Contents

INTRODUCTION ..................................................................................................1
CAB Right Console ............................................................................7
Left Console ..............................................................................7
Electric Levers ...........................................................................9
Monitor Display ........................................................................ 11
Information Display Unit (IDU) ................................................. 11
Behind Operator’s Seat ...........................................................13
AIR CONDITIONER UNIT Compressor .............................................................................15
Filters.......................................................................................15
Receiver Tank ..........................................................................17
ENGINE Fuel Filters (Stage 1) ...............................................................19
5 Bar Electric Priming & Starting Assist Pump .........................19
Fuel Filter Wrench ...................................................................21
Left Bank .................................................................................23
Fuel Filters (Stage 2) and Fuel Supply Pump ..........................23
Fuel Filters...............................................................................25
Fuel Supply Pump ...................................................................25
Fuel Line..................................................................................27
Engine Control Module (ECM).................................................27
Starting Motor ..........................................................................29
Coolant Filters .........................................................................29
Cranking ..................................................................................31
Specifications...........................................................................31
Right Bank Pre-Lube Pump & Oil Filters..................................33
Sensors ...................................................................................33
Electric Supply Lines to Injectors.............................................35
Injectors ...................................................................................35
Turbochargers & Exhaust Manifolds........................................37
Turbocharger Lubrications .......................................................37
Intake.......................................................................................39
LTA & Alternator .......................................................................39
Contents
Flywheel Crank Position Sensor ..............................................41
Oil Pressure Sensor.................................................................41
Wet Type Flywheel ..................................................................43
Air Cleaners & Exhaust Mufflers ..............................................45
Oil Reserve Tank .....................................................................47
Coolant Reservoir ....................................................................49
PUMP TRANSMISSION Transmission Oil Cooler...........................................................51
Bottom of T/M Case.................................................................51
Lubrication Pipings ..................................................................53
T/M Oil Filters ..........................................................................53
PUMP Main Pumps (MP1 to 8) ...........................................................55
Radiator Fan Motor Drive & Oil Cooler Fan Motor Drive..........55
PUMP T/M Oil Cooling Pump ..................................................57
Air Fan Motor Drive Pump .......................................................57
Pilot Pump ...............................................................................59
Regulator .................................................................................59
Pump Drain Pressure Sensor & Contamination Sensor ..........61
PUMP CONTROLS EHC Valve ...............................................................................63
CONTROL VALVE ................................................................................................65
Main Relief Valve .....................................................................65
Overload Relief Valve & Make-Up Valve..................................67
ARM CYLINDER BOTTOM & ROD PRESSURE SENSORS ..................................................67
QUICK RESPONSE VALVES ................................................................................................69
EHC VALVE FOR ELECTRIC LEVER CONTROL ...................................................................71
SWING DEVICE ................................................................................................73
Swing Motors...........................................................................73
Swing Motor & Contamination Sensor .....................................75
Swing Motor & Drain Pressure Sensor ....................................75
Pinions.....................................................................................77
Oil Level Check .......................................................................77
Contamination Sensor for Travel Motors .................................79
Contents
RADIATOR & LTA COOLER ................................................................................................81
Radiator Fan Motors ................................................................81
OIL COOLER ................................................................................................85
Oil Temperature Sensor (Outlet) ..............................................85
Oil Pressure Sensor (Inlet) ......................................................87
Air Fan Motor...........................................................................89
HYDRAULIC High Pressure Strainers...........................................................91
Pilot Filter.................................................................................91
Pilot Accumulators ...................................................................93
ELECTRIC Electric Equipment Box............................................................95
Contamination Sensor Unit......................................................95
ENGINE FAULT INDICATOR ................................................................................................97
ELECTRIC Ground Cut-off Switch .............................................................99
Relay Box ................................................................................99
FUEL TANK Fuel Level Sensor & Switches ...............................................101
HYDRAULIC OIL TANK Full Flow Filter .......................................................................103
Bypass Filter & Drain Filter ....................................................103
Level Gauges ........................................................................105
Level Switches.......................................................................105
Hydraulic Oil Tank..................................................................107
Stop Valves & Limit Switches.................................................107
GREASE SYSTEM .............................................................................................. 111
FAST-FILL SYSTEM .............................................................................................. 117
AIR HORN Air Compressor & Air Tank.....................................................121
Air Horns & Filter ...................................................................121
WINDOW WASHER Washer Tank..........................................................................123
FOLDING STAIRWAY ..............................................................................................125
Switch Box.............................................................................127
INTRODUCTION

0740-001

-1-
Line-Up of Excavators

Line-Up of Large Size Dump Trucks

-2-
INTRODUCTION

0740-002

-3-
300 t Spec Comparison
Manufacturer HITACHI KOMATSU CAT CAT O&K LIEBHERR
Model EX3600-6 EX3600-5 EX3500-3 PC4000 5230B 5230 RH170 R9350
Operating Weight (LD/BH) (t) 361/359 350/348 334/330 370/380 327/328 318.4/316.6 368/374
Manufacturer Cummins MHI Cummins Komatsu CAT CAT Cummins Cummins
Engine Model QSKTA60-CE S16R KT38-C900 SDA16V160 3516B EUI 3516EUI KTA-38C 1200 QSK45
Rated Engine Speed (min-1) 1800 1600 1800 1800 1800 1800 1800
Displacement (l) 60.4 65.4 37.7 60 69 69 37.7 45
SAE J1995(gross)total (kw) 1450 1400 1312 1400 1232 1175 1492 1120
Engine

SAE J1995(gross) (kw) ↑ ↑ 2 × 656 ↑ ↑ ↑ 2 × 749 ↑

SAE J1349(net) (kw) (1400) (1400) 2 × 609 (1400) 1144 1095 2 × 749
Ground level with (m) 3050
100% Output Insured
Fuel Tank Capacity (l) 7450 7200 5000 6400 5330 5330 6300 5350
Fuel Tank Capacity/gross 5.14 5.14 3.81 4.57 4.33 4.54 5.08 5.08
Relief Pressure Setting (MPa) 29.4 29.4 29.4 31.0 31.0 31.0 30.0 32.0
(Trv 35.0) (Trv 35.0) (Sw 35.0, (Sw 35.0)
Sw acc 35 Dec 29 Trv 36.1)
Pump Oil Flow (l/min) 8 × 500 8 × 500 6 × 550 4140 6 × 412 6 × 375 4 x 743 3796
At Rated Engine Speed (Sw 2 × 500) (Sw 2 × 500) Sw 2 × 572 Sw 1 × 1590 Sw 2 × 464 Sw 2 × 464 Sw 4 × 326 3016
-1 Sw 780
Hydraulic

@1915 min
Swing Circuit Combined Combined Independent Combined/ Combined/ Independent Independent
Independent Independent
Front & Travel in Max. 4000 4000 3300 3400 3178 4276 3796
Swing in Max. 1000 1000 1144 928 928 1304 780
-1
@1915 min
Hydrauli Oil in the Tank (l) 1900 1900 1660 3900 1574 1574 2200
Totla Hydraulic Oil Capacity (l) 4000 4000 4000 5900 2200 ? 2200 5400 4200
Bucket Capacity (2:1) (m3) 21.0 21.0 18.0 21.0 17.0 17.0 18.0 15.3 - 18.0
15.0(@2.2t/m^3)
12.5(@2.7t/m^3)
Bucket Capacity (1:1) (m3) 23.5 21.0
Bucket Width (mm) 3950 3950 3950 4000 4200 4200 4570 4100
Max. Bucket Opening Width (mm) 2400 2400 2400 2650 2500 2500 2300 2500
Max. Digging Reach (mm) 15220 15220 15810 15100 14900 14800 15300 13750
Loader

