprit refer to this
NO
manual "Structure and function".
6-5
2) ENGINE STARTS BUT MACHINE DOES NOT OPERATE AT ALL
Cause Remedy
NO
Replenish
specified oil to
the standard
Is oil level in Abnormal noise level.
hydraulic oil YES comes out of YES
Hydraulic pump is Disassemble
tank within hydraulic pump
standard level? broken. and repair.
Do not hydraulic Abnormal noise
pump and pump YES comes out of YES
connections pump See item 1).
YES make abnormal
connection at page 6-5
noise?
Is primary pilot
pressure within ͽ
NO standard level?
YES
Clean pilot
Is not pilot piping piping interior or
YES clogged or is not
oil leakage present repair piping.
on pilot piping?
NO
Pilot valve is Disassemble
ͽ faulty. and repair.
YES
Pilot relief valve is Repair or
Is gear pump faulty. replace.
NO delivering oil?
NO Gear pump is Disassemble

broken. and repair.
6-6
3. HYDRAULIC SYSTEM
1) HYDRAULIC OIL IS CLOUDY
Cause Remedy
YES
Water is mixed. Put hydraulic oil
still, separate
Drop hydraulic oil water and
sample on hot dispose it or
plate and check if replace hydraulic
foams come up. oil.
NO Air is intruded. Check suction

line and return
line and eliminate
the air intruding
source.
2) HYDRAULIC OIL TEMPERATURE HAS RISEN ABNORMALLY
Cause Remedy
NO
Replenish
specified oil to
the standard
Is hydraulic oil level.
volume proper? YES
Clean oil cooler.
Is not oil cooler Secure air
clogged and is circulation route.
YES anything blocking YES
ͽ
air circulation?
Is fan belt
NO tension proper?
Adjust belt
NO
tension or
replace belt.
Is not the set YES
pressure of main Readjust set
relief, relief and pressure.
ͽ
travel relief valve Is main relief
lower than the YES
valve used very Reduce load.
standard level? NO often?
6-7
3) CAVITATION OCCURS WITH PUMP
Cause Remedy
NO
Replenish
specified oil to
the standard
Is hydraulic oil level.
volume proper? YES
Replace oil with
one of proper
Is not viscosity viscosity.
of hydraulic oil
YES YES
too high? Clean suction
Is not suction strainer.
NO strainer clogged? Is not air intruding
from pump Check for air
NO
suction line? intrusion in
suction line and
retighten or
replace parts.
4) HYDRAULIC OIL IS CONTAMINATED
Cause Remedy
YES
Replace
Has not hydraulic hydraulic oil to be
oil passed specified.
specified replace-
ment hours? Has return filter
NO
been replaced at Flush with
NO proper intervals?
hydraulic oil and
replace return
filter.
6-8
4. SWING SYSTEM
1) BOTH LH AND RH SWING ACTIONS ARE IMPOSSIBLE
Cause Remedy
NO
Replenish
YES specified oil to the
Is safety solenoid ͽ
YES
valve pressure standard level.
Is gear pump pilot within standard? Safety valve faulty Repair or replace.
NO
pressure within or not operated.
YES standard level?
Is oil in hydraulic
YES tank within
Gear pump faulty. Repair or replace.
standard level? NO
YES
Are broken pieces Pump connection Disassemble and
of coupling present coupling is broken. repair.
ͽ when dust plug
under engine fly
Are attachment Is not main relief NO Hydraulic pump is Disassemble and
wheel is removed? NO
and travel valve faulty?
out of order. repair.
motions
impossible at all? NO Swing control valve Disassemble and
Does swing
YES control valve spool is stuck. repair.
spool move
Is MCV pilot
YES
pressure within
lightly by hand? YES ;
standard level?
Does RH travel NO
Ϳ
NO function?
Does not symptom
change when front YES
Hydraulic pump is Disassemble and
NO and rear pump
discharge hoses broken. repair.
are exchanged?
YES
Swing brake Disassemble and
release valve is repair.
Is swing brake broken.
; release valve
faulty? YES Swing reduction Disassemble and
Does swing unit is broken. repair.
NO motor rotate?
Swing motor is Disassemble and
NO
broken. repair.
YES Pilot relief valve is Disassemble and

NO Is gear pump faulty. repair or replace.
delivering oil?
Gear pump is out Disassemble and
Is gear pump pilot NO
of order. repair.
Ϳ pressure within
standard level? YES
Is not there oil Clean pilot piping
leakage from interior or repair
YES pilot piping or is piping.
not it clogged? Pilot valve is Disassemble and
NO
broken. repair.
6-9
2) SWING SPEED IS LOW
Cause Remedy
YES
Swing port relief Disassemble and
YES
Does swing control valve is faulty. repair or replace.
valve spool move
smoothly by hand?
Swing control valve Disassemble
Is MCV pilot NO
spool is stuck. and repair.
pressure same
on LH and RH YES Clogged or oil
sides? Clean pilot piping
leak. interior or repair
Is not pilot piping
Single direction clogged or is not piping.
NO it leaking oil?
Is the trouble in Pilot valve or shuttle Disassemble
one direction or NO
valve is faulty. and repair.
in both direction? ͽ
Does swing
YES control valve
Both directions spool move
Is MCV pilot lightly by hand?
YES Swing control valve Disassemble
pressure within
Is Arm speed spool is stuck. and repair.
standard level?
within standard ;
value? NO
Ϳ
NO
Is swing motor's NO
ͽ drain rate within Swing motor is Disassemble
standard value? Check that pilot broken. and repair.
piping is not
YES clogged or oil is NO
Pilot valve or Disassemble
not leaking from shuttle valve is and repair.
it? faulty.
Clogged or oil leak. Clean pilot piping
Is gear pump pilot interior or repair
; pressure within piping.
standard level?
YES
Pilot relief valve Disassemble and
Is gear pump is defective. repair or replace.
NO delivering oil?
Gear pump is Disassemble
broken. and repair.
NO
Main relief valve Main relief valve
faulty. pressure resetting
or repair.
Is main relief valve Does the symptom YES Hydraulic pump Disassemble
Ϳ setting pressure change when front
YES
and rear pump is broken. and repair.
normal?
discharge hoses
Is safety valve are exchanged? Shuttle valve is Repair or replace.
pilot pressure faulty.
YES within standard
level? YES
Is gear pump Pilot relief valve Repair or replace.
output pressure is faulty.
NO within standard
level? Gear pump is Repair or replace.
NO
faulty.
6-10
3) SWING MOTION IS IMPOSSIBLE IN ONE DIRECTION
Cause Remedy
Does symptom YES
Swing port relief Disassemble and
change when LH
YES and RH port relief valve is faulty. repair.
valves are
exchanged Shuttle valve is Disassemble and
Does swing control NO
YES faulty. repair.
valve spool move
smoothly by hand?
Is MCV pilot NO Swing control valve Disassemble and

pressure same spool is stuck. repair.
for LH and RH?
Check if pilot YES
Pilot valve is faulty. Disassemble and
piping is not repair.
clogged or does
NO
not have oil Clogged or oil
leakage. leak. Clean pilot piping
interior or repair
piping.
4) MACHINE SWINGS BUT DOES NOT STOP
Cause Remedy
YES Pilot relief valve is Disassemble and
Is MCV pilot faulty. repair or replace.
YES YES Is gear pump pilot
pressure within pressure within
standard value? standard level?
Gear pump is Disassemble and
NO
broken. repair.
YES Does swing control
valve spool move
smoothly by hand? Pilot valve is faulty. Disassemble and
NO
repair.
Is swing control
valve's return
spring normal? Swing control Disassemble and
NO
valve spool is repair.
stuck.
Return spring is Disassemble and
NO
faulty. replace.
6-11
5) THE SWING UNIT DRIFTS WHEN THE MACHINE IS AT REST ON A SLOPE
Cause Remedy
YES
ͽ
YES Is swing shuttle
valve normal?
Shuttle valve is Disassemble
NO
faulty. and replace.
YES Is brake spring
normal?
Is return spring
of swing control Brake spring is Disassemble
NO
valve normal? faulty. and replace.
NO Return spring of Disassemble

swing control and replace.
valve is faulty.
YES
Is drain rate of Swing relief valve Disassemble
YES swing motor is faulty. and repair or
within standard replace.
Is swing relief value? Disassemble
NO Swing motor is
ͽ pressure within broken. and repair.
standard level?
NO Adjust swing
relief valve
pressure or
replace swing
relief valve.
6-12
5. TRAVEL SYSTEM
1) TRAVEL DOES NOT FUNCTION AT ALL ON ONE SIDE
Cause Remedy
YES
Does counterbalance ͽ
YES spool in travel
brake valve move
lightly by hand?
Is travel brake Counter spool in Disassemble
NO
YES valve pressure travel brake valve and repair or
within standard is stuck. replace.
level? Does the symptom
change when
relief valves in YES
Relief valve built Disassemble
Has travel NO travel motor are
YES control valve exchanged? in travel motor is and repair.
spool changed faulty.
over positively?
YES
Control system is Disassemble
defective. inspect and
Does spool move repair.
NO lightly by hand?
NO Travel control Disassemble

valve spool is and repair.
stuck.
Is bucket or arm
operation YES Disassemble
Travel reduction
possible? Do not metallic
particles come unit is faulty. and repair.
ͽ out of drain port
in travel
reduction unit? Travel motor is Disassemble
NO
out of order. and repair.
Does the symptom
NO
change when front YES
and rear pump Hydraulic pump is Disassemble
Does the discharge hoses
symptom change broken. and repair.
are exchanged?
when LH/RH
NO travel relief valves
are exchanged?
YES Travel relief Disassemble
valves are faulty. and repair or
replace.
6-13
2) SPEED ON ONE SIDE FALLS AND THE MACHINE CURVES
Cause Remedy
YES
Brake valve is Disassemble
Do LH and RH
travel speeds defective. and repair or
YES change when LH replace.
and RH travel YES
Does the symptom Relief valve built Disassemble
brake valves are change when in travel motor is and repair.
exchanged? relief valves in
faulty.
NO LH and RH
Has control valve travel motors are
YES
spool changed exchanged? ͽ
over positively? NO
YES
Control system is Disassemble,
Does spool move faulty . inspect and
lightly when it is
repair.
Is the lower NO cut off from
speed(Bucket or control spool?
arm) within Control valve Disassemble
NO
standard level? spool is stuck. and repair.
YES
Travel relief valve Disassemble
Do LH and RH is faulty. and repair or
travel speeds Does the symptom replace.
change over when change when
NO travel relief valves YES front and rear YES
pump discharge Hydraulic pump is Disassemble
are exchanged?
Is external pilot hoses are broken. and repair.
pressure within exchanged?
NO
standard level?
External pilot Disassemble
NO
piping is clogged and clean.
or oil is leaking
Does travel speed from it.
change when
YES parking brake YES
spring in the Travel motor's Disassemble
slower travel parking brake is and clean pilot
Is leak rate of motor is removed? not released piping.
ͽ travel motor within
standard level? properly.
Travel motor is Disassemble

NO
faulty. and repair.
6-14
3) MACHINE DOES NOT STOP ON A SLOPE
Machine is pulled forward as sprocket rotates during digging operation.
Cause Remedy
None Is parking brake YES
friction plate Friction plate is Disassemble
YES Check if parking worn? faulty. and repair.
brake pilot line is
not clogged.
Clogged Disassemble
and clean pilot
Is drain rate of piping.
Is travel brake YES travel motor NO
pressure within Travel motor is Disassemble
within standard
standard level? defective. and repair.
value?
Brake valve is Disassemble

NO
faulty. and repair or
replace.
4) LH AND RH TRAVEL MOTIONS ARE IMPOSSIBLE
Cause Remedy
YES
Inspect according
to the procedure
"Travel does not
function at all on
one side."
However, a case
where both LH
and RH travel
motions are
Is bucket or arm disabled is
operation extremelyseldom
possible? statistically.
OK
Disassemble both faulty. repair.
OK travel relief valves
Remove dust and inspect for
plug under engine any fault.
OK flywheel and Travel relief valve Disassemble and
check that there is Faulty
is faulty. repair or replace.
no coupling
element particles.
Check oil volume Particles present. Coupling at pump Disassemble and
in hydraulic oil connection is repair.
NO tank.
broken.
Replenish
Short hydraulic oil.
6-15
5) TRAVEL ACTION IS POWERLESS(Travel only)
Cause Remedy
YES
ͽ
Is travel motor's
YES
drain rate within
standard level?
Is travel brake Travel motor is Disassemble
YES pressure within NO
faulty. and repair.
standard level?
Is travel relief
valve pressure Travel brake Disassemble
NO
within standard valve is defective. and repair or
level?
replace.
NO Travel relief valve Disassemble
is faulty. and repair or
replace.
YES
Hydraulic circuit Disassemble
Does parking that releases and clean.
brake piston travel parking
Increases move lightly by
Remove parking brake is clogged
brake spring in hand?
with dirt.
travel motor,
Disassemble
ͽ draw out piston NO Parking brake
completely, refit piston in travel and repair.
cover and check motor is stuck.
if travel power
changes. Remains
unchanged Travel reduction Disassemble
unit is defective. and repair.
6) MACHINE RUNS RECKLESSLY ON A SLOPE
Cause Remedy
Travel brake valve
(counterbalance Disassemble
valve) is faulty. and repair or
replace.
6-16
7) MACHINE MAKES A CURVED TRAVEL OR DOES NOT TRAVEL AT ALL WHEN TRAVEL
AND ATTACHMENT OPERATIONS ARE EXECUTED AT THE SAME TIME
Cause Remedy
YES
Normal.
YES Is select valve

normal?
Select valve is Repair or

Is pilot pressure NO
for travel select faulty. replace.
valve within
standard level? YES
Remove dirt on
Is filter in pilot pilot line filter.
piping between
gear pump and YES Is pilot relief NO
NO control valve not Pilot relief valve is Disassemble
valve normal?
clogged? defective. and repair or
Is gear pump
replace.
NO delivering oil?

NO
broken. and repair.
6-17
6. ATTACHMENT SYSTEM
1) BOOM OR ARM ACTION IS IMPOSSIBLE AT ALL
Cause Remedy
YES
Does the Port relief valve is Disassemble
symptom change faulty. and repair or
YES
when port relief
replace.
valve is replaced
Is MCV pilot with other valve? NO ͽ
YES
pressure within
standard level?
Inspect if pilot
piping is not
OK
clogged or oil is Pilot valve is Disassemble
Are other NO
YES
not leaking from faulty. and repair.
attachments the piping.
operatable?
Pilot relief valve is Disassemble

Is gear pump pilot YES
Is gear pump faulty. and repair or
pressure within
NO delivering oil? replace.
standard level?
NO
broken. and repair.
Are LH/RH travel
operations OK
possible? Hydraulic pump is Disassemble
Disassemble broken. and repair.
YES main relief valve
Remove dust plug and check if it is
under engine not irregular.
OK flywheel and Faulty
Main relief valve Disassemble
check if coupling is defective. and repair or
element particles replace.
Inspect oil are not present. Particles present Coupling at pump Disassemble
NO
volume in
hydraulic oil tank. connection is and repair.
broken.
Short Replenish
hydraulic oil.
YES
Cylinder interior is Disassemble
Does control
broken. and repair.
ͽ valve spool move
lightly by hand?
NO Control valve Disassemble
6-18
2) BOOM, ARM OR BUCKET SPEED IS LOW
Cause Remedy
YES
Normal.
YES
Are other ͽ
YES attachment
Is combination speeds within
Is speed low only of oil streams standard levels? NO ;
in composite YES
normal at boom YES
operation? hoisting and at Flow summation Disassemble and
Does spool of flow
arm extrusion? summation check check valve spool repair.
NO valve move lightly is stuck.
Are LH/RH travel
by hand?
NO speeds within NO
standard levels?
YES
Are both LH/RH faulty. repair.
travel speeds YES Ϳ
NO
low? Is MCV pilot
pressure within
NO
standard? ΀
NO
OK
Does the Port relief valve is Disassemble and
symptom change faulty. repair or replace.
YES
when port relief
valve is replaced
Does control with other valve? Cylinder is faulty. Disassemble and
YES NO
valve spool move repair.
lightly by hand?
NO
Control valve spool Disassemble and
Is MCV pilot
ͽ pressure within is stuck. repair.
standard level?
YES
Clean pilot piping
Is not MCV pilot
pressure piping interior or repair
NO clogged or is not piping.
there oil leakage? Pilot valve is Disassemble and
NO
defective. repair.
YES
Pilot relief valve is Disassemble and
Is primary pilot NO Is gear pump faulty. repair or replace.
; pressure within
delivering oil?
standard level?
NO
Gear pump is Disassemble and
broken. repair.
Is engine NO
Ϳ revolution within Adjust engine
standard level? revolution.
YES
Clean orifice in
control valve.
Is not orifice in
΀ control valve YES
clogged? Is pilot piping not Clean pilot piping
clogged or is oil interior or repair
NO not leaking from piping.
the piping? Is pilot valve
Pilot valve is faulty. Disassemble and
NO normal? NO
repair.
6-19
3) BOOM, ARM OR BUCKET CYLINDER EXTENDS OR CONTRACTS ITSELF AND
ATTACHMENT FALLS
Cause Remedy
YES
Port relief valve is Disassemble
Does the symptom faulty. and repair or
change when port
Normal replace.
relief valve is YES
replaced with ͽ
normal valve? Is control valve
return spring
YES
Is not hydraulic NO
normal?
oil temperature Control valve's Disassemble
high? NO
return spring is and replace.
faulty.
Is genuine Abnormally high. Locate the cause
hydraulic oil or of hydraulic oil
equivalent being
temperature rise
used?
and lower it to
proper level.
Replace with
NO
genuine
hydraulic oil or
equivalent.
OK
Pressure Disassemble
Disassemble and tightness and repair.
YES inspect check between control
valve in hydraulic
circuit and check valve casing and
for any fault. spool is poor.
Is cylinder internal Abnormal Contact surface Disassemble
ͽ leakage within between poppet and repair.
standard level?
and seat is poor.
Cylinder is faulty. Disassemble

NO
and repair.
6-20
4) BOOM, ARM OR BUCKET POWER IS WEAK
Cause Remedy
YES
Check according
Is cylinder to the procedure
YES internal leakage in Item "Speed is
within standard low".
level?
Is relief pressure
YES in port relief Cylinder is faulty. Disassemble
valve within NO
and repair.
standard level?
Is relief pressure
in main relief Port relief valve is Adjust pressure,
valve within NO
faulty. repair or replace.
standard level?
Main relief valve Adjust pressure,

NO
is defective. repair or replace.
5) ONLY BUCKET OPERATION IS TOTALLY IMPOSSIBLE
Cause Remedy
YES
Port relief valve is Disassemble
Does the
symptom change defective. and repair or
YES
when port relief replace.
YES
valve is replaced Does control Cylinder interior is Disassemble
with other valve? valve spool broken. and repair.
Is MCV pilot NO move smoothly
pressure within by hand?
NO
Control valve Disassemble
standard level?
NO Pilot valve is Disassemble

faulty. and repair.
6-21
6) BOOM MAKES A SQUEAKING NOISE WHEN BOOM IS OPERATED
Cause Remedy
YES
Frictional noise
occurs between
the sliding faces
of boom
cylinder's oil
Is boom foot pin seal and boom
greased proper.
sufficiently?
ö Frictional
noise will
disappear if
they are kept
used.
Boom foot pin Supply grease

NO
has run out of to it.
grease. ö
If seizure is in
an initial stage,
supply sufficient
grease.
If seizure is in
a grown state,
correct it by
paper lapping
or with an oil
stone.
6-22
ö HOW TO CHECK INTERNAL BOOM CYLINDER LEAKAGE
1. Lower the bucket teeth to the ground with
bucket cylinder fully retracted and arm
cylinder rod retracted almost in full.
14076BY01
2. Disconnect hose(A) from rod side of boom

cylinder and drain oil from cylinders and
hose.(Put cups on piping and hose ends)
A
6-20(2) 140-7
3. Raise bucket OFF the ground by retracting

the arm cylinder rod.
If oil leaks from piping side and boom

cylinder rod is retracted there is an internal
leak in the cylinder.
If no oil leaks from piping side and boom
cylinder rod is retracted, there is an internal
leak in the control valve.
14076BY02
6-23
GROUP 3 ELECTRICAL SYSTEM
1. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT
APPEAR
Before disconnecting the connector, always turn the starting switch OFF.
Before carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No.7.
After checking, insert the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
Defective cluster Replace
YES Check voltage
between CN-56
(1) and chassis Disconnection in Repair or
NO
wiring harness or replace
Check voltage
between CN-5(3) poor contact (After clean)
and chassis between CN-5(3)-
CN-56(1)
Starting switch : ON
Voltage : 20~32V
NO Disconnection in Repair or
wiring harness or replace
poor contact (After clean)
between CN-5(3)-
and fuse No.7
CLUSTER FUSE
POWER IG(24V) 1 3
NO.7
GND 2 9
RX
TX
CN-56 CN-5
Check voltage 1607A6ES04
YES 20 ~ 30V
NO 0V
6-24
2. COMMUNICATION ERROR FLASHES ON THE CLUSTER
Before carrying out below procedure, check all the related connectors are properly inserted.
Cause Remedy
YES
Defective controller Replace
YES Check voltage

between CN-56
(3,4) and chassis
Disconnection in Repair or replace
NO wiring harness or (After clean)
Check voltage
between CN-5 poor contact
between CN-56
(10,11)and (3,4)-CN-5(10,11)
chassis
KEY ON
NO
wiring harness or (After clean)
poor contact
between CN-5
(10,11)-CN-50
(29,30)
Check voltage CONTROLLER

YES *4V *12V 29
NO 0V 0V
30
CN-50
CLUSTER
POWER IG(24V)
GND 2 9
RX *12V 3 10
TX *4V 4 11
CN-56 CN-5
2107A6ES02
6-25
3. BATTERY CHARGING WARNING LAMP LIGHTS UP(Starting switch : ON)
Cause Remedy
YES
YES Check voltage
between CN-51
(9) and chassis Disconnection in Repair or replace
NO
Check voltage wiring harness or (After clean)
YES poor contact
between CN-
2(3) and chassis between CN-51(9)
-CN2(3)
Check voltage Disconnection in Repair or replace

NO wiring harness or (After clean)
between alternator
poor contact
terminal "I" and between
chassis CN-2(3)-alternator
Voltage : 20~32V terminal "I"
Engine : Running
Defective alternator Replace

NO
Check voltage
YES 20 ~ 32V
NO 0V
CONTROLLER ALTERNATOR
B+
U
9 3 ~
3
1 I
2 R G
CN-74
CN-51 CN-2
1607A6ES01
6-26
4. WHEN COOLANT OVERHEAT WARNING LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
Is the CAN poor contact
YES communication between
between CPU ECU-coolant temp
and ECU OK?
sensor
Starting switch : ON YES
Check resistance Defective controller Replace
Does the gauge
light up and between CN-98 or ECU
down at lamp NO (A-B) & CN-99
check? (A-B).
Defective wiring Replace
NO
Starting switch : ON Spec : 120 harness
NO Defective cluster Replace
12th step Check Table

Range 1st step 2nd~10th step 11th~12th step
Temperature ~29 C 30~105 C 105 C ~
1 st step
RESISTOR RESISTOR
A A A A
ECU
ECU
B B
B C B C
CN-98 CN-99
CONTROLLER
25 20
26 21
CN-50 CN-93
1607A6ES03
6-27
5. WHEN AIR CLEANER WARNING LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
Clogged air filter or Check filter or
defective switch replace switch
Does display go
off when
disconnect CD-
10? YES
Short circuit in Repair or replace
Engine : Start Check resistance wiring harness (After clean)
between CN-51
NO
(16) and chassis
Starting switch : OFF Defective controller Replace
NO
Disconnect CN-51
Check resistance
YES MAX 1
NO MIN 1M
CONTROLLER AIR CLEANER SWITCH
Pa
16
CD-10
CN-51
2907A6ES07
6-28
6. WHEN ENGINE OIL PRESSURE WARNING LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
between CPU ECU-engine oil
and ECU OK?
pressure switch.
Starting switch : ON YES
Does the gauge Check resistance
light up and between or ECU
down at lamp NO CN-98 (A-B) &
check? CN-99 (A-B) Defective wiring Replace
NO
Starting switch : ON Spec : 120 harness
NO Defective cluster Replace
Check resistance
YES MAX 1
NO MIN 1M
RESISTOR RESISTOR
A A A A
ECU
B B
B C B C
CN-98 CN-99
CONTROLLER
25 20
26 21
CN-50 CN-93
1607A6ES03
6-29
7. WHEN HYDRAULIC OIL TEMPERATURE WARNING LAMP LIGHTS UP(Engine is
started)
Cause Remedy
YES
High temperature Check hydraulic
Resistance oil temperature
YES between CD-1
(1,2) is in range (100 C 2 C ) ,
of 130~150 ? Replace
Starting switch : ON Defective torque Replace
Does display go NO
Disconnect CD-1 sensor
off when
disconnect CD-1? YES
Short circuit Check and repair
Starting switch : ON Resistance
Engine : Start between CN-51
NO (31,34) is 0~1 ?
Starting switch : OFF NO Defective controller Replace

Disconnect CN-51
CONTROLLER HYDRAULIC OIL

TEMPERATURE SENDER
34 2
C
31 1
CN-51 CD-1
R29076ES04
6-30
8. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE
Cause Remedy
YES
between CPU
ECU-coolant temp
and ECU OK?
sensor
YES
Check resistance Defective controller Replace
Does the gauge
light up and between CN-98 or ECU
down at lamp NO (A-B) & CN-99
check? (A-B).
NO
Defective wiring Replace
Starting switch : ON Spec : 120
harness
NO
12th step
Check Table
Range 1st step 2nd~10th step 11th~12th step
Temperature ~29 C 30~105 C 105 C ~
1 st step
RESISTOR RESISTOR
A A A A
ECU
B B
B C B C
CN-98 CN-99
CONTROLLER
25 20
26 21
CN-50 CN-93
1607A6ES03
6-31
9. WHEN FUEL GAUGE DOES NOT OPERATE
Cause Remedy
YES
Disconnection in Check and repair
wiring harness
Is resistance
YES between CN-51
(24) and (31)
over 1k ?
Starting switch : OFF YES
Disconnect CN-51 Defective controller Replace
Does the gauge
light up and Check resistance
down at lamp NO
between CD-2(1)
check? and (2)
Defective fuel Replace
Disconnect CD-2
NO
Starting switch : ON sensor
See Table

