R200W 7 PDF

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 a WARN
「Do Not Operate」tag on the right side control lever. DO

NOT
OPERATE
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.
Be careful of slippery conditions on platforms, steps,
and handrails when leaving the machine. 13031GE03
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 ear-
muffs 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
operating the machine in congested areas. Coordinate
hand signals before starting the excavator. 13031GE09
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:
・Park machine on a level surface.
・Lower bucket to the ground.
・Turn auto idle switch off.
・Run engine at 1/2 speed without load for 2 minutes.
・Turn key switch to OFF to stop engine. Remove key
from switch.
・Move pilot control shutoff lever to locked position.
・Allow 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 solely by
a jack. Follow recommended procedures in this manual.
13031GE10
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:
・ If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
・ If 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 fluids.
If an accident occurs, see a doctor immediately. Any 13031GE18
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 heat
goes beyond the immediate flame area. Install fire
13031GE20
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 16°
C(60° F).
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.
Use only recommended replacement parts.(See Parts
manual.) 13031GE23
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 relevant environmental
protection regulations when disposing of oil, fuel,
coolant, brake fluid, filters, batteries, and other harmful
waste. 13031GE24
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
Tooth Outrigger Tool box Fuel tank Hydraulic tank Main pump
Engine
Radiator
Oil cooler
Bucket Tire Turning joint Swing motor Main control valve
Arm Arm cylinder Boom Boom cylinder Cab Muffler Counterweight
Dozer cylinder
Dozer blade
Connecting link Side cutter Foot step Tool box Travel motor Rear axle
Bucket cylinder Connecting rod Front axle Front drive shaft Transmission Rear drive shaft
20W72SP01
1-9
2. SPECIFICATIONS
1) 5.65m(18' 6") ONE PIECE BOOM, 2.90m(9' 6") ARM, FRONT OUTRIGGER AND REAR DOZER BLADE
I(I') D
E
G
F
J K
A B(L)
20W72SP02
Description Unit Specification
Operating weight kg(lb) 20500(45290)

Bucket capacity(SAE heaped), standard m3(ydІ) 0.80(1.05)
Overall length A 9490(31' 2")
Overall width B 2490( 8' 2")
Overall height C 3100(10' 2")
Upperstructure width D 2530( 8' 4")
Cab height E 3180(10' 5")
Ground clearance of counterweight F 1310( 4' 3")
Engine cover height G mm(ft-in) 2570( 8' 5")
Minimum ground clearance H 345( 1' 2")
Rear-end distance I 2765( 9' 1")
Rear-end swing radius I' 2800( 9' 2")
Wheel base J 2800( 9' 2")
Tread K 1874( 6' 2")
Dozer blade width L 2490( 8' 2")
Low 8.3(5.2)
Travel speed km/hr(mph)
High 33(20.5)
Swing speed rpm 11.0
Gradeability Degree(%) 31.5(61)
1-10
3. WORKING RANGE
1) 5.65m(18' 6") BOOM
A
A'
F
D
E
C
B'
B
8ft 20W72SP03
Description 2.0m(6' 7") Arm 2.40m(7' 10") Arm 2.90m(9' 6") Arm
Max digging reach A 9110mm (29'11") 9480mm (31' 1") 9900mm (32' 6")
Max digging reach on ground A' 8870mm (29' 1") 9260mm (30' 5") 9690mm (31' 9")
Max digging depth B 5480mm (18' 0") 5880mm (19' 3") 6380mm (20'11")
Max digging depth (8ft level) B' 5240mm (17' 2") 5670mm (18' 7") 6210mm (20' 4")
Max vertical wall digging depth C 4970mm (16' 4") 5440mm (17'10") 5810mm (19' 1")
Max digging height D 9500mm (31' 2") 9730mm (31'11") 9870mm (32' 5")
Max dumping height E 6670mm (21'11") 6900mm (22' 8") 7050mm (23' 2")
Min swing radius F 3700mm (12' 2") 3620mm (11'11") 3540mm (11' 7")
133 [146] kN 133 [146] kN 133 [146] kN
SAE 13600 [14840] kgf 13600 [14840] kgf 13600 [14840] kgf
29980 [32710] lbf 29980 [32710] lbf 29980 [32710] lbf
Bucket digging force
152 [166] kN 152 [166] kN 152 [166] kN
ISO 15500 [16910] kgf 15500 [16910] kgf 15500 [16910] kgf
34170 [37280] lbf 34170 [37280] lbf 34170 [37280] lbf
135 [148] kN 113 [123] kN 97 [106] kN
SAE 13800 [15050] kgf 11500 [12550] kgf 9900 [10800] kgf
30420 [33190] lbf 25350 [27650] lbf 21830 [23810] lbf
Arm digging force
142 [155] kN 118 [128] kN 101 [110] kN
ISO 14500 [15820] kgf 12000 [13090] kgf 10300 [11240] kgf
31970 [34880] lbf 26460 [28870] lbf 22710 [24770] lbf
[ ] : Power boost
1-11
4. WEIGHT
1) MONO BOOM
R200W-7
Item
kg lb
Upperstructure assembly 8950 19730
Main frame weld assembly 1660 3660
Engine assembly 520 1150
Main pump assembly 170 370
Main control valve assembly 200 440
Swing motor assembly 230 510
Hydraulic oil tank assembly 240 530
Fuel tank assembly 200 440
Counterweight 3400 7500
Cab assembly 310 680
Lower frame weld assembly 2370 5230
Swing bearing 260 570
Travel motor assembly 83 180
Turning joint 100 220
Transmission assembly 130 290
Front axle assembly 640 1410
Rear axle assembly 480 1060
Dozer blade assembly 990 2180
Front attachment assembly(5.65m boom, 2.90m arm,
3930 8640
0.80m3 SAE heaped bucket)
5.65m boom assembly 1480 3260
2.90m arm assembly 770 1690
0.80m3 SAE heaped bucket assembly 690 1520
Boom cylinder assembly 190×2EA 420×2EA
Arm cylinder assembly 290 640
Bucket cylinder assembly 180 400
Bucket control link assembly 150 330
Oscillating cylinder assembly 30 70
Front outrigger assembly 390 860
Rear outrigger assembly 1020 2250
Outrigger cylinder assembly 100 220
Blade cylinder assembly 82 180
1-12
5. LIFTING CAPACITIES
1) ROBEX 200W-7
(1) 5.65m(18' 6") boom, 2.0m(6' 7") arm equipped with 0.80m3(SAE heaped) bucket and 4 outrigger
down.
・ : Rating over-front ・ : Rating over-side or 360 degree
Load radius At max. reach

Load point 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) 7.5m(25ft) Capacity Reach
height
m(ft)
7.5m kg *3810 *3810 6.85

(25ft) lb *8400 *8400 (22.5)
6.0m kg *4230 *4230 *3890 *3890 7.89
(20ft) lb *9330 *9330 *8580 *8580 (25.9)
4.5m kg *8260 *8260 *5650 *5650 *4710 *4710 *4020 3370 8.48
(15ft) lb *18210 *18210 *12460 *12460 *10380 *10380 *8860 7430 (27.8)
3.0m kg *7340 *7340 *5450 *5450 *4650 4020 *4190 3150 8.73
(10ft) lb *16180 *16180 *12020 *12020 *10250 8860 *9240 6940 (28.6)
1.5m kg *8700 *8700 *6180 5580 *4980 3920 *4370 3140 8.67
(5ft) lb *19180 *19180 *13620 12300 *10980 8640 *9630 6920 (28.4)
Ground kg *9260 8680 *6620 5440 *4570 3350 8.30
Line lb *20410 19140 *14590 11990 *10080 7390 (27.2)
-1.5m kg *13240 *13240 *9110 8680 *6630 5420 *4710 3920 7.57
(-5ft) lb *29190 *29190 *20080 19140 *14620 11950 *10380 8640 (24.8)
-3.0m kg *11640 *11640 *8210 *8210 *4620 *4620 6.30
(-10ft) lb *25660 *25660 *18100 *18100 *10190 *10190 (20.7)
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.
1-13
up.
height
m(ft)
7.5m kg *3810 2550 6.85

(25ft) lb *8400 5620 (22.5)
6.0m kg *4230 3130 3690 1870 7.89
(20ft) lb *9330 6900 8140 4120 (25.9)
4.5m kg *8260 *8260 *5650 4760 *4710 2970 3190 1550 8.48
(15ft) lb *18210 *18210 *12460 10490 *10380 6550 7030 3420 (27.8)
3.0m kg *7340 4240 *5450 2740 3790 1860 2970 1400 8.73
(10ft) lb *16180 9350 *12020 6040 8360 4100 6550 3090 (28.6)
1.5m kg 8200 3860 5230 2540 3690 1760 2960 1380 8.67
(5ft) lb 18080 8510 11530 5600 8140 3880 6530 3040 (28.4)
Ground kg 8010 3710 5090 2420 3160 1490 8.30
Line lb 17660 8180 11220 5340 6970 3280 (27.2)
-1.5m kg *13240 7100 8010 3700 5070 2400 3690 1780 7.57
(-5ft) lb *29190 15650 17660 8160 11180 5290 8140 3920 (24.8)
-3.0m kg *11640 7310 8150 3820 *4620 2520 6.30
(-10ft) lb *25660 16120 17970 8420 *10190 5560 (20.7)
(3) 5.65m(18' 6") boom, 2.0m(6' 7") arm equipped with 0.80m3(SAE heaped) bucket, front outrigger
and rear dozer blade down.
height
m(ft)
7.5m kg *3830 *3830 6.85

(25ft) lb *8440 *8440 (22.5)
6.0m kg *4260 *4260 *3910 3230 7.89
(20ft) lb *9390 *9390 *8620 7120 (25.9)
4.5m kg *8320 *8320 *5680 *5680 *4730 *4730 *4030 2770 8.48
(15ft) lb *18340 *18340 *12520 *12520 *10430 *10430 *8880 6110 (27.8)
3.0m kg *7370 *7370 *5480 4760 *4670 3300 *4190 2570 8.73
(10ft) lb *16250 *16250 *12080 10490 *10300 7280 *9240 5670 (28.6)
1.5m kg *8720 7060 *6190 4540 *4990 3200 *4380 2550 8.67
(5ft) lb *19220 15560 *13650 10010 *11000 7050 *9660 5620 (28.4)
Ground kg *9260 6880 *6630 4400 *4560 2730 8.30
Line lb *20410 15170 *14620 9700 *10050 6020 (27.2)
-1.5m kg *13190 *13190 *9100 6880 *6620 4380 *4700 3200 7.57
(-5ft) lb *29080 *29080 *20060 15170 *14590 9660 *10360 7050 (24.8)
-3.0m kg *11570 *11570 *8170 7020 *4580 4390 6.30
(-10ft) lb *25510 *25510 *18010 15480 *10100 9680 (20.7)
1-14
(4) 5.65m(18' 6") boom, 2.0m(6' 7") arm equipped with 0.80m3(SAE heaped) bucket, front outrigger
and rear dozer blade up.
height
m(ft)
7.5m kg *3830 2550 6.85

(25ft) lb *8440 5620 (22.5)
6.0m kg *4260 3130 3690 1870 7.89
(20ft) lb *9390 6900 8140 4120 (25.9)
4.5m kg *8320 *8320 *5680 4760 *4730 2970 3190 1550 8.48
(15ft) lb *18340 *18340 *12520 10490 *10430 6550 7030 3420 (27.8)
3.0m kg *7370 4240 5460 2740 3790 1860 2970 1400 8.73
(10ft) lb *16250 9350 12040 6040 8360 4100 6550 3090 (28.6)
1.5m kg 8190 3860 5230 2540 3690 1760 2960 1380 8.67
(5ft) lb 18060 8510 11530 5600 8140 3880 6530 3040 (28.4)
Ground kg 8010 3700 5090 2420 3160 1490 8.30
Line lb 17660 8160 11220 5340 6970 3280 (27.2)
-1.5m kg *13190 7100 8010 3700 5070 2400 3690 1780 7.57
(-5ft) lb *29080 15650 17660 8160 11180 5290 8140 3920 (24.8)
-3.0m kg *11570 7310 8150 3820 *4580 2520 6.30
(-10ft) lb *25510 16120 17970 8420 *10100 5560 (20.7)
(5) 5.65m(18' 6") boom, 2.4m(7'10") arm equipped with 0.80m3(SAE heaped) bucket and 4 outrigger
down.
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 *3520 *3520 7.34
(25ft) lb *7760 *7760 (24.1)
6.0m kg *3830 *3830 *3610 3570 8.31
(20ft) lb *8440 *8440 *7960 7870 (27.3)
4.5m kg *5090 *5090 *4350 *4350 *4050 *4050 *3740 3110 8.87
(15ft) lb *11220 *11220 *9590 *9590 *8930 *8930 *8250 6860 (29.1)
3.0m kg *6790 *6790 *5130 *5130 *4390 4020 *3900 2910 9.10
(10ft) lb *14970 *14970 *11310 *11310 *9680 8860 *8600 6420 (29.9)
1.5m kg *8290 *8290 *5920 5580 *4790 3900 *4090 2900 9.05
(5ft) lb *18280 *18280 *13050 12300 *10560 8600 *9020 6390 (29.7)
Ground kg *9300 *9300 *9080 8630 *6460 5410 *5070 3810 *4290 3070 8.70
Line lb *20500 *20500 *20020 19030 *14240 11930 *11180 8400 *9460 6770 (28.5)
-1.5m kg *10060 *10060 *13750 *13750 *9140 8580 *6610 5350 *4460 3530 8.00
(-5ft) lb *22180 *22180 *30310 *30310 *20150 18920 *14570 11790 *9830 7780 (26.2)
-3.0m kg *14300 *14300 *12340 *12340 *8490 *8490 *6120 5420 *4500 *4500 6.84
(-10ft) lb *31530 *31530 *27210 *27210 *18720 *18720 *13490 11950 *9920 *9920 (22.4)
-4.5m kg *9540 *9540 *6550 *6550
(-15ft) lb *21030 *21030 *14440 *14440
1-15
(6) 5.65m(18' 6") boom, 2.4m(7'10") arm equipped with 0.80m3(SAE heaped) bucket and 4 outrigger
up.
height
m(ft)
7.5m kg *3520 2230 7.34
(25ft) lb *7760 4920 (24.1)
6.0m kg *3830 3170 3370 1680 8.31
(20ft) lb *8440 6990 7430 3700 (27.3)
4.5m kg *5090 4860 *4350 3000 3910 1950 2940 1400 8.87
(15ft) lb *11220 10710 *9590 6610 8620 4300 6480 3090 (29.1)
3.0m kg *6790 4310 *5130 2760 3790 1850 2750 1270 9.10
(10ft) lb *14970 9500 *11310 6080 8360 4080 6060 2800 (29.9)
1.5m kg 8220 3870 5220 2530 3670 1740 2730 1240 9.05
(5ft) lb 18120 8530 11510 5580 8090 3840 6020 2730 (29.7)
Ground kg *9300 6840 7970 3660 5060 2380 3580 1660 2900 1320 8.70
Line lb *20500 15080 17570 8070 11160 5250 7890 3660 6390 2910 (28.5)
-1.5m kg *10060 *10060 *13750 6910 7920 3620 5000 2330 3330 1570 8.00
(-5ft) lb *22180 *22180 *30310 15230 17460 7980 11020 5140 7340 3460 (26.2)
-3.0m kg *14300 *14300 *12340 7100 8020 3700 5070 2400 4360 2140 6.84
(-10ft) lb *31530 *31530 *27210 15650 17680 8160 11180 5290 9610 4720 (22.4)
-4.5m kg *9450 7490 *6550 3960
(-15ft) lb *21030 16510 *14440 8730
(7) 5.65m(18' 6") boom, 2.4m(7'10") arm equipped with 0.80m3(SAE heaped) bucket, front outrigger
height
m(ft)
7.5m kg *3520 *3520 7.34
(25ft) lb *7760 *7760 (24.1)
6.0m kg *3830 *3830 *3610 2940 8.31
(20ft) lb *8440 *8440 *7960 6480 (27.3)
4.5m kg *5090 *5090 *4350 *4350 *4050 3410 *3740 2550 8.87
(15ft) lb *11220 *11220 *9590 *9590 *8930 7520 *8250 5620 (29.1)
3.0m kg *6790 *6790 *5130 4780 *4390 3290 *3900 2370 9.10
(10ft) lb *14970 *14970 *11310 10540 *9680 7250 *8600 5220 (29.9)
1.5m kg *8290 7080 *5920 4530 *4790 3170 *4090 2350 9.05
(5ft) lb *18280 15610 *13050 9990 *10560 6990 *9020 5180 (29.7)
Ground kg *9300 *9300 *9080 6830 *6460 4370 *5070 3090 *4290 2490 8.70
Line lb *20500 *20500 *20020 15060 *14240 9630 *11180 6810 *9460 5490 (28.5)
-1.5m kg *10060 *10060 *13750 *13750 *9140 6790 *6610 4310 *4460 2880 8.00
(-5ft) lb *22180 *22180 *30310 *30310 *20150 14970 *14570 9500 *9830 6350 (26.2)
-3.0m kg *14300 *14300 *12340 *12340 *8490 6890 *6120 4380 *4500 3790 6.84
(-10ft) lb *31530 *31530 *27210 *27210 *18720 15190 *13490 9660 *9920 8360 (22.4)
-4.5m kg *9540 *9450 *6550 *6550
(-15ft) lb *21030 *21030 *14440 *14440
1-16
(8) 5.65m(18' 6") boom, 2.4m(7'10") arm equipped with 0.80m3(SAE heaped) bucket, front outrigger
height
m(ft)
7.5m kg *3520 2230 7.34
(25ft) lb *7760 4920 (24.1)
6.0m kg *3830 3170 3370 1680 8.31
(20ft) lb *8440 6990 7430 3700 (27.3)
4.5m kg *5090 4860 *4350 3000 3910 1950 2940 1400 8.87
(15ft) lb *11220 10710 *9590 6610 8620 4300 6480 3090 (29.1)
3.0m kg *6790 4310 *5130 2760 3790 1850 2750 1270 9.10
(10ft) lb *14970 9500 *11310 6080 8360 4080 6060 2800 (29.9)
1.5m kg 8220 3870 5220 2530 3670 1740 2730 1240 9.05
(5ft) lb 18120 8530 11510 5580 8090 3840 6020 2730 (29.7)
Ground kg *9300 6840 7970 3660 5060 2380 3580 1660 2900 1320 8.70
Line lb *20500 15080 17570 8070 11160 5250 7890 3660 6390 2910 (28.5)
-1.5m kg *10060 *10060 *13750 6910 7920 3620 5000 2330 3330 1570 8.00
(-5ft) lb *22180 *22180 *30310 15230 17460 7980 11020 5140 7340 3460 (26.2)
-3.0m kg *14300 *14300 *12340 7100 8020 3700 5070 2400 4360 2140 6.84
(-10ft) lb *31530 *31530 *27210 15650 17680 8160 11180 5290 9610 4720 (22.4)
-4.5m kg *9540 7490 *6550 3960
(-15ft) lb *21030 16510 *14440 8730
down.
height
m(ft)
9.0m kg *3120 *3120 6.47
(30ft) lb *6880 *6880 (21.2)
7.5m kg *3180 *3180 7.92
(25ft) lb *7010 *7010 (26.0)
6.0m kg *3370 *3370 *2400 *2400 *3290 3240 8.81
(20ft) lb *7430 *7430 *5290 *5290 *7250 7140 (28.9)
4.5m kg *3920 *3920 *3690 *3690 *3430 2850 9.34
(15ft) lb *8640 *8640 *8140 *8140 *7560 6280 (30.6)
3.0m kg *10160 *10160 *6150 *6150 *4750 *4750 *4090 4050 *3600 2680 9.56
(10ft) lb *22400 *22400 *13560 *13560 *10470 *10470 *9020 8930 *7940 5910 (31.4)
1.5m kg *8440 *8440 *7810 *7810 *5610 5610 *4550 3900 *3790 2650 9.51
(5ft) lb *18610 *18610 *17220 *17220 *12370 12370 *10030 8600 *8360 5840 (31.2)
Ground kg *9800 *9800 *8830 8640 *6260 5400 *4920 3790 *3990 2790 9.18
Line lb *21610 *21610 *19470 19050 *13800 11900 *10850 8360 *8800 6150 (30.1)
-1.5m kg *9190 *9190 *12890 *12890 *9140 8520 *6560 5300 *5050 3740 *4200 3150 8.53
(-5ft) lb *20260 *20260 *28420 *28420 *20150 18780 *14460 11680 *11130 8250 *9260 6940 (28.0)
-3.0m kg *12400 *12400 *13070 *13070 *8760 8570 *6340 5320 *4360 3960 7.46
(-10ft) lb *27340 *27340 *28810 *28810 *19310 18890 *13980 11730 *9610 8730 (24.5)
-4.5m kg *10830 *10830 *7410 *7410
(-15ft) lb *23880 *23880 *16340 *16340
1-17
up.
height
m(ft)
9.0m kg *3120 2960 6.47
(30ft) lb *6880 6530 (21.2)
7.5m kg *3180 1950 7.92
(25ft) lb *7010 4300 (26.0)
6.0m kg *3370 3250 *2400 2070 3060 1500 8.81
(20ft) lb *7430 7170 *5290 4560 6750 3310 (28.9)
4.5m kg *3920 3060 *3690 2000 2700 1260 9.34
(15ft) lb *8640 6750 *8140 4410 5950 2780 (30.6)
3.0m kg *10160 8080 *6150 4430 *4750 2800 3820 1870 2530 1140 9.56
(10ft) lb *22400 17810 *13560 9770 *10470 6170 8420 4120 5580 2510 (31.4)
1.5m kg *8440 6980 *7810 3940 5250 2550 3670 1740 2500 1110 9.51
(5ft) lb *18610 15390 *17220 8690 11570 5620 8090 3840 5510 2450 (31.2)
Ground kg *9800 6760 7970 3660 5050 2370 3560 1640 2630 1170 9.18
Line lb *21610 14900 17570 8070 11130 5220 7850 3620 5800 2580 (30.1)
-1.5m kg *9190 *9190 *12890 6780 7860 3560 4950 2290 3520 1600 2970 1350 8.53
(-5ft) lb *20260 *20260 *28420 14950 17330 7850 10910 5050 7760 3530 6550 2980 (28.0)
-3.0m kg *12400 *12400 *13070 6920 7910 3600 4970 2310 3730 1780 7.46
(-10ft) lb *27340 *27340 *28810 15260 17440 7940 10960 5090 8220 3920 (24.5)
-4.5m kg *10830 7230 *7410 3780
(-15ft) lb *23880 15940 *16340 8330
(11) 5.65m(18' 6") boom, 2.9m(9' 6") arm equipped with 0.80m3(SAE heaped) bucket, front outrgger
height
m(ft)
9.0m kg *3130 *3130 6.42
(30ft) lb *6900 *6900 (21.1)
7.5m kg *3200 *3200 7.88
(25ft) lb *7050 *7050 (25.9)
6.0m kg *3370 *3370 *2290 *2290 *3310 2680 8.78
(20ft) lb *7430 *7430 *5050 *5050 *7300 5910 (28.8)
4.5m kg *3920 *3920 *3700 3460 *3450 2340 9.30
(15ft) lb *8640 *8640 *8160 7630 *7610 5160 (30.5)
3.0m kg *10070 *10070 *6130 *6130 *4750 *4750 *4100 3320 *3610 2180 9.53
(10ft) lb *22200 *22200 *13510 *13510 *10470 *10470 *9040 7320 *7960 4810 (31.3)
1.5m kg *8690 *8690 *7800 7180 *5610 4560 *4560 3180 *3800 2160 9.48
(5ft) lb *19160 *19160 *17200 15830 *12370 10050 *10050 7010 *8380 4760 (31.1)
Ground kg *9950 *9950 *8830 6850 *6270 4360 *4930 3070 *4010 2270 9.15
Line lb *21940 *21940 *19470 15100 *13820 9610 *10870 6770 *8840 5000 (30.0)
-1.5m kg *9250 *9250 *13040 *13040 *9150 6740 *6560 4270 *5050 3030 *4230 2580 8.49
(-5ft) lb *20390 *20390 *28750 *28750 *20170 14860 *14460 9410 *11130 6680 *9330 5690 (27.9)
-3.0m kg *12490 *12490 *13090 *13090 *8770 6780 *6340 4290 *4390 3260 7.42
(-10ft) lb *27540 *27540 *28860 *28860 *19330 14950 *13980 9460 *9680 7190 (24.3)
-4.5m kg *10820 *10820 *7400 7000
(-15ft) lb *23850 *23850 *16310 15430
1-18
(12) 5.65m(18' 6") boom, 2.9m(9' 6") arm equipped with 0.80m3(SAE heaped) bucket, front outrgger
height
m(ft)
9.0m kg *3130 3000 6.42
(30ft) lb *6900 6610 (21.1)
7.5m kg *3200 1970 7.88
(25ft) lb *7050 4340 (25.9)
6.0m kg *3370 3250 *2290 2070 3080 1510 8.78
(20ft) lb *7430 7170 *5050 4560 6790 3330 (28.8)
4.5m kg *3920 3060 *3700 2000 2710 1270 9.30
(15ft) lb *8640 6750 *8160 4410 5970 2800 (30.5)
3.0m kg *10070 8120 *6130 4450 *4750 2810 3820 1870 2540 1150 9.53
(10ft) lb *22200 17900 *13510 9810 *10470 6190 8420 4120 5600 2540 (31.3)
1.5m kg *8690 7010 *7800 3950 5260 2550 3680 1740 2520 1120 9.48
(5ft) lb *19160 15450 *17200 8710 11600 5620 8110 3840 5560 2470 (31.1)
Ground kg *9950 6770 7980 3670 5050 2380 3570 1640 2650 1180 9.15
Line lb *21940 14930 17590 8090 11130 5250 7870 3620 5840 2600 (30.0)
-1.5m kg *9250 *9250 *13040 6780 7860 3570 4960 2290 3520 1600 2990 1370 8.49
(-5ft) lb *20390 *20390 *28750 14950 17330 7870 10930 5050 7760 3530 6590 3020 (27.9)
-3.0m kg *12490 *12490 *13090 6930 7910 3610 4980 2310 3770 1800 7.42
(-10ft) lb *27540 *27540 *28860 15280 17440 7960 10980 5090 8310 3970 (24.3)
-4.5m kg *10820 7240 *7400 3790
(-15ft) lb *23850 15960 *16310 8360
1-19
6. BUCKET SELECTION GUIDE
1) GENERAL BUCKET
0.51m3 SAE ※0.80m3 SAE 0.87m3 SAE 0.92m3 SAE 1.20m3 SAE 1.34m3 SAE
heaped bucket heaped bucket heaped bucket heaped bucket heaped bucket heaped bucket
Recommendation
Capacity Width
5.65m (18' 6") boom
Weight
SAE CECE Without With 2.0m arm 2.4m arm 2.90m arm
heaped heaped side cutter side cutter (6' 7") (7' 10") (9' 6")
0.51m3 0.45m3 700mm 820mm 580kg

(0.67yd3) (0.59yd3) (27.6") (32.3") (1280lb)
※0.80m3 0.70m3 1000mm 1120mm 650kg

(1.05yd3) (0.92yd3) (39.4") (44.1") (1430lb)
0.87m3 0.75m3 1090mm 1210mm 660kg

(1.14yd3) (0.98yd3) (42.9") (47.6") (1460lb)
0.92m3 0.80m3 1130mm 1250mm 710kg

(1.20yd3) (1.05yd3) (44.5") (49.2") (1570lb)
1.20m3 1.00m3 1400mm 770kg

-
(1.57yd3) (1.31yd3) (55.1") (1700lb)
1.34m3 1.15m3 1550mm 800kg

-
(1.75yd3) (1.50yd3) (61.0") (1760lb)
※ : Standard bucket
Applicable for materials with density of 2000kg/m3 (3370lb/yd3) or less
1-20
2) HEAVY DUTY, ROCK AND SLOPE FINISHING BUCKET
◈0.74, 0.90, 1.05m3 SAE

heaped bucket 0.87m3 SAE heaped bucket ▣0.75m3 SAE heaped bucket
Recommendation
Capacity Width
5.65m (18' 6") boom
Weight
SAE CECE Without With 2.0m arm 2.4m arm 2.92m arm
heaped heaped side cutter side cutter (6' 7") (7' 10") (9' 7")
◈0.74m3 0.65m3 915mm 750kg

- (1650lb)
(0.97yd3) (0.85yd3) (36.0")
◈0.90m3 0.80m3 1070mm 790kg

- (1740lb)
(1.18yd3) (1.05yd3) (42.1")
◈1.05m3 0.92m3 1220mm 870kg

- (1920lb)
(1.37yd3) (1.20yd3) (48.0")
0.87m3 0.75m3 1140mm 860kg

(1.14yd3) (0.98yd3) (44.9") - (1900lb)
▣0.75m3 0.65m3 1810mm 880kg

(0.98yd3) (0.85yd3) (71.3") - (1940lb)
◈ : Heavy duty bucket : Rock bucket(Heavy) ▣ : Slope finishing bucket
Applicable for materials with density of 2000kgf/m3 (3370lbf/yd3) or less

1-21
7. SPECIFICATIONS FOR MAJOR COMPONENTS
1) ENGINE
Item Specification
Model Cummins B5.9-C

4-cycle, turbocharged, charge air cooled, diesel engine,
Type low emission
Cooling method Water cooling
Number of cylinders and arrangement 6 cylinders, in-line
Firing order 1-5-3-6-2-4
Combustion chamber type Direct injection type
Cylinder bore×stroke 102×120mm(4.02"×4.72")
Piston displacement 5880cc(359cu in)
Compression ratio 17.3 : 1
Rated gross horse power(SAE J1349) 166Hp at 1950rpm(124kW at 1950rpm)
Maximum torque at 1500rpm 68.4kgf・m(495lbf・ft)
Engine oil quantity 14.2ℓ(3.8U.S. gal)
Dry weight 505kg(1113lb)
High idling speed 2200+50rpm
Low idling speed 1000±100rpm
Rated fuel consumption 173g/Hp・hr at 1950rpm
Starting motor Nippon denso(24V-4.5kW)
Alternator Delco Remy (24V-50A)
Battery 2×12V×100Ah
2) MAIN PUMP
Item Specification
Type Variable displacement axial piston pump

Capacity 2×113cc/rev
Maximum pressure 330kgf/cm2 (4694psi) [360kgf/cm2 (5120psi)]
Rated oil flow 2×220ℓ/min (58.1U.S. gpm/ 48.4U.K. gpm)
Rated speed 1950rpm
[ ] : Power boost
1-22
3) GEAR PUMP
Item Specification
Type Fixed displacement gear pump single stage

Capacity 15cc/rev
Maximum pressure 40kgf/cm2(570psi)
Rated oil flow 29.3ℓ/min(7.7U.S. gpm/6.4U.K. gpm)
4) MAIN CONTROL VALVE
Item Specification
Type 9 spools double-block

Operating method Hydraulic pilot system
Main relief valve pressure 330kgf/cm2(4695psi)[360kgf/cm2(5120psi)]
Overload relief valve pressure 390kgf/cm2(5550psi)
[ ]: Pooer boost
5) SWING MOTOR
Item Specification
Type Fixed displacement axial piston motor

Capacity 151cc/rev
Relief pressure 240kgf/cm2(3414psi)
Braking system Automatic, spring applied hydraulic released
Braking torque 59kgf・m(427lbf・ft)
Brake release pressure 33~50kgf/cm2(470~711psi)
Reduction gear type 2 - stage planetary
Swing speed 12.5rpm
6) TRAVEL MOTOR
Item Specification
Type Variable displacement bent-axis axial piston motor

Relief pressure 360kgf/cm2(5120psi)
Counter balance valve Applied
Capacity(Max/min) 160/65cc/rev
1-23
7) POWER TRAIN
Item Description Specification

Type 2 speed power shift transmission
Transmission 1st 5.35
Gear ratio
2nd 1.39
Type Multi disc brake integrated in transmission
Parking brake
Maximum braking power 168kgf・m(2390lb・ft)
Type 4 wheel drive with differential
Axle Gear ratio 13.55
Brake Multi disc brake
8) REMOTE CONTROL VALVE
Item Specification
Type Pressure reducing type

Minimum 6.5kg/cm2(92psi)
Operating pressure
Maximum 26kg/cm2(370psi)
Single operation stroke Lever 82.7mm(3.3in)
9) CYLINDER
Item Specification
Bore dia×Rod dia×Stroke Ø120×Ø85×1290mm

Boom cylinder
Cushion Extend only
Arm cylinder
Cushion Extend and retract
Bucket cylinder
Cushion Extend only
Dozer cylinder
Cushion Extend only
Outrigger cylinder
Cushion -
2 Piece boom Bore dia×Rod dia×Stroke Ø160×Ø100×425mm

Adjust cylinder Cushion Extend only
1-24
10) BUCKET
Capacity Tooth Width
Item
SAE heaped CECE heaped quantity Without side cutter With side cutter
STD 0.80m (1.05yd )

3 3
0.70m3(0.92yd3) 5 1090mm(42.9") 1210mm(47.6")
0.51m3(0.67yd3) 0.45m3(0.59yd3) 3 700mm(27.6") 820mm(32.3")
0.87m (1.14yd )
3 3
0.75m (0.98yd )
3 3
5 1000mm(39.4") 1120mm(44.1")
0.92m3(1.20yd3) 0.80m3(1.05yd3) 5 1130mm(44.5") 1250mm(49.2")
1.20m (1.57yd )
3 3
1.00m (1.31yd )
3 3
6 1400mm(55.1") -
1.34m3(1.75yd3) 1.15m3(1.50yd3) 5 1550mm(61.1") -
OPT
◈0.74m (0.97yd )
3 3
0.65m (0.85yd )
3 3
5 915mm(36.0") -
◈0.90m3(1.18yd3) 0.80m3(1.05yd3) 5 1070mm(42.1") -
◈1.05m (1.37yd )
3 3
0.92m (1.20yd )
3 3
5 1220mm(48.0") -
0.87m3(1.14yd3) 0.75m3(0.98yd3) 5 1140mm(44.9") -
▣0.75m (0.98yd )
3 3
0.65m (0.85yd )
3 3
- 1810mm(71.3") -
◈ : Heavy duty bucket
: Rock bucket(Heavy)
▣ : Slope finishing bucket
1-25
8. 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
ℓ(U.S. gal) -20 -10 0 10 20 30 40
(-4) (14) (32) (50) (68) (86) (104)
Engine SAE 30
oil pan 14.2(3.8)
SAE 10W
Engine oil
SAE 10W-30
Transmission
case 3.8(1.0)
SAE 15W-40
Gear oil 5.0(1.3) SAE 85W-140
Swing drive
NLGI NO.1
Grease 1.2(0.3)
NLGI NO.2
Front axle Center :

12×2(3.2×2)
Gear oil SAE 85W-90 LSD or UTTO
Hub :
Rear axle 2×4(0.5×4)
Tank: ISO VG 32
180(47.6)
Hydraulic tank Hydraulic oil ISO VG 46
System:
270(71.3) ISO VG 68
ASTM D975 NO.1

Fuel tank Diesel fuel 320(84.5)
ASTM D975 NO.2
NLGI NO.1
Fitting
(Grease nipple) Grease As required
NLGI NO.2
Mixture of
Radiator antifreeze
35(9.2) Ethylene glycol base permanent type
(Reservoir tank) and water
50 : 50
SAE : Society of Automotive Engineers ASTM : American Society of Testing and
API : American Petroleum Institute Material
ISO : International Organization for Standardization UTTO : Universal Tractor Transmission Oil
NLGI : National Lubricating Grease Institute
1-26
SECTION 2 STRUCTURE AND FUNCTION
Group 1 Pump Device 2-1

Group 2 Main Control Valve 2-21
Group 3 Swing Device 2-47
Group 4 Travel Device 2-59
Group 5 RCV Lever 2-65
Group 6 Accelerator pedal 2-72
Group 7 Brake pedal 2-73
Group 8 Transmission 2-76
Group 9 Transmission control valve 2-83
Group 10 Steering valve 2-85
Group 11 Axle 2-87
SECTION 2 STRUCTURE AND FUNCTION
GROUP 1 PUMP DEVICE
1. STRUCTURE
The pump device consists of main pump, regulator and gear pump.
Di
Dr2 a3
A3
Pm2
Pi2 A2 B3
a4
Psv
A1
Dr1
Pm1 Pi1
Qmax adjusting screw

Regulator Psv a4 Regulator
Qmin adjusting screw
Gear pump
Di
Dr1
a3
Dr1
Dr2
B3
a1 B1
a2
Do B1
20W72MP01
A1 Psv a4 A2
Port Port name Port size

a2 a1 A1,A2 Delivery port SAE6000psi 3/4"
B1 Suction port SAE2500psi 2 1/2"
Dr1 Drain port PF 3/4 - 20
Pi1,Pi2 Pilot port PF 1/4 - 15
Pm1 Pm2 Pm1,Pm2 Qmax cut port PF 1/4 - 15
Pi1 Pi2 Psv Servo assist port PF 1/4 - 15
(Fl,MCV) (Fr,MCV)
Di a1,2,4 Gauge port PF 1/4 - 15
D0 Dr1
a3 Gauge port PF 1/4 - 14
B1
Dr2 A3 Gear pump delivery port PF 3/8 - 15
B3 A3 a3 B3 Gear pump suction port PF 3/4 - 20.5
Dr2 Gear pump drain port PF 3/8 - 15
Di Inlet port PF 3/4 - 20
Do Outlet port PF 3/4 - 20
2-1
1) MAIN PUMP(1/2)
The main pump consists of two piston pumps(front & rear) and valve block.
536 490 793 548 901 732 807 412 080

406 703 532 531 789 953
806 534 214 535 410
408 954 492 885
543 545
888 406 469 725 981 409 316 735 541
251 157 211 728 141 467 983
212 156 152 153 151 410 709 724
726
828 123 724 469 129 826 271 491 314 490
728 491
171 490 124 04
127
824
113
192
709
827
774
111
261
825
126
191 122 823 752 124 886 312
828 887 751 490 128 726 313
210N72MP02
2-2
04 Gear pump 271 Pump casing 724 O-ring
080 Proportional reducing 312 Valve cover 725 O-ring
valve assy 313 Valve plate (R) 726 O-ring
111 Drive shaft 314 Valve plate (L) 728 O-ring
113 Driven shaft 316 Cover 732 O-ring
122 Roller bearing 406 Hexagon socket bolt 735 O-ring
123 Roller bearing 408 Hexagon socket bolt 751 Packing
124 Needle bearing 409 Hexagon socket bolt 752 Seat packing
126 Bearing spacer 410 Hexagon socket bolt 774 Oil seal
127 Bearing spacer 412 Hexagon socket bolt 789 Back up ring
128 Bearing spacer 467 Plug 793 Back up ring
129 Bearing spacer 469 Plug 806 Nut
141 Cylinder block 490 Plug 807 Nut
151 Piston 491 Plug 823 Snap ring
152 Shoe 492 Restrictor 824 Snap ring
153 Set plate 531 Tilting pin 825 Snap ring
156 Bushing 532 Servo piston 826 Snap ring
157 Cylinder spring 534 Stopper (L) 827 Snap ring
171 Front casing 535 Stopper (S) 828 Snap ring
191 Drive gear 536 Servo cover 885 Valve plate pin
192 Driven gear 541 Seat 886 Spring pin
211 Shoe plate 543 Stopper 887 Spring pin
212 Swash plate 545 Steel ball 888 Pin
214 Tilting bushing 548 Feed back pin 901 Eye bolt
251 Swash plate support 703 O-ring 953 Set screw
261 Front cover 709 O-ring 954 Set screw
2-3
MAIN PUMP(2/2)
490
490 724 407 467,725
724
079 732 325 210N72MP03
079 Proportional reducing valve 467 Plug 725 O-ring

325 Valve casing 490 Plug 732 O-ring
407 Hexagon socket screw 724 O-ring
2-4
2) REGULATOR(1/2)
412 897 876 874

A 755
612 B
858 A
KR3G-9S09
614 P2
615
Pf
613 Pm
611
Pi Pb
A B 875
Hydraulic circuit
B
647 Pi
723 438
642
801 924
801
648 730 643 708 644 646 645 728
SECTION B-B
735 413 496 438 Pm 413
438
656
210N72RG01
Port Port name port size

722 724 725 436
Pi Pilot port PF 1/4 - 15
VIEW C
Pm Qmax cut port PF 1/4 - 15
2-5
REGULATOR(2/2)
734 653 654 836 651 652 601 624 629 630
655
641
814
628
733
732 801
C 925
898
627
631
732
756
622 621 623 625 626 887 763
SECTION A-A
210N72RG02
412 Hexagon socket screw 631 Sleeve, pf 730 O-ring

413 Hexagon socket screw 641 Pilot cover 732 O-ring
436 Hexagon socket screw 642 Adjust screw(QMC) 733 O-ring
438 Hexagon socket screw 643 Pilot piston 734 O-ring
496 Plug 644 Spring seat(Q) 735 O-ring
601 Casing 645 Adjust stem(Q) 755 O-ring
611 Feed back lever 646 Pilot spring 756 O-ring
612 Lever(1) 647 Stopper 763 O-ring
613 Lever(2) 648 Piston(QMC) 801 Nut
614 Center plug 651 Sleeve 814 Snap ring
615 Adjust plug 652 Spool 836 Snap ring
621 Compensator piston 653 Spring seat 858 Snap ring
622 Piston case 654 Return spring 874 Pin
623 Compensator rod 655 Set spring 875 Pin
624 Spring seat(C) 656 Block cover 876 Pin
625 Outer spring 708 O-ring 887 Pin
626 Inner spring 722 O-ring 897 Pin
627 Adjust stem(C) 723 O-ring 898 Pin
628 Adjust screw(C) 724 O-ring 924 Set screw
629 Cover(C) 725 O-ring 925 Adjust screw(QI)
630 Lock nut 728 O-ring
2-6
3) GEAR PUMP
435
433
700 353 351
B3
354
434
709
311
361 850
312
Dr3 Dr3 355
732
a4
309 307 310 308 434 466,725
210N72GP01
307 Poppet 353 Drive gear 466 Plug

308 Seat 354 Driven gear 700 Ring
309 Spring seat 355 Filter 709 O-ring
310 Spring 361 Front case 725 O-ring
311 Adjusting screw 433 Flange socket 732 O-ring
312 Lock nut 434 Flange socket 850 Snap ring
351 Gear case 435 Flange socket
2-7
2. FUNCTION
1) MAIN PUMP
The pumps may be 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). 156
The drive shaft is supported by 151
313 152
bearings(122,124) at its both ends.
141 124
The shoe is caulked to the piston to from 157 111
a spherical coupling. It has a pocket to 153
122
relieve thrust force generated by loading
pressure and to take hydraulic balance so 211
that it slides lightly over the shoe
plate(211). The sub group composed by
a piston and a shoe is pressed against
the shoe plate by the action of the 210N72MP04
cylinder spring via a retainer and a
spherical bush.
Similarly, the cylinder block is pressed
against valve plate(313) by the action of
the cylinder spring.
(2) Swash plate group
531
The swash plate group consists of swash
214
plate(212), shoe plate(211), swash plate
support(251), tilting bush(214), tilting
pin(531) and servo piston(532).
532
The swash plate is a cylindrical part
211
formed on the opposite side of the sliding
212
surface of the shoe and is supported by
the swash support. 251
If the servo piston moves to the right and
210N72MP05
left as hydraulic force controlled by the ɷ
regulator is admitted to hydraulic
chamber located on both sides of the
servo piston, the swash plate slides over ɷ
the swash plate support via the spherical
part of the tilting pin to change the tilting
angle(ɷ)
2-7 (210-7)
2-8
(3) Valve cover group
The valve cover group consists of valve
cover(312), valve plates(313, 314) and
valve plate pin(885).
The valve plate having two melon-
shaped ports is fixed to the valve cover
and feeds and collects oil to and from the
cylinder block.
The oil changed over by the valve plate is
connected to an external pipeline by way
of the valve cover.
Now, if the drive shaft is driven by a prime 885
mover(electric motor, engine, etc), it
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 312 313
make a reciprocating motion with respect 314
to the cylinder block, while they revolve
with the cylinder block.
If you pay attention to a single piston, it 210N72MP06
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.
2-9
2) REGULATOR
Regulator consists of the negative flow control, total horsepower control and power shift control
function.
(1) Negative flow control

By changing the pilot pressure Pi, the
pump tilting angle(delivery flow) is
regulated arbitrarily, as shown in the
figure.
This regulator is of the negative flow
Delivery flow, Q
control in which the delivery flow Q
decreases as the pilot pressure Pi 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, Pi
uselessly.
2-10
① Flow reducing function
654 643 651 652 613 646
P1 CL
B(E)
874
897
C
A
875
611
Servo piston Small diameter

Large diameter 548 chamber
chamber D
531
210N72RG07
As the pilot pressure Pi 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.
2-11
② Flow increasing function
654 643 651 652 613 646
P1 CL
B(E)
874
897
C
A
875
611
Servo piston Small diameter

Large diameter 548 chamber
chamber D
531
210N72RG08
As the pilot pressure Pi 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.
2-12
③ Adjustment of flow control characteristic
The flow control characteristic can be
adjusted with the adjusting screw.
Adjust it by loosening the hexagon nut 801
(801) and by tightening(or loosening) the 924
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 (210-7)
Speed
Tightening Flow control Flow
amount of starting change
adjusting pressure amount
screw(924) change
Delivery flow, Q
amount
(min -1) (Turn) (kgf/cm2) (ℓ/min)
1950 +1/4 +1.5 +12.6
Pilot pressure, Pi
2-13
(2) Total horsepower control
The regulator decreases the pump tilting
angle(delivery flow) automatically to limit
the input torque within a certain value
Delivery flow, Q
with 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/2Л + P2×q/2Л
= (P1+P2)×q/2Л
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).
2-14
① Overload preventive function
621 651 652 623 612 601 625 626
P1 CL
B(E)
897
F
P2 P1
875
611
Large diameter Servo piston Small diameter

chamber chamber
D
210N72RG09
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.
2-15
② Flow reset function
621 651 652 623 612 601 625 626
P1 CL
B(E)
897
F
P2 P1
875
611

chamber chamber
D
210N72RG10
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.
2-16
Ι 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.
Κ 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
nut(630) and by tightening (or
loosening) the adjusting screw C(628).
Tightening the screw shifts the control 801
chart to the right and increases the
925
input horsepower as shown in the
figure. Since turning the adjusting
screw C by N turns changes the setting
of the inner spring(626), return the
adjusting screw CI(925) by NÝA turns
at first.(A=1.48)
ö Adjusting values are shown in table.
2-16 (210-7)
Adjustment of outer spring

Speed
Tightening Compens- Input torque
Delivery flow, Q
amount of ating control change

adjusting starting amount
screw(C) pressure
(628) change
amount
(min -1) (Turn) (kgf/cm2) (kgfÂm)
1950 +1/4 +16 +4.2

Delivery pressure, (P1+P2)
2-17
b. Adjustment of inner spring 626
Adjust it by loosening the hexagon nut
(801) and by tightening(or loosening)
the adjusting screw QI(925).
801
Tightening the screw increases the flow
and then the input horsepower as
925
shown in the figure.
※ Adjusting valves are shown in table.
Adjustment of inner spring

Speed
Tightening Compens- Input torque
amount of ating control change 2-17 (210-7)
adjusting starting amount

screw(QI) pressure
(925) change
amount
Delivery flow, Q
(min -1) (Turn) (kgf/cm2) (kgf・m)
1950 +1/4 +27 +4.0
Delivery pressure, (P1+P2)
2-18
(3) Power shift control
621 651 652 623 612 601 625 626
P1 CL
B(E)
897
898 F
Pf
P2 P1
875
611

chamber chamber
D
210N72RG11
The set horsepower valve is shifted by varying the

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

provided. However, the secondary pressure Pf Pf=
MIN
(power shift pressure) is admitted to the Pf= .
MA
horsepower control section of each pump X.
regulator through the pump's internal path to shift
it to the same set horsepower level. Delivery pressure, (P1+P2)
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.
2-19
(4) Adjustment of maximum and minimum flows
954 806
① Adjustment of maximum flow
Adjust it by loosening the hexagon
nut(806) and by tightening(or loosening)
the set screw(954).
The maximum flow only is adjusted without
changing other control characteristics.
210N72MP12
Adjustment of max flow

Speed
Tightening Flow change
Delivery flow, Q
amount of amount
adjusting screw
(954)
(min -1) (Turn) (ℓ/min)
1950 +1/4 -5.6

Pilot pressure, Pi
② Adjustment of minimum flow

Adjust it by loosening the hexagon 807
nut(807) 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
210N72MP13
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) (ℓ/min)

Pilot pressure, Pi
1950 +1/4 +4.5
2-20
GROUP 2 MAIN CONTROL VALVE
1. STRUCTURE
Mark Port name Port size Tightening torque
20~25kgf・m
R1 Make up port for swing PF 1 (115~180lbf・ft)
P2
Ck1 Bucket in confluence port 15~18kgf・m
Ck2 Bucket in confluence port PF 3/4 (109~130lbf・ft)
TL DO
XAtr Travel right pilot port

P1
XBtr Travel right pilot port
S OP
XAo Option pilot port
XBo Option pilot port
R2 PW
SP XAk Bucket out pilot port
(B2) B1
XBk Bucket in pilot port
XAb1 Boom up pilot port
A1 BK XBb1 Boom down pilot port
7~8kgf・m
Dr4 XAa2 Arm in confluence pilot port PF 3/8 (50.6~57.8lbf・ft)
BC A2
XBa2 Arm out confluence pilot port
XAtl Travel left pilot port
NR1 PBP XBtl Travel left pilot port
XAs Swing pilot port
VIEW A XBs Swing pilot port
XAa1 Arm in pilot port
XBa1 Arm out pilot port
XAb2 Boom up confluence pilot port
PG (NZx) (XBp1) (Bucket in confluence pilot port)
Pz CMR1 CMR2
(XBp2) (Drain port)
R2(P2) MR
R1
CP2 C1 R1 Pz Main relief pilot pressure
(Px)
PG Pilot pressure port
(Px) Signal for other acutuators
XBtr C2 DOZER XAtr XBtl TRAVEL XAtL
Btr Atr DO TL AtL BtL Dr1 Drain port
LCo
Dr4 Dr4 Pns
Pns
Dr2 Drain port
XBo OPTION XAo XAs SWING Dr6 XBs Dr3 Drain port
(Bo) (Ao) S 3.5~3.9kgf・m
Dr6 As Bs Dr4 Drain port PF 1/4
LCb1 OP CCb (25.3~28.2lbf・ft)
A ROD Dr6 Drain port
XBb1 PbL BOOM1 XAb1 XAb2 BOOM2 SP
Bb1 HEAD B2 PaL CSP
FL Negative control signal port(P1 port side)
B1 HV
LCk PbL
PaL LCa1
HEAD
FR Negative control signal port(P2 port side)
ROD A1
XAk Ab1
BUCKET XBk XBa1 ARM1 XAa1 Pns Swing logic valve pilot port
ROD
Ak1 HEAD BK
Aa1 PaL Lock valve pilot port
LCa2 Ck1
Bk1 BC NR2
Ba1
Dr1
PbL Lock valve pilot port
XBa2 (XBp1) (XBp2)
XAa2 ARM2 A2
Dr3 FR FL PBP Drain port
Dr2 Atr Travel motor right side port
PBP Dr2 Dr3
Btr Travel motor right side port
(Ao) Option port
(Bo) Option port
Ak1 Bucket rod side port
Bk1 Bucket head side port
Ab1 Boom head side port
Bb1 Boom rod side port 5~6.6kgf・m
Atl Travel motor left side port M10
(36.1~47.7lbf・ft)
Btl Travel motor left side port
Dr3
As Swing motor port
Bs Swing motor port
Aa1 Arm head side port
FR Ba1 Arm rod side port
P1 Pump port(P1 side)
P2 Pump port(P2 side)
R2 Return port 8.5~11.5kgf・m

FL M12 (61.5~83.1lbf・ft)
20W72MC01
2-21
A
P1 103 P1
B
PG
RELIEF VALVE 154 164 974
BLOCK 975
I MR I L
R2(P2) 159 P2
R2
R1 162
K K
152
159 DO
TL XBtL XAtL XBtr XAtr
DO TL
TRAVEL DOZER
C Pns
C
Dr4
OP
L
S OP
XAs XBs XBo XAo
S Dr6 SWING OPTION
D D M
B1
N
B2 XAb2 XBb1 XAb1
B1
B2 PaL BOOM 2 BOOM 1
E PbL E
BK
159
A1
A1 BK
XBa1 XAa1 XAk XBk
ARM 1 BUCKET
F NR2
F
A2 975 XBa2
A2
A2 BC (XBp1) (XBp2) XAa2
Dr3
ARM 2 ARM 2
G G
K1
Dr2
A M N 976
102
J J 101 153 561
B 159 273
SECTION A-A 104 SECTION B-B
101 Casing A 264 O-ring 378 Spring

102 Casing B 273 Socket screw 379 Spring
561 153
CCb HV
Ba1 Aa1 103 Straight travel valve 301 Travel spool 392 Bypass cut spool
104 Boom priority valve 302 Arm 1 spool assy 395 Swing priority spool
152 Plug 303 Boom 1 spool assy 401 Spool
153 Plug 304 Bucket spool 424 Spring
B2 154 Plug 305 Swing spool 425 Spring
Pz CMR1 CMR2 A1
155 Plug 306 Arm 2 spool 438 Rod
BC B2 A1 BC 159 Plug 307 Boom 2 spool 511 Poppet
MR 162 O-ring 309 Spool(Option) 515 Poppet
A2
164 O-ring 310 Travel spool 516 Poppet
d3 B1 BK B1 BK
601 d1 dr1
165 O-ring 328 Spring 517 Poppet
J2
166 O-ring 329 Spring 521 Spring
DR1 P1 A2
P2
167 O-ring 331 Spring seat 523 Spring
168 O-ring 332 Spring seat 551 Plug
SECTION I-I 169 O-ring 333 Bolt 552 Plug
201 Cover 334 Stopper 553 Plug
Ab1 Bk1 Bb1 Ak1
202 Cover 335 Stopper 561 O-ring
SECTION M-M SECTION N-N 203 Cover 336 Bolt 601 Main relief valve
204 Cover 337 Stopper 602 Port relief valve
209 Flange 339 Stopper 611 Nega-con relief valve
251 Control valve assy 370 Spring 971 Socket screw
252 Lock valve assy 372 Spring 974 Socket screw
254 Swing logic valve assy 374 Spring 975 Socket screw
261 O-ring 377 Spring 976 Socket screw
262 O-ring
20W72MC02
2-22
201
203 203 201 336
203 379 332
333 XAtr XAtl 333 XAs 336 370 XAb1 XAb2 201
333 XAo 332 335
331 331 331 332 261 336
334 337 335 159 332
334
329 379 339
329 329 602
370 159 372
328 328 328 Ab1R 374
AtLR 159 332
331 331 331 252 332
262 B2
262 262 261 261
168 553 159 307
166 AtrR AoR
561 166 165
165
553 165 561
971 166 552 CCb 551
165 523 Ab1
165 As 165 561 521
AtL 165 209 (Ao) 516 LCb1
Atr 511
515 511 254 165
164 561
521 521 CSP 551
154 521 LCo 551
Pns 521
551 561 SP
561 511 Bb1 511
551 303 551
971 Bs 251
561 165 165 561
Btr BtL 165 (Bo)
209 305 264 B1 SP 264
310 309 264 204
602 XBb1 164
301 165 561 204
OP S 204 Bb1R 154
169 169 553 BoR
TR TL
BtrR 202 169
553 XBo 166
XBs
202 602 202
XBtr XAtL
BtLR
SECTION C-C SECTION D-D SECTION E-E
201 154
332 164 424
XBk XBa1 201 201 203
336 336 XAa2 (XBp1) 425 K1
332 333
335 336 332 438
331
370 335 335
379 379 372 337 P P
332 370 374 378
261 BkR Ba1R 332
332 377
261 331 401
602 261
602 166 262
166 392
252 Dr2 SECTION J-J SECTION P-P
516 165 551
NR2
517 Bk1 523 561
521 HV 552 611
561
561 511 551 561 521 511 551
521 165 L1
CP2
LCk LCa1 FR 561
C1 C2 C2 561
551 LCa2 153 155 521
551 Ak1 561 (Ck1) 511
Aa1 551 167
304 FL P2
561 611 CP2
302 P2
551
BK A1 264
306 561 551 561 521 511 P2
264 204
602 XAk XAa1 602 165 A2 BC NR1 L1
204
AkR Aa1R 264 169 SECTION K-K SECTION L-L SECTION L 1 -L1
204 XBa2 164 202
154 (XBp2)
SECTION F-F SECTION G-G

20W72MC03
2-23
2. HYDRAULIC CIRCUIT
PBP
XBp1 XBp2
PaL Dr3 Ck1 Fl Fr Dr2
XAa1
Dr1
ARM 1 Aa1
Ba1 XBa2
XBa1 XAa2 ARM 2
Ak1
XAk
Bk1
XBk BUCKET
BOOM 2 XAb2
Dr4
Pns PbL
As Ab1
XBs XAb
Bs Bb1
SWING XAs XBb BOOM 1
Dr6
B0
XB0
Atl A0
XBtl
Btl XA0 OPTION
TRAVEL XAtl Atr

XAtr
Btr
XBtr DOZER
(Px)
R1
P2
RELIEF
BLOCK
PW
Pz P1 PG
20W72MC04
2-24
3. FUNCTION
1) CONTROL IN NEUTRAL POSITION
103 P1
TS
STRAIGHT
TRAVEL
21
TL XBtl XAtl
TRAVEL(L)
22
S XAs XBs
SWING
B2 XAb2
BOOM 2
A1 XBa1 XAa1
ARM 1
13
(XBp1) (XBp2)
101 4
SECTION A-A 20W72MC25
P2 R2
XBtr XAtr
TR
TRAVEL(R)
OP
XBo XAo OPTION
6
XBb1 XAb1
B1
BOOM 1
18
XAk XBk
BK
BUCKET
XBa2 XAa2
A2
ARM 2
K1
4
102
SECTION B-B 20W72MC26
2-25
XAa2 (XBp1)
4
Dr2
NR2 4
611
FR
LCa2
(Ck1)
FL 611
A2 BC NR1
13
13
XBa2 (XBp2)
SECTION G-G 21072MC27
A
B P1
PG
H PZ H
TS MR
R2(P2) Px
R1
TR TL
C Dr4 Pns C
OP
S
Dr6
D D
B1
B2
PaL
E PbL E
BK
A1
F NR2 F
BC
A2
Dr3
G G
Dr2
A
J J
B
21072MC28
2-26
The hydraulic fluid from the pump P1 flows into casing A(101) through the inlet port(P1), through the
center bypass(21) and the parallel path(22). The hydraulic fluid from the pump P2 flows into casing
B(102) through the inlet port(P2) through the center bypass(18) and the parallel path(6).
The hydraulic fluid from the pump P1 is directed to the tank through the center bypass(21), negative
control orifice(NR1), the return path(13) and the return port(R2). The hydraulic fluid from the pump
P2 also flows to the tank through the center bypass(18), negative control orifice(NR2), return path
(4) and return port(R2). The hydraulic fluid in paths (6) and (22) is blocked and cannot return to the
tank.
In case a control lever is operated, the hydraulic fluid from the pump P2 is supplied to the travel
spool(301) from path(18) and to the spools: option(309), boom1(303), bucket(304) and arm2(306)
from path(6). Additionally, the hydraulic fluid from the pump P1 is supplied to the dozer spool (310)
from path(7) while the swing(305), boom2(307) and arm(302) spools are supplied from path(22).
2-27
2) NEGATIVE CONTROL
(1) General operation
303 18 21 3 4 5
10
7
9
611
P2 P1 611
Fl Fr
19 6 27 28 22 13
21072MC29
The negative control signal pressure from the center bypass(18, 21) occurs in the following cases
and controls the discharge of the pump.
1. Neutral condition when no function is being actuated.
2. The pilot control lever is partially operated.
The hydraulic fluid of the pump P1(28) flows into the return passage(13) through the center bypass
(21), the path(3) and orifice(9)(Within the poppet(15)). The restriction caused by this orifice thereby
pressurizes path(3). This pressure is transferred as the negative control signal pressure Fl to the
pump P1 regulator through the negative control line(4). It controls the pump regulator so as to
decrease the discharge of the pump P1(28).
2-28
21
FL
15
611
16
BC NR1
101
13
(XBp2)
21072MC30
Q FL
Qmax
FL1
Qmin
FL QN
FL1
21072MC31
The negative control relief valve(611) consists of poppet(15), spring(16) and casing(101). When
the hydraulic fluid in the center bypass increases to the level that the pressure in the path(3)
reaches the set pressure of the spring(16), the hydraulic fluid in the path(3) pushes open the poppet
(15) and escapes into the return path(13).
In the unloaded state, the hydraulic fluid of the pump P1(28) entirely flows to the tank through the
path(21), orifice(9) and the return path(13). Therefore the pressure FL in the path(3) becomes
maximum(FL1) because all the discharge is reduced by the orifice(9) which in turn destrokes the
pump P1(28) so as to minimize the tilting angle and consequent discharge of the pump P1(28).
(Qmin)
2-29
(2) Negative control(With fine metering)
303 511 370 379
4 6 LCb1 Ab1
Bb1
Ab1R
Bb1R
XBb1 XAb1
B1
18 19
21072MC32
In the case, for example, when the pilot control lever for main boom is slightly operated, the pilot
pressure XAb1 shifts the main boom spool(303) partially in the left direction. So the path(19) is
partially opened and the center bypass(18) is shut slightly. The hydraulic fluid thereby separates.
One part flows via the orifice(7) through the path(18) and the other portion flows into the parallel
path(6), the path(19) and the port Ab1. The flow from the path(18) through the orifice(7) decreases
slightly and the pressure Fr in the path(10) thereby also slightly decreases. As the pressure Fr
becomes lower, the discharge of the pump P2(27) increases. With the pilot control lever shifted
even more the path(18) is shut off by the shifting of the spool(303) and then the flow through the
bypass becomes zero. The pressure in the path(10) becomes zero and the discharge of the pump
P2(27) becomes maximum.(Qmax)
Because the discharge of the pump is adjusted by operating the pilot control lever slightly, the
precise moving of the actuator is realized.
For the pump P1(28) the same negative control principle of operation occurs utilizing the orifice(9).
2-30
3) EACH SPOOL OPERATION
(1) Boom control
① Boom up operation
511 516 8
303
LCb1 Ab1 18
Bb1 370 379
Ab1R
Bb1R
XBb1 XAb1
6 B1
B2 4
13 SP
XAb2
SP CSP CCb
511 21 511 307 374 372
20W72MC33
The main boom up operation becomes fast because the hydraulic fluid from the pump P2 that is
directed to the port P2 is combined in the casing that of the pump P1 which enters port P1. The
confluence flow is supplied to the head side of the boom cylinder. In low speed operation, only the
boom1 spool(303) operates and is supplied with hydraulic fluid from the pump P2.
The hydraulic fluid from the pump P2 flows into the boom1 spool(303) through port P2 and parallel
path(6). The hydraulic fluid from the pump P1 flows to the boom2 spool(307) through pump port
P1 and the parallel path(22).
During the boom up operation, the pilot pressure from the pilot control valve is supplied into the port
XAb1 and shifts the boom1 spool(303) in the left direction against the springs(370) and (379). the
hydraulic fluid from the pump P2 enters the parallel path(6) and then passes through the load check
valve LCb1(511) and boom1 spool(303) and check valve HV(516) then flows into the port Ab1.
Following this it flows into the head side of the boom cylinder.
At the same time, the pilot pressure through the port XAb2 shifts the boom2 spool(307) in the left
direction against the springs(374) and (372). The hydraulic fluid from the pump P1 enters via the
parallel path(22) and center bypass(21), then passes through the load check valve CSP(511),
boom2 spool(307) and the load check valve CCb(511). Then flows combine in path(8) and are
directed to port Ab1 and the head side of the boom cylinder.
The flow from the rod side of the boom cylinder returns to the boom1 spool(303) through the port
Bb1. Thereafter it is directed to the return port R2 through path(13).
2-31
② Boom down operation
303 511 516 45 370 379