Max. Digging Reach on Ground (mm) 13920 13920 14910 13510 14100 14100 14000 App. 13000
Min. Leveling Distance on Ground (mm) 8870 8870 9440 7910 7900 7800 8800 App. 7800
Leveling Distance on Ground (mm) 5050 5050 5470 5600 5500 5500 5000 App. 5200
Max. Cutting Height (mm) 16300 16300 17170 17320 15200 14900 14200
Max. Dumping Height (mm) 10990 10990 12420 11910 10400 10300 10800 11200
Arm Digging Force (SAE, PCSA) (kN) 1200 1200 1196 1330 1145 1250 (ISO) 1200 1040
Bucket Digging Force (SAE, PCSA) (kN) 1130 1130 1030 1250 1162 1125 (ISO) 1200 1300
Ｍａｘ．Break-out Force (kN) 1635/2076 1635/2076 1060
Bucket Capacity (1:1) (m3) 22.0 22.0 20.6 22.0 16.0 (17.5) 20.0 15.3 - 18.0
17.0
Bucket Width (mm) 3790 3790 ← 3800 3900 3900 3400
Backhoe (BE)

Max. Digging Reach (mm) 18190 18190 ← 17500 17700 17700 17800 16300
Max. Digging Reach on Ground (mm) 17610 17610 ← 16600 17200 17200 17000
Max. Digging Depth (mm) 8580 8580 ← 8000 9500 9400 7100 9500
Max. Cutting Height (mm) 17690 17690 ← 15000 15000 15000 17000 15400
Max. Dumping Height (mm) 11590 11590 ← 9600 9800 9800 11300 10200
Arm Digging Force (SAE, PCSA) (kN) 951 951 ← 1155 885 873 980 880
Bucket Digging Force (SAE, PCSA) (kN) 1050 1050 ← 1050 855 874 970 1020
Overall Height (mm) 7830 7750 ← 8260 7455 7455 8150 7570
Height of Eye Level (mm) 6764 6950 6990 7560 6750 7050
Center to center (Idler and Tumbler) (mm) 6660 6660 ← 6245 6260 6200 6385
Overall Length of Undercarriage (mm) 8700 8700 ← 8375 8174 8090 8070 8334
Overall Width of Undercarriage (mm) 6770 6770 ← 6550 6296 6296 6600 5850
Shoe Width (mm) 1270 1270 ← 1200 1100/1300/1500 1100 1200 850
Dimensions

No.of Rollers (Upper/Lower) 3/8 3/8 ← 3/7 3/8 2/7 2/9

Ground Pressure (kPa) 189/188 181/180 171 216/221 208/207 202 219/221 253/246
175/178 @1100 shoe 188/191
(1500 mm) (1500 mm)
167/169
(1600 mm)
Rear Swing Radius (mm) 6780 6780 ← 6500 6450 6450 7000 6525
Rear Length (mm) 6650 6650 ← 6090 6280 6280 6780 6360
Min. Clearance (mm) 905 905 ← 980 1108 1090 980 982
Track Gauge (mm) 5500 5500 ← 5350 5196 5196 5400 5000
Swing Speed (rpm) 3.2 3.2 3.6 4.0 4.8 3.7
Swing Torque (Kn⋅m) 1582 1582 1151 1120
Perform

Travel Speed (km/h) 2.2/1.7 2.2/1.7 2.4/1.8 2.1 2.5 2.5 2.6 2.3/3.0
Traction Force (kN) 1760 1760 1760 1545 1545 2000
Gradiability (%) 60 60 60 70 58
Grease Tank Capacity (L) 200 L 200 L 200 L
Wind Washer Tank Capacity (L) 20.0 L 7.6 L 7L 75 L

-4-
INTRODUCTION

0740-109

-5-
Main Component Arrangement

BATTERY × 4
OIL COOLER 2 × 2
PUMP × 2
FAN MOTOR High Pressure Strainer
×2 (Strainer) 2 × 4

AIR CLEANER
×2

MUFFLER × 2

FAN MOTOR
×4

-6-
CAB – Right Console

Emergency Stop Switch

Engine Control Dial

Engine Stop Switch Engine Start Switch

Work Light Switch Dome Light Switch

Maintenance Switch Entrance Light Switch

Travel Speed Switch Auto Idle Switch
Buzzer Stop Switch Fast Fill
System Switch

Key Switch

0740-003

CAB – Left Console

A/C Control (Rear) A/C Control (Front) Key Pad

Display
Radio A/C Control Wiper Washer Wiper Interval Contrast
(Side) Switch Switch Switch

0740-004

-7-
Cab Inside

1 2

T18G-01-02-053
T18M-01-02-004

29 3 4 5

28 6

27 7

8
26 9
25 10
24
11
23
22 12

21 13
20
14

19 18 17 16 15 13 T18M-01-02-005

1 - Monitor Display
2 - Hour Meter
3 - Left Control Lever/Horn
Switch
4 - Right Control Lever/Horn
Switch
5 - Pilot Control Shutoff Lever
6 - Emergency Switch
7 - Engine Control Dial
8 - Engine Start Switch
9 - Dome Light Switch
10 - Entrance Light Switch
11 - Auto-Idle Switch
12 - Fast Filling System Switch
13 - Auxiliary
14 - Key Switch
15 - Buzzer Stop Switch
16 - Travel Speed Switch
17 - Maintenance Switch
18 - Work Light Switch
19 - Engine Stop Switch
20 - Radio
21 - Air Conditioner Control
(Rear)
22 - Air Conditioner Control
(Side)
23 - Air Conditioner Control
(Front)
24 - Wiper/Washer Switch
25 - Wiper Interval Switch
26 - Display Contrast Switch
27 - Key Pad
28 - Engine Warning Lamp
(Yellow)
29 - Engine Stop Lamp (Red)

-8-
ELECTRIC LEVERS
New Cab for New EX (EX1900 and UP)

0740-110

ELECTRIC LEVER
Boom, Arm, Bucket, Swing Travel, Bucket Open/Close
15 to 20° 15 to 20° 12.4°±1° 12.4°±1°

Controller
To ELU
T18G-03-04-001C
T18G-03-04-002C

-9-
Boom, Arm, Bucket, Swing

90%±2%
Short Zone
About 3°

Output Voltage Ratio

50%±1.5%

10%±2%

Center
±15° to ±20°
Mechanical Control Angle

2 (Yellow)

1 (Black) 3 (Red)
Short Zone 4 (Blue) Short Zone
Resistor for Calibration Resistor for Calibration
30°±5°
Electrical Turning Angle
Total Resistance 2kΩ±15%
+ Direction on XY Axis
T18G-03-04-003

Travel, Bucket Open/Close

(Control Curve 25±5°C)

Control Torque Output Voltage

N⋅m v
100
16.0 VOUT
15.3±1.5 80±7.5

Output
12.0 50±5
Voltage
Ratio
20±7.5
8.0 0
5.5±1.0 12.4±1 0 12.4±1 deg

4.0 T18M-03-04-004

Neutral Switch Voltage

0
12.4±1 0 12.4±1 deg
T18M-03-04-003

deg
T18G-03-04-006

-10-
CAB – Monitor Display

Periphery watch
Monitor

Monitor Display

0740-005

CAB – Information Display Unit (IDU)

IDU
(Under Left Console)