NO
2nd~10th step
Check Table
1 st step 11th~12th
step Range 1st step 2nd~10th step 11th~12th step
Item
Unit Resistance( ) 700~601 600~101 ~100
Tolerance(%) 5 5 5
CONTROLLER FUEL SENDER
24 2
CD-2
31
CN-51
1607A6ES06
6-32
10. WHEN SAFETY SOLENOID DOES NOT OPERATE
short of fuse No. 26.
Cause Remedy
YES
Hydraulic system Check hydraulic
YES Check operation malfunction system
of solenoid
Defective solenoid Replace
NO
Safety lever : ON-OFF
YES
YES Check voltage

between CS-4
Check voltage (C) and chassis
between CN-68 Disconnect in Repair or replace
(1) - CN-68(2) Check voltage Starting switch : ON NO
YES between CN-4(8) Voltage : 20~30V wiring harness or (After clean)
Starting switch : ON and chassis Disconnect CN-4 poor contact
Voltage : 20~30V between
Safety state Starting switch : ON CN-4(8)-CS-4(C)
Voltage : 20~30V
Disconnect CN-4
Check voltage Disconnect in Repair or replace
between CN-68 NO
NO (1) with chassis
poor contact
Safety lever : OFF between
Starting switch : ON CN-4(8)-CN-68(1)
Voltage : 20~30V
NO Disconnection in Replace
fuse
YES
Defective switch Repair or replace
Check voltage
between CS-20 (CS-20)
and chassis
NO
Defective switch Repair or replace
Starting switch : ON (CS-4)
Voltage : 20~30V
SAFETY SW
FUSE
CS-20
NO.26
EARTH 1
SAFETY SWITCH
B C A 6 SAFETY SOLENOID
B 7 2
A C 8 1
CS-4 CN-68
CN-4
2107A6ES04
6-33
11. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE
short of fuse No.24 .
Cause Remedy
YES
Defective hydraulic Check hydraulic
system system
YES Check voltage YES Check operation
between CN-50 YES
of solenoid Defective controller Replace
(13) and chassis
Check resistance
Check if travel Starting switch : ON Starting switch : ON between CN-70
Voltage : 20~30V : OFF NO
speed lamps( , (1) and (2)
Disconnect CN-50 : ON
) change when Defective solenoid Replace
Starting switch : OFF NO
pressing the travel
speed switch on SPEC : 15~25
Disconnect CN-70
the cluster YES
Check controller
Y R G
NO
NO
CONTROLLER
TRAVEL SOLENOID
13 1
CN-50 CN-70
FUSE
NO.24
45076ES03
6-34
12. WHEN ENGINE DOES NOT START
CN-8
CS-2
II I O H
1
I,O
9
Cause Remedy 2
4
H
YES 10 3
Defective battery Check engine
ACC BR
4 1
B
11 2
system charge or 5 3
replace(After 12
6
C ST
checking specific 5
6
gravity of battery)
ECU POWER RY START SWITCH
Check operation YES
Check voltage Defective magnet Replace 30 30 86
of start motor YES between starter of start motor 86
magnet coil and 87
Starting switch : START chassis Defective start relay Replace 85
NO
Starting switch : START 87a 87a 87 85
YES
SPEC : 20~30V CR-45
Check operation Check voltage
YES
of start relay CR- between CR-5 POWER RY
NO
23 (30) and chassis 30 30 86
Defective start Repair or replace
Starting switch : START anti-restart relay (After clean) 86
Check operation Starting switch :START
87
of start anti- SPEC : 20~30V CS-74
BATTERY RY
1
85 2 2
NO restart relay 87a 87a 87 85 1
CR-5 CN-60
CR-1
CR-35
YES
Check voltage Defective relay Replace FUSE
between CR-5
NO (86) and chassis Disconnection in Repair or replace NO.1
NO
wiring harness or (After clean) DO-2 DO-1
Starting switch : ON poor contact
Voltage : 20~30V between CR-5(86)
1
2
2
CS-2(5)
YES
Defective start relay Replace
Check voltage CN-51
between CR-23
9
and chassis
NO
Starting switch : ON wiring harness or (After clean) CPU CONTROLLER
poor contact CN-92
between CR-5(87)- 11
CR-23
CN-50
ANTI-RESTART RY
START RY STARTER
86 30 30
86
M M
1
87 2
85
85 87 87a CR-23 B+
87a
CN-45
CR-5 CN-2
1607A6ES12
6-35
13. WHEN STARTING SWITCH ON DOES NOT OPERATE
master switch ON
After checking, insert the disconnected connectors again immediately unless otherwise specified. CN-8
CS-2
II I O H
1
I,O
9
2
4
H
10 3
Cause Remedy
ACC BR
4 1
B
11 2
3
YES 5
Disconnection in Repair or replace 12
6
C ST
wiring harness or (After clean) 5
6
poor contact
YES Check voltage ECU POWER RY START SWITCH
between DO-2 between DO-2(1)-
30 30 86
(1) and chassis CR-1 or defective
86
Voltage : 20~30V
battery relay 87
85
YES Check voltage Disconnection in Replace 87a 87a 87 85
between CS-2 NO
wiring harness or CR-45
(2) and chassis POWER RY
poor contact
30 30 86
Voltage : 20~30V between CS-2(2)-
Check voltage Starting switch : ON 86
YES CN-8(11)- DO-2(1)
between CS-2(1) 87 CS-74
BATTERY RY
1
and chassis 85 2 2
Defective start Replace 87a 87a 87 85 1 CN-60
CR-1
Voltage : 20~30V NO CR-35
switch
FUSE
Check voltage Disconnection in Replace
and specific NO NO.1
gravity of battery wiring harness or
DO-2
poor contact
Specific gravity : MIN 1.28
Voltage : MIN 24V between CS-2(1)-
1
2
CN-8(12)-CN-60-
CR-1-Battery
Battery capacity too Charge or replace
NO
low (After clean)
CPU CONTROLLER
11
CN-50
ANTI-RESTART RY
START RY STARTER
86 30 30
86 1
M M
87 2
85
85 87 87a CR-23 B+
87a
CN-45
CR-5 CN-2
1607A6ES13
6 - 36
14. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE
Before carrying out below procedure, check all the related connectors are properly inserted and the fuse
No.5, 10 and 15 is not blown out. CN-21
After checking, insert the disconnected connectors again immediately unless otherwise specified. 3 1
2
5 3
Cause Remedy 4
NO 4
Defective wiper Replace 5
CN-5
cut switch 6 M 2 6
NO 1
Disconnection in Repair or replace FUSE
Check operation wiring harness or (After clean) WIPER MOTOR
4
wiper cut switch poor contact NO.5
CN-141
between CN-141 CN-6
FEED BACK 1 FUSE
Front sliding door Check voltage (11)- CS-53
open-close MOTOR DRIVE SIG 2 CN-17 5
between CN-141 YES
3 6 NO.15
YES (11) and chassis Defective switch Replace MOTOR DRIVE- 1
CN-22
panel MOTOR DRIVE+ 4 2 9
NO Check voltage 2 M
Front sliding door-close between CN-116 GND 5 3 10
Voltage : 4~5V (6) and chassis VCC 6 4 11 1
Check operation 1)Recheck fuse Replace CONTINUE 24V 7 5
NO No.10 WASHER PUMP
YES of switch panel
Voltage : 20~30V WASHER P/P 8 6
LED ON. 2)Disconnection in Repair or replace
WASHER SIG. 9 7
Starting switch : ON INT. SIG 10 8
Push wiper switch button YES
poor contact
between CN- WIPER CUT SW 11
116(6)-Fuse N.C 12 CN-7
between CN- FEED BACK 13 3 FUSE
116(13)-Chassis WIPER MOTOR CONTROLLER 5
NO 9 NO.10
Check voltage between Defective switch Replace
CN-116(4) and chassis 10
panel WIPER CUT SW
Intermittent
NO
1) Recheck fuse Replace
Check voltage CN-116 No.5 CS-53 CN-9
(12) and chassis 2) Disconnection Repair or replace
Washing
Check operation in wiring harness (After clean)
of wiper motor or poor contact
CN-116 4
Check voltage CN-116 and controller between CN-
(15) and chassis check voltage HEAD LIGHT OUT 1
YES CN-141(7) and 141(7)-Fuse, WORK LIGHT OUT 2
Starting switch : ON CN-21(4)-Fuse WORK LIGHT OUT 3
Voltage : 0~1V
chassis, CN-21(4)
NO WIPER MOTOR DRIVE 4
and chassis 1) Recheck fuse Replace PRE-HEAT 5
Starting switch : OFF No.15 POWER 24V 6
Voltage : 20~30V Check voltage
2) Disconnection Repair or replace CABIN LIGHT OUT 7
CN-141(6)-and CABIN LIGHT OUT 8
YES chassis CN-141(6)-Fuse (After clean)
HEAD LIHGT 24V 9
WORK LIGHT 24V 10
Starting switch : ON YES WORK LIGHT 24V 11
Check continuity Voltage : 20~30V
NO WASHER SIG 12
between Disconnection in Repair or replace GND 13
CN-141(2)-CN-116(4), wiring harness or (After clean) TRAVEL ALARM 14
CN-141(9)-CN-116(12), poor contact INT. SIG 15
CN-141(10)-CN-116(15), CABIN LIGHT 24V 16
NO
CN-141(5)-Chassis , Check wiper Defective wiper Replace CABIN LIGHT 24V 17
CN-141(1)-CN-21(5), motor resistance motor SWITCH PANEL
CN-141(3)-CN-21(6),
YES between CN-21
CN-141(4)-CN-21(2), (2)-CN-21(6) Defective wiper Replace
CN-141(13)-CN-21(3) YES motor controller
Resistance : 3~4
2107A6ES14
6-37
15. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP
short of fuse No.16.
HEAD LAMP
1
2
Cause Remedy
NO CL-4
Defective lamp Replace switch
switch
HEAD LAMP RY
30 30 86
86
Check voltage 87
YES
between CN-116 YES 85
(1) and chassis Defective bulb Replace 87a 87a 87 85
YES
Check voltage
between CL-4(2) CR-13
Head lamp switch : ON and chassis
Voltage : 20~30V Disconnection in Repair or replace
Starting switch : ON NO
Head lamp switch : ON wiring harness or (After clean) CN-7
Check voltage CN-116
between CN-7(1)
Voltage : 20~30V poor contact
1 1 HEAD LIGHT OUT
YES and chassis between CN-7(1)- 2 WORK LIGHT OUT
CL-4(2) 3 WORK LIGHT OUT
Starting switch : ON 4 WIPER MOTOR DRIVE
Head lamp switch : ON 5 PRE-HEAT
Check voltage Voltage : 20~30V Disconnection in Repair or replace 6 POWER 24V
NO 7
between CN-116 wiring harness or (After clean) 7 CABIN LIGHT OUT
(9) and chassis 8 CABIN LIGHT OUT
poor contact 9 HEAD LIHGT 24V
Starting switch : ON between 10 10 WORK LIGHT 24V
Head lamp switch : 11 WORK LIGHT 24V
ON-OFF
CN-116(1)-CN- 12 WASHER SIG
7(1) 13 GND
14 TRAVEL ALARM
YES 15 INT. SIG
Disconnection in Repair or replace 16 CABIN LIGHT 24V
17 CABIN LIGHT 24V
SWITCH PANEL
Check voltage poor contact
between CN- between CN-116
NO 7(7) and chassis (9)-CN-7(7)
Head lamp switch : ON FUSE
Recheck fuse Replace NO.16
NO
2107A6ES06
6-38
16. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP
short of fuse No.17.
Cause Remedy WORK LAMP
NO
Defective lamp Replace switch 1
switch 2
CL-5
Check voltage CN-12 WORK LAMP
YES between CN-116
YES 2 1
and (2, 3) and Defective bulb Replace
chassis 1 2
Check voltage
YES
Starting switch : ON between CL-5(2) CL-6
Work lamp switch : ON and chassis
Voltage : 20~30V Disconnection in Repair or replace
Starting switch : ON NO
Work lamp switch : ON wiring harness or (After clean)
Check voltage Voltage : 20~30V poor contact CN-7
between CN-7(2) CN-116
YES and chassis between CN-7(2)
1 HEAD LIGHT OUT
-CL-5(2) and 2 2 WORK LIGHT OUT
Starting switch : ON 3 WORK LIGHT OUT
Work lamp switch : ON
CL-6 (2)
Check voltage 4 WIPER MOTOR DRIVE
Voltage : 20~30V 5 PRE-HEAT
between CN-116
(10,11) and Disconnection in Repair or replace 6 POWER 24V
NO 8 7 CABIN LIGHT OUT
chassis wiring harness or (After clean) 8 CABIN LIGHT OUT
Starting switch : ON poor contact 9 HEAD LIHGT 24V
Work lamp switch : 10 10 WORK LIGHT 24V
ON-OFF
between CN-116
11 WORK LIGHT 24V
Voltage : 20~30V (2,3)-CN-7(2) 12 WASHER SIG
13 GND
14 TRAVEL ALARM
YES 15 INT. SIG
Disconnection in Repair or replace 16 CABIN LIGHT 24V
17 CABIN LIGHT 24V
SWITCH PANEL
Check voltage poor contact
between CN-7(8) between CN-116
NO and chassis
(10,11)-CN-7(8)
Head lamp switch : ON FUSE
Voltage : 20~30V
NO Recheck fuse Replace NO.17
No.17
36076ES09
6-39
GROUP 4 MECHATRONICS SYSTEM
1. ALL ACTUATORS SPEED ARE SLOW

Boom, Arm, Bucket, Swing and travel speed are slow, but engine speed is good.
Spec : M-mode 2100 50rpm H-mode 1900 50rpm S-mode 1800 50rpm
1) INSPECTION PROCEDURE
Cause Remedy
YES
Defective
YES Check pressure hydraulic system
at EPPR valve
NO
Check electric NO Defective Replace
SPEC : 5~20kgf/cm2
current at EPPR See TEST 3
EPPR valve
Check if Er : 03 valve
current error display SPEC : 200~550mA Defective CPU Replace
on the LCD See TEST 2 NO
controller
YES
Short circuit or Check & repair
poor connection wire harness or
Check resistance between CN-50 - between CN-50-
YES at EPPR valve CN-75 CN-75
SPEC : 45~50 (20 C) Defective EPPR Replace

See TEST 1 NO
valve
Wiring diagram
RESISTOR
FUSE
1
NO.11(CPU)
2
CN-47
CONTROLLER
8 2
24 EMERGENCY
1
28
CN-19B
EPPR VALVE
36 2 2
CN-50 1 1
CN-19A CN-19 CN-75

NORMAL 1607A6MS01
6-40
2) TEST PROCEDURE
SPEC : 45~50 (20 C)
(1) Test 1 : Check resistance at connector
CN-75. CN-75
① Starting key OFF.

Multimeter
Disconnect connector CN-75 from EPPR
valve at main hydraulic pump.
Check resistance between 2 lines as
figure.
EPPR valve
Main pump
2107A5MS15
(2) Test 2 : Check electric current at EPPR SPEC : 200~550mA(S mode)

valve.
CN-75
① Install multimeter as figure.
Multimeter
Start engine.
Set the accel dial at "10"(MAX)
Set S-mode and cancel auto decel mode.
If tachometer show approx 1800 50rpm, EPPR valve
check electric current.
Main pump
2107A5MS12
(3) Test 3 : Check pressure at EPPR valve. SPEC : 5~20kgf/cm2 (70~280psi)

① Remove plug and connect pressure
Pressure adjusting
gauge as figure. screw locknut
Pilot pressure
Gauge capacity : 0 to 40~50kgf/cm2 supply line CN-75
(0 to 570~710psi)
Start engine.
Set the accel dial at "10"(Max).
Set S-mode and cancel auto decel mode.
If tachometer show approx 1800 50rpm, EPPR valve
check pressure.
If pressure is not correct, adjust it. Main pump
After adjust, test the machine.
2107A5MS13
6-41
2. ENGINE STALL
Cause Remedy
YES
Not enough engine Contact cummins
YES Check pressure power engine dealer
at EPPR valve
Defective EPPR Replace
SPEC:5~20kgf/cm2 NO
See TEST 5
valve
Check electric
current at EPPR
valve YES
Short circuit or Check and repair
SPEC : 200~550mA
See TEST 4 poor connection wire harness
Check resistance
between between
NO at EPPR valve CN-50 - CN-75
SPEC : 45~50 (20 C)
See TEST 1 NO
Defective EPPR Replace
valve
Wiring diagram
RESISTOR
FUSE
1
NO.11(CPU)
2
CN-47
CONTROLLER
8 2
24 EMERGENCY
1
28
CN-19B
EPPR VALVE
36 2 2
CN-50 1 1
CN-19A CN-19 CN-75

NORMAL
1607A6MS01
6-42
2) TEST PROCEDURE SPEC : 200~550mA CN-75
(1) Test 4 : Check electric current at EPPR Multimeter
valve at S-mode
① Install multimeter as figure.
Start engine.
EPPR valve
Set the accel dial at "10"(max)
Set S-mode with 1800 50rpm.
Check electric current.
Main pump
2107A5MS12
(2) Test 5 : Check pressure at EPPR valve at SPEC : 5~20kgf/cm2(70~280psi) Pressure adjusting
S-mode screw locknut
Pilot pressure
① Connect pressure gauge at EPPR valve. supply line CN-75
Start engine.
Set the accel dial at "10"(max)
Set S-mode with 1800 50rpm.
Operate bucket lever completely push or
EPPR valve
pull.
Hold arm lever at the end of stroke.
Check pressure at relief position. Main pump
2107A5MS13
6-43
3. MALFUNCTION OF CLUSTER OR MODE SELECTION SYSTEM
Cause Remedy
YES
No power supply to Check fuse
See if all lamps the CPU controller
YES
off in the CPU
controller case YES
Y R G CPU failure Replace
See if Y R G
current error display NO
on the LCD
NO Y R G
NO
OK
Check connection Cluster failure Replace
between CN-50
(29) - CN-5(10) or
CN-50(30) - CN-
5(11) No connection Check and repair
NO
KEY OFF
Wiring diagram
CPU CONTROLLER
CLUSTER
24
POWER IG(24V)
GND 28
RX 3 10 29
TX 4 11 30
CN-56 CN-5 CN-50
FUSE
NO.11(CPU)
36076MS02
6-44
4. AUTO DECEL SYSTEM DOES NOT WORK
Cause Remedy
YES
Defective CPU Replace
controller
NO
Check resistance Short circuit or Replace or repair
between CN-51 poor connection
(1)-GND and between CN-
CN-51(13)-GND
51(1)- pressure
SPEC : switches
Actuator operating :
0~1V
Actuator stop : 4~5V Defective auto Replace
See TEST 6 NO
decel pressure
switch
Wiring diagram
CONTROLLER
AUTO DECEL PRESSURE SWITCH
1 Pa
1 2
CD-7
CN-51
1607A6MS10
6-45
2) TEST PROCEDURE SPEC : Actuator stop : 4~5V
(1) Test 6 : Check voltage at CN-51(1) and Actuator operating : 0~1V
ground.
① Prepare 1 piece of thin sharp pin, steel or Y R G
copper.
CPU
Starting key ON. CONTROLLER
Insert prepared pin to rear side of PIN
connectors : One pin to (1) of CN-51. CN-50 CN-51

Check voltage as figure.
CN-51 12 1
24
36 25
Ground
Multimeter
1607A6MS11
6-46
5. MALFUNCTION OF WARMING UP
Cause Remedy
YES
Defective cluster or Repair or Replace
Check resistance CPU controller or
YES
between CN-50 ECU
(26) - CN -93(21)
SPEC : Below 10 NO Poor connection Repair
Check resistance KEY OFF
between CN-
between CN -50
(25) - CN -93(20) 50(26) - CN -93(21)
SPEC : Below 10
KEY OFF Poor connection Repair
NO
between CN-
50(25) - CN -93(20)
Wiring diagram
RESISTOR RESISTOR
A A A A
ECU
ECU
B B
B C B C
CN-98 CN-99
CONTROLLER
25 20
26 21
CN-50 CN-93
1607A6ES03
6-47
6. MALFUNCTION OF POWER MAX
Cause Remedy
YES Check resistance
between CN-88 Defective power Repair or replace
Resistance (1) - (2) max. solenoid valve
YES
between CN-51 SPEC: 15-30
(2)-GND normal? See TEST 8
NO Short circuit or poor Repair or replace

SPEC : Power max button pressed ON : 0 connection
Is voltage between Power max button released OFF : between CN-51(2) -
CN-88(2) -GND See TEST 9
normal? CS-29 and CN-50
(3) -CN-88(1)
SPEC
KEY ON : 24 1V
KEY OFF : 0V
See TEST 8
NO Short circuit or poor Repair or replace
connection
between CN-88(2)-
battery relay(+)
Wiring diagram
CPU CONTROLLER
POWER MAX SOLENOID

3 1
2
CN-50
CN-88
1
2 2
FUSE
CN-51 CN-4 NO.25
POWER MAX SWITCH
2
CS-29
50076MS04
6-48
2) TEST PROCEDURE SPEC : Key ON : 24 1V
Key OFF : 0V
(1) Test 8: Check voltage between connector Resistance : 15~30
CN-88 - GND.
① Start key ON.
Disconnect connector CN-88 from power
Power max switch
max solenoid valve.
Check voltage as figure.
LH RCV-lever CN-88
CN-88
Power max.
solenoid valve
Multimeter
2107A5MS16
(2) Test 9 : Check resistance between

connector CN-51(2)-GND. SPEC : Power max button pressed ON : 0
Power max button released OFF :
① Starting key OFF.
Remove CPU controller and disconnect Y R G
connector CN-51 from CPU controller. CPU

Check resistance as figure. CONTROLLER
CN-51
CN-50
CN-51
12 2
24 13
36 25
Ground
Multimeter
R29076MS15
6-49
Group 1 Operational Performance Test 7-1

Group 2 Major Components 7-21
Group 3 Track and Work Equipment 7-31
GROUP 1 OPERATIONAL PERFORMANCE TEST
1. PURPOSE
Performance tests are used to check:
1) OPERATIONAL PERFORMANCE OF A
NEW MACHINE
Whenever a new machine is delivered in
parts and reassembled at a customer's site,
it must be tested to confirm that the
operational performance of the machine
meets Hyundai spec.
WORKING MACHINE
With the passage of time, the machine's
operational performance deteriorates, so
that the machine needs to be serviced
periodically to restore it to its original
performance level.
Before servicing the machine, conduct
performance tests to check the extent of
deterioration, and to decide what kind of 140LC7MS01
service needs to be done(by referring to the
"Service Limits" in this manual).
REPAIRED MACHINE
After the machine is repaired or serviced, it
must be tested to confirm that its operational
performance was restored by the repair
and/or service work done.
7-1
2. TERMINOLOGY
1) STANDARD
Specifications applied to the brand-new
machine, components and parts.
140LC7MS02
2) SERVICE LIMIT
The lowest acceptable performance level.
When the performance level of the machine
falls below this level, the machine must be
removed from work and repaired.
Necessary parts and components must be
replaced.
140LC7MS03
7-2
3. OPERATION FOR PERFORMANCE
TESTS
1) Observe the following rules in order to carry
out performance tests accurately and
safely.
(1) The machine
Repair any defects and damage found,
such as oil or water leaks, loose bolts,
cracks and so on, before starting to test.
(2) Test area
① Select a hard, flat surface.
Secure enough space to allow the
machine to run straight more than 20m,
and to make a full swing with the front
attachment extended.
If required, rope off the test area and
provide signboards to keep unauthorized
personnel away.
(3) Precautions
① Before starting to test, agree upon the
signals to be employed for communication
7-3 (140-7 TIER)
among coworkers. Once the test is
started, be sure to communicate with
each other using these signals, and to
follow them without fail.
Operate the machine carefully and
always give first priority to safety.
While testing, always take care to avoid
accidents due to landslides or contact
with high voltage power lines. Always
confirm that there is sufficient space for
full swings.
Avoid polluting the machine and the
ground with leaking oil. Use oil pans to
catch escaping oil. Pay special attention
to this when removing hydraulic pipings.
(4) Make precise measurements
① Accurately calibrate test instruments in
advance to obtain correct data.
Carry out tests under the exact test
conditions prescribed for each test item.
Repeat the same test and confirm that
the test data obtained can be procured
repeatedly. Use mean values of
measurements if necessary.
7-3
2) ENGINE SPEED
(1) Measure the engine speed at each power
mode
The engine speed at each power mode
must meet standard RPM; if not, all other
operational performance data will be
unreliable. It is essential to perform this
test first.
(2) Preparation
① Warm up the machine, until the engine
coolant temperature reaches 50 C or
more, and the hydraulic oil is 50 5 C.
Set the accel dial at 10(Max) position.
Push the M-mode switch and confirm
that the fuel injection pump governor
lever comes into contact with the high-
idle stopper.
Measure the engine RPM.
(3) Measurement
① Start the engine. The engine will run at
start idle speed. Measure engine speed
with a tachometer.
Measure and record the engine speed at
each mode(M, H, S).
Select the M-mode.
Lightly operate the bucket control lever a
few times, then return the control lever to
neutral; The engine will automatically
enter the auto-idle speed after 4
seconds.
Measure and record the auto deceleration
speed.
(4) Evaluation
The measured speeds should meet the following specifications.
Unit : rpm
Model Engine speed Standard Remarks
Start idle 850 100

M mode 2100 50
R160LC-7A H mode 1900 50
S mode 1800 50
Auto decel 1000 50
Condition : Set the accel dial at 10(Max) position.
7-4
3) TRAVEL SPEED
(1) Measure the time required for the
excavator to travel a 20m test track.
(2) Preparation
① Adjust the tension of both tracks to be
equal.
Prepare a flat and solid test track 20m in
length, with extra length of 3 to 5m on
both ends for machine acceleration and 0.3~0.5m
deceleration.
Hold the bucket 0.3 to 0.5m above the
ground with the arm and bucket rolled in.
Keep the hydraulic oil temperature at 160LC7MS04
50 5 C.
(3) Measurement
① Measure both the low and high speeds of
the machine.
Before starting either the low or high
speed tests, adjust the travel mode
switch to the speed to be tested, then
select the following switch positions.
Mode selector : M mode
Start traveling the machine in the
acceleration zone with the travel levers at 3 ~ 5m 20m 3 ~ 5m
full stroke.
Measure the time required to travel 20m.
After measuring the forward travel speed, 160LC7MS05
turn the upperstructure 180 and

measure the reverse travel speed.
Repeat steps and three times in
each direction and calculate the average
values.
(4) Evaluation
The average measured time should meet the following specifications.
Unit : Seconds / 20m
Model Travel speed Standard Maximum allowable Remarks
1 Speed 19.5 1.0 24.3

R160LC-7A
2 Speed 12.9 1.0 16.1
7-5
4) TRACK REVOLUTION SPEED
(1) Measure the track revolution cycle time
with the track raised off ground.
(2) Preparation
① Adjust the tension of both side tracks to
be equal.
On the track to be measured, mark one 90 ~ 110
shoe with chalk.
Swing the upperstructure 90 and lower
the bucket to raise the track off ground.
Mark
Keep the boom-arm angle between 90 to
110 as shown. Place blocks under
machine frame.
50 5 C.
(3) Measurement
① Select the following switch positions.
Travel mode switch : 1 or 2 speed
Auto decel switch : OFF
Operate the travel control lever of the
raised track in full forward and reverse.
Rotate 1 turn, then measure time taken
for next 3 revolutions.
Raise the other side of machine and
repeat the procedure.
Repeat steps and three times and
calculate the average values.
(4) Evaluation
The revolution cycle time of each track should meet the following specifications.
Unit : Seconds / 3 revolutions
Model Travel speed Standard Maximum allowable
1 Speed 25.0 2.0 30.0

R160LC-7A
2 Speed 16.0 2.0 19.2
7-6
5) TRAVEL DEVIATION
(1) Measure the deviation by the tracks from
a 20m straight line.
(2) Preparation
① Adjust the tension of both tracks to be
equal.
Provide a flat, solid test yard 20m in
length, with extra length of 3 to 5m on
0.3~0.5m
both ends for machine acceleration and
deceleration.
Hold the bucket 0.3 to 0.5m above the
ground with the arm and bucket rolled in.
160LC7MS04
Keep the hydraulic oil temperature at
50 5 C.
(3) Measurement
① Measure the amount of mistracking at
high and low travel speeds.
Before beginning each test, select the
following switch positions. 3~5m extra length
Mode selector : M mode a
M
20
Start traveling the machine in the
acceleration zone with the travel levers at
full stroke. 3~5m extra length
Measure the distance between a straight
20m line and the track made by the
machine.(Dimension a)
After measuring the tracking in forward 7-7(2) 140-7
travel, turn the upperstructure 180 and
measure that in reverse travel.
(4) Evaluation
Mistrack should be within the following specifications.
Unit : mm / 20m
Model Standard Maximum allowable Remarks
R160LC-7A 200 below 240
7-7
6) SWING SPEED
(1) Measure the time required to swing three
complete turns.
(2) Preparation
① Check the lubrication of the swing gear
and swing bearing.
Place the machine on flat, solid ground
with ample space for swinging. Do not
conduct this test on slopes.
With the arm rolled out and bucket rolled
in, hold the bucket so that the height of
the bucket pin is the same as the boom
foot pin. The bucket must be empty.
50 5 C.
(3) Measurement
Operate swing control lever fully.
Swing 1 turn and measure time taken to
swing next 3 revolutions.
Repeat steps and three time and
(4) Evaluation
The time required for 3 swings should meet the following specifications.
Unit : Seconds / 3 revolutions
Model Standard Maximum allowable Remark
R160LC-7A 14.9 1.5 18.6
7-8
7) SWING FUNCTION DRIFT CHECK
(1) Measure the swing drift on the bearing
outer circumference when stopping after a
360 full speed swing.
(2) Preparation
① Check the lubrication of the swing gear
and swing bearing.
Place the machine on flat, solid ground
with ample space for swinging. Do not
conduct this test on slopes.
in, hold the bucket so that the height of 160LC7MS07

foot pin. The bucket must be empty.
Make two chalk marks: one on the swing
bearing and one directly below it on the
track frame.
Swing the upperstructure 360 .
50 5 C.
(3) Measurement
① Conduct this test in the M mode.
Select the following switch positions.
Operate the swing control lever fully and
return it to the neutral position when the
mark on the upperstructure aligns with
that on track frame after swinging 360
Measure the distance between the two
marks.
Align the marks again, swing 360 , then
test the opposite direction.
Repeat steps and three times each
and calculate the average values.
140LC7MS08
(4) Evaluation
The measured drift angle should be within the following specifications.
Unit : Degree
Model Mode select switch Standard Maximum allowable Remarks
R160LC-7A M mode 90 below 157.5
7-9
8) SWING BEARING PLAY
(1) Measure the swing bearing play using a
dial gauge to check the wear of bearing
races and balls.
(2) Preparation
① Check swing bearing mounting cap
screws for loosening.
Check the lubrication of the swing
bearing. Confirm that bearing rotation is
smooth and without noise.
Install a dial gauge on the track frame as
shown, using a magnetic base.
Position the upperstructure so that the 7-10(1) 140-7
boom aligns with the tracks facing
towards the front idlers.
Position the dial gauge so that its needle
point comes into contact with the bottom
face of the bearing outer race.
Bucket should be empty.
(3) Measurement
① With the arm rolled out and bucket rolled Measurement : (h1)
in, hold the bottom face of the bucket to
the same height of the boom foot pin.
Record the dial gauge reading(h1).
Lower the bucket to the ground and use it
to raise the front idler 50cm. Measurement : (h2)
Record the dial gauge reading(h2).
Calculate bearing play(H) from this
data(h1 and h2) as follows.
H=h2-h1
(4) Evaluation 160LC7MS09
The measured drift should be within the following specifications.