LCb1 Ab1
Bb1
Bb1R Ab1R
XBb1 XAb1
6 B1
B2 4
13 SP
XAb2
SP CSP CCb
374 372
511 511 307
20W72MC34
During the boom lowering operation, the pilot pressure from the pilot control valve is supplied to port
XBb1 and PbL and shifts the boom1 spool(303) in the right direction against the springs(370) and
(379).
The hydraulic fluid from the pump P2 enters the parallel path(6) and is directed to the port Bb1
through the load check valve LCb1(511). Following this is flows into the rod side of the boom
cylinder.
The return flow from the head side of the boom cylinder returns to the boom1 spool(303) through
the port Ab1. Thereafter it is directed to the return port R2 through path(4).
Additionally, the return flow is restricted in path(45), which lowers the boom cylinder at a suitable
speed.
2-32
(2) Arm control
① Arm roll out operation
306 374 372
LCa2
XAa2 XBa2
A2
A1
XAa1 XBa1
Aa1R
Ba1R
13
Aa1
LCa1 HV Ba1
22
302 511 516 370 379
20W72MC35
During the arm roll out operation, the pilot pressure from the pilot control valve is supplied to the
pilot ports(XBa1& XBa2) and shifts the arm1 spool(302) in the left direction against the springs
(370) and (379) and shifts the arm2 spool(306) in the left direction against the springs(374) and
(372). The hydraulic fluid from the pump P1 flows through the load check valve LCa1(511), lock
valve HV(516), and then through parallel path(22). It is then directed to the rod side of the arm
cylinder through the port Ba1.
At the same time, the pilot pressure through the port XBa2 shifts the arm2 spool(306) in the left
direction against the springs (374) and (372). The hydraulic fluid from the pump P2 enters via the
parallel path(22) and center bypass(21), then passes through the check valve of the boom priority
valve(104), arm2 spool(306). The flows are combined and directed to port Ba1 and the rod side of
the arm cylinder.
The flow from the head side of the arm cylinder returns to the arm1 spool(302) through the port
Aa1. Thereafter it is directed to the return port R2 through path(13).
2-33
② Arm roll in operation
・During light load only
306
374 372
LCa2
XAa2 XBa2
A2
(c) (a)
A1
XAa1 XBa1
Aa1R
Ba1R
13 Aa1
LCa1
HV Ba1
22
302 511 516 370 379
20W72MC36
2-34
・The pressure in the arm cylinder head side increases
306 374 372
LCa2
XAa2 XBa2
A2
(d) (e) (f) (a) (b)

A1
XAa1 XBa1
Aa1r
Ba1R
13 Aa1
LCa1 HV Ba1
22
302 511 516 370 379
20W72MC37
2-35
During the arm roll in operation, the pilot pressure from the pilot control valve is supplied to the
ports XAa1, XAa2 and PaL and shifts the arm1 spool(302) in the right direction against the
springs (370) and (379) and shifts the arm2 spool(306) in the right direction against the springs
(374) and (372).
During the arm roll in operation, the hydraulic fluid from the pump P1 flows into the arm1
spool(302) through the parallel path(22). Then it enters into the head side of the arm cylinder
through the load check valve LCa1(511), check valve HV(516) and port Aa1.
At the same time, the hydraulic fluid from the pump P2 flows into the arm2 spool(306) through
the parallel path(22). Then it enters into the head side of the arm cylinder through the check
valve of boom priority valve(104) and port Aa1.
The return flow from the rod side of the arm cylinder is pressurized by self-weight of arms and so
on, and returns to port Ba1. The pressurized oil returning to port Ba1 enters into the arm1 spool
through the outside of the arm1 spool. During a light load only, it pushes open the sleeve check
valve, flows the parallel path reversely from spool hole(c), and joints into port Aa1. This is called
the arm regeneration function.
When the pressure in the arm cylinder head side increases, the piston(d) and sub spool(e) are
transferred in the right direction, and at the same time the sleeve check valve(f) is from the arm
cylinder rod side enters flow port Ba1 through the periphery hole(a) of the arm1 spool into the
spool, flows out through the periphery hole(b) of the spool, and returns through the tank port R2
to the hydraulic oil tank.
2-36
(3) Bucket control
① Bucket roll in operation
379 370
517
LCk
Ak1 Bk1
AkR BkR
XAk XBk
BK
13 304 6 4
20W72MC38
During the bucket roll in operation, the pilot pressure from the pilot control valve is supplied to port
XBk and shifts the bucket spool(304) in the left direction against the springs(370) and (379).
The hydraulic fluid from the pump P2 enters the parallel path(6) and is directed to the port Bk1
through the load check valve LCk(517). Following this it flows into the head side of the bucket
cylinder.
The retutn flow from the rod side of the bucket cylinder returns to the bucket spool(304) through the
port Ak1. Thereafter it is directed to the return port R2 through path(13).
2-37
② Bucket out operation
379 370
517
Ak1 LCk Bk1
AkR BkR
XAk XBk
BK
13 304 6 4
20W72MC39.
During the bucket roll out operation, the pilot pressure from the pilot control valve is supplied to port
XAk and shifts the bucket spool(304) in the right directed agains the springs (370) and (379).
The hydraulic fluid from the pump P2 enters the parallel path(6) and is directed to the port AK1
through the load check valve LCk(517). Following this it flows into the rod side of the bucket
cylinder.
The return flow from the head side of the bucket cylinder returns to the bucket spool(304) through
the port Bk1. Thereafter it is directed to the return port R2 through path(4).
2-38
(4) Swing control
XBs XAs
22
13
4
Bs As
305 251 254 370 379

Pns
21072MC40
During the swing right or left operation, only the hydraulic fluid of the pump P1 is supplied to the
swing motor.
The pilot pressure from the pilot control valve is supplied to the port XAs and shifts the swing spool
(305) in the left direction against springs (370) and (379). Hydraulic fluid from the pump P1 flows
into the swing spool(305) through the parallel path(22). Then it is directed to the swing motor
through the check valve LCs(254) and the port As. As a result, the swing motor turns and the
return flow from the swing motor enters port Bs. The flow from the motor returns to the tank port
R2 through the swing spool(305) and path(13). In the case of the opposite operation, the operation
is similar.
2-39
(5) Travel operation
Btr Atr
BtrR AtrR
XBtr XAtr
TR
TL
XAtl XBtl
BtLR AtLR
Btl Atl
310 328 329
20W72MC41
When pilot port XAtl of the travel spool (301) is pressurized, the bypass circuit(2) in the arm 1 side is
shut off and pressurized oil from port P1 passes through port Atl and flows to the travel motor.
On the other hand, the return oil from the travel motor passes through port Btl and returns to the
hydraulic oil tank through the tank port(R2).
2-40
(6) Dozer operation
301 329 328

Btr Atr
BtrR AtrR
XBtr XAtr
TR
TL
XBtl XAtl
BtLR AtLR
Btl Atl
20W72MC43
When pilot port XAtr(or XBtr) of the dozer spool (310) is pressurized, the bypass circuit(2) in the
boom1 side is shut off and pressurized oil from port P2 passes through port Atr(or Btr) and flows to
the dozer cylinder. On the other hand, the return oil from the dozer cylinder passes through port
Btr(or Atr) and returns to the hyydraulic oil tank through the tank port(R2).
2-41
4) CIRCUIT PRESSURE PROTECTION
The control valve has two kinds of relief valve to limit the pressure in a circuit.
(1) Main relief valve
Limits the pressure of the main hydraulic system.
Pz CMR1 CMR2
MR
d3
601 d1
J2 dr1
DR1 P1
P2
20W72MC42
The hydraulic fluid from the pump P1 and the pump P2 enters the control valve through ports P1
and P2, respectively. From here the flow is directed to the main relief valve(601) through the check
valve CMR1 or CMR2(511) and path(11). The pressure in path(11) is limited by the main relief
valve(601) to its set pressure.
2-42
Main relief operation while working
30 35 32 33
14
11 31 38 34 24 39 25
21072MC43
While the pressure in path(11) is lower than the set pressure of main relief valve(601), the poppet
(24) is seated and the hydraulic fluid in path(11) can not escape to the return(14). When the
pressure in path(11) approaches the pressure setting, poppet(24) opens against the spring(39). As
the flow in chamber(33) escapes into the return(14) through path(32), its pressure decreases. At
the same time, hydraulic fluid in path(11) flows into path(30) with a pressure drop across orifice(31).
Then pressure in spring chamber(35) becomes lower because it bleeds off through path(30). The
pressure from path(11) pushes the plunger(38) in the left direction against the spring(34). Then
plunger(38) opens and hydraulic fluid in path(11) escapes into the return(14) and maintains the
pressure setting. The pressure setting is adjusted with adjustment screw(25).
2-43
(2) Port relief valve
Limits the service pressure in a cylinder circuit.
10 9 8 7
6 5 4 3 2 1
21072MC44
Port relief valves and make up valves are fitted between the cylinders of the working devices(Boom,
arm, bucket) and their spools. In the case of an external force acting on the cylinder rod with its
spool in neutral, the pressure in the cylinder could become excessive. The port relief valve(602)
restricts this pressure to the set pressure of the valve.
Port relief valve(602) have also the additional function of a make up valve. It is possible, under the
influence of an external force acting on a cylinder that a condition can occur where insufficient flow
is available to match cylinder velocity. If this occurs then a vacuum and thereby cavitation could
exist. To eliminate such an occurrence, a make up valve operates to break this vacuum by
supplying the return flow into the cylinder.
The hydraulic fluid between the cylinder and its spool flows into the path(6) to pressurize the port
relief valve(602). The hydraulic fluid in the path(6) flows into the spring chamber(3) through the
path(4) in the piston(10). If the pressure is lower than the pressure setting, the poppet(2) is shut off
because the force of the spring(1) overcomes the pressure. So the path(6) and the spring
chamber(3) have the same pressure. Because the spring chamber(3) side pressured area of the
seat(8) and the plunger(9) is larger than that of the path(6) side, seat(8) and the plunger(9) are
pushed in the right direction to be seated securely and then the hydraulic fluid in the path(6) doesn't
escape into the return path(5).
2-44
① Port relief function
10 9 7 13
6 12 5 4 3 2 11 1
21072MC45
When the pressure in the path(6) is pressurized to the pressure setting, the poppet(2) is pushed
open against the spring(1). The hydraulic fluid in the chamber(11) flows into the return path(5)
through the path(13) with reducing its pressure. The piston(10) is shifted in the left direction by the
pressure in the path(6) and stops on the end of the plug(7).
The hydraulic fluid in the path(6) flows into the chamber(11) through the path(4) in the piston(10)
and the spring chamber(3). Because the differential pressure occurs between the pass(6) and the
pass(4) by the orifice between the outernal diameter of the end of the piston(10) and the internal
diameter of the plunger(9), the pressure in the spring chamber(3) becomes low and therefore the
plunger(9) is pushed in the left direction with the path(12) opened so that the hydraulic fluid in the
path(6) flows into the return path(5).
2-45
② Make up function
9 8 11
6 5 4 3
21072MC46
Following this then the case of a port relief valve operating as a make up valve is now explained.
In the case that the hydraulic fluid in the cylinder rod(Head) side escapes from the port relief valve
(602), then hydraulic fluid needs to be supplied because vacuum occurs in the head(Rod) side.
When cacuum occurs in the side of the path(6), it also occurs in the spring chamber(3) through the
path(4). The pressure in the side of the return path(5) acts on the seat(8). The seat(8) is shifted in
the left direction by the return pressure because the spring chamber(3) sides of the seat(8) and the
plunger(9) are under a vacuum. The hydraulic fluid in the return path(5) flows into the path(6) so as
to break the vacuum in the path(6) side.
2-46
GROUP 3 SWING DEVICE
A. SWING DEVICE(T3X150CHB, up to #0114)

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 Swing motor Time delay valve Relief valve
Grease filling port SH

Air vent port
Swing reduction PG
gear oil drain port
Dr2
Mu
GA GB
A B
Air vent port
SH A Main port PF 3/4

PG B Main port PF 3/4
Dr2 Drain port PF 3/8
Mu Make up port PF 1
SH Brake release port PF 1/4
PG Stand by port PF 1/4
GA, GB Gage port PF 1/4
Dr2
A Mu B
21072SF03
2-47
1) SWING MOTOR
27 4 5 6 7 8 9 10 11 12 13 14 29 30, 31 32 33 40
3
2
1 15
41
42
43
35, 44
28 26 25 24 39 23 38 22 21 20 19 18 37 36 34 35 16, 17
21072SF04
1 Inner ring 16 Cap 31 O-ring

2 Oil seal 17 O-ring 32 O-ring
3 Taper roller bearing 18 Coned disc spring 33 Cover
4 Backing spring 19 Teflon ring 34 Relief assembly
5 Cam plate 20 Bushing 35 O-ring
6 Return plate 21 Balance plate 36 Hexagon socket bolt
7 Piston assembly 22 Needle bearing 37 Time delay valve
8 Lining plate 23 Snap ring 38 O-ring
9 Plate 24 Cylinder 39 O-ring
10 O-ring 25 Housing 40 Hexagon socket bolt
11 Piston 26 Collar 41 Check
12 O-ring 27 Plug 42 Spring
13 Spring 28 Snap ring 43 Cap
14 Parallel pin 29 Bypass valve assembly 44 Back up ring
15 Piston 30 Back up ring
2-48
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
21072SF05
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 bearing 21 Pin 1 34 Cover plate
9 Carrier 2 22 Needle cage 35 Hexagon socket bolt
10 Stop ring 23 Bush 2 36 Lock plate
11 Ring gear 24 Planet gear 1 37 Hexagon socket bolt
12 Knock pin 25 Lock washer 38 Stop ring
13 Pinion gear 26 Side plate 3 39 Side plate 2
14 Thrust gear 27 Sun gear 1
2-49
2. FUNCTION
1) ROTARY PART
When high pressurized oil enters a cylinder through port(a), which is the inlet of balance plate(1),
hydraulic pressure acting on the piston causes axial force F. The pressure force F works via the
piston(2) upon the return plate(3) which acts upon the swash plate(4) via an hydrostatic bearing.
Force F1 perpendicular to swash plate(4) and force F2 perpendicular to cylinder center.
Being transferred to the cylinder block(5) 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.
p×q F
T= , q=Z・A・PCD・tanθ, F1 = , F2=F tanθ, S=PCD×tanθ
2Л COSθ
Where p : Effective difference of pressure(kgf/cm2)
q : Displacement(cc/rev)
T : Output torque(kgf・cm)
Z : Piston number(9EA)
A : Piston area(cm2)
θ: Tilting angle of swash plate(degree)
S : Piston stroke(cm)
PCD
S
θ
F2
a a
High High Low
pressure oil pressure oil pressure oil
4 3 2 5 1
2-46 (210-7)
2-50
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
2-47 (210-7)
2-51
3) RELIEF VALVE
1 Body
5 11
2 Seat
3 Plunger
6 10
4 Spring
5 Adjusting screw
9 7
6 Piston
8 7 Bushing
3 8 Spring seat
12 9 Shim
10 O-ring
11 Back up ring
1
12 O-ring
2-48(1) 210-7
(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
on the relief valve is related to its rising P P=pressure, T=time
process. Here is given the function, Ps
referring to the figure following page.
4
P2
3
P1
T
1
2-48(2) 210-7
2-52
① Ports (P,R) at tank pressure.
A2 m h n g
A1
P
2-49 (210-7)
② When hydraulic oil pressure(P×A1) reaches the preset force(FSP) of spring(4), the plunger(3)
moves to the right as shown.
P1×A1=Fsp+Pg×A2
Fsp+Pg×A2
P1=
A1
4 g
P=P1
2-49 (210-7)
2-53
③ The oil flow chamber g via orifice m and n. When the pressure of chamber g reaches the preset
force(FSP) of spring(4), the piston(6) moves left and stop the piston(6) hits the bottom of bushing(7).
4 m n g
P=P2
6
2-49 (210-7)
④ When piston(6) hits the bottom of bushing(7), it stops moving to the left any further. As the
result, the pressure in chamber(g) equals(Ps).
Ps×A1=Fsp+Ps×A2
Fsp
Ps=
A1-A2
P=Ps
7 6 g
2-49 (210-7)
2-54
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

2-48(1) 210-7
(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.
① Brake assembly
Circumferential rotation of separate
plate(9) is constrained by the groove
located at housing(26). When housing
is pressed down by brake spring(16)
through lining plate(10), separate
plate(9) and brake piston(12), friction 14
force occurs there. 12
Cylinder(25) is constrained by this friction 9
force and brake acts, while brake 10
releases when hydraulic force exceeds
25
spring force.
26 Groove
2-51 ( 210-7)
9 Separate plate 14 Spring

10 Lining plate 25 Cylinder
12 Brake piston 26 Housing
2-55
② 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(6) to the upward against the force of the spring(9).
Thus, it releases the brake force.
3 10 7
9 11
G
6
D
8
5
Pg Sh
1 Swing control lever

2 Swing control valve(MCV)
3 Time delay valve
4 Shuttle valve 12
5 Spool
P3
6 Piston
7 Poppet
8 Spring 2 2
9 Spring 4
10 Orifice
11 Spring
12 Pilot pump 2-52 (210-7)
2-56
b. Meantime, the oil pressure of port D balance with the preset force of spring(11), the pressure of
chamber G keeps constant pressure.
3 10 7
9 11
G
6
D
8
5
Pg Sh

3 Time delay valve
12
4 Shuttle valve
5 Spool P3
6 Piston
7 Poppet
2 2
8 Spring
4
9 Spring
10 Orifice
11 Spring
2-52 (210-7)
12 Pilot pump
2-57
c. When the swing control(1) lever is set the neutral position, the spool(5) returns right in the time
delay valve(3).
Then, the piston(6) is moved lower by spring force and the return oil from the chamber G flows
back to D-port through orifice(10) of the poppet(7).
At this time, the poppet(7) works to make a time lag for 5 seconds.
3 10 7
9 11
G
6
D
8
5
Pg Sh

3 Time delay valve
4 Shuttle valve 12
5 Spool
P3
6 Piston
7 Poppet
8 Spring 2 2
9 Spring 4
10 Orifice
11 Spring
12 Pilot pump 2-52 (210-7)
2-58
B. SWING DEVICE(RMF151, #0115 and up)
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
Swing gear A,B A B
GA GB
Mu
Gear oil
drain port
Time delay valve PG Relief valve SH Dr
SH
PG
A Main port Ø20
B Main port Ø20
Au Dr Drain port PF 1/2
Mu Make up port PF 1
PG Brake release port PF 1/4
SH Stand by port PF 1/4
Dr
GA, GB Gage port PF 1/4
Au Air vent port PF 1/4
GB GA
B Mu A
22007SF03A(1)
2-58-1
1) SWING MOTOR
DETAIL : K
36
7 6 5 12 11 10 17 20 8 23 39 41 33 44 35 40
30
29
31
28
32
K
34
2 3 4 1 9 14 1316 15 18 19 24 21 22 42 27 37 45
25 43 38 46
26
220072SM02
1 Body 18 O-ring 35 Time delay valve

2 Oil seal 19 O-ring 36 Wrench bolt
3 Roller bearing 20 Spring 37 Plug
4 Snap ring 21 Rear cover 38 O-ring
5 Shaft 22 Needle bearing 39 Plug
6 Bushing 23 Pin 40 Plug
7 Stop ring 24 Valve plate 41 Plug
8 Pin 25 O-ring 42 Name plate
9 Shoe plate 26 O-ring 43 Rivet
10 Cylinder block 27 Wrench bolt 44 Level gauge
11 Spring 28 Plug 45 Flange
12 Ball guide 29 Back up ring 46 O-ring
13 Set plate 30 O-ring 47 Plug
14 Piston assy 31 Spring 48 O-ring
15 Friction plate 32 Check 49 O-ring
16 Plate 33 Relief valve 50 Back up ring
17 Brake piston 34 Anti-inversion valve
2-58-2
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
1 8 14 12 23 15 16 21 17 20 24 22 39
220072SF05A
1 Casing 14 Thrust washer 26 Side plate 3

2 Drive shaft 15 Planet gear 2 27 Sun gear 1
3 Spacer 16 Pin 2 28 Stop ring
5 Roller bearing 17 Spring pin 29 Plug
6 Oil seal 18 Sun gear 2 30 Plug
7 Roller bearing 19 Carrier 1 31 Socket bolt
8 Thrust plate 20 Side plate 1 34 Cover plate
9 Carrier 2 21 Pin 1 35 Hexagon bolt
10 Stop ring 22 Needle cage 36 Lock plate
11 Ring gear 23 Bush 2 37 Hexagon bolt
12 Knock pin 24 Planet gear 1 38 Stop ring
13 Pinion gear 25 Lock washer 39 Side plate 2
2-58-3
2. PRINCIPLE OF DRIVING
2.1 Generating the turning force
The high hydraulic supplied from a hydraulic pump flows into a cylinder(10) through valve casing of
motor(21), and valve plate(24).
The high hydraulic is built as flowing on one side of Y-Y line connected by the upper and lower sides of
piston(14).
The high hydraulic can generate the force, F1=P×A(P : supplied pressure, A : water pressure area),
like following pictures, working on a piston.
This force, F1, is divided as N1 thrust partial pressure and W1 radial partial pressure, in case of the
plate of a tilt angle, α.
W1 generates torque, T=W1+R1, for Y-Y line connected by the upper and lower sides of the piston as
following pictures.
The sum of torque(ΣW1×R1), generated from each piston(4~5 pieces) on the side of a high
hydraulic, generates the turning force.
This torque transfers the turning force to a cylinder(10) through a piston; because a cylinder is
combined with a turning axis and spline, a turning axis rotates and a turning force is sent.
W1 Pistion
Cylinder
W1
R1
N1
O A
f1 F1 P
High Y Low
pressure pressure
21078TM05
2-58-4
2.2 Working of relief valve
Relief valve carries on two functions of followings
1) It standardizes a pressure in case of driving a hydraulic motor; bypasses an extra oil in a motor inlet
related to acceleration of an inertia to an outlet.
2) In case of an inertia stopped, it forces an equipment stopped, according to generating the pressure
of a brake on the projected side.
Once high pressure oil supplied to P port, the inside pressure of shock less spool increases.
If the pressure is stronger than the power of the spring, it will be standardized.
In case of driving a hydraulic motor, it standardizes a pressure. And in the event of stopping an
inertia, it forces an equipment stopped, according to generating the pressure of break on the
projected side.
12 6 7 2 8 9 11 10 1 5 4 3
220072SM10
2-58-5
2.3 Working of parking brake
1) Parking brake OFF
If swing control level sets the swing position, pilot oil will moves swing spool and also it will be
supplied to SH port of time delay valve of swing motor through shuttle salve against the power of the
spring. The pressure of the spring switches spool to left and moves awaiting PG port oil of delay
valve to parking position. After then it moves up parking piston pressing frictional plate to release
parking brake.
2) Parking brake ON
If swing control level sets neutrality, swing pilot suplied to SH port of time delay valve through shuttle
valve will be stopped.
According to this process, spool is returned by the power of the spring and the pressure of PG port
of time delay valve which is always standing by release valve is stopped to parking piston.
In that time, orifice in spool stops leaking out working oil to create 6 second time delay in order to
prevent the impact which may be happened at the moment of sudden stop of swing brake.
5 10 17 20 8 23
1 9 16 15 24
220072SM11
2-58-6
2.4 Make up check valve
In case of rapid rotation which is faster than the amount of supplied oil to swing motor entrance,
mounted make up check valve supplies working oil to prevent cavitation according to the shortage of
supplying oil.
In the event of sudden stop of the operating excavator, supplying working oil to entrance of swing
motor is stopped. However, by means of inertia of rotation, swing motor will be stopped after more
rotation. In that time, make up check valve is opened and supplies working oil according to the
pressure of hydraulic oil line to the entrance of the motor, which is lower than working oil awaiting in a
make up check valve port.
12 6 7 2 8 9 11 10 1 5 4 3
220072SM10
2-58-7
2.5 Working description of plowing switch
The capacity of driving motor is changeable depending on the change of plowing angle of the plate.
That is operated by a plowing valve.
1) The pressure of external pilot : when Pi = 0 (large plowing)
A high pressure oil operated at a motor works on port P of a switching valve, by the highpressure
selecting function installed in valve casing.
Spool assembled at the switching part of plowing is adhered to plug by spring.
So the high pressure oil of port P flows to port Sb.
The pressure of this oil can be operated from port Sb to room A, through valve casing and the path
A' of shaft casing. An oil in room B flows into a drain line through the path of B → Sa.
Plowing piston moves to the right side because of the high pressure oil; the plate moves to the
place adhered to stopper, based on the shaft "0" ; it is fixed.
10 9 8
13
11
12
Pg Sh
2 7 6 1 3 5 4
220072SM12
2-58-8
2.6 Working of anti-inversion valve
In the event of swing motor operates switch part to drive and stop the swing part. By the action of
pump on motor, there is break on both-side of port because of the block on both sides.
Swing part is stopped by pressure of brake(in order words, 4-5 times of inversion)
Under the operating condition, the side of anti-inversion blocks off both ports but bypassing
compressed oil which is blocked in processing of anti-inversion fixed time and amount to inverse port,
prevent increasing pressure of motor and decrease inversing action.
5 1 3 4 2 6 7
220072SM13
2-58-9
GROUP 4 TRAVEL MOTOR
1. CONSTRUCTION
Travel motor consists motor unit, regulator and counter balance valve.
Motor unit Regulator Counter balance valve

U T M1
Mb
Ma
M1
T G1 X Ma,Mb S
B A
A, B Main port SAE 6000psi 1 1/4"

G1 Gauge port M14×1.5
M1 Gauge port M14×1.5
S
G1 X Gauge port M14×1.5
X
T Drain port M26×1.5
VIEW K U Gauge port M22×1.5
S Make up port M27×2.0
U Mb X M1 Ma, Mb Gauge port M18×1.5
B
S
Ma G1 T
Hydraulic circuit
200W34TM01
2-59
1) MOTOR UNIT
1 22 8 23 24 13 26 5 29 12
9 11 10 20 21 27 25 28 30 31 17 18 32 33
200W34TM02
1 Drive shaft 17 Threaded pin 26 Piston

5 Housing 18 Seal lock nut 27 Center pin
8 Locking screw 20 Retaining ring 28 Pan head screw
9 Retaining ring 21 Back up plate 29 Steel sealing ring
10 Shaft seal ring 22 Taper roller bearing 30 Cylinder block
11 Back up plate 23 Shim 31 Pressure spring
12 O-ring 24 Taper roller bearing 32 Adjustment shim
13 Locking screw 25 Retaining plate 33 Control lens
2-60
2) REGULATOR
2
20 23 32
7 24
15
4
16 8
28
34 26 5
50
33
55
56
57
29 58
51
59
52
21 60
53 1
19 54
61
62
64 67 68 70 69 71
63
33
65 66
200W34TM03
1 Control housing 28 Double break off pin 59 Retaining ring

2 Cover 29 Plug 60 Control piston
4 Positioning piston 32 Double break off pin 61 Control bushing
5 Positioning trunnion 33 O-ring 62 Retaining disc
7 Piston 34 Locking screw 63 Locking screw
8 Threaded pin 50 Relief valve 64 Double break off pin
15 Socket head screw 51 Adjusting bushing 65 Double break off pin
16 Socket head screw 52 Cylinder pin 66 Socket head screw
19 O-ring 53 Threaded pin 67 Cover
20 O-ring 54 Seal lock nut 68 Throttle screw
21 O-ring 55 Pressure spring 69 Socket head screw
23 Socket head screw 56 Spring collar 70 O-ring
24 Square ring 57 Pressure spring 71 Locking screw
26 Cylinder pin 58 O-ring
2-61
2. FUNCTION
Port plate
Counter balance valve
Motor unit
200W34TM05
1) VARIABLE DISPLACEMENT MOTOR(With integrated counterbalance valve)

The variable displacement motor has a rotary group in bent axis design.
The torque is generated directly at the drive shaft.
The cylinder barrel is driven by a tapered piston arrangement.
The change of displacement is generated by the control lens via positioning piston. The control
lens slides on a circular shaped surface.
In case of constant pump flow volume and high pressure
- The output speed is increased at smaller swivel angle, the torque is reduced
- The torque rises at swivel angle increase, the output speed is decreased
The max swivel angle is 25°, the min swivel angle is 0°.
The variable displacement motor with integrated counterbalance valve is designed to be operated
in open loop.
Min and max displacement are limited by a stop screw. Stepless adjustment to various higher
values is possible.
※ Reduction to smaller displacement may result in overspeeding the motor.
2) PORT PLATE
With high pressure dependent control HA1, mounted counterbalance valve, integrated secondary
pressure relief valves, plugged gauge and boosting ports, service ports to the rear.
2-62
Port plate
Motor unit
200W34TM05
3) HIGH PRESSURE DEPENDENT CONTROL

The displacement is-dependent on operating pressure - automatically adjusted. Upon reaching
the operating pressure set at the control valve - internally measured at A or B - the motor swivels
from Vgmin to Vgmax until output torque = load torque. For values lower than the adjusted one the
motor keeps min swivel angle. The necessary positioning energy is taken from the respective high
pressure side via shuttle valve.
Swivelling results in a change of the displacement.
Swivel time is controlled by an orifice installed in the cover of the large positioning piston side.
4) COUNTERBALANCE VALVE
Mounted at the rear of the port plate.
Incase of downhill traveling or deceleration of the machine a counterbalance valve avoids
overspeeding and cavitation of hydraulic motor.
5) FUNCTION AS TO CIRCUIT DIAGRAM
Check valves in the inlet line A and B for by passing of the counterbalance valve.
At traveling forward the return oil flow is controlled by a counterbalance spool. At drop in inlet
pressure the counterbalance spool throttles the return oil flow. The motor is locked. The oil
behind the spool is led to the low pressure side via an additional check valve. Same function for
traveling forward and backward.
Braking means for the motor that
- At reduced or zero inlet flow the counterbalance spool reaches a modulating position or a neutral
position caused by spring force
- The high pressure oil(At outlet side of the motor) is returned to the low pressure side(At inlet side)
of the motor via crossover relief valves.
As the control pressure for regulation of the HA control via the integrated shuttle valve is no longer
available, the motor with HA control and counterbalance valve will swivel to its minimum
displacement during deceleration.
In addition, an external boost flow/pressure can be applied at port S for preventing cavitation.
※ Counterbalance valves do not replace the service and parking brake.
2-63
Port plate
Motor unit
200W34TM05
6) INSTALLATION
The housing must be filled entirely with oil and shall also not run empty at rotary group standstill.
7) FILTRATION
According to purity class 9 as to NAS 1638, 6 as to SAE, ASTM, AIA and 18/15 as to ISO/DIS
4406.
8) PRESSURE
Ports A or B : Normal 400bar, peak pressure 450bar
Port A + B : Pressure summation below 700bar
Max permissible intermittent case pressure : 6bar
9) DIRECTION OF ROTATION/ DIRECTION OF FLOW
With view on the drive shaft - clockwise/ A to B; Counter-clockwise/ B to A
10) LEAKAGE OIL TEMPERATURE
In the bearing area max permitted -25°
C to +80°
C; Short time operation -40°
C to +115°
C
11) COMMISSIONING
Fill the housing entirely with oil through highest located T port. Also connect the leakage oil pipe at
this port. After commissioning check sealing and make visual control of the complete installation.
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
19
25
Single
operation Simultaneous
operation
Handle bending direction

(No. push rod direction)
4
P
1
T 3
2
30
30
VIEW A
25032RL01
A
Port LH RH Port size

P Pilot oil inlet port Pilot oil inlet port
T Pilot oil return port Pilot oil return port
1 Left swing port Bucket out port
PF 1/4
T 2 Arm in port Boom down port
P 3 Right swing port Bucket in port
4 Arm out port Boom up port
1 32 4
Hydraulic circuit
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(14) 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 O-ring

2 Plug 12 Rod seal 22 Handle connector
3 Plug 13 O-ring 23 Nut
4 O-ring 14 Push rod 24 Insert
5 Spool 15 Plate 25 Boot
6 Shim 16 Bushing 26 Handle
7 Spring 17 Joint assembly 27 Switch assembly
8 Spring seat 18 Swash plate 28 Screw
9 Stopper 19 Adjusting nut 29 Switch assembly
10 Spring 20 Lock nut 30 Switch cover
40 Boot
2-66
CROSS SECTION
14072SF80
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) 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(20) 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(8) 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.
2-68
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 (210-7)
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
7
10
P 5
1 3
25032RL03
The force of the spring(7) 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
25032RL04
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 ACCELERATOR PEDAL
1. STRUCTURE
The casing has the oil inlet port A(Primary pressure), and the oil return port T(Tank). In addition the
secondary pressure is taken out through port P.
25
42
T
P
17032RP01
T
A
P
A Pilot oil inlet port
T Pilot oil return port G 1/4
Hydraulic circuit P Pilot oil output port
17032RP01(2)
2-72
GROUP 7 BRAKE PEDAL(VALVE)
1. STRUCTURE
The casing(Spacer) has the oil inlet port A(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.
15
10 12
14 5
6
37
1
19
36
21
28
51
24 21
11
31
38
52
25 22
12
Leading edge
32 35
1732BR01(1)
1 Base plate 15 Pedal cover 32 Spring

5 Piston 19 Distance washer 35 Plug
6 Bellows 21 Spring set 36 Screw
10 Retainer ring 28 Upper spool 37 Restriction screw
12 Pedal 31 Lower spool 38 Plug
14 Pin

24 11 Port M16×1.5
51
11 21
12 Port M16×1.5
21 Brake cylinder port M16×1.5
22 Brake cylinder port M16×1.5
24 Pluging M10×1.0
25
52 25 Pluging M10×1.0
12 22
51 Drain port M16×1.5
52 Drain port M16×1.5
1732BR01(2)
Hydraulic circuit
2-73
2. FUNCTION
1) PURPOSE
The purpose of the brake valve is to sensitively increase and decrease the braking pressure when
the brake pedal is actuated.
2) READY POSITION
When the braking system is ready for operation, its accumulator pressure acts directly on port 11/12
of the brake valve. A connection is established between ports 21/22 and port 51/52 so that the
wheel brakes ports 21/22 are pressureless via the returns ports 51/52.
3) PARTIAL BRAKING
When the brake valve is actuated, an amount of hydraulic pressure is output as a ratio of the foot
force applied.
The spring assembly(21) beneath base plate(1) is designed in such a way that the braking pressure
changes depending on the angle. In the lower braking pressure range, the machine can be slowed
sensitively.
When the braking process is commenced, the upper spool(28) is mechanically actuated via spring
assembly(21), and the lower spool(31) is actuated hydraulically by spool(28). As spools(28 and
31) move downward, they will first close returns 51/52 via the control edges, thus establishing a
connection between accumulator port 11/12 and ports 21/22 for the wheel brake cylinders. The
foot force applied now determines the output braking pressure. The control spools(28 and 31) are
held in the control position by the force applied(Spring assembly) above the spools and the
hydraulic pressure below the spool(Balance of forces).
After output of the braking pressure, spools(28 and 31) are in a partial braking position, causing
ports 11/12 and 51/52 to close and holding the pressure in ports 21/22.
4) FULL BRAKING POSITION
When pedal(12) is fully actuated, an end position of the brakes is reached and a connection
established between accumulator ports 11/12 and brake cylinder ports 21/22. Returns 51/52 are
closed at this point.
When the braking process ended, a connection is once again established between brake cylinder
ports 21/22 and return ports 51/52, closing accumulator ports 11/12.
The arrangement of spools in the valve ensures that even if one braking circuit fails the other
remains fully operational. This is achieved by means of the mechanical actuation of both spools
and requires slightly more pedal travel.
5) LIMITING THE BRAKING PRESSURE
Pedal restriction screw(37) on base plate(1) below pedal(12) is used to limit the braking pressure.
6) FAILURE OF A CIRCUIT
In the event of the lower circuit failing, the upper circuit will remain operational. Spring assembly
(21) will mechanically actuate spool(28). In the event of the upper circuit failing, the lower circuit will
remain operational since the lower spool(31) is mechanically actuated by spring assembly(21) and
spool(28).
7) INSTALLATION REQUIREMENTS
Return lines 51/52 must be connected directly to the tank.
The connecting lines must be installed in such a way as to permit proper bleeding.
2-74
8) MAINTENANCE OF THE BRAKE VALVE
No special maintenance beyond the legal requirements is necessary.
When using high pressure cleaners on the machined, please make sure that the water jet is not
aimed directly at the brake valve(to prevent damaging the bellows).
※ For safety reasons the whole of the brake valve must be replaced if parts other than those
listed above are damaged.
9) REPAIR WORK
※ When working on the braking system, always make sure that there is absolutely no
pressure in the system. Even when the engine is switched off there will be some residual
pressure in the system.
※ When doing repair work, make sure your environment is very clean.
immediately close all open ports on the components and on pipes using plugs.
10) REPLACING THE PEDAL COVER
Pedal cover(15) is simply pulled off by hand. The new pedal covers is pushed over pedal(12) and
tightened manually. Fasten the bellows with the strap retainers.
11) REPLACING THE COMPLETE ACTUATING MECHANISM
Carefully clamp the unit vertically in a fixture. The actuating mechanism can be removed by taking
out the four screws(36) below base plate(1). Make sure that spring assembly(21) does not fall out.
When installing the new actuating mechanism, make sure that spring assembly(21) is fitted in the
right order. Tighten the four screws(36).
12) REPLACING THE BELLOWS
To change bellows(6) it is advisable to remove pedal(12). For this purpose, loosen retaining
ring(10) and knock out pin(14) using a mandrill. When knocking out the pin, make sure that the
mandrill is applied to the side of the pin without a knurl. Remove pedal(12) and bellows(6).
Now fit the new bellows(6) and proceed in reverse order as described above. The upper portion of
bellows(6) is fastened to piston(5), its lower portion to base plate(1) secure the bellows using
clamps.
13) REPLACING THE GROOVED RING
Carefully clamp the unit vertically in a fixture. Unscrew screw plug(35) and pull spools(28 and 31)
out downwards. Check the spools for damage. If they are found to be damaged, the whole brake
valve needs to be replaced(Pairs of spools and housings are matched in manufacturing).
If the spools are not damaged in any way, remove the whole actuating mechanism as described
above. Remove spring assembly(21) and grooved ring(27) and put in a new greased grooved ring
with its lips pointing downwards. Install both the spring assembly as shown in the drawing, and the
pedal. Put in spring(30), followed by spool(31), using a slight turning motion if possible.
Insert spring(32) and close the unit with screw plug(35).
Check return port 51/52 to see if there is a gap of approx. 2mm between the lower edge of the hole
and the control edge of spool(28). If this is not the case, take out screw plug(35) once more and
change the setting by removing or adding distance washers(19) in the upper spring plate. Replace
the screw plug and once again check the distance between the lower edge of the hole at port 51/52
and the control edge of spool(28).
2-75
GROUP 8 TRANSMISSION
1. STRUCTURE
Gauge port(High speed, J)

Gauge port(Low speed, M)
Brake breather E
X
Y
P1
P2
Oil drain
Leakage oil port(E)
Oil filler hole

Oil level check
Shift pressure port(Low speed, P2)

Shift pressure port(High speed, P1)
Disconnection device
(Lever position
when towing machine)
VIEW X VIEW Y
17032TM01
2-76
2. TRANSMISSION DIAGRAM
From/To power control valve
M J B K P2 P1 L
Throttle Non return valve

check valve
Shift piston
Brake Accumulator Non return
change over valve
Brake Leakage oil
breather non return valve
Clutch Disconnection
device
Pressure
relief valve
E
Oil supply
transmission
Oil supply
transmission Lubricating oil pump
control
Lubricating oil
17032TM02
Port Name Size Port Name Size
P1 Shift pressure, High speed M16×1.5 M Gauge port, Low speed M14×1.5
P2 Shift pressure, Low speed M16×1.5 L Gauge port, Shift interlock M12×1.5
J Gauge port, High speed M14×1.5 E Leakage oil M14×1.5
2-77
3. OPERATION OF TRANSMISSION
1) DESCRIPTION
4 5 6 7
8
9
1 2 3
17032TM03
1 Travel motor 4 Disc clutch 7 Shift interlock

2 Spring cup 5 Planetary gear set 8 Helical gear 1
3 Disc brake 6 Disconnect device 9 Helical gear 2
Coaxially-mounted variable displacement travel motor(1) with specific displacement 160cm3/rev.

The 2-speed powershift transmission comprises a planetary gear set(5), a 2-shaft helical gear
drive(8) with output flanges to front and rear axle.
The powershift mechanism for the planet drive comprises a rotating multi-disc clutch(4) underneath
a multi-disc brake(3) rigidly connected to the housing. Both are closed by spring pressure(2) and
released hydraulically.
Between the planet drive and the helical drive, a disconnect device(6) is provided(Shifting when
machine standstill). It is actuated by means of a lever mounted on the transmission housing, with
firm locking in IN/OUT positions. This disconnect device interrupts the power drive train between
the powershift section and the output and thus allows the machine to be towed up to its maximum
speed and without special restrictions on distance.
When the disconnect device disconnected, the parking brake does not function.
2-78
The disconnect device should only be used in emergency in order to remove the machine from a
danger zone should power fail or should transmission control pressure not be available.
The shift interlock(7) prevents downshifts at high machine speeds and thus prevents over-rotation of
the travel motor. If the low speed gear is selected while the high speed gear is engaged and input
speed is above approx. 800rpm, the low speed gear shift is inhibited and only performed if input
speed is below this limit. With higher viscosity oil(Cold starting), the downshift is performed at a
lower input speed. Upshifts are always possible.The speed-dependent interlock is effective in both
directions. It does not prevent the possibility of over-rotation when the machine is coasting. For this,
a drive brake valve should be fitted to the travel motor.
2) LOW SPEED(Forward & reverse)
Low speed pilot pressure applied
P2 P1
Ring gear Planetary carrier Helical gear 1
Input
Helical gear 2
Piston
Spring Sun gear
Clutch Output Output
Brake
17032TM04
In low speed operation, the planet drive ring gear is supported on the closed brake fixed to the
housing. In this gear, there is no pressure in the brake piston space so spring force acts on the
multi-disc pack. Therefore, the clutch is opened.
2-79
3) HIGH SPEED(Forward & reverse)
High speed pilot pressure applied
P2 Planetary carrier Helical gear 1

P1
Input
Helical gear 2
Piston
Spring Sun gear
Clutch Output Output
Brake
17032TM05
In high speed operation, the clutch is held closed under spring pressure and the brake is
hydraulically opened.
When a gear shift occurs-for example from high speed to low speed gear- the oil from the brake
piston space is fed back to the tank through a restrictor(Throttle non-return valve) due to the spring
pressure acting on the brake piston. At the same time the clutch is filled with oil and opened.
Required oil flow is necessary for the transmission control to ensure the clutch is open before the
brake begins to transmit torque.
A spring accumulator is also integrated in the transmission. This modulates the pressure sequence
at the brake during a downshift in order to achieve good shift quality.
The gear shift equipment also has the function of a parking brake. When the brake is operated-for
example with high speed gear engaged-the clutch is closed and is statically loaded.
2-80
4) BRAKES
Travel high & low speed

pilot pressure not applied
P2
P1
Output Output
17032TM06
When the travel high/low speed pilot pressure is not applied in the piston space, the piston
compress against the multi disc pack due to the spring force. Thus the parking brake is engaged.
2-81
4. TECHNICAL DATA
1) GENERAL DATA
(1) Max input power : 110kW
(2) Max input torque : 78.5kg·m
(3) Max input speed : 4500rpm
(4) Hydraulic motor : 160cm3/rev
(5) Transmission ratio
Gear step : 3.85
·Low speed gear : 5.35
·High speed gear : 1.39
(6) Shift interlock
Downshift possible at operating temperature with input speed 800rpm(Downshift point lower when
oil temperature cold).
(7) Disconnection device
For towing away machine auxiliary release device for parking brake.
(8) Brake
Parking brake. Necessary brake deceleration by controlled locking of planetary drive. Braking
torque depends on opening pressure set at brake valve(13bar).
(9) Output flange
Bolts for propshaft connection : M10×1.0(Class 10.9)
(10) Transmission weight : 125kg
2) TRANSMISSION CONTROL
Following data are valid for oil temperature 30。
C to 40。
C in hydraulic tank, measured at connections
at powershift transmission(See Structure and Diagram).
(1) Control pressure
① At connection P1 and P2 at Low/High engine speed : 33+1kg/cm2
② Definition of lubricants : API GL-5, SAE 10W-30, 15W-40
(2) Oil flow
① Min oil flow at 24+1kg/cm2 counter pressure(Low engine speed) : 5.5ℓ/min
② Max oil flow : 25ℓ/min
(3) Residual pressure
① Max residual pressure in control line to tank connection P1 respectively P2 : 1.0kg/cm2
(4) Leakage oil transmission control
① Pressure in input housing connection(E) max : 1.0kg/cm2
② Max oil flow(Low speed actuated) : 1ℓ/min
2-82
GROUP 9 TRANSMISSION CONTROL VALVE
1. STRUCTURE
CT2
CT7
CT3 CT1
Travel pilot PG
T1
AC1GP
P1 CHOCK A AG
AC1
B BG
CT4
CT6
CT5
20W72TCV02
AC1 AG AB BG
CT8 Port name Port size
P1, T1, AC1 PF 1/2

CT6
AC1GP Travel pilot, A, B PF 3/8
CT5
AG, BG, PG, CHOCK PF 1/4
CT2 CT4
TRAVEL CT3
PILOT
CT7
CT1
CHOCK P1 PG T1
Hydraulic circuit
20W72TCV03
2-83
2. COMPONENT
5
10
6,8,11
7,8
2,8
3 4
20W72TCV01
1 Body 7 Solenoid valve

2 Solenoid valve 8 Coil
3 POD valve 9 Relief valve
4 Reducing valve 10 Orifice
5 Check valve 11 Lock nut
6 Solenoid valve
2-84
GROUP 10 STEERING VALVE
1. STRUCTURE
Section A-A
L R
T P
A A
17032SV01
L R
L Left port
R Right port
3/4-16UNF
T Tank port
P Pump port
P T
Hydraulic circuit
17032SV01
2-85
2. COMPONENTS
26
26
2
25
2
1
24
27
29
5
2 6
7
9 3 8
4
2
2
12
2
11
10
13
14
15
16 18
21
15
16
17
18
20
20W72STV01
1 Dust seal ring 10 Spacer 18 Washer

2 *Housing assy 11 Shaft 20 Pin screw
3 Ball 12 Spring set 21 Screw
4 Bushing 13 O-ring 24 Pressure relief valve
5 O-ring 14 Distributor plate 25 Wire spring
6 Kin-ring 15 Gear wheel set 26 Shock valve
7 Bearing assy 16 O-ring 27 Ball
8 Ring 17 End cover 29 Bushing
9 Cross pin
2-86
GROUP 11 AXLE
1. OPERATION
・The power from the engine passes through main pump, travel motor and transmission and drive
shafts, and is then sent to the front and rear axles.
・Inside the axles, the power passes from the bevel pinion to the bevel gear and is sent at right
angles. At the same time, the speed is reduced and passes through the both differentials to the axle
shafts. The power of the axle shafts is further reduced by planetary-gear-type final drives and is sent
to the wheels.
1) FRONT AXLE
Oil filler/level check
Oil drain Oil drain Oil filler/level check
Steering port
Air breather (M18x1.5)
A
A
Final drive Brake port Differential VIEW A
(M14x1.5)
17032AX01(1)
2) REAR AXLE
Oil filler/level check
Oil drain Brake port Oil drain Oil filler/level check

(M14x1.5)
A
VIEW A
Final drive Air breather Differential

17032AX01(2)
2-87
2. SECTION OF DIFFERENTIAL
2.2 9 23.1 3 22 27 21 20.1 17 12 11 10

1.2
25
24
28
26
25
29
30
4
2.1
5
1.1
9 23.2 20.2 7 19 18 16 15 14 13
17032AX02
1.1 Axle 1 11 Hex head nut 22 Allen head screw

1.2 Axle 2 12 Washer 23.1 Differential housing 1
2.1 Shim 13 Drive flange 23.2 Differential housing 2
2.2 Shim 14 Cover 24 Thrust washer
3 Tapered roller bearing 15 Shaft seal ring 25 Tapered gear
4 Tapered roller bearing 16 Tapered roller bearing 26 Differential axle
5 O-ring 17 Bushing 27 Thrust washer
6 Hex head screw 18 Shim 28 Differential axle
7 Screw 19 Tapered roller bearing 29 Roll pin
8 Washer 20.1 Pinion 30 Roll pin
9 Tie rod 20.2 Ring
10 Lock washer 21 Washer
2-88
3. DIFFERENTIAL
Rear axle
Differential
Front axle
17032AX03
The differential is installed on the front and rear axle to transfer the driving torque from the axle to
the wheels. The differential transfers half of the output torque of the transmission via the universal
drive shaft to the planetary gear of the wheel hubs and transfers the rpm and torque from the gear
via the pinion and the ring.
In addition, the differential also servers as an equalizer when going around curves. If the
mechanical connection from the transmission to the universal drive shaft, differential, shaft, and
planetary gears to the wheels would be rigid, every steering movement would strain the axle
construction and would result in increased tire wear.
The equalizing function comes from the special construction of the differential. The power input
from the input flange to the pinion shaft, ring and differential housing to the equalizing axle in the
differential housing meshes the four equalizing tapered gears with the axle gears, which are located
in the equalizing axles. This changes the relative direction of rotation between the shafts meshed
with the side gears. This means that one shaft turns clockwise and the other counterclockwise, and
one shaft turns faster than the other.
This balancing movement has the disadvantage that when traveling off road, traction is reduced on
uneven ground, on loose ground or on snow or ice only wheel per axle is engaged. This
disadvantage can be corrected in part by installing a self locking differential.
2-89
4. FINAL DRIVE
1) FRONT AXLE
3 2
17032AX04
1 Axle shaft 2 Planetary gear 3 Ring gear

4 Sun gear
(1) To gain a large drive force, the final drive uses a planetary gear system to reduce the speed and
send drive force to the tires.
(2) The power transmitted from the differential through axle shaft(1) to sun gear(4) is transmitted to
planetary gear(2). The planetary gear rotates around the inside of a fixed ring gear(3) and in this
way transmits rotation at a reduced speed to the planetary carrier.
This power is then sent to the wheels which are installed to the planetary carriers.
2-90
2) REAR AXLE
1 3 2
17032AX05
1 Axle shaft 2 Planetary gear 3 Ring gear

4 Sun gear
(1) To gain a large drive force, the final drive uses a planetary gear system to reduce the speed and
send drive force to the tires.
(2) The power transmitted from the differential through axle shaft(1) to sun gear(4) is transmitted to
planetary gear(2). The planetary gear rotates around the inside of a fixed ring gear(3) and in this
way transmits rotation at a reduced speed to the planetary carrier.
This power is then sent to the wheels which are installed to the planetary carriers.
2-91
5. TIRE AND WHEEL
17032TJ01
1 Wheel rim 3 Flap 5 Stone resister ring

2 Tire 4 Tube 6 Valve assembly
1) The tire acts to absorb the shock from the ground surface to the machine, and at the same time
they must rotate in contact with the ground to gain the power which drives the machine.
2) Various types of tires are available to suit the purpose. Therefore it is very important to select the
correct tires for the type of work and bucket capacity.
2-92
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 3-30
SECTION 3 HYDRAULIC SYSTEM
GROUP 1 HYDRAULIC CIRCUIT
R/PIPE 35 36 33 34 51 52
E 1 Main pump
4 2 Main control valve
46 47 46 47 R/PIPE 3 Swing motor
22 MA MB
4 Travel motor
49 49
5 RCV lever(LH)
14 15 X
V2 Pi1
50 E
6 RCV lever(RH)
12 G1 M1 7 RCV pedal
T Pi1 8 Turning joint
13 R/PIPE
V2 9 Transmission control valve
T
54 53 56 10 Steering valve
P2 P1
P
S/motror
66 11 Shuttle valve
"PG"
64 12 Locking valve
k A B
13 Transmission
C/V C/V
14 Front axle
A(fw) S B(bw) DR "a"
XBp1
"b"
R/PIPE PBP
a
15 Rear axle
XBp2 Pedal b Pedal
A
B
A1
A2 PaL Dr3 Fl Fr Dr2 "1" "2" 16 Brake supply valve
B1
B2
MCV
R P
MCV
17 Accumulator
"XBP1" "XBP1" 18 Accumulator
F N P A H D C
8 G
Q M L K B J
R 57 19 Accumulator
Pi XAa1
Dr1
20 Terminal assy
2-SOL' "B"
Aa1 XBa2 21 RCV dozer
Ba1 22 Oscillating cylinder
S/Motor"dr4" XBa1 XAa2 23 Check valve
R/PIPE"R1"
TM1 TM2 27 24 Check valve
63 XAk
25 Oil cooler
10 18 19
Ak1
P2 P1 9 62 Bk1 26 Strainer assy
L R AC1 A B
ACC1GP ACC1 ACC2 38 XAb2
XBk
27 Bypass valve
BR2 X
41 40 BR1 Dr4
65 28 Return filter
42 XBs
PBP
PbL 29 Spin filter
CT5 CT6 As Pns
AC1GP XAb1 Ab1
ACGP
T1
BR1 Bs Bb1
30 Air breather
CT4
P1 XAs 31 Hydraulic tank
TP
16 CT2
43 Dr6 27 XBb1
32 Line filter
XBtl A0
T2
Atl 33 Boom cylinder(LH)
B0
CT1 CT3
TGP P2
BR2 Btl XA0
XB0
34 Boom cylinder(RH)
XAtl
r4 r5 35 Arm cylinder
P T CHOCK P1 TP P T 3 XAtr
r3 r1 PGP r2 Atr 36 Bucket cylinder
SH Btr 37 Last guard filter
XBtr
38 Brake valve
PG (Px)
39 Pressure switch
Au
TM R1 40 Pressure switch
dr4 P2 41 Pressure switch
42 Pressure switch
21 5 6 39 43 Pressure switch
7 GA GB 44 5 solenoid valve
TRAVEL PEDAL DOZER OUTRIGGER SWING ARM BUCKET BOOM
Pz P1 PG 45 2 solenoid valve
A(cw) Mu B(ccw)
46 Outrigger cylinder(RH)
47 Outrigger cylinder(LH)
37 A1 A2
48 Gear pump
55 1 61 59
P A 1 2 49 Safety lock valve
(1) (3) (2) (4) (3) (1) (2) (4) 58 60
37 60 50 Safety lock valve
XAtR XBtR 11 SH 20
B 51 Adjust cylinder
BREAKER
45 Pi
A B D E G F H J 1 1
C 52 Safety lock valve
2 2
B a
24 FL
Pi1 Pi2
FR 53 Shut off valve
XBs XAs XBa1 XAa1 XBk XAk XAb1 XBb1 XAO XBO b
23 Pm2
A
Dr#, R#, r# A3 Pm1 54 Pressure switch
MCV "Pns" Pm2 Pm1
25 55 Option pedal
67 r7
30 56 Pressure switch
T P Psv
31 M 57 Selector valve
XBtl(fw)
XAtl(re) Pm1(Pump) Pz 17 44 A 58 Accumulator
Dr
A5 A4 A3 A2 ACC A1 X 29 28 27 48 Dr2
59 Accumulator
P5 PG(MCV) Pump R5
P4
"Dr" D S1 60 Stop valve
Psv(Pump)
P6 P3 PG(S/Motor) 26 C S2
61 Selector valve
P2
32 62 Port relief valve
A B
R6 P1
63 Port relief valve
64 Control valve
65 Shuttle valve
66 Orifice fitting
20W73HC01
67 Selector valve
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 it 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
(290LC-7) 3-2
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 3.0kgf/cm 2
Main control valve Actuators
Check valve(1)
5.0kgf/cm 2
Check valve(3)
1.5kgf/cm 2
20W73CI01
All oil 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 3.0kgf/cm2(43psi) and 5.0kgf/cm2(71psi). 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 5.0kgf/cm2(71psi), 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 return 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 return 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
Transmission
dr2 ~ dr8
Return filter
Hydraulic Spin filter

oil tank
dr1
Check valve
1.5kgf/cm 2
20W73CI02
Besides internal leaks from the motor, transmission, front and rear axle 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 leaking from the travel motor comes out of the drain ports provided in the respective motor
casing and joins with each other. This oil passes through joint and returns to the hydraulic tank
after being filtered by return filter.
2) SWING MOTOR DRAIN CIRCUIT
Oil leaking from the swing motor come out and return to the hydraulic tank passing through a return
filter.
3) MAIN PUMP DRAIN CIRCUIT
Oil leaking from main pump come out and return to the hydraulic tank passing through spin filter.
4) TRANSMISSION DRAIN CIRCUIT
Oil leaking from transmission comes out and returns to the hydraulic tank passing through return
filter.
3-4
GROUP 3 PILOT CIRCUIT
Remote control valve Dozer & outrigger Remote control valve