0740-006

-11-
 1

3 T18M-01-02-006

1 - Monitor Display 2- IDU 3- ELU

-12-
CAB – Behind Operator’s Seat
Cigar ORBCOMM Data Link
Lighter Fuse Box (Option) Connector (DLU)

DC-DC Data Link Data Buzzer Power Source

Converter Connector Logging Terminal
(ECM) Unit

0740-007

-13-
 T18G-01-02-030
1

M18M-01-007

2 3 4 5 6 7

10

T18G-01-02-026
13 12 11

Layout of Power Source Terminal T146-01-03-023

1 - Fuse Box (Cab) 5- Data Link Connector 9- DC/DC Converter 13 - Controller

(Auxiliary) (View Camera)
2 - DC/DC Converter 6 - Data Link Connector 10 - Power Source Terminal
(ECM)
3 - Cigar Lighter 7 - Data Link Connector (DLU) 11 - DLU
4 - ORBCOMM (Option) 8 - Buzzer 12 - Data Link Connector
(MMS)

-14-
AIR CONDITIONER UNIT – Compressor

Air Conditioner
Compressor Drive Motor

Refrigerant Quantity:
1400 ± 50 g

0740-008

AIR CONDITIONER UNIT – Filters

Air
Conditioner
Units with
Filters

Air Circulating
Filters

0740-009

-15-
ELECTRICAL COMPONENTS

Left Frame
1

11
10

2
9

8 5

7
7 6

T18M-01-02-003

1- Work Light (2 Used) 4- Fuel Level Switch 7- Work Light 10 - Horn

(On the Cab) (Fuel Gauge) (Left-Frame Front)
2- Air Conditioner Unit 5- Fuel Level Switch 8- A/C Condenseｒ (3 Used) 11 - Wiper Motor
(3 Used) (Fuel Indicator) Condenser Fan Motor (6 Used)
3 - Fuel Tank 6 - Electrical Equipment Box 9- Receiver Dryer Control Pressure
(Refer to T1-2-4) Switch (3 Used)

-16-
AIR CONDITIONER UNIT – Receiver Tank

0740-010

-17-
-18-
ENGINE – Fuel Filters (Stage 1)

7 μ Stage 1

Vent Cap

Inlet Check Valve

Water-in Fuel Sensor

0740-033

ENGINE – 5 Bar Electric Priming & Starting Assist Pump

Electric Priming &

Starting Assist Pump Bypass Valve

0740-034

-19-
 ISO 4402
Particle Size: Reported Sizes

μm

Critical Region

Bosch Target
Cleanliness Per 100 Milliliter Fluid Sample:
12   Up to 4000 particles > 4 μm ©

12/9/6
9   Up to 500 particles > 6 μm ©

6   Up to 64 particles > 14 μm ©

FILTRATION
ISO 18-16-13 and 200 ppm Water

･ 7µ Stage 1 (Industrial Pros) and 3µ-in-3µ Stage 2

･ 95% free and emulsified Water Separation
･ To provide most consistent filtration efficiency, we are specifying a 250 hour filter Change Interval

ISO 12-9-6

-20-
ENGINE – Fuel Filter Wrench

0740-035

-21-
 ISO Code Histogram Frequency
WW Fuel Particulate Cumulative %
< 4um
60 120%

50 100%

40 80%
Frequency

30 60%

20 40%

10 20%

0 0%
14 15 16 17 18 19 20 21 22 23 More

Source: SGS WW fuel survey

Bin Frequency Cumulative %

14 6 2.76%
15 15 9.68%
16 24 20.74%
17 52 44.70%
18 42 64.06%
19 29 77.42%
20 17 85.25%
21 16 92.63%
22 13 98.62%
23 3 100.00%
More 0 100.00%
Only 64% meet ISO 18 Max.

-22-
ENGINE – Left Bank

0740-011

ENGINE – Fuel Filters (Stage 2) and Fuel Supply Pump

High Pressure Fuel Pump Air Bleed Valve

Supply Line

Fuel Shut-off Drain Line Fuel Filters

Cock (3 μ - in - 3 μ)
0740-012

-23-
 EX2500-1 EX2500-5 EX2500-6 EX3600-6
Model EX3500-3 EX1900-5 EX1900-6 EX3600-5 EX3600-5
EX5500-1 EX5500-5 EX5500-6 EX8000-6
EPA − Tier1 Tier2 − Tier1 Tier2 Tier1 Tier1 Tier2
Engine Model KTA38 S12A2 QSK38 KTA50 QSK45 QSK50 S16R QSK60 QSK60
Displacement L 37.7 33.9 37.7 50 45 50 65.37 60 60
Cylinder − 12 12 12 16 12 16 16 16 16
Bore mm 159 150 159 159 159 159 170 159 159
Stroke mm 159 160 159 159 190 159 180 190 190
Compression − 13.8 15.0 13.8 13.8 16.5 13.8 15.0 16.5 16.5
Rated output KW 656 765 810 969 1007 1044 1400 1491 1450
Rated Torque N⋅m 3482 4061 4300 5144 5345 5542 8361 7915 7697
Rated Speed min-1 1800 1800 1800 1800 1800 1800 1600 1800 1800
-1
Low Idle min 750 700 700 780 780 780 800 800 800
-1
High Idle min 1990 2000 2000 2080 2050 2050 1740 1900 1900
RAD+ RAD+ RAD+ RAD+ RAD+ RAD+
Cooling System RAD RAD RAD
Intercooler LTA LTA LTA Intercooler LTA
Allowable
° 30 20 20(30) 20(30) 20(30) 20(30) 30 20(30) 20(30)
Inclination (F/R)
Allowable
° 30 30 20(30) 20(30) 20(30) 20(30) 30 20(30) 20(30)
Inclination (R/L)
Cold Start °C 0 -12.2 -12.2 -12.2 0 -12.2 -12.2
Cold Start with Aid °C -20(A/H) -32(ether) -32(ether) -32(ether) -20(A/H) -32(ether) -32(ether)
High Elevation m 2400 2000 3300 2000 4267 3300 2000 3353 3100

MCRS SYSTEM

-24-
ENGINE – Fuel Filters

Fuel Supply Vibration Isolation

Temp. Sensing
Line

Fuel Supply
Pressure
Outlet Line Inlet Line Sensing Line

0740-013

ENGINE – Fuel Supply Pump

Fuel High
Pressure Line

Fuel Accum.
Pressure Sensor

Camshaft
Speed/Position
Sensor

Intake Manifold
Temp. Sensing Line

0740-014

-25-
FILTRATION

First Stage Off-Engine (? = 98.7%)

QSK MCRS
M14
Temperature Sensor
Vibration Isolation
T

M14 IMV
M14
Inlet Check Valve WIF
Water-in-Fuel Sensor Gerotor P
Pressure Sensor
Fuel
Tank

Fault 2261- Fuel pump delivery Fault 2262- Fuel pump delivery Fault 261- Engine fuel
pressure valid but above normal pressure valid but below normal temperature valid but above
operating range operating range normal operating range

QSK19 895 kPa (130 psi) 560 kPa (81 psi) 71 C (160 F)

QSK38 1000 kPa (145 psi) 560 kPa (81 psi) 76.6 C (170 F)

QSK50 1000 kPa (145 psi) 560 kPa (81 psi) 76.6 C (170F)

QSK60 895 kPa (130 psi) 560 kPa (81 psi) 71 C (160 F)