Unit : mm
Model Standard Maximum allowable Remarks
R160LC-7A 0.5 ~ 1.5 3.0
7-10
9) HYDRAULIC CYLINDER CYCLE TIME
(1) Measure the cycle time of the boom,
standard arm, and standard bucket
cylinders.
(2) Preparation
Boom cylinder
① To measure the cycle time of the boom
Raise
cylinders:
With the arm rolled out and the empty
bucket rolled out, lower the bucket to the
ground, as shown. Lower
To measure the cycle time of the arm
cylinder.
With the empty bucket rolled in, position
the arm so that it is vertical to the ground. Arm cylinder
Lower the boom until the bucket is 0.5m
above the ground.
Roll out Roll in
To measure the cycle time of the bucket
cylinder.
90
The empty bucket should be positioned
0.5m
at midstroke between roll-in and roll-out,
so that the sideplate edges are vertical to
the ground.
Bucket cylinder
50 5 C.
(3) Measurement
Mode selector : M mode Roll out Roll in
To measure cylinder cycle times.
- Boom cylinders. 0.5m
Measure the time it takes to raise the
160LC7MS10
boom, and the time it takes to lower the
boom. To do so, position the boom at
one stroke end then move the control
lever to the other stroke end as quickly as
possible.
- Arm cylinder.
Measure the time it takes to roll in the
arm, and the time it takes to roll out the
arm. To do so, position the bucket at one
stroke end, then move the control lever to
the other stroke end as quickly as
possible.
7-11
- Bucket cylinder
Measure the time it takes to roll in the
bucket, and the time it takes to roll out the
bucket. To do so, position the bucket at
one stroke end, then move the control
lever to the other stroke end as quickly as
possible.
- Repeat each measurement 3 times and
(4) Evaluation
The average measured time should meet the following specifications.
Unit : Seconds
Model Function Standard Maximum allowable Remarks
Boom raise 3.0 0.4 3.6

Boom lower 2.6 0.4 3.2
Arm in 2.9 0.4 3.5
R160LC-7A
Arm out 2.8 0.3 3.4
Bucket load 3.5 0.4 4.2
Bucket dump 2.0 0.3 2.5
7-12
10) DIG FUNCTION DRIFT CHECK
(1) Measure dig function drift, which can be
caused by oil leakage in the control valve
and boom, standard arm, and standard
bucket cylinders, with the loaded bucket.
When testing the dig function drift just
after cylinder replacement, slowly operate
each cylinder to its stroke end to purge air.
(2) Preparation
① Load bucket fully. Instead of loading the
bucket, weight(W) of the following
specification can be used.
W=M3 1.5
Where :
M3 = Bucket heaped capacity(m3)
1.5= Soil specific gravity
Position the arm cylinder with the rod 20
to 30mm extended from the fully retracted
position. 160LC7MS11
Position the bucket cylinder with the rod

20 to 30mm retracted from the fully
extended position.
in, hold the bucket so that the height of
foot pin.
50 5 C.
(3) Measurement
① Stop the engine.
Five minutes after the engine has been
stopped, measure the changes in the
positions of the boom, arm and bucket
cylinders.
Repeat step three times and calculate
the average values.
(4) The measured drift should be within the following specifications.
Unit : mm / 5min
Model Drift to be measured Standard Maximum allowable Remarks
Boom cylinder 10 below 20

R160LC-7A Arm cylinder 10 below 20
Bucket cylinder 40 below 50
7-13
11) CONTROL LEVER OPERATING FORCE
(1) Use a spring scale to measure the
maximum resistance of each control lever
at the middle of the grip.
(2) Preparation
① Keep the hydraulic oil temperature at
50 5 C.
(3) Measurement
① Start the engine.
Select the following switch positions.
Operate each boom, arm, bucket and
swing lever at full stroke and measure the
maximum operating force for each.
Lower the bucket to the ground to raise
one track off the ground. Operate the
travel lever at full stroke and measure the
maximum operating force required.
When finished, lower the track and then
jack-up the other track.
(4) Evaluation
The measured operating force should be within the following specifications.
Unit : kgf
Model Kind of lever Standard Maximum allowable Remarks
Boom lever 1.6 or below 2.0

Arm lever 1.6 or below 2.0
R160LC-7A Bucket lever 1.6 or below 2.0
Swing lever 1.6 or below 2.0
Travel lever 2.1 or below 3.15
7-14
12) CONTROL LEVER STROKE
(1) Measure each lever stroke at the lever top
using a ruler.
When the lever has play, take a half of this
value and add it to the measured stroke.
(2) Preparation
50 5 C.
(3) Measurement
Measure each lever stroke at the lever
top from neutral to the stroke end using a
ruler.
the average values.
(4) Evaluation
The measured drift should be within the following specifications.
Unit : mm
Model Kind of lever Standard Maximum allowable Remarks
Boom lever 87 10 109

Arm lever 87 10 109
R160LC-7A Bucket lever 87 10 109
Swing lever 87 10 109
Travel lever 142 10 178
7-15
13) PILOT PRIMARY PRESSURE
(1) Preparation
Loosen the cap and relieve the pressure
in the tank by pushing the top of the air
breather.
Loosen and remove plug on the pilot
a4
pump delivery port and connect pressure
gauge.
Start the engine and check for oil
leakage from the port.
50 5 C.
(2) Measurement
Mode selector : M mode 2507A7MS02
Auto decel switch : OFF
Measure the primary pilot pressure in the
M mode.
(3) Evaluation
The average measured pressure should meet the following specifications:
Unit : kgf / cm2
Model Engine speed Standard Allowable limits Remarks
R160LC-7A M mode 35 5 -
7-16
14) FOR TRAVEL SPEED SELECTING
PRESSURE:
(1) Preparation
breather.
To measure the speed selecting pressure:
Install a connector and pressure gauge
assembly to turning joint P port as shown.
Start the engine and check for on
leakage from the adapter.
50 5 C.
(2) Measurement
① Select the following switch positions. 21077MS13
Travel mode switch : 1 speed

2 speed
Measure the travel speed selecting
pressure in the Hi or Lo mode.
Lower the bucket to the ground to raise
the track off the ground. Operate the
travel lever at full stroke and measure the
fast speed pressure.
(3) Evaluation
The average measured pressure should be within the following specifications.
Unit : kgf / cm2
Model Travel speed mode Standard Maximum allowable Remarks
1 Speed 0 -
R160LC-7A
2 Speed 35 5 -
7-17
15) SWING PARKING BRAKE RELEASING
PRESSURE
(1) Preparation
breather.
a4
leakage from the adapter.
50 5 C.
(2) Measurement
Operate the swing function or arm roll in
function and measure the swing brake 2507A7MS02
control pressure with the brake

disengaged. Release the control lever
to return to neutral and measure the
control pressure when the brake is
applied.
the average values.
(3) Evaluation
Unit : kgf / cm2
Model Description Standard Allowable limits Remarks
Brake disengaged 35 15~44

R160LC-7A
Brake applied 0 -
7-18
16) MAIN PUMP DELIVERY PRESSURE
(1) Preparation
breather.
To measure the main pump pressure.
assembly main pump gauge port as
shown.
50 5 C.
(2) Measurement 2507A7MS03A

Measure the main pump delivery
pressure in the M mode(High idle).
(3) Evaluation
The average measured pressure should meet the following specifications.
Unit : kgf / cm2
Model Engine speed Standard Allowable limits Remarks
R160LC-7A High ilde 330 10 -
7-19
17) S YSTEM PRESSURE REGULATOR
RELIEF SETTING
(1) Preparation
breather.
To measure the system relief pressure.
assembly main pump gauge port, as
shown.
50 5 C.
(2) Measurement
2507A7MS03A
Slowly operate each control lever of
boom, arm and bucket functions at full
stroke over relief and measure the
pressure.
In the swing function, place bucket
against an immovable object and
measure the relief pressure.
In the travel function, lock undercarriage
with an immovable object and measure
the relief pressure.
(3) Evaluation
Unit : kgf / cm2
Model Function to be tested Standard Maximum allowable
Boom, Arm, Bucket 330(360) 10 380 + 10

0
R160LC-7A Travel 330 10 -
Swing 240 10 -
( ) : Power boost
7-20
GROUP 2 MAJOR COMPONENT
1. MAIN PUMP
3 1 2
9 5 6 4 7 8
1607A7MP01
Standard Recommended
Part name & inspection item replacement Counter measures
dimension value
Clearance
between piston (1) & Replace piston
d D 0.028 0.056
cylinder bore (2) or cylinder.
(D-d)
Play between
piston (1) & shoe caulking
0-0.1 0.3
section (3)
( ) Replace
assembly of
Thickness of shoe piston & shoe.
(t) t 3.9 3.7
Free height of cylinder

spring (4) Replace cylinder
31.3 30.5
(L) spring.
L
Combined height of set

plate (5) (H) & spherical h H
19.0 18.3 Replace retainer
bushing (6) or set plate.
(H-h)
Surface roughness for valve Surface roughness

necessary to be corrected 3z
plate (Sliding face) (7,8),
swash plate (shoe plate Lapping
area) (9), & cylinder (2) Standard surface roughness 0.4z or lower
(Sliding face) (Corrected value)
7-21
2. MAIN CONTROL VALVE
Part name Inspection item Criteria & measure
Casing Existence of scratch, rusting or corrosion. In case of damage in following section,
replace part.
- Sliding sections of casing fore and spool,
especially land sections applied with
holded pressure.
- Seal pocket section where spool is inserted.
- Seal section of port where O-ring contacts.
- Seal section of each relief valve for main,
travel, and port.
- Other damages that may damage normal
functions.
Spool Existence of scratch, gnawing, rusting or Replacement when its outside sliding
corrosion. section has scratch(Especially on seals-
contacting section).
O-ring seal sections at both ends. Replacement when its sliding section has
scratch.
Insert spool in casing hole, rotate and Correction or replacement when O-ring is
reciprocate it. damaged or when spool does not move
smoothly.
Poppet Damage of poppet or spring Correction or replacement when sealing is

incomplete.
Insert poppet into casing and function it. Normal when it can function lightly without
being caught.
Around spring Rusting, corrosion, deformation or breaking Replacement for significant damage.
of spring, spring seat, plug or cover.
Around seal External oil leakage. Correction or replacement.

for spool
Rusting, corrosion or deformation of seal Correction or replacement.
plate.
Main relief valve, External rusting or damage. Replacement.

port relief valve &
Contacting face of valve seat. Replacement when damaged.
negative control
relief valve Contacting face of poppet. Replacement when damaged.
Abnormal spring. Replacement.
O-rings, back up rings and seals. 100 replacement in general.
7-22
3. SWING DEVICE
1) WEARING PARTS
Standard Recommended
Inspection item replacement Counter measures
dimension value
Replace piston or
Clearance between piston and cylinder block bore 0.028 0.058
cylinder block
Replace assembly
Play between piston and shoe caulking section( ) 0 0.3
of piston and shoe
Replace assembly
Thickness of shoe(t) 5.5 5.3
of piston and shoe
Replace set of
Combined height of retainer plate and spherical retainer plate and
6.5 6.0
bushing (H-h) spherical bushing
Thickness of friction plate 4.0 3.6 Replace
h H
t
2507A7MS04 2507A7MS05
2) SLIDING PARTS
Part name Standard roughness Allowable roughness Remark
Shoe 0.8-Z(Ra=0.2) 3-Z(Ra=0.8)

(LAPPING)
Shoe plate 0.4-Z(Ra=0.1) 3-Z(Ra=0.8)

(LAPPING)
Cylinder 1.6-Z(Ra=0.4) 12.5-Z(Ra=3.2)

(LAPPING)
Valve plate 0.8-Z(Ra=0.2) 6.3-Z(Ra=1.6)

(LAPPING)
7-23
4. TRAVEL DEVICE
Disassembling and inspection of the motor must be done in strict accordance with the servicing
standards described here. During servicing, handle each part very carefully not to damage them,
especially for their movable or sliding sections.
1) SEALS
Once the seals(O-rings, oil seals, and floating seals) have been disassembled, they must be
replaced with new ones even if no damage is observed.
2) TABLE OF MAINTENANCE STANDARD
(1) Replace all parts having a seriously damaged appearance.
(2) Replace the part if any one of the states(Symptoms) listed in the table below is observed.
Item Maximum allowable
No. Part name Situation Standard dimension value(Criteria)
Spindle kit
2 Spindle assembly Seriously damaged in
8 Spindle appearance.
- -
17 Coupling gear
Pin Galling or other forms of
excessive wear are observed.
Carrier assembly
3 Carrier The tooth surface of the cluster
6 Cluster gear gear(6) is nonuniformly worn out
9 Shaft and damaged. - -
14 Thrust collar
The cluster gear(6) does not
25 Needle bearing
move smoothly.
34 Dowel pin
4 Ring gear A The tooth surface is

nonuniformly worn out and - -
damaged.
5 Ring gear B The tooth surface is

nonuniformly worn out and - -
damaged.
7 Sun gear The tooth surface is

nonuniformly worn out and
- -
damaged.
The spline section is worn.
8 Coupling gear Excessive wear or pitching is

- -
observed on the tooth surface.
19 Coupling The spline section is worn. - -
20 Thrust bearing Worn out. Axial clearance Clearance : 0.8mm

between coupling
gear(8) and cover(13)
: 0.3 to 0.6mm
7-24
22 Distance piece The sliding surface is damaged.

- -
The sliding surface is excessively
worn out.
24 Ball bearing Dents are present.

Flaking develops. - -
Nonuniform wear is present.
Rear flange kit The movable section contacting Linear clearance : Linear clearance :
101 Rear flange the spool(123) is damaged. 10 to 20 25
The clearance against the spool
(123) is too large.
The surface contacting the valve
(127) is damaged.
The depth to the surface
contacting the valve (127) is too
large.
123 Spool The outer surface is damaged.
The outer surface is
nonuniformly worn out.
102 Shaft The surface contacting the oil

seal(132) is worn out. - -
The spline section is worn out.
103 Swash plate Seizure is observed. - -
104 Cylinder block The spline section is worn out.

The bore inner surface is worn
out too much. - -
The sliding surface that contacts
the timing plate(109) is damaged
or nonuniformly worn out.
Piston assembly An axial clearance is present Clearance : 0.05mm Clearance : 0.15mm

105 Piston between the piston(105) and the
106 shoe shoe(106).
The shoe is excessively worn out.
The shoe is nonuniformly worn
out.
107 Retainer plate The peripheral edge is

- -
nonuniformly worn out.
7-25
108 Thrust ball The spherical sliding section that

contacts the retainer plate(107)
is nonuniformly worn out. - -
109 Timing plate The sliding surface has the traces
of seizure or nonuniformly wear.
115 Friction plate Both edges are nonuniformly Braking torque Braking torque
worn out. 40.6kgf m or more 40.6kgf m or less
116 Mating plate The required torque cannot be
achieved.
The traces of seizure are present.
118 Valve seat The seat surface is damaged. - -
119 Valve The outer surface is damaged.

- -
The seat surface is damaged.
Body kit
136 Body The sliding section that contacts Linear clearance : Linear clearance :
the spool(137) is damaged. 7 to 15 20
The clearance against the
spool(137) is too large.
137 Spool The outer surface is damaged.
The outer surface is nonuniformly
worn out.
149 Roller bearing Dents are present.

150 Ball bearing
Flaking develops. - -
Nonuniform wear is observed.

- -
164 Stopper The seat surface is damaged. - -

- -
172 Valve seat The seat surface is damaged. - -
7-26
5. RCV LEVER
Maintenance Criteria Remark
check item
Leakage The valve is to be replaced when the leakage Conditions :
becomes more than 1000cc/m at neutral handle Primary pressure : 30kgf/cm2
position, or more than 2000cc/m during operation. Oil viscosity : 23cSt
Spool This is to be replaced when the sliding surface has The leakage at the left condition is
worn more than 10 m, compared with the non- estimated to be nearly equal to the
sliding surface. above leakage.
Push rod
1mm
This is to be replaced when the top end has worn

more than 1mm.
Play at operating The pin, shaft, and joint of the operating section are When a play is due to looseness of a
section to be replaced when their plays become more than tightened section, adjust it.
2mm due to wears or so on.
Operation stability When abnormal noises, hunting, primary pressure

drop, etc. are generated during operation, and
these cannot be remedied, referring to section 6.
Troubleshooting, replace the related parts.
Notes 1. It is desirable to replace seal materials, such as O-rings, every disassembling. However,
they may be reused, after being confirmed to be free of damage.
2. When loosening the hexagon socket head cap screw(125), replace the seal washers(121)
without fail.
7-27
6. RCV PEDAL
Maintenance Criteria Remark
check item
Leakage The valve is to be replaced when the leakage effect Conditions :
to the system. For example, the primary pressure Primary pressure : 30kgf/cm2
drop. Oil viscosity : 23cSt
Spool This is to be replaced when the sliding surface has The leakage at the left condition is
worn more than 10 m, compared with the non- estimated to be nearly equal to the
sliding surface. above leakage.
Push rod
1mm
This is to be replaced when the top end has worn

more than 1mm.
Play at operating The pin, shaft, and joint of the operating section are When a play is due to looseness of a
section to be replaced when their plays become more than tightened section, adjust it.
2mm due to wears or so on.
Operation stability When abnormal noises, hunting, primary pressure

drop, etc. are generated during operation, and
these cannot be remedied, referring to section 6.
Troubleshooting, replace the related parts.
Notes 1. It is desirable to replace seal materials, such as O-rings, every disassembling. However,
they may be reused, after being confirmed to be free of damage.
7-28
7. TURNING JOINT
Part name Maintenance standards Remedy

Sliding surface with Plating worn or peeled due to seizure or contamination. Replace
sealing sections.
Sliding surface Worn abnormality or damaged more than 0.1mm Replace

between body and (0.0039in) in depth due to seizure contamination.
Body, stem other than
Damaged more than 0.1mm(0.0039in) in depth. Smooth with oilstone.
Stem sealing section.
Sliding surface Worn more than 0.5mm(0.02in) or abnormality. Replace

with thrust plate.
Worn less than 0.5mm(0.02in). Smooth
Damage due to seizure or contamination remediable Smooth
within wear limit (0.5mm)(0.02in).
Sliding surface Worn more than 0.5mm(0.02in) or abnormality. Replace

with thrust plate.
Cover Worn less than 0.5mm(0.02in). Smooth
Damage due to seizure or contamination remediable Replace
within wear limit (0.5mm)(0.02in).
Extruded excessively from seal groove square ring. Replace
- Extrusion
Square ring
Slipper ring 1.5mm(0.059in) narrower than seal Replace

groove, or narrower than back ring.
Seal set
-
1.5mm (max.)
(0.059in)
Worn more than 0.5mm(0.02in) ~ 1.5mm(MAX.) Replace

(0.059in)
7-29
8. CYLINDER
Part name Inspecting section Inspection item Remedy
Piston rod Neck of rod pin Presence of crack Replace

Weld on rod hub Presence of crack Replace
Stepped part to which piston Presence of crack Replace
is attached.
Threads Presence of crack Recondition or replace
Plated surface Plating is not worn off to base Replace or replate
metal.
Rust is not present on plating. Replace or replate
Scratches are not present. Recondition, replate or replace
Rod Wear of O.D. Recondition, replate or replace
Bushing at mounting part Wear of I.D. Replace
Cylinder tube Weld on bottom Presence of crack Replace

Weld on head Presence of crack Replace
Weld on hub Presence of crack Replace
Tube interior Presence of faults Replace if oil leak is seen
Bushing at mounting part Wear on inner surface Replace
Gland Bushing Flaw on inner surface Replace if flaw is deeper

than coating
7-30
GROUP 3 TRACK AND WORK EQUIPMENT
1. TRACK
1) TRACK ROLLER
32077MS01
Unit : mm
No. Check item Criteria Remedy
Standard size Repair limit

1 Outside diameter of flange
200 -
Rebuild or
2 Outside diameter of tread 160 148 replace
3 Width of tread 48 54
4 Width of flange 21.5
Standard size & Tolerance Standard Clearance
Clearance between shaft Shaft Hole clearance limit Replace
5
and bushing -0.29 +0.46 0.39 bushing
70 -0.33 70.1 0 to 0.476 2.0
Side clearance of roller Standard clearance Clearance limit

6 Replace
(Both side) 0.2 to 1.2 2.0
7 - 31
2) CARRIER ROLLER
5
1
4 3
16077MS02
Unit : mm

1 Outside diameter of flange
169 155
Rebuild or
2 Outside diameter of tread 144 134 replace
4 Width of flange 17
Clearance between shaft Shaft Hole clearance limit
5 Replace
and support -0.05
55 55 +0.3 0.15 to 0.4 1.2
-0.1 +0.1
7-32
3) IDLER
8
1
2
7
3 5
4
21037MS03
Unit : mm

1 Outside diameter of protrusion
560 -
2 Outside diameter of tread 520 510 Rebuild or
3 Width of protrusion 84 - replace
4 Total width 160 -

Clearance between shaft Shaft Hole clearance limit Replace
6
and bushing 0 +0.05 bushing
75 -0.03 75.35 0 0.35 to 0.43 2.0
Clearance between shaft 0 +0.07
7 and support 75 -0.03 75 +0.03 0.03 to 0.1 1.2 Replace
Side clearance of idler Standard clearance Clearance limit

8 Replace
(Both side) 0.25 to 1.2 2.0
7 - 33
4) TRACK
2 1
4
3
5
32077MS04
Unit : mm
Standard size Repair limit Turn or

1 Link pitch replace
171.45 175.65
2 Outside diameter of bushing 54 46
Rebuild or
3 Height of grouser 25 16 replace
4 Height of link 101.6 93.6
5 Tightening torque Initial tightening torque :40 4kgf m Retighten
7 - 34
5) TRACK FRAME AND RECOIL SPRING
2
3
1
21037MS05
Unit : mm
Standard size Tolerance Repair limit

+2
1 Vertical width of idler guide Track frame 113 0
117
- 0.5 Rebuild or
Idler support 110 - 1.0 106
replace
+2
Track frame 272 0 276
2 Horizontal width of idler guide
Idler support 270 - 267

3 Recoil spring Free Installation Installation Free Installation
length length load length load Replace
225 552 420 11,908kg 9,526kg
7 - 35
2. WORK EQUIPMENT
A C D E F
B K J I H G
160LC7MS20
Unit : mm
Pin Bushing
Remedy
Measuring point Normal Recomm. Recomm.
Mark Limit Limit &
(Pin and Bushing) value service service
of use of use Remark
limit limit
A Boom Rear 75 74 73.5 75.5 76 Replace