(LH lever) lever (RH lever)
Dozer & outrigger

selector valve
Boom priority valve
Safety lock
solenoid valve Swing parking brake
Control valve
Power boost solenoid valve
Max flow cut off solenoid valve
Main pump Travel forward solenoid valve
Line filter
Travel reverse solenoid valve
Relief valve
40kgf/cm 2
Pilot pump Suction filter
20W73CI03
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, EPPR valve, solenoid valve
assemblies, swing parking brake, main control valve and safety lock solenoid valve through line filter.
3-5
1. SUCTION, DELIVERY AND RETURN CIRCUIT
FRONT AXLE REAR AXLE OSCILLATING OUTRIGGER CYLINDER DOZER CYLINDER ARM CYLINDER BUCKET CYLINDER BOOM CYLINDER
CYLINDER
TRAVEL MOTOR
TRANSMISSION
C/V C/V
dr4 "a" "b"
R/PIPE PBP
XBp1
XBp2
A
PaL Dr3 Fl Fr Dr2
B
TURNING Pi
JOINT XAa2
2 SOL."B" Dr1
XAa1
Aa1
XBa2
Ba1 ARM2
XAa2
XBa1
L R
XBa2 ARM1
SWING MOTOR XAk
Ak1
XAb2 Bk1
BOOM2 XBk
XAa1 BUCKET
Dr4
PBP PbL
XBs XAb1
As Pns XAb2 Ab1
Bs Bb1
SWING
XAs
XBb1
BOOM1
P T Dr6
r3 XBtl
Atl
XA0
TM1 TM2
Btl
P2 P1
ACC1 ACC2
BRAKE VALVE XAtl
XB0
AC1 A B ACC1GP
BR2 TRAVEL OPTION XAtr
BR1 Atr
Btr
AC1GP
XBtr
(Px) DOZER/
CT4
TP R1 OUTRIGGER
CT2
P2 R2
CT1 CT3
r4 r5
CHOCK P1 TP P T
PGP r2
r1
Pz P1 PG
DOZER/OUTRIGGER
LEVER RCV LEVER(LH) RCV LEVER(RH)
TRAVEL PEDAL
TRAVEL DOZER OUTRIGGER SWING ARM BUCKET BOOM
A1 A2 MAIN PUMP
P A
dr10 (1) (3) (2) (4) (3) (1) (2) (4)
XAtR XBtR
Pi1 Pi2
Sh FL FR
Pm2
2 SOLENOID A3 Pm1
Pi
VALVE A B D E G F H J Pm2 Pm1
B
XBs XAs XBa1 XAa1 XBk XAk XAb1 XBb1 Dr#, R#, r#
A MCV "Pns" Psv
SAFETY E/G
SOLENOID HYD Dr
Dr2
XBtl(fw) XAtl(re) Pm1(Pump) Pz VALVE TANK
R5
A5 A4 A3 A2 ACC A1 D S1
P5 PG(MCV)
P4
MAIN PUMP
Psv(Pump) "Dr" C S2
P6 P3 PG(S/Motor)
P2
LINE
A B
FILTER
R6 P1
20W73HC02
The pilot pump receives 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 from remote control valve is returned to the hydraulic tank.
3-6
2. SAFETY SOLENOID VALVE(SAFETY LEVER)
CYLINDER
TRAVEL MOTOR
TRANSMISSION
C/V C/V
dr4 "a" "b"
R/PIPE PBP
XBp1
XBp2
A
PaL Dr3 Fl Fr Dr2
B
TURNING Pi
JOINT XAa2
2 SOL."B" Dr1
XAa1
Aa1
XBa2
Ba1 ARM2
XAa2
XBa1
L R
XBa2 ARM1
SWING MOTOR XAk
Ak1
XAb2 Bk1
BOOM2 XBk
XAa1 BUCKET
Dr4
PBP PbL
XBs XAb1
As Pns XAb2 Ab1
Bs Bb1
SWING
XAs
XBb1
BOOM1
P T Dr6
r3 XBtl
Atl
XA0
TM1 TM2
Btl
P2 P1
ACC1 ACC2
BRAKE VALVE XAtl
XB0
AC1 A B ACC1GP
BR1 Atr
Btr
AC1GP
XBtr
(Px) DOZER/
CT4
TP R1 OUTRIGGER
CT2
P2 R2
CT1 CT3
r4 r5
CHOCK P1 TP P T
PGP r2
r1
Pz P1 PG
DOZER/OUTRIGGER
TRAVEL PEDAL
A1 A2 MAIN PUMP
P A
dr10 (1) (3) (2) (4) (3) (1) (2) (4)
XAtR XBtR
Pi1 Pi2
sh FL FR
Pm2
2 SOLENOID A3 Pm1
Pi
B
A MCV "Pns" Psv
SAFETY SOLENOID E/G

VALVE HYD Dr
Dr2
XBtl(fw) XAtl(re) Pm1(Pump) Pz
LEVER UP TANK
R5
P5 PG(MCV)
P4
MAIN PUMP
Psv(Pump) "Dr" C S2
P6 P3 PG(S/Motor)
P2
LINE
A B
FILTER
R6 P1
LEVER DOWN
20W73HC03
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 moved downward, oil does not flows into the remote
control valve, because of blocked port.
3-7
3. MAIN RELIEF PRESSURE CHANGE SYSTEM
CYLINDER
TRAVEL MOTOR
TRANSMISSION
C/V C/V
dr4 "a" "b"
R/PIPE PBP
XBp1
XBp2
A
PaL Dr3 Fl Fr Dr2
B
TURNING Pi
JOINT XAa2
2 SOL."B" Dr1
XAa1
Aa1
XBa2
Ba1 ARM2
XAa2
XBa1
L R
XBa2 ARM1
SWING MOTOR XAk
Ak1
XAb2 Bk1
BOOM2 XBk
XAa1 BUCKET
Dr4
PBP PbL
XBs XAb1
As Pns XAb2 Ab1
Bs Bb1
SWING
XAs
XBb1
BOOM1
P T Dr6
r3 XBtl
Atl
XA0
TM1 TM2
Btl
P2 P1
ACC1 ACC2
BRAKE VALVE XAtl
XB0
AC1 A B ACC1GP
BR1 Atr
Btr
AC1GP
XBtr
(Px) DOZER/
CT4
TP R1 OUTRIGGER
CT2
P2 R2
CT1 CT3
r4 r5
CHOCK P1 TP P T
PGP r2
r1
Pz P1 PG
DOZER/OUTRIGGER
LEVER RCV LEVER(LH) RCV LEVER(RH) MAIN RELIEF
TRAVEL PEDAL VALVE
A1 A2 MAIN PUMP
P A
dr10 (1) (3) (2) (4) (3) (1) (2) (4)
XAtR XBtR
Pi1 Pi2
sh FL FR
Pm2
2 SOLENOID A3 Pm1
Pi
B
A MCV "Pns" Psv
POWER BOOST E/G

SOLENOID VALVE
HYD Dr
Dr2
XBtl(fw) XAtl(re) Pm1(Pump) Pz TANK
R5
P5 PG(MCV)
P4
MAIN PUMP
Psv(Pump) "Dr" C S2
P6 P3 PG(S/Motor)
P2
LINE
A B
FILTER
R6 P1
20W73HC04
When the power boost switch on the left control lever is pushed ON, the power max solenoid valve is
actuated, the discharged oil from the pilot pump into Pz port of the main relief valve in main control
valve ; Then the setting pressure of the main relief valve is raises from 330kgf/cm2 to 360kgf/cm2 for
increasing the digging power. And even when press continuously, it is canceled after 8 seconds.
3-8
4. SWING PARKING BRAKE RELEASE
CYLINDER
TRAVEL MOTOR
TRANSMISSION
C/V C/V
dr4 "a" "b"
R/PIPE PBP
XBp1
XBp2
A
PaL Dr3 Fl Fr Dr2
B
TURNING Pi
JOINT XAa2
2 SOL."B" Dr1
XAa1
Aa1
XBa2
Ba1 ARM2
XAa2
SWING MOTOR XBa1
L R
XBa2 ARM1
SH XAk
Ak1
XAb2 Bk1
PG
BOOM2 XBk
XAa1 BUCKET
Au Dr4
dr4 PBP PbL
XBs XAb1
As Pns XAb2 Ab1
Bs Bb1
SWING
XAs
XBb1
GA GB BOOM1
P T Dr6
r3 XBtl
A(cw) Mu B(ccw) Atl
XA0
TM1 TM2
Btl
P2 P1
XB0
AC1 A B XAtl
BRAKE VALVE TRAVEL OPTION XAtr

ACC1 ACC2 Atr
ACC1GP
BR2
BR1
Btr
AC1GP
XBtr
(Px) DOZER/
TP R1 OUTRIGGER
CT4
P2 R2
CT2
CHOCK P1 TP CT1 CT3
r1 r4 r5
P T
PGP Pz P1 PG
r2
DOZER/OUTRIGGER
TRAVEL PEDAL
A1 A2 MAIN PUMP
P A
dr10 (1) (3) (2) (4) (3) (1) (2) (4)
XAtR XBtR
Pi1 Pi2
SH FL FR
Pm2
2 SOLENOID A3 Pm1
Pi
B
A MCV "Pns" Psv
SAFETY SOLENOID E/G

VALVE HYD Dr
Dr2
R5
P5 PG(MCV)
P4
MAIN PUMP
Psv(Pump) "Dr" C S2
P6 P3 PG(S/Motor)
P2
LINE
A B
FILTER
R6 P1
20W73HC05
When the swing control lever is operated, the pilot oil flow into SH port of shuttle valve, this pressure
move spool so, discharged oil from pilot pump flow into PG port.
This pressure is applied to swing motor disc, thus the brake released.
When the swing control lever is set neutral position, oil in the swing motor disc cylinder is drain, thus
the brake is applied.
3-9
5. TRAVEL SPEED SELECTION SYSTEM
CYLINDER
TRAVEL MOTOR
TRANSMISSION
C/V C/V
dr4 "a" "b"
R/PIPE PBP
XBp1
XBp2
A
PaL Dr3 Fl Fr Dr2
B
TURNING Pi
JOINT XAa2
2 SOL."B" Dr1
XAa1
Aa1
XBa2
Ba1 ARM2
XAa2
XBa1
L R
XBa2 ARM1
SWING MOTOR XAk
Ak1
XAb2 Bk1
BOOM2 XBk
XAa1 BUCKET
Dr4
PBP PbL
XBs XAb1
As Pns XAb2 Ab1
Bs Bb1
SWING
XAs
XBb1
BOOM1
P T Dr6
r3 TRAVEL SPEED XBtl
VALVE Atl
HIGH XA0
SPEED LOW
Btl
P2 P1 SPEED
XB0
AC1 A B XAtl
PARKING BRAKE VALVE TRAVEL OPTION
SOLENOID ACC1 ACC2 XAtr
ACC1GP Atr
VALVE BR2
BR1 Btr
AC1GP
XBtr
(Px) DOZER/
TP R1 OUTRIGGER
CT4
P2 R2
CT2
CHOCK P1 TP TCV CT1 CT3
r1 r4 r5
P T
PGP r2 Pz P1 PG
DOZER/OUTRIGGER
TRAVEL PEDAL
A1 A2 MAIN PUMP
P A
dr10 (1) (3) (2) (4) (3) (1) (2) (4)
XAtR XBtR
Pi1 Pi2
sh FL FR
Pm2
2 SOLENOID A3 Pm1
Pi
B
A MCV "Pns" Psv
E/G
HYD Dr
Dr2
R5
P5 PG(MCV)
P4
MAIN PUMP
Psv(Pump) "Dr" C S2
P6 P3 PG(S/Motor)
P2
LINE
A B
FILTER
R6 P1
20W73HC06
When RH multifunction switch was placed in high or low position, the pressure oil from pilot pump
flows through parking solenoid valve of transmission control valve to travel speed solenoid valve,
thus the transmission is changed into high or low speed condition.
3 - 10
6. MAX FLOW CUT OFF SYSTEM
CYLINDER
TRAVEL MOTOR
TRANSMISSION
C/V C/V
dr4 "a" "b"
R/PIPE PBP
XBp1
XBp2
A
PaL Dr3 Fl Fr Dr2
B
TURNING Pi
JOINT XAa2
2 SOL."B" Dr1
XAa1
Aa1
XBa2
Ba1 ARM2
XAa2
XBa1
L R
XBa2 ARM1
SWING MOTOR XAk
Ak1
XAb2 Bk1
BOOM2 XBk
XAa1 BUCKET
Dr4
PBP PbL
XBs XAb1
As Pns XAb2 Ab1
Bs Bb1
SWING
XAs
XBb1
BOOM1
P T Dr6
r3 XBtl
Atl
XA0
TM1 TM2
Btl
P2 P1
ACC1 ACC2
BRAKE VALVE XAtl
XB0
AC1 A B ACC1GP
BR1 Atr
Btr
AC1GP
XBtr
(Px) DOZER/
CT4
TP R1 OUTRIGGER
CT2
P2 R2
CT1 CT3
r4 r5
CHOCK P1 TP P T
PGP r2
r1
Pz P1 PG
DOZER/OUTRIGGER
TRAVEL PEDAL
A1 A2 MAIN PUMP
P A
dr10 (1) (3) (2) (4) (3) (1) (2) (4)
XAtR XBtR
Pi1 Pi2
sh FL FR
Pm2
2 SOLENOID A3 Pm1
Pi
B
A MCV "Pns" Psv
E/G
HYD Dr
Pm1(Pump) Dr2
XBtl(fw) XAtl(re) Pz TANK
R5
P5 PG(MCV)
P4
MAIN PUMP
Psv(Pump) "Dr" C S2
P6 P3 PG(S/Motor)
P2
LINE
A B
FILTER
R6 P1
20W73HC02
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. BOOM PRIORITY SYSTEM
CYLINDER
TRAVEL MOTOR
TRANSMISSION
C/V C/V
dr4 "a" "b"
R/PIPE PBP
XBp1
XBp2
A
PaL Dr3 Fl Fr Dr2
B
TURNING Pi
JOINT XAa2
2 SOL."B" Dr1
XAa1
Aa1
XBa2
Ba1 ARM2
XAa2
XBa1
L R
XBa2 ARM1
SWING MOTOR XAk
Ak1
XAb2 Bk1
BOOM2 XBk
XAa1 BUCKET
Dr4
PBP PbL
XBs XAb1
As Pns SWING XAb2 Ab1
REDUCING
Bs Bb1
SWING SPOOL
XAs
XBb1
BOOM1
P T Dr6
r3 XBtl
Atl
XA0
TM1 TM2
Btl
P2 P1
ACC1 ACC2
BRAKE VALVE XAtl
XB0
AC1 A B ACC1GP
BR1 Atr
Btr
AC1GP
XBtr
(Px) DOZER/
CT4
TP R1 OUTRIGGER
CT2
P2 R2
CT1 CT3
r4 r5
CHOCK P1 TP P T
PGP r2
r1
Pz P1 PG
DOZER/OUTRIGGER
TRAVEL PEDAL
A1 A2 MAIN PUMP
P A
dr10 (1) (3) (2) (4) (3) (1) (2) (4)
XAtR XBtR
Pi1 Pi2
sh FL FR
SWING REDUCING A3
Pm2
Pm1
Pi SOLENOID VALVE Pm1
A B D E G F H J Pm2
B
A MCV "Pns" Psv
SAFETY
E/G
SOLENOID HYD Dr
Dr2
R5
P5 PG(MCV)
P4
MAIN PUMP
Psv(Pump) "Dr" C S2
P6 P3 PG(S/Motor)
P2
LINE
A B
FILTER
R6 P1
20W73HC08
When carrying out the combined operation of swing and boom or arm, the boom or arm operating
speed is lowered then normal operation.
To increase working efficieny, swing speed reducing system is used.
When heavy duty working mode in work mode is on, pilot oil from pilot pump flow into Pns port in
main control valve through solenoid valve. Pns oil pressure move swing reducing spool to lower
position and oil flow rate to the swing motor decreased. Then, the boom or arm speed is increased.
This is called the boom priority system.
3 - 12
GROUP 4 SINGLE OPERATION
1. BOOM UP OPERATION
CYLINDER
TRAVEL MOTOR
TRANSMISSION
C/V C/V
dr4 "a" "b"
R/PIPE PBP
XBp1
XBp2
A
PaL Dr3 Fl Fr Dr2
B
TURNING Pi
JOINT XAa2
2 SOL."B" Dr1
XAa1
Aa1
XBa2
Ba1 ARM2
XAa2
XBa1
L R
XBa2 ARM1
SWING MOTOR XAk
XAb2 MAKE UP
BOOM2 VALVE
XAa1 BUCKET
BOOM Dr4
PBP HOLDING PbL
XBs VALVE XAb1
As Pns XAb2 Ab1
Bs Bb1
SWING
XAs
XBb1
BOOM1
P T Dr6 RELIEF
r3 XBtl VALVE
Atl
TM1 TM2
Btl
P2 P1
ACC1 ACC2
BRAKE VALVE XAtl
AC1 A B ACC1GP
BR1 Atr
Btr
AC1GP
XBtr
(Px) DOZER/
CT4
TP R1 OUTRIGGER
CT2
P2 R2
CT1 CT3
r4 r5
CHOCK P1 TP P T
PGP r2
r1
Pz P1 PG
FRONT REAR PILOT

PUMP PUMP PUMP
HYD
TANK
20W73HC09
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
CYLINDER
TRAVEL MOTOR
TRANSMISSION
C/V C/V
dr4 "a" "b"
R/PIPE PBP
XBp1
XBp2
A
PaL Dr3 Fl Fr Dr2
B
TURNING Pi
JOINT XAa2
2 SOL."B" Dr1
XAa1
Aa1
XBa2
Ba1 ARM2
XAa2
XBa1
L R
XBa2 ARM1
SWING MOTOR XAk
Ak1
XAb2 Bk1
BOOM2 XBk
XAa1 BUCKET
Dr4
PBP PbL
XBs XAb1
As Pns XAb2 Ab1
Bs Bb1
SWING
XAs
XBb1
BOOM1
P T Dr6
r3 XBtl
Atl RELIEF
TM1 TM2 VALVE
Btl
P2 P1
ACC1 ACC2
BRAKE VALVE XAtl
AC1 A B ACC1GP
BR1 Atr
Btr
AC1GP
XBtr
(Px) DOZER/
CT4
TP R1 OUTRIGGER
CT2
P2 R2
CT1 CT3
r4 r5
CHOCK P1 TP P T
PGP r2
r1
Pz P1 PG
FRONT REAR PILOT

PUMP PUMP PUMP
HYD
TANK
20W73HC10
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
CYLINDER
TRAVEL MOTOR
TRANSMISSION
C/V C/V
dr4 "a" "b"
R/PIPE PBP
XBp1
XBp2
A PaL Dr3 Fl Fr Dr2
B RELIEF
VALVE
MAKE UP
VALVE
TURNING Pi
JOINT XAa2
2 SOL."B" Dr1
XAa1
Aa1
XBa2
Ba1 ARM2
XAa2
XBa1
L R
XBa2 ARM1
SWING MOTOR XAk
Ak1
XAb2 Bk1
BOOM2 XBk
XAa1 BUCKET
Dr4
PBP PbL
XBs XAb1
As Pns XAb2 Ab1
Bs Bb1
SWING
XAs
XBb1
BOOM1
P T Dr6
r3 XBtl
Atl
XA0
TM1 TM2
Btl
P2 P1
ACC1 ACC2
BRAKE VALVE XAtl
XB0
AC1 A B ACC1GP
BR1 Atr
Btr
AC1GP
XBtr
(Px) DOZER/
CT4
TP R1 OUTRIGGER
CT2
P2 R2
CT1 CT3
r4 r5
CHOCK P1 TP P T
PGP r2
r1
Pz P1 PG
FRONT REAR PILOT

PUMP PUMP PUMP
HYD
TANK
21073HS11
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
CYLINDER
TRAVEL MOTOR
TRANSMISSION
C/V C/V
dr4 ARM "a" "b"
R/PIPE PBP
HOLDING XBp1
XBp2
A VALVE
PaL Dr3 Fl Fr Dr2
B
TURNING Pi
JOINT XAa2
2 SOL."B" Dr1
XAa1
Aa1
XBa2
Ba1 ARM2
XAa2
XBa1
L R
XBa2 ARM1
SWING MOTOR XAk
Ak1
XAb2 Bk1
BOOM2 XBk
XAa1 BUCKET
Dr4
PBP PbL
XBs XAb1
As Pns XAb2 Ab1
Bs Bb1
SWING
XAs
XBb1
BOOM1
P T Dr6
r3 XBtl
Atl
XA0
TM1 TM2
Btl
P2 P1
ACC1 ACC2
BRAKE VALVE XAtl
XB0
AC1 A B ACC1GP
BR1 Atr
Btr
AC1GP
XBtr
(Px) DOZER/
CT4
TP R1 OUTRIGGER
CT2
P2 R2
CT1 CT3
r4 r5
CHOCK P1 TP P T
PGP r2
r1
Pz P1 PG
FRONT REAR PILOT

PUMP PUMP PUMP
HYD
TANK
20W73HC12
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
When the arm is roll out and the control lever is returned to neutral position, the circuit for the holding
pressure at the rod end of the arm cylinder is closed by the arm holding valve. This prevent the
hydraulic drift of arm cylinder.
3 - 16
5. BUCKET ROLL IN OPERATION
CYLINDER
TRAVEL MOTOR
TRANSMISSION
C/V C/V
dr4 "a" "b"
R/PIPE PBP
XBp1
XBp2
A
PaL Dr3 Fl Fr Dr2
B
TURNING Pi
JOINT XAa2
2 SOL."B" Dr1 MAKE UP
XAa1 VALVE
Aa1
XBa2
Ba1
XAa2
XBa1
L R
ARM2
XBa2
ARM1
SWING MOTOR XAk
Ak1
XAb2 Bk1
BOOM2 XBk
XAa1 BUCKET
Dr4
PBP PbL
XBs XAb1
As Pns XAb2 Ab1
Bs Bb1
XAs SWING
XBb1
BOOM1
P T Dr6
r3 XBtl
Atl
XA0
TM1 TM2
Btl
P2 P1
ACC1 ACC2
BRAKE VALVE XAtl
XB0
AC1 A B ACC1GP
BR1 Atr
Btr
AC1GP
XBtr
(Px)
DOZER/
CT4
TP R1 OUTRIGGER
CT2
P2 R2
CT1 CT3
r4 r5
CHOCK P1 TP P T
PGP r2
r1
Pz P1 PG
FRONT REAR PILOT

PUMP PUMP PUMP
HYD
TANK
20W73HC13
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
CYLINDER
TRAVEL MOTOR
TRANSMISSION
C/V C/V
dr4 "a" "b"
R/PIPE PBP
XBp1
XBp2
A
PaL Dr3 Fl Fr Dr2
B
TURNING Pi
JOINT XAa2
2 SOL."B" Dr1 MAKE UP
XAa1 VALVE
Aa1
XBa2
Ba1
XAa2
XBa1
L R
ARM2
XBa2
ARM1
SWING MOTOR XAk
Ak1
XAb2 Bk1
BOOM2 XBk
XAa1 BUCKET
Dr4
PBP PbL
XBs XAb1
As Pns XAb2 Ab1
Bs Bb1
XAs SWING
XBb1
BOOM1
P T Dr6
r3 XBtl
Atl
XA0
TM1 TM2
Btl
P2 P1
ACC1 ACC2
BRAKE VALVE XAtl
XB0
AC1 A B ACC1GP
BR1 Atr
Btr
AC1GP
XBtr
(Px)
DOZER/
CT4
TP R1 OUTRIGGER
CT2
P2 R2
CT1 CT3
r4 r5
CHOCK P1 TP P T
PGP r2
r1
Pz P1 PG
FRONT REAR PILOT

PUMP PUMP PUMP
HYD
TANK
20W73HC14
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.
bucket cylinder.
At the same time, the oil from the large chamber of bucket cylinder retums 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. DOZER UP OPERATION
CYLINDER
TRAVEL MOTOR
TRANSMISSION
C/V C/V
dr4 "a" "b"
R/PIPE PBP
XBp1
XBp2
A
PaL Dr3 Fl Fr Dr2
B
TURNING Pi
JOINT 2 SOL."B"
XAa2
Dr1
SELECTOR XAa1
Aa1
VALVE XBa2
Ba1 ARM2
XAa2
XBa1
L R
XBa2 ARM1
SWING MOTOR XAk
Ak1
XAb2 Bk1
BOOM2 XBk
XAa1 BUCKET
Dr4
PBP PbL
XBs XAb1
As Pns XAb2 Ab1
Bs Bb1
SWING
XAs
XBb1
BOOM1
P T Dr6
r3 XBtl
Atl
XA0
TM1 TM2
Btl
P2 P1
ACC1 ACC2
BRAKE VALVE XAtl
XB0
AC1 A B ACC1GP
BR1 Atr
Btr
AC1GP
XBtr
(Px) DOZER
CT4
TP R1
CT2
P2 R2
CT1 CT3
r4 r5
CHOCK P1 TP P T
PGP r2
r1
Pz P1 PG
DOZER LEVER
DOZER/OUTRIGGER
SELECTOR SWITCH
Pi
XAtR XBtR
B 2 SOLENOID FRONT REAR PILOT
VALVE PUMP PUMP PUMP
A
HYD
TANK
A5 A4 A3 A2 ACC A1
P5 PG(MCV)
P4 Psv(Pump)
P3 PG(S/Motor)
P2
LINE
FILTER
P1
20W73HC15
Push the outrigger or dozer selector switch on the switch panel to the dozer position.
Then, the oil from pilot pump will go through the 2 solenoid valve and make the selector valve move
to the dozer position.
When the dozer control lever is pulled back, the dozer spool in the main control valve is moved to the
dozer up position by the pilot oil pressure from the remote control valve.
dozer cylinders.
At the same time, the oil from the large chamber of dozer cylinders returns to the hydraulic oil tank
through the dozer spool in the main control valve. When this happens, the dozer goes up.
3 - 19
8. DOZER DOWN OPERATION
CYLINDER
TRAVEL MOTOR
TRANSMISSION
C/V C/V
dr4 "a" "b"
R/PIPE PBP
XBp1
XBp2
A
PaL Dr3 Fl Fr Dr2
B
TURNING Pi
JOINT 2 SOL."B"
XAa2
Dr1
SELECTOR XAa1
Aa1
VALVE XBa2
Ba1 ARM2
XAa2
XBa1
L R
XBa2 ARM1
SWING MOTOR XAk
Ak1
XAb2 Bk1
BOOM2 XBk
XAa1 BUCKET
Dr4
PBP PbL
XBs XAb1
As Pns XAb2 Ab1
Bs Bb1
SWING
XAs
XBb1
BOOM1
P T Dr6
r3 XBtl
Atl
XA0
TM1 TM2
Btl
P2 P1
ACC1 ACC2
BRAKE VALVE XAtl
XB0
AC1 A B ACC1GP
BR1 Atr
Btr
AC1GP
XBtr
(Px) DOZER
CT4
TP R1
CT2
P2 R2
CT1 CT3
r4 r5
CHOCK P1 TP P T
PGP r2
r1
Pz P1 PG
DOZER LEVER
DOZER/OUTRIGGER
SELECTOR SWITCH
Pi
XAtR XBtR
A
HYD
TANK
A5 A4 A3 A2 ACC A1
P5 PG(MCV)
P4 Psv(Pump)
P3 PG(S/Motor)
P2
LINE
FILTER
P1
20W73HC16
Push the outrigger or dozer selector switch on the switch panel to the dozer position.
to the dozer position.
When the dozer control lever is pushed forward, the dozer spool in the main control valve is moved
to the dozer down position by the pilot oil pressure from the remote control valve.
dozer cylinders.
At the same time, the oil from the small chamber of dozer cylinders returns to the hydraulic oil tank
through the dozer spool in the main control valve. When this happens, the dozer blade is down.
3 - 20
9. OUTRIGGER UP OPERATION
CYLINDER
TRAVEL MOTOR
TRANSMISSION
C/V C/V
dr4 "a" "b"
R/PIPE PBP
XBp1
XBp2
A
PaL Dr3 Fl Fr Dr2
B
TURNING Pi
JOINT 2 SOL."B"
XAa2
Dr1
SELECTOR XAa1
Aa1
VALVE XBa2
Ba1 ARM2
XAa2
XBa1
L R
XBa2 ARM1
SWING MOTOR XAk
Ak1
XAb2 Bk1
BOOM2 XBk
XAa1 BUCKET
Dr4
PBP PbL
XBs XAb1
As Pns XAb2 Ab1
Bs Bb1
SWING
XAs
XBb1
BOOM1
P T Dr6
r3 XBtl
Atl
XA0
TM1 TM2
Btl
P2 P1
ACC1 ACC2
BRAKE VALVE XAtl
XB0
AC1 A B ACC1GP
BR1 Atr
Btr
AC1GP
XBtr
(Px) OUTRIGGER
CT4
TP R1
CT2
P2 R2
CT1 CT3
r4 r5
CHOCK P1 TP P T
PGP r2
r1
Pz P1 PG
OUTRIGGER LEVER
DOZER/OUTRIGGER
SELECTOR SWITCH
Pi
XAtR XBtR
A
HYD
TANK
A5 A4 A3 A2 ACC A1
P5 PG(MCV)
P4 Psv(Pump)
P3 PG(S/Motor)
P2
LINE
FILTER
P1
20W73HC17
Push the outrigger or dozer selector switch on the switch panel to the outrigger position.
to the outrigger position.
When the outrigger control lever is pulled back, the outrigger spool in the main control valve is
moved to the outrigger up position by the pilot oil pressure from the remote control valve.
outrigger cylinders.
At the same time, the oil from the large chamber of outrigger cylinders returns to the hydraulic oil
tank through the outrigger spool in the main control valve. When this happens, the outrigger goes up.
3 - 21
10. OUTRIGGER DOWN OPERATION
CYLINDER
TRAVEL MOTOR
TRANSMISSION
C/V C/V
dr4 "a" "b"
R/PIPE PBP
XBp1
XBp2
A
PaL Dr3 Fl Fr Dr2
B
TURNING Pi
JOINT 2 SOL."B"
XAa2
Dr1
SELECTOR XAa1
Aa1
VALVE XBa2
Ba1 ARM2
XAa2
XBa1
L R
XBa2 ARM1
SWING MOTOR XAk
Ak1
XAb2 Bk1
BOOM2 XBk
XAa1 BUCKET
Dr4
PBP PbL
XBs XAb1
As Pns XAb2 Ab1
Bs Bb1
SWING
XAs
XBb1
BOOM1
P T Dr6
r3 XBtl
Atl
XA0
TM1 TM2
Btl
P2 P1
ACC1 ACC2
BRAKE VALVE XAtl
XB0
AC1 A B ACC1GP
BR1 Atr
Btr
AC1GP
XBtr
(Px) OUTRIGGER
CT4
TP R1
CT2
P2 R2
CT1 CT3
r4 r5
CHOCK P1 TP P T
PGP r2
r1
Pz P1 PG
OUTRIGGER LEVER
DOZER/OUTRIGGER
SELECTOR SWITCH
Pi
XAtR XBtR
A
HYD
TANK
A5 A4 A3 A2 ACC A1
P5 PG(MCV)
P4 Psv(Pump)
P3 PG(S/Motor)
P2
LINE
FILTER
P1
20W73HC18
Push the outrigger or dozer selector switch on the switch panel to the outrigger position.
to the outrigger position.
When the outrigger control lever is pushed forward, the outrigger spool in the main control valve is
moved to the outrigger down position by the pilot oil pressure from the remote control valve.
outrigger cylinders.
At the same time, the oil from the small chamber of outrigger cylinders returns to the hydraulic oil
tank through the outrigger spool in the main control valve. When this happens, the outrigger is
down.
3 - 22
11. SWING OPERATION
CYLINDER
TRAVEL MOTOR
TRANSMISSION
C/V C/V
dr4 "a" "b"
R/PIPE PBP
XBp1
XBp2
A
PaL Dr3 Fl Fr Dr2
B
TURNING Pi
JOINT XAa2
2 SOL."B" Dr1
XAa1
Aa1
XBa2
Ba1 ARM2
XAa2
XBa1
L R
SWING MOTOR XBa2 ARM1
XAk
Ak1
XAb2 Bk1
BOOM2 XBk
XAa1 BUCKET
Dr4
PBP PbL
XBs XAb1
As Pns XAb2 Ab1
Bs Bb1
SWING
XAs
XBb1
BOOM1
P T Dr6
r3 XBtl
Atl
XA0
TM1 TM2
Btl
P2 P1
ACC1 ACC2
BRAKE VALVE XAtl
XB0
AC1 A B ACC1GP
BR1 Atr
Btr
AC1GP
XBtr
(Px) DOZER/
CT4
TP R1 OUTRIGGER
CT2
P2 R2
CT1 CT3
r4 r5
CHOCK P1 TP P T
PGP r2
r1
Pz P1 PG
FRONT REAR PILOT

PUMP PUMP PUMP
HYD
TANK
20W73HC19
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
motor. The cavitation which will happen to the swing motor is also prevented by the make up valve
in the swing motor itself.
3 - 23
SWING CIRCUIT OPERATION
SWING MOTOR DEVICE PARKING BRAKE
BRAKE OFF
SH
BRAKE RELEASE VALVE
PG
BRAKE ON
Au
dr4
REACTIONLESS VALVE
MOTOR BRAKE VALVE
MAKE UP VALVE
GA GB
A MAKE UP
B
PORT(Mu)
TO / FROM MAIN CONTROL VALVE
210N73HC15A
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".
4) REACTIONLESS VALVE
This reactionless valve absorbs shocks produced as swing motion stops and reduces oscillation
cause by swing motion.
3 - 24
12. TRAVEL FORWARD AND REVERSE OPERATION
CYLINDER
TRAVEL MOTOR
TRANSMISSION
C/V C/V
dr4 "a" "b"
R/PIPE PBP
XBp1
XBp2
A
PaL Dr3 Fl Fr Dr2
B
TURNING Pi
JOINT XAa2
2 SOL."B" Dr1
XAa1
Aa1
XBa2
Ba1 ARM2
XAa2
XBa1
L R
XBa2 ARM1
SWING MOTOR XAk
Ak1
XAb2 Bk1
BOOM2 XBk
XAa1 BUCKET
Dr4
PBP PbL
XBs XAb1
As Pns XAb2 Ab1
Bs Bb1
SWING
XAs
XBb1
BOOM1
P T Dr6
XBtl
r3
Atl
XA0
TM1 TM2
Btl
P2 P1
ACC1 ACC2
BRAKE VALVE XAtl
XB0
AC1 A B ACC1GP
BR1 Atr
Btr
AC1GP
XBtr
(Px) DOZER/
CT4
TP R1 OUTRIGGER
CT2
P2 R2
CT1 CT3
r4 r5
CHOCK P1 TP P T
PGP r2
r1
Pz P1 PG
FRONT REAR PILOT

PUMP PUMP PUMP
HYD
TANK
20W73HC20
When the RH multifunction switch is placed in forward or reverse position, the travel spool in the
main control valve is moved to the forward or reverse position by the pilot oil pressure from pilot
pump through the travel pilot solenoid of transmission control valve and travel Forward/Reverse
solenoid valve. The oil from the front pump flows into the main control valve and then goes to the
travel motor. At the same time, the oil returned from the travel motor returns to the hydraulic oil tank
through the turning joint and travel spool in the main control valve.
When this happens, the machine moves forward or reverse.
The cavitation which will happen to the travel motor is prevented by the make-up valve in the main
control valve.
3 - 25
TRAVEL CIRCUIT OPERATION
MA MB
X OVERLOAD
RELEASE VALVE
G1 M1
T COUNTER
BALANCE VALVE
CHECK VALVE
A(fw) S B(bw)
TURNING
JOINT
TO/FROM MAIN CONTROL VALVE
20W73HC21
Valves are provided on travel motor to offer the following functions.
1) COUNTER BALANCE VALVE

When stopping the motor on a slope descending, this valve prevents the motor from over running.
2) OVERLOAD RELIEF VALVE
Relief valve limits the circuit pressure below 350kgf/cm2 to prevent high pressure from being
generated at the time of stopping the machine. When stopping the motor, this valve sucks the oil
from lower pressure passage for preventing the negative pressure and the cavitation of the motor.
3 - 26
13. FRONT AND REAR AXLE BRAKE SYSTEM(SERVICE BRAKE)
CYLINDER
TRAVEL MOTOR
TRANSMISSION
C/V C/V
dr4 "a" "b"
R/PIPE PBP
XBp1
XBp2
A
PaL Dr3 Fl Fr Dr2
B
TURNING Pi
JOINT XAa2
2 SOL."B" Dr1
XAa1
Aa1
XBa2
Ba1 ARM2
XAa2
XBa1
L R
XBa2 ARM1
SWING MOTOR XAk
Ak1
XAb2 Bk1
BOOM2 XBk
XAa1 BUCKET
Dr4
PBP PbL
XBs XAb1
As Pns XAb2 Ab1
Bs Bb1
SWING
XAs
XBb1
BOOM1
P T Dr6
r3 XBtl
Atl
XA0
TM1 TM2
Btl
P2 P1
ACC1 ACC2
BRAKE VALVE XAtl
XB0
AC1 A B
ACC1GP
BR1 Atr
Btr
CT5 CT6
AC1GP
XBtr
(Px) DOZER/
CT4
TP CT2 R1 OUTRIGGER
P2 R2
CT1 CT3
TGP
r4 r5
CHOCK P1 TP P T
r1 PGP r2
BRAKE SUPPLY P1 PG
Pz
VALVE
DOZER/OUTRIGGER
TRAVEL PEDAL
A1 A2 MAIN PUMP
P A
dr10 (1) (3) (2) (4) (3) (1) (2) (4)
XAtR XBtR
Pi1 Pi2
sh FL FR
Pm2
2 SOLENOID A3 Pm1
Pi
B
A MCV "Pns" Psv
E/G
HYD Dr
Dr2
R5
P5 PG(MCV)
P4
MAIN PUMP
Psv(Pump) "Dr" C S2
P6 P3 PG(S/Motor)
P2
LINE GEAR
A B
FILTER PUMP
R6 P1
20W73HC22
When the brake pedal(Valve) is pushed, the discharged oil from the gear pump(B) flows into the front
and rear axle brake disc through the solenoid valve of brake supply valve.
This pressure is applied to axle brake disc, thus the brake is applied.
3 - 27
14. STEERING CIRCUIT OPERATION
CYLINDER
TRAVEL MOTOR
TRANSMISSION
STEERING
CYLINDER
C/V C/V
dr4 "a" "b"
R/PIPE PBP
XBp1
XBp2
A
PaL Dr3 Fl Fr Dr2
B
TURNING Pi
JOINT XAa2
2 SOL."B" Dr1
BRAKE VALVE XAa1
Aa1
XBa2
Ba1 ARM2
XAa2
XBa1
L R
XBa2 ARM1
SPOOL SWING MOTOR XAk
Ak1
XAb2 Bk1
GEROTOR BOOM2 XBk
XAa1 BUCKET
Dr4
PBP PbL
XBs XAb1
As Pns XAb2 Ab1
Bs Bb1
SWING
XAs
XBb1
BOOM1
P T Dr6
r3 XBtl
Atl
XA0
TM1 TM2
Btl
P2 P1
ACC1 ACC2
BRAKE VALVE XAtl
XB0
AC1 A B
ACC1GP
BR1 Atr
Btr
CT5 CT6
AC1GP
XBtr
(Px) DOZER/
CT4
TP CT2 R1 OUTRIGGER
P2 R2
CT1 CT3
TGP
r4 r5
CHOCK P1 TP P T
r1 PGP r2
Pz P1 PG
DOZER/OUTRIGGER
TRAVEL PEDAL
A1 A2 MAIN PUMP
P A
dr10 (1) (3) (2) (4) (3) (1) (2) (4)
XAtR XBtR
Pi1 Pi2
sh FL FR
Pm2
2 SOLENOID A3 Pm1
Pi
B
A MCV "Pns" Psv
E/G
HYD Dr
Dr2
R5
P5 PG(MCV)
P4
MAIN PUMP
Psv(Pump) "Dr" C S2
P6 P3 PG(S/Motor)
P2
LINE GEAR
A B
FILTER PUMP
R6 P1
20W73HC23
When the steering wheel is turned to the left or right, the spool within the steering valve turns left or
right hand direction : Because the spool is connected with steering column.
At this time, the oil discharged from the gear pump(A) flows into steering cylinder through spool and
gerotor within the steering valve.
Then the steering direction is applied.
3 - 28
15. RAM LOCK CIRCUIT OPERATION
CYLINDER
TRAVEL MOTOR
TRANSMISSION
LOCKING
VALVE dr4
C/V
"a"
C/V
"b"
R/PIPE PBP
XBp1
XBp2
A
PaL Dr3 Fl Fr Dr2
B
TURNING Pi
JOINT XAa2
2 SOL."B" Dr1
XAa1
Aa1
XBa2
Ba1 ARM2
XAa2
XBa1
L R
XBa2 ARM1
SWING MOTOR XAk
Ak1
XAb2 Bk1
BOOM2 XBk
XAa1 BUCKET
Dr4
PBP PbL
XBs XAb1
As Pns XAb2 Ab1
Bs Bb1
SWING
XAs
XBb1
BOOM1
P T Dr6
r3 XBtl
Atl
XA0
TM1 TM2
Btl
P2 P1
ACC1 ACC2
BRAKE VALVE XAtl
XB0
AC1 A B ACC1GP
BR1 Atr
Btr
AC1GP
XBtr
(Px) DOZER/
CT4
TP R1 OUTRIGGER
CT2
P2 R2
CT1 CT3
r4 r5
CHOCK P1 TP P T
PGP
RAM LOCK r1 r2
SOLENOID P1 PG
Pz
DOZER/OUTRIGGER
TRAVEL PEDAL
A1 A2 MAIN PUMP
P A
dr10 (1) (3) (2) (4) (3) (1) (2) (4)
XAtR XBtR
Pi1 Pi2
sh FL FR
Pm2
2 SOLENOID A3 Pm1
Pi
B
A MCV "Pns" Psv
SAFETY
E/G
SOLENOID HYD Dr
Dr2
R5
P5 PG(MCV)
P4
MAIN PUMP
Psv(Pump) "Dr" C S2
P6 P3 PG(S/Motor)
P2
LINE
A B
FILTER
R6 P1
20W73HC24
When the ram lock switch is selected on the switch panel, the ram lock solenoid is changed over.
Thus, the oil discharged from the pilot pump flows into oscillating cylinder through ram lock solenoid
and locking valve.
This pressure is applied to check valve and oscillating cylinder, thus the oscillating function is
operated(Ram lock released).
3 - 29
GROUP 5 COMBINED OPERATION
1. OUTLINE
CYLINDER
TRAVEL MOTOR
TRANSMISSION
C/V C/V
dr4 "a" "b"
R/PIPE PBP
XBp1
XBp2
A PaL Dr3 Fl Fr Dr2
B
TURNING Pi
JOINT XAa2
2 SOL."B" Dr1
XAa1
Aa1
XBa2
Ba1 ARM2
XAa2
XBa1
L R
XBa2 ARM1
SWING MOTOR XAk
Ak1
XAb2 Bk1
BOOM2 XBk
XAa1 BUCKET
Dr4
PBP PbL
XBs XAb1
As Pns XAb2 Ab1
Bs Bb1
SWING
XAs
XBb1
BOOM1
P T Dr6
XBtl
r3
Atl
XA0
TM1 TM2
Btl
P2 P1
ACC1 ACC2
BRAKE VALVE XAtl
XB0
AC1 A B ACC1GP
BR1 Atr
Btr
AC1GP
XBtr
(Px) DOZER/
CT4
TP R1 OUTRIGGER
CT2
P2 R2
CT1 CT3
r4 r5
CHOCK P1 TP P T
PGP r2
r1
Pz P1 PG
FRONT REAR PILOT

PUMP PUMP PUMP
HYD
TANK
20W73HC25
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.
3 - 30
2. COMBINED SWING AND BOOM OPERATION
CYLINDER
TRAVEL MOTOR
TRANSMISSION
C/V C/V
dr4 "a" "b"
R/PIPE PBP
XBp1
XBp2
A
PaL Dr3 Fl Fr Dr2
B
TURNING Pi
JOINT XAa2
2 SOL."B" Dr1
XAa1
Aa1
XBa2
Ba1 ARM2
XAa2
XBa1
L R
XAk
XAb2
BOOM2 MAKE UP
XAa1 BUCKET VALVE
BOOM Dr4
PBP HOLDING PbL
XBs VALVE XAb1
As Pns XAb2 Ab1
Bs Bb1
SWING
XAs
XBb1
BOOM1
P T Dr6
RELIEF
XBtl VALVE
r3
Atl
TM1 TM2
Btl
P2 P1
ACC1 ACC2
BRAKE VALVE XAtl
AC1 A B ACC1GP
BR1 Atr
Btr
AC1GP
XBtr
(Px) DOZER/
CT4
TP R1 OUTRIGGER
CT2
P2 R2
CT1 CT3
r4 r5
CHOCK P1 TP P T
PGP r2
r1
Pz P1 PG
FRONT REAR PILOT

PUMP PUMP PUMP
HYD
TANK
20W73HC26
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 boom2 spool.
The oil from the rear pump flows into the boom cylinders through the boom1 spool in the right control
valve.
The superstructure swings and the boom is operated.
3 - 31
3. COMBINED SWING AND ARM OPERATION
CYLINDER
TRAVEL MOTOR
TRANSMISSION
C/V C/V
dr4 "a" "b"
R/PIPE PBP
XBp1
XBp2
A PaL Dr3 Fl Fr Dr2
B
TURNING Pi
JOINT XAa2
2 SOL."B" Dr1
XAa1
Aa1
XBa2
Ba1 ARM2
XAa2
XBa1
L R
XAk
Ak1
XAb2 Bk1
BOOM2 XBk
XAa1 BUCKET
Dr4
PBP PbL
XBs XAb1
As Pns XAb2 Ab1
Bs Bb1
SWING
XAs
XBb1
BOOM1
P T Dr6
r3 XBtl
Atl
XA0
TM1 TM2
Btl
P2 P1
ACC1 ACC2
BRAKE VALVE XAtl
XB0
AC1 A B ACC1GP
BR1 Atr
Btr
AC1GP
XBtr
(Px) DOZER/
CT4
TP R1 OUTRIGGER
CT2
P2 R2
CT1 CT3
r4 r5
CHOCK P1 TP P T
PGP r2
r1
Pz P1 PG
FRONT REAR PILOT

PUMP PUMP PUMP
HYD
TANK
20W73HC27
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 arm1 spool.
The oil from the rear pump flows into the arm cylinder through the arm2 spool of the right control
valve.
The superstructure swings and the arm is operated.
3 - 32
4. COMBINED SWING AND BUCKET OPERATION
CYLINDER
TRAVEL MOTOR
TRANSMISSION
C/V C/V
dr4 "a" "b"
R/PIPE PBP
XBp1
XBp2
A
PaL Dr3 Fl Fr Dr2
B
TURNING Pi
JOINT XAa2
2 SOL."B" Dr1
XAa1
Aa1
XBa2
Ba1 ARM2
XAa2
XBa1
L R
XAk
Ak1
XAb2 Bk1
BOOM2 XBk
XAa1 BUCKET
Dr4
PBP PbL
XBs XAb1
As Pns XAb2 Ab1
Bs Bb1
SWING
XAs
XBb1
BOOM1
P T Dr6
r3 XBtl
Atl
XA0
TM1 TM2
Btl
P2 P1
ACC1 ACC2
BRAKE VALVE XAtl
XB0
AC1 A B ACC1GP
BR1 Atr
Btr
AC1GP
XBtr
(Px) DOZER/
CT4
TP R1 OUTRIGGER
CT2
P2 R2
CT1 CT3
r4 r5
CHOCK P1 TP P T
PGP r2
r1
Pz P1 PG
FRONT REAR PILOT

PUMP PUMP PUMP
HYD
TANK
20W73HC28
When the swing and bucket functions are operated, simultaneously the swing spool and bucket
spool 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 the swing spool in the left control
valve.
The oil from the rear pump flows into the bucket cylinder through the bucket spool in the right control
valve.
The superstructure swings and the bucket is operated.
3 - 33
5. COMBINED SWING, BOOM, ARM AND BUCKET OPERATION
CYLINDER
TRAVEL MOTOR
TRANSMISSION
C/V C/V
dr4 "a" "b"
R/PIPE PBP
XBp1
XBp2
A PaL Dr3 Fl Fr Dr2
B
TURNING Pi
JOINT XAa2
2 SOL."B" Dr1
XAa1
Aa1
XBa2
Ba1 ARM2
XAa2
XBa1
L R
XAk
Ak1
XAb2 Bk1
BOOM2 XBk
XAa1 BUCKET
Dr4
PBP PbL
XBs XAb1
As Pns XAb2 Ab1
Bs Bb1
SWING
XAs
XBb1
BOOM1
P T Dr6
r3 XBtl
Atl
XA0
TM1 TM2
Btl
P2 P1
ACC1 ACC2
BRAKE VALVE XAtl
XB0
AC1 A B ACC1GP
BR1 Atr
Btr
AC1GP
XBtr
(Px) DOZER/
CT4
TP R1 OUTRIGGER
CT2
P2 R2
CT1 CT3
r4 r5
CHOCK P1 TP P T
PGP r2
r1
Pz P1 PG
FRONT REAR PILOT

PUMP PUMP PUMP
HYD
TANK
20W73HC29
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 in the left
control valve. 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 in the right control valve.
The superstructure swings and the boom, arm and bucket are operated.
3 - 34
SECTION 4 ELECTRICAL SYSTEM
Group 1 Component Location 4-1

Group 2 Electrical Circuit 4-3
Group 3 Electrical Component Specification 4-22
Group 4 Connectors 4-31
SECTION 4 ELECTRICAL SYSTEM
GROUP 1 COMPONENT LOCATION
1. LOCATION 1
19 20
21
18
17 Switch
16 panel 1
B
A
C
15 Switch
panel 2 22
F
N
R
23
P
W
24
25
P
26
14 27
13
12
11
BAL
VOL
ON BAND
SEEK
push
FAD
4 PROG
3
PLL
SYNTHESIZE
R
TUNNING
10
9
8
7
6
5
4
CAB
20A
KEY
START
3
MOTOR
WIPER
CN-92 28
2
CN-19B
29
CN-19 &19A
30
31
1
33 32
34
35
20W74EL01
1 Master switch 13 Parking brake switch 25 Washer switch

2 Quick clamp switch 14 Hazard switch 26 Wiper switch
3 Overload switch 15 Travel warning indicator 1 27 Main light switch
4 Service meter 16 Travel warning indicator 2 28 Prolix resistor
5 Ciger lighter 17 Forward/Reverse pilot lamp 29 Emergency engine
6 Cluster 18 Start switch starting controller
7 Multi function switch(RH) 19 Accel dial 30 CPU controller
8 Breaker operation switch 20 Beacon switch 31 RS232 serial connector
9 Horn switch 21 Breaker selection switch 32 Fuse box
10 Work/travel switch 22 Cab light switch 33 One touch decel switch
11 Outrigger/Dozer switch 23 Travel alarm switch 34 Power max switch
12 Ram lock switch 24 Preheat switch 35 Multi function switch(LH)
4-1
2. LOCATION 2
1
ON
1
OFF
CAB BOOM
6 7
3
8
2 9
10
13 11
12
15
14
20W74EL02
1 Lamp 6 Speed sensor 11 Alternator

2 Fuel sender 7 Start relay 12 Air cleaner switch
3 Fuel filler pump 8 Engine oil pressure switch 13 Battery
4 Beacon lamp 9 Temp sender 14 Travel alarm buzzer
5 Horn 10 Heater valve 15 Battery relay
4-2
GROUP 2 ELECTRICAL CIRCUIT
5W 113
112 3R
110 3L R 86 AC COMP
POWER RY FUSE BOX
(24L1-05100) (24L1-05100)
R/DRYER HORN RY HORN
(21N5-10050)
(21N5-10060)
(11N6-90060) (24L1-05100)
10
1
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
85
86
85
86
20A
20A
10A
10A
10A
10A
10A
10A
10A
20A
10A
10A
10A
20A
10A
20A
10A
10A
10A
10A
10A
10A
10A
10A
Pa
5A
5A
5A
5A
87a 87
30
WORK LAMP
87a 87
30
CN-25
HARNESS BOOM
CN-20
112
115
85
86
5W 113
5W 114
21N6-20211
ALT,FUEL CUT-OFF
CASSETTE RADIO
1
2
87a 87
1
2
30
HARNESS FRAME : 21N6-24011
B/OR FUEL FILLER P/P
CN-29
CIGAR LIGHTER
CR-35
87a
21N6-21160
DO-5
SWITCH PANEL
CR-7
GY/W WIPER MOTOR
21N4-01320
BEACON LAMP
87a
30
86
85
87
ILLUMINATION
ILLUMINATION
3R
11E
3R
2
21N4-01311
30
GY/W
86
1
85
87
AC& HEATER
CONVERTOR
AC& HEATER
SAFETY SOL
ROOM LAMP
WORK LAMP
AC BLOWER
CABIN LAMP
SOLENOID 1
SOLENOID 2
2
TURN LAMP
HEAD LAMP
BATTERY
START KEY
96A
87a
V WORKLAMP RY
CR-2
CLUSTER
30
86
85
G
87
FUEL PUMP
G
1 21E6-20270
CL-5
CL-6
CN-60
TRAVEL
21E4-0011
WIPER+
CPU B+
DIODE DIODE DIODE
CN-95
1
2
V/W
1
2
21N6-20300
CN-36
G
G
HORN
3L
DIODE
W
R
21EA-50550
B
21EA-50550 21EA-50550
2
1
CPU
G
L
L
60B
2
1
60R 60B
BR
BR
G73
G72
M
23A
G
119
Y
G32
CN-22
3
1
110
4A
4E
23
77
119
11A
118
B
V
B
8A
V
R
84
2RW
M BREAKER SOL.
G/W
10A
R/W
2
L/W
DO-1
DO-3
DO-2
GY
OR
GY
GY
GY
BR
BR
BR
2R
10
23
13
2L
96 12V X 2
W
V 31N6-91230
2A
1A
4
2
R
R
MASTER SW
Y
L
2
1
1
1
2
1
21L7-10500
CN-61
WASHER P/P FUSIBLE LINK
CR-3
25A
NO. DESTINATION
4
2
3
8
76
59
79
75
11
98
99
78
15
91
82
95
17
18
93
12
10
14
16
19
1
2
CN-11 (21EG-30630)
CN-66
114
115
4
6
3
2
1
B G11
1 AC CONTROLLER GND 1 NUMBERPLATE
W
G
G
B
2
1
2B G22
G
V
LAMP
OR/W
2
1
2 BLOWER MOTOR GND 2
B/OR
4 21EK-10160
GY
G84
2L
21A
R
9E
9A
V
3 AC 24V 3
B
V
B
2R 75
85
GY
9
120
4 AC CONTROLLER B+
B
4 CR-1
1F
CN-12
92
18
2RW 76
G83
19E
5 AC CONTROLLER B+ 5 9
2
1
G
CL-21
G66
G 77
111
6 AC COMP 6
1
2
G85 B TO:STARTER "B" TERM.
7 AC CONDENSOR FAN 7
R 2A
8 ILLUMINATION
V
B
8 BATT RY
AIR-CON 21E5-0003
R
B
G71
120
G51
1H
NO. DESTINATION CN-10
V 78
1 CASSETTE RADIO 24V 1
R 2
2 ILLUMINATION 2
3 NC 3
2B G21
4 GND 4
5 NC 5
Y 79
6 CASSETTE&ROOM LAMP B+ 6
7 NC 7
B G12
8 CASSETTE GND 8
9 NC 9
G 80
10 BEACON LAMP 10
OR 116
11 CABIN LIGHT 11
12 NC 12
CABIN HARNESS

B G27
1 HORN SW 1
Y 13A
2 HORN SW 2
3 NC 3
BR 89
4 INT. SIG 4
B 27A
5 ACCEL DIAL(-) 5
W 46 CD-38
6 ACCEL DIAL(SIG) 6
7 ACCEL DIAL(+) 7
G/OR 28A 2 Pa
1
8 SPARE SW 8
CN-131 WORKING BREAKE PS
107 L/OR L/OR 1
CN-8 1
G3 B B 2
1 SPARE SW 1 2 CD-4
20 GY GY 3
2 SPARE SW 2 3 2 Pa
Y 12 12A Y Y 4
3 BEACON LAMP 24V 3 4 1
G 80
4 BEACON LAMP SIG 4 STOP LAMP PS
OR 3E
5 BRAKER SW 24V 5
GY 111
6 BRAKER SIG 6
7 SPARE SW 7
8 SPARE SW 8
BR 83
9 START KEY (START SIG) 9
R 84
10 START KEY (ACC) 10
V 85
11 START KEY (BR) 11
W 8
12 START KEY (COM) 12
CN-140
CN-7 94 Y
2
R 86
1 ILLUMINATION 1 G61 B
V 87 1
2 HEAD LIHGT SIG 2
W 88 QUICK COUPLING
3 WIPER DRIVE SIG 3 34EA-91720
BR 65
4 Pre-Heat 4
L 91
5 SW PANEL 24V 5
OR 116
6 CABIN LIGHT SIG 6
GY 18A CN-96B
7 ILLUMINATION 7 G34 B
Y 17A 2
8 HEAD LIHGT 24V 8
L 90
9 WASHER SIG 9 CN-96A
B G28 24A OR/W
10 GND 10 1
OR/W 92
11 WORK LAMP SIG 11 CR-5
R 93 83 BR
12 CABIN LIGHT 24V 12 30
102 V/W 87a 87 85
13 NC 13 86
81 GY
14 NC 14 87
24 OR/W
15 NC 15 85
30 86
RH CONSOL 87a
ANTI-RESTART
24L1-05100
OR 3A
1 QUICK COUPLING SW 24V 1
Y 94
2 QUICK COUPLING SW SIG 2 CR-36
L/W 52 19 B/OR
3 OVERLOAD SW 3 30
G 106 19A B/OR 87a 87 85
4 OVERLOAD SW 4 86
GY/W 95 117 V
5 WIPER MOTOR 24V 5 87
B G26 58 G/OR
6 GND 6 85
GY 14A 30 86
7 CIGARLIGHTER 24V 7 87a
R 1E PRE-HEAT
8 CIGARLIGHTER ILL. 8
W 88 24L1-05100
9 WIPER DRIVE SIG 9 CR-23
BR 89
10 INT. SIG 10 21N6-30120 CN-45
V 96 G52
CN-3
11 WASHER PUMP 11 B B 1 1 B M
12 NC 12 81 GY
1
2
GY 2 2 GY M
21 W W 3
3
CN-5
L 90 117 V V 4 START RY. B+
4 FROM BATT.RY
1 WASHER SIG 1 53 G B 5
5 STARTER
2 NC 2 70 B G 6
BR 99 6
3 CLUSTER 24V 3
R 11 7 CN-74
4 WIPER MOTOR CONT. 4 8R
GY 15 8 B+
5 CONVERTOR 24V 5 G
W/OR 57
6 HOUR METER SIG 6
15A
HARNESS ENGINE FRONT
21N6-21020 3 W 3 ~
7 HOUR METER 24V 7
OR I
10 R U
SH 31E GND
8 SHIELD 8
B 122
9 CLUSTER GND 9 ALTERNATOR(21E6-40030)
Y 68
10 CLUSTER SERIAL+ (RX) 10
L 69
11 CLUSTER SERIAL- (TX) 11 CD-8
CD-31 B 5
12 NC 12 52 L/W C 1
13 FLASER(L)
V/OR 97 2 Pa G 6 CR-24
13 G74 B 2 15R
1 4 V
14 NC 14 WATER TEMP SENDOR
G/W 98 OVERLOAD PS 21EN-40100
15 FLASHER(B) 15 15R
31E5-50320
RH SIDE PRE-HEAT RY Pre-heater
E225-0006
CD-18
1 GY/W
Pa
V/W 124 ENG OIL PS
1 MULTI SW(TR1) 1 (21E3-5001)
L 100
2 MULTI SW(TR2) 2 CL-4
W 7 30A R/OR
3 MULTI SW(SOL COM) 3 1 Lo
L/W 101 29A R/W CN-28
4 MULTI SW(REV. SIG) 4 2 Hi 2 V/W
V/W 102 G81 B 1
5 MULTI SW(NEU. SIG.) 5 3 E
OR 103
6 MULTI SW(FWD. SIG) 6 HEAD LAMP RH
V/OR 97 21EK-10120 AC COMP
7 MULTI SW(TURN COM) 7
Y 17
8 MULTI SW(30) 8
R/W 29
9 MULTI SW(56a) 9 CL-3 CN-147
R/OR 30 30 R/OR 11 G
10 MULTI SW(56b) 10 1 Lo B
V 87 29 R/W 10 B
11 MULTI SW(56) 11 2 Hi A
Y 13 G1 B
12 MULTI SW(H) 12 3 E
CN-2 FUEL HEATER
HEAD LAMP LH 36 GY/W GY/W 1
CN-98 21EK-10120 1
G/W 66 118 V/W V/W 2
1 PARKING SW 1 2 CN-79
V 104 G54 B B 3 3 B
2 PARKING SW 2 3 G
GY 14 81A GY GY 4 4 GY
3 LAMP 24V 3 4 F
B/W 105 82 L/W L/W 5 5 L/W
4 RAMLOCK SW 4 5 H
G 74 B 10
5 D/OUTTRIGGER 5 6 FUEL CUT OFF SOL
OR 3K G 11
6 D/OUTTRIGGER 6 7
BR/OR 126
7 T/W SELECT SW 7 8 CN-75
26 OR OR 6 6 OR
8 NC 8 9 2
B G5 131 BR BR 7 7 BR
9 GND 9 10 1
G 132 48 Y Y 8
10 T/W SELECT SW 10 11 EPPR V/V
49 L L 9
12
CN-99 CD-17
1 MULTI SW 1 8 Y
ENGINE HARNESS REAR 2
m
R 1A 9 L
rp
2 HAZARD SW 2 1
B G4
3 GND 3 TACHO SENSOR
Y/W 35
4 MULTI SW(L) 4 (21E3-0042)
Y/OR 34
5 MULTI SW(R) 5
GY/W 64
6 BRAKE FAIL LAMP 6
B/OR 63
7 TM LOW PS LAMP 7
L/OR 107 CN-1 CD-42
8 WORK BRAKE LAMP 8 37 R/W R/W 1 1 R/W R
1 3 24V
MULTI-FUNCTION SW 2
3 W
2
G
SIG
PUMP1 PRESS
21EG-32200
38 B B 2 2 B W
3 1 GND
39 W W 3
4
NO. DESTINATION CN-4 40 BR BR 4
B G23 5
1 POWER MAX SW 1 41 V V 5
Y 33 6 CD-43
2 POWER MAX SW 2 31E
1A R/W R
G24 3 24V
B 4 BR G PUMP2 PRESS
3 O/T DECEL SW 3
GY 42 2 SIG 21EG-32200
4 O/T DECEL SW 4 2A B W
1 GND
5 NC 5
B G25
6 SAFETY SW (Com) 6 31A
7 SAFETY SW (NC) 7 CD-44
G 108 1E R/W R
8 SAFETY SW (NO) 8 3 24V
5 V G PUMP3 PRESS
LH CONSOL 2E B
2
W
SIG
21EG-32210
1 GND
CL-16 HARNESS PUMP PS
R 1G
TA 1 21N8-11170
Y/OR 34
22A
TU 2
G44
R/OR 54
22
47
G43
51
NC
50
3
B G63
EH 4
L/W
L/OR
G 5
G65
V/W
B
BU 5
74
B
20A
131
GY
CD-1
26
CD-2
ST 6
CD-5
CD-3
1
2
1
2
REAR COMBI RH
1
G
2
OR
B
BR
1
2
21EA-30460
128
C
32
CN-73
1
2
CN-19
Pa
Pa
CL-25 HYD TEMP
Y/OR
Y/OR
R 2F 21EN-40100 FUEL SENDOR
1
2
C 1 21N6-10701
16A
121
126
108
B G82 T/M PS
62
61
27
45
G/OR 28
E 2 BREAKE PS
D/O SOL 31EM-30550 31L1-0095
CN-19B
CN-15
CN-19A
Y/OR 34A
1
2
1
2
T 3
BR/OR
2
1
W
FRONT COMBI RH
G
V
B
G
21EK-10350
Y
CN-76
125 OR
123 OR
130 BR
G31 B
CR-47
129
6
5
4
3
2
1
1
4
2
124
132
127
130
106
3
6
CL-15
123
46
Y/OR 32
33
GY/W 36
37
38
21
39
40
41
42
44
27
G/OR 28
45
47
48
49
50
L/OR 51
22
53
R/OR 54
BR/W 55
56
W/OR 57
G/OR 58
59
60
OR/W 24
61
B/OR 63
GY/W 64
65
66
62
25
67
68
69
70
71
72
73
R 2E
SIG
TA
121
M+
P+
1
NC
M-
3
P-
16
G55
Y/W 35
L/OR
128
G/W
R/W
V/W
V/W
B/W
L/W
GW
TU 2
OR
GY
GY
4
1
BR
BR
BR
BR
1
5
W
W
W
W
G
R
Y
B
Y
2
31
L
M
NC
G
G35
3
Y
CN-15
101
6
2
G36
Y/OR
7A
B G41
109
OR 103
CN-51
CN-50
127
3F
7E
5
CN-68
56
EH 4
100
6
55
3H
105
3
104
CN-47
G33
6A
3
R/W 6E
5F
1
G62
B
G
2
B
G64
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
GOV. MOTOR
G53
109
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
125 OR
44
5E
BU 5
L/W
73
72
71
60
SAFETY SOL RY 2
5A
21EN-32260
W
20
CN-137 BR/W
W
GY
G
CN-88 L/OR
B
CD-7
R/W
E125-2545 25 OR
B/W
R/W
ST 6
OR
OR
1
GW
OR
1
2
CR-29
G
L
CR-30
B
B/W
B
B
V
REAR COMBI LH
G
B
WATER TEMP SENDOR