-26-
ENGINE – Fuel Line

Air Bleed Valve

To Fuel Tank

From Fuel To Fuel Filters

Filters Stage 2
Stage 1
From Fuel Filters
Stage 2
0740-015

ENGINE – Engine Control Module (ECM)

ECM × 3

0740-016

-27-
-28-
ENGINE – Starting Motor

Intake
Manifold Temp.
Sensing Line

DELCO-REMY
50MT-400
DC24V 9kW × 2

0740-017

ENGINE – Coolant Filters

Coolant Filters

Coolant Temp.
Sensor

Overheat Point:
101.7 °C

0740-018

-29-
 Fuel Engine Oil Coolant
Current
Stage 1 Stage 2 Oil Filter Filter
1000 h 500 h 500 h
EX1900-5 S12A2
2 2 172 L 4+1
250 h 500 h* 500 h
EX2500-5 QSK45
3 260 L 3 2
1000h 500 h 500 h
S16R
3 4 310 L 4+1
EX3600-5
250 h 400 h* 500 h
QSK60 4+1
3 260 L 4

Fuel Engine Oil Coolant

New
Stage 1 Stage 2 Oil Filter Filter
250 h 250 h 500 h* 500 h
EX1900-6 QSK38
2 3 166 L* 3 2
250 h 250 h 500 h* 500 h
EX2500-6 QSK50
3 3 235 L* 4 2
250 h 250 h 500 h* 500 h
EX3600-6 QSK60
3 3 410 L* 4 2

-30-
ENGINE – Cranking

Access to Make Alignment

0740-019

ENGINE – Specifications

0740-020

-31-
-32-
ENGINE – Right Bank Pre-Lube Pump & Oil Filters

Oil Filters

Post Filter Oil

Pressure
Sensing Line

Pre-Lube Pump

0740-021

ENGINE – Sensors

Intake Manifold
Temp. Sensing Line

Two Danfoss
Pressure Sensors,
One Per Bank

Four Temperature
Sensors, One Per
Bank

0740-022

-33-
Engine Protection

• High Temperature - Inlet Air Temp.

- Fuel Temp.
- Engine Oil Temp.
- Coolant Temp.

• Low Pressure - Engine Oil Pressure

- Coolant Pressure

• High Pressure - Blow – By Pressure

• Low Level - Coolant Level

-34-
ENGINE – Electric Supply Lines to Injectors

Injectors

Electric Supply
Lines to Injectors

Intake Manifold
Temp. Sensing
Line & Crank
Case Pressure
Sensing Line

Pre Filter Oil Pressure Sensing Line

& Coolant Pressure Sensing Line
0740-023

ENGINE – Injectors

Injectors

Fuel Supply Lines Electric Supply Lines

0740-024

-35-
-36-
ENGINE – Turbochargers & Exhaust Manifolds

0740-025

ENGINE – Turbocharger Lubrications

0740-026

-37-
-38-
ENGINE – Intake

Turbocharger

0740-027

ENGINE – LTA & Alternator

Engine Loop
Bypass Tube

LTA Loop
Bypass Tube

LTA Pump
Outlet Tube

Engine Cool-
ant Impeller

LTA Coolant Alternator

Impeller Leece Neville
DC24 140 Amps.
0740-028

-39-
-40-
ENGINE – Flywheel Crank Position Sensors

Crank Position Sensors

No. of Teeth on Ring
Gear: 168

0740-029

ENGINE – Oil Pressure Sensor

Oil Pressure Sensor

For Pre-Lube 4.5 PSi

Oil Pressure Sensor

0740-030

-41-
Fuel Derate Start Points

Engine Speed (min-1) Engine Oil Pressure (kPa)

0-500 0
500-800 0
800-1200 138
1200-1700 193
1700-2200 276
2200- 276

Engine Speed Derate Start Points

Engine Speed (min-1) Engine Oil Pressure (kPa)

0-500 0
500-800 0
800-1200 138
1200-1700 193
1700-2200 276
2200- 276

-42-
ENGINE – Wet Type Flywheel

0740-038

-43-
-44-
ENGINE – Air Cleaners & Exhaust Mufflers

Air Cleaners Exhaust Mufflers

0740-032

-45-
-46-
ENGINE – Oil Reserve Tank

Pumping Unit

Shut-off Valve

Capacity of
Reserve Tank:
280 L

Premium Engine Oil

Oil Pan: 260 L
Reserve Tank: 120L

0740-036

ENGINE – Oil Reserve Tank

From Engine Oil Pan

To Engine Oil Pan

Pump 2

Pump 1

To Reserve
Tank
From
Reserve Tank

0740-037

-47-
Withdrawal Pipe Suction Line Pump Unit
Screen Pump 1
Screen

Pump 2 Float Switch

Engine Oil Pan

Return Line
Reserve tank

Cock
Shut-off Valve
Drain Line

Supply Line

Electric Circuit Diagram for Automatic Fill System

How to operate automatic fill system 7 6 4 5

1. Turn power switch (4) to ON position.
2. Turn start switch (5) to ON position.
3. The shut-off valve on the reserve tank opens. The
shut-off valve open indicator (6) lights up.
4. Oil can begin filling the reserve tank through the
shut-off valve.
5. When the oil in the reserve tank reaches the
proper full level, the shut-off valve closes and full
indicator (7) lights up.
6. Turn power switch (4) to the OFF position to turn
the power off.
M18M-01-020

-48-
ENGINE – Coolant Reservoir

Sight Glass

Two Level
Switches For
Green Lamp

0740-039

Engine – Coolant Reservoir

Coolant Capacity:
614 L

Level Switch
For Warning
Lamp
0740-040

-49-
-50-
PUMP TRANSMISSION – Transmission Oil Cooler

Fuel Cooler Transmission Oil Cooler

0740-041

PUMP TRANSMISSION – Bottom of T/M Case

Engine Oil: 62 L
Change Interval: 500 hrs

0740-042

-51-
-52-
PUMP TRANSMISSION – Lubrication Pipings

Lubrication Pipings

T/M Oil Level Sensor

on the Block

0740-043

PUMP TRANSMISSION – T/M Oil Filters

Replacement Interval: 500 hrs

Filtration: 105 μm
0740-044

-53-
-54-
PUMP – Main Pumps (MP1 to 8)

K3V280DTH150R
514 L/min

0740-045

PUMP – Radiator Fan Motor Drive & Oil Cooler Fan Motor Drive
Radiator Fan Motor
Drive Pump
K3V180DTH100L
367 L/min

Oil Cooler Fan

Motor Drive Pump
K3V180DTH100L

0740-046

-55-
Engine and Pump Components
3 6

2 4

1 5

5 10 9 8 7

13

12 11 1
T18M-01-02-002

1 - Main Pump 1 (Transmission Side) 3- Radiator Fan Motor Drive 5- Main Pump 7 9- Generator
Main Pump 2 Pump (Transmission Side) 10 - Oil Filter (4 Used)
(Pump Tip Side) (Transmission Side) Main Pump 8 11 - CUMMINS ECM
Pump Transmission Oil Circulation Oil Cooler Fan Motor Drive (Pump Tip Side) 12 - Fuel Filter (3 Used)
Pump (Pump Tip) Pump (Pump Tip Side) Pilot Pump (Pump Tip) 13 - Coolant Filter (2 Used)
2- Main Pump 3 (Transmission Side) 4 - Main Pump 5 6 - Water Tank
Main Pump 4 (Pump Tip Side) (Transmission Side) 7 - LTA Cooler (2 Used)
Air Conditioner Compressor Drive Main Pump 6 8 - Radiator (2 Used)
Pump (Pump Tip) (Pump Tip Side)
Air Fan
Motor Drive Pump
(Pump Tip)