B Boom Cylinder Head 70 69 68.5 70.5 71
C Boom Cylinder Rod 75 74 73.5 75.5 76
D Arm Cylinder Head 70 69 68.5 70.5 71
E Boom Front 75 74 73.5 75.5 76
F Arm Cylinder Rod 70 69 68.5 70.5 71
G Bucket Cylinder Head 70 69 68.5 70.5 71
H Arm Link 70 69 68.5 70.5 71
I Bucket and Arm Link 70 69 68.5 70.5 71
J Bucket Cylinder Rod 70 69 68.5 70.5 71
K Bucket Link 70 69 68.5 70.5 71
7 - 36
Group 1
Precaution - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1
Group 2
Tightening Torque - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-4
Group 3
Pump Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-7
Group 4
Main Control Valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-29
Group 5
Swing Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-43
Group 6
Travel Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-66
Group 7 RCV Lever - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-110
Group 8 Turning Joint - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-125
Group 9 Boom, Arm and Bucket Cylinder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-130
GROUP 1 PRECAUTIONS
1. REMOVAL WORK
1) Lower the work equipment completely to the ground.
If the coolant contains antifreeze, dispose of it correctly.
2) After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
3) When draining oil, prepare a container of adequate size to catch the oil.
4) Confirm the match marks showing the installation position, and make match marks in the
necessary places before removal to prevent any mistake when assembling.
5) To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors.
6) Fit wires and hoses with tags to show their installation position to prevent any mistake when
installing.
7) Check the number and thickness of the shims, and keep in a safe place.
8) When raising components, be sure to use lifting equipment of ample strength.
9) When using forcing screws to remove any components, tighten the forcing screws alternately.
10) Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
11) When removing hydraulic equipment, first release the remaining pressure inside the hydraulic tank
and the hydraulic piping.
12) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
number D d L
06 6 5 8
08 8 6.5 11
10 10 8.5 12
12 12 10 15
14 14 11.5 18 Taper 1/8
θD θd
16 16 13.5 20
18 18 15 22
20 20 17 25
L
22 22 18.5 28
24 24 20 30
27 27 22.5 34
8-1
2. INSTALL WORK
1) Tighten all bolts and nuts(Sleeve nuts) to the specified torque.
2) Install the hoses without twisting or interference.
3) Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
4) Bend the cotter pin or lock plate securely.
5) When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded
portion with 2-3 drops of adhesive.
6) 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.
7) Clean all parts, and correct any damage, dents, burrs, or rust.
8) Coat rotating parts and sliding parts with engine oil.
9) When press fitting parts, coat the surface with antifriction compound(LM-P).
10) After installing snap rings, check that the snap ring is fitted securely in the ring groove(Check that
the snap ring moves in the direction of rotation).
11) When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then
connect securely.
12) When using eyebolts, check that there is no deformation or deterioration, and screw them in fully.
13) When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
14) When operating the hydraulic cylinders for the first time after repairing and reassembling the
hydraulic cylinders, pumps, or other hydraulic equipment or piping, always bleed the air from the
hydraulic cylinders as follows:
(1) Start the engine and run at low idling.
(2) Operate the control lever and actuate the hydraulic cylinder 4-5 times, stopping 100mm before the
end of the stroke.
(3) Next, operate the piston rod to the end of its stroke to relieve the circuit. (The air bleed valve is
actuated to bleed the air.)
(4) After completing this operation, raise the engine speed to the normal operating condition.
ö If the hydraulic cylinder has been replaced, carry out this procedure before assembling the rod to
the work equipment.
ö Carry out the same operation on machines that have been in storage for a long time after
completion of repairs.
8-2
3. COMPLETING WORK
1) If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run
the engine to circulate the water through the system. Then check the water level again.
2) 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.
3) If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been
removed for repair, always bleed the air from the system after reassembling the parts.
4) Add the specified amount of grease(Molybdenum disulphied grease) to the work equipment related
parts.
8-3
GROUP 2 TIGHTENING TORQUE
1. MAJOR COMPONENTS
Torque
No. Descriptions Bolt size
kgf m lbf ft
1 Engine mounting bolt(Bracket-Frame, FR) M16 2.0 30 3.5 217 25.3
2 Engine mounting bolt(Bracket-Frame,RR) M20 2.5 55 3.5 398 25.3
3 Engine Engine mounting bolt(Engine-Bracket) M12 1.75 10.0 1.0 72.3 7.2
4 Radiator mounting bolt, nut M12 1.75 12.2 1.3 88.2 9.4
5 Coupling mounting bolt M16 2.0 22.0 1.0 159 7.2
6 Main pump housing mounting bolt M10 1.5 6.9 1.4 49.9 10.1
7 Hydraulic Main pump mounting bolt M16 2.0 22.5 0.5 163 3.6
8 system Main control valve mounting bolt M12 1.75 12.2 1.3 88.2 9.4
9 Fuel tank mounting bolt M20 2.5 45 5.1 325 36.9
10 Hydraulic oil tank mounting bolt M20 2.5 45 5.1 325 36.9
11 Turning joint mounting bolt, nut M12 1.75 12.2 1.3 88.2 9.4
Power
12 train Swing motor mounting bolt M20 2.5 57.9 8.7 419 62.9
system
13 Swing bearing upper mounting bolt M20 2.5 57.8 6.4 418 46.3
14 Swing bearing lower mounting bolt M20 2.5 57.8 6.4 418 46.3
15 Travel motor mounting bolt M16 2.0 23 2.5 166 18.1
16 Sprocket mounting bolt M16 2.0 29.7 4.5 215 32.5
17 Under Carrier roller mounting bolt, nut M20 2.5 54.7 6.0 396 43.4
18 carriage Track roller mounting bolt M20 2.5 54.7 6.0 396 43.4
19 Track tension cylinder mounting bolt M16 2.0 29.7 4.5 215 32.5
20 Track shoe mounting bolt, nut 5/8-18UNF 42 4 304 28.9
21 Track guard mounting bolt M20 2.5 57.9 8.7 419 62.9
22 Counterweight mounting bolt M30 3.5 199 30 1439 217
Others
23 Cab mounting bolt, nut M12 1.75 12.8 3.0 92.6 21.7
24 Operator's seat mounting bolt M 8 1.25 4.05 0.8 29.3 5.8
8-4
2. TORQUE CHART
Use following table for unspecified torque.
1) BOLT AND NUT - Coarse thread
8T 10T
Bolt size
kgf m lbf ft kgf m lbf ft
M 6 1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6
M 8 1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.73 ~ 4.12 19.7 ~ 29.8
M10 1.5 4.0 ~ 6.0 28.9 ~ 43.4 5.5 ~ 8.3 39.8 ~ 60
M12 1.75 7.4 ~ 11.2 53.5 ~ 79.5 9.8 ~ 15.8 71 ~ 114
M14 2.0 12.2 ~ 16.6 88.2 ~ 120 16.7 ~ 22.5 121 ~ 167
M16 2.0 18.6 ~ 25.2 135 ~ 182 25.2 ~ 34.2 182 ~ 247
M18 2.5 25.8 ~ 35.0 187 ~ 253 35.1 ~ 47.5 254 ~ 343
M20 2.5 36.2 ~ 49.0 262 ~ 354 49.2 ~ 66.6 356 ~ 482
M22 2.5 48.3 ~ 63.3 350 ~ 457 65.8 ~ 98.0 476 ~ 709
M24 3.0 62.5 ~ 84.5 452 ~ 611 85.0 ~ 115 615 ~ 832
M30 3.5 124 ~ 168 898 ~ 1214 169 ~ 229 1223 ~ 1655
M36 4.0 174 ~ 236 1261 ~ 1703 250 ~ 310 1808 ~ 2242
2) BOLT AND NUT - Fine thread

8T 10T
Bolt size
kgf m lbf ft kgf m lbf ft
M 8 1.0 2.17 ~ 3.37 15.7 ~ 24.3 3.04 ~ 4.44 22.0 ~ 32.0
M10 1.25 4.46 ~ 6.66 32.3 ~ 48.2 5.93 ~ 8.93 42.9 ~ 64.6
M12 1.25 7.78 ~ 11.58 76.3 ~ 83.7 10.6 ~ 16.0 76.6 ~ 115
M14 1.5 13.3 ~ 18.1 96.2 ~ 130 17.9 ~ 24.1 130 ~ 174
M16 1.5 19.9 ~ 26.9 144 ~ 194 26.6 ~ 36.0 193 ~ 260
M18 1.5 28.6 ~ 43.6 207 ~ 315 38.4 ~ 52.0 278 ~ 376
M20 1.5 40.0 ~ 54.0 289 ~ 390 53.4 ~ 72.2 386 ~ 522
M22 1.5 52.7 ~ 71.3 381 ~ 515 70.7 ~ 95.7 512 ~ 692
M24 2.0 67.9 ~ 91.9 491 ~ 664 90.9 ~ 123 658 ~ 890
M30 2.0 137 ~ 185 990 ~ 1338 182 ~ 248 1314 ~ 1795
M36 3.0 192 ~ 260 1389 ~ 1879 262 ~ 354 1893 ~ 2561
8-5
3) PIPE AND HOSE(FLARE TYPE)
Thread size(PF) Width across flat(mm) kgf m lbf ft
1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 9.5 68.7
3/4" 36 18 130.2
1" 41 21 151.9
1-1/4" 50 35 253.2
4) PIPE AND HOSE(ORFS TYPE)
Thread size(UNF) Width across flat(mm) kgf m lbf ft
9/16-18 19 4 28.9
11/16-16 22 5 36.2
13/16-16 27 9.5 68.7
1-3/16-12 36 18 130.2
1-7/16-12 41 21 151.9
1-11/16-12 50 35 253.2
5) FITTING
Thread size Width across flat(mm) kgf m lbf ft
1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 9.5 68.7
3/4" 36 18 130.2
1" 41 21 151.9
1-1/4" 50 35 253.2
8-6
GROUP 3 PUMP DEVICE
1. REMOVAL AND INSTALL

1) REMOVAL
(1) Lower the work equipment to the ground
and stop the engine.
(2) Operate the control levers and pedals
several times to release the remaining
pressure in the hydraulic piping
(3) Loosen the breather slowly to release the 13031GE18
pressure inside the hydraulic tank.

Escaping fluid under pressure can
penetrate the skin causing serious 9
74
injury.
(4) Loosen the drain plug under the hydraulic
tank and drain the oil from the hydraulic
A
2
tank.
A
1
Hydraulic tank quantity : 160
(42.2 U.S.gal)
(5) Remove socket bolts (74) and disconnect 72
3
21078DA01
pipe (9).
(6) Disconnect pilot line hoses (48, 49, 55, 58,
64, 69, 71, 78).
(7) Remove socket bolts (72) and disconnect
pump suction tube (3).
When pump suction tube is disconnected,
the oil inside the piping will flow out, so
catch it in oil pan.
(8) Sling the pump assembly and remove the
pump mounting bolts.
Weight : 90kg (200lb)
Pull out the pump assembly from housing.
1408DA02
When removing the pump assembly,
check that all the hoses have been
disconnected.
8-7
2) INSTALL
(1) Carry out installation in the reverse order
to removal.
(2) Remove the suction strainer and clean it.
(3) Replace return filter with new one.
(4) Remove breather and clean it.
(5) After adding oil to the hydraulic tank to the
specified level.
(6) Bleed the air from the hydraulic pump.
① Remove the air vent plug(2EA).
Tighten plug lightly.
Start the engine, run at low idling, and
check oil come out from plug.
Tighten plug.
(7) Start the engine, run at low idling(3~5
minutes) to circulate the oil through the
system.
(8) Confirm the hydraulic oil level and check
the hydraulic oil leak or not.
8-8
2. MAIN PUMP(1/2)
1) STRUCTURE
548
535 789 732 532 531 214 702 792 901 719 124 151 152 113 406 710
808 534
724 954
953
886
717
406 04
774
111
261
127
123
710
824
251
490 212 211 153 156 157 467 313 312 114 466 885 314 141 981 271 401
728 725 983
1607A2MP02
04 Gear pump 271 Pump casing 719 O-ring

111 Drive shaft(F) 312 Valve block 724 O-ring
113 Drive shaft(R) 313 Valve plate(R) 725 O-ring
114 Spline coupling 314 Valve plate(L) 728 O-ring
123 Roller bearing 401 Hexagon socket bolt 732 O-ring
124 Needle bearing 406 Hexagon socket bolt 774 Oil seal
127 Bearing spacer 466 VP Plug 789 Back up ring
141 Cylinder block 467 VP Plug 792 Back up ring
151 Piston 490 Plug 808 Hexagon head nut
152 Shoe 531 Tilting pin 824 Snap ring
153 Set plate 532 Servo piston 885 Pin
156 Bushing 534 Stopper(L) 886 Spring pin
157 Cylinder spring 535 Stopper(S) 901 Eye bolt
211 Shoe plate 548 Pin 953 Set screw
212 Swash plate 702 O-ring 954 Set screw
214 Bushing 710 O-ring 981 Plate
251 Support 717 O-ring 983 Pin
261 Seal cover(F)
8-9
2) TOOLS AND TIGHTENING TORQUE
(1) Tools
The tools necessary to disassemble/reassemble the pump are shown in the follow list.
Tool name & size Part name
Hexagon socket PT plug PO plug Hexagon socket

Name B
head bolt (PT thread) (PF thread) head setscrew
Allen wrench 4 M 5 BP-1/16 - M 8
5 M 6 BP-1/8 - M10
6 M 8 BP-1/4 PO-1/4 M12, M14
B
8 M10 BP-3/8 PO-3/8 M16, M18
17 M20, M22 BP-1 PO-1, 1 1/4, 1 1/2 -
Double ring spanner, Hexagon socket VP plug
- Hexagon nut
socket wrench, double(Single) head bolt (PF thread)
open end spanner
19 M12 M12 VP-1/4
24 M16 M16 -
B
27 M18 M18 VP-1/2
30 M20 M20 -
36 - - VP-3/4
Adjustable angle wrench Medium size, 1 set
Screw driver Minus type screw driver, Medium size, 2 sets
Hammer Plastic hammer, 1 set
Pliers For snap ring, TSR-160
Steel bar Steel bar of key material approx. 10 8 200
Torque wrench Capable of tightening with the specified torques
8-10
(2) Tightening torque
Torque Wrench size
Part name Bolt size
kgf m lbf ft in mm
Hexagon socket head bolt M 5 0.7 5.1 0.16 4
Material : SCM435) M 6 1.2 8.7 0.20 5
M 8 3.0 21.7 0.24 6
M10 5.8 42.0 0.31 8
M12 10.0 72.3 0.39 10
M14 16.0 116 0.47 12
M16 24.0 174 0.55 14
M18 34.0 246 0.55 14
M20 44.0 318 0.67 17
PT Plug(Material : S45C) PT1/16 0.7 5.1 0.16 4
Wind a seal tape 1 1/2 to 2 PT 1/8 1.05 7.59 0.20 5
turns round the plug
PT 1/4 1.75 12.7 0.24 6
PT 3/8 3.5 25.3 0.31 8
PT 1/2 5.0 36.2 0.39 10
PF Plug(Material : S45C) PF 1/4 3.0 21.7 0.24 6
PF 1/2 10.0 72.3 0.39 10
PF 3/4 15.0 109 0.55 14
PF 1 19.0 137 0.67 17
PF 1 1/4 27.0 195 0.67 17
PF 1 1/2 28.0 203 0.67 17
8-11
3) DISASSEMBLY
(1) Select place suitable to disassembling.
Select clean place.
Spread rubber sheet, cloth or so on on
overhaul workbench top to prevent parts
from being damaged.
(2) Remove dust, rust, etc, from pump
surfaces with cleaning oil or so on.
(3) Remove drain port plug(468) and let oil
out of pump casing(Front and rear pump).
(4) Remove hexagon socket head bolts(412,

413) and remove regulator.
MP01 (140-7)
(5) Loosen hexagon socket head bolts(401)

which tighten swash plate support(251),
pump casing(271) and valve block(312).
If gear pump and so on are fitted to rear
face of pump, remove them before
starting this work.
(6) Place pump horizontally on workbench

with its regulator-fitting surface down and
separate pump casing(271) from valve
block(312).
Before bringing this surface down, spread
rubber sheet on workbench without fail to
prevent this surface from being damaged.
MP02 (140-7)
8-12
(7) Pull cylinder block(141) out of pump
casing(271) straightly over drive
shaft(111). Pull out also pistons(151), set
plate(153), spherical bush(156) and
cylinder springs(157) simultaneously.
Take care not to damage sliding surfaces
of cylinder, spherical bushing, shoes,
swash plate, etc.
MP03 (140-7)
(8) Remove hexagon socket head bolts(406)

and then seal cover(F, 261).
Fit bolt into pulling out tapped hole of seal
cover(F), and cover can be removed
easily.
Since oil seal is fitted on seal cover(F),
take care not to damage it in removing
cover.
(9) Remove hexagon socket head bolts(408) MP04 (140-7)
and then seal cover(R, 262).
In case fitting a gear pump, first, remove
gear pump.
(10) Tapping lightly fitting flange section of
swash plate support(251) on its pump
casing side, separate swash plate support
from pump casing.
MP05 (140-7)
(11) Remove shoe plate(211)and swash

plate(212) from pump casing(271).
MP06 (140-7)
8-13
(12) Tapping lightly shaft ends of drive shafts
(111, 113) with plastic hammer, take out
drive shafts from swash plate supports.
MP07 (140-7)
(13) Remove valve plates(313, 314) from valve

block(312).
These may be removed in work(6).
MP08 (140-7)
(14) If necessary, remove stopper(L, 534),

stopper(S, 535), servo piston(532) and
tilting pin(531) from pump casing(271),
and needle bearing(124) and splined
coupling(114) from valve block(312).
In removing tilting pin, use a protector to
prevent pin head from being damaged.
Since loctite is applied to fitting areas of
tilting pin and servo piston, take care not
to damage servo piston.
Do not remove needle bearing as far as
possible, except when it is considered to
be out of its life span.
Do not loosen hexagon nuts of valve block
and swash plate support.
If loosened, flow setting will be changed.
8-14
4) ASSEMBLY
(1) For reassembling reverse the
disassembling procedures, paying
attention to the following items.
① Do not fail to repair the parts damaged
during disassembling, and prepare
replacement parts in advance.
Clean each part fully with cleaning oil and
dry it with compressed air.
Do not fail to apply clean working oil to
sliding sections, bearings, etc. before
assembling them.
In principle, replace seal parts, such as
O-rings, oil seals, etc.
For fitting bolts, plug, etc., prepare a
torque wrench or so on, and tighten them
with torques shown in page 8-10, 11.
For the double-pump, take care not to
mix up parts of the front pump with those
of the rear pump.
(2) Fit swash plate support (251) to pump

casing (271), tapping the former lightly
with a hammer.
After servo piston, tilting pin, stopper (L)
and stopper (S) are removed, fit them
soon to pump casing in advance for
reassembling.
In tightening servo piston and tilting pin,
use a protector to prevent tilting pin head
MP09 (140-7)
and feedback pin from being damaged.
In addition, apply loctite (Medium
strength) to their threaded sections.
8-15
(3) Place pump casing with its regulator fitting
surface down, fit tilting bush of swash plate
to tilting pin(531) and fit swash plate (212)
to swash plate support(251) correctly.
Confirm with fingers of both hands that
swash plate can be removed smoothly.
Apply grease to sliding sections of swash
plate and swash plate support, and drive
shaft can be fitted easily.
MP10 (140-7)
(4) To swash plate support(251), fit drive

shaft(111) set with bearing(123), bearing
spacer(127) and snap ring(824).
Do not tap drive shaft with hammer or so
on.
Assemble them into support, tapping
outer race of bearing lightly with plastic
hammer.
Fit them fully, using steel bar or so on.
MP11 (140-7)
(5) Assemble seal cover(F, 261) to pump

casing(271) and fix it with hexagon socket
head bolts(406).
Apply grease lightly to oil seal in seal
cover(F).
Assemble oil seal, taking full care not to
damage it.
For tandem type pump, fit rear cover(263)
and seal cover(262) similarly.
MP12 (140-7)
(6) Assemble piston cylinder subassembly

cylinder block(141), piston subassembly
(151, 152), set plate(153), spherical bush
(156), spacer(158) and cylinder spring
(157) .
Fit spline phases of retainer and cylinder.
Then, insert piston cylinder subassembly
into pump casing.
MP13 (140-7)
8-16
(7) Fit valve plate(313) to valve block(312),
entering pin into pin hole.
Take care not to mistake suction / delivery
directions of valve plate.
MP14 (140-7)
(8) Fit valve block(312) to pump casing(271)

and tighten hexagon socket head bolts
(401).
At first assemble this at rear pump side,
and this work will be easy.
Take care not to mistake direction of valve
block.
Clockwise rotation(Viewed from input
shaft side) - Fit block with regulator up and
MP16 (140-7)
with delivery flange left, viewed from front
side.
Counter clockwise rotation(Viewed from
input shaft side) - Fit block with delivery
flange right, viewed from front side.
(9) Putting feedback pin of tilting pin into

feedback lever of regulator, fit regulator
and tighten hexagon socket head bolts
(412, 413).
Take care not to mistake regulator of front
pump for that of rear pump.
MP17 (140-7)
(10) Fit drain port plug(468).

This is the end of reassembling procedures.
8-17
3. REGULATOR
1) STRUCTURE(1/2)
412 876 874 755 858

A 642 723 648 647 646 438
897 B
614
612
615
613
C
875
A 611
B
801 730 643 708 644 645 728 924 801
SECTION B-B
656 735 413 438 405 735 413 438
438
722
496 724 725 436 699 496 724 725 436
VIEW C(FRONT) VIEW C(REAR)
KR38-9C07(FR) A
KR38-9C05(RR)
P2
Pf
Pm
Pi
1607A2MP03
8-18
REGULATOR(2/2)
655 734 653 654 836 651 652 601 624 629 630 628 802
641
814
898
631
732
733
622
621 623 625 626 887 763 756 753 627
SECTION A-A
1607A2MP04
405 Hexagon socket screw 631 Sleeve, Pf 730 O-ring

412 Hexagon socket screw 641 Pilot cover 732 O-ring
413 Hexagon socket screw 642 Pilot cover (QMC) 733 O-ring
436 Hexagon socket screw 643 Pilot piston 734 O-ring
438 Hexagon socket screw 644 Spring seat (Q) 735 O-ring
496 Plug 645 Adjust stem (Q) 753 O-ring
601 Casing 646 Pilot spring 755 O-ring
611 Feed back lever 647 Stopper 756 O-ring
612 Lever (1) 648 Piston (QMC) 763 O-ring
613 Lever (2) 651 Sleeve 801 Nut
614 Fulcrum plug 652 Spool 802 Nut
615 Adjust plug 653 Spring seat 814 Snap ring
621 Compensator piston 654 Return spring 836 Snap ring
622 Piston case 655 Set spring 858 Snap ring
623 Compensator rod 656 Block cover 874 Pin
624 Spring seat (C) 699 Valve casing 875 Pin
625 Outer spring 708 O-ring 876 Pin
626 Inner spring 722 O-ring 887 Pin
627 Adjust stem (C) 723 O-ring 897 Pin
628 Adjust screw (C) 724 O-ring 898 Pin
629 Cover (C) 725 O-ring 924 Set screw
630 Lock nut 728 O-ring
8-19
(1) Tools
The tools necessary to disassemble/reassemble the pump are shown in the follow list.
Tool name & size Part name

Hexagon socket PT plug PO plug Hexagon socket
Name B
head bolt (PT thread) (PF thread) head setscrew
Allen wrench 4 M 5 BP-1/16 - M 8
B
5 M 6 BP-1/8 - M10
6 M 8 BP-1/4 PO-1/4 M12, M14
Double ring spanner,
socket wrench, double(Single) Hexagon head VP plug
open end spanner - Hexagon nut
bolt (PF thread)
B
6 M 8 M 8 -
Adjustable angle wrench Small size, Max 36mm
Screw driver Minus type screw driver, Medium size, 2 sets
Hammer Plastic hammer, 1 set
Pliers For snap ring, TSR-160
Steel bar 4 100mm
Pincers -
Bolt M4, Length : 50mm
8-20
Torque Wrench size
Part name Bolt size
kgf m lbf ft in mm
Hexagon socket head bolt M 5 0.7 5.1 0.16 4
Material : SCM435) M 6 1.2 8.7 0.20 5
M 8 3.0 21.7 0.24 6
M10 5.8 42.0 0.31 8
M12 10.0 72.3 0.39 10
M14 16.0 116 0.47 12
M16 24.0 174 0.55 14
M18 34.0 246 0.55 14
M20 44.0 318 0.67 17
PT Plug(Material : S45C) PT1/16 0.7 5.1 0.16 4
Wind a seal tape 1 1/2 to 2 PT 1/8 1.05 7.59 0.20 5
turns round the plug
PT 1/4 1.75 12.7 0.24 6
PT 3/8 3.5 25.3 0.31 8
PT 1/2 5.0 36.2 0.39 10
PF Plug(Material : S35C) PF 1/4 3.0 21.7 0.24 6
PF 1/2 10.0 72.3 0.39 10
PF 3/4 15.0 109 0.55 14
PF 1 19.0 137 0.67 17
PF 1 1/4 27.0 195 0.67 17
PF 1 1/2 28.0 203 0.67 17
8-21
3) DISASSEMBLY
Since the regulator consists of small
precision finished parts, disassembly and
assembly are rather complicated.
For this reason, replacement of a regulator
assembly is recommended, unless there is
a special reason, but in case disassembly is
necessary for an unavoidable reason, read
through this manual to the end before
starting disassembly.
(1) Choose a place for disassembly.
Choose a clean place.
Spread rubber sheet, cloth, or so on top of
work-bench to prevent parts from being
damaged.
(2) Remove dust, rust, etc. from surfaces of
regulator with clean oil.
(3) Remove hexagon socket head screw

(412, 413) and remove regulator main
body from pump main body.
Take care not to lose O-ring.
REG01 (140-7)
(4) Remove hexagon socket head screw

(438) and remove cover(C,629)
Cover(C) is fitted with adjusting screw
(C,QI) (628, 925), adjusting ring(C, 627),
lock nut(630), hexagon nut(801) and
adjusting screw(924).
Do not loosen these screws and nuts.
If they are loosened, adjusted pressure-
flow setting will vary.
REG02 (140-7)
8-22
(5) After removing cover(C, 629) subassembly,
take out outer spring(625), inner spring
(626) and spring seat(C, 624) from
compensating section.
Then draw out adjusting ring(Q, 645), pilot
spring(646) and spring seat(644) from
pilot section.
Adjusting ring(Q,645) can easily be drawn
out with M4 bolt.
REG03 (140-7)
(6) Remove hexagon socket head screws

(436, 438) and remove pilot cover(641).
After removing pilot cover, take out set
spring(655) from pilot section.
REG04 (140-7)
(7) Remove snap ring(814) and take out

spring seat(653), return spring(654) and
sleeve(651).
Sleeve(651) is fitted with snap ring(836).
When removing snap ring(814), return
spring(654) may pop out.
Take care not to lose it.
REG05 (140-7)
(8) Remove locking ring(858) and take out

fulcrum plug(614) and adjusting plug
(615).
Fulcrum plug(614) and adjusting plug
(615) can easily be taken out with M6 bolt.
REG06 (140-7)
8-23
REG07 (140-7)
(9) Remove lever(2, 613). Do not draw out

pin(875).
Work will be promoted by using pincers or
so on.
REG08 (140-7)
(10) Draw out pin(874) and remove feedback

lever(611).
Push out pin(874, 4mm in dia.) from above
with slender steel bar so that it may not
interfere with lever(1, 612).
REG09 (140-7)
REG10 (140-7)
8-24
(11) Remove lever(1, 612). Do not draw out
pin(875).
(12) Draw out pilot piston(643) and spool(652).
(13) Draw out piston case(622), compensating
piston(621) and compensating rod(623).
Piston case(622) can be taken out by
pushing compensating rod(623) at
opposite side of piston case.
This completes disassembly.
8-25
4) ASSEMBLY
(1) For assembly, reverse disassembly
procedures, but pay attention to the
following items.
① Always repair parts that were scored at
disassembly.
Get replacement parts ready beforehand.
Mixing of foreign matter will cause
malfunction.
Therefore, wash parts well with cleaning
oil, let them dry with jet air and handle
them in clean place.
Always tighten bolts, plugs, etc. to their
specified torques.
Do not fail to coat sliding surfaces with
clean hydraulic oil before assembly.
Replace seals such as O-ring with new
ones as a rule.
(2) Put compensating rod(623) into

compensating hole of casing(601).
(3) Put pin force-fitted in lever(1, 612) into
groove of compensating rod and fit lever
(1) to pin force-fitted in casing.
(4) Fit spool(652) and sleeve(651) into hole in

spool of casing.
Confirm that spool and sleeve slide
smoothly in casing without binding.
Pay attention to orientation of spool.
Spool
Feedback lever
8-27 (140-7)
8-26
(5) Fit feedback lever(611), matching its pin
hole with pin hole in spool.
Then insert pin(874).
Insert pin in feedback lever a little to ease
Lever (1) side Lever (2) side
operation.
(Fulcrum plug of
Take care not to mistake direction of
adjusting plug side)
feedback lever.
8-28 (140-7)
(6) Put pilot piston(643) into pilot hole of

casing.
Confirm that pilot piston slides smoothly
without binding.
(7) Put pin force-fitted in lever(2, 613) into
groove of pilot piston.
Then fix lever(2).
REG11 (140-7)
(8) Fit fulcrum plug(614) so that pin force-

fitted in fulcrum plug(614) can be put into
pin hole of lever(2).
Then fix locking ring(858).
(9) Insert adjusting plug(615) and fit locking
ring.
Take care not to mistake inserting holes
for fulcrum plug and adjusting plug.
At this point in time move feedback lever
to confirm that it has no large play and is
free from binding. REG12 (140-7)
(10) Fit return spring(654) and spring seat

(653) into spool hole and attach snap ring
(814).
REG13 (140-7)
8-27
(11) Fit set spring(655) to spool hole and put
compensating piston(621) and piston
case(622) into compensating hole.
Fit pilot cover(641) and tighten it with
hexagonal socket head screws(436, 438).
REG14 (140-7)
(12) Put spring seat(644), pilot spring(646) and

adjusting ring(Q, 645) into pilot hole.
Then fix spring seat(624), inner spring
(626) and outer spring(625) into
compensating hole.
When fitting spring seat, take care not to
mistake direction of spring seat.
REG15 (140-7)
(13) Install cover(C, 629) fitted with adjusting

screws(628), adjusting ring(C, 627), lock
nut(630), hexagon nut(801) and adjusting
screw(924).
Then tighten them with hexagonal socket
head screws(438).
This completes assembly. REG16 (140-7)
8-28
GROUP 4 MAIN CONTROL VALVE