GND(PRES.SENSOR)
RESISTER
CD-37
TRAVEL SPEED SOL
3
2
4
HYD TEMP SENDOR

1
G
3
2
24V(PRES.SENSOR)
4
R
1
B
CN-70
TRAVEL ALARM SW
FUEL LEVEL SENSOR

CN-69
CN-123
SAFETY
CN-71
21EA-30450
BOOM PRIORITY SOL
TACHO SENSOR(+)
CN-122
TACHO SENSOR(-)
ANTI-RESTART RY
WATER LEVEL SW
21E9-4018
CN-133
PUMP PROLIX SW
BRAKE FAIL LAMP
ENG.OIL FILTER SW
1
AIR CLEANER SW
ENG PREHEATER
2
POWER MAX SOL

1
2
1
TRAVEL Hi/Lo SW
PROGRAM DUMP
1
CN-81
2
2
1
2
1
Pa
TRAVEL BUZZER
2
POWER MAX SW
GND (POT&DIAL)
1
BATTERY 24V(+)
2
ACCEL DIAL SIG
BKT&ARM IN PS
HEAVY LIFT SW
MAX FLOW SOL
CD-10
OVERLOAD SIG
CN-126
BRAKE FAIL PS
GND (SENSOR)
P1 PRESS SIG.
P2 PRESS SIG.
P3 PRESS SIG.
O/T DECEL SW
ENG STOP SIG
PUMP EPPR(+)
5V (POT&DIAL)
CL-24
PRE-HEAT SW
PUMP EPPR(-)
ACCEL ACT(+)
2
1
HOUR-METER
T/M OIL LAMP
ACCEL ACT(-)
2
4
WORKING PS
2
4
Pa
PARKING SW
BOOM UP PS
RS232 (GND)
R 1
3
4
1
2
ENG OIL PS
GND (MAIN)
TRAVEL PS
C 1
SERIAL-RX
Pa
ALT LEVEL
T/M OIL PS
ACCEL SW
SERIAL-TX
POWER IG
C.EARTH AUTO IDLE

RS232 (+)
B G2
RS232 (-)
POT-SIG
1
3
1
3
E 2 RAMLOCK TRAVEL MAX 31M6-51310

Y/W 35A REV. FWD. PARKING RS232 BOOM POWER AIR
GND
T 3 PRIORITY MAX FLOW CLEANER SW

CONN.
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
REV.RY FWD.RY 21L7-20100 31M6-51310

FRONT COMBI LH
21EK-10350 TRAVEL BZ 21E4-0011 21E4-0011
21N6-20321 CPU CONTROLLER (21N6-32400)
20W74EL04
4-3
OVERLOAD SW QUICK CLAMP SW
(21E6-40130) (21E9-20110)
CN-21
WIPER CUT
2
8
7
8
2
7
9
1
MULTI-FUNCTION SW 3 1 (21M5-50250)
R 10
2 I
CS-53
LEFT LEVER RIGHT LEVER GY 12
5 3
R 4A
4
4 G 8
10
5
10
5
6
CS-50
5
CS-67
L 9
2
10
3
7
6
6
6
4
5
8
M
10
3
7
2
6
1
4
5
8
9
OR
L/W
COM
COM
OR
OR
1A GY
11
Gnd
OR
9 COM
1 GND
WIPER MOTOR
G1 B
Hn
3 TR2
B+
TR1
2A Y
G2 B
Lo
Hi
R
L
(21N6-00240)
8 R
2 N
4 F
4
3
1
6
5
11
7
6
7
9
12
10
4
7
CN-141 8
G
11
12
11
12
10
10
1
2
3
4
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
FEED BACK 1
W 1
MOTOR DRIVE SIG 2 CN-17
L 9
21
21
23
10
12
21
11
10
26
27
5
2
6
1
4
3
7
8
9
MOTOR DRIVE- 3 1
8 7 9 R 10 1 W W 9
24 IG 24V MOTOR DRIVE+ 4 2
3 8 B 2 2 B B G3
21 E GND 5 3
2 7 GY/W 3 3 GY/W GY/W 3
1 VCC 6 4
26 CN-97 NO. DESTINATION 4 R 29
6
6
CONTINUE 24V 7
R 4 R
7 1 5
5 5 1 1 CPU V 5 5 V V 11
4 WASHER P/P 8 6
2 6 13
4 2 2 TRAVEL SOL L 6 L L
27 3 WASHER SIG. 9 7
3 3 3 FUSE BR 7 7 BR BR 10
7 FLASHER L 4 INT. SIG 10 8
2 4 4 REV SOL OR 11
5 WIPER CUT SW 11
1 5 5 START SAFETY RY
6 N.C 12 CN-6 NO. DESTINATION
HARZARD(21N4-01210) 6 6 FWD SOL GY 12 4 OR
7 FEED BACK 13 WIPER MOTOR HARNESS 1 1 FUSE
7 7 FLASHER UNIT (21N8-10090) 2 Y
10 8 WIPER MOTOR CONTROLLER 2 2 QUICK CLAMP SOL
8 8 FUSE (21N8-21060) 5 L/W
8 7 9 9 3 3 OVERLOAD PS
15 IG 24V 9 9 HEAD LAMP(Hi) 6 G
3 8 10 4 4 CPU CONTROLLER
2 31 10 10 HEAD LAMP(Lo) 3 GY/W
1 7 11 CL-2 5 5 FUSE
13 CPU 11 11 LIGHT SW B G5 G1 B
6
6 12 6 6 GND
5 21 E 12 12 HORN RY GY 1 1 GY
4 5 7 7 FUSE
R 8 8 R
4 8 8 ILLUMINATION
31 9 W
3 CIGAR LIGHTER 9 9 SWITCH PANEL
21 10 BR
2 (21E4-0008) 10 10 SWITCH PANEL
14 SOL 11 V
1 CN-48 11 11 WASHER PUMP
OR 16 12 L
PARKING(21N4-01220) CN-98 NO. DESTINATION 1 12 12 CPU CONTROLLER
10
13 1 1 CPU h 2
W/OR 15 CS-52
GY 1E
14 9 10 10
8 7 9 2 2 PARKING SOL HOUR METER G 28 CR-11
15 IG 24V 15 (21L1-0010) 9 G6 B
3 8 3 3 FUSE 3 E
2 32 16 8 23 G/W G
1 7 4 4 RAM LOCK SOL 8 2 B
6
6
17
5 5 D/O SOL CN-138 2
6 7
B G8
24 V/OR
1 L RH SIDE HARNESS
18 14 6
4
5 5
19
6 6 FUSE
24V 24V A
GY
G10
7
5
B G9 FLASHER UNIT (21N4-11051)
4 7 7 SAFETY RY B 5 (21ER-60700)
GND B 1
32 OR 22 4
3 8 8 NC 12V 12V C
21 E 21 3
2 9 9 GND DC/DC CONVERTER L 12
16 SOL 22 ( 21N8-20201) 2 CN-5
1 10 10 CPU G 28 13 L
1 1 1 SWITCH PANEL
RAMLOCK(21N4-01230)
SPARE 2 2 NC
33 17 BR
8 7 10 CN-99 NO. DESTINATION 3 3 FUSE
21 23 29 R
9 1 1 NC CN-139 4 4 FUSE
3 17 22 14 GY
2 8 24 OR
1
2 2 ILL. SIG 2 5 5 FUSE
21 E 21 B G7 15 W/OR
7 3 3 GND 1 6 6 CPU CONTROLLER
6 26 16 OR
5 6 4 4 LH TURN LAMP CN-56 7 7 FUSE
4 27 12V SOCKET RR BR 17 21 SH
5 5 5 RH TURN LAMP POWER IG(24V) 1 8 8 NC
10
9
4 28 (21N8-20010) B 18 18 B
SOL
6 6 CPU GND 2 9 9 GND
17 29 Y 19 19 Y
3 7 7 CPU RX 3 10 10 CPU CONTROLLER
18 IG 24V 30 L 20 20 L
2 8 8 WORKING BRAKE PS TX 4 11 11 CPU CONTROLLER
1 CLUSTER 12 12 NC
D/O SELECT(21N4-01240) (21N8-30012) 24 V/OR
13 13 NC
F/R SELECT(21N4-01250,OPTION) 14 14 NC
23 G/W
15 15 MULTIFUNCTION SW
26
31
30
32
29
28
27
9
15 IG 24V
8 7 10
34
9 B : BLACK
3 15
2 8 CS-29
1 35 B 1 W : WHITE
7 1
6 Y 2 R : RED
5 6 2
4 21 E
5 NO. DESTINATION G : GREEN
POWER MAX CN-4
21
15
15
15
21
15
15
21
9 1 B
10 4 1 1 GND L : BLUE
19 SOL 2 Y
3 CS-19 2 2 CPU CONROLLER BR : BROWN
21 B 3 3 B
2 1 3 3 GND
22 GY 4 4 GY OR : ORANGE
1 2 4 4 CPU CONROLLER
T/W SELECT 5 5 NC Y : YELLOW
ONE TOUCH DECEL
G B
6 6 GND V : VIOLET
CS-4 6 V
OR 5 7 7 NC GY : GREY
B C A 7 G
V 6 8 8 SAFETY SOL
B
A C
G 7 LH HARNESS
SAFETY SW (21N8-11160)
(21N8-20300) CS-26A
1.25GY 18A CS-5
CN-24 1 1.25B 8
B/W 12 1.25GY 5A 1
2 CS-1 CS-20 2 1.25B 9
GY 11 8 GY 2
1 5 OR
BREAKER PEDAL
B G HORN
SPEAKER RH(21N6-10400)
DOOR SW CS-26
CN-23 (E123-3022) 1.25GY 18
B/OR 10 SAFETY SW 1
2 (21M5-50250) 1.25GY 5 CN-9 NO. DESTINATION
OR 9 2 8 B
1 1 1 GND
CS-54 BREAKER 9 Y
SPEAKER LH(21N6-10400) CL-1 B G2 2 2 HORN RELAY
8 GY 9 10 10
1 L 7A 3 3 NC
4 Y 9 10 BR
2 GY 14 4 4 WIPER CONTROLLER
8 11 B
ROOM LAMP 8 5 5 CPU CONTROLLER
CN-27 INTAKE M/ACT TEMP M/ACT MODE(D/FOOT) MODE(VENT) RESISTOR RELAY(HI) RELAY(M2) 6 7 12 W
(21EH-0011) (11N6-90740) (11N6-90720) (11N6-90810) (11N6-90710) (11N6-90750) (11N6-90820) (11N6-90820) 2 B 19 6 6 CPU CONTROLLER
N.C 1 6 13 G/OR
B/W 12 7 OR 20 7 7 CPU CONTROLLER
S.R- 2 2 2
BLOWER 5 14 GY
1 4
7
1 4
7 (11N6-90700) 5
3 M M 3 M 7 M 1 8 8 NC
3
3 7
1
1
S.R- 4
Lo 1
10
ML 2
MH 3
B/OR 5 5
4 CN-8
M
S.L- 3
Hi
4
2
2
G 15 15 G
5
6
7
5
6
7
5
6
7
1
2
3
4
5
6
7
5
1
2
3
4
1
2
3
4
1
2
3
4
S.L- 2 1 1 NC
CN-10 NO. DESTINATION L 7 7 L
1
2
3
4
N.C 6 2 NC
1
2
2
1
1
1
4
4
2
3
2
3
R 2 1 V 16 Y
GW
WR
BW
WB
BG
BG
GB
GB
ILL+ 7 1 1 FUSE SPARE SW

GL
YB
LR
LB
3 3 FUSE
Y
GY 11 2 R 6 G
YBr
YW
8 2 2 ILLUMINATION
LG
S.R+ BEACON LAMP
YW
4
BG
4
RY
RY
2B
YB
L
R
17
L
20A
OR
L
9A
9B
21
22
17
20
18
19
23
24
25
16
15
S.R+ 9 3 3 CS-23 5 5 FUSE

V 1 3 2B 18
36A
B G1 GY
26
35
27
33A
ACC 10 4 GND
32
36
6B
6A
4
29
33
36
28
35 10 6 6 BRAKER SOL
Y 4a 9 10 19
B+ 11 5 5 G 6A B
9 9 7 7 NC
OR 4 Y 20 OR
S.L+ 12 6 6 FUSE 8 8 8 FUSE
S.L+ 13 7
8 21 BR
7 6 7 9 9 SAFETY RELAY
B 5 5 B 2 Y 16 22 R
GND 14 8 8 GND 6 10 10 POWER RELAY
9 7 23 V
9 5 5 11 11 DIODE(DO-2)
CN-143 6 G 1 24 W
10 10 BEACON SW 4 12 12 FUSE
N.C 1 7 OR
R 20 11 11 SWITCH PANNEL 3
RADIO ON/OFF 2 G 6 CN-7
G 21 12 12 2 25 R
BAND 3 1 1 ILL. LAMP FUSE
L 22 4 V
BAND 4
BR 23
CABIN HARNESS CN-11 NO. DESTINATION BEACON LAMP SW
1
26 W
2 2 MULTIFUNCTION SW
SEEK 5
OR 24 (21N6-00012) 1,2 BR
1 1 GND(CONTROLLER) (21E6-30440) 27 BR
3 3 WIPER CONTROLLER
SEEK 6 32 2B 4 4 CPU CONTROLLER
2 2 GND(BLOWER) 28 L
N.C 7 6 RY 5 5 FUSE
B 13 3 3 FUSE(IG) 3 OR
GND 8
7
CL-9 3,4 RW 6 6 CABIN LIGHT
Y 14 OR 4 FUSE(Battery) CS-27 29 GY
VOL/R OUT 9 2 4
33 2R B G3 7 7 FUSE
V 15 3 B
5 5 FUSE(Battery) 10 10 2 Y
VOL/L OUT 10 1 9 GY 5A 8 8 FUSE
GY 16 30 LW
9 30 L
VOL/R IN 11 CABIN LIGHT 6 6 DPS(COMPRESSOR)
31 LY 9 9 WIPER CONTROLLER
W 17 (21N6-20211) 7 7 CONDENSOR FAN 8 G1 B
VOL/L IN 12 5 G 8 10 10 GND
B 18 8 8 ILLUMINATION 6 7 31 OR/W
GND 13 CL-8 2 11 11 WORK LAMP RY
R 19 7a OR HARESS AIR CON 6 1 R
N.C 14 2 7 OR 17 12 12 FUSE
3a B (11N6-90830) 5 5
CASSETTE RADIO 1 1 13 13 NC
4
14 14 NC
WB 15
BW 16
17
BG 18
GL 19
20
21
22
23
24
25
26
27
28
29
30
31
1
2
RW 3
RW 4
5
RY 6
8
9
G4
4A
OR 3A
2A
1A
CN-144
25
26
BR 27
28
GY 29
30
OR/W 31
BR 10
CL-7 15 15 NC
OR 3
1
18
11
12
G/OR 13
B
GW
BrR
WR
YBr
LW
BG
BG
GB
9
BR
BR
BR 21
22
23
24
YB
LG
YB
6 2
LR
G
LB
LY
EARTH(VOLUME) 1
G
Y
GY 5
W 17
RH HARNESS
W
2 3b B M 1
1.25LgB
R
R
V
V
Y
Y
B
VOLUME L/IN
W
16
R
V
GY
W
1.25G
BREAKER SW (21N8-11151)
B
VOLUME R/IN 3
CN-116
BEACON LAMP
10
11
12
13
14
15
16
17
18
10
11
12
13
14
15 (21E6-30540)
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
CS-2
CN-142
1
4
5
8
2
6
(21EK-104200
9
10
11
12
13
14
15
16
17
VOLUME L/OUT 4
5
4
1
14
2
3
C
B
A
Y
VOLUME R/OUT 5
B 13
TEMP MOTOR ACT(+)
DUCT SENSOR(GND)
WIPER MOTOR DRIVE

TEMP MOTOR ACT(-)
BLOWER RELAY(M1)
BLOWER RELAY(M2)
COMPRESSOR(DPS)
BLOWER RELAY(LO)
1
2
MODE M/ACT(FOOT)
EARTH(MAIN) 6
INLET MOTOR(REC)
BLOWER RELAY(HI)
+
INLET MOTOR(FRE)
-
S
MODE M/ACT(PBR)
0, I
MODE M/ACT(DEF)
1
19
TEMP M/ACT(PBR)
R
MOTOR ACT(REF)
CONDENSER FAN
DUCT SENSOR(+)
MODE M/ACT(M+)
MODE M/ACT(M-)
CABIN LIGHT OUT
WORK LIGHT OUT

CABIN LIGHT OUT
N.C 7
HEAD LIGHT OUT

HEAD LIGHT OUT
CABIN LIGHT 24V

CABIN LIGHT 24V
HEAD LIGHT 24V
HEAD LIGHT 24V
R 20
ILLUMINATION
ILL. LIHGT 24V

8
ILL.LIGHT OUT
RADIO ON/OFF
BATTERY(+)
BATTERY(+)
WASHER SIG
G 21
POWER 24V
POWER IG
BAND 9 H0 I
PRE-HEAT
4
22
3
2
6
5
L DUCT ST C BR ACC H
INT. SIG
BAND 10 SENSOR ACCEL DIAL
23
GND
GND
BR START KEY SW
GND
(21N8-20901)
NC
NC
NC
NC
NC
NC
SEEK UP 11
OR 24 (21E6-10430)
SEEK UP 12
REMOCONE(21N8-21050) AC&HEATER CONTROLLER (11N6-90030) SWITCH PANEL(21N4-20500)
20W74EL03
4-4
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〕
Fuse box〔No.1〕 l/conn〔CN-8(12)〕 Start switch〔CS-2(1)〕
Power relay〔CR-35(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〔3, 4〕
Fuse box〔No.4〕 I/conn〔CN-11(5)〕 Relay(Hi, M2)
Fuse box〔No.5〕 CPU controller〔CN-50(7)〕
Fuse box〔No.6〕 I/conn〔CN - 5(4)〕 I/conn〔CN -17(5)〕 Wiper motor controller
〔CN-141(7)〕
Wiper motor〔CN-21(4)〕
※ I/conn : Intermediate connector
2) CHECK POINT
Engine Start switch Check point Voltage
① - GND (Battery 1EA) 10~12.5V

② - GND (Battery 2EA) 20~25V
OFF OFF
③ - GND (Battery 2EA) 20~25V
④ - GND (Fusible link) 20~25V
※ GND : Ground
4-5
CR-35
W
CN-27 CN-10 30
N.C 1 R 87a 87 85
1 86
S.R- 2 3L
2 87
S.R- 3 B
3 85
POWER RY
S.L- 30 86
4 4 87a
S.L- 5 5
Y Y
N.C 6 6
ILL+ 7 7
S.R+ 8 CN-36
8
W START KEY 20A
S.R+ 9 9
POWER CIRCUIT
1
ACC 10 10 Y ROOM LAMP 5A
Y 2
CASSETTE RADIO
B+ 11 11
2R AC& HEATER 5A
S.L+ 12 3
12
2RW AC BLOWER 20A
S.L+ 13 4
GND 14 GY CPU B+ 10A
GY
GY
Y
5
CN-8
3L
3R
R WIPER+ 10A
1
2
6
CS-1
CL-1
TURN LAMP 10A
2
7
3 CLUSTER 10A
DOOR SW
8
4
CASSETTE RADIO 10A
5 9
C
6 CPU 10A
5 CS-2 6 10
ST
6 7 CONVERTOR 5A
11
5 8
ACC
3 SWITCH PANEL 10A
2 12
B
1
BR
4 9
R R R ALT,FUEL CUT-OFF 20A
3 10 13
H
4
10A
0, I
2 11 WIPER MOTOR
W 14
W W
1 12 HEAD LAMP 10A
H 0 I
START KEY SW
15
WORK LAMP 10A
16
CN-11 CABIN LAMP 20A
4-6
17
1
2
BEACON LAMP 10A
2B 2B
18
M 1
2
RW/ 20A
CR-1
BATTERY(+) AC& HEATER
BLOWER
3 3 19
RW/ RW RW
BATTERY(+) 4 4 HORN 10A
3
2R 2R 20
AC & HEATER CONTROLLER 5 10A
BATTERY RY
CIGAR LIGHTER
21
6
TRAVEL 10A
1 2 1 7 22
R
2 SAFETY SOL 5A
8
23
2
3 10A
SOLENOID 1
3 4 4 24
60R
SOLENOID 2 10A
1 2 1 CN-5 25
R 1 10A
2
FUEL FILLER P/P
26
2 10A
3 ILLUMINATION
3 27
3 4 4
CN-17 R R ILLUMINATION 10A
RELAY(M2) RELAY(HI)
4 28
BATTERY
CN-21 1
5
3 1 2
6 FUSE BOX
2 3
60B
7
5 3 4
R R 8
4 5
4 9
5 6 5W
10 2
6 M 2 6 7 5W
11 1
8
12 CN-50 CN-95
MASTER SW
GY
WIPER MOTOR 10 BATTERY 24V(+) 7 3R
CN-141 2
R 11 CPU CONTROLLER 3R
60B
CONTINUE 24V 7 1
FUSIBLE LINK
12
WIPER MOTOR CONT CN-60
4
20W74EL05
2. STARTING CIRCUIT
1) OPERATING FLOW
Battery(+) terminal 〔CR-1〕
Battery relay Fusible link〔CN-60〕 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(30) → (87)〕
l/conn〔CN-3(2)〕 Start relay〔CN-23〕
2) CHECK POINT
① - GND(Battery)
② - GND(Start key)
③ - GND(Battery relay M4)
OPERATING START ④ - GND(Starter B+) 20~25V
⑤ - GND(Starter M)
⑥ - GND(Start relay)
⑦ - GND(Battery relay M8)
※ GND : Ground
4-7
12
TR1 7 11
10
CN-36
STARTING CIRCUIT
1 GND 9
8 START KEY 20A
3 TR2
7
1
9 COM
6 ROOM LAMP 5A
8 R 2
5
2 N
4 AC& HEATER 5A
4 F 3
3
5 2 AC BLOWER 20A
6
4
1
CPU B+ 10A
5
WIPER+ 10A
6
TURN LAMP 10A
7
CLUSTER 10A
8
G
CASSETTE RADIO 10A
F 9
CPU 10A
H 10
CONVERTOR 5A
11
SWITCH PANEL 10A
FUEL CUT OFF SOL

12
ALT,FUEL CUT-OFF 20A
13
WIPER MOTOR 10A
14
HEAD LAMP 10A
4-8
15
WORK LAMP 10A
16
CABIN LAMP 20A
17
BEACON LAMP 10A
18
AC& HEATER 20A
19
HORN 10A
20
CIGAR LIGHTER 10A
21
TRAVEL 10A
22
SAFETY SOL 5A
23
SOLENOID 1 10A
24
SOLENOID 2 10A
25
FUEL FILLER P/P 10A
26
ILLUMINATION 10A
27
ILLUMINATION 10A
28
FUSE BOX
20W74EL06
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(13)〕 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〕 Fuse box
2) CHECK POINT
① - GND(Battery voltage)
② - GND(Battery relay)
Run ON ③ - GND(Alternator B+ terminal) 20~30V
④ - GND(Alternator I terminal)
⑤ - GND(CPU)
※ GND : Ground
4-9
CN-36
START KEY 20A
1
ROOM LAMP 5A
2
AC& HEATER 5A
3
AC BLOWER 20A
4
CPU B+ 10A
5
WIPER+ 10A
6
CHARGING CIRCUIT
TURN LAMP 10A

7
CLUSTER 10A
8
CASSETTE RADIO 10A
9
CPU 10A
10
CONVERTOR 5A
11
SWITCH PANEL 10A
12
13
WIPER MOTOR 10A
14
HEAD LAMP 10A
15
WORK LAMP 10A
16
CABIN LAMP 20A
17
BEACON LAMP 10A
18
AC& HEATER 20A
19
HORN 10A
20
CIGAR LIGHTER 10A
4 - 10
21
TRAVEL 10A
22
SAFETY SOL 5A
23
SOLENOID 1 10A
24
SOLENOID 2 10A
25
FUEL FILLER P/P 10A
26
ILLUMINATION 10A
27
ILLUMINATION 10A
28
FUSE BOX
20W74EL07
4. HEAD AND WORK LIGHT CIRCUIT
1) OPERATING FLOW
Fuse box (No.15) I/conn〔CN-7(8)〕 Switch panel〔CN-116(10,11)〕
Fuse box (No.16) I/conn〔CN-7(7)〕 Switch panel〔CN-116(9)〕
(1) Main light switch ON : 1st step
Head light switch ON〔CN-116(2,3)〕 l/conn〔CN-7(2)〕〔CN-97(11)〕
l/conn
Mutifunction sw left lever(3) (5) 〔CN-97(10)〕〔CL-3(1), CL-4(1)〕
Head light ON
: Head lamp ON
(2) Main light switch ON : 2nd step

Work light switch ON〔CN-116(14)〕 l/conn〔CN-7(11)〕 l/conn〔CN-3(1), (4)〕
〔CN-12(1)〕
I/conn Work light ON〔CL-5(2), CL-6(2)〕
2) CHECK POINT
① - GND(Fuse box)
② - GND(Switch power input)
STOP ON 20~25V
③ - GND(Switch power output)
④ - GND(Head light)
⑤ - GND(Fuse box)
⑥ - GND(Switch power input)
STOP ON 20~25V
⑦- GND(Switch power output)
⑧ - GND(Work light)
※ GND : Ground
4 - 11
CR-3
OR/W CN-36
1 2 1
GY START KEY 20A
2 1
R ROOM LAMP 5A
3 2
21E4-0011
V 5A
4 4 3 AC& HEATER
3
AC BLOWER 20A
WORKLAMP RY
4
CPU B+ 10A
CN-12 CL-5 5
B B B WIPER+ 10A
2 1 6
V V V
10A
3
1 2 TURN LAMP
7
CN-116 CLUSTER 10A
ILL.LIGHT OUT 1 B 8
V
8
1 CASSETTE RADIO 10A
2
21N6-20211
HEAD LIGHT OUT CN-7 V 9
WORK LAMP
V 2
HEAD LIGHT OUT 3 1 CPU 10A
V CL-6 10
WIPER MOTOR DRIVE 4 2 5A
CONVERTOR
5 11
PRE-HEAT 3
SWITCH PANEL 10A
POWER 24V 6 4 12
6
20A
1
CABIN LIGHT OUT 7 5 ALT,FUEL CUT-OFF
13
CABIN LIGHT OUT 8 6 10A
HEAD AND WORK LIGHT CIRCUIT
GY GY WIPER MOTOR
14
ILL. LIHGT 24V 9 7
Y Y Y HEAD LAMP 10A
HEAD LIGHT 24V 10 8 15
Y 10A
HEAD LIGHT 24V 11 9 GY WORK LAMP
16
SWITCH PANEL
WASHER SIG 12 10 CABIN LAMP 20A
OR/W 17
2
GND 13 11
Y BEACON LAMP 10A
WORK LIGHT OUT 14 12 18
5
AC& HEATER 20A

INT. SIG 15 19
CABIN LIGHT 24V 16 HORN 10A
7
20
CABIN LIGHT 24V 17 10A
CIGAR LIGHTER
CN-97 21
4 - 12
1 TRAVEL 10A
22
2 SAFETY SOL 5A
R 11 23
12 3
8 SOLENOID 1 10A
COM 10 11 4 24
SOLENOID 2 10A
5
10
L 9 25
9
6 FUEL FILLER P/P 10A
B+ 12 26
7
8
ILLUMINATION 10A
Y
3 7 8 27
R/W R ILLUMINATION 10A
6 9 28
R/OR
10
5
Hi 10
4 V
11 11 FUSE BOX
3
9 12
LEFT LEVER
Lo 5 2
COM 4 1
MULTI FUNCTION SW
4
Gnd 4 3 9
B
B
2
4
R/W
R/W
Hn 1 1
R/OR
R/OR
CL-3
CL-4
3 E
2 Hi
1 Lo
3 E
2 Hi
1 Lo
WARNING LAMP
HEAD LAMP LH
HEAD LAMP RH
20W74EL08
5. BEACON LAMP AND CAB LIGHT CIRCUIT
1) OPERATING FLOW
Fuse box (No.18) I/conn〔CN-8(3)〕 Beacon lamp switch〔CN-23(6)〕
Fuse box (No.17) 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
④ - GND(Beacon lamp)
⑤ - GND(Fuse box)
⑥ - GND(Switch power input)
STOP ON 20~25V
⑦ - GND(Switch power output)
⑧ - GND(Cab light)
※ GND : Ground
4 - 13
CS-23
B
9 10 10
G
9 CN-8
8 1
8
6 7 2
2 Y Y
6 3
7 G
5 5 4
1
4 5 CN-36
2
3 6 START KEY 20A
G 1
BEACON LAMP SW
2 7
ROOM LAMP 5A
1 8 2
AC& HEATER 5A
9
3
3
10 AC BLOWER 20A
4
11
CN-116 CPU B+ 10A
12 5
ILL.LIGHT OUT 1 10A
WIPER+
6
HEAD LIGHT OUT 2
TURN LAMP 10A
HEAD LIGHT OUT 3 7
4 CLUSTER 10A
WIPER MOTOR DRIVE
7
CN-7 8
PRE-HEAT 5 1 CASSETTE RADIO 10A
9
POWER 24V 6 2
OR CPU 10A
CABIN LIGHT OUT 7 3 10
OR 5A
CABIN LIGHT OUT 8 4 CONVERTOR
11
ILL. LIHGT 24V 9 5 SWITCH PANEL 10A
G 12
BEACON LAMP AND CAB LIGHT CIRCUIT
HEAD LIGHT 24V 10 6 20A

ALT,FUEL CUT-OFF
HEAD LIGHT 24V 11 7 13
SWITCH PANEL
WIPER MOTOR 10A
WASHER SIG 12 8 14
B
9 HEAD LAMP 10A
5
GND 13
15
WORK LIGHT OUT 14 10 10A
WORK LAMP
11 16
INT. SIG 15
R OR/W R 20A
4 - 14
CABIN LAMP
CABIN LIGHT 24V 16 12 17
R 10A
CABIN LIGHT 24V 17 Y BEACON LAMP
18
AC& HEATER 20A
19
6
CN-10
HORN 10A
1 20
1
2 CIGAR LIGHTER 10A

21
3 TRAVEL 10A
22
4
SAFETY SOL 5A
5 23
SOLENOID 1 10A
6 24
7 SOLENOID 2 10A
25
8
FUEL FILLER P/P 10A
9 26
G ILLUMINATION 10A
10
27
OR
11 ILLUMINATION 10A
28
12
FUSE BOX
8
B
4
OR
OR
B
G
2
1
2
1
CL-9
CL-8
CL-7
M
CABIN LIGHT
CABIN LIGHT
BEACON LAMP
20W74EL09
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.6) I/conn〔CN-5(4)〕 I/conn〔CN-17(5)〕 Wiper motor controller〔CN-141(7)〕
Wiper motor〔CN-21(4)〕
Washer pump〔CN-22(2)〕
Fuse box (No.14) I/conn〔CN-6(5)〕 l/conn〔CN-17(4)〕 Wiper motor controller〔CN-141(6)〕
(2) Wiper 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 pump〔CN-22(1)〕 Washer operating
Fuse box(No.14) I/conn〔CN-6(5)〕 I/conn〔CN-17(4)〕
Wiper motor controller〔CN-141(6) → (4)〕 Wiper motor operating〔CN-21(2), Low speed〕
(5) Auto parking(When switch OFF)
Switch OFF〔CN-116(15)〕 Wiper motor parking position by wiper motor controller
2) CHECK POINT
① - GND(Fuse box)
24V
STOP ON 0 ~ 5V
④ - GND(Wiper Power input)
⑤ - GND(Wiper power output)
0 or 24V
⑥ - GND(Wiper motor)
※ GND : Ground
4 - 15
CN-36
START KEY 20A
1
ROOM LAMP 5A
CN-9 2
1 AC& HEATER 5A
3
2
20A
1
AC BLOWER
3 4
BR CPU B+ 10A
4 5
5 V WIPER+ 10A
6
6 10A
TURN LAMP
7 7
CLUSTER 10A
CN-116 8 8
3
ILL.LIGHT OUT 1 CASSETTE RADIO 10A
9
HEAD LIGHT OUT 2
10A
1
CPU
HEAD LIGHT OUT 3 10
W
CN-7
CONVERTOR 5A
WIPER MOTOR DRIVE 4 1
11
PRE-HEAT 5 2 L SWITCH PANEL 10A
L W 12
POWER 24V 6 3 20A
ALT,FUEL CUT-OFF
CABIN LIGHT OUT 4 13
7
L GY/W WIPER MOTOR 10A
WIPER AND WASHER CIRCUIT
CABIN LIGHT OUT 8 5 14

ILL. LIHGT 24V 9 6 HEAD LAMP 10A
2
15
HEAD LIGHT 24V 10 7 WORK LAMP 10A
16
1
HEAD LIGHT 24V 11 8

L L CABIN LAMP 20A
SWITCH PANEL
WASHER SIG 12 9 17
BEACON LAMP 10A
GND 13 10
18
3
WORK LIGHT OUT 14 11 AC& HEATER 20A
BR 19
INT. SIG 15 12
HORN 10A
CABIN LIGHT 24V 16 20
CIGAR LIGHTER 10A
CABIN LIGHT 24V 17 21
TRAVEL 10A
3
22
CN-5 5A
L SAFETY SOL
1 23
4 - 16
SOLENOID 1 10A
2
24
CS-53
OR 3 SOLENOID 2 10A
6
R 25
CN-21 4 10A
FUEL FILLER P/P
3 1 5 26
R ILLUMINATION 10A
2 6 27
GY
5 3 7 ILLUMINATION 10A
R 28
4 8
WIPER CUT SW
4 G
5 9 FUSE BOX
L
6 2 6 10
M
WIPER MOTOR
11
12
4
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
V
VCC 6 4 5
R R R
V
R
GY/W
CONTINUE 24V 7 5 6
V V V
WASHER P/P 8 6 7
L L L
WASHER SIG. 9 7 8
1
2
1
2
BR BR BR W
DO-5
INT. SIG 10 8 9
CN-22
DIODE
OR BR
WIPER CUT SW 11 10
M
V
N.C 12 11
WIPER MOTOR CONTROLLER

GY
FEED BACK 13 12
WASHER PUMP
20W74EL10
3
6
CN-51
WORKING PS 1
M
h
2
POWER MAX SW 2
1
TRAVEL ALARM SW 3
P-
1
M-
2
NC
P+
M+
-
SIG
+
ENG OIL PS
S
4
CN-48
NC 5
HOUR METER
1
2
3
4
5
6
A
B
C
ACCEL DIAL
BOOM UP PS 6
OR
CN-142
CN-76
24V(PRES.SENSOR) 7
W/OR
B
V
GND(PRES.SENSOR) 8
G
W
W
GOVERNOR MOTOR
ALT LEVEL 9
G/OR
P1 PRESS SIG. 10
P2 PRESS SIG. 11
P3 PRESS SIG. 12
TRAVEL PS 13
O/T DECEL SW 14
8
7
5
4
1
6
2
3
9
8
7
5
4
1
6
3
15
14
13
12
11
10
WATER LEVEL SW 15
AIR CLEANER SW 16
CN-9
CN-5
HEAVY LIFT SW 17
BKT&ARM IN PS 18
OR
CONTROLLER CIRCUIT
TRAVEL Hi/Lo SW
W/OR
19
B
GND (POT&DIAL) 20
G/OR
5V (POT&DIAL) 21
W CN-36
POT-SIG 22
W 20A
ACCEL DIAL SIG 23 START KEY
1
CPU CONTROLLER
FUEL LEVEL SENSOR 24
ROOM LAMP 5A
Y
TACHO SENSOR(-) 25 2
L 5A
TACHO SENSOR(+) 26 AC& HEATER
3
BRAKE FAIL PS 27 20A
AC BLOWER
T/M OIL PS 28 4
ACCEL SW GY CPU B+ 10A

29
5
NC 30 10A
WIPER+
GND (SENSOR) 31 6
PUMP PROLIX SW TURN LAMP 10A
32
7
WATER TEMP SENDOR 33
CLUSTER 10A
HYD TEMP SENDOR 34 8
NC 35 CASSETTE RADIO 10A
9
NC 36
BR CPU 10A
10
CN-50 GY CONVERTOR 5A
BOOM PRIORITY SOL 1 11
4 - 17
MAX FLOW SOL 2 SWITCH PANEL 10A
12
POWER MAX SOL 3
W/OR ALT,FUEL CUT-OFF 20A
HOUR-METER 4 13
ENG PREHEATER 5 WIPER MOTOR 10A
14
ENG STOP SIG 6
GY HEAD LAMP 10A
BATTERY 24V(+) 7 15
BR
PUMP EPPR(-) 8 WORK LAMP 10A
16
NC 9
CABIN LAMP 20A
PROGRAM DUMP 10 17
ANTI-RESTART RY 11 BEACON LAMP 10A
V 18
ACCEL ACT(+) 12
AC& HEATER 20A
TRAVEL SPEED SOL 13 19
BR
OR
T/M OIL LAMP 14 HORN 10A
20
BRAKE FAIL LAMP 15
CIGAR LIGHTER 10A
2
1
TRAVEL BUZZER 21
L
16
Y
BR
OR
PRE-HEAT SW 17 TRAVEL 10A

22
NC 18
2
1
5A
2
1
SAFETY SOL
2
9
8
7
5
4
1
6
3
12
11
10
PARKING SW 19 23
10A
CN-19B
OVERLOAD SIG 20 SOLENOID 1
CN-2
CN-19 CN-19A
24
ENG.OIL FILTER SW 21 B
SOLENOID 2 10A
OR
BR
OR
NC 22 25
G
ACCEL ACT(-) 23 FUEL FILLER P/P 10A
BR 26
POWER IG 24
ILLUMINATION 10A
NC 25 27
NC 26 ILLUMINATION 10A
28
NC 27
GND (MAIN) 28
SERIAL-TX 29
FUSE BOX
SERIAL-RX 30
OR
GND 31 OR
OR
BR
L
Y
RS232 (+) 32
1
2
RS232 (-) 33
1
2
CN-47
1
2
RS232 (GND) 34
CN-75
CD-17
NC 35
OR
RESISTER
rp
PUMP EPPR(+) 36 m
20W74EL11
EPPR VLV
TACHO SENSOR
ILLUMINATION CIRCUIT
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
1
9
20A
20A
10A
10A
10A
10A
10A
10A
10A
20A
10A
10A
10A
20A
10A
20A
10A
10A
10A
10A
10A
10A
10A
10A
5A
5A
5A
5A
ALT,FUEL CUT-OFF
CASSETTE RADIO
FUEL FILLER P/P

CIGAR LIGHTER
SWITCH PANEL
WIPER MOTOR
BEACON LAMP
ILLUMINATION
ILLUMINATION
FUSE BOX
AC& HEATER
CONVERTOR
AC& HEATER
SAFETY SOL
ROOM LAMP
WORK LAMP
AC BLOWER
CABIN LAMP
SOLENOID 1
SOLENOID 2
TURN LAMP
HEAD LAMP
START KEY
CLUSTER
TRAVEL
WIPER+
CPU B+
CN-36
HORN
CPU
NUMBERPLATE LAMP
CL-21
L
1
2
GND 1
GND 2
R
B
BATTERY(+) 3
BATTERY(+) 4
G CN-11
ILLUMINATION 5
1
POWER IG 6
NC 7 2
DUCT SENSOR(+) 8
3
DUCT SENSOR(GND) 9
NC 10 4
NC 11
5
NC 12
NC 13 6
NC 14
7
AC & HEATER CONTROLLER R
8
CN-10
1
R
N.C 1 2
S.R- 2
3
S.R- 3
4
S.L- 4
S.L- 5 5
N.C 6 6
R
ILL+ 7 7
S.R+ 8
8
S.R+ 9
ACC 10
9
B+ 11 10
S.L+ 12 11
S.L+ 13
12
GND 14
CASSETTE RADIO
CN-7 R
R
ILL.LIGHT OUT 1
HEAD LIGHT OUT 2
HEAD LIGHT OUT
3
WIPER MOTOR DRIVE
PRE-HEAT 4
L B
POWER 24V 5
CABIN LIGHT OUT 6
CABIN LIGHT OUT
7
ILL. LIHGT 24V
HEAD LIGHT 24V 8
HEAD LIGHT 24V 9
WASHER SIG 10
GND
11
WORK LIGHT OUT
INT. SIG 12
CABIN LIGHT 24V
CABIN LIGHT 24V
SWITCH PANEL
CN-6
1
2
3
4
5
6
7
R B
8
9
10
11
12
10
CN-99
8 7 9 1
R
3 8 2
2 7
1 3
R
B
R
6
R
B
R
6
4
CL-25
CL-24
5 5
CL-16
4
CL-15
2
1
2
1
4 5
2
IG 24V
1
3
4
5
6
2
1
3
4
5
6
3 6
C
E
T
C
E
T
BU
NC
EH
NC
BU
TU
EH
ST
TA
TU
ST
TA
2
7
1
8
HARZARD
REAR COMBI RH FRONT COMBI RH REAR COMBI LH FRONT COMBI LH
20W74EL13
4 - 18
4
1
3
6
8
7
1 1 6
5
2
IG 24V
2 1 Hn 2 1
HARZARD
3
7
9
2
6
1
4
5
8
10
3 3
Gnd 4 F 4
4 4
N 2
LIFT LEVER
1 5
RIGHT LEVER
COM
R 8
4 6
2 COM 9
3 Lo 5 7
TR2 3
4 8 CN-36
Hi 9
5 GND 5 START KEY 20A
6 10 1
7 11 TR1 7 ROOM LAMP 5A
2
MULTI FUNCTION SWITCH

3
8 12
AC& HEATER 5A
9 B+ 3
12
10 20A
MULTI FUNCTION SWITCH

9 L AC BLOWER
11 4
10A
COM 10
12 CPU B+
5
R 11
WIPER+ 10A
6
TURN LAMP 10A
COMBINATION LAMP CIRCUIT
7
CLUSTER 10A
8
CASSETTE RADIO 10A
9
CPU 10A
8
7
5
4
1
6
2
3
9
8
7
5
4
1
6
3
10
12
11
10
CONVERTOR 5A
CN-97
CN-99
11
SWITCH PANEL 10A
W
12
OR
LW
Y/W
Y/OR
13
WIPER MOTOR 10A
14
CL-16 HEAD LAMP 10A
TA 15
1
Y/OR WORK LAMP 10A
TU 2 16
NC 20A
4 - 19
3 CABIN LAMP
17
EH 4
G Y BEACON LAMP 10A
BU 5 18
GY
ST 6 AC& HEATER 20A
REAR COMBI RH
19
HORN 10A
20
CIGAR LIGHTER 10A
21
Y
GY
CL-25
W TRAVEL 10A
C 1 22
3
4
1
2
E 2 SAFETY SOL 5A
Y/OR 23
Y
CN-131
GY
T 3
SOLENOID 1 10A
24
SOLENOID 2 10A
FRONT COMBI RH
25
10A
1
2
FUEL FILLER P/P
CL-15 26
TA 1 ILLUMINATION 10A
Y/W 27
Pa
TU 2
10A
CD-4
ILLUMINATION
NC 3 28
STOP LAMP PS
EH 4
G
BU 5 FUSE BOX
GY
ST 6
REAR COMBI LH
CL-24
C 1
B
E 2
Y/W
T 3
B
V
W
B
G
G
B
B
W
G
B
V
OR
L/W
FRONT COMBI LH
1
1
2
2
1
4
2
3
1
4
3
1
2
2
CR-29
CN-65
CR-30
REV
4
2
4
2
FWD
CN-123
CN-122
3
1
3
1
20W74EL14
FWD.RY
REV.RY
TRAVEL BUZZER
1
2
8
7
9
B
CS-4
CS-19
CS-26
CS-29
CS-27
CS-26A
A
BREAKER
SAFETY SW
2
1
2
1
2
1
2
1
POWER MAX
BREAKER SW
5
6
10
BREAKER PEDAL
A
B
C
B
Y
B
ONE TOUCH DECEL

3
7
9
2
6
GY
1
4
5
8
10
V
1.25GY
1.25GY
1.25GY
1.25GY
G
OR
B
GY
GY
OR
CS-50
OR
1
G
2
3
4
B 1
OVERLOAD SW
ELECTRIC CIRCUIT FOR HYDRAULIC
5 5
L/W 7
OR
6
2
7 6
8
8
OR
CD-5 9
B GY 10 9
Pa 1 10
CS-20
L/OR
2
T/M PS
SAFETY SW
CS-67
B
1
CD-3 Y
B 2
Pa 1
V/W
I
2 3
V
B
B
Y
B
G
GY
BREAKE PS
4
8
7
5
4
1
6
2
3
CD-1 5 1
B OR
CN-4
C 1 6 5
R/OR 7
B
B
Y
B
G
QUICK COUPLING SW
GY
7 2
HYD TEMP
8 6
Y 8
CN-51 9
B 10 9
WORKING PS 1 10
Y
Y
POWER MAX SW 2
GY
OR
GY
OR
L/W
TRAVEL ALARM SW 3
ENG OIL PS 4 9
8
7
5
9
8
7
5
4
1
4
1
6
6
2
2
3
3
12
11
10
12
11
10
NC 5
CN-8
Y
BOOM UP PS
G
6
RW
GY
CN-6 OR
GY
OR
L/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
TRAVEL PS 13
GY
O/T DECEL SW 14
CN-36
WATER LEVEL SW 15
START KEY 20A
AIR CLEANER SW 16 1
HEAVY LIFT SW 17 5A
ROOM LAMP
BKT&ARM IN PS 18 2
TRAVEL Hi/Lo SW 19 AC& HEATER 5A
3
GND (POT&DIAL) 20
AC BLOWER 20A
5V (POT&DIAL) 21 4
POT-SIG 22 CPU B+ 10A
ACCEL DIAL SIG 23 5
CPU CONTROLLER
FUEL LEVEL SENSOR 24 WIPER+ 10A
6
TACHO SENSOR(-) 25
TURN LAMP 10A
TACHO SENSOR(+) 26 7
V/W
BRAKE FAIL PS 27 CLUSTER 10A
L/OR
T/M OIL PS 28 8
4-20
ACCEL SW CASSETTE RADIO 10A
29
9
NC 30
B CPU 10A
GND (SENSOR) 31 10
PUMP PROLIX SW 32 CONVERTOR 5A
WATER TEMP SENDOR 33 11
B 10A
HYD TEMP SENDOR 34 SWITCH PANEL
12
NC 35
NC 36 13
WIPER MOTOR 10A
CN-50 GW
14
BOOM PRIORITY SOL 1 10A
BR/W
HEAD LAMP
MAX FLOW SOL 2 15
L/OR 10A
POWER MAX SOL 3 WORK LAMP
16
HOUR-METER 4
CABIN LAMP 20A
ENG PREHEATER 5 17
ENG STOP SIG 6 BEACON LAMP 10A
BATTERY 24V(+) 7 18
AC& HEATER 20A
PUMP EPPR(-) 8
19
NC 9
HORN 10A
PROGRAM DUMP 10 20
ANTI-RESTART RY 11 GY CIGAR LIGHTER 10A
ACCEL ACT(+) 21
12
TRAVEL 10A
T/M OIL LAMP 14 5A
GY SAFETY SOL
BRAKE FAIL LAMP 15 23
TRAVEL BUZZER 16 SOLENOID 1 10A
24
PRE-HEAT SW 17
OR SOLENOID 2 10A
NC 18 25
PARKING SW 19 10A
G FUEL FILLER P/P
OVERLOAD SIG 20 26
ENG.OIL FILTER SW 21 ILLUMINATION 10A
27
NC 22
ILLUMINATION 10A
ACCEL ACT(-) 23 28
POWER IG 24
NC 25 FUSE BOX
NC 26
NC 27
GND (MAIN) 28
SERIAL-TX 29
SERIAL-RX 30
GND 31
B
V
W
BR
RS232 (+)
R/W
32
RS232 (-) 33
RS232 (GND) 34
5
3
4
1
6
2
NC 35
CN-1
PUMP EPPR(+) 36
V
B
BR
W
R/W
CN-133
GW
1
OR
2
BOOM
PRIORITY
CN-88 L/OR
1
OR
MAX
2
POWER
CN-137 BR/W
Y
G
G
1
B
V
B
R/W
BR
B
W
R/W
R/W
OR
MAX
2
FLOW
B
L/W
Y
B
1
2
3
1
2
3
1
2
3
2
4
6
3
1
Y
B
GY
CD-43
CD-42
CD-44
CR-47
3
1
2
R
R
G
G
R
G
W
W
W
1
4
1
1
2
1
2
2
CD-31
6
2
CN-68
CN-66
PUMP1 PRESS
CN-140
PUMP2 PRESS
PUMP3 PRESS
SIG
24V
24V
24V
SIG
SIG
Pa
SAFETY SOL RY
GND
GND
GND
SAFETY SOL
OVERLOAD PS
BREAKER SOL
QUICK COUPLING
20W74EL15
C
CD-8
2
1
h
TX
RX
GND
B
G
CLUSTER
1
2
POWER IG(24V)
CN-48
HOUR METER
MONITORING CIRCUIT
OR
RR
WATER TEMP SENDOR

W/OR
4
3
2
1
CN-56
L
B
Y
BR
B
G
5
3
4
1
8
7
6
2
CN-3
CD-10
L
AIR
Pa B
B
G
CLEANER SW
CD-2
B
1
L/W
2
FUEL SENDOR
CN-51
WORKING PS 1
L
Y
B
SH
BR
OR
POWER MAX SW 2
W/OR
TRAVEL ALARM SW 3
GY/W
ENG OIL PS 4
3
6
4
1
9
8
7
5
2
15
14
13
12
11
10
NC 5
CN-5
BOOM UP PS 6
L
Y
B
24V(PRES.SENSOR) 7
SH
BR
OR
GND(PRES.SENSOR) 8
W/OR
ALT LEVEL 9
P1 PRESS SIG. 10
P2 PRESS SIG. 11
P3 PRESS SIG. 12
TRAVEL PS 13
O/T DECEL SW 14
CN-36
WATER LEVEL SW 15
L START KEY 20A
AIR CLEANER SW 16 1
HEAVY LIFT SW 17 5A
ROOM LAMP
BKT&ARM IN PS 18 2
TRAVEL Hi/Lo SW 19 AC& HEATER 5A
3
GND (POT&DIAL) 20
AC BLOWER 20A
5V (POT&DIAL) 21 4
POT-SIG 22 CPU B+ 10A
ACCEL DIAL SIG 23 5
CPU CONTROLLER
L/W
FUEL LEVEL SENSOR 24 WIPER+ 10A
6
TACHO SENSOR(-) 25
TURN LAMP 10A
TACHO SENSOR(+) 26 7
BRAKE FAIL PS 27 GY CLUSTER 10A
4-21
T/M OIL PS 28 8
ACCEL SW CASSETTE RADIO 10A
29
9
NC 30
B CPU 10A
GND (SENSOR) 31 10
PUMP PROLIX SW 32 GY CONVERTOR 5A
G
WATER TEMP SENDOR 33 11
HYD TEMP SENDOR SWITCH PANEL 10A

34
12
NC 35
NC 36 13
WIPER MOTOR 10A
CN-50 14
BOOM PRIORITY SOL 1 10A
HEAD LAMP
MAX FLOW SOL 2 15
POWER MAX SOL 3 WORK LAMP 10A

W/OR 16
HOUR-METER 4
CABIN LAMP 20A
ENG PREHEATER 5 17
ENG STOP SIG 6 BEACON LAMP 10A
BATTERY 24V(+) 7 18
AC& HEATER 20A
PUMP EPPR(-) 8
19
NC 9
B/W HORN 10A
PROGRAM DUMP 10 20
ANTI-RESTART RY 11 CIGAR LIGHTER 10A
ACCEL ACT(+) 21
12
TRAVEL 10A
T/M OIL LAMP 14 5A
SAFETY SOL
BRAKE FAIL LAMP 15 23
TRAVEL BUZZER 16 SOLENOID 1 10A
24
PRE-HEAT SW 17
SOLENOID 2 10A
NC 18 25
PARKING SW 19 10A
FUEL FILLER P/P
OVERLOAD SIG 20 26
ENG.OIL FILTER SW 21 ILLUMINATION 10A
27
NC 22
ILLUMINATION 10A
ACCEL ACT(-) 23 28
POWER IG 24
NC 25 FUSE BOX
NC 26
NC 27
GND (MAIN) 28
Y
SERIAL-TX 29
L
SERIAL-RX 30
B
GND 31
R
RS232 (+) 32
G
RS232 (-) 33
B
RS232 (GND) 34
NC 35
PUMP EPPR(+)
GY/W
36
9
8
7
6
5
4
3
2
1
12
11
10
CN-2
GY/W
CN-126
B
1
G
2
R
3
RS232
CONN.
B/W
4
GY/W
Pa
CD-18
ENG OIL PS
20W74EL16
GROUP 3 ELECTRICAL COMPONENT SPECIFICATION
Part name Symbol Specification Check
※ Check specific gravity

12V × 100Ah 1.280 over : Over charged
Battery
(2EA) 1.280 ~ 1.250 : Normal
1.250 below : Recharging
※ Check coil resistance (M4 to M4)

Rated load : 24V
Normal : About 50Ω
Battery relay 100A(continuity)
1000A(30seconds) ※ Check contact
Normal : ∞Ω
CR-1
6
5
4
3
2
1
B
※Check contact
B-BR : 24V 1A
1
Ι ,O OFF : ∞Ω(For each terminal)

Start key B-ACC : 24V 10A
ON : 0Ω(For terminal 1-3 and 1-2)
B-ST : 24V 40A
ΙΙ Ι O H START : 0Ω(For terminal 1-5)
6
5
3
2
C ST ACC BR H
CS-2
Pressure switch 2 Pa 3 ~ 6kgf/cm2 ※ Check contact

(For overload) 1 (N.O TYPE) Normal : ∞(OPEN)
CD-31
Pressure switch Pa 0.5 kgf/cm2 ※ Check resistance

(For engine oil) (N.C TYPE) Normal : 0Ω(CLOSE)
CD-18
C 1 ※ Check resistance
Temperature 50°C : 804Ω
-
sensor 2 80°C : 310Ω
100°C : 180Ω
CD-8
CD-1
4-22
Pressure: ※ Check contact

Air cleaner Pa 635mmH2O
pressure switch Normal : ∞Ω
(N.O TYPE)
CD-10
※ Check resistance
Full : 50Ω 6/12 : 350
2 11/12 : 100Ω 5/12 : 400Ω
10/12 : 150Ω 4/12 : 450Ω
Fuel sender - 9/12 : 200Ω 3/12 : 500Ω
1
8/12 : 250Ω 2/12 : 550Ω
CD-2 7/12 : 300Ω 1/12 : 600Ω
CD-2 Empty warning :700Ω
1
m
rp
Tacho sensor -
2 Normal : 300Ω(For terminal 1,2)
CD-17
CD-17
30
87a 87 85
86 ※ Check resistance
Relay 87
Normal : About 160Ω
(Horn, Safety, 85
24V 16A0 (For terminal 85-86)
Ac comp, 87a
30 86
Power, Preheat) CR-2 CR-7 CR-35 : 0Ω(For terminal 30-87a)

CR-3 CR-29 CR-36 : ∞Ω(For terminal 30-87)
CR-5 CR-30 CR-47
M- 6
6 5
M M+ 5
NC 4
2 Normal : 1-2Ω(For terminal 5-6)
Accel actuator P- 3 -
3 1
SIG 2
0.8-1.2kΩ
P+ 1 (For terminal 1-3)
CN-76
Solenoid valve 24V 1A Normal : 15~25Ω
(For terminal 1-2)
CN-66 CN-68 CN-69 CN-70
CN-71 CN-73 CN-88 CN-122
CN-123 CN-133 CN-137 CN-140
4-23
2 ※ Check resistance
EPPR valve 700mA Normal : 18~25Ω
1 (For terminal 1-2)
CN-75
1
Resistor 50Ω 20W± 5%
Normal : 50Ω
2
CN-47
※Check resistance
Speaker 4Ω 20W
Normal : 4Ω
CN-23(LH)
CN-24(RH)
10 9 8 7 6 5 4 3 2 1
※ Check contact
10 6 5 Normal
Switch ON - 0Ω(For terminal 1-5,2-6)
(Locking type) 24V 8A
- ∞Ω(For terminal 5-7,6-8)
9 8 2 7 1
OFF - ∞Ω(For terminal 1-5,2-6)
CS-23 CS-27 CS-50
- 0Ω(For terminal 5-7,6-8)
CS-52 CS-54
8
2
7
9
1
I
※ Check contact
Normal
ON - 0Ω(For terminal 1-5,2-6)
Switch 24V 8A
5
10
- ∞Ω(For terminal 5-7,6-8)

(Quick clamp)
10
OFF - ∞Ω(For terminal 1-5,2-6)