-56-
PUMP – PUMP T/M Oil Cooling Pump

MP1 & 2

T/M Oil Temperature

Sensor
T/M Oil Cooling Pump
KFP3225CFMSS
46 L/min

0740-047

PUMP – Air Fan Motor Drive Pump

MP5 & 6

Air Fan Motor

Drive Pump
KFP3225CFMSS
46 L/min

0740-048

-57-
 MC

Level Sensor

Engine Engine

PS T

EX8000 EX3600-6

T/M Oil Overheat Warning T/M Oil level Warning

Oil Level
ON High

Low

OFF
10 sec

110 115 °C
Warning
ON

OFF

(T)
(While the engine is running)

-58-
PUMP – Pilot Pump

Pilot Pump
KFP4163CFMSS
115.8 L/min

MP7 & 8

0740-049

PUMP – Regulator
Pf: Power Reducing Control Pressure Psv: Pump Sero
Assist Pressure
(From Pilot Pump)

Pz: Power Increasing

Control Pressure

Pi: Flow Rate Control Pressure

0740-050

-59-
 Main Pump P-Q Diagram
P Q
Location MPa (kgf/cm2) L/min Q (Flow Rate)
(psi) (US gal/min) L/min
4.9 (50) 502±5 600
A
(711) (132±1.3)
AB
[5.5±1.5 500 D I
B (56±15) [501 (132)] J
C E
(796±213)] 400
9.8 (100) 400±30
C
(1422) (106±8) 300
[13.4±0.5 F G
D (137±5) [491 (130)] 200 H
(1948±71)]
16.7 (170) 415±15 100
E
(2417) (109±3.9)
19.6 (200) 258±30 0
5 10 15 20 25 30 P (Pressure)
F
(2844) (68±8) MPa
24.5 (250) 284±15 T146-04-04-004
G
(3555) (75±3.9)
[29.4 (300)
H [277 (73)] NOTE: [ ]: Reference Value
(4266)]
[19.2±1.0
I (196±10) [483 (127)]
(2787±142)]
22.5 (230) 406±30
J
(3271) (107±8)

Pi-Q Diagram
Q (Flow Rate)
Flow Rate Control L/min
Flow Rate
Pilot Pressure 500
Location L/min B
MPa (kgf/cm2) 400
(US gal/min)
(psi)
300
0.39±0.1(4±1) 100±5
A
(57±14) (26.4±1.3) 200
2.83±0.1(28.9±1) 502±5 A
B 100
(411±14) (132±1.3)
0 1 2 3

Pi (Flow Rate Control Pilot Pressure)

MPa

-60-
PUMP – Regulator

Adjustment of
Maximum Flow Rate

Adjustment of Pump
Drive Torque

Adjustment of
Minimum Flow Rate

0740-051

PUMP – Pump Drain Pressure Sensor & Contamination Sensor

Pump Drain
Pressure Sensor

Contamination
Sensor

0740-052

-61-
Adjustment of Torque Control
The torque control is performed by pump delivery
pressure P. Therefore, the torque constant control is
adjusted by changing the set-force of inner spring (2)
and outer spring (1).
(Before adjust the screws (4) and (6), mark the end
of the adjusting screw with a white marker for the
record of the original position.)
When resetting inner spring (2), loosen nut (5) and
adjust screw (6).
When resetting outer spring (1), loosen nut (3) and
adjust screw (4).
NOTE: When adjusting screw (4) is turned, inner
spring (2) set-force varies. Therefore, when
adjusting screw (4) is turned, turn adjusting
screw (6) 2.17 times the turns of adjusting
screw (4) in the opposite direction to keep
inner spring (2) set-force unchanged.
: 36 mm : Nut (3)
: 24 mm : Screw (4)
: 13 mm : Nut (5)
: 4 mm : Screw (6)

1 2
3 4

5 6

T117-05-04-005

Outer Spring Adjustment Data Inner Spring Adjustment Data

Adjusting Screw Turn 1/4 Adjusting Screw Turn 1/4
Flow Rate Change 42 L/min (11 US gal/min) Flow Rate Change 19 L/min (5 US gal/min)
Pressure Change 1.86 MPa (19 kgf/cm2) Pressure Change 1.77 MPa (18 kgf/cm2)
(270 psi) (256 psi)
Engine Torque Change 74.5 N⋅m (7.6 kgf⋅m) Engine Torque Change 85 N⋅m (8.7 kgf⋅m)
(55 lbf⋅ft) (63 lbf⋅ft)
(Pump Flow (Pump Flow
Rate) Rate) Q
Q

P (Pump Delivery P (Pump Delivery

Pressure) Pressure)

-62-
PUMP CONTROLS – EHC Valve
Right Side:
MP Control (4)
MP Control (3)
Radiator Fan Control
Oil Cooler Fan Control

0740-082

PUMP CONTROLS – EHC Valve

Left Side:
Power Increase Control
Power Decrease Control
MP Control (1, 2, 5, 6, 7, 8)

0740-083

-63-
EHC Valve (For Main Pump Control)

8 1

7 2

6 3

5 4

T18M-03-07-005

1 - Main Pump Displacement
Control (No.4 Main Pump)
2 - Main Pump Displacement
Control (No.3 Main Pump)
3 - Radiator Fan Control 5 - Auxiliary 7 - Power Decrease Control
4 - Oil Cooler fan Control 6 - Main Pump Displacement 8 - Power Increase Control
Control (No.1, 2, 5, 6, 7, 8
Main Pump)

Increase Control Power Decrease Control

Amps to Pz Amps to Pf
SOL. Pressure SOL. Pressure

400 3.51
219 0.93

155 0.11
50 0
50 0

1780 1800 1900 1650 1750

Engine Speed Engine Speed
Lever
Operation Control
ON

OFF
2.2
1.3 0.5
0.9
400

50

-64-
CONTROL VALVE

KVS-1000
Main Relief Pressure: 29.4 MPa
Overload Relief Pressure: 31.4 MPa
(Boom, Arm, Bucket , Bucket Open (LD))
Overload Relief Pressure: 15.7 MPa
(Bucket Close (LD))
0740-053

CONTROL VALVE – Main Relief Valve

Main Relief
Valve

0740-054

-65-
CONTROL VALVE
NOTE: This drawing indicates the arrangement viewed from the base machine front.
Control Valve 4 (Upper-Right) Control Valve 2 (Upper-Left)
1 2 3 4 23 24 25 26 27 28 29 30 31

14 15 16 17 38 39 40 41 42
13
18
12 11

32
5 6 7 8 9 10 33 34 35 36 37

19 20 21 22 43 44 45 46 47 48
Control Valve 3 (Lower-Right) Control Valve 1 (Lower-Left)

T146-01-03-013

Control Valve 4 (Upper-Right) Control Valve 2 (Upper-Left)