1) REMOVAL
pressure in the hydraulic piping.

penetrate the skin causing serious
injury.
When pipes and hoses are disconnected,
(4) Remove bolts and disconnect pipe.
(5) Disconnect pilot line hoses.
(6) Disconnect pilot piping. 1408DA10
(7) Sling the control valve assembly and

remove the control valve mounting bolt.
Weight : 80k (180lb)
(8) Remove the control valve assembly.
When removing the control valve
assembly, check that all the piping have
been disconnected.
2) INSTALL
to removal.
1408DA11
(2) Bleed the air from below items.
① Cylinder (Boom, arm, bucket)
Swing motor
Travel motor
See each item removal and install.
(3) Confirm the hydraulic oil level and recheck
1408DA12
8-29
2. STRUCTURE(1/4)
91
30
71
16
82
28, 29
91 90 73
43
42 78
90
16 45
41
90
40
5 46
67 7
10 31
85
12
65 69
68
14
64 77
87
76
66 39 87
77
68 84 79
62
38 89
63 37 44
36
52 35 79
53
75 33 47
54
1 34
DETAIL OF LOCK VALVE

90 1607A8MC04
63
15 53 Spring
62 49
90 54 Plug
48
66 51 91 57 Plug
57 62 Poppet
76
64 63 Filter
32 64 Spring seat
65
69 65 Spring
85 66 Piston
50 35 Restrictor 67 Socket
74 36 Spring 68 Plug
67
37 Poppet guide 69 Plug
1 Housing-P1 38 Pilot poppet 71 Plug
5 Spool assy 39 Poppet seat 73 Plug
7 Spool assy 40 Piston 1 74 Socket head bolt
10 Spool assy 41 Piston guide 75 O-ring
12 Spool assy 42 Spring 1 76 O-ring
14 Spool assy 43 Piston 2 77 O-ring
15 Pilot cover A 44 Sleeve 78 O-ring
16 Pilot cover B1 45 Spool 79 O-ring
28 Lock valve kit A 46 Spring 2 82 O-ring
29 Lock valve kit B 47 Stopper 84 O-ring
30 Socket head bolt 48 Regeneration selector spool 85 O-ring
31 Holding block 49 Spring 87 Back up ring
32 Regeneration block 50 Stopper 89 Back up ring
33 C-ring 51 Piston 90 O-ring
34 Poppet 52 Poppet 91 Socket head bolt
8-30
STRUCTURE(2/4)
24
25
72
80
19
20
84
80 18
72
80 84
76 72 18
86 22
78 23
88 81
81 21
61 80
68
72
76
86 19
78 20
88
81 25 84
27 18
59
25
1607A8MC05
18 Plug 25 Overload relief valve 78 O-ring

19 Poppet 1 27 Plug 80 O-ring
20 Spring 59 Plug 81 O-ring
21 Plug 61 Plug 84 O-ring
22 Poppet 2 68 Plug 86 Back-up ring
23 Spring 72 Plug 88 Back-up ring
24 Main relief valve 76 O-ring
8-31
STRUCTURE(3/4)
73
91 78
91
30
16 71
16
28,29 82
90 90
91 43 73
42 78
91
91 16 45
90
41
90 17 3
4 40
16
46
90 6
90
11
9 31
13 69
92 72 77
80 87 76
39 87
77
84 79
89
38
2 37 44
36
80 79
35
72 47
90 33
81 34
21 15
76 DETAIL OF LOCK VALVE

91
8186 78
60 1607A8MC06
90 73
15
8
91
90 47 Stopper
60 Plug
17
69 Plug
71 Plug
91 72 Plug
2 Housing-P2 31 Holding block 73 Plug
3 Spool assy 34 Poppet 74 Socket head bolt
4 Spool assy 35 Restrictor 76 O-ring
6 Spool assy 36 Spring 77 O-ring
8 Spool assy 37 Poppet guide 78 O-ring
9 Spool assy 38 Pilot poppet 79 O-ring
11 Spool assy 39 Poppet seat 80 O-ring
13 Spool assy 40 Piston 1 81 O-ring
15 Pilot cover A 41 Piston guide 82 O-ring
16 Pilot cover B1 42 Spring 1 87 Back up ring
17 Lock valve kit B2 43 Piston 2 89 Back up ring
21 Plug 44 Sleeve 90 O-ring
28 Lock valve kit A 45 Spool 91 Socket head bolt
29 Lock valve kit B 46 Spring 2 92 Spool assy
8-32
STRUCTURE(4/4)
18
84
20
21 19 58
81
82
77 25
70 87 26
83 72 56
80 55
26
59
81
77
87
72
80 21
81
23
22
18
84 21
20 81
19
21
81
70
83
26
25
26
1607A8MC07

19 Poppet 1 55 Orifice 80 O-ring
20 Spring 56 Coin type filter 81 O-ring
22 Poppet 2 59 Plug 83 O-ring
23 Spring 70 Plug 84 O-ring
25 Overload relief valve 72 Plug 87 Back-up ring
8-33
3. DISASSEMBLY AND ASSEMBLY
1) GENERAL PRECAUTIONS
(1) All hydraulic components are manufactured to a high precision. Consequently, before
disassembling and assembling them, it is essential to select an especially clean place.
(2) In handling a control valve, pay full attention to prevent dust, sand, etc. from entering into it.
(3) When a control valve is to be remove from the machine, apply caps and masking seals to all
ports. Before disassembling the valve, recheck that these caps and masking seals are fitted
completely, and then clean the outside of the assembly. Use a proper bench for working. Spread
paper or a rubber mat on the bench, and disassemble the valve on it.
(4) Support the body section carefully when carrying or transferring the control valve. Do not lift by
the exposed spool, end cover section etc.
(5) After disassembling and assembling of the component it is desired to carry out various tests(For
the relief characteristics, leakage, flow resistance, etc.), but hydraulic test equipment is necessary
for these tests. Therefore, even when its disassembling can be carried out technically, do not
disassemble such components that cannot be tested, adjusted, and so on. Additionally one
should always prepare clean cleaning oil, hydraulic oil, grease, etc. beforehand.
2) TOOLS
Before disassembling the control valve, prepare the following tools beforehand.
Name of tool Quantity Size(mm)

Vice mounted on bench(Soft jaws) 1 unit
Hexagon wrench Each 1 piece 5, 6, 10, 12 and 14
Socket wrench Each 1 piece 27 and 32
Spanner Each 1 piece 32(Main relief valve)
8-34
3) DISASSEMBLY
(1) Disassembly of spools without holding valve
① Loosen hexagon socket head bolts with washer
(Hexagon wrench : 5mm)
Remove the pilot cover.
Pay attention not to lose the O-ring under the pilot cover.
Remove the spool assembly from the body by hand slightly.
When extracting each spool from its body, pay attention not to damage the body.
When extracting each spool assembly, it must be extracted from spring side only.
When any abnormal parts are found, replace it with completely new spool assembly.
When disassembled, tag the components for identification so that they can be reassembled
correctly.
Return spring
Pilot cover
Socket head bolt

O-ring 1607A8MC10
8-35
(2) Disassembly of spools with holding valve(Boom 1, Arm 1 spool)
① Loosen hexagon socket head bolts with washer
(Hexagon wrench : 5mm)
Remove the pilot cover with internal parts.
Pay attention not to lose the O-ring and the poppet under the pilot cover.
Pay attention not to damage the "piston A" under pilot cover.
Remove the spool assembly from the body by hand slightly.
When extracting each spool from its body, pay attention not to damage the body.
When extracting each spool assembly, it must be extracted from spring side only.
When any abnormal parts are found, replace it with completely new spool assembly.
When disassembled, tag the components for identification so that they can be reassembled
correctly.
Boom 1 spool
Pilot cover
Socket head bolt
O-ring
Poppet seat
Poppet Piston A
1607A8MC11
8-36
(3) Disassembly of the holding valve
① Remove the pilot cover with the holding valve as described on previous page.
Do not disassembled internal parts of the pilot cover.
Loosen the poppet seat and remove the poppet, the spring seat, the spring and the check.
(Spanner : 26 mm)
Pay attention not to lose the poppet.
Do not disassembled internal parts of the check.
Boom 1 spool
Pilot cover
Socket head bolt
Spring Poppet Poppet seat
Check Spring seat
1607A8MC12
8-37
(4) Disassembly of the load check valve and the negative relief valve
① The load check valve
a. Fix the body to suitable work bench.
Pay attention not to damage the body.
b. Loosen the plug (Hexagon wrench : 10mm).
c. Remove the spring and the load check valve with pincers or magnet.
The negative relief valve
a. Loosen the socket (Hexagon wrench : 12mm).
b. Remove the spring, the spring holder, the piston and the negative control poppet.
Plug
Spring
Load check valve
Coin type filter Spring holder
Negative Piston Spring Socket

control
poppet
1607A8MC13
8-38
(5) Disassembly of the main and overload relief valve
① Fix the body to suitable work bench.
Remove the main relief valve.
(Spanner : 32mm)
Remove the overload relief valve.
(Spanner : 32mm)
When disassembled, tag the relief valve for identification so that they can be reassembled
correctly.
Pay attention not to damage seat face.
When any abnormal parts are found, replace it with completely new relief valve assembly.
32mm HEX
Main relief valve
32mm HEX
Overload relief valve 1607A8MC14
8-39
(6) Inspection after disassembly
Clean all disassembled parts with clean mineral oil fully, and dry them with compressed air.
Then, place them on clean papers or cloths for inspection.
① Control valve
a. Check whole surfaces of all parts for burrs, scratches, notches and other defects.
b. Confirm that seal groove faces of body and block are smooth and free of dust, dent, rust etc.
c. Correct dents and damages and check seat faces within the body, if any, by lapping.
Pay careful attention not to leave any lapping agent within the body.
d. Confirm that all sliding and fitting parts can be moved manually and that all grooves and path's
are free foreign matter.
e. If any spring is broken or deformed, replace it with new one.
f. When a relief valve does not function properly, repair it, following it's the prescribed disassembly
and assembly procedures.
g. Replace all seals and O-rings with new ones.
Relief valve
a. Confirm that all seat faces at ends of all poppets and seats are free of defects and show uniform
and consistent contact faces.
b. Confirm manually that main poppet and seat can slide lightly and smoothly.
c. Confirm that outside face of main poppet and inside face of seat are free from scratches and so
on.
d. Confirm that springs are free from breakage, deformation, and wear.
e. Confirm that orifices of main poppet and seat section are not clogged with foreign matter.
f. Replace all O-rings with new ones.
g. When any light damage is found in above inspections, correct it by lapping.
h. When any abnormal part is found, replace it with a completely new relief valve assembly.
8-40
4) ASSEMBLY
(1) General precaution
① In this assembly section, explanation only is shown.
For further understanding, please refer to the figures shown in the previous structure &
disassembly section.
Pay close attention to keeping all seals free from handling damage and inspect carefully for
damage before using them.
Apply clean grease or hydraulic oil to the seal so as to ensure it is fully lubricated before
assembly.
Do not stretch seals so much as to deform them permanently.
In fitting O-rings, pay close attention not to roll them into their final position in addition, a twisted
O-ring cannot easily untwist itself naturally and could thereby cause inadequate sealing and
thereby both internal and external oil leakage.
Tighten fitting bolts for all sections with a torque wrench adjusted to the respective tightening
torque.
Do not reuse removed O-rings and seals.
(2) Load check valve
① Assemble the load check valve and spring.
Put O-rings on to plug.
Tighten plug to the specified torque.
Hexagon wrench : 10mm
Tightening torque : 6~7kgf m(43.4~50.6lbf ft)
(3) Negative control relief valve
① Assemble the nega-con poppet, piston, spring holder and spring together into body.
Put O-ring on to plug and tighten the latter to its specified torque.
(4) Main relief, port relief valves
Install main relief valve, overload relief valve into the body and tighten to the specified torque.
Tightening torque
Component Tools
kgf m lbf ft
Main relief valve Spanner 32mm 8~9 57.8~65.1
Overload relief valve Spanner 32mm 8~9 57.8~65.1
(5) Main spools

① Carefully insert the previously assembled spool assemblies into their respective bores within of
body.
Fit spool assemblies into body carefully and slowly. Do not under any circumstances push them
forcibly in.
8-41
(6) Covers
① Fit spool covers to the non-spring assembly end of the spool, and tighten the hexagonal socket
head bolts to the specified torque.
Tightening torque : 1.0~1.1kgf m(7.2~7.9lbf ft)
Confirm that O-rings have been fitted.
Fit spring covers to the spring end for the spools, and tighten hexagon socket head bolts to the
specified torque.
Confirm that O-rings have been fitted.
(7) Holding valves
① Assemble the check, spring seat and poppet together into body.
Tighten the poppet seat to the specified torque.
Spanner : 26mm
Fit the "piston A" under pilot cover with internal parts into hole on the poppet seat.
Tighten hexagon socket head bolt to specified torque.
8-42
GROUP 5 SWING DEVICE
1. REMOVAL AND INSTALL OF MOTOR

1) REMOVAL

injury. 2
When pipes and hoses are disconnected, B

the oil inside the piping will flow out, so A
(4) Disconnect hose assembly (2). 1
(5) Disconnect pilot line hoses (3,4,5,6,7,8,9).

(6) Sling the swing motor assembly (1) and
remove the swing motor mounting bolts 17W78SM01
(10).
Motor device weight : 250kg (550lb)
(7) Remove the swing motor assembly. 3
When removing the swing motor 7
assembly, check that all the piping have 4
been disconnected.
5
2) INSTALL
10 8
to removal. 9
6
(2) Bleed the air from the swing motor.
① Remove the air vent plug. 17W78SM02
Pour in hydraulic oil until it overflows from

the port.
Start the engine, run at low idling and
Tighten plug fully.
8-43
2. DISASSEMBLY AND ASSEMBLY OF SWING MOTOR
1) STRUCTURE
117 121 118 114 706 707 702 712 472 106 994 469 488 355 351 052 841
438
432 X X
A 303
106
748
471
A 747
443
444
304
468
487
746
101
433
491
745
437
124 451
301 401 051 993

131
122 123 113 116 111 744 742 031 743 058 060 053 054
464 485
059
057
056
055
SECTION A-A SECTION X-X 17W72SM02
031 Brake valve 122 Shoe 471 O-ring

051 Relief valve 123 Retainer 472 O-ring
052 Reactionless valve assy 124 Shoe plate 485 O-ring
053 Valve 131 Valve plate 487 O-ring
054 Block 301 Casing 488 O-ring
055 Plug 303 Casing 491 Oil seal
056 Back up ring 304 Front cover 702 Piston
057 O-ring 351 Plunger 706 O-ring
058 Plug 355 Spring 707 O-ring
059 O-ring 401 Hexagon socket bolt 712 Brake spring
060 O-ring 432 Snap ring 742 Friction plate
101 Drive shaft 433 Snap ring 743 Separate plate
106 Spacer 437 Snap ring 744 Plug
111 Cylinder block 438 Snap ring 745 Plug
113 Bushing 443 Roller bearing 746 Plug
114 Spring 444 Roller bearing 841 Hexagon socket bolt
116 Push rod 451 Spring pin 993 Plug
117 Spacer 464 Plug 994 Plug
118 Spacer 468 Plug
121 Piston 469 Plug
8-44
2) DISASSEMBLY
(1) Lift the motor out. Clean the motor in
kerosene and dry with compressed air.
To avoid dust inside the motor, mask all
the ports of the motor with tapes.
32038SM01
(2) Loosen the drain plug to discharge oil in

the casing(301).
32038SM02
(3) Fix the drive shaft(101) on the workbench

with the end of output shaft down. Put
matching marks on casing (301) and valve
casing(303) for easy reassembly.
32038SM03
(4) Remove the valve(052).
32038SM04
8-45
(5) Remove the relief valve(051) from valve
casing(303).
32038SM05
(6) Remove plug(469) from valve casing

(303) and spring(355), plunger(351).
Be careful not to damage the plunger seat
assembly.
32038SM06
(7) Remove valve casing(303) from casing

(301). Then, remove the valve plate(131)
from valve casing(303) with care.
32038SM07
(8) Remove the brake spring(712) from brake

piston(702).
32038SM08
8-46
(9) Remove brake piston(702) from casing
(301).
32038SM09
(10) Remove the cylinder(111) from the output

shaft (101) with the motor positioned
horizontally. Remove piston(121), retainer
(123), bushing(113), spacer (117) and
shoe plate(124).
If shoe plate would not removed easily, try
again after procedure(14).
32038SM10
(11) Remove friction plate(742) and separate

plate(743) from casing(301).
32038SM11
(12) Remove snap ring(437) with plier and

remove the front cover(304) from casing
(301).
Front cover could be removed with sliding
shaft if necessary.
32038SM12
8-47
(13) Remove drive shaft(101) from casing (301).
32038SM13
(14) Remove the shoe plate(124) from casing

(301).
32038SM14
(15) Proceed with following job only when

necessary.
① Remove the snap ring(432), spacer(106)
from drive shaft(101) and remove the
cone of roller bearing(443) by press.
Do not reuse bearings.
Press
32038SM15
Output shaft
Roller bearing
Remove oil seal(491) from front cover

(304).
32038SM16
8-48
Remove the roller bearing(444) from the
valve casing(303) by using slide hammer
bearing puller.
32038SM17
When disassembling the relief valve,

release the plug(3). 3
Remove the piston(7), spring seat(9), 5
spring(8) and plunger(6) with the body(1) 4
downwards. 15
Do not release the lock nut(15). 11
14
7
13
9
12
2
1
10
29078SM04
This completes disassembly.
8-49
3) ASSEMBLY
Do the reassembly in the reverse procedure
of the disassembly.
(1) Place the casing(301) on the workbench
with the valve casing(303) downward.
32038SM20
(2) When reassembling the roller bearing,

install the snap ring(432), and spacer(106)
to the drive shaft(101). Insert the collar
and cone of the roller bearing(443).
Install the spacer(106) and stop ring(432).
Install stop ring(433) to the output shaft
(101) by heating the cone of the roller
bearing(444).
32038SM21
Out put
Round ring parts of

the collar toward
spacer
Spacer
32038SM22
(3) Insert the drive shaft(101) into the casing

(301) with the end of output shaft upward
and tap the outer race of roller bearing
with the hammer.
32038SM23
8-50
(4) Tack O-ring(471) to the casing(301).
32038SM25
(5) Reassemble the front cover(304) to the

casing(301).
Apply grease to the rib of oil seal to avoid
damage to the rib.
32038SM26
(6) Install the snap ring(437) to the casing

(301).
32038SM27
(7) Insert the shoe plate(124) with the casing

(301) position horizontally.
32038SM28
8-51
(8) Insert the push rod(116) into the cylinder
(111). Place the bushing(113) assembled
with spacer(117) onto the cylinder.
Insert two push rods in each hole.
32038SM29
(9) Install the piston sub-assembly(121, 122)

to the retainer(123).
32038SM30
(10) Reassemble the piston assembly(121,

122) to the cylinder(111).
32038SM31
(11) Place the casing(301) under the front

cover(304) and reassemble 3 sheets of
separate plate(743) and then 2 sheets of
friction plate(742) to the casing(301).
32038SM32
8-52
(12) Insert O-ring(706, 707) inside the casing
(301).
32038SM33
(13) Reassemble brake piston(702) to the

casing(301).
32038SM34
(14) Reassemble brake spring(712) to the

brake piston(702).
32038SM35
(15) When assembling the roller bearing(444),

insert the roller bearing(444) into valve
casing(303) by hammering.
32038SM36
8-53
(16) Reassemble valve plate(131) to the valve
casing(303) and reassemble O-ring(472).
32038SM37
(17) Connect the valve casing(303) with the

casing(301) and tighten the hexagon
screw(401).
32038SM38
(18) Insert plunger(351) and spring(355) in the

valve casing and install O-ring(488).
Tighten plug(469) to the valve casing.
32038SM39
(19) Insert O-rings(051-1) to the relief valve

(051) and reassemble them to valve
casing(303).
32038SM42
8-54
(20) Tighten the plug(468) to valve casing(303)
with O-ring(487) and tighten the plug(464)
to casing(301) with O-ring(485).
32038SM43
(21) Connect the valve casing(303) with the

casing(301).
This completes assembly.
8-55
3. REMOVAL AND INSTALL OF REDUCTION GEAR
1) REMOVAL
(1) Remove the swing motor assembly.
For details, see removal of swing motor
assembly.
(2) Sling reduction gear assembly(1) and
remove mounting bolts(2).
(3) Remove the reduction gear assembly.
Reduction gear device weight : 180kg
(396lb)
13031GE18
2) INSTALL
to removal.
Tightening torque : 49.2 66.6kgf m
(356 481lbf ft)
21078DA05
8-56
4. DISASSEMBLY AND ASSEMBLY OF REDUCTION GEAR
1) STRUCTURE
25 37 36 13 3 35 34 5 2 30 29 6 7 10 9 11 18 19 26 31
28
27
38
33 32 1 8 14 12 23 15 16 21 17 20 24 22 39
17W72SM03
1 Casing 15 Planet gear 2 28 Stop ring

2 Drive shaft 16 Pin 2 29 Plug
3 Spacer 17 Spring pin 30 Plug
5 Roller bearing 18 Sun gear 2 31 Socket bolt
6 Oil seal 19 Carrier 1 32 Gauge pipe
7 Roller bearing 20 Side plate 1 33 Gauge bar
8 Thrust plate 21 Pin 1 34 Cover plate
9 Carrier 2 22 Needle cage 35 Hexagon bolt
10 Stop ring 23 Bushing 2 36 Lock plate
11 Ring gear 24 Planet gear 1 37 Hexagon bolt
12 Knock pin 25 Lock washer 38 Stop ring
13 Pinion gear 26 Side plate 3 39 Side plate 2
14 Thrust washer 27 Sun gear 1
8-57
2) DISASSEMBLY
(1) Spread off the 4 corners of lock washer 2 25 37 36 13
(25) with a tool.
Do not reuse lock washer(25).
Loosen the hexagon bolts(37) and then 3
remove lock washer(25) and lock plate 1 35 34
(36) from the pinion gear(13).
Remove pinion gear(13) and spacer(3)
from the drive shaft(2). 21078SR001
Remove cover plate(34) from the casing

(1) by loosening the hexagon bolts (35).
(2) Remove gauge bar(33) and gauge pipe

(32) from the swing motor casing.
Pour the gear oil out of reduction gear into 33
the clean bowl to check out the friction 32
decrease.
21078SR002
(3) Loosen the socket bolts(31) to separate

swing motor from reduction gear.
31
21078SR003
(4) Tighten 3 M16 eye bolts to the ring gear

(11) and then lift the ring gear(11) out of
the casing(1).
11
1
21078SR004
8-58
(5) Remove stop ring(28) and then sun gear 28
1(27).
27
19
21078SR005
(6) Tighten two M10 eye bolts to carrier 1(19)

and lift up and remove carrier 1(19) as
subassembly.
19
21078SR006
(7) Disassembling carrier 1(19) assembly.

① Remove stop ring(38).
Remove side plate 2(39), planet gear 1
19 26 38 39 22
(24), needle cage(22), side plate 1(20)
and side plate 3(26) from the carrier. 24
Using M8 solid drill, crush spring pin(17) 20
17
so that the pin 1(21) can be removed by 21
hammering.
Remove side plate 3(26) from carrier 1(19).
21078SR007
Do not reuse spring pin(17).
Do not remove pin 1(21), carrier 1(19) and
spring pin(17) but in case of replacement.
Put matching marks on the planet gear 1
(24) and the pin 1(21) for easy reassembly.
8-59
(8) Remove sun gear 2(18) and thrust
washer(14).
18
14
21078SR008
(9) Remove carrier 2(9) assembly from

casing(1).
9
21078SR009
(10) Disassembling carrier 2(9) assembly

① Using M8 solid drill, crush spring pin(17)
so that the pin 2(16) can be removed. 9 17
Do not reuse spring pin(17).
Remove pin 2(16), planet gear 2(15) and 16
15
bushing 2(23) from the carrier 2(9). 23
Put matching marks on the planet gear 2
(15) and the pin 2(16) for easy reassembly.
Do not disassemble pin 2(16), carrier 2(9)
21078SR010
and spring pin(17) but in case of
replacement.
(11) Remove thrust plate(8) and stop ring (10)

from the drive shaft(2).
8
10 2
21078SR011
8-60
(12) Remove drive shaft(2) with roller bearing
(7) and oil seal(6) assembled. 2
Remove knock pin(12) from the casing(1). 7
6
12
21078SR012
(13) Remove roller bearing(7) and oil seal(6)

from the drive shaft(2).
Do not reuse oil seal(6) once removed.
6
7
21078SR013
(14) Using the bearing disassembly tool,

remove roller bearing(5).
5
21078SR014
(15) Remove plugs(29, 30) from the casing(1).

30
29
30
21078SR015
8-61
3) ASSEMBLY
(1) Assemble roller bearing(5) inside the
casing(1). 5
21078SR016
(2) Assemble the drive shaft(2) into the

casing(1) and then install oil seal(6) and 7
roller bearing(7).
6
21078SR017
(3) Install stop ring(10) and thrust plate(8) on

top of drive shaft(2).
8
10 2
21078SR018
(4) Assembling carrier 2(9) assembly.

① Install thrust washer(14) inside the carrier
2 (9). 9 17
Install bushing 2(23) inside the planet
gear 2 (15) and then assemble them to 16
15
the carrier 2(9). 23
Assemble the pin 2(16) to the carrier 2(9)
and then press the spring pin(17) by
hammering.
21078SR019
Punch 2 points of the spring pin(17) lip.
Take care not to mistake the matching
marks of each part.
8-62
(5) Assemble carrier 2(9) assembly correctly
to the drive shaft(2).
9
21078SR020
(6) Assemble sun gear 2(18) and thrust

washer(14) to the center of the carrier 2(9)
assembly. 18
14
9
21078SR021
(7) Assembling carrier 1(19) assembly.

① Assemble the pin 1(21) to the carrier
1(19) and then press the spring pin(17)
19 26 38 39 22
by hammering.
Punch 2 points of the spring pin's(17) lip. 24
Install side plate 3(26) onto the center of 20
17
carrier 1(19). 21
Install needle cage(22) into the planet
gear 1(24).
21078SR022
Assemble side plate(20), planet gear 1
(24), side plate 2(39) and then stop ring
(38) to the pin 1(21).
Take care not to mistake the matching
marks of each part.
8-63
(8) Install sun gear 1(27) onto the side plate 3
(26).
27
26
19
21078SR023
(9) Assemble carrier 1(19) assembly onto the

carrier 2 assembly.
19
21078SR024
(10) Apply loctite to the tapped holes of casing(1).

(11) Tighten 3 M16 eye bolts to the ring
gear(11) and lift up and then assemble it
onto the casing(1).
Don't fail to coincide the knock pin(12)
holes. 11
1
21078SR025
(12) Hammer 4 knock pins(12) around the ring

gear(11). 28
(13) Assemble stop ring(28) to the drive shaft 12
of the swing motor.
11
1
21078SR026
8-64
(14) Apply loctite to the tapped holes of the
ring gear(11) and then mount swing motor
onto the ring gear(11).
Don't fail to coincide the gauge bar(33)
hole.
(15) Tighten socket bolts(31) around the swing
motor assembly. 31
Tightening torque : 24kgf m(173lbf ft)
21078SR027
(16) Assemble plugs(29, 30), gauge bar(33)

and gauge pipe(32).
33
32
30
1
29
30 21078SR028
(17) Turn the swing motor assembly upside

down and assemble cover plate(34) by 2 25 37 36 13
tightening the hexagon bolts(35).
Install spacer(3) and pinion gear(13) to
the drive shaft(2). 3
Assemble lock plate(36) on the pinion 1 35 34
gear(13).
Assemble 2 lock washers(25) on the lock
plate(36) with their 2 hole coincided
21078SR029
individually to the tapped holes of drive
shaft(2).
Tighten hexagon bolts(37) to the drive
shaft(2) and then fold all the lock
washer(25) corners over the hexagon
bolts(37).
Tightening torque : 24kgf m(173lbf ft)
(18) Inject oil into the reduction gear.
8-65
GROUP 6 TRAVEL DEVICE

1) REMOVAL
(1) Swing the work equipment 90 and lower it
completely to the ground.