9
3
7
2
6
1
4
5
CS-67 - 0Ω(For terminal 5-7,6-8)
2
Head lamp,
Work lamp, 24V 70W ※ Check disconnection
1
Cab lamp, (H3 TYPE) Normal : 1.2Ω
Number plate
CL-5 CL-6 CL-8
CL-9 CL-21
4-24
※ Check disconnection
Room lamp 24V 10W
Nomal : A few Ω
CL-1
1 M
24V 10A ※ Check resistance
Fuel filler pump 35 ℓ/min
2 Normal : 1.0Ω
CN-61
CN-61
1 ※ Check operation
h ・Supply powe(24V) to
Hour meter 2 16V ~ 32V
terminal No. 2 and connect
CN-48 terminal No. 1 and ground.
※ Check operation
DC 22.0 ~ 28.0V
Horn ・Supply power(24V) to each
2A
terminal and connect ground.
CN-20 CN-25
※ Check contact
Normal : 0Ω(For terminal 1-2)
24V 15A
Safety switch 1 : ∞Ω(For terminal 1-3)
(N.C TYPE)
Operating : ∞Ω(For terminal 1-2)
: 0Ω(For terminal 1-3)
CS-4
Safety switch 2 24V ※ Check contact

Wiper cut sw (N.C TYPE) Normal : 0Ω(one pin to ground)
CS-20 CS-53
4-25
E 3
Fuel cut-off S 2 24V
Normal : 15~25Ω
I 1
CN-79
Pressure switch
(T/M, Breaker, Pa 2 10bar ※ Check contact
auto idle) (N.C type) Normal : 0.1Ω
1
CD-3 CD-5 CD-7
※ Check disconnection
Beacon lamp 24V 70W
Normal : 1.1Ω
CL-7
Switch
1
(Power max,
※Check contact
One touch 2 24V 6A
decel, Breaker, Normal : ∞Ω
Horn) CS-5 CS-19
CS-26 CS-26A CS-29
※Check contact
Washer tank 24V 3.8A
Normal : 10.7Ω(For terminal 1-2)
CN-22
※Check coil resistance

Normal : About 1MΩ
Cigar lighter 24V 5A 1.4W ※ Check contact
Normal : ∞Ω
Operating time : 5~15sec
CL-2
4-26
※Check resistance
Door switch 24V 2W
Normal : About 5MΩ
CS-1
3 1
2
5 3
4
4 ※Check contact
Wiper motor 5 24V 2A
Normal : 7Ω(For terminal 2-6)
6 M 2 6
CN-21
N.C 1
S.R- 2
S.R- 3
S.L- 4
S.L- 5
N.C 6
ILL+
S.R+
7
8
※ Check voltage
Cassette radio S.R+
ACC
9
10
24V 2A 20 ~ 25V
B+ 11
S.L+ 12
13
(For terminal 10-14,11-14)
S.L+
GND 14
CN-27
※ Check contact
Receiver dryer 24V 2.5A
Normal : 0Ω
CN-29
※ Check contact
Start relay 24V 300A
Normal : 0.94Ω(For terminal 1-2)
CR-23
B+
M
Delco Remy ※ Check contact
Starter 28MT 24V Normal : 0.1Ω
M
CN-45
4-27
B+ G
※ Check contact
3~
Alternator 24V 60A Normal : 0Ω(For terminal B⁺-1)
Ι
U Normal : 24 ~ 27.5V
GND
CN-74
Travel alarm 1 ※ Check contact

24V 0.5A
buzzer 2 Normal : 5.2Ω
CN-81
1
Aircon ※ Check contact
compressor 24V 79W
Normal : 13.4Ω
CN-28
Normal : About 5kΩ
(For terminal A-C)
A +
※ Check valtage
Accel dial B S - Normal : About 5V
C - (For terminal A-C)
CN-142 : 2 ~ 4.5V
(For terminal C-B)
3 24V
Transducer 2 SIG 0bar : 1V(For terminal 1-2)
(Pump 1,2) 500 bar
1 GND 500bar : 5V(For terminal 1-2)
CD-42 CD-43
3 24V
Transducer 0bar : 1V(For terminal 1-2)
2 SIG
(Pump 3) 50 bar 50bar : 5V(For terminal 1-2)
1 GND
CD-44
4-28
A 24V
24V
DC/DC B GND 24V(A-B)
12V 3A
Converter C 12V 12V 12V(B-C)
CN-138
1 M ※ Check resistance
Blower motor 24V 9.5A
2.5Ω(For terminal 1-2)
2
1 Lo 1 ※ Check resistance
2 MH 3 1.12Ω(For terminal 4-2)
Aircon resistor -
3 ML 2 2.07Ω(For terminal 2-3)
4 Hi 4 3.17Ω(For terminal 3-1)
Duct sensor 1
1°
C OFF ※ Check resistance
(Switch) 2 4°
C ON : 0Ω(For terminal 1-2,
the atmosphere temp : over 4°
C)
※ Check contact
Preheater 24V 200A Normal : 0.94Ω
relay
(For terminal 1-GND)
CR-24
※ check resistance
Preheater 24V 200A
: 0.25 ~ 0.12Ω
4-29
※Check contact
Quick clamp 24V 6A
Normal : 28.9MΩ(For terminal 1-2)
CN-140
※Check disconnection
Normal : 0Ω
Fusible link 60A
(Connect ring terminal and check
resist between terminal 1 and 2)
CN-60 CN-95
TA 1
TU 2
NC
※Normal : 4.8Ω
Rear 3
EH 4
24V 21W×3 (For terminal 1-4)
combination
BU 5
24V 10W Normal : 2.1Ω
lamp-LH.RH
ST 6 (For terminal 2-4, 4-5, 4-6)
CL-15 CL-16
1 Lo ※Normal : 4.8Ω
Front
2 Hi 24V 21W (For terminal 1-2)
combination
24V 10W Normal : 2.1Ω
lamp-LH, RH 3 E
(For terminal 2-3)
CL-24 CL-25
C 1 ※Normal : 1.0Ω
Head lamp E 2 (For terminal 1-3, 2-3)
24V 75/70W
-LH, RH T 3 Normal : 1.5Ω
CL-3 CL-4 (For terminal 1-2)
4-30
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 2-frame harness) S816-006002 S816-106002
CN-4 AMP 8 I/conn(Console harness LH-frame harness) S816-008002 S816-108002
CN-5 Econoseal J 15 I/conn(Side harness RH-frame harness) 2-85262-1 368301-1
CN-6 AMP 12 I/conn(Side harness RH-frame harness) S816-012002 S816-112002
CN-7 AMP 15 I/conn(Console harness RH-frame harness) 2-85262-1 368301-1
CN-8 AMP 12 I/conn(Console harness RH-frame harness) A816-012002 S816-112002
CN-9 AMP 8 I/conn(Console harness RH-frame harness) S816-008002 S816-108002
CN-10 DEUTSCH 12 I/conn(Cab harness-frame harness) DT06S-12S DT04-12P
CN-11 DEUTSCH 8 Air-con harness DT06-8S -
CN-12 DEUTSCH 2 Work lamp harness DT06-2S-P012 DT04-2P-P012
CN-15 KET 2 2pcs auto idle pressure S814-002100 S814-102100
CN-17 DEUTSCH 8 I/conn(Side harness RH-wiper harness) DT06-8S DT04-8P
CN-20 MOLEX 2 Horn 35825-0211 -
CN-21 AMP 6 Wiper motor 925276-0 -
CN-22 KET 2 Washer tank MG640605 -
CN-23 KET 2 Speaker-LH MG610070 -
CN-24 KET 2 Speaker-RH MG610070 -
CN-25 MOLEX 2 Horn 35825-0211 -
CN-27 AMP 14 Cassette radio 173852 -
CN-28 MWP 1 AC compressor MWP01F-B -
CN-29 KET 2 Receiver dryer MG640795 -
CN-36 DEUTSCH 3 Fuse box body 21N8-20041 -
CN-45 RING-TERM - Start motor B ST710264-2 -
CN-47 AMP 2 Resistor S810-002202 -
CN-48 AMP 2 Hour meter GP-890469 -
CN-50 AMP 36 CPU controller 3441110 -
CN-51 AMP 36 CPU controller 3441110 -
CN-56 DEUTSCH 4 Cluster - DT04-4P-E004
CN-60 YAZAKI 2 Fusible link 7122-4125-50 -
CN-61 DEUTSCH 2 Fuel filler pump DT06-2S-P012 -
CN-65 KET 2 Back up buzzer DT06-2S -
CN-66 DEUTSCH 2 Breaker solenoid DT06-2S-P012 DT04-2P-P012
CN-68 DEUTSCH 2 Safety solenoid DT06-2S-P012 DT04-2P-P012
4 - 31
pin Female Male
CN-69 KET 2 Ram lock solenoid S814-002100 -
CN-70 KET 2 Travel solenoid S814-002100 -
CN-71 KET 2 Parking solenoid S814-002100 -
CN-73 DEUTSCH 2 Dozer & Outrigger DT06-2S-P012 DT04-2P-P012
CN-74 RING-TERM - Alternator "l" term S820-105000 -
CN-75 AMP 2 EPPR valve S816-002002 -
CN-76 DEUTSCH 6 DC motor DT06-6S-EP06 -
CN-79 PACKARD 3 Fuel cut off S818-020311 -
CN-81 DEUTSCH 2 Travel buzzer solenoid DT06-2S-P012 -
CN-88 DEUTSCH 2 Power max solenoid DT06-2S-P012 -
CN-95 YAZAKI 2 Fusible link - S813-130201
CN-97 AMP 12 Mutifunction switch - S816-112002
CN-116 PA 17 Switch panel S811-017002 -
CN-122 DEUTSCH 2 FWD DT06-2S-P012 DT04-2P-P012
CN-123 DEUTSCH 2 REV DT06-2S-P012 DT04-2P-P012
CN-126 DEUTSCH 4 RS 232 connector DT06-4S-P012 DT04-4P-E004
CN-131 AMP 4 Pressur switch S816-002002 S816-102002
CN-133 DEUTSCH 2 Boom prioity solenoid DT06-2S-P012 -
CN-137 DEUTSCH 2 Max flow sclenoid DT06-2S-P012 -
CN-138 DEUTSCH 3 DC/DC converter DT06-3S-P012 -
CN-139 DEUTSCH 2 12V socket - DT04-2P-E004
CN-140 DEUTSCH 2 Quick clamp DT06-2S -
CN-141 AMP 13 Wiper motor controller 142176-2 -
CN-142 DEUTSCH 3 Accel dial DT06-3S-P012 -
CN-143 KET 12 Cassette radio(With remocon) MG610406 -
CN-144 AMP 12 Remocon-cassette radio 174045-2 -
・Relay
CR-1 RING-TERN - Battery relay - S820-208002
CR-3 AMP 4 Work lamp relay S810-004202 -
CR-23 RING-TERM 2 Start relay - S814-102001
CR-24 RING-TERM 1 Pre-heater relay S822-014000 -
CR-29 AMP 4 Fwd relay S810-004202 -
CR-30 AMP 4 Rev relay S810-004202 -
CR-47 AMP 6 Safety relay S810-006202 -
4 - 32
pin Female Male
・Switch
CS-1 SHUR 1 Door switch S822-014004 -
CS-2 SWP 6 Start key switch S814-006000 -
CS-4 DEUTSCH 3 Safety switch DT06-3S-P012 -
CS-5 DEUTSCH 1 Horn switch - DT04-2P-E004
CS-19 DEUTSCH 2 One touch decel - DT04-2P-E004
CS-20 AMP 1 Safety switch S822-014002 -
CS-23 SWF 10 Beacon lamp switch SWF593757 -
CS-26 DEUTSCH 1 Breaker switch DT06-2S-P012 -
CS-27 SWF 10 Breaker switch SWF593757 -
CS-29 DEUTSCH 2 Powe max switch DT06-2S-P012 -
CS-50 SWF 10 Overload switch SWF593757 -
CS-53 SHUR 1 Wiper cut switch S822-014002 -
CS-54 SWF 10 Spare switch SWF593757 -
・Light
CL-1 KET 2 Room lamp MG 610406 -
CL-2 AMP 1 Cigar light S822-014002 -
CL-3 AMP 3 Head lamp S810-003702 -
CL-4 AMP 3 Head lamp S810-003702 -
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 S822-114004
CL-8 DEUTSCH 2 Cab light-LH - DT04-2P
CL-9 DEUTSCH 2 Cab light-RH - DT04-2P
CL-15 KET 6 Rear combination lamp-LH S814-006000 -
CL-16 KET 6 Rear combination lamp-RH S814-006000 -
CL-21 KET 2 Numberplate lamp S814-002100 -
CL-24 KET 3 Front combination lamp-LH S814-003000 -
CL-25 KET 3 Front combination lamp-RH S814-003000 -
・Sensor, sendor
CD-1 AMP 2 Hydraulic oil temp sender 85202-1 -
CD-2 DEUTSCH 2 Fuel sender DT06-2S-P012 -
CD-7 KET 2 Auto idle pressure switch 21EA-00310 -
CD-8 AMP 2 Water temp sender 85202-1 -
CD-10 RING-TERM - Air cleaner switch - S820-104002
CD-17 PACKARD 2 Tachosensor - S818-120221
CD-18 RING-TERM 1 Engine oil pressure switch - S820-104000
CD-31 DEUTSCH 2 Overload pressure switch DT06-2S-P012 DT04-2P-P012
4 - 33
pin Female Male
CD-42 AMP 3 Pump pressure 1 S816-003002 -
4 - 34
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 - 35
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
10 21
1 11
21
1 11 10 21
S811-021002 S811-121002
4 - 36
2) J TYPE CONNECTOR
No. of
pin
1 2
1
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 - 37
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 - 38
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 - 39
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 4
1 3 2 3
S810-004202 S810-104202
4 - 40
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 - 41
5) 375 FASTEN TYPE CONNECTOR
No. of
pin
1 2 1 2
S810-002402 S810-102402
6) AMP ECONOSEAL CONNECTOR

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

No. of
pin
85202-1
4 - 42
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
925276-0 480003-9
4 - 43
11) KET 090 CONNECTOR
No. of
pin
2 1
MG610070
12) KET 090 WP CONNECTORS

No. of
pin
1
2
MG640605
2 1
MG640795
4 - 44
13) KET SDL CONNECTOR
No. of
pin
1
14
14 6
MG610406
4 - 45
14) DEUTSCH DT CONNECTORS
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
6 1 1 6
4 3 3 4
DT06-6S DT04-6P
4 - 46
No. of
pin
4 5 5 4
1 8 8 1
DT06-8S DT04-8P
6 7 7 6
12
1 12 12 1
DT06-12S DT04-12P
4 - 47
15) MOLEX 2CKTS CONNECTOR
No. of
pin
1 2
35215-0200
16) ITT SWF CONNECTOR

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

No. of
pin
1
1
NMWP01F-B
4 - 48
18) ECONOSEAL J TYPE CONNECTORS
No. of
pin
S816-001002 S816-101002
S816-002002 S816-102002
S816-003002 S816-103002
S816-004002 S816-104002
4 - 49
No. of
pin
S816-006002 S816-106002
S816-008002 S816-108002
10
S816-010002 S816-110002
12
S816-012002 S816-112002
4 - 50
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
23
HD36-24-23SN HD34-24-23PN
4 - 51
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 5-15
Group 11 EPPR(Electro Proportional Pressure Reducing) Valve 5-22
Group 12 Monitoring System 5-25
SECTION 5 MECHATRONICS SYSTEM
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
Machine condition monitoring

Machine monitoring system
Electric signal monitoring
One touch deceleration system
Boom priority system
5-1
SYSTEM DIAGRAM
Transmission
Travel motor
Auto deceleration pressure switch
Main control valve
Boom priority
valve Arm 2 Boom priority
solenoid valve
Arm 1 Bucket
Travel forward
Boom 1 solenoid valve
Boom 2
Swing Option Travel reverse

solenoid valve
Travel Dozer
Power boost
solenoid valve
Main relief
valve
Max flow CO
solenoid valve
Engine speed
sensor
Engine
P1 P2
Coolant
temp sensor
Main pump Pilot pump
Accel Max flow

Fuel injection Hyd temp
actuator CO valve
pump sensor
One touch P M
Horn decel button
EPPR valve
Engine speed sensor signal
Potentiometer signal
Power boost
Option
Motor drive signal
button
button
RH control LH control
lever lever signal Hyd temperature signal
signal Drive signal
Drive signal
Coolant temperature signal
CPU controller Drive signal
Drive signal
Drive signal
Accel dial signal
CN-19
Accel dial
Serial Communication(-) CN-19A CN-19B
Drive signal
Serial Communication(+)
Prolix Battery
Resistor
Pressure switch signal
Cluster
20W75MS01
5-2
GROUP 2 MODE SELECTION SYSTEM
1. POWER MODE SELECTION SYSTEM
RK
WO
EL
AV
TR
CN-19
CN-19A CN-19B
20W75MS02
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

Default Other case Default Other case
Mode Application
Current Pressure Current Pressure
Unload Load Unload Load
(mA) (kgf/cm2) (mA) (kgf/cm2)
M Maximum power 1850±50 1650 1800±50 1650 260±30 5 150±30 0
H High power 1750±50 1550 1700±50 1600 260±30 5 260±30 5
S Standard power 1650±50 1450 2050±50 1500 330±30 9 330±30 9
AUTO DECEL Engine deceleration 1200±100 - 1200±100 - 600±30 31 600±30 25
One touch decel Engine quick deceleration 1000±100 - 1000±100 - 650±30 35 650±30 35
KEY START Key switch start position 1000±100 - 1000±100 - 650±30 35 650±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
Boom priority
valve Arm 2
Boom priority
solenoid valve
Arm 1 Bucket
Boom 2 Boom 1
Swing Option
Travel Dozer
Main relief
valve
CN-19
CN-19A CN-19B
Cluster
20W75MS03
1) HEAVY DUTY WORK MODE

The boom priority solenoid is activated to make the boom operation speed faster.
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 Boom priority solenoid Max flow cut-off solenoid

Heavy duty ON OFF
General OFF 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) U mode has a initial set which are mid-range of
max engine speed, auto decel rpm, and EPPR
valve input current. When you select U, cluster
LCD displays.
2) To change the engine high idle speed, press the
USER mode switch and SELECT switch at the
21074OP03G
same time and then ACCEL blinks at 0.5 seconds
interval.
- By pressing or switch, will increase or
decrease.
3) To change DECEL rpm, press the USER mode
switch and SELECT switch once more and then
DECEL blinks at 0.5 seconds interval.
decrease.
4) To change EPPR current, press the USER mode
switch and SELECT switch one more and then
EPPR blinks at 0.5 seconds interval.
decrease.
・ LCD segment vs parameter setting
Segment ACCEL DECEL EPPR
( ) (rpm) (rpm) (mA)
Low idle
1 High idle-900 1000 150
2 High idle-800 1050 200

3 High idle-700 1100 250
4 High idle-600 1150 300
Decel rpm
5 High idle-500 350
1200
6 High idle-400 1250 400
7 High idle-300 1300 450
8 High idle-200 1350 500
9 High idle-100 1400 550
10 High idle 1500 600
5) To memorize the final setting, press the USER
mode switch and SELECT switch one more time.
20W75MS04
5-5
GROUP 3 AUTOMATIC DECELERATION SYSTEM
Work equipment
pressure switch Travel oil pressure switch
Accel
Fuel injection actuator
pump
P M
Main control valve
Motor drive signal
Auto decel switch signal Pressure switch signal

CPU controller
Accel dial signal
Accel dial
21075MS04
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 drives the governor motor to reduce the engine speed to 1200rpm. 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
1200 rpm
Max Max
4sec 1.5sec 1.5sec
Lever Lever Time

neutral operation
21075MS05
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.
Note : Auto decel function can be activated when accel dial position is over 4.
5-6
GROUP 4 POWER BOOST SYSTEM
Main control valve
Boom priority
valve Arm 2
Arm 1 Bucket
Boom 2 Boom 1
Swing Option
Travel Dozer
Main relief Power boost

valve solenoid valve
Engine speed
sensor
Engine
P1 P2
Accel Max flow

Fuel injection actuator CO valve
pump
One touch P M
decel button
EPPR valve
Engine speed sensor signal
Power boost
Motor drive signal
button
LH control
lever signal
Drive signal
Mode switch signal
CPU controller
20W75MS10
・ 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 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
Power set H or S H
Main relief valve set pressure 330kgf/cm2 360 kgf/cm2
Even when pressed continuously,
Time of operation -
it is canceled after 8 sec.
※ Default - Power boost solenoid valve : OFF
5-7
GROUP 5 TRAVEL SPEED CONTROL SYSTEM
Transmission
Main control valve
Boom priority
valve Travel motor
Arm 2
Arm 1 Bucket
Boom 2 Boom 1
Swing Option
Travel Dozer
Travel speed
solenoid valve
Engine
Max flow
CO valve
EPPR valve
Drive signal
CPU controller
Lamp signal Travel speed switch signal
20W75MS07
Travel speed can be switched manually by turning the travel speed switch on the multifunction switch.
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
5-8
GROUP 6 AUTOMATIC WARMING UP FUNCTION
Engine
Coolant
temp sensor
Accel Max flow

pump
P M
EPPR valve
Motor drive signal
Drive signal
Warming up lamp signal

CPU controller
140W75MS08
1. CPU controller reads engine coolant temperature through the temperature sensor, and if the coolant
temperature is less than 30°
C, it increases the engine speed from key start rpm to 1200rpm. 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 : - Mode : Default(S mode)
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
Coolant
temp sensor
Accel Max flow

pump
P M
EPPR valve
Motor drive signal

Drive signal
Overheat warming signal

CPU controller
140W75MS09
1. CPU controller reads engine coolant temperature through the temperature sensor and when the
engine coolant boils up to 110°
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 100°C, 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 100° C.
3. LOGIC TABLE
Description Condition Function
- Coolant temperature : Above 110°

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

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.
The current or recorded error codes are displayed at the error display mode selected by touching
SELECT switch 2 times while pressing BUZZER STOP switch.
2. CURRENT ERROR DISPLAY
Cluster displays Co : Err and makes buzzer sound itself to warn the communication error when
communication problem caused by wire-cut or malfunction of the CPU controller occurs.
Cluster displays real time error codes received from CPU controller through communication. In case
of no problem it displays CHECK Er : 00.
If there are more than 2 error codes, each one can be displayed by pressing and switch
respectively.
Examples :
1) Communication Error
Co : Err & Buzzer sound
2) No problem
CHECK Er : 0 0
3) 4 Error codes(03, 06, 10, 43) display

CHECK Er : 0 3
Press Press Press

0 3 0 6 1 0 4 3 No change
Start Press Press Press Press
3. RECORDED ERROR DISPLAY

The recorded error can be displayed only when the key switch is at ON position.
Examples : 5 Recorded error codes(03, 06, 10, 20, 32) display
TIME Er : 0 3
Press Press Press Press

0 3 0 6 1 0 2 0 3 2 No change
Start Press Press Press Press Press
4. DELETE ALL RECORDED ERROR CODES

Select recorded error(TIME Er) display and press engine and select switch at the same time for
2 seconds or more. Cluster display changes to TIME Er : 00, which shows that CPU controller deleted
all the recorded error codes in the memory.
5 - 12
6. 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 Boom priority solenoid circuit is open or shorted to ground
56 Travel alarm buzzer circuit is shorted to battery +
58 Boom priority solenoid circuit is shorted to battery +
5 - 14
GROUP 10 ENGINE CONTROL SYSTEM
1. CPU CONTROLLER
BAND
4 PROG
PLL
SYNTHESIZE
R
TUNNING
CAB
20A
KEY
START
MOTOR
WIPER
1 CPU controller 1
2 Electric box
3 Bolt(M8)
3
20W75MS11
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 - 15
3. EXCHANGE METHOD OF THE ROM IN
THE CLUSTER
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 assmelbe the cluster in the reverse
order to removal).
21075MS14
5 - 16
4. ENGINE ACCEL ACTUATOR
1 Accel actuator
2 Push-pull cable for manual control (opt)
25075MS06
1) ENGINE THROTTLE LEVER
Throttle lever
SL : Stopper, low idle
SH : Stopper, high idle
SL SH
Accel actuator
(290-7TIER) 5-18(2)
2) EMERGENCY CABLE (Push-pull cable)

It controls engine speed by connecting onto the lever of the injection pump when the malfunction of
the CPU controller or the accel actuator happen.
5 - 17
3) ACCEL ACTUATOR
2 4
5
1 DC motor
2 Cable
3 Nut
4 Ball joint
5 Connector
(290-7TIER) 5-19(1)
6 1
Connector 5 2
4 3
Type 6P, female

1 White(Potentiometer 5V)
2 Blue(Potentiometer SIG)
Line color 3 Black(Potentiometer GND)
& description 4 -
5 Green(Motor+)
6 Yellow(Motor -)
Check resistance
Inspection Spec : 1~2Ω (Between No.5-6)
0.8~1.2kΩ (Between No.1-3)
5 - 18
4) ACCEL ACTUATOR CABLE SETTING PROCEDURE
(1) Key OFF
① Connect the ball joint of cable to engine throttle lever.
② Pull the cable to high stopper and put nut A edge to yoke of the bracket.
※ Make throttle lever not contact to the edge of high stopper.
③ Turn nut A to clockwise until touching to the edge of high stopper.
④ Make 1 turn more to clockwise in condition of the nut A contact to the edge of high stopper.
(2) Key START
⑤ Confirm if the engine speed on cluster is same as each mode specification.
⑥ If the engine speed displayed on cluster is highter than each mode specification, then turn the nut
A to counter clockwise and make the engine speed same to each mode specification.
⑦ If the engine speed displayed on cluster is lower than each mode specification, then turn the nut
A to clockwise and make the engine speed same to each mode specification.
⑧ Turn nut B to clockwise and fix the cable to bracket.
Nut A Nut B Ball joint Throttle lever
Hi Lo
Cable Bracket
13W5MS05
Mode RPM
M 1850±50
H 1750±50
S 1650±50
Auto decel 1200±100
Key start 1000±100
5 - 19
5. ENGINE SPEED SENSOR
1) DETECT ACTUAL ENGINE RPM AND SEND SIGNAL TO TACHOMETER
3 2
2 Gear teeth, flywheel

3 Lock nut, speed sensor
Flywheel housing
A Clearance
(290-7TIER) 5-20
2) INSTALLATION
(1) Clean contacting point of sensor.
(2) Loosen lock nut.
(3) Screw speed sensor into flywheel housing.
(4) Turn it back 135°when it contacts with gear teeth.
(5) Tight lock nut and connect wiring.
3) INSPECTION
(1) Check resistance
・SPEC : 300±30Ω
(2) Check voltage while engine run.
・SPEC : 2~28Vac, dependent on the engine speed(rpm)
5 - 20
6. CPU CONTROLLER
(1) To match the engine torque with the pump absorption torque, CPU
LED controller varies EPPR valve output pressure, which control pump
discharge amount whenever feedbacked engine speed drops under
the reference rpm of each mode set.
YR
G
(2) Three LED lamps on the CPU controller display as below.
MO
PA DEL
RT :R
NO OB
:21 EX
N8 290
-32 LC
LED lamp Trouble Service

10 -7
2
G is turned ON Normal -
29073CD72
R is turned ON Trouble on CPU ・ Change the controller
G and Y are Trouble on serial ・ Check if serial communication

turned ON communication line lines between controller and
cluster are disconnected
Three LED are Trouble on CPU ・ Check if the input power wire
turned OFF controller power (24V, GND) of controller is
disconnected
・ Check the fuse
G : green, R : red, Y : yellow
5 - 21
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/cm 2
psi (mA) (At accel dial 10)
M 5±3 58 ± 40 260 ± 30 1850 ± 50

Standard
H 5±3 58 ± 40 260 ± 30 1750 ± 50
(Ver : 1.x)
S 9±3 100 ± 40 330 ± 30 1650 ± 50
M 0 0 150 ± 30 1850 ± 50
Option
H 5±3 58 ± 40 260 ± 30 1800 ± 50
(Ver : 2.x)
S 9±3 100 ± 40 330 ± 30 1700 ± 50
★ Manually operated condition when prolix switch is selected emergency position.
2. HOW TO SWITCH THE VERSION(1.x ↔ 2.x) ON THE CLUSTER

You can switch the EPPR valve pressure set by selecting the version(1.x ↔ 2.x).
Step 1. Turn the key switch ON.
Step 2. Press the SELECT switch 3 times.
Step 3. While 7 segment on the cluster shows the version of the CPU controller program, for example
20C1.1 press the buzzer stop switch( ) + travel speed control switch( ) at the same
time for 2 seconds.
The display changes to 20C2.1, and it indicates that version 2.2(Option) is selected.
※ If you want to get back to ver:1.x, go to step 1~3.
5-22
2. OPERATING PRINCIPLE
1) STRUCTURE
6 7
2 3 4 5
(290-7TIER) 5-22(1)
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
(290-7TIER) 5-22A
2) AT H MODE
Pressure line is blocked and A oil returns to tank.
P A
T P T
A
(290-7TIER) 5-22B
3) AT S MODE
Secondary pressure enters into A.
P A
T
P T
A
(290-7TIER) 5-22C
(290-7TIER) 5-22(2)
5 - 23
3. EPPR VALVE CHECK PROCEDURE Spec : 200~450mA
1) CHECK ELECTRIC VALUE AT EPPR VALVE
(1) Start engine.
(2) Set S-mode and cancel auto decel mode.
(3) Position the accel dial at 10.
CN-75
(4) If tachometer show approx1750±50rpm,
disconnect one wire harness from EPPR
valve.
(5) Install multimeter as figure. EPPR VALVE
Multimeter
(6) Check electric current at bucket circuit
relief position.
(290-7TIER) 5-23(1)
2) CHECK PRESSURE AT EPPR VALVE Spec : 2~25kgf/cm2(30~350psi)

(1) Remove plug and connect pressure
gauge as figure.
・Gauge capacity : 0 to 40-50kgf/cm2
(0 to 580-725psi)
(2) Start engine.
(3) Set S-mode and cancel auto decel mode. Supply line, pilot press
(4) Position the accel dial at 10. CN-75

Pressure adjusting
(5) If tachometer show approx 1750±50rpm, screw
locknut
check pressure at relief position of bucket
circuit by operating bucket control lever.
(6) If pressure is not correct, adjust it.
(7) After adjust, test the machine.
(290-7TIER) 5-23(2)
5 - 24
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
Monitoring display
Fuel low level warning lamp Fuel gauge
Hyd oil temp warning lamp Hyd oil temp gauge
Overheat warning lamp Engine coolant temp gauge
CPU controller
Air cleaner warning lamp check warning lamp
Power max pilot lamp
Engine oil pressure warning lamp
Cold start aid pilot lamp
Battery charging warning lamp
Warming up pilot lamp
Overload warning lamp
Decel pilot lamp
Coolant level warning lamp

Work mode switch
Power mode switch
Travel speed switch

User mode switch
Buzzer stop switch

Auto deceleration switch Select switch
20W75MS09
5- 25
2) CLUSTER CHECK PROCEDURE
(1) Start key : ON
① Check monitor initial 5 seconds
a. All lamps light up.
b. Buzzer sound.
② Check monitor after 5 seconds : Indicate cluster version and machine condition
a. Cluster program version : CL : 1.4 Indicates program version 1.4 for 2 seconds.
b. Tachometer : 0rpm
c. Fuel gauge : All light up below appropriate level
d. Hydraulic temperature : 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.
③ 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)
② When warming up operation
a. Warming up lamp : ON
b. 10 seconds after engine started, engine speed increases to1200rpm(Auto decel LED : ON)
※ Others same as above ①.
③ 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- 26
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)
21075MS16
5- 27
4. CLUSTER FUNCTION
1) MONITORING DISPLAY
(1) This displays the current time and machine information such as
engine rpm, coolant/hydraulic oil temperature, hydraulic oil
pressure and also error codes.
※ Refer to the page 5-34 for details.
14073CD03
2) FUEL GAUGE
(1) This gauge indicates the amount of fuel in the fuel tank.
(2) Fill the fuel when the white range or warning lamp blinks.
※ If the gauge illuminates the white range or warning lamp
White range blinks even though the machine is on the normal condition,
check the electric device as that can be caused by the
21073CD04
poor connection of electricity or sensor.
3) HYDRAULIC OIL TEMPERATURE GAUGE

(1) This indicates the temperature of coolant.
・White range : Below 30° C(86° F)
・Green range : 30-105 ° C(86-221° F)
Red range ・Red range : Over 105° C(221° F)
(2) The green range illuminates when operating.
21073CD05
(3) Keep idling engine at low speed until the green range
illuminates, before operation of machine.
(4) When the red range illuminates, reduce the load on the system.
If the gauge stays in the red range, stop the machine and
check the cause of the problem.
4) Engine coolant temperature gauge

(1) This indicates the temperature of coolant.
・White range : Below 30° C(86° F)
・Green range : 30-105 ° C(86-221° F)
Red range ・Red range : Over 105° C(221° F)
(2) The green range illuminates when operating.
21073CD05
(3) Keep idling engine at low speed until the green range
illuminates, before operation of machine.
(4) When the red range illuminates, turn OFF the engine, check
the radiator and engine.
5- 28
5) FUEL LOW LEVEL WARNING LAMP
(1) This lamp blinks and the buzzer sounds when the level of fuel
is below 32ℓ(8.5U.S. gal).
(2) Fill the fuel immediately when the lamp blinks.
21073CD04A
6) HYDRAULIC OIL TEMPERATURE WARNING LAMP

(1) This warning lamp blinks and the buzzer sounds when the
temperature of hydraulic oil is over 105°
C(221°
F).
(2) Check the hydraulic oil level when the lamp blinks.
(3) Check for debris between oil cooler and radiator.
21073CD05A
7) OVERHEAT WARNING LAMP

(1) This lamp blinks and the buzzer sounds when the temperature
of coolant is over the normal temperature 110°
C( 230°
F) .
(2) Check the cooling system when the lamp blinks.
21073CD06A
8) ENGINE OIL PRESSURE WARNING LAMP

(1) This lamp blinks and the buzzer sounds after starting the
engine because of pressure.
(2) If the lamp blinks during engine operation, shut OFF engine
immediately. Check oil level.
21073CD07
9) AIR CLEANER WARNING LAMP

(1) This lamp is operated by the vacuum caused inside when the
filter of air cleaner is clogged which supply air to the engine.
(2) Check the filter and clean or replace it when the lamp blinks.
21073CD08
5- 29
10) COOLANT LEVEL WARNING LAMP
(1) This lamp blinks and the buzzer sounds when the coolant is
below LOW in the reservoir tank of radiator.
(2) Check the reservoir tank when the lamp blinks.
21073CD09
11) CPU CONTROLLER CHECK WARNING LAMP

(1) Communication problem with CPU controller makes the lamp
blinks and the buzzer sounds.
(2) Check if any fuse for CPU burnt off.
(3) If not check the communication line between them.
21073CD10
12) 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.
(2) Check the battery charging circuit when this lamp blinks, during
engine operation.
21073CD13
13) OVERLOAD WARNING LAMP

(1) When the machine is overload, the overload warning lamp
blinks during the overload switch ON.
21073CD15
14) POWER MAX PILOT LAMP

(1) The lamp will be ON when pushing power max switch on the
LH RCV lever.
21073CD11
5- 30
15) DECEL PILOT LAMP
(1) Operating auto decel or one touch decel makes the lamp ON.
(2) The lamp will be ON when pushing one touch decel switch on
the LH RCV lever.
21073CD17
16) WARMING UP PILOT LAMP

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

(1) Turning the start key switch ON position starts preheating in
cold weather.
(2) Start the engine as this lamp is OFF.
21073CD12
18) WORK MODE SWITCH

(1) This switch is to select the machine operation mode, which
shifts from general operation mode to heavy operation mode
and breaker mode in a raw by pressing the switch.
・ : Heavy duty work mode(Fast boom operation)
・ : General work mode(Fast swing operation)
21073CD20
・ : Breaker operation mode
5- 31
19) USER MODE SWITCH
(1) This switch is to select the maximum power or user mode.
・M : Maximum power
・U : Memorizing operators preferable power setting.
21073CD21
20) AUTO DECELERATION SWITCH

(1) This switch is used to actuate the auto deceleration function so
the engine speed is lowered automatically when all control
levers and pedals are at neutral position to save the fuel.
・Light ON : Auto deceleration function is selected.
・Light OFF : ①Auto deceleration function is cancelled so that
21073CD22 the engine speed increased to previous
setting value.
②One touch decel function is available.
(2) Operating the auto deceleration function makes the decel
indicate lamp on the LCD panel ON.
21) POWER MODE SWITCH

(1) The lamp of selected mode is turned ON by pressing the
switch( ), when selecting the mode to use.
・H : This is used for high power work.
・S : This is used for standard power work.
21073CD23
22) TRAVEL SPEED CONTROL SWITCH

(1) This switch is to control the travel speed which is changed to
high speed(Rabbit mark) by pressing the switch and low
speed(Turtle mark) by pressing again.
21073CD24
23) BUZZER STOP SWITCH

(1) When the starting switch is turned ON first, normally the alarm
buzzer sounds for 2 seconds during lamp check operation.
(2) The red lamp lights ON and the buzzer sounds when the
machine has a problem.
In this case, press this switch and buzzer stops, but the red
21073CD25
lamp lights until the problem is cleared.
5- 32
24) SELECT SWITCH
(1) This switch is used to select the monitor display function.
(2) If the switch is pressed for 3 seconds in time display mode, it is
selected time adjusting function, as below.
・Hour by auto decel( )switch
21073CD25A ・Minute by buzzer stop( ) switch.
(3) After time set, the switch is pressed, it is returned clock.
5- 33
5. MONITORING DISPLAY
1) OUTLINE
Information of machine performance as monitored by the CPU controller can be displayed on the
cluster when the operator selects a display mode by touching SELECT switch alone or with BUZZER
STOP switch on the cluster as below.
How to select display mode
Display group Name Display on the cluster
Group selection Display mode selection
Initial Engine rpm
Way 1 Touch SELECT 1 time Time

Key switch Power shift pressure
ON or START Touch SECLET 2 times (EPPR valve)
Group 0 Touch SELECT 3 times CPU model & version
Way 2
(Default)
Touch AUTO DECEL
Touch SELECT
switch while pressing 4 times Option Front pump pressure
BUZZER STOP at (Only when
group 1~4. Touch SELECT
a pressure Rear pump pressure
5 times
sensor is
Touch SELECT installed) Pilot pressure
6 times
Default Battery voltage(V)
Touch SELECT switch Touch SELECT 1 time Potentiometer voltage(V)

Group 1
once while pressing
(Volt, temp,
BUZZER STOP. Touch SELECT 2 times Accel dial voltage(V)
EPPR press,
In this group SELECT
version) Hydraulic oil
LED ON Touch SELECT 3 times temperature(° C)
Touch SELECT 4 times Coolant temperature(°

C)
Touch SELECT switch Default Current error

twice while pressing
Group 2 Recorded error
(Error code)
BUZZER STOP. Touch SELECT 1 time
(Only key switch ON)
In this group BUZZER
STOP LED blinks
Press down( ) & Recorded error deletion
SELECT at the same time (Only key switch ON)
Default Pump prolix switch or
Touch SELECT 1 time Auto decel pressure switch or
Touch SELECT switch Power boost switch

Touch SELECT 2 times or
3 times while pressing
Group 3 BUZZER STOP.
Travel oil pressure switch
(Switch input) In this group SELECT Touch SELECT 3 times or
LED blinks at 0.5sec

Touch SELECT 4 times One touch decel switch or
interval
Touch SELECT 5 times Travel alarm switch or
Touch SELECT 6 times Preheat switch or
5- 34
How to select display mode
Display group Name Display on the cluster
Group selection Display mode selection
Default Hourmeter or
Neutral relay
Touch SELECT 1 time (Anti-restart relay) or
Touch SELECT 2 times Travel speed solenoid or

Touch SELECT
switch 4 times while Power boost solenoid
Touch SELECT 3 times (2-stage relief solenoid) or
Group 4 pressing BUZZER
(Output) STOP.
In this group Touch SELECT 4 times Boom priority solenoid or
SELECT LED blinks

at 1sec interval Touch SELECT 5 times Travel alarm or
Touch SELECT 6 times Max flow cut off solenoid or
Touch SELECT 7 times Preheat relay or
※By touching SELECT switch once while pressing BUZZER STOP, display group shifts.
Example : Group 0 1 2 3 4 0
5- 35
2) DESCRIPTION OF MONITORING DISPLAY
Group Display Name Description
It displays current engine speed detected by engine speed

2250 rpm Engine speed sensor from 500 to 3000rpm.
Range : 500~3000rpm by 10rpm
It displays current time(12 is hour and 30 is minute)

TIME 12 : 30 Time
Range : Hour(1~12), minute(00~59)
Power shift It shows that pump power shift pressure of EPPR valve being
EP : 10bar pressure of controlled by the CPU controller is 10bar.
EPPR valve Range : 00~50bar by 1bar
It shows that machine model(R200W-7) and the program

Model and CPU
20 : C1.1 version of the CPU controller is 1.4.
Group 0 program version
Version display range : 0.0~9.9 by 0.1
It displays front pump pressure of 100bar which is detected by

P1 : 100bar Front pump
pressure sensor.
(Option) pressure
Range : 000~500bar by 10bar
It displays rear pump pressure of 200bar which is detected by

P2 : 200bar Rear pump
pressure sensor.
(Option) pressure
It displays pilot pump pressure of 30bar which is detected by

P3 : 30bar Pilot pump
pressure sensor.
(Option) pressure
It shows that battery power of 24.8V is supplied into CPU controller.

b : 24.8V Battery voltage
Range : 00.0~48.0V by 0.1V
Potentiometer It shows that potentiometer signal voltage is 2.5V.

Po : 2.5V
voltage Range : 0.0~5.0V by 0.1V
Accel dial It shows that accel dial signal voltage is 3.8V.

Group 1 dL : 3.8V
voltage Range : 0.0~5.0V by 0.1V
It shows that hydraulic oil temperature detected by temperature

Hydraulic oil
°
Hd : 50°
C sensor is 50°C.
temperature
Range : 0~150° C by 1° C
It shows that coolant oil temperature detected by temperature

Coolant
°
Ct : 85°
C sensor is 50°C.
temperature
Range : 0~150° C by 1°C
5- 36
It shows that current error of 03(Short circuit in pump EPPR valve

system) is diagnosed by self diagnosis system in the CPU controller.
CHECK Er : 03 Current error If more than 2 errors, when pressing or switch, other
error codes show.
Range : 00~58
Group 2 It shows recorded error code of 03 which is diagnosed before.

If more than 2 error codes, when pressing or switch,
TIME Er : 03 Recorded error
other error codes show.
Range : 00~58
Recorded error It shows all recorded error codes are removed in the CPU
TIME Er : 00
deletion controller memory.
PP : on Shows that pump prolix switch is turned on(At

Pump prolix emergency position).
PP : on or oFF
switch PP : oFF Shows that pump prolix switch is turned off(At normal
position).
dP : on Shows that auto decel pressure switch is pressed on

Auto decel (No operation of control lever).
dP : on or oFF
pressure switch dP : oFF Shows that auto decel pressure switch is released off
(Operation of control lever).
Pb : on Shows that power boost switch is pressed on

Power (Activated).
Pb : on or oFF boost switch Pb : oFF Shows that power boost switch is released off
(Canceled).
Group 3
oP : on Shows that travel oil pressure switch is pressed on
Travel oil (No operation of travel control lever).
oP : on or oFF pressure switch oP : oFF Shows that travel oil pressure switch is released off
(Operation of travel control lever).
One touch od : on Shows that one touch decel switch is pressed.

od : on or oFF
decel switch od : oFF Shows that one touch decel switch is released.
Travel alarm br : on Shows that travel alarm function is selected.

br : on or oFF switch br : oFF Shows that travel alarm function is canceled.
PH : on Shows that preheat switch is pressed.

PH : on or oFF Preheat switch PH : oFF Shows that preheat switch is released.
5- 37
Ho : on Shows that hourmeter is activated by CPU controller.

Ho : on or oFF Hourmeter Ho : oFF Shows that hourmeter is turned off.
nr : on Shows that neutral relay for anti-restarting function is

Neutral relay activated(Engine start is possible).
nr : on or oFF (Anti-restart nr : oFF Shows that neutral relay is turned off to disable the
relay) engine restart.
ts : on Shows that travel speed solenoid is activated

Travel speed (High speed).
ts : on or oFF ts : oFF Shows that travel speed solenoid is released
solenoid
(Low speed).
PS : on Shows that power boost solenoid is activated to

Group 4 Power boost maximize the power(Power up).
PS : on or oFF PS : oFF Shows that power boost solenoid is turned off(Cancel
solenoid
the power boost function).
Boom priority bs : on Shows that boom priority solenoid is activated.

bs : on or oFF bs : oFF Shows that boom priority solenoid is released.
solenoid
Ru : on Shows that travel buzzer is activated.

Ru : on or oFF Travel alarm Ru :oFF Shows that travel buzzer is canceled.
Max flow cut off FS : on Shows that max flow cut off solenoid is activated.
FS : on or oFF FS : oFF Shows that max flow cut off solenoid is released.
solenoid
PR : on Shows that preheat relay is activated.

PR : on or oFF Preheat relay PR : oFF Shows that preheat relay is released.
5- 38
SECTION 6 TROUBLESHOOTING
Group 1 Before Troubleshooting 6-1

Group 2 Hydraulic and Mechanical System 6-4
Group 3 Electrical System 6-23
Group 4 Mechatronics System 6-38
SECTION 6 TROUBLESHOOTING
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
Fault codes HRDT

displayed on
monitor display by Hyundai
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
(290-7TIER) 6-2(3)
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.
(290-7TIER) 6-3(1)
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.
(290-7TIER) 6-3(3)
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.
① Was there any strange thing about machine before failure occurred?
② Under what conditions did the failure occur?
③ Have any repairs been carried out before the failure?
(5) Check before troubleshooting.
① Check oil and fuel level.
② Check for any external leakage of oil from components.
③ 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 ⓐ
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
ⓐ 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
ⓐ
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.
ⓐ
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 ⓐ
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.
ⓐ when dust plug
under engine fly Is not main relief NO Hydraulic pump is
Are attachment wheel is removed? NO valve faulty? Disassemble and
and travel 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 travel NO
ⓒ
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.
ⓒ 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? YES ⓐ
Does swing
YES control valve
Both directions spool move
Is MCV pilot lightly by hand?
YES Swing control valve Disassemble
pressure within NO
Is Arm speed spool is stuck. and repair.
standard level?
within standard ⓑ
value? NO
ⓒ
NO
Is swing motor's NO
ⓐ 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
NO
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
ⓒ setting pressure change when front
YES
and rear pump is broken. and repair.
normal?
discharge hoses
Is safety valve are exchanged? NO 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 valve is faulty. repair.
and RH port relief
valves are
exchanged Shuttle valve is Disassemble and
Does swing control NO
YES faulty. repair.
valve spool move
smoothly by hand?
Is MCV pilot Swing control valve Disassemble and

NO
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
ⓐ
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
ⓐ 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
ⓐ
YES
Travel motor relief
valve within
standard pressure
Travel relief valve Disassemble and
NO
YES Is the travel is faulty repair or replace.
speed solenoid
valve normal?
Travel speed Disassemble and

NO
Is the travel pilot solenoid valve is repair or replace.
YES
pressure within faulty
standard?
YES
Accelerator pedal Disassemble and
or travel Forward repair or replace.
Travel pilot /Reverse solenoid
NO solenoid valve valve is faulity
normal?
Travel pilot Disassemble and

NO
solenoid valve is repair or replace.
Is swing operation
faulity
possible?
YES
Transmission unit Disassemble and
is faulty repair.
ⓐ Does travel
motor rotate?
Travel motor is out Disassemble and
NO
of order repair.
Does the symptom
change when front
YES
and rear pump Hydraulic pump is Disassemble and
NO discharge hoses
broken repair.
are exchanged?
6 - 13
2) TRAVEL ACTION IS POWERLESS(Travel only)
Cause Remedy
YES
ⓐ
YES Travel motor relief
valve within
standard pressure
YES Is the travel Travel relief valve Disassemble and
NO
speed solenoid is faulty repair or replace.
valve normal?
Travel speed Disassemble and
NO
YES
Is the travel pilot
pressure within faulty
standard?
YES
Accelerator pedal Disassemble and
or travel Forward/ repair or replace.
Travel pilot Reverse solenoid
solenoid valve
NO normal? valve is faulty
Travel pilot Disassemble and

NO
Is the travel action faulty
powerless in both
direction? YES
Disassemble and
Transmission unit
Does travel is faulty repair.
ⓐ
motor rotate?
Travel motor is out Disassmble and
NO
of order repair.
YES
The travel relief Disassemble and
Does the symptom valve is faulty repair or replace.
change when
YES
NO travel relief valve Travel motor is out Disassemble and
are exchanged? Does the symptom
change when travel of order repair.
NO motor suction hoses
are exchanged? Disassemble and
Travel motor
NO
suction valve is repair or replace.
faulty
6 - 14
3) THE HYDRAULIC MOTOR DOSE NOT GET STARTED
Cause Remedy
The spool does Screw the fitting

work properly. bolts one more
(The spool keeps time with correct
fully open) tightening torque.
The hydraulic If the spool turns
motor does not out to be damaged,
get started it should be
repaired or the new
one should be used
The anti-cavitation Ditto

check valve does
not work properly.
(The check valve
is kept open.)
4) IT TAKES TIME TO ACCELERATE THE MOTOR
Cause Remedy
The spool does Screw the fitting

not work properly. bolts one more
time with correct
tightening torque.
If the spool turns
out to be damaged,
it should be
It takes time to repaired, or the
accelerate the new one should be
motor used.
The orifice for Remove the

closing the foreign matter by
counterbalance is disassembling
clogged. and cleaning.
Wrong setting of Adjust at the

pressure of the correct value.
relief valve. If the relief valve
turns out to be
out of order, the
new one should
be used.
6 - 15
5) IT IS NOT POSSIBLE TO REDUCE THE MOTOR SMOOTHLY
Cause Remedy
The orifice for Remove the

closing the foreign matter by
counterbalance is disassembling
It is not possible clogged. The and cleaning.
to reduce the opening of the
motor smoothly neutral position of
the spool is clogged.
Wrong setting of Adjust at the

pressure of the correct value.
relief valve. If the relief valve
turns out to be
out of order, the
new one should
be used.
6) EXTRAORDINARY NOISE IS HEARD WHEN SUDDENLY REDUCING THE SPEED FROM THE HIGH-
SPEED MODE
Cause Remedy
It takes time to
accelerate the The anti-cavitation Screw the fitting
motor valve does not not bolts one more
work properly. time with correct
tightening torque.
If the valve turns
out to be
damaged, is
should be
repaired.
6 - 16
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 ⓐ
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?
YES
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?
Gear pump is Disassemble
NO
broken. and repair.
Are LH/RH
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.
ⓐ valve spool move
lightly by hand?
NO Control valve Disassemble
6 - 17
2) BOOM, ARM OR BUCKET SPEED IS LOW
Cause Remedy
YES
Normal.
YES
Are other ⓐ
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.
Is travel speeds
by hand?
NO within standard NO
levels?
NO
Hydraulic pump is Disassemble and
Is swing within faulty. repair.
NO standard levels? YES ⓒ
Is MCV pilot
pressure within
YES
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
ⓐ 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
ⓒ 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 - 18
3) BOOM, ARM OR BUCKET CYLINDER EXTENDS OR CONTRACTS ITSELF AND ATTACHMENT FALLS
Cause Remedy
YES
Does the Port relief valve is Disassemble
symptom change faulty. and repair or
Normal when port relief replace.
valve is replaced YES
with normal ⓐ
Is control valve
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
hydraulic oil or cause of
equivalent being hydraulic oil
used?
temperature rise
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
ⓐ leakage within between poppet and repair.
standard level?
and seat is poor.
Cylinder is faulty. Disassemble

NO
6 - 19
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 defective. and repair or
YES
symptom change
when port relief replace.
YES
valve is replaced Cylinder interior is Disassemble
Does control
with other valve? valve spool broken. and repair.
Is MCV pilot NO move smoothly
YES
pressure within by hand? Control valve Disassemble
standard level? NO
Is travel
possible? Pilot valve is Disassemble
NO
faulty. and repair.
Hydraulic pump is Disassemble

NO
broken. and repair.
6 - 20
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?
※ Frictional
noise will
disappear if
they are kept
used.
Boom foot pin Supply grease

NO
has run out of to it.
grease. ※
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 - 21
※ 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.
29076TS01
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
(290-7TIER) 6-20(2)
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.
20W76TS02
6 - 22
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.8.
・After checking, insert the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
Defective clucter Replace
YES Check voltage
between CN-56
(1) and chassis Disconnection in Repair or
NO
wiring harness or replace
Check voltage
between CN-5 poor contact (After clean)
(3) 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.8
Check voltage
YES 20 ~ 32V
NO 0V
20W76TS03
6 - 23
2. COMMUNICATION ERROR "Co : Err" 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
29076ES02
6 - 24
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-3
(3) and chassis between CN-51(9)
-CN3(3)
Check voltage Disconnection in Repair or replace

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

NO
Check voltage
YES 20 ~ 32V
NO 0V
25076ES02
6 - 25
4. WHEN COOLANT OVERHEAT WARNING LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
Coolant overheat Check engine
Resistance
YES between CD-8 (110°
C±2° C) cooling system
(1,2) is in range
of 120~150Ω?
NO
Defective temp Replace
Disconnect CD-8 sensor
Does display go
off when
disconnect CD-8?
YES
Starting switch : ON Short circuit in Repair or replace
Resistance wiring harness (After clean)
Engine : Start
between CN-50,
NO (31) and CN-51
(33) is 0~1Ω? Defective Controller Replace
Disconnect CN-51 NO
KEY OFF
CONTROLLER
WATER TEMP SENDER
33 5 1 C
6 2
CN-51
CN-3 CD-8
31
CN-50
20W76TS04
6 - 26
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
CONTROLLER AIR CLEANER SWITCH
Pa
16
20
CD-10
51
CN-50
Check resistance
YES MAX 1Ω
NO MIN 1MΩ
25036EL05
6 - 27
6. WHEN ENGINE OIL PRESSURE WARNING LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
Engine oil leakage, Check engine oil
or defective switch level or replace
Does display go off switch
when disconnect
YES
CD-18? Defective controller Replace
Starting switch : ON Check resistance
Engine : Start between CN-51
NO
(4) and chassis
Starting switch : OFF NO
Disconnect CN-51 wiring harness or (After clean)
poor contact
between
CN-51(4)-CD-18
CONTROLLER ENGINE OIL PRESSURE SWITCH
4 1 Pa
CN-51 CN-2 CD-18
Check resistance
YES MAX 1Ω
NO MIN 1MΩ
29076ES03
6 - 28
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 (100° C±2° C) ,
(1,2) is in range replace
of 130~150Ω?
Starting switch : ON Defective temp Replace
Does display go Disconnect CD-1 NO
sensor
off when
disconnect CD-1? YES
Short circuit Check and repair
Engine : Start
Resistance
between CN-51
NO (31,34) is 0~1Ω?