1 - Overload Relief Valve (Boom Raise) 23 - Main Relief Valve
2 - Make-Up Valve (Boom Raise) 24 - Overload Relief Valve (LD: Bucket Close)
3 - Overload Relief Valve 25 - Overload Relief Valve (LD: Bucket Close)
(LD: Bucket Tilt-Out, BH: Bucket Roll-Out) 26 - Overload Relief Valve (LD: Arm Extend, BH: Arm Roll-In)
4 - Make-Up Valve (LD: Bucket Tilt-Out, BH: Bucket Roll-Out) 27 - Make-Up Valve (LD: Arm Extend, BH: Arm Roll-In)
5 - Make-Up Valve (BH: Arm Roll-In) 28 - Overload Relief Valve (LD: Bucket Tilt-In, BH: Bucket Roll-In)
6 - Overload Relief Valve (BH: Arm Roll-In) 29 - Make-Up Valve (LD: Bucket Tilt-In, BH: Bucket Roll-In)
7 - Make-Up Valve (Boom Lower) 30 - Overload Relief Valve (Boom Raise)
8 - Overload Relief Valve (Boom Lower) 31 - Make-Up Valve (Boom Raise)
9 - Make-Up Valve (LD: Bucket Tilt-In, BH: Bucket Roll-In) 32 - Make-Up Valve (LD: Bucket Open)
10 - Overload Relief Valve (LD: Bucket Tilt-In, BH: Bucket Roll-In) 33 - Overload Relief Valve (LD: Bucket Open)
11 - Main Relief Valve 34 - Make-Up Valve (LD: Arm Retract, BH: Arm Roll-Out)
35 - Overload Relief Valve (LD: Arm Retract, BH: Arm Roll-Out)
36 - Make-Up Valve (LD: Bucket Tilt-Out, BH: Bucket Roll-Out)
37 - Overload Relief Valve
(LD: Bucket Tilt-Out, BH: Bucket Roll-Out)

Control Valve 3 (Lower-Right) Control Valve 1 (Lower-Left)

12 - Main Relief Valve 38 - Main Relief Valve
13 - Overload Relief Valve (Boom Raise) 39 - Overload Relief Valve (LD: Arm Retract, BH: Arm Roll-Out)
14 - Make-Up Valve (Boom Raise) 40 - Make-Up Valve (LD: Arm Retract, BH: Arm Roll-Out)
15 - Overload Relief Valve (Left Swing) 41 - Overload Relief Valve (Boom Raise)
16 - Make-Up Valve (Left Swing) 42 - Make-Up Valve (Boom Raise)
17 - Overload Relief Valve (LD: Bucket Tilt-In, BH: Bucket Roll-In) 43 - Make-Up Valve (LD: Arm Extend, BH: Arm Roll-In)
18 - Make-Up Valve (LD: Bucket Tilt-In, BH: Bucket Roll-In) 44 - Overload Relief Valve (LD: Arm Extend, BH: Arm Roll-In)
19 - Make-Up Valve (Right Swing) 45 - Make-Up Valve (LD: Bucket Tilt-In, BH: Bucket Roll-In)
20 - Overload Relief Valve (Right Swing) 46 - Overload Relief Valve (LD: Bucket Tilt-In, BH: Bucket Roll-In)
21 - Make-Up Valve (LD: Arm Extend, BH: Arm Roll-In) 47 - Make-Up Valve (Boom Lower)
22 - Overload Relief Valve (LD: Arm Extend, BH: Arm Roll-In) 48 - Overload Relief Valve (Boom Lower)
NOTE: LD: Loading Shovel
BH: Backhoe

-66-
CONTROL VALVE – Overload Relief Valve & Make-Up Valve

Make-Up Valve

Overload Relief
Valve

0740-055

ARM CYLINDER BOTTOM & ROD PRESSURE SENSORS

For Rod Side For Bottom Side

0740-054

-67-
-68-
QUICK RESPONSE VALVES

Quick
Response
Valve (2)

Quick
Response
Valve (1)

0740-057

QUICK RESPONSE VALVES

-69-
 D.Q.R Spool Position When Control Lever is in D.Q.R Spool Position When Control Lever is Op-
Neutral: erated:

Signal Pressure Oil Port

(From the EHC Valve)

Spool
Output Port
Spool
(To the control valve spool)

Port T
(To the
hydraulic
oil tank)

Passage
Output Port

Port P
(From the
Port P Notch
EHC Valve)

Spring T18B-03-05-003C Spring T18B-03-05-004C

Spool

Output Port

Port P

T18B-03-05-005C

Spring (Set Pressure: 0.15 MPa Spring Chamber

2
(1.5 kgf/cm , 21 psi))

-70-
EHC VALVE FOR ELECTRIC LEVER CONTROL

EHC Valve (Left)

0740-059

EHC VALVE FOR ELECTRIC LEVER CONTROL

EHC Valve (Right)

0740-060

-71-
EHC Valve (For Electric Lever Control)

EHC Valve (Left Side) EHC Valve (Right Side)

17

1 5 9 13

2 6 10 14

3 7 11 15

4 8 12 16

T18M-03-04-001 T18M-03-04-002

1- Right Travel Forward 6- Bucket Open 10 - Left Swing 14 - Bucket Tilt-Out

2- Right Travel Reverse 7- Bucket Close 11 - Right Swing 15 - Boom Lower
3- Left Travel Forward 8- Left Travel Reverse 12 - Bucket Tilt-In 16 - Auxiliary
4- Auxiliary 9- Boom Raise 13 - Arm Extend 17 - Gate Lock Pressure Sensor
5- Arm Retract

D.Q.R Valve

Electric Lever

Spool

Port T

ELU Port P

Pilot
Pump Actuator
From Pilot Control Shutoff
Lever Solenoid Valve
Control Valve

Spring
EHC Valve
(For Electric Lever Control)

Spool Main Pump Hydraulic Oil Tank T18G-02-02-002

-72-
SWING DEVICE

2-Stage Planetary
Reduction Device

Gear Oil: 75 L × 4
Change Interval
1000 hrs

0740-061

SWING DEVICE – Swing Motors

MX750
Relief Pressure Setting: 29.4 MPa
Cracking Pressure for Releasing
Parking Brake: 2.7 MPa

0740-062

-73-
-74-
SWING DEVICE – Swing Motor & Contamination Sensor
Contamination
Sensor
Brake Valve

Parking Brake Relief Valve

Control Line

0740-063

SWING DEVICE – Swing Motor & Drain Pressure Sensor

Drain Pressure
Sensor

0740-064

-75-
 Contamination Sensor Layout

Main Pump Swing Motor, Travel Motor

Rear Side

3 4

2
1

T146-01-03-020

5
7
6
8
Front Side

T146-05-02-048
View A View B
9 10
12 13

11

Center Joint

T18M-01-02-014

T18M-01-02-013

1 - Contamination Sensor 5 - Contamination Sensor 8 - Contamination Sensor 11 - Contamination Sensor

(Main Pump 4) (Main Pump 7) (Main Pump 2) (Travel Motor)
2 - Contamination Sensor 6 - Contamination Sensor 9 - Contamination Sensor 12 - Contamination Sensor
(Main Pump 3) (Main Pump 8) (Right Side Rear Swing (Left Side Front Swing
Motor) Motor)
3 - Contamination Sensor 7 - Contamination Sensor 10 - Contamination Sensor 13 - Contamination Sensor
(Main Pump 6) (Main Pump 1) (Left Side Rear Swing (Right Side Front Swing
Motor) Motor)
4 - Contamination Sensor
(Main Pump 5)

-76-
SWING DEVICE – Pinions

0740-065

SWING DEVICE – Oil Level Check

Cocks Open
When Checking
Oil Levels

0740-066

-77-
-78-
CENTER JOINT – Contamination Sensor for Travel Motors

Contamination
Sensor

Cushion Cylinder
End Pressure
Sensor

0740-067

-79-
TRAVEL SHOCK ABSORBING / TRAVEL
STOP CIRCUIT
Operation
Purposes
Protects the front idlers from shocks.
Depending on shocks to the front idlers, the travel
shock absorbing/travel stop circuit functions as fol-
lows.
• When subjected to ordinary shocks:
The accumulators works to absorb shocks.
• When subjected to excessive shocks
Refer to CONTROL SYSTEM/Cushion Cylinder
End Travel Limit Control.
• When subjected to ordinary shocks:
When moving the travel lever, ELU activates the
control solenoid valve (refer to Operation Circuit.)
Pilot pressure is routed to D.Q.R valve via the
control solenoid valve. Thereby, pilot pressure oil
from the pilot pump is routed to the travel spool in
the control valve via D.Q.R valve, thus moving the
travel spool to open the travel port. Then, pres-
sure oil from the main circuit is delivered to left
and right travel motors, causing the machine to
travel. At the same time, pressure oil from the
main circuit is pressure-reduced by the pres-
sure-reducing valve, and is delivered to the
cushion cylinder.
When the front idler is subjected to shocks, the
cushion piston is pushed to deliver hydraulic oil
from behind the cushion piston into accumulators.
Then, bladders in accumulators are contracted to
absorb shocks.