E scaping fluid under pressure can
injury. 1
Dr P
(4) Remove the track shoe assembly. 2
B
For details, see removal of track shoe A
assembly.
(5) Remove the cover.
(6) Remove the hose. 21078DA47
Fit blind plugs to the disconnected hoses.

(7) Remove the bolts and the sprocket.
(8) Sling travel device assembly (1).
(9) Remove the mounting bolts (2), then
remove the travel device assembly.
2) INSTALL
to removal.
(2) Bleed the air from the travel motor.
① Remove the air vent plug.
Pour in hydraulic oil until it overflows from
the port.
Start the engine, run at low idling, and
Tighten plug fully.
8-66
2) STRUCTURE
14072SF61
1 Hub 25 Needle bearing 106 Shoe 151 Roller 219 O-ring 355 O-ring
2 Spindle 27 Parallel pin 107 Retainer plate 161 Piston 2 220 Piston seal 357 RO plug
3 Carrier 28 O-ring 108 Thrust ball 162 Shoe 2 301 Rear flange 358 O-ring
4 Ring gear A 29 O-ring 109 Timing plate 167 Pivot 323 Spool 359 O-ring
5 Ring gear B 30 PT plug 110 Washer 171 Parallel pin 324 Plug 363 Spool 2
6 Cluster gear 31 Floating seal 111 Collar 193 Spring 325 Stopper 366 Spring
7 Sun gear 32 Socket bolt 112 Piston 201 Valve 326 Plug 368 Steel ball
8 Coupling gear 33 Spring washer 113 Spring 202 Sleeve 327 Valve 379 Filter
9 Cluster shaft 34 Parallel pin 114 Spring 203 Spring retainer 328 Spring 380 Plug
12 Distance piece 35 Socket bolt 115 Friction plate 204 Plug 330 Spring 381 Piston
13 Cover 36 Steel ball 116 Mating plate 205 Shim 336 O-ring 382 Plug
14 Thrust collar 40 O-ring 132 Oil seal 206 Spring 337 O-ring 383 O-ring
15 Ring 42 Parallel pin 135 O-ring 208 O-ring 341 Parallel pin 384 O-ring
17 Pin 102 Main shaft 139 O-ring 209 O-ring 343 Socket bolt 385 Steel ball
19 Coupling 103 Swash plate 145 Snap ring 210 O-ring 346 PT plug 397 Orifice
20 Thrust plate 104 Cylinder block 149 Ball bearing 211 Back-up ring 352 RO plug 398 PT plug
23 Seal ring 105 Piston 150 Ball bearing 217 Back-up ring 354 PT plug 399 Name plate
24 Ball bearing
8-67
(1) Tools
Tool name Remark
Allen wrench 5, 6, 8, 10, 14 B
Socket 22, 30, 32, 41

Socket for socket wrench, spanner
Rod 5, 6, 8, 10, 14, 19
Pliers -
(-) Driver 150mm
Plastic and iron hammer Wooden hammer allowed. Normal 1 or so
Steel rod approx 7 7 200mm
Monkey wrench -
Oil seal inserting jig -
Bearing pliers -
Seal tape -
Eye bolt M12, M16
Press(0.5 ton) -
Oil stone -
Bearing assembling jig -
Liquid packing Loctite #577
Screw lock Loctite #243

Torque
Part name Item Size
kgf m lbf ft
Hexagon socket plug 30 PT 1/2 6.0 2.0 43.4 14.5
Hexagon socket bolt 32 M12 1.75 50 10.4 1.6 75.2 11.6
Hexagon socket bolt 35 M16 2.0 30 25.7 4.0 186 28.9
Sleeve 202 PF 1 25.0 5.0 181 36.2
Plug 204 PF 1/2 10.0 2.0 72.3 14.5
Plug 324 M36 1.5 45.0 9.0 326 65.1
Plug 326 M36 1.5 26.0 4.0 188 28.9
Hexagon socket bolt 343 M16 2.0 40 25.7 4.0 186 28.9
Plug 346 PT 1/4 3.0 0.5 21.7 3.6
Plug 352 PF 1/4 3.0 0.5 21.7 3.6
Hexagon socket plug 354 NTPF 1/16 0.6 0.25 4.3 1.8
Plug 357 PF 1/2 10.0 2.0 72.3 14.5
Plug 380 PF 3/8 6.0 1.0 43.4 7.2
Plug 382 PF 1/8 1.5 0.25 10.8 1.8
Hexagon socket plug 398 PT 1/8 1.25 0.25 9.0 1.8
8-68
3. DISASSEMBLY
(1) Before disassembling the motor, check the items to be inspected and, for remedy against trouble,
closely examine the nature of the trouble, so that the motor can be disassembled effectively.
(2) To disassemble the motor, use the disassembling procedures described in section 2) and select a
clean place.
(3) Place a rubber or vinyl sheet or other such protective materials on your working bench to protect
the surface of the motor to be serviced.
(4) During disassembly, give a match mark to the mating surfaces of each part.
(5) Arrange removed parts in order so that they will not become damaged or missing during
disassembly.
(6) Once seals have been disassembled, they should be replaced even if damage is not observed.
Have replacement seals ready on hand before starting your disassembling job.
8-69
2) DISASSEMBLING PROCEDURE
(1) Disassembling the brake valve section
and the hydraulic motor section
When inspecting or repairing the motor,
use the disassembling procedures
described below.
Numbers in parentheses ( ) following the
part name denote the item numbers
shown in the attached assembly
drawings.
25038TM02(1)
Prior to disassembly, install the motor on
an inversion working bench.
① Remove valve kit from the rear flange

(301).
Remove the O-rings(208, 209, 210) and
back up rings(211, 217) from the valve
kit.
Do not reuse the O-ring after removal.
25038TM02(2)
Remove the twelve hexagon socket head

bolts(343).
25038TM02(3)
Remove the rear flange kit(301) from the

spindle(2).
Pay attention, shaft(102) may pulled up
with the rear flange kit.
Proceed to pages 8-72 through 8-76 to
see the brake valve disassembling
procedure.
25038TM02(4)
8-70
Remove the timing plate(109), the two
pins(341) and the ball bearing(150) from
the rear flange kit(301).
Remove the two O-ring(27) and O-ring
(29) from spindle(2).
Do not reuse the O-rings(27, 29) after
removal.
Proceed to pages 8-77 through 8-79 to
see the description of the hydraulic motor
25038TM03(1)
disassembling procedure.
(2) D isassembling the reduction gear/

Hydraulic motor shafts and oil seals
① Turn the motor and cover(8) over.
Remove three plugs(33).
Remove twelve hexagon socket head
bolts(35).
25038TM03(2)
Install two eye bolt(PF 1/2) to the threads

for plugs(33).
Fasten hook to the eye bolts then lift up
cover(8).
When cover(8) do not come up easily
due to friction of O-ring(30), bang cover
(8) evenly using a plastic hammer.
Remove O-ring(30) from cover(8).
Do not reuse the removed O-ring.
25038TM03(3)
Drain lubricating oil from the reduction
gear.
Proceed to page 8-80 through 8-84 to
see the reduction gear disassembling
procedure.
8-71
3) DISASSEMBLY OF BRAKE VALVE
(1) Disassembly of the spool(323)
① Remove the two plugs(324) from the rear
flange(301).
Remove the two O-ring(336) from the
plug(324).
Removal of the two plugs(324) from the
rear flange(301) is facilitated by
loosening plugs(324) with rear flange
(301) attached to the spindle(2).
25038TM03(4)
Do not reuse the O-ring(336) after
removal.
Remove the two springs(328), the two

stoppers(325), and the spool(323) from
the rear flange(301).
Be careful not to damage the outer
surface of the spool(323) and the sliding
surface of the rear flange(301).
Spool is selectively fitted to the rear
flange(301). When replacing either or
them, therefore, the rear flange kit should
25038TM04(1)
be replaced.
(2) Disassembly of the check valves

① Remove the two plugs(326) from the rear
flange(301).
Removal of the two plug(326) from the
rear flange(301) is facilitated by
loosening plug(326) with the rear flange
(301) attached to the spindle(2).
25038TM04(2)
8-72
Remove the two springs(330) and the
two valves(327) from the rear flange(301).
Be careful not to damage the seat
sections of the valves(327) or rear flange
(301).
25038TM04(3)
Remove the O-ring(337) from the plug

(326).
removal.
(3) Disassembly of the spool(363) from the

rear flange(301)
① Remove plug(357) from rear flange(301).
Removal of plug(357) from rear
flange(301) is facilitated by loosening
plugs(324) with rear flange(301) attached
to spindle(2).
25038TM04(4)
Take out spool(363) from rear flange

(301).
Remove O-ring(355) from plug(357).
Do not reuse removed O-ring(355).
25038TM05(1)
8-73
(4) Removal inner parts of the rear flange
assembly
① Remove the two plugs(380) from rear
flange(301).
25038TM05(2)
Remove the two O-rings(359) from each

plug(380).
Take out piston(381) from rear flange
(301).
Do not reuse removed the O-rings(359).
Be careful not to scratch the outer
surface of the piston(381) and the sliding
surface of the rear flange(301).
Piston(381) is selectively fitted to rear
25038TM05(3)
flange(301). When replacing either of
them, therefore, the rear flange kit should
be replaced.
Removed the two plugs(382) from rear

flange(301).
25038TM05(4)
Take out each two O-rings(383, 384)

from each plug(382).
Do not reuse removed O-rings(383, 384).
8-74
3Take out two steel balls(385) from the
rear flange.
25038TM06(1)
(5) Removal of the valve kit

① Remove the plug(204) from sleeve(202).
The valve kit is pressure adjusted by
shim(205), when replacing of inner parts,
therefore, the valve kit should be
replaced.
25038TM06(2)
Remove the O-ring(210) from plug(204).

Take out shim(205) from plug(204).
Do not reuse removed the O-ring(210).
25038TM06(3)
8-75
Take out spring retainer(203), spring
(206) and valve(201) in that order.
25038TM06(4)
25038TM07(1)
25038TM07(2)
Remove piston seal(220) from valve

Piston seal
(201).
Valve
25038TM14
8-76
4) DISASSEMBLY OF HYDRAULIC
MOTOR
(1) Disassembly of the parking brake parts
① Remove the piston(112) by injecting
compressed air from the parking brake
access hole in the spindle(2).
Take care that abrupt injection of
compressed air(3~5kgf/cm2) may cause
the piston(112) to pop out.
To ensure your safety, apply a protective
25038TM07(3)
cover to the piston.
Remove the two O-rings(135, 139) from

the piston(112).
Do not reuse O-rings(135, 139) after
removal.
25038TM07(4)
(2) Disassembly of the internal parts of the

motor
① Lay the motor body on the side.
Drain out the oil from the motor.
Hold the cylinder block(104) with both
hands, and remove it from the spindle(2).
When laying the motor on its side, place
a receptacle under it to receive spilling
hydraulic oil.
25038TM08(1)
Before pull out cylinder block(104), turn it
alternately clockwise & counterclockwise
two or three times to separate the piston
kit from swash plate(103). This means
that the parts attached to the cylinder
block(104) come out of it and fall in the
spindle.
8-77
3Detach the two friction plates(115) and
two mating plates(116) from cylinder
block(104) which has been taken out in
step .
Separate the piston assembly(105, 106),
retainer plate(107), thrust ball(108),
washer(111) and five needle rollers(151)
from cylinder block(104) which has been
taken out in step .
25038TM08(2)
Cylinder block(104), piston assembly,
retainer plate, etc. which are included in
cylinder & piston kit and are not supplied
one by one, therefore, cylinder & piston
kit should be replaced.(Refer to class
shown in parts list.)
Take out swash plate(103) from spindle

(2).
25038TM08(3)
Take out shaft(102) from spindle(2). At

this time, ball bearing(149) is also taken
out together with shaft(102).
Oil seal(132) cannot be taken out.
Lightly shaft(102) end on the reduction
gear side with a plastic hammer to make
the removal easier.
Take notice when removing the shaft
(102) rap strongly and swiftly, the shaft
25038TM08(4)
will come quickly free from the spindle.
Take out two pivots(167) and two pins
(171) from spindle(2).
8-78
Remove the piston assembly and spring
(193) by compressed air(3~5kgf/cm2)
trough the passage for the piston
assembly in spindle(2).
Piston(161) and shoe(162) are included
in the piston assembly and are not
supplied one by one, therefore, the piston
assembly should be replaced.
Abrupt compressed air causes the piston
25038TM09(1)
assembly to spring out which dangerous.
The piston assembly can be taken out
safely by putting a protective cover or the
lie on it.
(3) Disassembly of the cylinder block

① Place the cylinder block on the work
bench and take out snap ring(145) with
the snap ring pliers while pressing the
retainer against washer(110).
Before compressing spring(114), make
sure that cylinder block(104), retainer
and press arbor are in good alignment:
This is for galling or denting cylinder
25038TM09(2)
block(104).
Put a vinyl cover on the sliding surface of
cylinder block(104) for protection.
Slacking the press force slowly, until free
of the spring force.
Do not remove spring(114) if it not to be
replaced.
When disassembling there is a possibility
that the spring may be injured.
Slacking very slowly in order to prevent
injury to the spring.
Remove the snap ring(145), washer(110),

spring(114) and washer(110).
25038TM09(3)
8-79
5) DISASSEMBLY OF REDUCTION GEAR
(1) Disassembly of Input gear A(4)
① Before removing ring gear A, give an
alignment match mark to both the ring
gear and hub(1).
Remove the ring gear A(4) using a
crowbar or any other suitable tool.
After ring gear A(4) has been removed,
remove any adhesive residue from the
mating surfaces of the ring gear and the
TM27 (140-7)
hub.
Remove the ten dowel pins(27) from the
hub(1).
Ring gear A(4)
Crowbar
R210TDD1(7)
(2) Disassembly of the hub(1), ring gear

B(5), and the coupling gear(8)
① Remove the ten hexagon socket head
bolts(35).
Since the hexagon socket head bolts(35)
have their threaded sections coated with
an adhesive, a loosening torque larger
than the tightening one is needed to
remove the bolts.
TM-SPARE07
Tightening torque : 35.5 5.5 kgf m
(256.8 39.8 lbf ft)
Be extra careful during removal not to let
the threaded sections of the hexagonal
socket head bolts(35) seize.
Before removing the coupling gear(8)
from the spindle(2), mark the mating
surfaces of the coupling gear(8) and the
spindle(2) using a paint marker.
8-80
Mount ring bolts in the M12 tapped holes
of the hub(1),and then lift the hub(1) Lift up Hub(1)
Spindle(2)
using lifter and separate the hub(1) and
the spindle(2).
This also disconnects the two ball
bearings(24), the seal ring(23), the O-
ring(40), the coupling gear(8), ring gear
B(5), the ring(15), and the distance
piece(12).
R210TDD1(8)
Proceed as follows if disassembly is not
possible with the method mentioned
above :
Rotate the motor through 180 degrees to
let the spindle side of the motor face
upward.
As shown in the photo, lightly tap the
edge of the hub(1) equally with an
aluminum rod and a hammer until the
hub(1) has become disconnected from
the spindle(2).
This will also disconnect the following TM29 (140-7)
parts :
Two ball bearing(24), seal ring(23), O-
ring(40), coupling gear(8), ring gear B(5),
ring(15), distance piece(12).
Lay a rubber mat under the working
bench to the prevent damage to hub(1)
and other parts due to possible fall from
the working bench.
8-81
(3) Disassembly of the inside of the
spindle(2) Hammer
① Remove the O-ring(29) from the spindle(2).
Screwdriver
Rotate the spindle(2) through 180 degrees.
Remove the oil seal(132) from the
spindle(2). Spindle(2)
(To remove the oil seal, set a (-) screwdriver Oil seal(132)
at the cylindrical edge of the oil seal and
lightly tap with a hammer.)
R210TDD2(1)

removal.
Remove the oil seal(132) only if it is to
be replaced.
Do not reuse the oil seal(132) once it
has been removed.
Remove the floating seal(31) from the
spindle(2).
TM30 (140-7)
8-82
(4) Disassembly of the inside of the hub(1)
① Place the hub(1) on the working bench
so that the cover side of the hub faces
upward.
Remove one of the two ball bearings(24)

from the hub(1) as shown in the figure. Hub(1) Hammer
This also lets the seal ring(23) come
loose.
In principle, the ball bearings(24) should
not be removed from the hub(1) since
Steel bar
the former is shrinkage-fitted into the
latter. Ball bearing(24)
Do not reuse the ball bearings(24) after Seal ring(23)
R210TDD2(2)
removal.
Place the hub(1) on the working bench
so that the hub end facing the spindle
points upward. Hammer
Remove the other ball bearing(24) from Hub(1)
the hub(1) as shown in the figure.
Remove the O-ring(40) from the hub(1).

Do not reuse the O-ring(40) after Steel bar
removal.
Ball bearing(24)
R210TDD2(3)
8-83
(5) Disassembly of the coupling gear(8)
① Remove the ring(15) from ring gear B(5).
Do not reuse the ring(15) after removal.
TM31 (140-7)
Remove the coupling gear(8) from ring

gear B(5).
Except for their replacement, do not
disassemble the coupling gear(8) or ring
gear B(5).
(6) Disassembly of the carrier assembly
① Do not disassemble the carrier assembly
any further.
If a component of the carrier assembly is
irrecoverably damaged, replace the
entire carrier assembly with a new one.
Components of the carrier assembly
Carrier(3)
Cluster gear(6)
Shaft(9)
Thrust collar(14)
Needle bearing(25)
Dowel pin(34)
TM32 (140-7)
8-84
4. ASSEMBLY
(1) Reassemble in work area that is clean and free from dust and grit.
(2) Handle parts with bare hands to keep them free of linty contaminates.
(3) Repair or replace the damaged parts.
Each parts must be free of burrs its corners.
(4) Do not reuse O-rings, oil seal and floating seal that were removed in disassembly.
Provide the new parts.
(5) Wash all parts thoroughly in a suitable solvent.
Dry thoroughly with compressed air.
Do not use the cloths.
(6) When reassembling oil motor components of motor, be sure to coat the sliding parts of the motor
and valve with fresh hydraulic oil.(NAS class 9 or above)
(7) Use a torque wrench to tighten bolts and plugs, to the torque specified as follows.
8-85
2) ASSEMBLY OF BRAKE VALVE
(1) Assembly of the check valve
① Fit the O-ring(337) on the plug(326).
Insert the spring(330) and the valve(327)
into the plug(326), and then grease the
spring(330) and the valve(327) and
hand-lock the former.
Insert the plug(326) in conjunction with
the spring(330) and the valve(327) into
the rear flange(301), and tighten the plug
25038TM04(2)
to the required torque.
Apply grease to the O-ring(337).
Tighten the plug(326) to a torque of
26 4kgf m(188 29lbf ft).
(2) Assembly of the spool

① Insert the spool(323) into the rear flange
(301).
Apply a working fluid to the spool(323)
and insert it into the rear flange(301).
Align the center of the hole in the rear
flange with the axial center of the spool to
prevent damage to the inner surface of
the rear flange and the outer surface of
25038TM04(1)
the spool due to contact.
Above mentioned damage causes
internal leakage after reassembly, thus
degrading the motor performance.
Attach the O-ring(336) to the plug(324).
Apply grease to O-ring(336).
Install stopper(325) and the spring(328)

into both plugs(324) and tighten the
plugs(324) into the rear flange(301) at the
required torque.
Apply grease to the O-ring(355).
Required torque : 45 9kgf m
(325 65lbf ft)
Even if either the rear flange(301) or the
spool(323) is to be replaced, their entire
25038TM03(4)
assembly(kit) must be replaced.
8-86
(3) Assembly of the two-speed control
valve
① Fit O-ring(355) on plug(357).
Insert spring(366) in spool(363) and
insert spool(363) to rear flange(301).
Apply hydraulic oil to spool(363).
25038TM05(1)
the spool due to contact.
Above mentioned damage causes
internal leakage after reassembly, thus
degrading the motor performance.
Tighten plug(357) to rear flange(301)

with specified torque.
Tightening torque : 10 2kgf m
(72.3 14.5lbf ft)
25038TM04(4)
8-87
(4) Assembly the inner parts of the rear
flange assembly
① Insert steel ball(385) to rear flange(301).
25038TM06(1)
Fit O-rings(383, 385) on plug(382).

Tighten plug(382) to rear flange(301)
with specified torque.
(10.8 1.8lbf ft)
Apply grease to O-rings(383, 384).
Apply sealant to threaded section of
plug(382).
25038TM05(4)
Insert piston(381) to rear flange(301).

Apply hydraulic oil to piston(381) and
then insert it into rear flange(301).
the piston due to contact. The above
mentioned damage causes internal
25038TM05(3)
leakage after reassembly, thus degrading
the motor performance.
Rear flange(301) and piston(381)
constitutes a rear flange kit. When
replacing either of them, therefore,
replace the rear flange kit.
8-88
Fit O-ring(359) on plug(380).
Install plug(380) to rear flange(301), and
tighten plug(380) to rear flange(301) with
the specified torque.
(43.4 7.2lbf ft)
25038TM05(2)
After fitted O-ring(358) on plug(352),

install steel ball(368) and plug(352) to
rear flange(301).
Apply grease to O-ring(358),
Do not disassemble and assemble any
further.
1408DA50
Install orifice(397) and filter(379) to rear

flange(301).
Do not disassemble and assemble any
further.
1408DA51
1408DA52
8-89
(5) Assembly of the relief valve
① Fit O-rings(208, 209, 219) and back up
rings(211, 217) on sleeve(202).
Fit O-ring(210) on plug(204).
Apply grease to the O-ring.
Insert shim(205) into plug(204).
Use the disassembled shim, because the
pressure adjustment made by shim.
When replacing the inner parts of relief
25038TM06(3)
valve, therefore, the valve kit should be
replaced.
Fit piston seal(220) to valve(201).

Piston seal
Piston seal(220) consist of O-ring and
Valve
polyester ring, apply grease to them and
then fit the O-ring and after fit the
polyester ring to valve(201).
25038TM14
8-90
Insert valve(201), spring(206) and spring
retainer(203) to sleeve(202) and tighten
plug(204) fitted with shim(205) to the
specified torque.
Apply hydraulic oil to valve(201) and then
insert it to sleeve(202).
Align the center of hole in sleeve(202)
with the axial center of valve(201) to
25038TM07(2)
the sleeve and outer surface of the valve
due to contact.
(72.3 14.5lbf ft)
Use the disassembled parts, because
the relief valve is pressure adjusted.
When replacing the inner parts of the
relief valve, therefore, the valve kit should
be replaced.
Apply grease to mating surface of the
shim and then fit into the plug. The
above mentioned will keep the two faces 25038TM07(1)
practically glued together, the shim will

not drop down when install the plug to
the sleeve.
25038TM06(4)
25038TM06(2)
8-91
3) ASSEMBLY OF REDUCTION GEAR AND HYDRAULIC MOTOR
Before reassembling the reduction gear and the hydraulic motor following completion of parts
replacement, one of the following two operations must be carried out:
Selecting a distance piece(12) of the appropriate thickness.
Selecting a thrust bearing(20) of the appropriate thickness.
Reassembling must be down only after clearance adjustment of these parts.
Prior to the start of reassembling, check for parts that require replacement.
No A : Reassembling
(See page 8-93 through 8-105)
Parts
replacement
Parts to be replaced
B : Thickness selection of a distance
Hub kit
piece(12)
Spindle kit
(See page 8-106)
Ball bearing(24)
Yes
Parts to be replaced C : Thickness selection of a thrust

Carrier assembly bearing(20)
Cover(13) (See page 8-107 through 8-109)
If all of the above-name parts can be reused in reassembly, be sure to make these adjustments.
Disregard of these adjustments will result in malfunction or premature failure of the motor.
8-92
A : REASSEMBLING
Hammer
(1) Assembly of the hub section Force-fitting jig
① Mount the hub(1) on a working bench so
that the mounting side of the cover(13) Ball bearing
faces upward.
Hub
Insert the ball bearing(24) into the hub(1)
using a force-fitting jig.
Heat the hub(1) to a temperature of
90 5 C R210TDD2(6)
Shrinkage-fit the ball bearing(24).