Starting switch : OFF NO
Disconnect CN-51
CONTROLLER HYDRAULIC OIL

TEMPERATURE SENDER
34 2
C
31 1
CN-51 CD-1
29076ES04
6 - 29
8. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE
Cause Remedy
YES
Is resistance poor contact
YES between CN-50 between
(31) and CN-51 CN-50, 51-CD-8
(33) over 2kΩ?
Starting switch : OFF YES
Disconnect CN-50 Defective controller Replace
Does the gauge
light up and Check resistance
down at lamp NO
between CN-3(5)
check? and (6)
Defective temp Replace
See Table
NO
Starting switch : ON sensor
Defective cluster Replace

NO
Check Table
Green range Red range Temperature White range Green range Red range
Item (~29° C) (30~105° C) (105°C ~)
Unit Resistance(Ω) 1646~ 1645~158 ~139
White range Tolerance(%) ±20 ±20 ±20
CPU CONTROLLER
WATER TEMPERATURE SENSOR
33 5 1 C
CN-51 6 2
CD-8
CN-3
31
CN-50
20W76MS05
6 - 30
9. WHEN FUEL GAUGE DOES NOT OPERATE(Check warning lamp ON/OFF)
Cause Remedy
YES
Disconnection in Check and repair
wiring harness
Is resistance
YES between CN-51
(24) and (31)
over 1kΩ? YES
Starting switch : OFF
Disconnect CN-51
Check resistance
Does the gauge between CD-2(1)
light up and NO and (2)
down at lamp Defective fuel Replace
NO
check? Disconnect CD-2
sensor
See Table
Defective cluster Replace

NO
Green range Red range Check Table

Level White range Green range Red range
Item
Unit Resistance(Ω) 700~601 600~101 ~100
White range Tolerance(%) ±5 ±5 ±5
CONTROLLER
FUEL SENDER
24 1
CD-2
31
CN-51
29076ES06
6 - 31
10. WHEN SAFETY SOLENOID DOES NOT OPERATE
short of fuse No.23.
Cause Remedy
YES
Hydraulic Check hydraulic
YES Check operation malfunction system
of solenoid
Defective solenoid Replace
Safety lever : ON-OFF NO
YES
Defective switch Replace
YES Check voltage
between CS-4(C)
Check voltage and chassis
between CN- Disconnection in Repair or replace
68(1) - CN-68(2) Start switch : ON NO
YES Check voltage Voltage : 20~30V
Starting switch : ON between CN-4(8) Disconnect CN-4 poor contact
Voltage : 20~30V and chassis between
Safety state
CS-4(C)-CN-68(2)
Voltage : 20~30V
Disconnect CN-4 Disconnect in Repair or replace
Check voltage NO
between CN-68(2) wiring harness or (After clean)
NO
with chassis poor contact
between
Safety lever : OFF
Starting switch : ON CN-4(8)-CN-68(2)
Voltage : 20~30V
Disconnection in Replace
NO
fuse No. 23
20W76TS05
6 - 32
11. WHEN ENGINE DOES NOT START
・Check supply of the power at engine stop solenoid while starting switch is ON.
START SWITCH
II I O H
1
I,O
・After checking, insert the disconnected connectors again immediately unless otherwise specified. 9
2
10 3 4
H
Cause Remedy 4 1
ACC BR
B
11 2
3
YES 5
Defective battery Check engine 12
6
system charge or
C ST
5
6
replace(After CN-8
checking specific CS-2
gravity of battery) POWER RY
30
Check operation YES 30 86
Check voltage Defective magnet Replace 86
of start motor YES between starter of start motor 87
magnet coil and
85
Starting switch : START chassis Defective start relay Replace 87a 87 85
NO 87a
BATTERY RY
Starting switch : START YES
SPEC : 20~30V ⓐ CR-35
Check operation YES
Check voltage
MASTER SWITCH
CR-1
NO of start relay
between CR-5
(30) and chassis FUSE
NO
Starting switch : START
Starting switch :START wiring harness or (After clean)
Check operation poor contact NO.1
of start safety DO-1 DO-2
CN-60
CN-95
NO relay between CR-5
2
1
1
(86) and CN-97(5)
YES
1
2
2
Starting switch : ON FUSIBLE LINK
Check voltage Defective relay Replace
between CR-5
NO (87) and chassis ⓑ
NO CN-51
Starting switch : ON FUSE 9
YES
Defective relay Replace NO.13
Check voltage CPU CONTROLLER
ⓐ CN-92
between CR-23
11
and chassis
NO
Starting switch : ON wiring harness or (After clean) CN-50
poor contact START SAFETY RY
between CR-5(30)- 86 30
30
START RY STARTER
CR-23 86
B+ M
YES 87 2
Check voltage Defective fuel cut Replace 85 1
ⓑ between CN-79 off solenoid 85 87 87a
87a M
(2) and chassis CR-5 CR-23
NO Disconnection in Repair or replace CN-3 CN-45
FUSE
Voltage : 20~30V
poor contact MULTI FUNCTION SW-RH
Starting switch :
between CN-2(4)-
CN-79(2) FUEL CUT -OFF
3 G
9 COM
GND
3 TR2
TR1
4 F
8 R
2 N
4 F
6
1
7
5 H
11
12
10
1
2
3
4
5
6
7
8
9
CN-2 CN-79
20W76TS06
6 - 33
12. WHEN STARTING SWITCH ON DOES NOT OPERATE
START SWITCH
master switch ON
II I O H
1
I,O
・After checking, insert the disconnected connectors again immediately unless otherwise specified. 9
2
10 3 4
H
4 1
ACC BR
B
11 2
3
5
12
Cause Remedy 6
C ST
5
YES 6
Disconnection in Repair or replace CN-8
CS-2
POWER RY
poor contact
YES Check voltage 30
30 86
between DO-1 between DO-2(1)- 86 TO STARTER
(1) and chassis CR-1 or defective 87
Voltage : 20~30V
battery relay 85
87a 87 85
87a
BATTERY RY
YES Check voltage Disconnection in Replace CR-35
between CS-2 NO
wiring harness or MASTER SWITCH
CR-1
(2) and chassis
poor contact FUSE
Voltage : 20~30V between CS-2(2)-
Check voltage
YES CN-8(11)- DO-1(1) NO.1
between CS-2(1) DO-1
CN-60
CN-95
and chassis
2
1
1
Defective start Replace
Voltage : 20~30V NO
1
2
switch FUSIBLE LINK
Check voltage Disconnection in Replace

and specific NO
gravity of battery wiring harness or FUSE
poor contact
Specific gravity : MIN 1.28 NO.13
Voltage : MIN 24V between CS-2(1)- CPU CONTROLLER
CN-8(12)-CN-60-
11
CR-1-Battery ANTI-RESTART RY
86 30
30 CN-50
Battery capacity too Charge or replace 86
NO FUEL CUT -OFF
low (After clean) 87
3 3 E
85
85 87 87a 4 2 S
87a
CR-5 5 1 I
CN-2 CN-79
20W76TS07
6 - 34
13. 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.4,11 and 13 is not blown out.
Cause Remedy
NO
Defective wiper Replace
cut switch
NO
Check operation wiring harness or (After clean)
wiper cut switch poor contact
between CN-141
Front sliding door Check valtage (11)- CS-53
open-close
between CN-141 YES
YES (11) and chassis Defective switch Replace
panel
NO Check voltage
Front sliding door-close between CN-116
Voltage : 4~5V (6) and chassis
Check operation 1)Recheck fuse Replace
NO NO.12
YES of switch panel
LED ON. Vottage : 20~30V 2)Disconnection in Repair or replace
Starting switch : ON ⓐ poor contact
Push wiper switch button YES
between CN-
116(6)-Fuse
between CN-
116(13)-Chassis
Check voltage between NO
Defective switch Replace
CN-116(4) and chassis panel
Intermittent
NO
1) Recheck fuse Replace
Check voltage CN-116 NO.6
ⓐ (12) and chassis 2) Disconnection Repair or replace
Washing
Check operation in wiring harness (After clean)
of wiper motor or poor contact
Check voltage CN-116 and controller between CN-
(15) and chassis check voltage 141(7)-Fuse,
YES CN-141(7) and
Sarting switch : ON CN-21(4)-Fuse
Voltage : 0~1V
chassis, CN-21(4)
and chassis NO
1) Recheck fuse Replace
Starting switch : OFF NO.14
Voltage : 20~30V Check voltage
2) Disconnection Repair or replace
CN-141(6)-and
YES chassis CN-141(6)-Fuse (After clean)
Starting switch : ON ⓑ
Check continuity YES
Voltage : 20~30V
NO
between Disconnection in Repair or replace
CN-141(2)-CN-116(4), wiring harness or (After clean)
CN-141(9)-CN-116(12), poor contact
CN-141(10)-CN-116(15),
ⓑ NO
CN-141(5)-Chassis , Check wiper Defective wiper Replace
CN-141(1)-CN-21(5), motor resistance motor
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 20W76TS08
Resistance : 2~4Ω
6 - 35
14. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP
short of fuse No.15.
Cause Remedy
NO
Defective lamp Replace switch
switch
Check voltage
YES
between CN-116 YES
10
11
12
13
14
15
16
17
1
4
5
8
2
6
3
9
(2) and chasis Defective bulb Replace
Check voltage
WIPER MOTOR DRIVE

YES
between CL-4(2)
CABIN LIGHT OUT
WORK LIGHT OUT

CABIN LIGHT OUT
HEAD LIGHT OUT
HEAD LIGHT OUT
CABIN LIGHT 24V

CABIN LIGHT 24V
HEAD LIGHT 24V

HEAD LIGHT 24V
ILL. LIHGT 24V
ILL.LIGHT OUT
Head lamp switch : ON and chassis
WASHER SIG
POWER 24V
PRE-HEAT
Voltage : 20~30V Disconnection in Repair or replace
INT. SIG
Starting switch : ON NO
GND
Check voltage Head lamp switch : ON
between CN-7(2)
Voltage : 20~30V poor contact
YES and chassis between CN-7(2)-
1 Lo
CL-4(2) 2 Hi
Head lamp switch : ON 3 E
Check voltage Voltage : 20~30V Disconnection in Repair or replace

NO
between CN-116 wiring harness or (After clean)
(10) and chassis
poor contact 1 Lo
Starting switch : ON between 2 Hi

Head lamp switch : 3 E
ON-OFF
CN-116(1)-CN-
7(1)
YES
10
12
11
9
8
7
6
5
4
3
2
1
4
3
2
1
10
12
11
1
3
4
COM
Lo
B+
Hi
COM
Gnd
Hn
poor contact
R
Check voltage
between CN- between CN-116
NO 7(8) and chassis
(10)-CN-7(8)
Head lamp switch : ON
NO
Check voltage Recheck fuse Replace
NO
between CN-97
(11) and (10) Defective Replace
YES
multifuction switch
20W76TS09
6 - 36
15. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP
・Before carrying out below procedure, check all the related connectors are properly inserted and FUSE
short of fuse No.15. NO.28
Cause Remedy CR-3

NO 1 2 1
Defective lamp Replace switch
2
switch
3
4 4 3
WORK LAMP RELAY
YES Check voltage

between CN-116 YES FUSE
(14) and chassis Defective bulb Replace
Check voltage NO.16
YES
Starting switch : ON between CL-5(1)
Work lamp switch : ON and chassis WORK LAMP
Voltage : 20~30V Disconnection in Repair or replace
Starting switch : ON NO
wiring harness or (After clean) 1
Work lamp switch : ON
Check voltage Voltage : 20~30V poor contact 2
between CN-7
YES (11) and chassis between CN-7 CL-5
(11) -CL-5(1) and
CN-12 WORK LAMP
Work lamp switch : ON
CL-6 (1)
Check voltage Voltage : 20~30V 2 1
between CN-116 1 2
(9) and chassis Disconnection in Repair or replace
NO
wiring harness or (After clean) CL-6
Starting switch : ON poor contact
Work lamp switch :
ON-OFF
between CN-116
Voltage : 20~30V (14)-CN-7(11)
CN-116
CN-7 1 ILL.LIGHT OUT
YES 2 HEAD LIGHT OUT
Disconnection in Repair or replace 3 HEAD LIGHT OUT
wiring harness or (After clean) 4 WIPER MOTOR DRIVE
Check voltage 5 PRE-HEAT

poor contact
6 POWER 24V
between CN-7(7) between CN-116
NO and chassis 7 CABIN LIGHT OUT
(9)-CN-7(7) 8 CABIN LIGHT OUT

7 9 ILL. LIHGT 24V
Head lamp switch : ON
10 HEAD LIGHT 24V
Voltage : 20~30V
NO Recheck fuse Replace 11 HEAD LIGHT 24V
11 12 WASHER SIG
13 GND
14 WORK LIGHT OUT
15 INT. SIG
16 CABIN LIGHT 24V
17 CABIN LIGHT 24V
SWITCH PANEL
20W76TS10
6 - 37
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 : H-mode 1750± 50rpm S-mode 1650 ± 50rpm
※ Before carrying out below procedure, check all the related connectors are properly inserted.
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 4 EPPR valve
valve
SPEC : 200~450mA Defective CPU Replace
See TEST 3 NO
Check if Er : 03 controller
on the cluster
YES
Short circuit or Check and repair
poor connection wire harness or
Check resistance between CN-50 - between CN-50-
YES at EPPR valve CN-75 CN-75
SPEC : 17.5±1Ω(20°
C) Defective EPPR Replace
See TEST 2 NO
valve
Wiring diagram
20W76MS01
6 - 38
2) TEST PROCEDURE SPEC : 17.5±1Ω(20°
C)
(1) Test 1 : Check resistance at connector Y R G
CN-50(8)-(36). CN-50
CPU 12 8 1
① Starting key OFF. CONTROLLER 24 13
② Disconnect connector CN-50. 36 25
③ Check resistance between pin and at CN-50 CN-51
connector CN-50(8)-(36).
Multimeter
29076MS02
(2) Test 2 : Check resistance at connector

SPEC : 17.5±1Ω(20°
C)
CN-75.
① Starting key OFF.
② Disconnect connector CN-75 from EPPR
CN-75
valve at main hydraulic pump.
③ Check resistance between 2 lines as
figure.
Multimeter
(290-7TIER) 6-38(2)
(3) Test 3 : Check electric current at EPPR SPEC : 200~450mA(S mode)

valve.
① Install multimeter as figure.
② Start engine.
③ Set the accel dial at "10"(MAX)
CN-75
④ Set S-mode and cancel auto decel mode.
⑤ If tachometer show approx 1650±50rpm,
check electric current.
EPPR VALVE
Multimeter
(290-7TIER) 6-38(3)
6 - 39
(2) Test 4 : Check pressure at EPPR valve. SPEC : 5~20kgf/cm2(70~280psi)
① Remove plug and connect pressure
gauge as figure.
・Gauge capacity : 0 to 40~50kgf/cm2
(0 to 570~710psi)
② Start engine. Supply line, pilot press
③ Set the accel dial at "10"(Max).
④ Set S-mode and cancel auto decel mode. CN-75
⑤ If tachometer show approx 1650 50rpm, Pressure adjusting
check pressure. screw locknut
⑥ If pressure is not correct, adjust it.

⑦ After adjust, test the machine.
(290-7TIER) 6-39(1)
6 - 40
2. ENGINE SPEED IS SLOW AT ALL MODE
1) INSPECTION PROCEDURE
Cause Remedy
Good
If test 7 is good,
Check tachometer check TEST 1~4
YES work properly or
not by changing YES
Misalignment Clean speed
the mode. between speed sensor and
Is resistance
YES Is resistance See TEST 6 sensor and fly adjust
between CN-50 No good between CN-51 wheel See : 5-20page
(12) - (23) (25) - (26)
SPEC : 0.2~0.4kΩ ⓐ
SPEC : 1~2Ω
See TEST 7 NO
See TEST 5
Check cable
between accel Defective accel Replace accel
NO
actuator and actuator or short actuator or
injection pump. circuit or poor harness
connection assembly
between CN-50-
CN-76
Improper operation Adjust or repair

NO
by loosening or
interference of cable
YES
Short circuit or poor Check and repair
connection
Is resistance
ⓐ between CN-50-
between CD-17
CN-2-CD-17
(1) - (2)
SPEC : 0.2~0.4kΩ
NO
Defective Replace
See TEST 8
speed sensor
Wiring diagram
ACCEL ACTUATOR
CPU CONTROLLER
1 P+
2
2 SIG
1 3
12 3 P-
4 NC
5 M+ 5 M 6
23 6 M-
CN-76 ACCEL DIAL
CN-50
C -
20 5 B S
21 7 A +
22 CN-142
CN-9
TACHO SENSOR
25 11 2
rp
m
26 12
1
CN-51 CN-2 CD-17 20W76MS02
6 - 41
2) TEST PROCEDURE SPEC : 1~2Ω
(1) Test 5 : Check resistance between CN-50 Y R G
(12)-(23). CPU
① Starting key OFF. CONTROLLER
② Disconnect connector CN-50 from CPU CN-50
controller. CN-51
③ Check resistance as figure.
CN-50
12 1
23 13
36 25
Multimeter 29076MS04
Unit : rpm
(2) Test 6 : Check tachometer(Work properly
Spec Remark
or not)
① Start engine. H-mode 2050±50 Check rpm after cancel
S-mode the Auto decel mode.
② Check tachometer reading. 1950±50
(3) Test 7 : Check resistance between CN-51

SPEC : 0.2~0.4kΩ
(25) and CN-51(26).
① Starting key OFF. Y R G
② Disconnect connector CN-51 from CPU CPU

CONTROLLER
controller.
CN-51
CN-50
CN-51 12 1
24 13
36 26 25
Multimeter
29076MS05
6 - 42
(4) Test 8 : Check resistance at speed
SPEC : 0.2~0.4kΩ
sensor.
② Disconnect connector CD-17 of speed Speed sensor
sensor at engine flywheel housing.
CD-17 CD-17
1 2
Engine flywheel
Multimeter
(290-7TIER) 6-42(1)
6 - 43
3. 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 4 valve
Check electric
current at EPPR YES
valve Short circuit or Check and repair
poor connection wire harness
SPEC : 200~450mA
See TEST 3 between
Check resistance CN-50 - CN-2 or
NO at EPPR valve
CN-50 - CN-75
SPEC : 17.5±1Ω(20°
C)
See TEST 2 Defective EPPR Replace
NO
valve
Wiring diagram
20W76MS01
6 - 44
2) TEST PROCEDURE SPEC : 200~450mA
(1) Test 9 : Check electric current at EPPR
valve at S-mode
① Install multimeter as figure. CN-75
② Start engine.
③ Set the accel dial at "10"(max)
④ Set S-mode with 1650±50rpm.
⑤ Check electric current.
EPPR VALVE
Multimeter
(290-7TIER) 6-44(1)
(2) Test 10 : Check pressure at EPPR valve SPEC : 5~20kgf/cm2(70~280psi)

at S-mode
① Connect pressure gauge at EPPR valve.
② Start engine.
③ Set the accel dial at "10"(max) Supply line, pilot press
④ Set S-mode with 1650±50rpm.
⑤ Operate bucket lever completely push or CN-75
pull. Pressure adjusting
screw locknut
⑥ Hold arm lever at the end of stroke.
⑦ Check pressure at relief position.
(290-7TIER) 6-44(2)
6 - 45
4. 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
Y R G
See if Co : Er
NO
on the cluster
NO Y R G
ⓐ
NO
OK
Check connection Cluster failure Replace
between CN-51
ⓐ (29) - CN-50(10)
or CN-50(30) -
CN-5(11) No connection Check and repair
NO
KEY OFF
Wiring diagram
CPU CONTROLLER
CLUSTER
POWER IG(24V) 24
GND 28
RX 3 10 29
TX 4 11 30
CN-56 CN-5 CN-50
FUSE
NO.10(CPU)
20W76MS03
6 - 46
5. SLOW ACTION OF ENGINE SPEED CHANGE WHEN CHANGE THE MODE
Cause Remedy
YES
Slow action of Check and repair
engine speed
control due to
interference
Check interference
between YES
connecting rod and Defective CPU Replace
Check voltage
accel actuator controller
YES between CN-51
(20)-(21) and check
resistance between
CN-51 (20)-(22)
Check resistance Defective accel Replace
NO
between CN-50 SPEC : (20)-(21) : 5±1V actuator
NO (20)-(22) : 0.1~0.9kΩ
(12)-(23) See TEST 12
SPEC : 1~2Ω
See TEST 11 Defective accel Replace
NO
actuator
Wiring diagram
ACCEL ACTUATOR
CPU CONTROLLER
1 P+
2
2 SIG
1 3
12 3 P-
4 NC
5 M+ 5 M 6
23 6 M-
CN-76 ACCEL DIAL
CN-50
C -
20 5 B S
21 7 A +
22 CN-142
CN-9
TACHO SENSOR
25 11 2
rp
m
26 12
1
CN-51 CN-2 CD-17
20W76MS02
6 - 47
2) TEST PROCEDURE SPEC : 1~2Ω
(1) Test 11 : Check resistance. Y R G

CPU
② Disconnect connector CN-50 from CPU CONTROLLER
controller. CN-50
③ Check resistance between CN-50(12)- CN-51
(23) as figure.
CN-50
12 1
23 13
36 25
Multimeter
29076MS04
6 - 48
(2) Test 12 : Check voltage and resistance. SPEC : 0.1~0.9kΩ
① Check resistance between CN-51(20)- Y R G
(22). CPU
CONTROLLER
- Starting key OFF.
CN-51
- Disconnect connector CN-51 from CPU CN-50
controller.
- Check resistance value with multimeter
as figure.
CN-51
12 1
24 22 20 13
36 25
Multimeter
29076MS08
② Check voltage between CN-51(20) and SPEC : 5±1V

CN-51(21). Y R G
- Prepare 2 pieces of thin sharp pin, steel CPU

CONTROLLER
or copper. PIN
- Starting key ON. CN-50
CN-51
- Insert prepared pins to rear side of
connectors : One pin to CN-51(20)
Other pin to CN-51(21)
- Check voltage.
CN-51
12 1
24 21 20 13
36 25
Multimeter
29076MS09
6 - 49
6. AUTO DECEL SYSTEM DOES NOT WORK
Cause Remedy
YES
Defective CPU Replace
controller
NO
Check resistance Short circuit or poor Replace or repair
between CN-51 connection
(1)-GND and between CN-51(1)-
CN-51(13)-GND
pressure switches
SPEC :
Actuator operating :
11~13V
Actuator stop :0~2V Defective auto Replace
See TEST 13 NO
See TEST 14 decel pressure
switch
Wiring diagram
CPU CONTROLLER AUTO DECEL PRESSURE SWITCH

1
Pa
1 2
CD-7
CN-51
20W76MS04
6 - 50
2) TEST PROCEDURE SPEC : Actuator stop : 11~13V
(1) Test 13 : Check voltage at CN-51(1) and Actuator operating : 0~2V
ground.
① Prepare 1 piece of thin sharp pin, steel or Y R G
copper. CPU
② Starting key ON. CONTROLLER
③ Insert prepared pin to rear side of PIN
connectors : One pin to (1) of CN-51. CN-50

CN-51
④ Check voltage as figure.
CN-51 12 1
24
36 25
Ground
Multimeter
140W76MS11
6 - 51
7. MALFUNCTION OF WARMING UP
Cause Remedy
YES
Defective cluster or Repair or Replace
Check resistance CPU controller or
YES
between CN-50 CD8(Sensor)
(31) - CD-8(2)
SPEC : Below10Ω NO Poor connection Repair
Check resistance KEY OFF
between CN-50
between CN -51
(33) - CD-8(1) (31) - CD-8(2)
SPEC : Below 10Ω
KEY OFF
NO
Poor connection Repair
between CN-
51(33) - CD-8(1)
Wiring diagram
CPU CONTROLLER
WATER TEMPERATURE SENSOR
33 5 1 C
CN-51 6 2
CD-8
CN-3
31
CN-50
20W76MS05
6 - 52
8. MALFUNCTION OF POWER MAX
Cause Remedy
YES Check resistance
between CN-88 Defective power Repair or replace
(1) - (2) max. solenoid valve
YES
Resistance
between CN-51 SPEC: 15-30Ω
(2)-GND normal? See TEST 15
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(1) -GND See Test 16
normal? CS-29 and CN-50
(3) -CN-88(1)
SPEC
KEY ON : 24±1V
KEY OFF : 0V
See TEST 15
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
1
CN-88
2 2
FUSE
CN-51 CN-4 NO.25
POWER MAX SWITCH
2
1
CS-29
20W76MS06
6 - 53
2) TEST PROCEDURE SPEC : Key ON : 24±1V
Key OFF : 0V
(1) Test 15: Check voltage between connector Resistance : 15~30Ω
CN-88 - GND.
① Start key ON.
② Disconnect connector CN-88 from power Power max. switch
max solenoid valve.
③ Check voltage as figure.
LH RCV-lever
CN-88
CN-88
Power max.
solenoid valve
Multimeter
29076MS04
(2) Test 16: Check resistance between

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

③ Check resistance as figure. CONTROLLER
CN-51
CN-50
CN-51
12 2
24 13
36 25
Ground
Multimeter
29076MS15
6 - 54
SECTION 7 MAINTENANCE STANDARD
Group 1 Operational Performance Test 7-1

Group 2 Major Components 7-19
Group 3 Track and Work Equipment 7-26
SECTION 7 MAINTENANCE STANDARD
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
Working
meets Hyundai spec. condition
2) OPERATIONAL PERFORMANCE OF A
WORKING MACHINE
With the passage of time, the machine's
operational performance deteriorates, so Maintenance
that the machine needs to be serviced record
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 Operating
service needs to be done(by referring to the
"Service Limits" in this manual).
3) OPERATIONAL PERFORMANCE OF A
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. 20W77MS07
7-1
2. TERMINOLOGY
1) STANDARD
Specifications applied to the brand-new
machine, components and parts.
20W77MS08
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.
20W77MS09
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.
② Secure enough space to allow the
machine to run straight more than 20m,
and to make a full swing with the front
attachment extended.
③ 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
among coworkers. Once the test is
started, be sure to communicate with
(290-7TIER) 7-3
each other using these signals, and to
follow them without fail.
② Operate the machine carefully and
always give first priority to safety.
③ 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.
④ 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.
② Carry out tests under the exact test
conditions prescribed for each test item.
③ 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.
② Push the H-mode switch and confirm
that the fuel injection pump governor
lever comes into contact with the high-
idle stopper.
③ To measure engine RPM.
(3) Measurement
① Start the engine. The engine will run at
start idle speed. Measure engine speed
with a tachometer.
② Measure and record the engine speed at
each mode(M, H, S, Travel).
③ Select the H-mode.
④ 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.
⑤ 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 1000±100

M mode 1850±50
H mode 1750±50
R200W-7
S mode 1650±50
Travel(High) 2150±50
Auto decel 1200±100
Condition : Set the accel dial at 10(Max) position.
7-4
3) TRAVEL SPEED
(1) Measure the time require for the
excavator to travel a 50m at high speed
and a 20m at low speed test run.
(2) Preparation
① Prepare a flat and solid test track 50m in
length, with extra length of 150m for
machine acceleration.
② Set the traveling position as figure.
③ Keep the hydraulic oil temperature at
50±5° C.
(3) Measurement
① Measure both the low and high speed of 20W77MS01
the machine.
② Before starting either the low or high
speed tests, adjust the LH multifunction
switch to the speed to be tested, then
select the following switch position.
・Mode selector : H mode
③ Start traveling the machine in the extra
length with the two speed switch at high
or low speed.
④ Measure the time required to travel 50m Extra
Extra lenght Test run
at high speed or 20m at low speed. lenght
100m High speed : 50m 50m
⑤ After measuring the Forward travel Low speed : 50m
speed, turn the upperstructure 180°and

measure the Reverse travel speed.
⑥ Repeat steps ④ and ⑤ three times in
each direction and calculate the average
20W77MS02
values.
(4) Evaluation
The average measured time should meet the following specifications.
Model Travel speed Standard Maximum allowable Remarks
Low speed 8.5 10.6 Seconds / 20m

R200W-7
High speed 5.5 6.8 Seconds / 50m
7-5
4) 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.
② Place the machine on flat, solid ground
with ample space for swinging. Do not
conduct this test on slopes.
③ Lower the dozer blade at ground.
④ 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.
⑤ Keep the hydraulic oil temperature at
50±5° C.
(3) Measurement
① Select the following switch positions.
② Operate swing control lever fully.
③ Swing 1 turn, and measure time taken to
swing next 3 revolutions.
④ Repeat steps ② and ③ three times and
20W77MS03
calculate the average values.
(4) Evaluation
The time required for swings should meet the following specifications.
Unit : Seconds / 3 revolutions
Model Power selector switch Standard Maximum allowable
R200W-7 H mode 14.4±1.5 18
7-6
5) 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.
② Place the machine on flat, solid ground
with ample spacer for swinging. Do not
conduct this test on slopes.
③ Lower the dozer blade at ground.
20W77MS03
foot pin. The bucekt must be empty.
⑤ Make two chalk marks: One on the swing
bearing and one directly below it on the
lower frame.
⑥ Swing the upperstructure 360°.
⑦ Keep the hydraulic oil temperature at
50±5° C.
(3) Measurement
① Conduct this test in the H mode.
② Select the following switch position.
・Mode selector : H mode 360 swing
Drift angle
③ Operate the swing control lever fully and Swing start and stop
return it to the neutral position when the
mark on the upperstructure aligns with
that on lower frame after swinging 360° . 20W77MS04
④ Measure the distance between the two
marks.
⑤ Align the marks again, swing 360°, then
test the opposite direction.
⑥ Repeat steps ④ and ⑤ three times each
and calculate the average values.
(4) Evaluation
The measured dirft angel should be within the following specifications.
Unit : Degree
Model Mode select switch Standard Maximum allowable Remarks
R200W-7 H mode 90 157.5
7-7
6) 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.
② Check the lubrication of the swing
bearing. Confirm that bearing rotation is
smooth and without noise.
③ Install a dial gauge on the track frame as
shown, using a magnetic base.
④ Position the upperstructure so that the
boom aligns with the tracks facing
towards the front idlers.
⑤ Position the dial gauge so that its needle
point comes into contact with the bottom
face of the bearing outer race.
⑥ Bucket should be empty.
(3) Measurement Measurement : (h1)
① With the arm rolled out and bucket rolled
in, hold the bottom face of the bucket to
the same height of the boom foot pin.
Record the dial gauge reading(h1).
② Lower the bucket to the ground and use
it to raise the front idler 50cm. Measurement : (h2)
Record the dial gauge reading(h2).
③ Calculate bearing play(H) from this
data(h1 and h2) as follows.
H=h2-h1
(4) Evaluation
The measured drift should be within the following specifications.
Unit : mm
Model Standard Maximum allowable Remarks
R200W-7 0.5 ~ 1.5 3.0
7-8
7) HYDRAULIC CYLINDER CYCLE TIME
(1) Measure the cycle time of the boom,
standard arm, and standard bucket
cylinders.
(2) Preparation
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 Lower
ground, as figure.
② 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.
Lower the boom until the bucket is 0.5m
above the ground. Roll in Roll out
③ To measure the cycle time of the bucket
90
cylinder.
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.
④ Keep the hydraulic oil temperature at
50±5° C.
(3) Measurement
① Select the following switch positions. Roll in Roll out
② To measure cylinder cycle times. 0.5m
- Boom cylinders.
Measure the time it takes to raise the
boom, and the time it takes to lower the
boom. To do so, position the boom at 20W77MS05
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.
7-9
- Bucket cylinders.
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 3.8±0.4 4.5

Boom lower 2.2±0.4 2.7
Arm in 3.0±0.4 3.6
R200W-7
Arm out 3.0±0.3 3.6
Bucket load 4.4±0.4 5.2
Bucket dump 2.6±0.3 3.1
7 - 10
8) 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
② Position the arm cylinder with the rod 20
to 30mm extended from the fully retracted
position.
③ Position the bucket cylinder with the rod
20 to 30mm retracted from the fully 20W77MS06
extended position.
foot pin.
50±5° C.
(3) Measurement
① Stop the engine.
② Five minutes after the engine has been
stopped, measure the changes in the
positions of the boom, arm and bucket
cylinders.
③ Repeat step ② three times and calculate
the average values.
(4) Evaluation
Unit : mm / 5min
Model Drift to be measured Standard Maximum allowable Remarks
Boom cylinder 10 below 20

R200W-7 Arm cylinder 10 below 20
Bucket cylinder 40 below 60
7 - 11
9) 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.
② Select the following switch positions.
③ Operate each boom, arm, bucket and
swing lever at full stroke and measure
the maximum operating force for each.
④ Operate each boom, arm, bucket and
swing lever at full stroke and measure
the maximum operating force for each.
⑤ Repeat steps ③ three times and
(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
R200W-7
Bucket lever 1.6 or below 2.0
Swing lever 1.6 or below 2.0
7 - 12
10) 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
Keep the hydraulic oil temperature at
50±5° C.
(3) Measurement
② Measure each lever stroke at the lever
top from neutral to the stroke end using a
ruler.
③ Repeat step ② three times and calculate
the average values.
(4) Evaluation
Unit : mm
Model Kind of lever Standard Maximum allowable Remarks
Boom lever 83±10 103

Arm lever 83±10 103
R200W-7
Bucket lever 83±10 103
Swing lever 83±10 103
7 - 13
11) PILOT PRIMARY PRESSURE
(1) Preparation
② Remove the top cover of the hydraulic
tank oil supply port with a wrench.
③ Loosen and remove plug on the pilot
pump delivery port and connect pressure
gauge.
④ Start the engine and check for oil
leakage from the port.
50±5° C.
(2) Measurement
・Auto decel switch : OFF
② Measure the primary pilot pressure in the
H mode. 210N77MS12
(3) Evaluation
The average measured pressure should meet the following specifications.
Unit : kgf / cm2
Model Engine speed Standard Allowable limits Remarks
R200W-7 H mode 40±5 -
7 - 14
12) FOR TRAVEL SPEED SELECTING PRESSURE
(1) Preparation
② Push the pressure release button to
bleed air.
Transmission
③ To measure the speed selecting pressure. Hose
Install a connector and pressure gauge Pressure
gauge
assembly to transmission P1, P2 port as P2
figure.
④ Start the engine and check for on P1
leakage from the adapter. Adapter
50±5° C.
(2) Measurement
① Lower the bucket and dozer blade to the
130W-3(7-14)
ground to raise the tires off the ground.
② Select the following switch position.
・Parking switch : OFF
③ Operate the travel speed switch turns to
the high or lower position and measure
the port P1 or P2 pressure.
④ Repeat steps ③ three times and
(3) Evaluation
The average measured pressure should be within the following specifications.
Unit : kgf / cm2
Standard Allowable limits
Model Travel speed mode
P1 port P2 port P1 port P2 port Remarks
Low Speed - 33+2 - 30~35

R200W-7
High Speed 33+2 - 30~35 -
7 - 15
13) SWING PARKING BRAKE RELEASING PRESSURE
(1) Preparation
② The pressure release L wrench to bleed
air.
SH
③ Install a connector and pressure gauge
assembly to swing motor SH port, as
figure.
④ Start the engine and check for oil
leakage from the adapter.
50±5° C.
(2) Measurement
② Operate the swing function or arm roll in 21077MS14
function and measure the swing brake

control pressure with the brake
disengaged. Release the control lever
to return to neutral and measure the
control pressure when the brake is
③ applied.
Repeat step ② three times and calculate
the average values.
(3) Evaluation
Unit : kgf / cm2
Model Description Standard Allowable limits Remarks
Brake disengaged 40 33~50

R200W-7
Brake applied 0 -
7 - 16
14) MAIN PUMP DELIVERY PRESSURE
(1) Preparation
Stop the engine.
Remove the top cover of the hydraulic
a2
Push the pressure release button to
bleed air.
To measure the main pump pressure.
Install a connector and pressure gauge a1
assembly to main pump gauge port as

figure.
Start the engine and check for oil
Keep the hydraulic oil temperature at
50 5 C.
210N77MS15
(2) Measurement
Select the following switch positions.
Mode selector : M mode
Auto decel switch : OFF
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
R200W-7 High idle 330 10 -
7-17
15) SYSTEM PRESSURE REGULATOR RELIEF SETTING
(1) Preparation
② Remove the top cover of the hydraulic
③ Push the pressure release button to
bleed air.
④ To measure the system relief pressure.
Install a connector and pressure gauge
assembly to main pump gauge port, as
a2
figure.
⑤ Start the engine and check for oil
⑥ Keep the hydraulic oil temperature at a1
50±5° C.
(2) Measurement
・Auto decel switch : OFF
② Slowly operate each control lever of
boom, arm and bucket functions at full
stroke over relief and measure the
pressure.
③ In the swing function, place bucket
against an immovable object and
210N77MS15
measure the relief pressure.
④ In the travel function, lock tires with an
immovable object and measure the relief
pressure.
(3) Evaluation
Model Function to be tested Normal Power boost Overload
Boom, Arm, Bucket 330±10 360±10 390

R200W-7 Travel 360±10 360±10 -
Swing 240 240 -
7 - 18
GROUP 2 MAJOR COMPONENT
1. MAIN PUMP
6 5 4 7,8
9 3 1 2
210N77MS16
Standard Recommende
Part name & inspection item d replacement Counter measures
dimension value
Clearance
between piston(1) & d D Replace piston
0.039 0.067
cylinder bore(2) or cylinder
(D-d)
Play between
piston(1) & shoe caulking
0-0.1 0.3
section(3)
(δ) Replace
assembly of
Thickness of shoe piston & shoe
δ
(t) t 4.9 4.7
Free height of cylinder

spring(4) Replace
41.1 40.3
(L) cylinder spring
L
Combined height of set

plate(H) & spherical Replace
bushing(5)(h) h H 23.0 22.0 retainer or set
(H-h) plate
Surface roughness for Surface roughness

3z
valve plate(Sliding face) necessary to be corrected
(7,8), swash plate(Shoe Lapping
plate area)(9), & cylinder(2) Standard surface roughness
0.4z or lower
(Sliding face) (Corrected value)
7 - 19
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 for spool ・ External oil leakage ・ Correction or replacement

・ Rusting, corrosion or deformation of seal ・ Correction or replacement
plate
Main relief valve, port ・ External rusting or damage ・ Replacement

relief valve & negative
・ Contacting face of valve seat ・ Replacement when damaged
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 - 20
3. SWING DEVICE
Part name Inspection item Criteria & measure
Balance plate ・ Worn less than 0.03mm ・ Lapping

・ Worn more than 0.03mm ・ Replace
・ Sliding surface has a seizure(Even ・ Replace
though small).
Shoe of piston ・ Sliding surface has a damage. ・ Lapping

assembly
・ Sliding surface depression( ) ・ Replace parts or motor
dimension less than 0.45mm or has a
large damage.
Piston of piston ・ Sliding surface has a seizure(Even ・ Replace motor

assembly though small).
Piston hole of ・ Sliding surface has a seizure. ・ Replace motor

cylinder assembly
・ Sliding surface has a damage. ・ Replace motor
Taper roller bearing ・ In case 3000hour operation. ・ Replace

Needle bearing
・ Rolling surface has a damage. ・ Replace
Roller bearing
7 - 21
4. RCV LEVER
Maintenance
Criteria Remark
check item
Leakage The valve is to be replaced when the leakage becomes Conditions :
more than 1000cc/m at neutral handle position, or more Primary pressure : 30kgf/cm2
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 10μm, compared with the non-sliding estimated to be nearly equal to the
surface. above leakage.
Push rod
Ø7
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 to When a play is due to looseness of
section be replaced when their plays become more than 2mm a tightened section, adjust it.
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 - 22
5. ACCELERATOR PEDAL
Maintenance
Criteria Remark
check item
Leakage The valve is to be replaced when the leakage effect to Conditions :
the system. For example, the primary pressure drop. Primary pressure : 30kgf/cm 2
Oil viscosity : 23cSt
Spool This is to be replaced when the sliding surface has The leakage at the left condition is
worn more than 10μm, compared with the non-sliding estimated to be nearly equal to the
surface. above leakage.
Push rod
Ø7
1mm
This is to be replaced when th top end has worn more

than 1mm.
Play at operating The pin, shaft, and joint of the operating section are to When a play is due to looseness of
section be replaced when their plays become more than 2mm a tightened section, adjust it.
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 - 23
6. 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
sealing section ・ Damaged more than 0.1mm(0.0039in) in depth Smooth with oilstone
Stem
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 ・ Worn less than 0.5mm (0.02in) Smooth
Cover
・ Damage due to seizure or contamination remediable
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 - 24
7. 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 ・ Replace or replate

base 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
Cylinder tube ・ Bushing at mounting part ・ Wear of I.D. ・ Replace
・ 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 - 25
GROUP 3 TRACK AND WORK EQUIPMENT
20W77MS10
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 90 89 88.5 90.5 91 Replace
B Boom cylinder head 80 79 78.5 80.5 81 〃
C Boom cylinder rod 80 79 78.5 80.5 81 〃
D Arm cylinder head 80 79 78.5 80.5 81 〃
E Boom front 90 89 88.5 90.5 91 〃
F Arm cylinder rod 80 79 78.5 80.5 81 〃
G Bucket cylinder head 80 79 78.5 80.5 81 〃
H Arm link 70 69 68.5 70.5 71 〃
I Bucket and arm link 80 79 78.5 80.5 81 〃
J Bucket cylinder rod 80 79 78.5 80.5 81 〃
K Bucket link 80 79 78.5 80.5 81 〃
L Dozer link(B) 70 69 68.5 70.5 71 〃
M Dozer link(A) 70 69 68.5 70.5 71 〃
N Dozer cylinder rod 70 69 68.5 70.5 71 〃
O Dozer link(A) 70 69 68.5 70.5 71 〃
P Dozer link(B) 70 69 68.5 70.5 71 〃
Q Dozer cylinder head 70 69 68.5 70.5 71 〃
R Outrigger cylinder head 80 79 78.5 80.5 81 〃
S Ourtigger cylinder rod 80 79 78.5 80.5 81 〃
T Outrigger cylinder leg 80 79 78.5 80.5 81 〃
U Outrigger cylinder foot 80 79 78.5 80.5 81 〃
7 - 26
SECTION 8 DISASSEMBLY AND ASSEMBLY
Group 1 Precautions 8-1

Group 2 Tightening Torque 8-4
Group 3 Pump Device 8-7
Group 4 Main Control Valve 8-36
Group 5 Swing Device 8-49
Group 6 Travel Motor 8-74
Group 7 Transmission 8-97
Group 8 Steering Valve 8-152
Group 9 Front Axle 8-177
Group 10 Rear Axle 8-229
Group 11 RCV Lever 8-280
Group 12 Turning Joint 8-295
Group 13 Boom, Arm, Bucket, Dozer and Outrigger Cylinders 8-302
Group 14 Work Equipment 8-323
SECTION 8 DISASSEMBLY AND ASSEMBLY
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 Taper 1/8
14 14 11.5 18
øD ød
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.
※ If the hydraulic cylinder has been replaced, carry out this procedure before assembling the rod to
the work equipment.
※ 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(Engine-Bracket) M12 × 1.75 10.0±0.5 72.3±3.6
2 Engine mounting bolt(Bracket-Frame) M20 × 2.5 55±3.5 398±25.3
Engine
3 Radiator mounting bolt, nut M12 × 1.75 10.0±0.5 72.3±3.6
4 Coupling mounting bolt M16 × 2.0 22.1±2.4 159±17.3
5 Main pump mounting bolt M20 × 2.5 42.0±4.5 304±32.5
6 Main control valve mounting bolt M12 × 1.75 12.2±1.3 88.2±9.4
7 Hydraulic Travel motor mounting bolt M16 × 2.5 29.6±3.2 214±23.1
8 system Fuel tank mounting bolt M20 × 2.5 46.0±5.1 333±36.9
9 Hydraulic oil tank mounting bolt M20 × 2.5 46.0±5.1 333±36.9
10 Turning joint mounting bolt, nut M12 × 1.75 12.2±1.3 88.2±9.4
11 Swing motor mounting bolt M20 × 2.5 57.9±8.7 419±62.9
12 Swing bearing upper mounting bolt M20 × 2.5 57.8±6.4 418±46.3
13 Swing bearing lower mounting bolt M20 × 2.5 57.8±6.4 418±46.3
15 Front axle mounting bolt, nut M16 × 2.5 29.6±3.2 214±23.1
16 Front M24 × 3.0 100±10 723±72.3
Power Rear axle mounting bolt, nut
17 Rear M24 × 2.0 107±10.7 774±77.4
train
18 system Transmission mounting bolt M20 × 2.5 39.0±4.2 282±30.4
19 Oscillating cylinder mounting bolt M22 × 1.5 69.4 502
20 Oscillating cylinder support bolt M16 × 2.0 29.6±3.2 214±23
21 Wheel nut M20 × 1.5 50.0±0.5 362±3.6
22 Front drive shaft mounting bolt, nut M10 × 1.0 5.9±0.6 42.7±4.3
23 Rear drive shaft mounting bolt, nut M10 × 1.0 5.9±0.6 42.7±4.3
24 Counter weight mounting bolt M36 × 3.0 350±30 2530±217
25 Others Cab mounting bolt, nut M12 × 1.75 12.2±1.3 88.2±9.4
26 Operator's seat mounting bolt M 8 × 1.25 1.17±0.1 8.5±0.7
※ For tightening torque of engine and hydraulic components, see each components disassembly and
assembly.
8-4
2. TORQUE CHART
The torques given are standard figures. Any figures specifically described in this manual has priority.
1) METRIC BOLT-coarse thread
8T 10T
Bolt size
kg・m lb・ft kg・m lb・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) METRIC BOLT-Fine thread

8T 10T
Bolt size
kg・m lb・ft kg・m lb・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 68 ~ 92 491 ~ 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 & HOSE
Thread size Width across flat(mm) kgf・m lbf・ft
1/4" 19 3 21.7
3/8" 22 4 28.9
1/2" 27 5 36.2
3/4" 36 12 86.8
1" 41 14 101
4) 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 6 43.4
3/4" 36 12 86.8
1" 41 14 101
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 injury. 13 4
1
5
(4) Loosen the drain plug under the hydraulic 2
tank and drain the oil from the hydraulic
tank.
・ Hydraulic tank quantity : 180ℓ
(5) Remove socket bolts(13) and disconnect
pipe (1,2). 12
3
(6) Disconnect pilot line hoses(4, 5, 6, 7, 8, 9, 210N78MP01
10, 11).
(7) Remove socket bolts(12) and disconnect
pump suction pipe (3). 6
8
※ When pump suction pipe is disconnected, 9
the oil inside the piping will flow out, so 7
catch it in oil pan.
(8) Sling the pump assembly and remove the
pump mounting bolts.
10
・ Weight : 170kg(370lb)
※ Pull out the pump assembly from housing. 11
210N78MP02
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 the return filter with a 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)
② Tighten plug lightly
③ Start the engine, run at low idling, and
check oil come out from plug.
④ Tighten plug.
(7) Start the engine, run at low idling(3~5
minutes) to circulate the oil through the
system.
(8) Confirmed the hydraulic oil level and
check the hydraulic oil leaks or not.
8-8
2. MAIN PUMP(1/2)
1) STRUCTURE
536 490 793 548 901 732 807 412 080

406 703 532 531 789 953
806 534 214 535 410
408 954 492 885
543 545
888 406 469 725 981 409 316 735 541
251 157 211 728 141 467 983
212 156 152 153 151 410 709 724
726
828 123 724 469 129 826 271 491 314 490
728 491
171 490 124 04
127
824
113
192
709
827
774
111
261
825
126
191 122 823 752 124 886 312
828 887 751 490 128 726 313
210N72MP02
8-9
04 Gear pump 312 Valve cover 712 O-ring
080 Proportional reducing 313 Valve plate(R) 724 O-ring
valve assy 314 Valve plate(L) 725 O-ring
111 Drive shaft 316 Cover 726 O-ring
113 Driven shaft 406 Hexagon socket bolt 728 O-ring
124 Needle bearing 410 Hexagon socket bolt 751 Packing
126 Bearing spacer 412 Hexagon socket bolt 752 Seat packing
127 Bearing spacer 467 Plug 774 Oil seal
141 Cylinder block 491 Plug 806 Nut
151 Piston 492 Restrictor 807 Nut
152 Shoe 531 Tilting pin 823 Snap ring
153 Set plate 532 Servo piston 824 Snap ring
156 Bushing 534 Stopper(L) 825 Snap ring
157 Cylinder spring 535 Stopper(S) 827 Snap ring
171 Front casing 536 Servo cover 828 Snap ring
191 Drive gear 541 Seat 885 Valve plate pin
192 Driven gear 543 Stopper 886 Spring pin
211 Shoe plate 545 Steel ball 887 Spring pin
212 Swash plate 548 Feed back pin 888 Pin
214 Tilting bushing 703 O-ring 901 Eye bolt
251 Swash plate support 709 O-ring 953 Set screw
261 Front cover 711 O-ring 954 Set screw
271 Pump casing
8-10
MAIN PUMP(2/2)
490
490 724 407 467,725
724
079 732 325 210N72MP03
079 Proportional reducing valve 467 Plug 725 O-ring

325 Valve casing 490 Plug 732 O-ring
407 Hexagon socket screw 724 O-ring
8-11
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
B Servo piston
Allen wrench head cap screw (PT thread) (PF thread)
4 M 5 BP-1/16 - -
5 M 6 BP-1/ 8 - -
6 M 8 BP-1/ 4 PF-1/4 -
B 8 M10 BP-3/ 8 PF-3/8 -
10 M12 BP-1/2 PF-1/2 -
14 M16, M18 BP-3/4 PF-3/4 M24
17 M20, M22 BP-1 PF-1 -
19 M24, M27 - - -
Double ring spanner, Hexagon socket

- Hexagon head screw Hexagon hut head set screw
socket wrench,
double(Single) open end 19 M12 M12 -
spanner
24 M16 M16 -
B 27 M18 M18 -
30 M20 M20 -
36 - - -
46 M30 M30 -
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, TSR200
Steel bar Steel bar of key material approx. 10×8×200
Torque wrench Capable of tightening with the specified torques
Seal tape For BP-1/4
8-12
(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 16.0 115.7 0.47 12
M16 24.0 173.6 0.55 14
M18 34.0 245.9 0.55 14
M20 44.0 318.3 0.67 17
M22 64.0 462.9 0.67 17
PT plug(Material : S45C) PT 1/16 0.7 5.1 0.16 4
※ Wind a seal tape 1 1/2 to
PT 1/ 8 1.05 7.59 0.20 5
2 turns round the plug
PT 1/ 4 1.75 12.66 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 15.0 108.5 0.55 14
PF 1 19.0 137.4 0.67 17
PF 1 1/4 27.0 195.3 0.67 17
PF 1 1/2 28.0 202.5 0.67 17
8-13
3) DISASSEMBLY
(1) Select place suitable to disassembling.
※ Select clean place.
※ Spread rubber sheet, cloth or so on
overhaul workbench top to prevent parts
from being damaged.
※ Fix pump casing(271) by using thread
2-M10×16 in disassembling.
(2) Remove dust, rust, etc, from pump
surfaces with cleaning oil or so on.
(3) Remove outlet port plug(469, lower part of
pump casing) and let the oil out of pump
casing.
※ In order to be let the oil out of pump
casing easily, remove oil filling port
plug(469, upper part of pump casing).
(4) Remove hexagon socket head cap

screws(412, 413) and remove regulators.
※ In order to avoid mixing up regulator of
drive shaft side with that of driven shaft
side, mark each of them.
Remove hexagon socket head cap
screws(435) and remove gear pump.
Remove hexagon socket head cap
screws(407) and remove proportional
reducing valve. 210N78MP29
(5) Loosen hexagon socket head cap

screws(410, 412) which tighteen valve
cover(312).
screws(410, 411) which tighten valve
cover(312).
※ Remove regulators, gear pump and
proportional reducing valve before starting
this work.
8-14
(7) Place pump horizontally on workbench
and separate pump casing(271) and valve
cover(312).
※ Remove valve cover carefully at this work
because it is heavy(about 29kgf).
※ There are two spring pins for fixing
position between pump casing and valve
cover. Since they have a tight fit, remove
valve cover upright with respect to drive
shaft(111) and driven shaft(113), while 210N78MP03
lightly tapping the valve cover with a
plastic hammer.
※ Take care not to damage fitting surfaces
between pump casing and valve cover.
Take care not to drop valve plates(313,
314), check valve subassemblies(541,
543, 545), O-rings (735) and seat
packing(752) in removing valve cover.
(8) If necessary, remove needle bearings(124)

from valve cover(312).
※ Do not remove needle bearings as far as
possible, except when it is considered to
be out of its life span.
※ Do not loosen hexagon nut(807) of the
valve cover. If loosened, flow setting will
be changed.
(9) Pull cylinders out of pump casing(271)

straightly over drive shaft(111) and driven
shaft(113). 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 bush, shoes, swash
plate, and so on.
210N78MP04
8-15
(10) Remove shoe plate(211) and swash
plate(212) from pump casing(271).
※ Separate shoe plate from swash plate,
using a flat-blade screwdriver.
Them remove swash plate.
210N78MP05
(11) If necessary, remove stopper(L, 534),

stopper(S, 535), servo piston(532), tilting
pin(531), and servo cover(536) from pump
casing(271).
※ In removing tilting pin, use a protector to
prevent pin head from being damaged.
※ Since adhesive(No.1305N of Threebond
make) is applied to fitting areas of tilting
pin and servo piston, take care not to
damage servo piston.
※ Do not loosen hexagon nut(806) on servo
cover(536). If loosened, flow setting will
be changed.
(12) Remove snap ring(827) and front

cover(261) from front casing(171).
※ A groove is provided on the outer
circumference of front cover straight with
respect to drive shaft(111) by placing a
minus type screwdriver in the groove.
※ Since oil seal(774) is fitted on front
cover(261), take care not to damage it in
removing.
(13) Loosen hexagon socket head cap 210N78MP06
screws(408) which tighten front

casing(171).
8-16
(14) Separate front casing(171) and pump
casing(271).
※ Take care of front casing not to fall
because it is heavy(about 23kgf).
※ There are two spring pins(887) for fixing
position between front casing and pump
casing. Tapping lightly with a plastic
hammer, remove front casing
perpendicular to drive shaft because they
are fitted firmly. When removing, take 210N78MP07
care not to damage oil seal sliding surface
of drive shaft.
between front casing and pump casing.
※ There is a packing(751) between front
casing and pump casing. The packing is
made of synthetic resin and easy to break.
In case it is broken or scored, replace it
with a new one.
(15) Remove snap rings(824, 825), bearing

spacers(126, 127), drive gear(191) and
driven gear(192).
210N78MP24
(16) Remove snap ring(828) and take out drive

shaft(111) and driven shaft(113) tapping
lightly ends of them by plastic hammer
and so on.
210N78MP08
8-17
(17) If necessary, remove snap rings(823, 825,
826), bearing spacer(128, 129), and roller
bearing(122, 123) from drive shaft(111)
and driven shaft(113).
※ Do not remove roller bearing as far as
possible, except when it is considered to
be out of its life span. Use a specified jig
in removing because roller bearing is
shrinkage fitted to shaft.

screws(406) which tighten swash plate
supports(251) and pump casing(271).
※ Adhesive(No.1305N of Threebond make)
is applied to hexagon socket head cap
screws(406).
(19) Remove swash plate supports(251) from

pump casing(271).
※ This is the end of disassembling

procedures.
210N78MP09
8-18
4) REASSEMBLY
(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 repair
replacement parts in advance.
② Clean each part fully with cleaning oil and
dry it with compressed air.
③ Do not fail to apply clean working oil to
sliding surfaces, bearings, etc. before
assembling them.
④ In principle, replace seal parts, such as
O-rings, oil seals, etc.
⑤ Apply grease to O-rings, seat packing,
and check valves in assembling them
because they tend to come off.
⑥ In case of parallel type pump, rotating
directions of drive shaft and driven shaft
are different. Take care not to mix up
parts of the drive shaft side with those of
the driven shaft side.
⑦ For fitting bolts, plug, etc., prepare a
torque wrench or so on, and tighten them
with specified torques in this service
manual.
(2) Select place suitable to assembling.

※ Select clean place.
※ Spread rubber sheet, cloth or so on
overhaul workbench top to prevent parts
from being damaged.
※ Fix pump casing(271) by using thread
2-M10×16 in assembling.
8-19
(3) Fit swash plate support(251) to pump
casing(271) and fix them with hexagon
socket head cap screws(406).
※ There are O-rings(724) on the matching
surface in contact with pump casing(271).
※ Fix them with grease so they do not come
off.
※ Positioning pin(888) is placed on the
pump casing(271) side. Adjust it so it
enters the groove of swash plate 210N78MP09
support(251) and fix it.
※ Fit swash plate support(251) so it enters
straight, while tapping it lightly.
※ Apply adhesive(No.1305N of Threebond
make) to hexagon socket head cap
screws.
210N78MP12
(4) To pump casing(271), fit drive shaft(111)

set and driven shaft(113) set with roller
bearing(122, 123), bearing spacer(128,
129), and snap rings(823, 826). Then fix
them with snap rings(828).
※ Direct the sharp edge side of snap
rings(823, 826) to the outside.
※ Do not tap shafts with hammer or so on.
※ Assemble them into pump casing, tapping
outer race of bearing lightly with plastic 45078MP13
hammer. Fit them fully using steel bar or
so on.
※ When fitting snap rings(828), direct the
sharp edge side of snap ring to the outside.
(5) Fit drive gear(191), driven gear(192), and

bearing spacers(126, 127) to drive
shaft(111) and driven shaft(113). Then fix
them with snap rings(824, 825).
※ Confirm the attaching direction of drive
gear before fitting.
※ Direct the sharp edge of snap rings(824,
825) to the outside.
210N78MP24
8-20
(6) Fit front casing(171) to pump casing(271) and
fix them with hexagon socket head cap
screws(408).
※ Take care of front casing not to fall because it
is heavy(about 23kgf).
position between front casing and pump
casing. Always fit spring pins(887) to the
pump casing side.
※ Fit front casing to pump casing perpendicular 210N78MP07
to drive shaft, while tapping it lightly because
spring pin(886) has a tight fit. When fitting,
take care not to damage oil seal sliding
surface of drive shaft.
※ Take care not to damage fitting surfaces of
front casing and pump casing.
※ There is a packing(751) between front casing
and pump casing. The packing is made of
symthetic resin and easy to break. In case it is
broken or scored, replace it with a new one.
※ Apply grease to seat packing(751) because it
210N78MP16
tends to come off.
(7) Fit front cover(261) to front casing(171)

and fix them with snap ring(827).
※ Apply grease lightly to oil seal in front
cover.
※ Assembling oil seal, take full care not to
damage it.
※ Direct the sharp edge of snap ring(827) to
the outside.
210N78MP06
(8) Place pump casing(271) horizontally. Fit

servo piston(532), tilting pin(531), stopper(L,
534), and stopper(S, 535) to pump casing.
Then fit servo cover(536) to pump casing and
fix them with hexagon socket head cap
screws(406).
※ Fix pump casing by using thread 2-M10×16
in assembling.
※ In tightening servo piston and tilting pin, use a
protector to prevent tilting pin head and
feedback pin from being damaged. In
addition apply adhesive (No.1305N of
Threebond make) to their threaded sections.
8-21
(9) Fit tilting bush(214) of swash plate(212) to
tilting pin(531) and fit swash plate to
swash plate support(251) correctly.
※ Take care not to mix up parts of drive shaft
side with those of driven shaft side.
※ Even after fitting, swash plate(212) comes
off from swash plate support(251), in
some cases. They do not come off easily
if grease is applied to the sliding surfaces.
※ Confirm with fingers of both hands that 210N78MP17
swash plate can be moved smoothly.
(10) Assemble piston cylinder subassembly

[cylinder(141), piston subassembly(151, 152),
set plate(153), spherical bush(156), cylinder
spring(157)]. Fit spline phases of spherical
bush and cylinder and insert piston cylinder
subassembly into pump casing with respect
to drive shaft(111) and driven shaft(113).
※ Take care not to mix up parts of drive shaft
side with those of driven shaft side.
※ Confirm that swash plate(212) is not off 210N78MP25
from swash plate support(251) and from
tilting pin(531), before inserting them.
(11) Fit valve plates(313, 314) to valve cover,

entering valve plate pin(885) into pin hole.
※ Take care not to mistake suction/delivery
directions of valve plate.
※ Apply grease to matching surface in
contact with valve cover(312) because
valve plates(313, 314) tend to come off.
210N78MP18
(12) Insert check valve subassemblies(541,

543, 545) and needle bearings(124) to
valve cover(312).
※ Insert check valve subassemblies into
valve cover in correct order.
※ Since check valve subassembly tends to
come off, apply grease to matching part of
valve cover(312).
210N78MP26
8-22
(13) Fit O-ring(724, 725, 726) and seat
packing(752) to the matching surface of
pump casing(271) in contact with valve
cover(312).
※ Since O-rings and seat packing tend to
come off, apply grease to matching
surface.
210N78MP19
(14) Fit valve cover(312) to pump casing(271)

and tighten them with hexagon socket
head cap screws(410, 412).
※ Crane valve cover at this work because it
is heavy(about 29kgf).
※ Confirm that swash plate(212) is not off
from swash plate support(251) and tilting
pin(531) before fitting.
※ Needle bearings(124) are located on the
valve cover side place the valve cover 210N78MP03
with care.
※ When fitting, take care as valve plates(313,
314) check valve subassemblies (541,
543, 545), O-rings (735), and seat
packing(752) may come off in some
cases.
position between pump casing and valve
cover. Since spring pin(886) has a tight fit,
fit valve cover upright to drive shaft(111)
and driven shaft(113), while tapping it with
210N78MP21
a plastic hammer.
between valve cover and pump casing.
8-23
(15) Putting feedback pin(548) of tilting
pin(531) into feedback lever of regulator, fit
regulator and tighten hexagon socket
head cap screws(412, 413).
※ Since the regulators on the drive shaft
side and the driven shaft side are set at
different pressure and flow values, take
care not to mistake one for another.
210N78MP29
(16) Install gear pump(04) and proportional

reducing valve(080) and tighten them with
flang socket bolt(435) (for gear pump) and
hexagon socket head cap screws(407)
(for proportional reducing valve).
※ Since gear pump is an aluminum casing,
the tightening torque for the flang socket
bolts(435) differs from it for hexagon
socket head cap screw.
210N78MP28
8-24
5) REGULATOR(1/2)
412 897 876 874

A 755
612 B
858 A
KR3G-9S09
614 P2
615
Pf
613 Pm
611
Pi Pb
A B 875
Hydraulic circuit
B
647 Pi
723 438
642
801 924
801
648 730 643 708 644 646 645 728
SECTION B-B
735 413 496 438 Pm 413
438
656
Port Port name port size

722 724 725 436
Pi Pilot port PF 1/4 - 15
VIEW C
210N72RG01 Pm Qmax cut port PF 1/4 - 15
8-25
REGULATOR(2/2)
734 653 654 836 651 652 601 624 629 630
655
641
814
628
733
732 801
C 925
898
627
631
732
756
622 621 623 625 626 887 763
SECTION A-A
210N72RG02
412 Hexagon socket screw 631 Sleeve, pf 730 O-ring

413 Hexagon socket screw 641 Pilot cover 732 O-ring
436 Hexagon socket screw 642 Adjust screw(QMC) 733 O-ring
438 Hexagon socket screw 643 Pilot piston 734 O-ring
496 Plug 644 Spring seat(Q) 735 O-ring
601 Casing 645 Adjust stem(Q) 755 O-ring
611 Feed back lever 646 Pilot spring 756 O-ring
612 Lever(1) 647 Stopper 763 O-ring
613 Lever(2) 648 Piston(QMC) 801 Nut
614 Center plug 651 Sleeve 814 Snap ring
615 Adjust plug 652 Spool 836 Snap ring
621 Compensator piston 653 Spring seat 858 Snap ring
622 Piston case 654 Return spring 874 Pin
623 Compensator rod 655 Set spring 875 Pin
624 Spring seat(C) 656 Block cover 876 Pin
625 Outer spring 708 O-ring 887 Pin
626 Inner spring 722 O-ring 897 Pin
627 Adjust stem(C) 723 O-ring 898 Pin
628 Adjust screw(C) 724 O-ring 924 Set screw
629 Cover(C) 725 O-ring 925 Adjust screw(QI)
630 Lock nut 728 O-ring
8-26
(1) Tools
The tools necessary to disassemble/reassemble the regulators 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
36 - - VP-3/4
Adjustable angle wrench Medium size, 1set
Screw driver Minus type screw driver, Medium size, 2 sets
Hammer Plastic hammer, 1 set
Pliers For snap ring, TSR-150
Steel bar Ø4×100mm
Pincers -
Hexagon socket head cap screw M4×50mm
8-27
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 Plut(Materal : 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 Plut(Materal : 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
8-28
3) DISASSEMBLY
Since the regulator consists of small
precision finished parts, disassembling and
assembling are rather complicated.
For this reason, replacement of a regulator
assembly is recommended, unless there is
a special reason, but in case disassembling
is necessary for an unavoidable reason,
read through this manual to the end before
starting disassembling.
(1) Select a place for disassembling.
※ Select 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.
※ Since the regulators on the drive shaft
side and the driven shaft side are set at
different pressure and flow values, mark
each of them so as not to mix up one of
drive shaft side with another.
(3) Remove hexagon socket head cap screw

(412, 413) and remove regulator main
body from pump main body.
※ Take care not to lose O-ring.
REG01 (210-7)
(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 (210-7)
8-29
(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 (210-7)
(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 (210-7)
(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 (210-7)
(8) Remove snap 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 (210-7)
8-30
REG07 (210-7)
(9) Remove lever(2, 613). Do not draw out

pin(875).
※ Work will be promoted by using pincers or
so on.
REG08 (210-7)
(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 (210-7)
REG10 (210-7)
8-31
(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 disassembling.
8-32
4) ASSEMBLY
(1) For assembling, reverse disassembling
procedures, but pay attention to the
following.
① Always repair parts that were scored at
disassembling.
Get replacement parts ready beforehand.
② 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.
③ Always tighten bolts, plugs, etc. to their
specified torques.
④ Do not fail to coat sliding surfaces with
clean hydraulic oil before assembling.
⑤ 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 (210-7)
8-33
(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.
※ Take care not to mistake direction of (Fulcrum plug of
adjusting plug side)
feedback lever.
8-28 (210-7)
(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 (210-7)
(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 snap ring(858).
(9) Insert adjusting plug(615) and fit snap
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 (210-7)
(10) Fit return spring(654) and spring seat

(653) into spool hole and attach snap ring
(814).
REG13 (210-7)
8-34
(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).
※ Confirm that pin(898) slides smoothly in pf
sleeve(631) without binding.
REG14 (210-7)
(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 (210-7)
(13) Install cover(C, 629) fitted with adjusting

screws(628, 925), 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 assembling. REG16 (210-7)
8-35
GROUP 4 MAIN CONTROL VALVE

1) REMOVAL

penetrate the skin causing serious injury.
※ When pipes and hoses are disconnected,
the oil inside the piping will flow out, so Atr
catch it in oil pan. Btr
Atl
(4) Remove bolts and disconnect pipe. Ba

1
As
Btl
Bs
1
Aa
(5) Disconnect pilot line hoses.

(6) Disconnect pilot piping.
21078MC01
(7) Sling the control valve assembly and
remove the control valve mounting bolt.
・Weight : 200kg(440lb)
(8) Remove the control valve assembly.
When removing the control valve
assembly, check that all the piping have
been disconnected.
2) INSTALL
to removal.
21078MC02
(2) Bleed the air from below items.
① Cylinder(Boom, arm, bucket)
② Swing motor
③ Travel motor
※ See each item removal and install.
(3) Confirm the hydraulic oil level and D
recheck the hydraulic oil leak or not.
21078MC03
8-36
2. STRUCTURE(1/5)
551
561
521
511
517
551
561
521
511
C1
C2
Cp2
252 159
601
425
424
103
438
401
162
152
561 102
153 104
254
251
561
153 101
252
20W78MC04
101 Casing A 162 O-ring 438 Rod

102 Casing B 251 Control valve 511 Poppet
103 Block 252 Lock valve 517 Poppet
104 Block 254 Logic valve 521 Spring
152 Plug 401 Spool 551 Plug
153 Plug 424 Spring 561 O-ring
159 Plug 425 Spring 601 Main relief valve
8-37
STRUCTURE(2/5)
203
201
333
331
201 336 337
332 329
201
154 335 328
164 336
379 331
332
273 336 370 262
339
203 332 372 332
335 261
374 310
333 379
332
331 370
261 305
337
332
378 159 159
261 551
377 307
561
331 611
T
L
262
S
302
S
2
A
1
B
C
392
T
L
S
S
2
602
A
1
B
C
602
602
611
561
551
20W78MC05
154 Plug 307 Boom2 spool 372 Spring

159 Plug 310 Travel spool 374 Spring
164 O-ring 331 Seat 377 Spring
201 Cover 332 Seat 378 Spring
203 Cover 333 Bolt 379 Spring
261 O-ring 335 Stopper 392 By pass cut spool
262 O-ring 336 Bolt 551 Plug
273 Socket screw 337 Stopper 561 O-ring
302 Arm1 spool 339 Stopper 602 Port relief valve
305 Swing spool 370 Spring 611 Nega con relief valve
8-38
STRUCTURE(3/5)
T
L
S
S
2
A
1
B
C
515
521
561
551
516
523
561
552
561
551 511
521
561
169 551
202
264 561
153
204
264
264
204
169
204
202
164
164 154
154
20W78MC06
153 Plug 264 O-ring 521 Spring

154 Plug 273 Socket screw 523 Spring
164 O-ring 511 Poppet 551 Plug
169 O-ring 515 Poppet 552 Plug
202 Cover 516 Poppet 561 O-ring
204 Cover
8-39
STRUCTURE(4/5)
203
203
201
333
201
331
201 333
334
273 331 329
336
334
332 328
329
336 335 331
332 379 328
336 262
335 331
332 370
379 262
335 332 301
370
372 261
332 309
374 261
332
261
303
306
304
553
602
561
159
159 155
167
T
R
O
P
154
164
B
1
B
159
K
A
2
159
561
602 553
20W78MC07
154 Plug 303 Boom1 spool 335 Stopper

155 Plug 304 Bucket spool 336 Bolt
159 Plug 306 Arm2 spool 370 Spring
164 O-ring 309 Option spool 372 Spring
167 O-ring 328 Spring 374 Spring
201 Cover 329 Spring 377 Spring
203 Cover 331 Seat 379 Spring
261 O-ring 332 Seat 553 Plug
262 O-ring 333 Bolt 561 O-ring
273 Socket screw 334 Stopper 602 Port relief valve
301 Travel spool
8-40
STRUCTURE(5/5)
552
561
523
516
551 154
561 164
521 976
511
974
T
551
R
561
O
P
971 165
B
1
B
K
209
A
2
975
168
166
165
169
264 273
202
204
20W78MC08
154 Plug 209 Flange 551 Plug

164 O-ring 264 O-ring 552 Plug
165 O-ring 273 Socket screw 561 O-ring
166 O-ring 511 Poppet 971 Socket screw
168 O-ring 516 Poppet 974 Socket screw
169 O-ring 521 Spring 975 Socket screw
202 Cover 523 Spring 976 Socket screw
204 Cover
8-41
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)
8-42
3) DISASSEMBLY
The figure in ( ) shown after the part name
in explanation sentence shows its number
in the construction figures.
(1) Place control valve on working bench
※ Disassemble the valve in a clean and dry
environment and pay careful attention not
to damage the sealing flange faces.
(2) Travel straight valve block

Loosen hexagon socket head bolts to and
remove straight travel valve block(103) in
its assembled state.
・Hexagon wrench : 14mm
20W78MC09
(3) Main spool

① Loosen hexagon socket head bolts(273)
and remove spring cover(201, 203).
20W78MC10
② Remove spool, springs, stopper, spring

seats and spacer bolt in spool assembly
condition from casing.
※ When extracting each spool assembly
from its casing, pay attention not to
damage the casing.
20W78MC11
8-43
(4) Covers
Loosen hexagon socket head bolts(273)
and then remove the spool cover(202,
204).
20W78MC12
(5) Removal of port relief

Remove port relief valves(602) from
casing.
・Socket wrench : 32mm
20W78MC13
(6) Removal of plug(Option section)

Remove plugs(553) from casing.
・Socket wrench : 27mm
(7) Lock valve

Loosen hexagon socket head bolts and
remove lock valve(252).
20W78MC14
8-44
(8) Negative control relief valve
① Remove plug(551).
20W78MC15
② Remove poppet(611), spring(621) and

damping rod(631).
20W78MC16
(9) Swing logic valve and check valve

① Loosen hexagon socket head bolts(251)
and remove logic valve(251) and take
check valve(254).
② Remove plug(551) or (552) and take out
poppet(511) or (515, 516) and spring
(521) or (523).
・Hexagon wrench : 6, 12mm
20W78MC17
(10) Boom priority valve

Loosen hexagon socket head bolts(104)
and remove boom priority valve(104).
8-45
(11) 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 casing and block are smooth and free of dust, dent, rust etc.
c. Correct dents and damages and check seat faces within the casing, if any, by lapping.
※ Pay careful attention not to leave any lapping agent within the casing.
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.
② 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.
8-46
4) ASSEMBLY
(1) General comments
① In this assembly section, explanation only is shown.
For further understanding, please refer to the figures and photographs shown in the previous
structure & disassembly section.
② Figure in ( ) shown after the part name in the explanation refers to the reference identity number
shown on the structure section.
③ Cautions in assembling seals
a. Pay close attention to keeping all seals free from handling damage and inspect carefully for
damage before using them.
b. Apply clean grease or hydraulic oil to the seal so as to ensure it is fully lubricated before
assembly.
c. Do not stretch seals so much as to deform them permanently.
d. 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.
e. Tighten fitting bolts for all sections with a torque wrench adjusted to the respective tightening
torque.
(2) Check valve

① Assemble poppet(511, 515, 516) and spring(521, 523).
② Put O-rings(561) on to plug(551, 552).
③ Tighten plug(551, 552) to the specified torque.
・Tightening torque : 23~27kgf・m(166~195lbf・ft)
(3) Negative control relief valve
① Assemble the poppets, springs and damping rods(2×611) together into casing A(101).
② Put O-ring(561) on to plug(551) and tighten the latter to its specified torque.
・Tightening torque : 23~27kgf・m(166~195lbf・ft)
(4) Lock valve
① Put O-rings onto the casing.
② Tighten hexagon socket head bolts to their specified torques.
・Tightening torque : 1~1.4kgf・m(7.23~10.12lbf・ft)
(5) Main relief, port relief valves
Install main relief valve(601), port relief valve(602) into the casing and tighten to the specified torque.
Tightening torque
Component Tools
kgf・m lbf・ft
Main relief valve Spanner 32mm 7~8 50.6~57.8
Port relief valve Socket wrench 32mm 7~8 50.6~57.8
8-47
(6) Main spools
① Carefully insert the previously assembled spool assemblies into their respective bores within of
casing A(101) and casing B(102).
※ Fit spool assemblies into casing A(101) and casing B(102) carefully and slowly. Do not under
any circumstances push them forcibly in.
(7) Covers
① Fit spool covers(202, 204) to the non-spring assembly end of the spool, and tighten the
hexagonal socket head bolts(273) to the specified torque.
・Tightening torque : 2.5~3.5kgf・m(18~25.3lbf・ft)
※ Confirm that O-rings(169, 264) have been fitted.
② Fit spring covers(201, 203) to the spring end for the spools, and tighten hexagon socket head
bolts(273) to the specified torque.
・Tightening torque : 2.5~3.5kgf・m(18~25.3lbf・ft)
※ Confirm that O-rings(261, 262) have been fitted.
(8) Swing logic valve and boom priority valve
① Put O-rings onto the casing.
② Tighten hexagon socket head bolts to their specified torques.
Tightening torque
Component Tools
kgf・m lbf・ft
Swing logic valve Hexagon wrench 6mm 2.5~3.5 18.0~25.3
Boom priority valve Hexagon wrench 10mm 8.5~11.5 61.5~83.1
8-48
GROUP 5 SWING DEVICE
A. SWING DEVICE(T3X150CHB, up to #0114)

1) REMOVAL
13031GE18
(3) Loosen the breather slowly to release the

penetrate the skin causing serious
injury. 1
ö When pipes and hoses are disconnected,
the oil inside the piping will flow out, so
catch it in oil pan. 2
(4) Disconnect hose assembly(2).