Cushion Piston

Travel Stop Valve

Cushion Cylinder
Relief Valve

(Grease)

Pressure-Reducing
Cushion Cylinder End Valve
Pressure Sensor

Pilot Pump
(Through Travel
Speed Select Valve)

T18M-02-04-005R
Travel Spool in
Control Valve Center Joint Pilot Pressure
Select Valve

-80-
RADIATOR & LTA COOLER

2 × Radiator
2 × LTA Cooler

0740-068

RADIATOR & LTA COOLER – Radiator Fan Motors

4 × Radiator Fan Motor

0740-069

-81-
Radiator Fan Speed Control

(1) Sensors: Radiator Inlet Temperature Sensor

Motor Capacity Fan Speed Control Pressure Current to SOL.

Fan Speed
L/min min-1 MPa mA
1st 76 400 3.51 400
2nd 225 1150 1.65 270
3rd 348 1530 0.00 50

Thermostat Setting
Cracking Temperature 82 °C
Full Open 94 °C
Speed
Fan Speed Temperature °C
3
1st → 2nd 85
2nd → 3rd 90 2

3rd → 2nd 85
1
2nd → 1st 80
70 80 90 100 °C

(2) Sensors: LTA Cooler Outlet Temperature Sensor

Fan Speed °C
1st → 3rd 49
3rd → 1st 44
* Condition:
Ambient Temperature > 25 °C

(3) Sensor Fault Conditions

> 4.5 V
< 0.15 V
(Remaining for more than 5 seconds)

-82-
 0740-070

-83-
Radiator Fan Speed Control

Input Output
Current
Radiator Inlet Temperature (mA)

MAX

LTA Cooler Outlet Temperature 1st 2nd 3rd

Switch ON Radiator Fan Speed
(Ambient Temp. > 25 °C)

Ambient Temp. In front of Ra-

diator

-84-
OIL COOLER

Oil Cooler Fan Motor

A2F125/6.1

0740-071

OIL COOLER – Oil Temperature Sensor (Outlet)

Top of Oil Cooler

v
0740-072

-85-
Oil Cooler Fan Speed Control

Fan Speed

1260

950

760

290

60 70 80 90 °C

Oil Temp. (Tank)

-86-
OIL COOLER – Oil Pressure Sensor (Inlet)

Bottom of Oil Cooler

0740-073

-87-
-88-
AIR FAN – Air Fan Motor

Air Fan Motor

M5BF-045

0740-074

-89-
-90-
HYDRAULIC – High Pressure Strainers
Replacement Interval:
12000 hrs
Filtration: 95 μm

0740-075

HYDRAULIC – Pilot Filter

Replacement Interval:
500 hrs
Filtration: 10 μm

Pilot Relief
Valve 4.4 MPa

0740-076

-91-
-92-
HYDRAULIC – Pilot Accumulators

0740-077

-93-
-94-
ELECTRIC – Electric Equipment Box

0740-078

ELECTRIC – Contamination Sensor Unit

1-8 MP1-MP8
17 Swing Motor (LF)
18 Swing Motor (LR)
19 Swing Motor (RF)
20 Swing Motor (RR)
21 Travel Motor

0740-079

-95-
Electrical Equipment Box

T18M-01-02-003

10 11 12 13

5
Relay
Arrangement
(Refer to T1-2-15)

4
3

T18M-01-02-007

1- Fuse Box2 5 - Auto Lubricator Interval Switch 9- Fault code INC/DEC Switch 13 - Box Light
2- Fuse Box 1 6 - Engine Fault Indicator 10 - HMU
3- Fuse Box 4 7 - MC 11 - CSU
4- Fuse Box 3 8 - Engine Diagnostic Switch 12 - Limit Switch (Box Light)

-96-
ENGINE FAULT INDICATOR

Engine Engine Warning

Maintenance Lamp
Lamp

Engine Stop Lamp

0740-080

-97-
HOW TO READ FAULT CODES
Engine Diagnostic
Switch
1. Stop the engine, and turn the key switch ON.
2. In case a fault code exists, the Engine Warning
Lamp (Amber) alone is lit, but in case no fault
code exists, none of the lamps are lit.
3. Turn the Engine Diagnostic Switch ON. Fault Code
INC/DEC
4. The Engine Warning Lamp (Amber) flickers once, Switch
and in a second, the Engine Stop Lamp (Red) in-
dicates the fault code at stake twice consecutively,
which is repeated.
5. A Fault code has four digits at the maximum. A
numeral is indicated by the number of times of Engine Stop
Lamp (Red) T18M-05-04-003
flickering of the Engine Stop Lamp (Red) for each
digit, and remains unlit for 1 second between digit Engine Maintenance Engine Warning
Lamp (Yellow) Lamp (Amber)
change.
6. When the key switch is turned off, indication of the
fault code is finished.
Example: Flickering of Engine Stop Lamp (Red)
NOTE: In case a plural number of fault codes are in case of Fault Code 132
in existence, the Engine Warning Lamp
(Amber) flickers once each time indication 100s digit 10s digit 1s digit
of a fault code is over, and a second later,
the Engine Stop Lamp (Red) indicates the Lit
next fault code twice, which is repeated.

NOTE: When indication of all the fault codes is

over, the Engine Warning Lamp (Amber)
flickers once, and a second later, the En- Unlit
gine Stop Lamp (Red) repeats indication of 1 second 1 second T141-05-03-004
the fault codes from the first one.

NOTE: IN case the Fault Code INC/DEC Switch is

moved toward INC once, indication of the
next fault code begins. In case the Fault
Code INC/DEC Switch is moved toward
DEC once, indication is changed to the
previous fault code.