If a force-fitting jig is not available, insert
the ball bearing(24) into the hub(1) and
then hammer the former.
Rotate the hub(1) through 180 degrees
to make the mounting side of the
spindle(2) face upward.
Insert th ball bearing(24) into the hub(1)
using a force-fitting jig.
Shrinkage-fit the ball bearing(24).
Assemble the O-ring(40) into the hub(1).
Apply a thin coat of grease to the O-
ring(40).
Assemble the seal ring(23) into the
hub(1).
The seal ring can better be assembled
into the hub by tapping the edge of the
seal ring lightly with a plastic hammer.
When assembling the seal ring(23) into
the hub(1).
Be extra careful not to damage the O-
ring(40).
8-93
(2) Assembly of the spindle(2) section
① Mount the two floating seals(26) in the
spindle(2).
Apply a thin coat of grease to the O-ring
in the floating seal(26).
Be extra careful to ensure that dust does
not stick to the seal surface.
TM-SPARE04
(3) Assembly of the hub(1) and the spindle(2)

① Mount the spindle(2) on a working bench
so that the cover side of the spindle
faces upward.
Fit eye-bolts to the hub(1), and then lift it
with a crane and gently insert it into the
spindle(2).
If the hub(1) or the spindle(2) does not
snugly fit because of the presence of the
TM-SPARE03
ball bearing(24) evenly tap the top of the
hub(1) with a plastic hammer during
fitting.
(4) Assembly of the coupling gear(8) in

ring gear B(5) and ring gear B(5)
① Mount the coupling gear(8) in ring gear
B(5).
Fit the ring(15) into the ring groove of
ring gear B(5).
Do not reuse the ring(15) after removal.
Use a new one during reassembling.
8-94
(5) Assembly of the coupling gear(8)
① Attach a distance piece(12) to the
coupling gear(8) using grease.
During attachment, apply a thin coat of
grease to the mounting surface of the
coupling gear(8) to prevent possible fall
of the distance piece(12).
Parts to be replaced
Hub kit B : Proceed to thickness
Spindle kit section of a distance piece(12)
Ball bearing(24) (see page 8-106)
No parts to Proceed directly to

be replaced the next step.
Mount the coupling gear(8)

(fitted with ring gear B(5)) on a coupling
gear lifter, and then lift it with the crane
and mount it in the spindle.
Match the match marks on the coupling
gear(8) and the spindle(2).
Insert the ten pins(17), and caulk the pin
hole edges of the coupling gear(8).
Do not reuse the pins(17) after removal.
TM42 (140-7)
Use new ones during reassembling.
Tighten the ten hexagonal socket
bolts(35) to the required torque using a
torque wrench.
Tightening torque : 25.7 4 kgf m
(185.9 28.9 lbf ft)
Apply an adhesive to the threaded
section of the spindle(2) and the pin
holes after degreasing both.
After completely degreasing the
hexagonal socket bolts(35), apply
TM-SPARE05
molycoat to the bottom of each such bolt
neck.
Rotate the motor through 180 degrees to
make the spindle side face upward.
8-95
(6) Assembly of the oil seal(132)
① Fit the oil seal(132) into the oil seal
mounting hole of the spindle(2).
Apply white petrolatum or lithium grease
to the lip section of the oil seal(132).
Use a new oil seal during reassembling.
TM44 (140-7)
(7) Assembly of the roller bearing(149)

① Shrinkage-fit the roller bearing(149) onto
the shaft(102).
If the roller bearing(149) has been
removed from the shaft(102) during
disassembling, replace the former with a
new one and then shrinkage-fit it onto
the shaft(102).
Shrinkage-fitting temperature :
TM45 (140-7)
100 10 C.
Apply molybdenum disulfide grease to
the outer contact surface of the roller
bearing(149).
When inserting the poller bearing(149),
use leather gloves and take care not to
get burned.
8-96
(8) Assembly of the piston assembly (161,
162)
① Mount spring(193) to piston assembly
(161,162).
Apply grease to spring(193).
Mount the piston assembly(161, 162) in
the piston hole of the spindle(2).
Apply grease to piston assembly
(161,162). TM46 (140-7)
Piston kit
Spindle
R210TDD2(7)
(9) Assembly of the pivot(167)

① Mount two pins(171) to the spindle(2)
and two pivots(171).
Apply grease on half round section of
pivot(167).
(10) Assembly of cylinder block section

① Insert washer(110), spring(114),
washer(110) and snap ring(145) in that
order, into the shaft bore of cylinder
block(104).
TM47 (140-7)
8-97
Set cylinder block in the press in order to
compress the spring(114).
Place retainer on the washer(110) and
push down this tool with the press arbor
until the snap ring groove becomes
cleared.
Fit snap ring(145) into the groove.
When working on the cylinder block,
protect its sliding face by covering it with
TM48 (140-7)
a vinyl sheet.
A push of about 200kgf(440.9lbf) will be
needed to compress the spring.
(11) Assembly of piston motor sub

assembly
① Fit 5-rollers(151) into the pin holes of
cylinder block(104), and then, put
collar(111) and thrust ball(108) on it.
Immerse piston assembly in hydraulic oil.
TM49 (140-7)
Insert piston assembly into retainer

plate(107).
Mount the piston assembly in the cylinder
block(104).
After mounting, immerse the entire them
in a working fluid.
TM50 (140-7)
8-98
As shown in the figure, mount the swash
plate(103), the thrust plate(153), the
thrust ball(108), collar(111) the retainer
plate(107), the roller(151), the cylinder
block(104), and the piston assembly
(105,106) in the shaft(102).
Then, mount a lifter( ) and make the
shaft(102) upright.
The outer lacing of the roller bearing
TM51 (140-7)
(149) must be mounted in the spindle(2)
beforehand.
Accurately align and assemble the
retainer plate(107) and the spherical
section of the thrust ball(108).
Lift the motor assembly using a lifter, and
mount it in the spindle(2). Lifter
Mounting must be done so that the steel-
ball hole in the swash plate(103) and the
steel ball(167) come into a fit. Mounting
must also be done gently so that no
parts come into contact with the
spindle(2) or other sections.
Spindle(2)
Contact may damage parts.
After the motor assembly has been
mounted, turn the cylinder block by hand
to check for backlash. Perform
inspections if back-lash is present.
R210TDD2(8)
8-99
(12) Assembly of the parking brake section
① Fit the mating plate(116) first and then
the friction plate(115), one by one, into
the grooves of the outer surface of the
cylinder block(104).
This order of fitting must be strictly
observed.
Immerse the friction plates(115) in a
working fluid before fitting them into the
TM52 (140-7)
grooves.
Fit the O-rings(139,178) in the O-ring

grooves of the piston(112).
Apply a thin coat of grease to the O-
rings(139,178).
TM53 (140-7)
Mount the piston(112) in the spindle(2).

If the piston(112) does not fit into the
spindle(2) because of the resistance of
the O-ring, tap the edge of the
piston(112) lightly and equally with a
plastic hammer.
Be careful not to damage the O-ring at
this time.
TM54 (140-7)
Arrange the twelve springs(113) correctly

in the spring mounting hole of the
piston(112).
TM55 (140-7)
8-100
Fit the two O-rings(39) and the O-
ring(29) in the O-ring grooves of the
spindle(2).
Apply a thin coat of grease to the two O-
rings(39).
Remount the O-ring(29) without
greasing it.
If this O-ring is greased and remounted,
possible oozing of the grease from the
TM56 (140-7)
contact surfaces of the rear flange(101)
and the spindle(2) during motor
operation may be mistaken for oil
leakage.
Fill the spindle(2) with a working fluid.
Quantity required : 1.7 liters.
(13) Assembly of the rear flange(101) back
in the spindle(2)
① Mount the ball bearing(150) in the rear
flange(101).
Apply molybdenum disulfide grease to
the outer contact surface of the ball
bearing(150).
Fit the two dowel pins(341) into the pin

holes of the rear flange(301).
Using the dowel pins(341) as a guide,
mount the timing plate(109) in the rear
flange(301).
At this time, apply grease to the contact
surfaces of the timing plate(109) and the
rear flange(301).
Fit the two dowel pins(42) into the
TM57 (140-7)
spindle(2).
Mount the timing plate(109) firmly in the
rear flange(301) to prevent the former
from falling out of the latter.
8-101
Mount the rear flange(301) on the
spindle(2).
At this time, the two dowel pins(42) that
have been fitted into the spindle(2) must
be aligned with the pin holes.
25038TM02(4)
Tighten the nine hexagon socket head

bolts into the spindle(2) at the required
torque.
Tightening torque :
25.7 4 kgf m(185.9 28.9 lbf ft)
If, in step (12)- above, the piston(112)
does not fit into the spindle(2) because of
the resistances of the O-rings, proceed
as follows to mount the rear flange(101)
25038TM02(3)
on the spindle(2) : mount four hexagon
socket bolts(182) in diagonal form, and
tighten them equally so that the rear
flange(101) is kept horizontal.
Assemble the relief valve to rear
flange(301), then tighten at required
torque.
Tightening torque :
25 5kgf m(185 36 lbf ft)
25038TM02(2)
8-102
(15) Assembly of the carrier assembly
① Attach one of the two thrust bearing(20)
to the coupling gear(8) using grease.
Apply a thin coat of molybdenum
disulfide grease to the thrust bearing(20).
Parts to be replaced if C : Thickness selection of a

required : thrust bearing(20)
Hub kit and spindle kit carrier (see pages 8-107
assembly cover(13) through 8-109)
No parts to Proceed directly to

be replaced the next step.
Mount the coupling(19) on the shaft

(102).
disulfide grease to the spline section of
the coupling(19).
Place the steel ball(36) in the sun

gear(7), and place the sun gear in the
coupling(19).
UNTITLED
8-103
Insert the carrier assembly into the
hub(1), and correctly engage the teeth of
ring gear B(5) and teeth B of the cluster
gear(6).
This must be done only after determining
the timing point of carrier assembly
reassembling
(see next for further details).
TM62 (140-7)
Determining the timing point of carrier

Teeth A Sun gear installer
assembly reassembling
Match marking position (pre-installing jig)
To insert the carrier assembly into the procedure
hub(1) and correctly engage teeth B of
the cluster gear(6) and the teeth of ring Carrier(3)
gear B(5), carry out the operating
procedure described after this figure :
Cluster gear(6)
Procedure " "
Align the match marks of the three R210TDD3(1)
cluster gears(6) at the positions shown.

At those positions, engage the sun gear
installer correctly with the cluster gears(6)
and fix the sun gear installer.
hub(1). This dismounts the sun gear
installer automatically.
(16) Assembly of ring gear A(4)
① Mount ring gear A(4) on the hub(1). Insert
Check at this time that the teeth of ring
Match mark Ring gear A(4)
gear A and teeth A of the cluster gear are
in correct engagement.
Hub(1)
Rotate the hub(1) to fit the match marks
on ring gear A and the hub.
Fit the ten dowel pins(27) into the hub(1).
After completely degreasing that surface
R210TDD3(2)
of ring A(4) that contacts the hub(1),
apply a thin coat #SS60F hermetic
sealant to that contact surface.
Fill the reducer section with a lubricating
oil.
Quantity required : Approx. 3.3 liters
8-104
(17) Assembly of the cover(13)
① Attach the thrust bearing(20) to the
carrier(3) using grease.
disulfide grease to the surface of the
thrust bearing(20).
Install cover(8) to hub(1).

Apply slightly loctite No. 24 to that
matching face of cover which is to mate
with the surface of hub(1).
TM63 (140-7)
Fasten cover(13) to hub(1) with 20

hexagonal bolts(32) and 20 supper lock
washers(33), applying to the specified
torque.
Tightening torque :
10.4 1.6 kgf m(75.2 11.6 lbf ft)
Before tighting bolts, apply loctite 242 to
the hexagon bolts(32).
Tighten 3-plugs(30) to cover(13) to the
TM64 (140-7)
specified torque.
Tightening torque :
6 2 kgf m(45 14 lbf ft)
Before tighting plugs, wrap the threaded
portion of each plug with two lagers of
the seal tape.
Tighten each plug until the last thread
becomes nearly flush with the cover
surface within an extent equal to plus or
minus one thread relative to the surface.
8-105
B : THICKNESS SELECTION OF A
DISTANCE PIECE(12)
(1) If the parts listed below have been
replaced, select a distance piece(12) of
the appropriate thickness.
After selection, return to the original
reassembling procedure [procedure (5) of
subsection 3] and carry out the next step
of that procedure.
Hub kit
Parts replacement Spindle kit
Ball bearing(24)
(2) Steps(1) through(4) of the original

reassembling procedure must be carried
out as directed.
① Mount a measure plate on the spindle(2)
without inserting a distance piece(12).
Lightly tighten a few hexagon socket
bolts(35).
As shown in the figure at right, measure
dimension A using a depth micrometer. TM65( 140-7)
Tighten the hexagon socket head bolts

equally.
Measure dimension C of the coupling
gear(8) to be mounted see the figure at
right.
Using the clearance measurements, Measure plate for distance Depth micrometer
piece thickness
calculate the appropriate distance piece
Spindle(2)
thickness as follows.
Measure the clearance between the
A
B
edge of the spindle(2) and that of the ball

X
bearing(24).
Take this clearance as X.
X=A-B Coupling gear(8)
Ball bearing(24)
Next, determine the distance piece of
c
Take this thickness as T.
T = (C + X) 0.1
Using the results of steps (1) through (5)

A : Dimension required
above, select the appropriate thickness.
B : Jig dimension
Then, proceed with the original
R210TDD3(3)
reassembling operation.
8-106
C : THICKNESS SELECTION OF A
THRUST BEARING(20)
(1) If the parts listed below have been

replaced, select a thrust bearing(20) of
After selection, return to the original
reassembling procedure [procedure (15)
at page 8-103] and carry out the next
step of that procedure.
Hub kit
Spindle kit
Parts replacement
Carrier assembly
Cover(13)
(2) Steps(1) through(4) of the original

reassembling procedure must be carried
out as directed.
① Attach one of the two thrust bearings(20)
to the coupling gear(8).
At this time, use the thinnest distance
piece.
Mount the coupling(19) on the shaft
(102). TM66 (140-7)
Place the sun gear(7) in the coupling

(19).
hub(1), and correctly engage the teeth B
of the cluster gear(6).
This must be done only after determining
the timing point of carrier assembly
reassembling (see page 8-105 for further
details.)
Do not apply molybdenum disulfide
grease to the thrust bearing(20).
8-107
Fit the match marks on ring gear A(4)
and the hub(1), and mount the ring gear Insert
on the hub. Check at this time that teeth
Match mark Ring gear A(4)
A of the cluster gear(6) and the teeth of
ring gear A(4) are in correct engagement.
Hub(1)
R210TDD3(2)
Mount a thrust-bearing adjusting plate

on the hub(1), and lightly tighten the
former using two M12 hexagon socket
bolts.
Don not mount the thrust bearing(20) at
this time.
TM67 (140-7)
As shown in the figure at right, measure

Depth micrometer
dimension A using a depth micrometer. Thrust bearing
adjusting plate
A
B
X
Carrier
Ring gear A(4)

R210TDD3(4)
Measure dimension C of the cover(13) to

be mounted.
See the figure at right.
Cover(13)
R210TDD3(5)
8-108
Using the clearance measurements,
calculate the appropriate thrust bearing
thickness as follows.
Measure the clearance between the
edge of the carrier(3) and that of ring
gear A(4).
Take this clearance as X
X=B-A
A : Dimension required
B : Jig dimension
Next, determine the thrust bearing of the
appropriate thickness.
Take this thickness as T.
T = (C - X) - (0.3 to 0.6)
Using the results of steps(7) through(9)
above,select the appropriate thickness
from three types.
Then, proceed with the original
reassembling operation.
8-109
GROUP 7 RCV LEVER

1) REMOVAL

penetrate the skin causing serious injury. 1
(4) Loosen the socket bolt (1).

2
(5) Remove the cover of the console box.
(6) Disconnect pilot line hoses (3). 3
(7) Remove the pilot valve assembly (2).
When removing the pilot valve assembly,
check that all the hoses have been
2507A8RL12
disconnected.
2) INSTALL
to removal.
8-110
1) STRUCTURE
27
25
26
24
22
18
21
19
15
14
20 16
12 11
17 9
29
13
28
8
6
7
10
23 5
1 3
2 4
Port 1,3 Port 2,4
2507A8RL01
8-111
1 Case 11 Plug 21 Adjusting nut
2 Plug 12 Rod seal 22 Lock nut
3 Plug 13 O-ring 23 O-ring
4 O-ring 14 Push rod 24 Handle bar
5 Spool 15 Push rod 25 Nut
6 Shim 16 Plate 26 Boot
7 Spring 17 Bushing 27 Handle assembly
8 Spring seat 18 Joint assembly 28 Spring
9 Stopper 19 Swash plate 29 Spring seat
10 Spring 20 Boot
8-112
(1) Tools
Tool name Remark
Allen wrench 6 B
22
Spanner
27
(+) Driver Length 150
(-) Driver Width 4~5

Torque
Part name Item Size
kgf m lbf ft
Plug 2 PT 1/8 3.0 21.7
Joint 18 M14 3.5 25.3
Swash plate 19 M14 5.0 0.35 36.2 2.5
Adjusting nut 21 M14 5.0 0.35 36.2 2.5
Lock nut 22 M14 5.0 0.35 36.2 2.5
8-113
3) DISASSEMBLY
(1) Clean pilot valve with kerosene.
Put blind plugs into all ports
(2) Fix pilot valve in a vise with copper(or
lead) sheets.
(3) Remove end of boot(26) from case(1) and
take it out upwards.
2507ARL04
For valve with switch, remove cord also

through hole of casing.
2507ARL05
(4) Loosen lock nut(22) and adjusting nut(21)

with spanners on them respectively, and
take out handle section as one body.
2507ARL06
(5) Remove the boot(20)
1408DA61
8-114
(6) Loosen adjusting nut(21) and plate(19)
with spanners on them respectively, and
remove them.
36078RL01
36078RL02
(7) Turn joint anticlockwise to loosen it,

utilizing jig(Special tool).
When return spring(10) is strong in force,
plate(16), plug(11) and push rod(14) will
come up on loosening joint.
Pay attention to this.
36078RL03
36078RL04
8-115
(8) Remove plate(16).
36078RL05
(9) When return spring(10) is weak in force,

plug(11) stays in casing because of
sliding resistance of O-ring.
Take it out with minus screwdriver.
Take it out, utilizing external periphery
groove of plug and paying attention not to
damage it by partial loading.
During taking out, plug may jump up due
to return spring(10) force.
36078RL06
Pay attention to this.
(10) Remove reducing valve subassembly

and return spring(10) out of casing.
Record relative position of reducing valve
subassembly and return springs.
36078RL07
(11) Loosen hexagon socket head plug(2) with

hexagon socket screw key.
36078RL08
8-116
(12) For disassembling reducing valve section,
stand it vertically with spool(5) bottom
placed on flat workbench. Push down
spring seat(8) and remove two pieces of
semicircular stopper(9) with tip of small
minus screwdriver.
Pay attention not to damage spool
surface.
Record original position of spring seat(8,
36078RL09
29).
Do not push down spring seat more than
6mm.
(13) Separate spool(5), spring seat(8),

spring(7) and shim(6) individually.
Until being assembled, they should be
handled as one subassembly group.
36078RL10
(14) Take push rod(14) out of plug(11).
36078RL11
(15) Remove O-ring(13) and seal(12) from

plug(11).
Use small minus screwdriver or so on to
remove this seal.
36078RL12
8-117
36078RL13
(16) Remove lock nut(22) and then boot(26).
36078RL14
2507ARL10
8-118
(16) Cleaning of parts
① Put all parts in rough cleaning vessel
filled with kerosene and clean them
(Rough cleaning).
If dirty part is cleaned with kerosene just
after putting it in vessel, it may be
damaged. Leave it in kerosene for a
while to loosen dust and dirty oil.
If this kerosene is polluted, parts will be
damaged and functions of reassembled
valve will be degraded.
Therefore, control cleanliness of
kerosene fully.
Put parts in final cleaning vessel filled
with kerosene, turning it slowly to clean
them even to their insides(Finish
cleaning).
Do not dry parts with compressed air,
since they will be damaged and/or rusted
by dust and moisture in air.
(17) Rust prevention of parts
Apply rust-preventives to all parts.
If left as they after being cleaned, they will
be rusted and will not display their
functions fully after being reassembled.
8-119
4) ASSEMBLY
(1) Tighten hexagon socket head plug(2) to
the specified torque.
Tighten two bolts alternately and slowly.
36078RL15
(2) Put shim(6), springs(7) and spring seat(8)

onto spool(5) in this order.
36078RL16
(3) Stand spool vertically with its bottom

placed on flat workbench, and with spring
seat pushed down, put two pieces of
semicircular stopper(9) on spring seat
without piling them on.
Assemble stopper(9) so that its sharp
edge side will be caught by head of spool.
Do not push down spring seat more than
6mm.
36078RL17
(4) Assemble spring(10) into casing(1).

Assemble reducing valve subassembly
into casing.
Assemble them to their original positions.
36078RL18
8-120
(5) Assemble O-ring(13) onto plug(11).
36078RL19
(6) Assemble seal(12) to plug(11).

Assemble seal in such lip direction as
shown below.
36078RL20
(7) Assemble push rod(14) to plug(11).

Apply working oil on push-rod surface.
36078RL21
(8) Assemble plug subassembly to casing.

When return spring is weak in force,
subassembly stops due to resistance of
O-ring.
36078RL22
8-121
(9) When return spring is strong in force,
assemble 4 sets at the same time, utilizing
plate(16), and tighten joint(18) temporarily.
36078RL23
(10) Fit plate(16).
(11) Tighten joint(18) with the specified torque

to casing, utilizing jig.
36078RL24
(12) Assemble swash plate(19) to joint(18).

Screw it to position that it contacts with 4
push rods evenly.
Do not screw it over.
36078RL25
(13) Assemble adjusting nut(21), apply

spanner to width across flat of plate(19) to
fix it, and tighten adjusting nut to the
specified torque.
During tightening, do not change position
of disk.
36078RL26
8-122
(14) Fit boot(20) to plate.
1408DA61
(15) Fit boot(26) and lock nut(22), and handle

subassembly is assembled completely.
2507ARL10
36078RL27
(16) Pull out cord and tube through adjusting

nut hole provided in direction 60 to 120
from casing hole.
1408DA66
8-123
(17) Assemble bushing(17) to plate and pass
cord and tube through it.
Provide margin necessary to operation.
2507ARL07
(18) Determine handle direction, tighten lock

nut(22) to specified torque to fix handle.
2507ARL08
(19) Apply grease to rotating section of joint

and contacting faces of disk and push rod.
2507ARL09
(20) Assemble lower end of bellows to casing.

(21) Inject volatile rust-preventives through all
ports and then put blind plugs in ports.
2507ARL11
8-124
GROUP 8 TURNING JOINT

1) REMOVAL

injury.
(4) Disconnect all hoses.
1
(5) Sling the turning joint assembly (1) and
remove the mounting bolt (2).
21078DA07
(88.9 9.4lbf ft)
(6) Remove the turning joint assembly.
When removing the turning joint, check
that all the hoses have been disconnected.
2) INSTALL
to removal. 1
Take care of turning joint direction.
Assemble hoses to their original positions.
Confirm the hydraulic oil level and check
2
21078DA08
8-125
1) STRUCTURE
14 3
15
10 6
12 4
5
11
11
9
8
21078DA09
1 Hub 6 Shim 11 Wear ring

2 Shaft 7 Slipper seal 12 Retainer ring
3 Cover 8 O-ring 13 Plug
4 Spacer 9 O-ring 14 Hexagon bolt
5 Shim 10 O-ring 15 Spring washer
8-126
2) DISASSEMBLY
14
Before the disassembly, clean the turning 15
joint.
3
(1) Remove bolts(14), washer(15) and
cover(3).
21078DA10
(2) Remove shim(6) and O-ring(10). 6

(3) Remove retainer ring(12), spacer(4) and 10
12
shim(5).
4
5
21078DA11
(4) Place hub(1) on a V-block and by using a

Secure with hand
wood buffer at the shaft end, hit out Wooden block
shaft(2) to about 1/2 from the body with a
hammer.
Take care not to damage the shaft(2)
when remove hub(1) or rest it sideway.
V block
Put a fitting mark on hub(1) and shaft(2).
Work bench
8-14(3) (360-7)
(5) Remove six slipper seals(7) and O-ring(9), 11

two ring wear(11) from hub(1).
7
11
9
1
21078DA12
8-127
3) ASSEMBLY
Clean all parts.
As a general rule, replace oil seals and O-
ring.
Coat the sliding surfaces of all parts with
engine oil or grease before installing.
(1) Fix seven slipper seal(7) and O-ring(9), 11

two ring wear(11) to hub(1).
(2) Fit O-ring(8) to shaft(2). 7
11
9
1
21078DA12
(3) Set shaft(2) on block, tap hub(1) with a

plastic hammer to install. 2
21078DA13
(4) Fit shim(5), spacer(4) and retainer ring

6
(12) to shaft(2). 10
12
(5) Fit O-ring(10) to hub(1).
(6) Fit shim(6) to shaft(2). 4
5
21078DA11
8-128
(7) Install cover(3) to body(1) and tighten
bolts(14). 14
Torque : 10~12.5kgf m(72.3~90.4lbf ft) 15
21078DA10
8-129
GROUP 09 BOOM, ARM AND BUCKET CYLINDERS

1) BUCKET CYLINDER
(1) Removal
Expand the arm and bucket fully, lower the
work equipment to the ground and stop
the engine.
Operate the control levers and pedals
pressure in the hydraulic piping. 13031GE18
Loosen the breather slowly to release the

injury.
Fit blind plugs in the hoses after
disconnecting them, to prevent dirt or dust
from entering.
① Set block between bucket cylinder and
arm.
1408DA80
Remove bolt (2), nut (3) and pull out pin

(1).
Tie the rod with wire to prevent it from
coming out.
1408DA81
Disconnect bucket cylinder hoses (4) and

put plugs (5) on cylinder pipe.
1408DA82
8-130
Sling bucket cylinder assembly(8) and
remove bolt(6) then pull out pin (5).
Remove bucket cylinder assembly(8).
Weight : 140kg(310lb)
1408DA83
(2) Install
① Carry out installation in the reverse order
to removal.
When aligning the mounting position of
the pin, do not insert your fingers in the
pin hole.
Bleed the air from the bucket cylinder.
8-131
2) ARM CYLINDER
(1) Removal
the engine.
Loosen the breather slowly to release the 13031GE18
injury.
from entering.
① Set block between arm cylinder and
boom.
1408DA84
Remove bolt (2) and pull out pin (1).

coming out.
1408DA85
Disconnect arm cylinder hoses (4) and

put plugs on cylinder pipe.
Disconnect greasing pipings (5).
1408DA86
8-132
Sling arm cylinder assembly (8) and
remove bolt (7) then pull out pin (6).
Remove arm cylinder assembly (8).
1408DA87
(2) Install
to removal.
When aligning the mounting position
of the pin, do not insert your fingers in
the pin hole.
Bleed the air from the arm cylinder.
8-133
3) BOOM CYLINDER
(1) Removal
the engine.
Loosen the breather slowly to release the 13031GE18
penetrate the skin causing serious injury.
from entering.
① Disconnect greasing hoses(1).
Sling boom cylinder assembly.
1408DA88
Remove bolt(4), stopper(5) and pull out 4

pin(2).
5 2
coming out.
2107A8DA23
Lower the boom cylinder assembly(6) on

a stand.
1408DA89
8-134
Disconnect boom cylinder hoses (7) and
put plugs on cylinder pipe.
1408DA90
Remove bolt (9) and pull out pin (8).