(5) Disconnect pilot line hoses(3, 4, 5, 6, 7).
(6) Sling the swing motor assembly(1) and
remove the swing motor mounting bolts 21078DA03
(8).
ÂMotor device weight : 230kg(510lb)
(7) Remove the swing motor assembly.
ö When removing the swing motor 3
4
D
r
M
u
been disconnected. 8
S
P
H
2) INSTALL 5
6
to removal. SG
r
7
(2) Bleed the air from the swing motor.
Η Remove the air vent plug.
21078DA04
Θ Pour in hydraulic oil until it overflows from
the port.
Ι Tighten plug lightly.
Κ Start the engine, run at low idling and
Λ Tighten plug fully.
(3) Confirm the hydraulic oil level and check
the hydraulic oil leak or not.
8-49
2. DISASSEMBLY AND ASSEMBLY OF SWING MOTOR
1) STRUCTURE
27 4 5 6 7 8 9 10 11 12 13 14 29 30, 31 32 33 40
3
2
1 15
41
42
43
35, 44
28 26 25 24 39 23 38 22 21 20 19 18 37 36 34 35 16, 17
21072SF04
1 Inner ring 16 Cap 31 O-ring

2 Oil seal 17 O-ring 32 O-ring
3 Taper roller bearing 18 Coned disc spring 33 Cover
4 Backing spring 19 Teflon ring 34 Relief assembly
5 Cam plate 20 Bushing 35 O-ring
6 Return plate 21 Balance plate 36 Hexagon socket bolt
7 Piston assembly 22 Needle bearing 37 Time delay valve
8 Lining plate 23 Snap ring 38 O-ring
9 Plate 24 Cylinder 39 O-ring
10 O-ring 25 Housing 40 Hexagon socket bolt
11 Piston 26 Collar 41 Check
12 O-ring 27 Plug 42 Spring
13 Spring 28 Snap ring 43 Cap
14 Parallel pin 29 Bypass valve assembly 44 Back up ring
15 Piston 30 Back up ring
8-50
2) DISASSEMBLY
(1) Removal of relief valve assembly
Remove cap of relief valve assembly(35)
with 14mm hexagonal wrench.
¡ Assemble removed relief valve assembly
(35) to original state when reassembling.
25038SM02(1)
(2) Removal of make up valve and bypass

valve assembly
Loosen cap(43) with 14mm hexagonal
wrench, and remove check valve(41) and
spring(42).
Remove bypass valve assembly(30) with
10mm hexagonal wrench.
¡ Assemble removed bypass valve
assembly(29) to original state when
25038SM02(2)
reassembling.
(3) Marking at swing motor

Before disassembling motor, make a
matching mark between cover(33) and
housing(26) for easy reassembling.
25038SM02(3)
(4) Remove mounting bolts of cover

Loosen hexagon socket bolt(37) with
14mm hexagonal wrench.
25038SM02(4)
8-51
(5) Removal of cover assembly
Place shaft of motor assembly to
downward and take cover(33) out.
25038SM03(1)
(6) Remove snap ring(23) with steel pointer

and remove inner race of needle-
bearing(22) by bearing puller.
25038SM03(2)
(7) Remove O-ring(12) from cover.
25038SM03(3)
(8) Remove balance plate

Balance plate(21) is adhered on end
surface of cylinder(24) by oil viscosity.
Take off balance plate(21) with hands.
Assembling method of balance plate(21)
depends on cover(34).
(Band groove and round groove of
high¡⁄low pressure transmission area)
Before removing, check and record
25038SM03(4)
location of balance plate(21) to prevent
misassembling.
8-52
(9) Remove bushing(20) and coned disk spring
(18) from teflon ring(19).
25038SM04(1)
(10) Removal of spring(13, brake area)

Remove spring(13) from piston(11).
Check and record original position of each
spring(14) for correct assembling.
25038SM04(2)
(11) Removal of brake piston

When removing piston(11) from housing
(25), there is a sliding resistance against
tightening of O-rings(10,12). Use tap
hole(M6) on piston(11) as shown in the
picture.
25038SM04(3)
(12) Remove O-rings(10,12) from piston(11)

and housing(25).
25038SM04(4)
8-53
(13) Remove friction plate(9) and lining plate
(8) from housing(25).
25038SM05(1)
(14) Removal of cylinder assembly

Holding end of cylinder assembly(24) with
hand, draw out cylinder assembly from
housing.
¡ Oil seal(2) and outer race of taper roller
bearing(3) are left inside of housing.
¡ End surface of cylinder(24) is sliding face .
So, protect the surface with a scrap of cloth
against damage.
25038SM05(2)
¡ Make a matching mark on piston hole of
cylinder(24) and piston assembly(7) to fit
piston into the same hole when
reassembling.
(15) Separate outer race of taper roller

bearing(3) from housing.
25038SM05(3)
(16) Removal of oil seal

Remove oil seal(2) from housing(25) with
driver and hammer.
¡ Do not reuse oil seal after removal.
25038SM05(4)
8-54
(17) Disassembly of cylinder assembly
¤ Removal of inner race of taper roller
bearing(3).
After removing snap ring(28), lift out
cylinder(24) with 2 inner race of roller
bearing(3) by applying gear puller at the
end of spline in the cylinder.
(210-7) SM16
¤Ł Separate cam plate(5), piston assembly

(7), return plate(6) from cylinder(24).
(210-7) SM17
¤Ø Get cam plate(5) slide on sliding face of

piston assembly(7) and remove it.
¡ Be cautious not to damage on sliding
face of cam plate.
(210-7) SM18
¤Œ Remove backing spring(4) from cylinder

(24).
(210-7) SM19
This completes disassembly.
8-55
3) ASSEMBLY
(1) Preparation
Before reassembling, perform below
procedure.
¤ Check each part for damage caused by
using or disassembling. If damaged,
eliminate damage by grinding with proper
sandpaper, wash them with cleaning oil
and dry with compressed air.
¤Ł Replace seal with new one.
(210-7) SM20
¤Ø Grind sliding face of piston assembly(7),
balance plate(21) and cam plate(5) with
sandpaper #2000.
(210-7) SM21
(210-7) SM22
¤Œ When assembling, lubricate with

specified clean hydraulic oil.
¤º When assembling piston assembly(7) to
piston hole of cylinder(24), check
matching mark between them.
8-56
(2) Cylinder assembly
¤ Lubricate grease on round area
(Contacting area with spring(4)) of
cylinder(24) and assemble spring(4).
(210-7) SM23
¤Ł Insert piston assembly(7) in hole of return

plate(6).
(210-7) SM24
¤Ø Assemble piston assembly(7) and return

plate(6) to cylinder(24). When
assembling, check matching mark
between them. Before assembling,
lubricate specified hydraulic oil in piston
hole of cylinder(24).
(210-7) SM25
¤Œ Lubricate specified hydraulic oil on shoe

sliding face of piston assembly(7) and
assemble cam plate(5).
(210-7) SM26
8-57
¤º Assemble inner race of taper roller
bearing(3) to cylinder(24).
(210-7) SM27
¤ Apply loctite to bearing mounting area of

inner race of cylinder(24) lightly.
(210-7) SM28
¤ Assemble inner race(1) to cylinder(24).
(210-7) SM29
(3) Oil seal

Apply three bond of white color on outer
surface of oil seal(2) and assemble and
insert it.
¡ Before assembling, lubricate lip of oil seal
with grease.
(210-7) SM30
8-58
(4) Assemble outer race of taper roller
bearing(3) to motor housing(25).
25038SM05(3)
(5) Cylinder assembly

Hold end of cylinder assembly(24) with
hands and assemble cylinder assembly to
housing(25). Be careful to prevent
damage of seal by spline of shaft.
¡ When assemble cylinder assembly, spline
shaft of cylinder is protruded from end of
housing, therefore put pads with length
30~50mm under bottom of housing.
(210-7) SM32
(6) Assemble plate(9) and lining plate(8).

¡ Lubricate specified hydraulic oil on each
side.
25038SM05(1)
(7) Insert O-rings(10,12) into housing(25) and

piston(11).
¡ Lubricate O-ring with grease.
25038SM06(1)
8-59
(8) Brake piston
Lubricate specified hydraulic oil on outer
sliding face of piston(11) and assemble
brake piston to housing(25).
¡ It is too tight to assemble piston(7)
because O-rings(10,12) are fitted,
therefore it is recommended to push
piston(11) horizontally by hands at once.
25038SM06(2)
(9) Spring(13, brake unit)

Assemble spring(13) to piston(11) of
brake unit.
¡ Insert spring(13) into original position.
25038SM04(2)
(10) Assemble bushing(20) with teflon ring(19)

and coned disk spring(18) to bushing hole
of cover(33).
¡ Lubricate on both end surfaces of
bushing(20) and outer face of teflon
ring(19) with grease and assemble cover
to housing, and parts are adhered on
cover by grease viscosity which makes
assembling easy.
(210-7) SM38
(11) Lubricate locating pin for antirotation of

balance plate(21) of cover(33) with grease
sufficiently and install locating pin to
housing.
25038SM07(1)
8-60
(12) Balance plate
Assemble balance plate(21) to cover(33).
¡ Be cautious of assembling direction.
25038SM07(2)
(13) Assemble inner race of needle bearing

(22) and snap ring(23) to cover(33).
25038SM08(1)
(14) Assemble O-ring(12) to cover(33).

¡ Lubricate O-ring with grease.
(210-7) SM41
(15) Apply three bond of white color to

distinguish oil leakage from remaining oil
in bolt hole(M16) of cover(33).
25038SM08(2)
8-61
(16) Cover
Assemble cover(33) and balance plate
(21) to housing(25) lightly, holding them
up with hands.
¡ When assembling, be careful not to
detach balance plate(21) and bushing
(20) from cover(33).
¡ Fit matching marks on housing(25) and
cover(33) made before disassembling.
25038SM03(1)
(17) Tighten cover(33) and housing(25) with

16mm hexagonal socket bolt(36).
¡⁄Tightening torque : 29kgf¡⁄m(210lbf¡⁄ft)
25038SM02(4)
(18) Make up valve

Assemble check(41) and spring(42) to
cover(33) and tighten cap(43) with 14mm
hexagonal socket bolt.
(19) Bypass valve assembly
Assemble bypass valve assembly(29) to
cover(33) with 10mm hexagonal socket bolt.
¡⁄Tightening torque : 8kgf¡⁄m(58lbf¡⁄ft) 25038SM09(1)
(20) Relief assembly

Assemble relief valve assembly(34) to
cover(33) with 14mm hexagonal socket
bolt.
¡ Be cautious of assembling method.
25038SM09(2)
8-62
(21) Check of assembly
Load pilot pressure of 30kgf/cm2 to brake
release port after opening inlet and outlet
port.
Check if output shaft is rotated smoothly
around torque of 4kgf¡⁄m.
If not rotated, disassemble and check.
This completes assembly. (210-7) SM47
8-63
3. REMOVAL AND INSTALL OF REDUCTION GEAR
1) REMOVAL
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
(400lb)
13031GE18
2) INSTALL
to removal.
¡⁄Tightening torque : 49.2~66.6kgf¡⁄m
(356~481lbf¡⁄ft)
21078DA05
8-64
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
21072SF05
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 bearing 21 Pin 1 34 Cover plate
9 Carrier 2 22 Needle cage 35 Hexagon socket bolt
10 Stop ring 23 Bush 2 36 Lock plate
11 Ring gear 24 Planet gear 1 37 Hexagon socket bolt
12 Knock pin 25 Lock washer 38 Stop ring
13 Pinion gear 26 Side plate 3 39 Side plate 2
14 Thrust gear 27 Sun gear 1
8-65
2) DISASSEMBLY
2 25 37 36
(1) Spread off the 4 corners of lock washer 13
(25) with a tool.
¡ Do not reuse lock washer(25). 3
Loosen the hexagon bolts(37) and then 1
remove lock washer(25) and lock plate 35
(36) from the pinion gear(13). 34
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 socket 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
8-66
(5) Remove stop ring(28) and then sun gear1 28
(27).
27
19
21078SR005
(6) Tighten two M10 eye bolts to carrier1(19)

and lift up and remove carrier1(19) as
subassembly.
19
21078SR006
(7) Disassembling carrier1(19) assembly.

¤ Remove stop ring(38).
¤Ł Remove side plate2(39), planet gear1 39
(24), needle cage(22), side plate1(20) 26 38
22
and side plate3(26) from the carrier.
24
¤Ø Using M8 solid drill, crush spring pin(17) 19
20
so that the pin1(21) can be removed by 17
21
hammering.
¤Œ Remove side plate3(26) from carrier1(19).
21078SR007
¡ Do not reuse spring pin(17).
¡ Do not remove pin1(21), carrier1(19) and
spring pin(17) but in case of
replacement.
¡ Put matching marks on the planet gear1
(24) and the pin1(21) for easy
reassembly.
8-67
(8) Remove sun gear2(18) and thrust gear
(14).
18
14
21078SR008
(9) Remove carrier2(9) assembly from casing

(1).
9
21078SR009
(10) Disassembling carrier2(9) assembly

¤ Using M8 solid drill, crush spring pin(17)
so that the pin2(16) can be removed.
¡ Do not reuse spring pin(17).
17
¤Ł Remove pin2(16), planet gear2(15) and
9 16
bush2(23) from the carrier2(9).
15
¡ Put matching marks on the planet gear2 23
(15) and the pin2(16) for easy reassembly.
¡ Do not disassemble pin2(16), carrier2(9)
21078SR010
and spring pin(17) but in case of
replacement.
(11) Remove thrust bearing(8) and stop ring

(10) from the drive shaft(2).
8
10 2
21078SR011
8-68
(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
8-69
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 bearing(8)

on top of drive shaft(2).
8
10 2
21078SR018
(4) Assembling carrier2(9) assembly.

¤ Install thrust gear(14) inside the carrier2
(9).
¤Ł Install bush2(23) inside the planet gear2 17
(15) and then assemble them to the
9 16
carrier2(9). 15
¤Ø Assemble the pin2(16) to the carrier2(9) 23
and then press the spring pin(17) by
hammering.
21078SR019
¤Œ Punch 2 points of the spring pin(17) lip.
¡ Take care not to mistake the matching
marks of each part.
8-70
(5) Assemble carrier2(9) assembly correctly
to the drive shaft(2).
9
21078SR020
(6) Assemble sun gear2(18) and thrust gear

(14) to the center of the carrier2(9)
assembly. 18
14
9
21078SR021
(7) Assembling carrier1(19) assembly.

¤ Assemble the pin1(21) to the carrier1(19)
and then press the spring pin(17) by
39
hammering. 26 38
22
¤Ł Punch 2 points of the spring pin's(17) lip.
24
¤Ø Install side plate3(26) onto the center of 19
20
carrier1(19). 17
¤Œ Install needle cage(22) into the planet 21
gear1(24).
21078SR022
¤º Assemble side plate(20), planet gear1
(24), side plate3(39) and then stop ring
(38) to the pin1(21).
¡ Take care not to mistake the matching
marks of each part.
8-71
(8) Install sun gear1(27) onto the side plate3
(26).
27
26
19
21078SR023
(9) Assemble carrier1(19) assembly onto the

carrier2 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) 11
holes.
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
8-72
(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
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 25 37 36
2 13
tightening the hexagon socket bolts(35).
Install spacer(3) and pinion gear(13) to
the drive shaft(2). 3
Assemble lock plate(36) on the pinion
35
gear(13). 34
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 socket bolts(37) to the
drive shaft(2) and then fold all the lock
washer(25) corners over the hexagon
bolts(37).
(18) Inject oil into the reduction gear.
8-73
B. SWING DEVICE(RMF151, #0115 and up)
1) REMOVAL
13031GE18

penetrate the skin causing serious
injury. 1
ö When pipes and hoses are disconnected,
catch it in oil pan. 2
(4) Disconnect hose assembly(2).

(5) Disconnect pilot line hoses(3, 4, 5, 6, 7).
(6) Sling the swing motor assembly(1) and
remove the swing motor mounting bolts 21078DA03
(8).
ÂMotor device weight : 230kg(510lb)
ö When removing the swing motor 3
4
D
r
M
u
been disconnected. 8
S
P
H
2) INSTALL 5
6
to removal. SG
r
7
(2) Bleed the air from the swing motor.
Η Remove the air vent plug.
21078DA04
Θ Pour in hydraulic oil until it overflows from
the port.
Ι Tighten plug lightly.
Κ Start the engine, run at low idling and
Λ Tighten plug fully.
8-63-1
2. DISASSEMBLY AND ASSEMBLY OF SWING MOTOR
1) STRUCTURE
DETAIL : K
36
7 6 5 12 11 10 17 20 8 23 39 41 33 44 35 40
30
29
31
28
32
K
34
2 3 4 1 9 14 1316 15 18 19 24 21 22 42 27 37 45
25 43 38 46
26
220072SM02
1 Body 18 O-ring 35 Time delay valve

2 Oil seal 19 O-ring 36 Wrench bolt
3 Roller bearing 20 Spring 37 Plug
4 Snap ring 21 Rear cover 38 O-ring
5 Shaft 22 Needle bearing 39 Plug
6 Bushing 23 Pin 40 Plug
7 Stop ring 24 Valve plate 41 Plug
8 Pin 25 O-ring 42 Name plate
9 Shoe plate 26 O-ring 43 Rivet
10 Cylinder block 27 Wrench bolt 44 Level gauge
11 Spring 28 Plug 45 Flange
12 Ball guide 29 Back up ring 46 O-ring
13 Set plate 30 O-ring 47 Plug
14 Piston assy 31 Spring 48 O-ring
15 Friction plate 32 Check 49 O-ring
16 Plate 33 Relief valve 50 Back up ring
17 Brake piston 34 Anti-inversion valve
8-63-2
2) DISASSEMBLING
(1) Disassemble the sub of a TURNING
AXIS
Η Unloosing wrench bolt and disassemble
time delay valve assy(35) from rear
cover(21)
14078SM201/201A
Θ Disassemble level gauge(44) from body

(1).
14078SM202/202A
Ι Hang rear cover(21) on hoist, unloose

wrench bolt(27) and disassemble from
body(1).
14078SM203/203A
8-63-3
Κ Using a jig, disassemble break piston(17)
from body(1).
14078SM204/204A
Λ Disassemble respectively cylinder block

assy, fricktion plate(15), plate(16) from
body(1).
14078SM205/205A/B
(2) Disassemble cylinder block assy sub

Η Disassemble pistion assy(14), set plate
(13) from cylinder block assy.
14078SM206/205B
Θ Disassemble ball guide(12) from cylinder

block(10).
14078SM207/207A
8-63-4
Ι Disassemble spring(11) from cylinder
block(10).
14078SM208/208A
Κ Disassemble shoe plate(9) from body(1).
14078SM209/209A
Λ Using a plier jig, disassemble snap ring

(4) from shaft(5).
14078SM210/210A
Μ Disassemble shaft assy from body(1).
14078SM211/211A
8-63-5
(3) Disassemble rear cover assy sub
Η Disassemble pin(8, 23), valve plate(24)
from rear cover(21).
14078SM212/212A
Θ Using a torque wrench, disassemble

relief valve assy(33) 2 set from rear
cover(21).
14078SM213/213A
Ι After disassembling plug with a L-wrench

from rear cover(21), disassemble
respectively back up ring, O-ring, O-ring,
spring, anti-inversion valve assy(34)
14078SM214/214A
Κ Disassemble make up check valve assy

with a torque wrench from rear cover(21).
14078SM215/215A
8-63-6
Λ Disassemble respectively plug(37, 40,
41), with a L-wrench from rear cover(21).
14078SM216/216A
8-63-7
3) ASSEMBLING
(1) Assemble the sub of a turning axls
Η Put roller bearing(3), bushing(6) on
preheater and provide heat to inner
wheel(compressing temp : 290Á C for
2minutes)
ÂRoller bearing Ý1EA
ÂBushingÝ 1EA
3 6
14078SM217/217A/B
Θ After assembling and compressing

preheated roller bearing(3), bushing(6)
into shaft(5).
ÂStop ring Ý1EA
ÂShaftÝ 1EA
14078SM218/218A/B
Ι Put body(1) on a assembling jig, fix it with

bolts to prohibit moving.
14078SM219
8-63-8
Κ Using a compressing tool and steel stick,
assemble oil seal(2) into body(1).
ÂOil seal Ý1EA
14078SM220/220A
Λ Insert above shaft sub into body(1) and

assemble it with a steel stick.
14078SM211/211A
Μ Fix snap ring(4) to shaft with a plier jig.

ÂSnap ring Ý1EA
14078SM210/210A
Ν Spread grease on shoe plate(9) and

assemble on the body.
ÂShoe plate Ý1EA
14078SM222/209A
8-63-9
(2) Assemble the sub of cylinder block
assy
Η Assemble spring(11) 9 set into cylinder
block(10).
ÂSpring Ý9EA
11
14078SM208/208A
Θ Assemble ball guide(12) into cylinder.

ÂBall guide Ý1EA
12
14078SM207/207A
Ι Assemble piston assy(14) 9 set into set

plate(13).
ÂPiston assy Ý9EA
ÂSET plate Ý1EA
14
13
14078SM223/223A
Κ Assemble above item Θ and Ι.
14078SM224
8-63-10
Λ Assemble cylinder block assy into body
(1).
14078SM225
Μ Assemble O-ring(18) into body(1).

ÂO-ring Ý1EA
18
14078SM226/226A
Ν Assemble 3 set of plate(16), friction

plate(15) respectively into body.
ÂPlate Ý3EA
ÂFriction plate Ý3EA
16
15
14078SM227/205A
Ξ Assemble O-ring(19) into break piston

(17).
ÂO-ring Ý2EA
19
14078SM228/226A
8-63-11
Ο Insert break piston assy into body(1) and
compress it with a jig and hammer.
14078SM229/229A
Π Assemble spring(20)(20EA) into break

piston(17).
ÂSpring Ý20EA
20
14078SM230/230A
(3) Assemble the sub of rear cover assy

sub
Η Assemble the sub of make up check
valve assy.
Assemble O-ring(30), back up ring(29)
into plug(28) with a O-ring assembling jig.
ÂPlugÝ1EA
ÂBack up ringÝ1EA Jig
ÂO-ringÝ1EA 30 28
29
14078SM231/231A/B
Θ Assemble respectively make up check 28

valve assy spring(31), check(32),
plug(28) into rear cover(21) after then
screw it torque wrench.
ÂMake up check sub Ý2set
ÂSpring Ý2EA
ÂCheck Ý3EA 31
32
14078SM215/215A
8-63-12
Ι Assemble respectively plug(47), back up
ring, O-ring, O-ring, spring, anti-rotating
valve assy(34) into rear cover(21).
(Bilateral symmetry assembling)
ÂAnti-Inversion v/v assyÝ2set
ÂO-ring(P12)Ý2EA
ÂO-ring(P18)Ý2EA
ÂBack up ring(P18)Ý2EA
14078SM214/214A
Κ Assemble relief valve assy(33) 2set into

rear cover(21) with a torque wrench.
(Bilateral symmetry assembling)
33
14078SM213/213A
Λ Assemble plug(37), plug(40, 41) into rear

cover(21) with a L-wrench.
* PlugÝ3EA(PF1/4)
37
14078SM216/216A
Μ After assembling needle bearing(22) into

rear cover(21), with a hammer assemble
pin(8, 23).
* PinÝ1EA
* PinÝ2EA
14078SM212
8-63-13
Ν Spreading grease on valve plate(24),
assemble into rear cover(21).
ÂValve plateÝ1EA
24
14078SM212/212A
Ξ Lift up rear cover assy on body(1) by a

crane and assemble it with a wrench
bolt(27).
14078SM203/203A
Ο Assemble level gauge(44) into body(1). 44
14078SM202/202A
Π Assemble time delay valve assy(35) into

rear cover(21) with a wrench bolt(36).
35
14078SM01/201A
8-63-14
(4) Air pressing test
Be sure of leakage, after press air into
assembled motor
14078SM232
(5) Leakage check

After cleaning motor by color check No.1,
paint No.3 and be sure of leakage.
14078SM233/233A
(6) Mount test bench

Mounting motor test bench, test the
availability of each part.
220078SM14
8-63-15
GROUP 6 TRAVEL MOTOR

1) REMOVAL
(3) Loosen the breather slowly to release the 1-6(3) (200W-3)

2
1
(4) Loosen the socket bolt(1) and remove the
pipe assy(2,3). 3
(5) Disconnect hoses(4,5).
(6) Loosen the hex bolt(6) and remove travel
motor(7). 4
5
・Weight : 83kg(180lb) 6
7
※ When removing the travel motor 20W78TO01
assembly, check that all the hoses have

been disconnected.
2) INSTALL
to removal.
8-74
2. STRUCTURE
1) MOTOR UNIT
1 22 8 23 24 13 26 5 29 12
9 11 10 20 21 27 25 28 30 31 17 18 32 33
200W34TO02
1 Drive shaft 17 Threaded pin 26 Piston

5 Housing 18 Seal lock nut 27 Center pin
8 Locking screw 20 Retaining ring 28 Pan head screw
9 Retaining ring 21 Back up plate 29 Steel sealing ring
10 Shaft seal ring 22 Taper roller bearing 30 Cylinder block
11 Back up plate 23 Shim 31 Pressure spring
12 O-ring 24 Taper roller bearing 32 Adjustment shim
13 Locking screw 25 Retaining plate 33 Control lens
8-75
2) CONTROL UNIT
2
20 23 32
7 24
15
4
16 8
28
34 26 5
50
33
55
56
57
29 58
51
59
52
21 60
53 1
19 54
61
62
64 67 68 70 69 71
63
33
65 66
200W34TM03
1 Control housing 28 Double break off pin 59 Retaining ring

2 Cover 29 Plug 60 Control piston
4 Positioning piston 32 Double break off pin 61 Control bushing
5 Positioning trunnion 33 O-ring 62 Retaining disc
7 Piston 34 Locking screw 63 Locking screw
8 Threaded pin 50 Relief valve 64 Double break off pin
15 Socket head screw 51 Adjusting bushing 65 Double break off pin
16 Socket head screw 52 Cylinder pin 66 Socket head screw
19 O-ring 53 Threaded pin 67 Cover
20 O-ring 54 Seal lock nut 68 Throttle screw
21 O-ring 55 Pressure spring 69 Socket head screw
23 Socket head screw 56 Spring collar 70 O-ring
24 Square ring 57 Pressure spring 71 Locking screw
26 Cylinder pin 58 O-ring
8-76
3. TIGHTENING TORQUE
The torques given are standard figures. Any figures specifically described in the procedure has
priority.
Page Item Size kgf・m lbf・ft

8 M22 × 1.5 6.1 44
13 M26 × 1.5 7.1 51
8-75
18 M12 7.0 50.9
28 M 6 × 20 1.4 10.3
15 M16 × 45 21.4 155
23 M14 × 25 13.8 99.5
34 M18 × 1.5 4.0 29
53 M 6 × 30 1.4 10.3
8-76 54 M6 1.0 7.4
63 M14 × 1.5 3.0 22
66 M 8 × 40 2.5 18.4
69 M12 × 35 12.2 88.4
71 M14 × 1.5 3.0 22
8-77
1) GENERAL PRECAUTIONS
(1) 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.
(2) Assembly
① Reassemble in a work area that is clean and free from dust and grit.
② Handle parts with bare hands to keep them free of linty contanminats.
③ Repair or replace the damaged parts.
Each parts must be free of burrs its corners.
④ Do not reuse O-ring oil seal and floating seal that were removed in disassembly.
Provide the new parts.
⑤ Wash all parts thoroughly in a suitable solvent.
Dry thououghly 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.
8-78
2) SEAL KITS AND COMPONENT GROUPS
Observe the following notices when
carrying out repair work at hydraulic
aggregates.
14W7TM004
(1) Close all ports of the hydraulic aggregates.
14W7TM005
(2) Replace all seals.

Use only original hydromatik spare parts.
14W7TM006
(3) Check all seal and sliding surfaces for

wear.
※ Rework of sealing area f.ex. with abrasive
paper can damage surface.
14W7TM007
8-79
(4) Fill up hydraulic aggregates with hydraulic
oil before start up.
14W7TM008
(5) Seal kit for drive shaft
14W7TM009
(6) External seal kit.
14W7TM010
(7) Housing.
14W7TM011
8-80
(8) Complete rotary group.
14W7TM012
(9) Port plate with control piston.
14W7TM013
(10) Counter balance valve.
14W7TM014
(11) Relief valve / Make up check valve.
14W7TM015
8-81
3) SEAL NUT
(1) Replace seal nut.
First measure and record setting height.
14W7TM016
(2) When tightening, counterhold setting

screw, then check setting height.
14W7TM017
8-82
4) SEALING THE DRIVE SHAFT
20W78TO18
(1) Protecting the drive shaft.

Remove retaining ring and shim.
14W7TM019
(2) Screw in sheet metal screw into the holes

fitted with rubber.
Pull out seal with pliers.
14W7TM020
(3) Press in shaft seal and shim with bush to

stop.
Pay pattention to pressing depth.
* Mark for pressing depth.
Assemble retaining ring.
14W7TM021
8-83
5) SEALING OF THE CONTROL PARTS
20W78TO22
(1) Disassembly position

Remove cover 1.
14W7TM023
1 O-ring
2 Input flow of oil control
3 Throttle pin
※ Installation position differs according to the
control components.
14W7TM024
1 Input flow of oil control

2 High pressure / Low pressure
3 High pressure / Low pressure
5
4 Leckage oil
5 Control piston
14W7TM025
8-84
(2) Disassembly position : Remove cover 2.
※ Atttention spring load.
20W78TO26
※ Dimension X : Note dimension(Begin of

regulation)
14W7TM027
1 Check of O-ring
14W7TM028
1 O-ring / High pressure-small control

position side
2 O-ring / Control pressure
3 O-ring / High pressure-check valve
4 O-ring / High pressure-check valve
14W7TM029
8-85
6) SEALING OF THE RELIEF VALVE /
COUNTER BALANCE VALVE
・Remove counter balance valve
・Inspect
・O-ring
20W78TO32
(1) Remove relief valve
14W7TM030
(2) Inspect.
O-ring.
14W7TM031
8-86
7) DISASSEMBLY OF THE PORT PLATE
・Note dimension X
・Remove Qmin screw
・Swivel rotary group to zero P
X
Qmin screw
20W78TO33-33(2)
(1) Port plate.

Mark position. Loosen screws.
Removal.
14W7TM039
(2) Check O-ring.

※ Stick new O-ring with some grease.
Do not swivel rotary group.
Piston rings to hang out from the cylinder
boring.
14W7TM040
8-87
8) REMOVE OF THE POSITIONING PISTON
20W78TO041
(1) Loosen fixing screw.

Use only socket wrench.
14W7TM042
(2) Remove piston with piston ring.
14W7TM043
(3) Warm up fixation screw * for positioning

plug via boring(Screw glued-to turn out).
※ Use new screw.
Precote coating.
Note tightening torque.
14W7TM044
8-88
※ Stick control lens in sliding surface with
grease. Assembly in reversal order.
Mount port plate.
※ Rotary group vertical.
14W7TM045
9) REMOVE ROTARY GROUP
20W78TO34
(1) Screw in threaded pin into center pin.

Fix the cylinder with disc and locknut.
M8×105ℓ
14W7TM046
(2) Press out rotary group.

※ If the bearings are used again do not hit on
the drive shaft.
14W7TM047
8-89
10) EXCHANGING OF THE ROTARY GROUP
Complete rotary group
※ Setting of hydraulic part necessary.
20W78TO48
Rotary group
1 Mechanical part : Adjust drive shaft
with bearing 1
2 Hydraulic part : Adjustment necessary 2
*
20W78TO49
(1) Remove fixing screw(Cylinder).

Remove cylinder.
14W7TM050
(2) Disassemble retaining plate.

※ Screws are glued.
Use Torx tools.
14W7TM051
8-90
11) INSPECTION INSTRUCTIONS
(1) Free of corrosion, erosion or fretting; No
damage to splines or keyways.
14W7TM052
(2) Pistons
No scoring and no pittings.
14W7TM053
(3) Center pin

No scoring and no pittings.
14W7TM054
(4) Retaining plate

No scoring and no evidence of wear.
14W7TM055
8-91
(5) Cylinder block / Control lens
1 Bores free of scoring, no evidence of
wear
2 Faces smooth and even, free of cracks
and scoring
14W7TM056
(6) Control housing

Sliding surface and side guides free of
scoring and no wear.
14W7TM057
(7) Visual check

Bearing areas free of scoring and no
evidence of wear.
14W7TM058
8-92
12) ROTARY GROUP ASSEMBLY
(1) Rotary group completely assembled ready
for assembly.
14W7TM059
(2) Place assembly sleeve.
14W7TM059
(3) Warm up housing to 80°

C.
14W7TM059
(4) Insert rotary group into housing to seat

position.
14W7TM060
8-93
(5) Insert rotary group into housing to seat
position.
14W7TM060
(6) Fix zero position of cylinder with Qmax 2 1

screw.
1 Disassemble cylinder fixing screw
2 Insert O-ring
14W7TM060
13) ROTARY GROUP ADJUTMENT

(1) Determine cylinder swivel range to max
angle with screw.
14W7TM064
(2) * Disc
14W7TM065
8-94
(3) Place centering disc.
14W7TM066
(4) Mount measuring device.
14W7TM067
(5) Check dimension X.
14W7TM068
14) ASSEMBLY OF THE PORT PLATE

(1) Assemble port plate.
※ Take care of assembly design. *
Tighten fixing screws with torque.
(2) Set Qmin screw to dimension(*).
(3) Assemble plug.
(4) Remove assembly sleeve.
14W7TM069
8-95
(5) Assemble control components.
14W7TM070
(6) Assemble cover.
14W7TM071
(7) Assemble shaft seal, disc and safety ring.

Press in with assembly sleeve.
※ Take care of press in depth.
14W7TM072
(8) Assemble counter balance valve.
14W7TM073
8-96
GROUP 7 TRANSMISSION
1) REMOVAL
(1) Swing the work equipment 90¡£
and lower it
completely to the ground.
13031GE18
¡ When pipes and hoses are disconnected,
the oil inside the piping will flow out, so 1
3
(4) Remove the propeller shaft mounting
nuts(3).
¡⁄Tightening torque : 5.9¡ 0.6kgf¡⁄m
(42.7¡ 4.3lbf¡⁄ft) 3
4
(5) Remove the travel motor mounting bolt(2).
(214¡ 23.1lbf¡⁄ft)
2 20W78TM01
(6) Remove the hoses.
¡ Fit blind plugs to the disconnected hoses.
(7) Remove the mounting bolts(2), then
remove the transmission device assembly.
¡⁄Weight : 130kg(290lb)
(282¡ 30.4lbf¡⁄ft)
2) INSTALL
to removal.
(2) Bleed the air from the transmission.
¤ Remove the air vent plug.
¤Ł Pour in hydraulic oil until it overflows from
the port.
¤Ø Tighten plug lightly.
¤Œ Start the engine, run at low idling, and
¤º Tighten plug fully.
8-97
2. GENERAL INSTRUCTIONS
1) GENERAL WORKING INSTRUCTIONS
(1) This manual has been developped for the skilled serviceman, trained by manufacturer.
(2) During all operations, pay attention to cleanliness and skilled working.
Therefore,transmission removed from the machine must be cleaned prior to open them.
(3) We assume that the special tools, specified by manufacturer, will be used.
The special tools are available from manufacturer.
(4) After the disassembly, all components must be cleaned, especially corners, cavities and recesses
of housing and covers.
(5) The old sealing compound must be carefully removed.
(6) Check lubricating holes, grooves and pipes for free passage. They must be free of residues,
foreign material or protective compounds.
(7) The latter refers expecially to new parts.
(8) Parts which have been inevitably damaged in a disassembly operation, must be generally
replaced by new ones, e.g. rotary seal rings, O-rings, U-section rings, cap boots, protective caps
etc..
(9) Components such as roller bearings, thrust washers, synchronizing parts etc. which are subject to
normal wear in automotive operation, must be checked by the skilled Serviceman.
He will decide if the parts can be reused.
(10) For the heating of bearings etc., hot plates, rod heaters or heating furnaces must be used.
(11) Never heat parts directly with the flame. An auxiliary solution would be to immerse the bearing in
a vessel filled with oil, which is then heated with the flame.
In this way, damage to the bearings could be avoided.
(12) Ball bearings, covers, flanges and parts like that must be heated to about 90 to 100¡£
C.
(13) Hot-mounted parts must be reset after cooling in order to assure a proper contact.
(14) Before pressing shafts, bearings etc. in position, both parts must be lubricated.
(15) During to reassembly, all specified adjustment values, testing specifications and tightening torque
must be respected.
(16) After the repair, units are filled up with oil.
(17) After the oil filling, the oil level plugs and oil drain plugs must be tightened to the specified
tightening torque.
8-98
2) IMPORTANT INSTRUCTIONS CONCERNING THE LABOUR SAFETY
(1) In principle, repairers are themselves responsible for the labour safety.
(2) The observance of all valid safety regulations and legal rules is a precondition to prevent damage
to individuals and products during the maintenance and repair operations.
(3) Before starting the work, the repairers have to make themselves familiar with these regulations.
(4) The proper repair of these products requires especially trained personnel.
(5) The repairer himself is obliged to provide for the training.
3) LUBRICANT SPECIFICATIONS
(1) Engine oil : API CD/CE/CF/SF/SG
MIL-L-2104 C/D/E
MIL-L-4615 C/D/E
(2) SAE 10W-30, 15W-40
8-99
3. DISASSEMBLY
1) REMOVE SHIFTING CLUTCHES
(1) Fasten gearbox in the assembly car.
Loosen screw plug(Arrow) and drain oil.
20W78TM301
(2) Remove the two lines, see Arrows.
20W78TM02
(3) Remove locking screw, see Arrow.
20W78TM03
(4) Squeeze out snap ring(Arrow).
20W78TM04
8-100
(5) Loosen socket head screws evenly, install
two adjusting screws and separate drive
casing from the gearbox.
¡ Drive casing is spring-loaded.
20W78TM05
(6) Remove the two cup springs.
20W78TM06
(7) Close supply line(Arrow) and press piston

out of the housing bore, using
compressed air.
20W78TM07
(8) Remove screw plug and breather(Arrows).
20W78TM08
8-101
(9) Remove seal ring and back-up ring from
the ring groove of the housing(Arrow).
20W78TM09
(10) Squeeze out snap ring.
20W78TM10
(11) Pull gasket out of the housing bore, using

offset screw driver.
20W78TM11
(12) Remove O-ring(Arrow).
20W78TM12
8-102
(13) Remove plate pack and backing plate.
20W78TM13
(14) Squeeze out circlip(Arrow).
20W78TM14
(15) Remove clutch unit.
20W78TM15
(16) Fix sun gear axially by means of assembly

jig, squeeze out circlip and relax the cup
spring pack.
20W78TM16
8-103
(17) Remove released disk and sun gear.
20W78TM17
(18) Separate internal gear from drive shaft.
20W78TM18
(19) Squeeze out circlip and remove centering

disk.
20W78TM19
(20) Remove plate pack.
20W78TM20
8-104
(21) Remove plate.
20W78TM21
(22) Pry inner plate carrier out of the piston.
20W78TM22
(23) Pry off piston from the drive shaft.
20W78TM23
(24) Remove cup spring pack.
20W78TM24
8-105
(25) Remove seal ring and O-ring.
Remove disk(Arrow).
¡ Renew sealing components at any rate.
20W78TM25
(26) Squeeze out circlip.
20W78TM26
(27) Remove circlip from the ring groove of the

guide bush(¤“85mm).
20W78TM27
(28) Separate guide bush from drive shaft.
20W78TM28
8-106
(29) Squeeze out snap ring and remove shaft
seal(Arrow).
20W78TM29
(30) Squeeze out circlip and press bearing

from shaft.
20W78TM30
(31) Remove throttle valve.
20W78TM31
8-107
2) REMOVE AND DISASSEMBLE
PLANETARY DRIVE
(1) Squeeze out circlip(Arrow).
20W78TM32
(2) Tilt housing for 90¡£

.
Separate and remove planetary carrier
from helical gear, using internal puller.
20W78TM33
20W78TM34
(4) Pry off planetary gear from planetary

shaft, using offset screw driver.
Remove released components.
20W78TM35
8-108
(5) Pull off bearing inner race.
20W78TM36
(6) Squeeze out circlip and remove ball

bearing.
20W78TM37
3) REMOVE AND DISASSEMBLE DECLUTCH

UNIT AND SPUR GEAR
(1) Loosen hex head screw(shift lever
locking) and remove sliding collar along
with sliding blocks.
20W78TM38
(2) Loosen screw plug.
20W78TM39
8-109
(3) Drive out roll pin(Arrow).
20W78TM40
(4) Pry shift lever out of the housing bore and

remove released shift fork.
20W78TM41
(5) Remove suction line.
20W78TM42
(6) Loosen socket head screws and separate

shift lock from housing.
20W78TM201
8-110
20W78TM202
(8) Remove pump shaft.
20W78TM203
20W78TM43
(10) Pry off helical gear and take it out of the

housing.
20W78TM44
8-111
20W78TM45
(11) Squeeze out circlip and remove shim.
20W78TM46
(12) Remove shift dog and spacer.

¡ According to the design, with or without
spacer, see Parts manual.
20W78TM47
(13) Pull needle bearing out of the housing

bore, using internal puller.
20W78TM48
8-112
(14) Press helical gear from bearing cap.
20W78TM49
(15) Squeeze out circlip and press ball bearing

out of the bearing cap.
20W78TM50
20W78TM51
(17) Pry off ball bearing from helical gear collar.
20W78TM52
8-113
4) DISASSEMBLE FINAL DRIVE(Separate
gearbox installation)
(1) Unlock and loosen hex head screws and
remove output flange.
20W78TM53
(2) Pry shaft out of the housing bore.
20W78TM54
(3) Tilt housing 180¡£

.
Unlock and loosen hex head screws and
remove output flange.
20W78TM55
(4) Remove shaft seal.
20W78TM56
8-114
(5) Loosen hex head screws.
20W78TM57
(6) Separate output gear along with cover

from the gear case, using hoist.
20W78TM58
(7) Press output gear out of the bearing cap,

reps. out of the ball bearing.
20W78TM59
(8) Remove oil baffle plate.
20W78TM60
8-115
20W78TM61
(10) Press ball bearing out of the bearing bore.
20W78TM62
(11) Remove oil baffle plate.
20W78TM63
(12) Drive ball bearing out of the bearing bore.
20W78TM64
8-116
5) DISASSEMBLE ALUMINUM DIE-CAST
GEAR BOX CONTROL
(1) Separate oil pipe as well as hose lines
from the cover.
20W78TM65
(2) Loosen socket head screws(4EA, see

Arrows) and separate shift lock from
transmission case.
20W78TM66
(3) Loosen all hex head screws and separate

cover as well as gasket from the case.
20W78TM67
(4) Loosen hex head screws and separate

pump cover from the case.
20W78TM68
8-117
(5) Pull internal rotor(Arrow) from the pump
shaft.
20W78TM69
(6) Remove the ball(position see Arrow) and

pull the control case along with the
external rotor from the pump shaft.
¡ Pay attention to the released balls and
compression springs.
20W78TM70
(7) Remove the pump shaft.
20W78TM71
(8) Pull needle cage out of the case bore.
20W78TM72
8-118
(9) Remove check valves and spool.
¡ Mark the installation position of the single
check valves.
20W78TM73
8-119
4. ASSEMBLY
1) REASSEMBLE ALUMINUM DIE-CAST GEAR
BOX CONTROL
(1) Wet contact surface of the orifice with
loctite and insert orifice until contact is
obtained.
Now, clean the orifice by means of
compressed air from loctite residues.
20W78TM74
(2) Install needle cage.

¡ By application of the prescribed drift, the
required installation depth of 0.2 + 0.5mm
is obtained.
install the needle cage with the reinforced
shell facing the pressing tool.
20W78TM75
(3) Install gasket(composed of plastic ring

and O-ring).
Insert O-ring(Arrow) into the annular
groove of the spool.
Guide the plastic ring by means of
installer(S) over the spool and position it
on the O-ring.
20W78TM76
(4) Calibrate plastic ring by means of bush

(S).
20W78TM77
8-120
(5) Install components according to the
illustration.
¡ Pay attention to the installation position of
the different check valves.
Oil components.
1 Check valve 1.0kg¡⁄m
2 Compression spring
3 Spool
4 Screw plug 5.1kg¡⁄m
5 Seal ring 20W78TM78
6 Screw plug 2.0kg¡⁄m
9 Pressure limiting valve 1.0kg¡⁄m
20W78TM79
¡ Equip all check valves as well as pressure

limiting valves with new O-rings.
Secure check valves and pressure limiting
valves(items 1, 7, 8 and 9) by
centerpunching each of them twice.
Pre-assemble pump cover according to
the illustration.
20W78TM80
(6) Insert compression spring(1) and balls(2)

with grease into the bores(Arrows) of the
pump cover.
20W78TM81
8-121
(7) Oil pump.
¡ The rotor set(Composed of control case,
external and internal rotor) may be
exchanged only completely.
Assemble control case along with the
external rotor.
20W78TM82
(8) Insert ball with grease into the

countersinking of the pump shaft(Arrow)
and assemble the internal rotor.
¡ The drive of the internal rotor is realized by
the ball.
Pay attention to the exact installation
position.
20W78TM83
(9) Insert pre-assembled pump cover into the

case bore and fasten it by means of hex
head screws(M6).
¡ Oil the rotor set.
¡⁄Tightening torque : 0.97kgf¡⁄m(7.0lb¡⁄ft)
20W78TM84
20W78TM85
8-122
(10) Insert O-ring into the annular groove
(Arrow) and grease it.
20W78TM86
(11) Install both adapters as well as the

threaded socket.
¡ Install new O-rings.
¡⁄Tightening torque(Adapter) : 2.5kgf¡⁄m
(18lbf¡⁄ft)
¡⁄Tightening torque(Threaded socket) :
3.6kgf¡⁄m(26.0lbf¡⁄ft)
20W78TM87
(12) Install two adjusting screws(M8).

Assemble gasket and cover.
20W78TM88
(13) Fasten cover by means of hex head

screws(Mount flat washers).
20W78TM89
8-123
(14) Introduce pump shaft until the splines are
engaged.
20W78TM90
(15) Install two adjusting screws and place the

shift lock against the transmission case
until contact is obtained.
Adjusting screw(M8).
20W78TM91
(16) Fasten the shift lock on the transmission

case, using socket head screws(mount
flat washers).
¡⁄Tighten torque : 2.3kgf¡⁄m(17.0lb¡⁄ft)
20W78TM92
(17) Install oil pipe as well as hose lines

(Arrows) according to the figure.
¡ Before the unit is put into service, pay
attention to the instructions for operation
and maintenance.
20W78TM93
8-124
2) REASSEMBLE FINAL DRIVE
(1) Undercool ball bearing and insert it firmly
against shoulder.
20W78TM94
(2) Insert baffle plate firmly against shoulder.

¡ Pay attention to the radial installation
position.
20W78TM95
(3) Undercool ball bearing and insert it in the

bore of the bearing cap until contact is
obtained.
20W78TM96
(4) Fix ball bearing by means of circlip.
20W78TM97
8-125
(5) Install oil baffle plate.
position.
20W78TM98
(6) Press bearing cap upon the short side of

the output gear.
¡ To avoid a damage to the ball bearing,
apply pressing sleeve(Arrow) on the
bearing inner race.
20W78TM99
(7) Insert O-ring(Arrow) in the ring groove and

grease it.
20W78TM100
(8) Heat ball bearing, install two adjusting

screws and assemble bearing cap until
contact is obtained.
20W78TM101
8-126
20W78TM102
(9) Fasten bearing cap by means of hex head

screws(M12).
20W78TM103
(10) Install shaft seal.

¡ By application of the prescribed driver, the
exact installation position is obtained.
If the outer diameter is rubber-coated, wet
the sealing surface with spirit.
Otherwise, use sealing compound(Curil
T).
Fill cavity between sealing lip and dust lip
with grease.
20W78TM104
(11) Insert hex head screws in the bores of the

output flange and press dust plate (Arrow)
against shoulder.
Pre-assemble the opposite output flange
accordingly.
20W78TM105
8-127
(12) Assemble output flange.
Grease O-ring and insert it in the gap of
output flange/output gear.
20W78TM106
(13) Mount washer and fix output flange by

means of hex head screws(M10).
20W78TM107
(14) Fix hex head screws by means of lock

plate.
20W78TM108
(15) Tilt gear case 180¡£.

Install shaft seal.
exact installation position is obtained.
If the outer diameter is rubber-coated, wet
the sealing surface with spirit.
Otherwise, use sealing compound(Curl T).
Fill cavity between sealing lip and dust lip
with grease.
20W78TM109
8-128
(16) Assemble output flange.
Grease O-ring and insert it in the gap of
output flange/output gear.
20W78TM110
(17) Mount washer and fasten output flange by

means of hex head screws.
Now, fix hex head screws(M10) by means
of lock plate(Arrow).
20W78TM111
8-129
3) REASSEMBLE HELICAL GEAR AND
DECLUTCH UNIT
(1) Insert ball bearing into the bearing cover
until contact is obtained and fix with circlip.
20W78TM112
(2) Press ball bearing over the collar of the

helical gear until contact is obtained and
fix by means of circlip.
20W78TM113
(3) Press bearing cover(Ball bearing) firmly

against shoulder with the circlip showing
toward above.
20W78TM114
(4) Install spacer and shift dog.

¡ According to the design with or without
spacer, see corresponding Parts manual.
20W78TM115
8-130
(5) Fix shift dog by means of shim and circlip.
¡ Pay attention to the permissible end play
max. 0.1mm.
20W78TM116
(6) Press needle bearing firmly against

shoulder.
¡ Pay attention to the installation position-
designation showing upward.
20W78TM117
(7) Insert pre-assembled helical gear into the

housing bore.
20W78TM118
(8) Fix bearing cover by means of circlip, see

Arrow.
20W78TM119
8-131
(9) Figure on the left shows the components
of the shift dog assembly.
20W78TM120
(10) Squeeze in circlip(1) and install O-ring(2).
20W78TM121
(11) Insert shift fork and sliding collar.
20W78TM122
(12) Introduce shift shaft until contact is

obtained.
20W78TM123
8-132
(13) Align shift shaft radially and fix it by driving
the roll pin in until it is flush.
20W78TM124
(14) Install screw plug(M22¡¿1.5).

¡ Mount new O-ring.
20W78TM125
4) COMPLETE AND INSTALL PLANETARY

CARRIER
(1) Pre-assemble planetary gear.
¡ Install cylindrical rollers with grease.
(2) Press pre-assembled planetary gears 20W78TM126
firmly against shoulder.
20W78TM127
8-133
(3) Install collar shim and circlip.
20W78TM128
(4) Insert ball bearing firmly against shoulder

and fix with circlip.
20W78TM129
(5) Heat ball bearing and mount planetary

carrier until contact is obtained.
20W78TM130
(6) Fix planetary carrier with circlip(Arrow).
20W78TM131
8-134
Adjust declutch unit
(7) Assemble shift lever and fix it provisionally
in the "OFF-Position3" by means of hex
head screw(Arrow).
20W78TM132
(8) Bring shift shaft by clockwise rotation to

the stop, using auxiliary screw(M8) and
jam shift lever by means of socket head
screw(M10) and flat washer.
20W78TM133
(9) Now, bring shift lever in "ON-Position"

(Arrow) and fasten by means of hex head
screw(M10).
20W78TM134
5) PREASSEMBLE AND INSTALL CLUTCH

(Road gear)
(1) Press ball bearing firmly against shoulder
and fix it by means of circlip.
20W78TM135
8-135
(2) Squeeze in the two rectangular rings
(Arrows) and engage them.
20W78TM136
(3) Install shaft seal.

exact installation depth is given. Wet
outer diameter of shaft seal with spirit.
Grease the sealing lip.
20W78TM137
(4) Fix shaft seal by means of snap ring.
20W78TM138
(5) Grease the two rectangular rings, align

them centrically and press the drive shaft
into the guide sleeve until contact is
obtained.
20W78TM139
8-136
(6) Fix sleeve by means of circlip.
20W78TM140
(7) Squeeze in circlip(Arrow) and replace

back-up plate, with the offset plane
surface showing upwards.
¡ Only installation of one new circlip
admitted.
20W78TM141
(8) Determine adjustment value "B", follow (9)

to (13).
¡⁄Adjustment value B with 11 plate pairs
= 7.8+0.2mm
20W78TM142
(9) Replace piston.
20W78TM143
8-137
(10) Assemble plate carrier and tap it against
shoulder until contact is obtained.
20W78TM144
20W78TM145
(11) Mount plate.
20W78TM146
(12) Assemble alternating plate pack, starting

with one inner plate.
¡ Number of inner and outer plates, see
corresponding list of parts manual.
For the moment, install the plate pack
without oil.
20W78TM147
8-138
(13) Determine dimension B from the end face
of the inner plate carrier to the outer plate.
¡⁄Dimension B e.g. : 7.5mm
¡ Carry out any corrections by means of the
corresponding outer plates(s = 1.0, 1.2,
1.4 or 1.8mm).
20W78TM148
(14) Determine adjustment value "D".