-98-
ELECTRIC – Ground Cut-off Switch

0740-084

ELECTRIC – Relay Box

0740-085

-99-
Relay Box
1

T18M-01-02-010

6
25

24

23
7

8
22 9
21 10

11

20
12
19
13

18 17 16 15 14 T18M-01-02-011

1- Battery Relay (3 Used)
2- Fusible Link 10A (Engine
Oil Reserve Tank Valve)
3 - Fusible Link 30A
(Zener Diode)
4 - Fusible Link 5A (IDU
Pre-lube Signal)
5 - Safety Relay
6- Engine Pre-lube Timer
7- Engine Oil Reserve Tank
System Relay 1
8- Engine Oil Reserve Tank 14 - Fusible Link5 (75A) 20 - Starter Relay (Lower)
System Relay 2 (Fuse Box)
9- Fusible Link6 (75A) 15 - Fusible Link4 (75A) 21 - Engine Pre-lube Relay
(Fuse Box) (Fuse Box)
10 - Fusible Link7 (45A) 16 - Fusible Link3 (75A) 22 - Circuit Breaker
(Option) (Fuse Box)
11 - Fusible Link8 (75A) 17 - Fusible Link2 (75A) 23 - Fusible Link 250A (Sliding
(Starter Relay) (Fuse Box) Fold-In Ladder Motor (Rear))
12 - Fusible Link9 (45A) 18 - Fusible Link1 (75A) 24 - Fusible Link 250A (Sliding
(ECM Main Power) (Fuse Box) Fold-In Ladder Motor (Front))
13 - Fusible Link10 (75A) (Sliding 19 - Starter Relay (Upper) 25 - Fusible Link 400A (Engine
Fold-In Ladder Relay) Pre-lube Relay)

-100-
FUEL TANK – Fuel Level Sensor & Switches
Tank Capacity:
7450 L

Fuel Level
Switch (Full)

Fuel Level Switch

Fuel Level Sensor

0740-089

-101-
FAST FILLING DEVICE

1 2

T18M-03-07-004

4 5 6 7 8 9 10 11

22

21 12

13

20 19 18 17 16 15 14 T18M-03-07-003

1 - Lift Cylinder (2 Used)
2 - Fast-Filling Panel
3 - Proximity Switch
4 - Fuel Fill Indicator
5 - Engine Oil Reserve Tank
Fill Indicator
6 - Engine Oil Reserve Tank
Shut-off Valve Open Indi-
cator
7 - Engine Oil Reserve Tank 13 - Auxiliary 18 - Gear Oil
Filling System Power Switch (Front Left Side Swing Device)
8 - Engine Oil Reserve Tank 14 - Pump Transmission Oil 19 - Coolant
Filling System Control Switch (Radiator Engine Side)
9 - Engine Oil Out 15 - Grease 20 - Fuel
(Reserve Tank)
10 - Engine Oil 16 - Gear Oil (Rear-Right) 21 - Coolant
(Engine Oil Pan) (Radiator Outside)
11 - Hyd. Oil 17 - Gear Oil (Left-Right) 22 - Engine Oil In
(Reserve Tank)
12 - Gear Oil (Front Right Side
Swing Device)

-102-
HYDRAULIC OIL TANK – Full-Flow Filters

Replacement Interval:
500 hrs
Filtration: 10 μm

0740-090

HYDRAULIC OIL TANK – Bypass Filter & Drain Filter

Drain Filter
Replacement Interval:
500 hrs
Filtration: 10 μm

Bypass Filter
Replacement Interval:
500 hrs
Filtration: 5 μm

0740-091

-103-
-104-
HYDRAULIC OIL TANK – Level Gauges

0740-092

HYDRAULIC OIL TANK – Level Switches

For Green Lamp

For Warning

0740-093

-105-
-106-
HYDRAULIC OIL TANK

Solenoid Valve

Air Release Valve

Stop Valve

0740-094

HYDRAULIC OIL TANK – Stop Valves & Limit Switches

Between Control
Valves and Oil
Coolers

Limit Switch

Stop Valve

0740-095

-107-
-108-
HYDRAULIC OIL TANK – Stop Valves & Limit Switches

Between Hyd. Tank

and Sub Tank

0740-096

-109-
-110-
GREASE SYSTEM

Auto-Lubrication Vent Valve

Solenoid Valve

Auto-Lubrication
Grease Pump

From Fast-Fill System

0740-097

GREASE SYSTEM

Auto-Lubrication
Hydraulic Motor

Reducing Valve
3 MPa

0740-098

-111-
-112-
GREASE SYSTEM

Grease Pressure Switch for Grease Pressure

Manual Greasing 23.5 MPa Switch for Auto
Greasing 17.6 MPa

Auto/Manual
Selector Switch

0740-099

GREASE SYSTEM
Grease Injectors

Grease Line to Boom Foot Pin

0740-100

-113-
-114-
GREASE SYSTEM

Hose Reel for Manual

Greasing

0740-101

-115-
-116-
FAST-FILL SYSTEM

Lift Cylinders

0740-102

FAST-FILL SYSTEM

Travel H/L Selector

Solenoid Valve

Fast-Fill Solenoid
Valve

0740-103

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FAST-FILLING SYSTEM

Refilling coolant, hydraulic oil, fuel, engine oil, swing

device gear oil, pump transmission oil and grease can
be achieved through this system. The major compo-
nents of this system are the fast-filling switch,
fast-filling panel, fast-filling solenoid valve, lift cylinders
and proximity switch.
(Refer to the SYSTEM / Control System group.)

Lift Cylinder Fast-Filling Panel

Proximity Switch T18M-03-07-004

Filler Port Layout on Fast-Filling Panel (View A)

Engine Oil Reserve Engine Oil Reserve Engine Oil Reserve
Engine Oil Reserve Tank Shut-off Valve Tank Filling System Tank Filling System
Tank Fill Indicator Open Indicator Power Switch Control Switch

Fuel Fill Indicator Engine Oil Out Engine Oil

(Reserve Tank) (Engine Oil Pan)
Engine Oil In
(Reserve Tank)
Hyd. Oil
Coolant
(Radiator Outside) Gear Oil (Front Right
Side Swing Device)

Fuel
Auxiliary

Pump Transmission Oil

T18M-03-07-003
Coolant Gear Oil Gear Oil Gear Oil Grease
(Radiator (Front Left Side (Left-Right) (Rear-Right)
Engine Side) Swing Device)

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FAST-FILL SYSTEM

Flow Adjuster

0740-104

FAST-FILL SYSTEM

Proximity Switch

0740-105

-119-
-120-
AIR HORN – Air Compressor & Air Tank

Air Compressor

Air Tank

0740-106

AIR HORN – Air Horns & Filter

0740-107

-121-
-122-
WINDOW WASHER – Washer Tank

0740-108

-123-
-124-
FOLDING STAIRWAY

0740-111

-125-
 45 °
0740-112

-126-
FOLDING STAIRWAY – Switch Box

SW (1)
Lowering

SW (2)
Raising

SW (3)
Emergency

0740-086

FOLDING STAIRWAY – Switch Box

0740-087

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From Battery

Sliding Fold-In
Ladder Cylinder
Sliding Fold-In
Ladder Relay 1

Sliding Fold-In Sliding Fold-In Holding Valve

Ladder Relay 2 Ladder Relay 3 Sliding Fold-In Holding
Ladder Relay 4 Valve

Storage Switch
Extend
Switch Sliding Fold-In
Sliding Fold-In Ladder Solenoid
Ladder Pump Valve 1
Unit 2

Sol. b
Orifice A
Sliding Fold-In
Ladder Pump
Unit 1 Sol. a
Sliding Fold-In
Ladder Solenoid
Valve 3
Limit Switch 1 Limit Switch 2 Sliding Fold-In
(For Expansion(For Expansion Ladder Solenoid
Detection) Slowdown Control) Valve 2

Stop Valve
Limit Switch 3 (Normally Closed)
Limit Switch 3
(For Storage (For Storage
Slowdown Control) Detection)
Air Conditioner
Motor

Limit Switch 5
(For Lock Lever)
Pilot Air Conditioner
Pump Compressor Drive
MC 76-58 Pump
76-19

Pilot Control Shutoff

Limit Switch

From Battery

76-58 ELU

T18M-02-02-012

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