Remove boom cylinder assembly (6).
6
8
9
1408DA91
(2) Install
to removal.
the pin hole.
Bleed the air from the boom cylinder.
Conformed the hydraulic oil level and
check the hydraulic oil leak or not.
8-135
1) STRUCTURE
(1) Bucket cylinder
9,10 6,7 22 8 4 3 11,12 5 27 26 11,13 1 2 14 16,17 15 18 19 20 21
Internal detail
28,29 24 23 25 28,29
17W78CY01
1 Tube assembly 11 O-ring 21 Lock nut

2 Rod assembly 12 Back-up ring 22 Socket head bolt
3 Gland 13 Back-up ring 23 Band assembly
4 Bushing 14 Cushion ring 24 Pipe assembly(R)
5 Snap ring 15 Piston 25 Pipe assembly(B)
6 Rod seal 16 O-ring 26 O-ring
7 Back-up ring 17 Back-up ring 27 Socket head bolt
8 Buffer ring 18 Piston seal 28 Pin bushing
9 Dust wiper 19 Wear ring 29 Dust seal
10 Snap ring 20 Dust ring
8-136
(2) Arm cylinder
9,10 6,7 8 4 24 30 5 29 3 11,12 1 2 13 15,16 14 17 18 19 23
Internal detail
31,32 27 25,26 28 31,32
17W78CY02
1 Tube assembly 11 O-ring 24 Socket head bolt

2 Rod assembly 12 Back-up ring 25 Band assembly(R)
3 Gland 13 Cushion ring 26 Band assembly(B)
4 Bushing 14 Piston 27 Pipe assembly(R)
5 Snap ring 15 O-ring 28 Pipe assembly(B)
6 Rod seal 16 Back-up ring 29 O-ring
7 Back-up ring 17 Piston seal 30 Socket head bolt
8 Buffer ring 18 Wear ring 31 Pin bushing
9 Dust wiper 19 Dust ring 32 Dust seal
10 Snap ring 23 Lock nut
8-137
(3) Boom cylinder
9,10 6,7 22 8 4 3 11,12 27 5 26 11,13 1 2 14 16,17 15 18 19 20 21
Internal detail
28,30 24 23 25 29,31
17W78CY03
1 Tube assembly 12 Buck-up ring 22 Socket head bolt

2 Rod assembly 13 Buck-up ring 23 Band assembly
3 Gland 14 Cushion ring 24 Pipe assembly(R, LH/RH)
4 Bushing 15 Piston 25 Pipe assembly(B, LH/RH)
5 Snap ring 16 O-ring 26 O-ring
6 Rod seal 17 Buck-up ring 27 Socket head bolt
7 Buck-up ring 18 Piston seal 28 Pin bushing
8 Buffer ring 19 Wear ring 29 Pin bushing
9 Dust wiper 20 Dust ring 30 Dust seal
10 Snap ring 21 Lock nut 31 Dust seal
11 O-ring
8-138
(1) Tools
6
8 B
Allen wrench
14
17
7
Spanner
8
(-) Driver Small and large sizes

Torque
Part name Item Size
kgf m lbf ft
Bucket cylinder
22 M18 32 3.0 232 21.7
Boom cylinder
Arm cylinder 24 M16 23 3.0 166 14.5
Socket head bolt
Bucket cylinder
27
Boom cylinder M10 5.4 0.5 39.1 3.6
Arm cylinder 30
Bucket cylinder 21 M55
Lock nut Boom cylinder 21 M55 100 10.0 723 72.3
Arm cylinder 23 M60
Bucket cylinder
15
Piston Boom cylinder - 150 15.0 1085 109
Arm cylinder 14
8-139
3) DISASSEMBLY
(1) Remove cylinder head and piston rod
Procedures are based on the bucket
cylinder.
① Hold the clevis section of the tube in a
vise.
Use mouth pieces so as not to damage
the machined surface of the cylinder
tube. Do not make use of the outside
piping as a locking means.
Pull out rod assembly(2) about 200mm

(7.1in). Because the rod assembly is
rather heavy, finish extending it with air
pressure after the oil draining operation.
m
0m
20
21078DA30
Loosen and remove socket bolts(22) of

the gland in sequence. Hexagon
socket wrench 22
Cover the extracted rod assembly(2) with
rag to prevent it from being accidentally
damaged during operation. Turn counter
clockwise
Cover here
with rag
2
21078DA31
Draw out cylinder head and rod assembly

together from tube assembly(1). Lift
Since the rod assembly is heavy in this
case, lift the tip of the rod assembly(2)
with a crane or some means and draw it Full straight
sideways
out. However, when rod assembly(2)
has been drawn out to approximately
two thirds of its length, lift it in its center to
Oil pan
draw it completely.
21078DA32
8-140
Note that the plated surface of rod
assembly(2) is to be lifted. For this
reason, do not use a wire sling and
others that may damage it, but use a
strong cloth belt or a rope.
Place the removed rod assembly on a

wooden V-block that is set level. Piston assy
Cover a V-block with soft rag.
Wooden block
21078DA33
(2) Remove piston and cylinder head

① Remove lock nut (21). 14 17 16 15 21
Since lock nut (21) is tightened to a high
torque, use a hydraulic and power
wrench that utilizers a hydraulic cylinder,
to remove the lock nut (21).
Remove piston assembly (15), back up
ring (17), and O-ring (16).
16078DA34
Remove the cylinder head assembly

from rod assembly (2). Plastic
hammer
If it is too heavy to move, move it by
Lift with a crane
striking the flanged part of cylinder head
with a plastic hammer.
Pull straight
Pull it straight with cylinder head
assembly lifted with a crane.
Exercise care so as not to damage the lip
of rod bushing (4) and packing
14W7A8DA35
(5,6,7,8,9,10) by the threads of rod
assembly (2).
8-141
(3) Disassemble the piston assembly
① Remove wear ring (19). 20 19 18 19 20
Remove dust ring (20) and piston seal
(18).
Exercise care in this operation not to
damage the grooves.
16078DA51
(4) Disassemble cylinder head assembly

① Remove back up ring (12, 13) and O- 9 10 7 6 8 4 1211 5 13 11
ring (11).
Remove snap ring (10), dust wiper (9).
Remove back up ring (7), rod seal (6),
buffer ring (8) and snap ring (5).
Exercise care in this operation not to
damage the grooves.
Do not remove seal and ring, if does not
14W7A8DA36
damaged.
Do not remove bushing (4).
8-142
4) ASSEMBLY
(1) Assemble cylinder head assembly
Check for scratches or rough surfaces if
found smooth with an oil stone.
① Coat the inner face of gland (3) with
hydraulic oil.
3
14W7A8DA37
Coat dust wiper (9) with grease and fit

Press here (Straight down)
dust wiper (9) to the bottom of the hole of
Metal
dust seal.
At this time, press a pad metal to the 9
metal ring of dust seal.
Fit snap ring (10) to the stop face.
14W7A8DA37A
Fit back up ring (7), rod seal (6) and buffer

ring (8) to corresponding grooves, in that
order.
Coat each packing with hydraulic oil Wrong Right
before fitting it.
Insert the backup ring until one side of it
is inserted into groove.
8-157(3) 210-7
Rod seal (6) has its own fitting direction.

Therefore, confirm it before fitting them. Push bar
Fitting rod seal (6) upside down may
damage its lip. Therefore check the
correct direction that is shown in fig.
14W7A8DA38
8-143
Fit back up ring (12, 13) to gland (3).
Put the backup ring in the warm water of 3 12 11 13 11
30~50 C.
Fit O-ring (11) to gland (3).
14W7A8DA39
(2) Assemble piston assembly

Check for scratches or rough surfaces.
If found smooth with an oil stone.
① Coat the outer face of piston (14) with
hydraulic oil.
8-158(2) 210-7
Fit piston seal (18) to piston.

Put the piston seal in the warm water of 18
60~100 C for more than 5 minutes.
After assembling the piston seal, press
its outer diameter to fit in.
16078DA52
Fit wear ring (19) and dust ring (20) to

piston (15). 20 19 18 19 20
15
16078DA53
8-144
(3) Install piston and cylinder head
① Fix the rod assembly to the work bench. Cylinder head assembly
Apply hydraulic oil to the outer surface of
Rod assembly
rod assembly (2), the inner surface of
piston and cylinder head.
Insert cylinder head assembly to rod
assembly.
14W7A8DA40
Insert cushion ring (14) to rod assembly.

Note that cushion ring (14) has a 14
direction in which it should be fitted. Insert
16078DA54
Fit piston assembly to rod assembly.

Piston assembly
Tightening torque : 150 15.0kgf m
(1085 109lbf ft)
8-159(3) 210-7
Fit lock nut to piston.

Tightening torque : 21
Item kgf m lbf ft
Bucket 21 100 10 723 72.3

Boom 21 100 10 723 72.3
Arm 23 100 10 723 72.3
16078DA55
8-145
(3) Overall assemble Fix with a bar
① Place a V-block on a rigid work bench.
Mount the tube assembly(1) on it and fix Lift
the assembly by passing a bar through
the clevis pin hole to lock the assembly.
Insert the rod assembly in to the tube Straight
assembly, while lifting and moving the
rod assembly with a crane.
Be careful not to damage piston seal by Appply liquid packing
21078DA41
thread of tube assembly.
Match the bolt holes in the cylinder head
flange to the tapped holes in the tube
assembly and tighten socket bolts to a Turn clockwise
specified torque. Apply loctite
Refer to the table of tightening torque.
Place rag
21078DA42
8-146
GROUP 10 UNDERCARRIAGE
1. TRACK LINK
1) REMOVAL
(1) Move track link until master pin is over
front idler in the position put wooden block
Master pin
as shown.
(2) Loosen tension of the track link.
ö If track tension is not relieved when the
grease valve is loosened, move the
machine backwards and forwards.
(3) Push out master pin by using a suitable
tool.
Block
8-161(1) 140-7
(4) Move the machine slowly in reverse, and

lay out track link assembly (1).
ö Jack up the machine and put wooden
block under the machine.
ö Don't get close to the sprocket side as the
track shoe plate may fall down on your
feet. 1
1408DA100
2) INSTALL
to removal.
ö Adjust the tension of the track link.
90 ~ 110
16078MS06
8-147
2. CARRIER ROLLER Frame
1) REMOVAL
(1) Loosen tension of the track link. Grease
valve
8-162(1) 140-7
(2) Jack up the track link height enough to

permit carrier roller removal.
Jack Carrier roller

8-162(2) 140-7
(3) Loosen the lock nut (1).

1 Carrier
(4) Open bracket(2) with a screwdriver, push roller
out from inside, and remove carrier roller 2
assembly.
ÂWeight : 20kg(45lb)
8-162(3) 140-7
2) INSTALL
to removal.
8-148
3. TRACK ROLLER Frame
1) REMOVAL
(1) Loosen tension of the track link. Grease
valve
8-163(1) 140-7
(2) Using the work equipment, push up track

frame on side which is to be removed.
ö After jack up the machine, set a block
under the unit.
90 ~ 110
16078MS06
(3) Remove the mounting bolt(1) and draw

out the track roller(2). 1 2
8-163(3) 140-7
2) INSTALL
to removal.
8-149
4. IDLER AND RECOIL SPRING
1) REMOVAL
(1) Remove the track link.
For detail, see removal of track link.
8-164(1) 140-7
(2) Sling the recoil spring(1) and pull out idler

and recoil spring assembly from track
frame, using a pry. 1
8-164(2) 140-7
(3) Remove the bolts(2), washers(3) and

separate idler from recoil spring.
2, 3
8-164(3) 140-7
2) INSTALL
to removal.
ö Make sure that the boss on the end face
of the recoil cylinder rod is in the hole of
the track frame.
8-164(4) 140-7
8-150
3) DISASSEMBLY AND ASSEMBLY OF IDLER
(1) Structure
6 5
8
3
1 2
4
4
3
5 21078DA43
1 Shell 4 Bushing 7 Spring pin

2 Shaft 5 Bracket 8 Plug
3 Seal assembly 6 O-ring
8-151
(2) Disassembly Press
Η Remove plug and drain oil.
Θ Draw out the spring pin(7), using a press.
7 8-166(1) 140-7
Ι Pull out the shaft(2) with a press.

Press
Κ Remove seal(3) from idler(1) and bracket
(5).
Λ Remove O-ring(6) from shaft.
2
8-166(2) 140-7
Μ Remove the bushing(4) from idler, using

a special tool.
ö Only remove bushing if replacement is
necessity.
4
8-166(3) 140-7
8-152
(3) Assembly
ö Before assembly, clean the parts.
ö Coat the sliding surfaces of all parts with 1 4 Press
oil.
Η Cool up bushing(4) fully by some dry ice
and press it into shell(1).
Do not press it at the normal temperature,
or not knock in with a hammer even after
the cooling.
8-167(1) 140-7
Θ Coat O-ring(6) with grease thinly, and

install it to shaft(2).
6
Ι Insert shaft(2) into bracket(5) and drive in
the spring pin(7). 2
8-167(2) 140-7
Κ Install seal(3) to shell(1) and bracket(5).

3
8-167(3) 140-7
Λ Install shaft(2) to shell(1).

2 1
8-167(4) 140-7
8-153
Μ Install bracket(5) attached with seal(3).
8-168(1) 140-7
Ν Knock in the spring pin(7) with a

5 7 1
hammer.
8-168(2) 140-7
Ξ Lay bracket(5) on its side.

5
Supply engine oil to the specified level,
and tighten plug.
8-168(3) 140-7
8-154
4) DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING
(1) Structure
4 7, 8 3 6 5 2 1 9 10 11 12
13
R210UCG1
1 Body 6 Lock plate 10 Back up ring

2 Tie bar 7 Bolt 11 Dust seal
3 Spring 8 Spring washer 12 Rod assembly
4 Bracket 9 Rod seal 13 Grease valve
5 Lock nut
8-155
(2) Disassembly
Η Apply pressure on spring(3) with a press.
ö The spring is under a large installed load.
This is dangerous, so be sure to set
properly.
ÂSpring set load : 11908kg(26253lb) 4
Θ Remove bolt(7), spring washer(8) and
7, 8
lock plate(6).
3
Ι Remove lock nut(5).
6
Take enough notice so that the press 5
which pushes down the spring, should
not be slipped out in its operation.
Κ Lighten the press load slowly and
remove bracket(4) and spring(3).
R210UCG2(1)
Λ Remove rod(12) from body(1).

1 12
Μ Remove grease valve(13) from rod(12).
13
R210UCG2(2)
Ν Remove rod seal(9), back up ring(10)

and dust seal(11). 1 9 10 11
R210UCG2(3)
8-156
(3) Assembly
Η Install dust seal(11), back up ring(10) and 1 9 10 11
rod seal(9) to body(1).
ö When installing dust seal(11) and rod
seal(9), take full care so as not to
damage the lip.
R210UCG2(3)
Θ Pour grease into body(1), then push in

1 12
rod(12) by hand.
After take grease out of grease valve
mounting hole, let air out.
ö If air letting is not sufficient, it may be
difficult to adjust the tension of crawler.
Ι Fit grease valve(13) to rod(12).
ÂTightening torque : 10Ü0.5kgÂm
(72.4Ü3.6lbÂft) 13
R210UCG2(4)
Κ Install spring(3) and bracket(4) to body

(1). Press
Λ Apply pressure to spring(3) with a press
and tighten lock nut(5).
ö Apply sealant before assembling.
ö During the operation, pay attention
specially to prevent the press from 4
slipping out.
3
R210UCG2(5)
8-157
Μ Lighten the press load and confirm the
set length of spring(3).
Ν After the setting of spring(3), install lock
plate(6), spring washer(8) and bolt(7).
16078UC08
8-158
GROUP 11 WORK EQUIPMENT
1. STRUCTURE
A
A
SECTION A SECTION B SECTION C
21078DA44
8-159
1) BUCKET ASSEMBLY
(1) Removal
① Lower the work equipment completely to A
ground with back of bucket facing down.
B
36078AT04
Remove nut (1), bolt (2) and draw out the

pin (A).
36078AT01
Remove nut (3), bolt (4) and draw out the

pin (B) then remove the bucket assembly.
36078AT02
(2) Install
to removal.
the pin hole.
Adjust the bucket clearance.
For detail, see operator's manual.
36078AT05
8-160
2) ARM ASSEMBLY
(1) Removal
Loosen the breather slowly to release the
penetrated the skin causing serious
injury.
① Remove bucket assembly.
For details, see removal of bucket 8-175(1) 210-7
assembly.
Disconnect bucket cylinder hose(1).
Fit blind plugs(5) in the piping at the
chassis end securely to prevent oil from 5
spurting out when the engine is started.
Sling arm cylinder assembly, remove 1
spring, pin stopper and pull out pin.
coming out.
1
For details, see removal of arm cylinder
assembly.
14W78AS10
Place a wooden block under the cylinder
and bring the cylinder down to it.
Remove bolt(2), plate(3) and pull out the
pin(4) then remove the arm assembly.
Weight : 800kg(1760lb)
When lifting the arm assembly, always lift Crane
the center of gravity.
2, 3, 4
8-175(3) 210-7
(2) Install
to removal.
When lifting the arm assembly, always lift
Bleed the air from the cylinder.
8-161
3) BOOM ASSEMBLY
(1) Removal
① Remove arm and bucket assembly.
For details, see removal of arm and
bucket assembly.
Remove boom cylinder assembly from
boom.
For details, see removal of arm cylinder
assembly. 8-176(1) 210-7
Disconnect head lamp wiring.

Disconnect bucket cylinder hose (2) and
arm cylinder hose (1).
When the hose are disconnected, oil
may spurt out.
Sling boom assembly (3).
1408DA101
Remove bolt (4), plate (5) and pull out

Crane
the pin (6) then remove boom assembly.
When lifting the boom assembly always
lift the center of gravity.
4, 5, 6
3
8-176(3) 210-7
(2) Install
to removal.
When lifting the arm assembly, always lift
Bleed the air from the cylinder.
21078DA46
8-162
Group 1 Introduction guide - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-1

Group 2 Engine system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-2
Group 3 Electric system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-4
Group 4 Hydraulic system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-6
Group 5 Undercarriage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-8
Group 6 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-9
Group 7 Work equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-13
GROUP 1 INTRODUCTION GUIDE
1. This section shows bolt specifications and

standard torque values needed when
mounting components to the machine.
2. Use genuine Hyundai spare parts.
We expressly point out that Hyundai will not
accept any responsibility for defects resulted
from non-genuine parts.
In such cases Hyundai cannot assume
liability for any damage.
ö Only metric fasteners can be used and
incorrect fasteners may result in machine
damage or malfunction.
ö Before installation, clean all the
components with a non-corrosive cleaner.
Bolts and threads must not be worn or 16079MS14
damaged.
9-1
GROUP 2 ENGINE SYSTEM
1. ENGINE AND ACCESSORIES MOUNTING
1 1
Air cleaner
3
6
Muffler
4
3 5 4
5
2
Fan
4 Engine
1607A9CM01
ÂTightening torque
Item Size kgfÂm lbfÂft Item Size kgfÂm lbfÂft

1 M 8Ý1.25 2.5Ü0.5 18.1Ü3.6 4 M12Ý1.75 10.0Ü1.0 72.3Ü7.2
2 M10Ý1.5 4.4Ü0.9 31.8Ü6.5 5 M16Ý2.0 30.0Ü3.5 217Ü25.3
3 M10Ý1.5 6.9Ü1.4 49.9Ü10.1 6 M20Ý2.5 55Ü3.5 398Ü25.3
9-2
2. COOLING SYSTEM AND FUEL TANK MOUNTING
Cooler & radiator

Pre filter Air compressor
2
2
Hyd tank Air con
idle pully
Fuel tank 3
Air con pully
4
A
2
DISCHARGE
Receiver drier -A
1
UID
LIQ
Condenser
6
VIEW A
Intercooler assy
3
7
Needle valve 3
Radiator 3
5
3
5
Reservoir
tank 5
3
3
Oil cooler Shroud

5
1607A9CM02
ÂTightening torque

1 M 6Ý1.0 1.05Ü0.2 7.6Ü1.45 5 M12Ý1.75 12.8Ü3.0 92.6Ü21.7
2 M 8Ý1.25 2.5Ü0.5 18.1Ü3.6 6 M20Ý2.5 45Ü5.1 325Ü36.9
3 M10Ý1.5 6.9Ü1.4 49.9Ü10.1 7 - 2.3Ü0.6 16.6Ü4.3
4 M10Ý1.5 8.27Ü1.7 59.8Ü12.3 - - - -
9-3
GROUP 3 ELECTRIC SYSTEM
1. ELECTRIC COMPONENTS MOUNTING 1
Work lamp
2 3
4
Heater relay
2
Fuel filler
pump
2
Travel alarm buzzer

ON
OFF
2 3
3
3
A
Battery
Battery relay
Horn DETAIL A
2
1
Washer
tank
1607A9CM03
Tightening torque
Item Size kgf m lbf ft Item Size kgf m lbf ft

1 M 6 1.0 1.05 0.2 7.6 1.45 3 M10 1.5 6.9 1.4 49.9 10.1
2 M 8 1.25 2.5 0.5 18.1 3.6 4 M12 1.75 12.8 3.0 92.6 21.7
9-4
2. ELECTRIC COMPONENTS MOUNTING 2
Beacon lamp
Wiper motor
VIEW A
Cluster ECU
-94
CN
Electric box
2
-93
CN
Prolix resistor
3 2
Fuse box
1
2
1 1
1 Y
RG
Wiper motor cover

1
1
CPU
controller
1607A9CM04
Tightening torque
Item Size kgf m lbf ft Item Size kgf m lbf ft

1 M 6 1.0 1.05 0.2 7.6 1.45 3 M10 1.5 6.9 1.4 49.9 10.1
2 M 8 1.25 2.5 0.5 18.1 3.6 - - - -
9-5
GROUP 4 HYDRAULIC SYSTEM
1. HYDRAULIC COMPONENTS MOUNTING 1
4
Solenoid
A valve
Air breather
2
4 4
Main pump
3
4
Hydraulic tank 6
7
Spin filter
4
Main control valve
4 Turning joint
5
10
5
9
Swing motor 5
RCV-LH VIEW A
4 7 Main pump
1 housing
RCV-RH Terminal 7
1 8
Coupling
4 5
RCV-pedal
4
Cross
4
4
1607A9CM05
ÂTightening torque

1 M 6Ý1.0 1.05Ü0.2 7.6Ü1.45 6 M12Ý1.75 14.7Ü2.2 106Ü15.9
2 M 6Ý1.0 1.44Ü0.3 10.4Ü2.2 7 M14Ý2.0 19.6Ü2.9 142Ü21
3 M 8Ý1.25 2.5Ü0.5 18.1Ü3.6 8 M16Ý2.0 22.5Ü0.5 163Ü3.6
4 M10Ý1.5 6.9Ü1.4 49.9Ü10.1 9 M20Ý2.5 57.9Ü8.7 419Ü62.9
5 M12Ý1.75 12.2Ü1.3 88.2Ü9.4 10 M20Ý2.5 45Ü5.1 325Ü36.9
9-6
2. HYDRAULIC COMPONENTS MOUNTING 2
Double acting attachment piping Arm safety lock system
2
2
Arm safety
lock valve
Arm cylinder
4
4 2
Stop
valve
Boom safety lock system

Boom safety
lock valve 2
2
1
2
6
Boom cylinder 2 2 BOOM CYLINDER
1
3
1 4
1
2 3 4
1
5 6
ARM CYLINDER BUCKET CYLINDER

1607A9CM07
ÂTightening torque

1 M10Ý1.5 3.2Ü0.3 23.1Ü2.2 4 M12Ý1.75 12.8Ü3.0 92.6Ü21.7
2 M10Ý1.5 5.4Ü0.5 39.1Ü3.6 5 M16Ý2.0 23Ü2.0 166Ü14.5
3 M12Ý1.75 5.5Ü0.6 39.8Ü4.3 6 M18Ý2.5 32Ü3.0 232Ü21.7
9-7
GROUP 5 UNDERCARRIAGE
ADJUST COMPONENT
Rod
4
Swing bearing
Idler
6
6
6
Idler
5
Carrier roller
8 Track chain
Cover
5
1
2
Adjust
component
Track roller
3
7
Travel motor Track guard
Sprocket 3
1607A9CM08
ÂTightening torque

1 M10Ý1.5 6.9Ü1.4 49.9Ü10.1 5 M20Ý2.5 54.7Ü6.0 396Ü43.4
2 M12Ý1.75 12.8Ü3.0 92.6Ü21.7 6 M20Ý2.5 57.8Ü6.4 418Ü46.3
3 M16Ý2.0 23Ü2.5 166Ü18.1 7 M20Ý2.5 57.9Ü8.7 419Ü62.9
4 M16Ý2.0 29.7Ü4.5 215Ü32.5 8 5/8-18UNF 42Ü4.0 304Ü43.4
9-8
GROUP 6 STRUCTURE
1. CAB AND ACCESSORIES MOUNTING
2
Sun roof
4
Sun visor
1
Latch
Cab
A Air vent cover

4
4 4
VIEW A 5
3
2
5
Door latch
6 Striker
2107A9CM09
ÂTightening torque

1 M 6Ý1.0 0.49Ü0.1 3.5Ü0.7 4 M10Ý1.5 6.9Ü1.4 49.9Ü10.1
2 M 8Ý1.25 2.5Ü0.5 18.1Ü3.6 5 M12Ý1.75 12.8Ü3.0 92.6Ü21.7
3 M10Ý1.5 4.7Ü0.9 34Ü6.5 6 M16Ý2.0 29.7Ü4.5 215Ü32.5
9-9
2. CAB INTERIOR MOUNTING
Seat
1
1
Storage
4 box cover
Aircon upper
cover
Console 1 5
box(RH) Storage
Wiper motor box
cover 1 5
Defroster 5
hose cover Aircon lower
cover
2 Console box(LH)
6 3
Travel
lever 5 Safety lever
Slide rail 2
Seat base 7
Pedal bracket
5
Viscous
mount
5
Foot rest
Bottom plate
5
Foot rest bracket
2107A9CM10
ÂTightening torque

1 M 6Ý1.0 0.49Ü0.1 3.5Ü0.7 5 M10Ý1.5 6.9Ü1.4 49.9Ü10.1
2 M 6Ý1.0 1.05Ü0.2 7.6Ü1.4 6 M10Ý1.5 8.27Ü1.7 59.8Ü12.3
3 M 8Ý1.25 3.43Ü0.7 24.8Ü5.1 7 M16Ý2.0 29.7Ü4.5 215Ü32.5
4 M 8Ý1.25 4.05Ü0.8 29.3Ü5.8 - - - -
9-10
3. COWLING MOUNTING
3
Engine hood
3
Side cover(RH)
Catch
Tank cover 2
3
3
2
3
3
3 3
3 Support(RH)
3
3
MCV hood
HY
UN
DA
I
FU
LL
LO
W
Air cleaner hood 2
Support(LH)
1607A9CM11
ÂTightening torque

1 M 6Ý1.0 0.49Ü0.1 3.5Ü0.7 3 M12Ý1.75 12.8Ü3.0 92.6Ü21.7
2 M 8Ý1.25 2.5Ü0.5 18.1Ü3.6 - - - -
9-11
4. COUNTERWEIGHT AND COVERS MOUNTING
Counterweight
2
Handle pipe
Fuel tank
A Fuel tank cover
2 2
Tool box
Upper frame
Pump under cover

Engine under cover
Radiator under cover
Hyd tank under cover
1
Fuel tank
under cover
MCV under cover

Cab under cover(B) Cab
1 under cover(C)
Swing bearing grease

drain cover 1
1
Cab under cover(A)
1607A9CM12
ÂTightening torque

1 M10Ý1.5 6.9Ü1.4 49.9Ü10.1 3 M30Ý3.9 199Ü30 1439Ü217
2 M12Ý1.75 12.8Ü3.0 92.6Ü21.7 - - - -
9-12
GROUP 7 WORK EQUIPMENT
Arm cylinder
rod pin
1 Arm cylinder
Bucket cylinder 1
head pin
Bucket 1 1
cylinder
Arm pin 1 Boom
Bucket cylinder Arm cylinder

rod pin head pin Boom cylinder head pin
Bucket control link Boom pin 1

1 Boom cylinder
Bucket 1
2
1
Side cutter(RH)
Bucket control
rod pin
Side cutter(LH)
16079CM13
ÂTightening torque

1 M16Ý2.0 29.7Ü4.5 215Ü32.5 2 M20Ý2.5 57.9Ü8.7 419Ü62.9
9-13

Hyundai R160LC-7A

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Hyundai R160LC-7A

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CONTENTS

Open index screen

SECTION 2 STRUCTURE AND FUNCTION

SECTION 3 HYDRAULIC SYSTEM

SECTION 4 ELECTRICAL SYSTEM

SECTION 5 MECHATRONICS SYSTEM

SECTION 7 MAINTENANCE STANDARD

SECTION 8 DISASSEMBLY AND ASSEMBLY

SECTION 9 COMPONENT MOUNTING TORQUE

2. Convert 550mm into inches.

Millimeters to inches ; 1mm = 0.03937 in

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

Kilogram to Pound 1kg = 2.2046lb

0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

Liter to U.K. Gallon 1˶ = 0.21997 U.K.Gal

0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

Group 1 Safety Hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1

FOLLOW SAFE PROCEDURE

WEAR PROTECTIVE CLOTHING

WARN OTHERS OF SERVICE WORK

USE HANDHOLDS AND STEPS

PROTECT AGAINST FLYING DEBRIS

PROTECT AGAINST NOISE

AVOID POWER LINES

MOVE AND OPERATE MACHINE SAFELY

OPERATE ONLY FORM OPERATOR'S

PARK MACHINE SAFELY

solely by a jack. Follow recommended procedur-

SERVICE COOLING SYSTEM SAFELY

HANDLE FLUIDS SAFELY-AVOID FIRES

Store flammable fluids away from fire hazards.

REMOVE PAINT BEFORE WELDING OR

ILLUMINATE WORK AREA SAFELY

STAY CLEAR OF MOVING PARTS

AVOID HIGH PRESSURE FLUIDS

PREVENT BATTERY EXPLOSIONS

PREVENT ACID BURNS

Use only recommended replacement parts.(See

DISPOSE OF FLUIDS PROPERLY

REPLACE SAFETY SIGNS

LIVE WITH SAFETY

Tool box Fuel tank Hydraulic tank Main pump

Tooth Bucket Turning joint Swing motor Main control valve

Arm Arm cylinder Boom Boom cylinder Cab Muffler Counterweight

Side cutter Idler

Description Unit Specification

Operating weight kg(lb) 17400(38360)

Description Unit Specification

Operating weight kg(lb) 17930(39530)

Description Unit Specification

Operating weight kg(lb) 18400(40570)

Description 2.2m(7' 3") Arm 2.6m(8' 6") Arm

7.5m kg 3400 3400 5.81