¡ The end play of plate carrier, ball bearing
and sun gear is determined by means of
the shim.
Max end play admitted 0.1mm.
Install ball bearing and sun gear.
20W78TM149
(15) Assemble shim(s = 3.0~3.9mm, see

Arrow), fix it by means of circlip and check
end play.
Now, squeeze out circlip again and
remove the components again, up to the
piston included.
20W78TM150
(16) Squeeze circlip into the ring groove

(Arrow) with the sealing lip facing the
pressure chamber(toward above).
¡ Use installer.
Grease sealing lip.
20W78TM151
8-139
(17) Install O-ring, see Arrow.
¡ Grease O-ring.
20W78TM152
(18) Pile cup springs according to the figure.
20W78TM153
(19) Assemble piston.
20W78TM154
(20) Install seal ring(Arrow) with the sealing lip

facing the pressure chamber(Toward
below) and insert the inner plate carrier
against shoulder, until contact is obtained.
¡ Grease seal ring.
20W78TM155
8-140
(21) Mount plate.
20W78TM156
(22) Assemble plate pack alternating, starting

with one inner plate.
¡ Number of inner and outer plates see
corresponding parts manual.
Oil plates prior to the installation.
20W78TM157
(23) Insert ball bearing into the centering disk

and fix by means of circlip.
20W78TM158
(24) Insert centering disk into the internal gear

bore and fix by means of circlip.
20W78TM159
8-141
(25) Align outer plates radially and assemble
internal gear until all plates are located.
20W78TM160
(26) Assemble sun gear.

¡ Pay attention to the installation position,
see figure.
20W78TM161
(27) Mount determined shim.
20W78TM162
(28) Preload cup spring pack by means of

assembly jig and squeeze in circlip.
¡ Installation of a new circlip admitted only.
20W78TM163
8-142
Check tightness and function of the clutch
(29) Install hydraulic connection.
20W78TM164
(30) Ventilate the piston area by repeated
filling. Build up test pressure p=35bar and
close connection to HP-Pump by means
of shutoff valve.
During a test period of 3 minutes no
pressure drop is admitted.
20W78TM165
(31) Remove pressure connection and install
throttle valve.
¡ Install new O-rings, see Arrows.
20W78TM166
(32) Introduce pre-assembled clutch.
20W78TM167
8-143
(33) Squeeze in circlip(190¡¿4).
20W78TM168
6) INSTALL BRAKE(Cross-country gear)

(1) Insert backing plate.
20W78TM169
Determine adjustment dimension "A = 1.4
+ 0.2mm" following (2) to Example "E".
(2) Assemble alternating plate pack, starting
with one outer plate.
¡ Number of outer and inner plates, see
corresponding parts manual.
Oil the plates.
20W78TM170
(3) Insert piston firmly against shoulder.
20W78TM171
8-144
(4) Insert the two cup springs and align them
centrically.
¡ Pay attention to the installation position,
see figure.
20W78TM172
(5) Assemble measuring cover and pull it

evenly against shoulder, using 4 socket
head screws(M12).
20W78TM173
(6) Determine dimension ¥ form the plane

surface of the measuring cover to the
plane surface/piston.
¡⁄Dimension ¥ e.g. : 32.60mm
Example D
¡⁄Dimension 32.60mm
¡⁄Manufacturing dimension
measuring cover -20.00mm
¡⁄Difference = Dimension X 12.60mm
¡ The manufacturing dimension is stamped 20W78TM174
on the measuring cover and is principally
20.00mm.
(7) Measure dimension Y from the locating
face of the drive casing to the flange-
mounted surface.
¡⁄Dimension Y e.g. : 11.10mm
Example E
¡⁄Dimension X 12.60mm
¡⁄Dimension Y -11.10mm
¡⁄Difference¡ adjustment value =1.50mm
¡ Carry out possible corrections with
corresponding outer plates(s=3.0, 3.2, 3.5). 20W78TM175
Now, take off the measuring cover and
remove the piston again.
8-145
(8) Insert O-ring in the ring groove of the
housing, see Arrow.
¡ Expand O-ring slightly prior to the
reassembly to ensure a perfect contact in
the recess.
20W78TM176
(9) The Draft on the right shows the

installation position of the disk, the piston
and its sealing components.
1 Drive casing
2 Clutch disk housing
3,4 Gasket(Back up and U-section ring)
5 Circlip
6 O-ring
7 Disk
8,9 Gasket(U section and back up ring) 20W78TM177
10 Piston
11 Cup springs
12 O-ring
(10) Insert back-up and U-section ring in the

ring groove(Arrow) and oil them
Insert disk until contact is obtained.
¡ Pay attention to the installation position.
20W78TM178
(11) Fix disk by means of snap ring.
20W78TM179
8-146
(12) Insert back-up ring and seal ring in the
ring groove of the housing(Arrow) and oil
them.
Assemble piston and place it evenly
against shoulder, using measuring cover
as well as socket head screws. Now,
remove measuring cover again.
20W78TM180
20W78TM181
(13) Insert the two cup springs and align them

centrically.
¡ Pay attention to the installation position.
20W78TM182
7) INSTALL DRIVE CASING

(1) Insert O-ring(Arrow 1) in the
countersinking.
Insert the two O-rings in the ring grooves
of the guide sleeve, see Arrows.
¡ Grease O-rings.
20W78TM183
8-147
(2) Insert O-ring into the ring groove of the
drive casing and grease.
20W78TM184
(3) Align guide bush radially.
20W78TM185
(4) Assemble drive casing.

¡ Pay attention to a radial installation
position.
20W78TM186
(5) Pull drive casing evenly against shoulder,

using socket head screws(M12).
20W78TM187
8-148
(6) Pull drive shaft, resp. guide bush out of
the housing bore, using internal puller,
until snap ring(Nominal width = 95mm) can
be engaged.
20W78TM188
(7) Fix guide bush radially by means of screw

plug, see Arrow.
¡ Install new CU-ring.
20W78TM189
(8) Insert gasket, composed of O-ring and

Turcon-ring into the ring groove of the
piston and grease.
¡ Heat Turcon-ring in an oil bath prior to the
installation.
Use installer.
Pay attention to the installation position,
see figure.
20W78TM190
(9) Insert pre-assembled piston and spring

into the housing bore and fix with screw
plug.
¡ Employ new O-ring for screw plug.
20W78TM191
8-149
(10) install breather(Arrow 1) and screw plug
(Arrow 2).
¡ Employ new O-ring for screw plug.
20W78TM192
(11) Install the two screw plugs(1) and shear-

off plugs(2).
Check tightness and function of the
brake(Cross-country gear).
Install hydraulic connection.
20W78TM193
(12) Ventilate piston chamber by filling it

several times.
Build up test pressure p=35bar and close
connection to HP-Pump by means of
shut-off valve.
During a Test of 3 minutes, no pressure
drop is admitted.
20W78TM194
(13) Remove the hydraulic connection and

install the throttle valve.
¡ Install new O-rings(Arrows).
20W78TM195
8-150
8) MOUNT SCREW PLUGS AND OIL LINES
(1) Mount suction pipe
20W78TM199
(2) Install connecting plug(Arrow 1, M10) and

screw plug(Arrow 2, M14).
¡⁄Tightening torque : 1 - 2.5kgf¡⁄m
(18.4lb¡⁄ft)
2 - 3.6kgf¡⁄m
(25.8lb¡⁄ft)
¡ Install new O-rings.
Different position of connecting piece and
screw plug according to the Version.
20W78TM196
(3) Install delivery lines.
20W78TM197
(4) Install screw plugs(M26¡¿1.5), see

Arrows.
¡ Before the transmission is put into service,
pay attention to the lubrication and
maintenance instructions.
20W78TM198
8-151
GROUP 8 STEERING VALVE

1) REMOVAL

(4) Disconnect steering line hoses(3). 3
2
(5) Loosen the hexagon bolt(2) and remove
the steering valve assembly(1).
・Tightening torque : 4.8± 0.3kgf・m
3
(34.7± 2.2lbf・ft) 1
2) INSTALL
140W78SV01
to removal.
※ When removing the steering valve
assembly, check that all the hoses
have been disconnected.
8-152
2. STEERING VALVE
1) STRUCTURE
26
26
2
25
2
1
24
27
29
5
2 6
7
9
3 8
2 4
2
12
2
11
10
13
14
15
16 18
21
15
16
17
18
20
20W78SV02
1 Dust seal ring 10 Spacer 18 Washer

2 *Housing assy 11 Shaft 20 Pin screw
3 Ball 12 Spring set 21 Screw
4 Bushing 13 O-ring 24 Relief valve assy
5 O-ring 14 Distributor plate 25 Wire spring
6 Kin ring 15 Gear wheel set 26 Shock valve
7 Bearing assy 16 O-ring 27 Ball
8 Ring 17 End cover 29 Suction valve pin
9 Cross pin
* Housing, spool and sleeve(Check valve and the seats for relief and dual shock valves are loctited).
8-153
2) TOOLS
(1) Holding tool.
2-1 (200W-3)
(2) Assembly tool for O-ring(5,13,16) and kin-

ring(6).
2-2 (200W-3)
(3) Assembly tool for cardan shaft(11).
3-1 (200W-3)
(4) Assembly tool for dust seal(1).
3-2 (200W-3)
8-154
(5) Torque wrench : 0~7.1kgf・m
(0~54.4lbf・ft).
13mm socket spanner.
6, 8mm and 12mm hexagon sockets.
12mm screwdriver.
2mm screwdriver.
13mm ring spanner.
6, 8mm and 12mm hexagon socket
spanners.
3-3 (200W-3)
Plastic hammer.
Tweezers.
8-155
3) TIGHTENING TORQUE AND HYDRAULIC CONNECTIONS
(1) Hydraulic connections
L : Left port
R : Right port
T : Tank
P : Pump
17038SV03

Max. tightening torque kgf・m(lbf・ft)
Screwed
connection With cutting With copper With aluminum
With O-ring
edge washer washer
1.4 BSP.F 4.1(29.7) 2.0(14.5) 3.1(22.4) -
3/8 BSP.F 6.1(44.1) 2.0(14.5) 5.1(36.9) -
1/2 BSP.F 10.2(73.8) 3.1(22.4) 8.2(59.3) -
7/16-20 UNF - - - 2.0(14.5)
3/4-16 UNF - - - 6.1(44.1)
M12×1.5 4.1(29.7) 2.0(14.5) 3.1(22.4) 2.0(14.5)
M18×1.5 7.1(51.4) 2.0(14.5) 5.1(36.9) 5.1(36.9)
M22×1.5 10.2(73.8) 3.1(22.4) 8.2(59.3) 7.1(51.4)
8-156
4) DISASSEMBLY
(1) Dissemble steering column from steering
valve and place the steering valve in the
holding tool.
Screw out the screws in the end cover(6-
off plus one special screw).
4-1 (200W-3)
(2) Remove the end cover, sideways.
4-2 (200W-3)
(3) Lift the gearwheel set(with spacer if fitted)

off the unit.
Take out the two O-rings.
4-3 (200W-3)
(4) Remove cardan shaft.
5-1(200W-3)
8-157
(5) Remove distributor plate.
5-2 (200W-3)
(6) Screw out the threaded bush over the

check valve.
5-3 (200W-3)
(7) Remove O-ring.
5-4 (200W-3)
(8) Shake out the check valve ball and

suction valve pins and balls.
6-1 (200W-3)
8-158
(9) Take care to keep the cross pin in the
sleeve and spool horizontal. The pin can
be seen through the open end of the
spool. Press the spool inwards and the
sleeve, ring, bearing races and needle
bearing will be pushed out of the housing
together.
6-2 (200W-3)
(10) Take ring, bearing races and needle

bearing from sleeve and spool. The
outer(thin)bearing race can sometimes
"stick" in the housing, therefore check that
it has come out.
6-3 (200W-3)
(11) Press out the cross pin. Use the special

screw from the end cover.
6-4 (200W-3)
※ A small mark has been made with a

pumice stone on both spool and sleeve
close to one of the slots for the neutral
position spring as figure.
If the mark is not visible, remember to
leave a mark of your own on sleeve and
spool before the neutral position springs
are disassembled.
7-1 (200W-3)
8-159
(12) Carefully press the spool out of the sleeve.
7-2 (200W-3)
(13) Press the neutral position springs out of

their slots in the spool.
7-3 (200W-3)
(14) Remove dust seal and O-ring/kin ring.
7-4 (200W-3)
8-160
(15) Disassemble the dual shock valve
① Remove plugs from shock valves using a
6mm hexagon socket spanner.
8-1 (200W-3)
② Remove seal washers(2-off).
8-2 (200W-3)
③ Unscrew the setting screws using a 6mm

hexagon socket spanner.
8-3 (200W-3)
④ Shake out the two springs and two valve

balls into your hand. The valve seats
are bonded into the housing and cannot
be removed.
9-1 (200W-3)
8-161
⑤ The dual shock valves are now disasse-
mbled.
9-2 (200W-3)
8-162
(16) Disassemble the pressure relief valve
(cartridge)
① Screw out the plug using an 8mm
hexagon socket spanner. Remove seal
washers.
9-3 (200W-3)
② Unscrew the setting screw using an 8mm

hexagon socket spanner.
10-1 (200W-3)
③ Shake out spring and piston. The valve

seat is bonded into the housing and
cannot be removed.
10-2 (200W-3)
④ The pressure relief valve is now disasse-

mbled.
10-3 (200W-3)
8-163
⑤ The steering valve is now completely
disassembled.
12-1 (200W-3)
※ Cleaning
Clean all parts carefully in shellsol K or
the like.
※ Inspection and replacement
Replace all seals and washers. Check
all parts carefully and make any
replacements necessary.
※ Lubrication
Before assembly, lubricate all parts with
hydraulic oil.
8-164
5) ASSEMBLY
(1) Assemble spool and sleeve.
When assembling spool and sleeve only
one of two possible ways of positioning
the spring slots is correct. There are three
slots in the spool and three holes in the
sleeve in the end of the spool / sleeve
opposite to the end with spring slots.
Place the slots and holes opposite each 14-1 (200W-3)
other so that parts of the holes in the
sleeve are visible through the slots in the
spool.
(2) Place the two flat neutral position springs

in the slot.
Place the curved springs between the flat
ones and press them into place(see
assembly pattern).
14-2 (200W-3)
※ Assembly pattern.
・Part no : 150N4035
14-3 (200W-3)
(3) Line up the spring set.
14-4 (200W-3)
8-165
(4) Guide the spool into the sleeve. Make
sure that spool and sleeve are placed
correctly in relation to each other.
15-1 (200W-3)
(5) Press the springs together and push the

neutral position springs into place in the
sleeve.
15-2 (200W-3)
(6) Line up the springs and center them.
15-3 (200W-3)
(7) Guide the ring down over the sleeve.

※ The ring should be able to rotate free of
the springs.
15-4 (200W-3)
8-166
(8) Fit the cross pin into the spool / sleeve.
16-1 (200W-3)
(9) Fit bearing races and needle bearing as

shown on below drawing.
16-2 (200W-3)
※ Assembly patted for standard bearings 1

1 Outer bearing race
2
2 Needle bearing
3
3 Inner bearing race
4 Spool
5 Sleeve 4
16-3 (200W-3)
Installation instruction for O-ring/Kin-ring

(10) Turn the steering unit until the bore is
horizontal. Guide the outer part of the
assembly tool into the bore for the spool /
sleeve.
17-1 (200W-3)
8-167
(11) Grease O-ring and kin-ring with hydraulic
oil and place them on the tool.
18-1 (200W-3)
18-2 (200W-3)
(12) Hole the outer part of the assembly tool in

the bottom of the steering unit housing
and guide the inner part of the tool right to
the bottom.
18-3 (200W-3)
(13) Press and turn the O-ring / kin-ring into

position in the housing.
18-4 (200W-3)
8-168
(14) Draw the inner and outer parts of the
assembly tool out of the steering unit bore,
leaving the guide from the inner part in the
bore.
18-5 (200W-3)
(15) With a light turning movement, guide the

spool and sleeve into the bore.
※ Fit the spool set holding the cross pin
horizontal.
20-1 (200W-3)
(16) The spool set will push out the assembly

tool guide. The O-ring and kin-ring are
now in position.
20-2 (200W-3)
(17) Turn the steering unit until the bore is

vertical again. Put the check valve ball
into the hole indicated by the arrow.
20-3 (200W-3)
8-169
(18) Screw the threaded bush lightly into the
check valve bore. The top of the bush
must lie just below the surface of the
housing.
20-4 (200W-3)
Assembly of the two suction valve

(19) Place a ball in the two holes indicated by
the arrows.
21-1 (200W-3)
(20) Place a pin in the same two holes.
21-2 (200W-3)
(21) In some cases a spring has to be fitted on

the pin before it is placed in the housing.
21-3 (200W-3)
8-170
(22) Grease the O-ring with mineral oil approx
viscosity 500 cST at 20°
C.
22-1 (200W-3)
(23) Place the distributor plate so that the

channel holes match the holes in the
housing.
22-2 (200W-3)
(24) Guide the cardan shaft down into the bore

so that the slot is parallel with the
connection flange.
22-3 (200W-3)
(25) Place the cardan shaft as shown so that it

is held in position by the mounting fork.
22-4 (200W-3)
8-171
(26) Grease the two O-rings with mineral oil
approx. viscosity 500 cST at 20° C and
place them in the two grooves in the gear
rim. Fit the gearwheel and rim on the
cardan shaft.
23-1 (200W-3)
(27) Fit the gearwheel(rotor) and cardan shaft

so that a tooth base in the rotor is
positioned in relation to the shaft slot as
shown. Turn the gear rim so that the
seven through holes match the holes in
the housing.
23-2 (200W-3)
(28) Fit the spacer, if any.
23-3 (200W-3)
(29) Place the end cover in position.
23-4 (200W-3)
8-172
(30) Fit the special screw with washer and
place it in the hole shown.
24-1 (200W-3)
(31) Fit the six screws with washers and insert

them. Cross-tighten all the screws and
the rolled pin.
・ tightening torque : 3.0±0.6kgf・m
(22.4±4.3lbf・ft)
24-2 (200W-3)
(32) Place the dust seal ring in the housing.

The dust seal ring must be placed only
after the pressure relief valve and shock
valves have been fitted.
24-3 (200W-3)
(33) Fit the dust seal ring in the housing.
24-4 (200W-3)
8-173
(34) Press the plastic plugs into the connection
ports.
※ Do not use a hammer!
25-1 (200W-3)
Assembly of the pressure relief valve

(35) Fit the piston.
25-2 (200W-3)
(36) Fit the spring.
25-3 (200W-3)
(37) Screw in the setting screw with an 8mm

hexagon socket spanner. Make the
pressure setting on a panel or the
machine.
26-1 (200W-3)
8-174
(38) Screw plug with dust seal into the housing
using an 8mm hexagon socket spanner.
・ tightening torque : 5.1±1kgf・m
(36.9±7.2lbf・ft)
26-2 (200W-3)
Assembly of the dual shock valve

(39) Put a ball in the two holes indicated by the
arrows.
27-1 (200W-3)
(40) Place springs and valve cones over the

two balls.
27-2 (200W-3)
(41) Screw in the two setting screws using a

6mm hexagon socket spanner. Make the
pressure setting on a panel or the
machine.
28-1 (200W-3)
8-175
(42) Screw plug with seal ring into the two
shock valves using a 6mm hexagon socket
spanner.
・ Tightening torque : 3.1kgf・m
(22.4lbf・ft)
Steering valve is now assembled. 28-2 (200W-3)
8-176
GROUP 9 FRONT AXLE
1. REMOVAL FRONT AXLE

1) Propeller shaft mounting nut(1, M10)
(42.7¡ 4.3lbf¡⁄ft)
2) Wheel nut(2, M22) LOWER
FRAME
+0
¡⁄Tightening torque : 60 -5 kgf¡⁄m
+0
(434 -36 lbf¡⁄ft)
3) Oscillating cylinder supporting mounting 4
bolt(3, M16)
3
(214¡ 23.1lbf¡⁄ft)
4) Pipe assy(4) 5
5) Hose assy(5) PROPELLER

SHAFT
6) Front axle weight : 640kg(1410lb) 1

FRONT
AXLE TIRE
20W78AX01
8-177
(1) This manual has been developed for the skilled serviceman, trained by the axle manufacturer.
Therefore, axle removed from the machine, must be cleaned prior to open them.
(4) The special tools have 10 digit subject numbers and are available from manufacturer.
(5) After the disassembly, all components must be cleaned, especially corners, cavities and recesses
of housing and covers.
foreign material or protective compounds. The latter refers especially to new parts.
etc..
(10) To heat bearings etc., hot plates, rod heaters or heating furnaces must be used.
(11) Never heat parts directly with the flame. An auxiliary solution would be to immerse the bearing into
a vessel, filled with oil, which is then heated with the flame, thus avoiding damage to the bearings.
C.
(14) Before pressing shafts, bearings etc. in place, both parts must be lubricated.
(15) During the reassembly, all specified adjustment values, testing specifications and torque limits
have to be respected.
(16) For the procedure and the permitted oil qualities refer to the operator's manual, resp. to the
lubrication instructions and the corresponding list of lubricants.
(17) After the oil filling, tighten the oil level and oil drain plugs to the specified torque.
(18) The numbers in brackets underneath the figures of the pages for the disassembly and the
reassembly, refer to an available dispositive for training purposes concerning the repair of the unit.
8-178
2) IMPORTANT INSTRUCTIONS CONCERNING THE LABOR SAFETY
(1) In principle, repairers are themselves responsible for the labor safety.
(1) Gear oils with limited - slip additives.
(2) API GL-5
(3) MIL-L-2105D(SAE 85W-90, 85W-140 with LS-Additive)
8-179
4) BRAKE LINING WEARING TEST
(1) General
¤ The brake lining wearing test gives a limited information about the overall condition of the brake
plate pack - without disassembly of the planetary carrier, resp. of the plates.
¤Ł The wearing test has to be carried out in case of the following criteria :
- In the course of the oil change intervals
- Braking noises
- Reduced braking power
- Change of deceleration of the brake fluid level as well as of the brake pressure
- In case of a general change of the brake performance.
¤Ø Carry out the wearing test on both final drive sides.
- Permitted piston stroke max. : 6.25mm
- Piston stroke in new condition of the plate pack : 2.4~2.8mm
(2) Carry out the wearing test

¤ Turn the planetary carrier until screw plug
A
A(M16¡¿1.5) is in the upper position(12
o'clock position).
Now, remove the screw plug.
¤Ł Apply the brake(Required brake
pressure min. 40bar). el
lev
Oil
¤Ø Screw measuring screw(M16¡¿1.5) in
until contact is obtained and tighten it
with a torque of 1kg¡⁄m. AXLE (200W-3)
¤Œ Determine dimension X according to the
figure on the right.
¤º Release the brake and equalize the plate
clearance by resetting the measuring
screw.
X
Torque limit 1kg¡⁄m.
¤ Determine dimension Y according to the
¤ The difference of the two dimensions
(X-Y) corresponds to the piston stroke
(Actual state).
AXLE2 (200W-3)
(3) Result
If the max. permitted piston stroke(5.0mm)
is exceeded, the lining plates must be
renewed on both final drive sides.
Y
AXLE3 (200W-3)
8-180
3. FINAL DRIVE DISASSEMBLY AND ASSEMBLY
1) DISASSEMBLY
Adjacent illustration shows the total view of
the ZF axle.
R208202a
(1) Planetary carrier

¤ Remove screw plug and drain oil.
R208202b
¤Ł Loosen socket head screws and

separate planetary carrier from the hub.
R208202E
¤Ø Squeeze out circlips and pull off

planetary gears.
Tow leg puller 5870 970 002
R208202d
8-181
¤Œ Squeeze out L-shaped rings and pull
bearing inner race(Together with
cylindrical rollers) out of the planetary
gear.
R208203a
(2) Internal gear

¤ Squeeze out circlip, remove shim and
loosen socket head screw.
R208203b
¤Ł Pull sun gear shaft together with inner

plate carrier from the universal shaft,
resp. out of the plate pack.
Remove released thrust washer.
R208203c
¤Ø Squeeze out circlip.

Clamping piers 5870 900 011
R208203d
8-182
¤Œ Remove backing plate and plate pack.
R208204a
¤º Remove lock plate
R208204b
¤ Apply hook spanner, assemble centering

disk and fix it axially by means of circlip.
Hook spanner 5870 401 105
Centering disk 5870 912 011
R208204c
¤ Loosen slotted nut.
R208204d
8-183
¤ Separate internal gear.
Internal gear carrier(Compl.) from the
steering knuckle hull.
R208205a
¤ Squeeze out snap rings(3 pieces) and

separate internal gear from internal gear
carrier.
R208205b
¤ Loosen lock nuts.
R208205c
¤æ Loosen all hexagon head screws and

remove them together with compression
springs and spring caps.
R208205d
8-184
¤ Press piston out of the bore of the
internal gear carrier.
R208206a
¤ Squeeze out snap ring and remove it

together with washer.
R208206b
(3) Hub
¤ Remove back up ring and O-ring, see
arrow and separate hub from the
steering knuckle hull by means of puller.
¡ Pay attention to the released tapered
roller bearing.
Tow leg puller 5870 970 007
R208206c
¤Ł Remove plug in seal ring.

If required, drive both bearing outer races
out of the hub bores.
R208206d
8-185
(4) Steering knuckle hull
¤ Remove spacing ring and pull tapered
roller bearing from the steering knuckle
hull.
Grab sleeve Super 5870 028 009
Two leg puller 5870 970 006
R208207a
¤Ł Unlock castle nut, loosen and unhook tie

rod.
R208207b
¤Ø Loosen hexagon head screws and

remove both bearing pins(Compl.).
¡ Pay attention to the released thrust
washer(Only with upper bearing pin).
Pry bar 5870 345 065
R208207c
¤Œ Separate steering knuckle hull from the

axle.
¡ Pay attention to the released universal
shaft.
R208207d
8-186
¤º Remove sealing components and pull
liner situated behind it out of the bore,
using internal puller.
Pry bar 5870 345 065
Internal puller 5870 300 007
Support 5870 300 003
R208208a
(5) Axle housing

¤ Remove sealing component and pull
liner out of the bore.
Pry bar 5870 345 065
Internal puller 5870 300 007
Support 5870 300 003
¡ If required, drive both sealing caps and
bearing outer races out of the steering
knuckle bores.
R208208b
8-187
2) REASSEMBLY
(1) Axle housing
¤ Install sealing caps, resp. bearing outer
races.
¡ Install sealing caps with loctite No.573.
Driver 5870 057 015
Driver 5870 058 078
Handle 5870 260 002
R208209a
¤Ł Drive in sleeve flush mounted.

position(lubricating groove below) of the
sleeve.
Drive 5870 055 081
Handle 5870 260 002
R208209b
¤Ø Install sealing component firmly against

shoulder.
¡ Cover outer diameter with sealing
compound(Curil T).
Lubricate sealing lip and liner.
Driver 5870 055 081
Handle 5870 260 002
R208209c
¤Œ Introduce universal shaft into the axle

housing until the splines have been
received in the differential.
R208209d
8-188
(2) Steering knuckle hull
¤ Drive in sleeve flush mounted.
¡ Pay attention to the installation position
with installed steering knuckle hull, the
lubricating groove of the sleeve must be
showing towards below.
¡ Cover shaft seal with sealing compound
and drive it firmly against shoulder.
Lubricate sealing lip of the shaft liner.
R208210a
Driver 5870 055 081
Handle 5870 260 002
¤Ł Close both bores by means of king plugs.

¡ Clean oil bores carefully from residues
(Anti-corrosion agent), prior to the
installation of the screw plugs.
Lever riveting tongs 5870 320 016
R208210b
¤Ø Grease O-ring, insert it into the annular

groove of the bearing pin and replace
sealing cap with the plane face showing
towards the O-ring.
Heat tapered roller bearing and replace it
¡ Cover collar of the planetary shaft(See
arrow) with anti-corrosion agent.
R208210c
¤Œ Guide steering knuckle hull over the dual

joint shaft and position it at the axle
housing.
¡ The lifting of the universal shaft would
avoid damaging of the shaft seal.
R208210d
8-189
¤º Fix steering knuckle hull by means of
both bearing pins.
¡ With the upper bearing pin insert spacing
washer(Experimental value s = 1.0mm).
Pay attention to the installation position
of the bearing pins threads for grease
nipple showing towards the axle center.
R208211a
¤ Fasten both bearing pins by means of

hexagon head screws.
¡⁄Torque limit : 41.8kgf¡⁄m(302.4lbf¡⁄ft)
R208211b
(3) Check bearing rolling moment of the

steering knuckle bearing.
Normal value 4.1~5.1kgf¡⁄m(29.5~36.9lbf¡⁄ft)
¤ In case of deviations from the prescribed
rolling moment, correct by means of a
corresponding spacing washer(Figure ¤º
above).
Spaner 5870 656 004
R208211c
(4) Hub
¤ Pull wheel studs into the hub bores.
Wheel stud puller basic set
5870 610 001
Insert M22¡¿1.5 5870 610 002
R208211d
8-190
¤Ł Press bearing outer races into both hub
bores.
R208212a
¤Ø Press in plug in seal ring flush mounted.

¡ Cover outer diameter with sealing
compound(Curil T).
Driver 5870 051 018
¡ To be used with hand lever press.
R208212b
Adjust rolling resistance of wheel bearing

¡ Rated value for new bearings : 13~1.8kgf¡⁄m
(With shaft seal)
¤Œ Heat bearing inner race and place it
against the collar of the steering knuckle
hull until contact is obtained.
R208212c
¤º Assemble spacing ring, see arrow.

¡ If the hub as well as both wheel bearings
have not been renewed, we recommend
to install the actual spacing ring again.
Important, however, is the rolling
resistance of the wheel bearings(See
figure (5), next page).
R208212d
8-191
¤ Assemble preassembled hub and fix by
means of heated bearing inner race.
R208213a
¤ Assemble internal gear carrier and

tighten slotted nut provisionally.
¡⁄Torque limit : 122.4~142.8kgf¡⁄m
(885~1033lbf¡⁄ft)
R208213b
(5) Check rolling resistance of the wheel

bearing "T=F¡¿R"
T = Rolling resistancein kgf¡⁄m
F = Traction force in kgf¡⁄m
R = Radius in m
¡ If the required rolling resistance
(1.3~1.8kgf¡⁄m) is not obtained, correct
by means of a corresponding ring(Figure
¤ºat page 8-190).
R208213c
¤ Afterwards, loosen slotted nut again and

remove internal gear carrier.
8-192
(6) Internal gear
¤ Close both bores by means of king
plugs, see arrows.
Lever riveting tongs 5870 320 016
R208214a
¤Ł Insert disk and fix it by means of snap

ring.
R208214b
¤Ø Heat both back up rings and insert them

into the recesses of the piston.
Install U section rings with the sealing lip
showing to the pressure chamber(Arrow).
¡ Lubricate back up rings and U section
rings(Use W10 oils).
1 Piston
2 Back up ring
3 U section ring
R208214c
¤Œ After the back up rings have cooled

down, insert piston firmly into the internal
gear carrier.
¡ Pay attention to a radial installation
position.
R208214e
8-193
¤º Assemble spring caps and compression
springs and fix piston by means of
hexagon head screws.
¡ Screw in the screws until a dimension X
of 0.5~1.0mm measured from the plane
face/piston to the screw end has been
obtained, see figure R208215b below.
R208215a
1 Piston
2 Retaining ring
3 Grooved ring
X 0.5~1.0mm
R208215b
¤ Hold hexagon head screws tight and

check them by means of lock nuts.
¡ Secure locking nut with loctite No.242.
R208215c
¤ Insert preassembled internal gear carrier

into the internal gear and fix by means of
snap rings(3 pieces).
¡ Installation position(See figure top of next
page).
R208215d
8-194
1 Internal gear
2 Ring gear carrier
3 Snap ring
R208216a
¤ Insert back up ring and O-ring into the

recess of the internal gear carrier, see
arrow.
¡ Install O-ring, showing towards the
pressure chamber(Towards above).
Lubricate back up ring and O-ring(Use
W10 oil).
R208216b
¤ Insert split back up ring as well as O-ring

(Showing towards the pressure
chamber) into the annular groove of the
steering knuckle hull, see arrow.
¡ Both ends of the back up ring must have
contact(Use assembly grease) in order to
allow a correct installation of the internal
gear carrier(Figure ¤ below).
R208216c
¤ Guide internal gear(Compl.) over the

splines of the steering knuckle hull and
pull it carefully by means of slotted nut
over the O-ring and the back up ring.
¡ During the assembly of the internal gear
carrier pay attention to a precise
overlapping of the pressure oil
lines(Steering knuckle hull/Internal gear
carrier.)
R208216d
8-195
¤æ Tighten slotted nut.
¡⁄Torque limit : 122.4~142.8kgf¡⁄m
(885~1033lbf¡⁄ft)
¡ Within the tolerance envelope of the
torque limit, a locking of the slotted nut is
possible by means of lock plate(Aim at
higher value).
Hook spanner 5870 401 105
Centering disk 5870 912 011
R208217a
¤ After location of the two locking lobes to

be beaded, by a provisional positioning of
the lock plate at the slotted nut, bead the
locking lobes in a vise.
R208217b
¤ Fix slotted nut by means of lock plate.
R208217c
¤ Make thrust washer adhere with grease.

¡ If a correct contact of the thrust washer at
the steering knuckle hull has been
obtained, both lobes of the lock
plate(Inside) have to be reset.
R208217d
8-196
¤ı Install inner plate carrier.
R208218a
(7) Multi disk brake

Clearance = Piston stroke to be adjusted
according to the following table figure ¤
to example ¥†:
Number of Number of Clearance
friction piston stroke in
inner plates surfaces mm
2 4 1.6 ~ 2.0
3 6 2.4 ~ 2.8
4 8 3.2 ~ 3.6
5 10 4.0 ~ 4.4
¤ Determine dimension A from the end

face(Internal gear to the plane face)
piston.
¡⁄Dimension A e.g. 90.5mm
¡ During the determination of the
dimension A pay attention to a correct
contact of the piston with the internal
gear carrier.
R208218c
¤Ł Engage circlip and place it against the

outer face of the recess(Direction of
arrow) until contact is obtained.
Measure dimension B from the end face/
internal gear to the inside shoulder of the
circlip.
¡⁄Dimension B e.g. 63.5mm
Afterwards, remove circlip again.
R208218d
8-197
Example ¥
Dimension A 90.5mm
Dimension B - 63.5mm
Difference = Dimension ¥ 27.0mm
¤Ø Determine dimension C(Thickness of

backing plate).
¡⁄Dimension C e.g. 9.5mm
R208219a
Determine total thickness of plate pack

¤Œ Measure each of the waved outer plates
separately(As illustrated on the adjacent
figure).
¡⁄Dimension D(Plate pack) e.g. 15.5mm
R208219b
Example ¥–
Dimension C 9.5mm
Dimension D + 15.5mm
Gives Dimension ¥– 25.0mm
Example ¥†
Dimension ¥ 27.0mm
Dimension ¥– - 25.0mm
Difference = Plate play e.g. 2.0mm
8-198
¡ If the required clearance(See table, page
8-197is not obtained, correct by means
of a corresponding outer plate.
¤º Install alternating outer(1) and inner
plates(2).
¡ Pay attention to the plate arrangement of
the waved outer plates, see right figure.
¡ If required, install thinner outer plates(s =
2.0mm) at the piston and backing plate
R208220a
side.
¤ Insert backing plate.
R208220b
¤ Fix plate pack by means of circlip.

Clamping pliers 5870 900 011
R208220c
8-199
Check brake hydraulic system for
tightness
¡ Bleed brake hydraulic system and
actuate it several times prior to start the
check.
High pressure test
Pressurize brake with 120bar. After 5
minutes the pressure drop may not
exceed 2%(117bar).
R208221a
Low pressure test
Pressurize brake with 5bar. After 5
minutes there may be no visible pressure
drop.
Test media
Motor oils SAE 10W, corresponding to
MIL-L 2104C ATF-oils, type A suffix A
dexron ¥–D.
HP pump compl. 5870 287 007
¤ Whilst the multi disk brake is pressurized

insert sun gear shaft and tighten socket
head screw.
R208221c
¤ Install shim and engage circlip, see figure.
R208221d
8-200
(8) Planetary carrier
¤ Install components as illustrated on the
adjacent figure.
¡ Install cylindrical rollers with grease.
Broad stop face of L-shaped rings
showing towards the bearing rollers.
R208222a
¤Ł Heat bearing inner race, replace

planetary gears firmly against shoulder
and fix them by means of circlip.
¡ Large radius of the bearing inner race is
showing towards the planetary carrier
(Towards below).
R208222b
Adjust end play of the universal shaft

(0.4~0.6mm)
¤Ø Measure dimension A from the flange
facing to the contact face of the thrust
washer.
¡⁄Dimension A e.g. 205.2mm
R208222c
¤Œ Slide sun gear, resp. inner plate carrier

Determine dimension B from the end
face/sun gear shaft to the flange facing/
hub.
¡⁄Dimension B e.g. 202.5mm
R208222d
8-201
Example
Dimension A 205.2mm
Dimension B - 202.5mm
Difference 2.7mm
Required end play e.g. - 0.5mm
Difference = Thrust washer thickness
e.g. s = 2.2mm
¤º Insert thrust washer(e.g. s = 2.2mm) and

fix by means of snap ring.
R208223b
¤ Insert O-ring into the annular groove of

the hub, see arrow.
R208223c
¤ Assemble planetary carrier and fasten by

means of two socket head screws.
R208223d
8-202
¤ Tighten stop screws, see arrow.
R208224a
¤ Engage tie rod, tighten castle nut and

secure by means of cotter pin.
¡ Pay attention to the lubrication
instructions for at page 8-178.
R208224b
8-203
GROUP 10 REAR AXLE
1. REMOVAL REAR AXLE

1) Rear axle mounting bolt(1, M24)
¡⁄Tightening torque : 107¡ 10.7(kgf¡⁄m) 1
(723¡ 72.3lbf¡⁄ft)
2) Propeller shaft mounting bolt(2, M10) LOWER
FRAME
¡⁄Tightening torque : 5.9 ¡ 0.6kgf¡⁄m
(42.7 ¡ 4.3lbf¡⁄ft)
3) Wheel nut(3, M22)
+0
¡⁄Tightening torque : 60 -5 kgf¡⁄m 4
0
(434 -36 lbf¡⁄ft)
RAER
4) Hose assy(4) AXLE
PROPELLER
5) Rear axle weight : 480kg(1060lb) SHAFT TIRE
20W78AX02
8-229
(1) This manual has been developed for the skilled serviceman, trained by axle manufacturer.
Therefore, axle removed from the machine, must be cleaned prior to open them.
The special tools are available from manufacturer.
(4) After the disassembly, all components must be cleansed, especially corners, cavities and
recesses of housing and covers.
foreign material or protective compounds.
(7) The latter refers especially to new parts.
etc..
(10) For the heating of bearings etc., hot plates, rod heaters or heating furnaces must be used.
(11) Never heat parts directly with the flame. An auxiliary solution would be to immerse the bearing in
a vessel filled with oil, which is then heated with the flame.
In this way, damage to the bearings could be avoided.
C.
(14) Before pressing shafts, bearings etc. in position, both parts must be lubricated.
(15) During to reassembly, all specified adjustment values, testing specifications and tightening torque
must be respected.
(16) After the repair, units are filled up with oil.
(17) After the oil filling, the oil level plugs and oil drain plugs must be tightened to the specified
tightening torque.
8-230
2) IMPORTANT INSTRUCTIONS CONCERNING THE LABOUR SAFETY
(1) In principle, repairers are themselves responsible for the labour safety.
(1) Gear oils with limited - slip additives.
(2) API GL-5
(3) MIL-L-2105D(SAE 85W-90, 85W-140 with LS-Additive)
8-231
4) BRAKE LINING WEARING TEST
(1) General
¤ The brake lining wearing test gives a limited information about the overall condition of the brake
plate pack - without disassembly of the planetary carrier, resp. of the plates.
¤Ł The wearing test has to be carried out in case of the following criteria :
- In the course of the oil change intervals
- Braking noises
- Reduced braking power
- Change of deceleration of the brake fluid level as well as of the brake pressure
- In case of a general change of the brake performance.
¤Ø Carry out the wearing test on both final drive sides.
- Permitted piston stroke max. : 6.25mm
- Piston stroke in new condition of the plate pack : 2.4~2.8mm
(2) Carry out the wearing test
A
¤ Turn the planetary carrier until screw plug
A(M16¡¿1.5) is in the upper position(12
o'clock position).
Now, remove the screw plug.
¤Ł Apply the brake(Required brake el
lev
pressure min. 40bar). Oil
¤Ø Screw measuring screw(M16¡¿1.5) in
until contact is obtained and tighten it
AXLE (200W-3)
with a torque of 1kg¡⁄m.
¤Œ Determine dimension X according to the
¤º Release the brake and equalize the plate
clearance by resetting the measuring
screw. X
Torque limit 1kg¡⁄m.
¤ Determine dimension Y according to the
¤ The difference of the two dimensions
(X-Y) corresponds to the piston stroke
(Actual state). AXLE2 (200W-3)
(3) Result
If the max. permitted piston stroke(5.0mm)
is exceeded, the lining plates must be
renewed on both final drive sides.
Y
AXLE3 (200W-3)
8-232
3. DISASSEMBLY OF THE OUTPUT
1) DISASSEMBLY OF THE OUTPUT WITH
MULTI DISK BRAKE.
20W78RX24
¤ Fasten the axle on the assembly truck.

Assmbly truck 5870 350 000
Holding fixtures 5870 350 077
Clamping braces 5870 350 075
20W78RX25
¤Ł Loosen the screw plug and drain oil from

the axle casing.
20W78RX26
¤Ø Loosen the screw plug and drain oil from

the planet carrier.
¡ To prevent any injury by a possible
pressure build-up in the oil sump of the
planet carrier, bring the filler and level
plug to the top position(12 o’clock) and
unscrew it cautiously.
Then bring the drain hole to the bottom
position (6 o’clock) and drain the oil.
20W78RX27
8-233
¤Œ Loosen the cap screws and pull off the
planet carrier from the hub.
Crowbar set 5870 345 071
20W78RX28
¤º Unsnap the retaining ring.

Set of external pliers 5870 900 015
20W78RX29
¤ Pull off the planet gear by means of two-

armed puller.
Two armed puller 5870 970 002
20W78RX30
¤ Unsnap the retaining rings and remove

the shims behind it.
Then pull the roller bearing out of the
planet gear.
20W78RX31
8-234
¤ Pull off the sun gear and the disc carrier
from the stub shaft and out of the disc set
respectively.
20W78RX32
¤ Pull the stub shaft out of the axle casing.
20W78RX33
¤ Unsnap the retaining ring.

20W78RX34
¤æ Remove the end shim and the disc set

from the ring gear.
20W78RX35
8-235
¤ Remove the thrust washer and the lock
plate behind it.
20W78RX36
¤ Loosen the slotted nut (Figure¤ ...¤ı)

The opposite sketch shows the single
parts of the special tool to loosen the
slotted nut.
Slotted nut wrench 5870 401 105
Centering disc cpl. 5870 912 011
20W78RX37
¤ Position the slotted nut wrench and the

support shim and fasten it by means of
retaining ring.
20W78RX38
¤ı Loosen the slotted nut.

¡ Pay attention to the released ring gear. By
supporting the slotted nut wrench on the
retaining ring, the ring gear is pulled from the
hub carrier when the slotted nut is
unscrewed.
¡ The high tightening torque of the slotted nut
makes it absolutely necessary to support
the axle and the assembly truck 20W78RX39
respectively.
Then unsnap the retaining ring and remove
the slotted nut wrench with slotted nut from
the ring gear.
8-236
§ Remove the O-ring(1) and the support
ring(2) from the annular groove of the
ring gear.
1 O-ring
2 Support ring
3 Piston
4 Ring gear
20W78RX40
§æ Loosen all locking nuts.
20W78RX41
§ Loosen all hexagon screws and remove

the released single parts.
20W78RX42
§ Unsnap the circlip.

20W78RX43
8-237
§ Press the piston out of the ring gear and
remove the support shim behind it.
20W78RX44
§ı Remove the support and U-rings from

the annular grooves of the piston.
1 Support ring
2 U-ring
3 Piston
20W78RX45
§ Press out the shaft seal from the hub

carrier bore.
20W78RX46
§ Remove the O-ring and support ring(see

arrow) from the annular groove of the
hub carrier.
Then pull off the hub by means of the two
armed puller from the hub carrier.
¡ Pay attention to the released bearing
inner ring.
20W78RX47
8-238
§ł Press the cassette type seal out of the
hub.
20W78RX48
§ø Expel both bearing outer rings from the

hub and remove the O-ring (see arrow).
20W78RX49
§œ Remove the bush and pull the bearing

inner ring from the hub carrier.
Rapid grip 5873 014 012
Pressure ring 5870 285 026
20W78RX50
§ß By means of three armed puller pull off

the support plate from the hub carrier.
Three armed puller 5870 971 003
20W78RX51
8-239
§ Loosen the union (with breather valve).
20W78RX52
§ Loosen two hexagon screws and replace

them by two adjusting screws.
Then loosen the remaining hexagon
screws.
Adjusting screws 5870 204 026
20W78RX53
§ Separate the hub carrier from the axle

casing.
20W78RX54
8-240
4. DISASSEMBLY OF THE AXLE INSERT
1) DISASSEMBLY OF AXLE INSERT TYPE :
BK / AE 650
20W78RX01
¤ Fasten the axle on the assembly truck.

Assembly truck 5870 350 000
Holding fixtures 5870 350 077
Clamping braces 5870 350 075
20W78RX02
¤Ł Loosen the screw plug and drain oil from

the axle casing.
20W78RX03
¤Ø Loosen the screw plug and drain oil from

the planet carrier.
¡ Step (Figure¤Ø...¤ )is to be carried out on
both output sides.
¡ To prevent any injury by a possible
pressure build up in the oil sump of the
planet carrier, bring the filler and level
plug to the top position (12 o’clock) and
unscrew it cautiously. 20W78RX04
Then bring the drain hole to the bottom

position (6 o’clock) and drain the oil.
8-241
¤Œ Loosen the cap screws and pull off the
planet carrier from the hub.
20W78RX05
¤º Pull off the sun gear and the disc carrier

from the stub shaft and out of the disc set
respectively.
20W78RX06
¤ Pull the stub shaft out of the axle casing.
20W78RX07
¤ Unsnap the retaining ring and remove

the end shim with disc set from the ring
gear.
¡ This step is necessary to allow the
later installation of the disc carrier.
20W78RX08
8-242
¤ Loosen two locking screws and replace
them by two adjusting screws.
Then loosen the remaining locking
screws.
¡ Mark the installation position of the axle
insert to the axle casing (see arrow).
20W78RX09
¤ By means of lifting tackle pull the axle

insert out of the axle casing.
Lifting chain 5870 281 047
20W78RX10
¤ Fasten the axle insert on the assembly

truck.
Assembly truck 5870 350 000
Holding fixture 5870 350 112
20W78RX11
¤æ Expel both slotted pins.
20W78RX12
8-243
¤ Loosen the adjusting nuts.
Pry bar set 5870 345 036
20W78RX13
¤ Heat the axle drive housing by means of

hot air blower.
Hot air blower 230V 5870 221 500
¡ Hexagon screws are installed with loctite
No.262.
20W78RX14
¤ Loosen the hexagon screws and take off

both bearing brackets.
¡ Mark the installation position of both
bearing brackets to the axle drive
housing (see arrow).
Loosen hexagon screws only by hand.
20W78RX15
¤ı Lift the differential out of the axle drive

housing.
¡ For disassembly of the various differentials,
see from page 8-247.
¡ Mark the installation position of the
differential to the axle drive housing.
20W78RX16
8-244
2) DISASSEMBLY OF THE INPUT PINION
¤ Heat the hexagon nut by means of hot air
blower.
¡ Hexagon nut is locked with loctite No.262.
20W78RX17
¤Ł Loosen the hexagon nut and remove the

washer behind it.
Fixture 5870 240 025
20W78RX18
¤Ø Pull the input flange from the input pinion.
20W78RX19
¤Œ Press the shaft seal out of the axle drive

housing.
20W78RX20
8-245
¤º By means of the two armed puller press
the input pinion out of the axle drive
housing and remove the released
bearing inner ring.
20W78RX21
¤ Take off the spacer ring and pull the

bearing inner ring from the input pinion.
Gripping insert 5873 001 037
Basic set 5873 001 000
20W78RX22
¤ If necessary, expel both bearing outer

rings from the axle drive housing.
20W78RX23
8-246
5. DISASSEMBLY OF DIFFERENTIALS
1) DISASSEMBLY OF DIFFERENTIAL TYPE :
D-700
20W78RX501
¤ Pull off the roller bearing from the

differential cage.
Pressure piece 5870 506 058
Back-off insert 5870 026 100
20W78RX502
¤Ł Pull off the crown wheel-sided roller

bearing.
Back-off insert 5870 026 100
20W78RX503
¤Ø Fasten the differential by means of press

and loosen all hexagon screws.
¡ Hexagon screws are installed with loctite
No.262.
20W78RX504
8-247
¤Œ Take off the differential cage half and
remove the released single parts.
20W78RX505
¤º Press off the crown wheel from the

differential cage.
20W78RX506
8-248
6. REASSEMBLY OF THE DIFFERENTIALS
1) REASSEMBLY OF DIFFERENTIAL TYPE :
D-700
¡ Prior to installation oil all single parts of the
differentials to list of lubricants TE-ML 05.
20W78RX601
¤ Install slotted pins(2pcs. / bore) aligned

into the blind holes (4x) of the differential
cage half I.
¡ Install openings of the slotted pins
always in circumferential direction and
180¡£offset to each other.
20W78RX602
¤Ł Heat crown wheel and press it upon the

slotted pins until contact.
20W78RX603
¤Ø Place the thrust washer and the axle

bevel gear into the differential cage half.
20W78RX604
8-249
¤Œ Install the complete compensating set.
¡ Pay attention to radial location of thrust
washers. Pins show vertically upwards
(see arrow).
20W78RX605
¤º Place the thrust washer and the axle

bevel gear into the differential cage half II.
20W78RX606
¤ Put on the differential cage half II.

¡ Observe radial location,
see description.
20W78RX607
¤ Fix the differential by means of press and

fasten the differential cage halves by
means of hexagon screws.
Tightening torque ¡ ⁄ ¡ ⁄ ¡⁄¡⁄
12.2kgf m
Tightening torque ¡ ⁄ ¡ ⁄ ¡⁄¡⁄
30.6kgf m
¡ Wet thread of the hexagon screws with
loctite No. 262.
20W78RX608
8-250
¤ Heat both roller bearings and assemble
them until contact.
20W78RX609
8-251
7. REASSEMBLY OF THE AXLE INSERT
1) REASSEMBLY OF AXLE INSERT TYPE :
BK / AE650
¡ If crown wheel or input pinion are damaged,
both parts have to be replaced together.
For new installation of a complete bevel gear
set pay attention to the same pair number of
input pinion and crown wheel.
20W78RX701
(1) Determine shim thickness for a perfect

tooth contact pattern
Make the following measuring steps at
maximum accuracy.
Inexact measurements result in a faulty
tooth contact pattern and require a
repeated dis-and reassembly of the input
drive pinion as well as of the differential.
¤ Install adapter pieces(1) and preliminarily

fasten the bearing bracket by means of
hexagon screws.
Then assemble the measuring shaft(2).
Adapter pieces 5870 500 035
Measuring shaft 5870 200 001
If available, additionally
Measuring pin 5870 500 002
20W78RX702
¤Ł Measure Dim. a, from the upper edge of

the measuring shaft to the mounting face
of the bearing outer ring and shim resp.
Dim. a e.g 178.05mm
Digital depth gauge 5870 200 072
EXAMPLE A :
Dim. a e.g 178.05mm
Dim. b e.g - 15.00mm
Results in Dim. X =163.05mm 20W78RX703
8-252
¤Ø Measure Dim. I (bearing width).
Dim.Ie.g 36.8mm
Gauge blocks 5870 200 066
20W78RX704
¤Œ Read Dim. II (pinion dimension).

Dim. II e.g 124.95mm
EXAMPLE B :
Dim. I e.g 36.80mm
Dim. II e.g +124.95mm
Results in Dim. Y =161.75mm
20W78RX705
EXAMPLE C :
Dim. X e.g 163.05mm
Dim. Y e.g -161.75mm
Difference = shim e.g s =1.3mm
(2) Install the input pinion

¤ Place the determined shim e.g. s = 1.3mm
into the bearing bore.
20W78RX706
8-253
¤Ł Undercool bearing outer ring and insert it
into the bearing bore until contact.
Driver 5870 058 078
Handle 5870 260 002
20W78RX707
¤Ø Undercool the bearing outer ring on the

input flange side and install it until
contact.
Driver 5870 058 061
Handle 5870 260 002
20W78RX708
¤Œ Heat the bearing inner ring and assemble

it until contact.
¡ After cooling-down install the bearing
inner ring subsequently.
20W78RX709
¤º Adjust rolling moment of input pinion

bearing 0.1...0.2kgf m(without shaft seal)
(figure ¤º...¤ )
Assemble the spacer ring (e.g. s = 16.96mm).
¡ As per experience the required rolling
moment is obtained by use of the spacer
ring (e.g. s = 16.96mm) available at
disassembly.
However, a later checking of the rolling 20W78RX710
moment is imperative.
8-254
¤ Place the preassembled input pinion into
the axle drive housing and assemble the
heated bearing inner ring until contact.
20W78RX711
¤ Insert the hexagon screws into the bores

of the input flange and press on the
protecting plate until contact.
Driver 5870 056 004
Handle 5870 260 002
20W78RX712
¤ Assemble the preassembled input

flange.
20W78RX713
¤ Assemble the washer.
20W78RX714
8-255
¤ Screw on the hexagon nut (with collar
showing to the washer) by hand and
then tighten it.
Tightening torque 61.2kgf¡⁄m
Fixture 5870 240 025
¡ When tightening rotate the input pinion in
both directions several times.
20W78RX715
¤æ Check the rolling moment(0.1...0.2kgf¡⁄m).

Torque wrench 5870 203 030
¡ For new bearings it should be tried to
achieve the max. value.
¡ If the required rolling moment is not
obtained, correct it with an adequate
spacer ring (Figure ¤º / Page 8-254)
according to the following indications :
Rolling moment too low - install a thinner 20W78RX716
spacer ring
Rolling moment too high - install a thicker
spacer ring.
Then detach the hexagon nut again and
pull off the input flange from the input
pinion.
¤ Install the shaft seal with the sealing lip to

the oil sump (showing downwards).
Driver 5870 048 114
¡ The exact installation position of the shaft
seal will be obtained by using the exact
driver.
¡ Wet the outer diameter of the shaft seal
with loctite No.574 and fill the space
between sealing-and dust lip with 20W78RX717
grease.
8-256
¤ Assemble the input flange by means of
shim and finally fasten it with hexagon
nut.
Fixture 5870 240 002
¡ Wet thread of the hexagon nut with loctite
No. 262.
20W78RX718
(3) Adjust backlash and bearing rolling

moment of the differential bearing
0.1...0.4kgf ¡⁄
¡⁄m
¤ Put on both bearing outer rings and place
the preassembled differential into the axle
drive housing.
¡ For assembly of various differentials, see
from page 8-247
¡ Observe installation position of the crown 20W78RX719
wheel, see marking. When the axle insert is

installed the crown wheel is - looking to the
input flange - on the “right”.
¤Ł Screw both adjusting nuts into the lower

halves of the threaded hole.
20W78RX720
8-257
¤Ø Put on both bearing brackets and fasten
them by means of hexagon screws and
washers.
¡ Observe the installation position of the
bearing brackets and clearance of the
adjusting nuts.
¡ Wet thread of the hexagon screws with
20W78RX721
loctite No. 262.
¤Œ Place dial indicator right-angled at the

outer diameter of the tooth flank (crown
wheel).
Then install both a djusting nuts only to
such an extent that the required backlash
- see value etched on the outer diameter
of the crown wheel is reached.
Magnetic stand 5870 200 055
Dial indicator 5870 200 057
20W78RX722
Pry bar set 5870 345 036
Plastic hammer 5870 280 004
¡ During the setting procedure rotate the
differential several times and relieve the
bearing by means of slight blows on both
bearing brackets (use a plastic hammer).
¤º Determine the bracket width and correct

it on both adjusting nuts, if required.
Bracket width 258.0 -0.1mm
Caliper gauge 5870 200 058
Then check the backlash once again.
¡ Adjusting of the bracket width results in
the required bearing rolling moment of
the differential bearing.
20W78RX723
8-258
¤ Check the contact pattern (Figure ¤ ...¤ )
Cover some concave and convex flanks
of the crown wheel with marking ink.
20W78RX724
¤ Roll the crown wheel in both directions

over the input pinion.
Compare the obtained tooth contact
pattern with the examples on page 8-219.
¡ If the tooth contact pattern differs, there
has been a measuring error at
determination of the shim (Figure ¤ ,
Page 8-253)
20W78RX725
¤ Lock both adjusting nuts by means of

slotted pins.
20W78RX726
(4) Install the preassembled axle insert

¤ Install two adjusting screws and place
the axle casing by means of lifting tackle
into the axle casing.
Lifting tackle 5870 281 047
¡ Observe radial location.
¡ Wet the mounting face with sealing
20W78RX728
compound loctite No. 574.
8-259
¤Ł Place the axle insert until contact and
fasten it by means of new locking screws.
¡ Only the use of new locking screws is
allowed.
20W78RX728
¤Ø Grease the O-ring and insert into the

annular groove of the disc carrier.
¡ Step (Figure ¤Ø...¤ ) is to be made on
both output sides.
20W78RX729
¤Œ Assemble the sun gear into the disc

carrier until contact.
Then pass the disc carrier over the teeth
of the stub shaft until contact.
20W78RX730
¤º Assemble the stub shaft with disc carrier

and sun gear until contact into the axle
casing and into the teeth of the axle bevel
gear respectively.
20W78RX731
8-260
¤ Install the outer and inner discs
alternately, starting with an outer disc.
¡ Oil the discs to ZF List of Lubricants TE-
ML 05.
¡ When installing outer discs of different
strength, the thinner outer discs have
always to be installed at the piston and
end shim side.
20W78RX732
¤ Place the end shim into the ring gear.

¡ Observe the installation position, see
picture.
20W78RX733
¤ Fasten the disc set and end shim by

means of retaining ring.
20W78RX734
¤ Place O-ring (see arrow) into the annular

groove and grease it.
20W78RX735
8-261
¤ Assemble the planet carrier until contact
and fasten it by means of cap screws.
¡ Prior to putting into operation of the axle,
fill up oil to lubrication and maintenance
instructions.
20W78RX736
8-262
8. REASSEMBLY OF THE OUTPUTS
1) REASSEMBLY OF THE OUTPUT WITH
MULTI-DISC BRAKE
20W78RX738
(1) Reassembly of the hub carrier

¤ Install two adjusting screws and
assemble the hub carrier until contact.
picture.
¡ Wet the mounting face with loctite No.
574.
20W78RX739
¤Ł Fasten the hub carrier to the axle casing

by means of hexagon screws.
20W78RX740
¤Ø Preassemble the union as shown in the

opposite figure.
1 O-ring
2 Union
3 Breather valve
20W78RX741
8-263
¤Œ Install the union.
20W78RX742
¤º Heat the screen sheet and place it until

contact to the hub carrier by means of
driver.
Driver 5870 048 129
20W78RX743
¤ Place the shaft seal into the bore of the

hub carrier.
Driver 5870 055 102
Handle 5870 260 002
below sketch.
Exact installation position of the shaft
seal will be obtained by use of the
specified driver. 20W78RX744
¡ Wet outer diameter of the shaft seal with

loctite No. 574.
Fill the space between the sealing lips
with grease.
1 Hub carrier
2 Shaft seal
20W78RX745
8-264
(2) Reassembly of the hub
¤ Press the wheel bolts into the hub bores
until contact.
Wheel bolt puller-basic set 5870 610 010
Insert M22¡¿1.5 5870 610 002
¡ Special tool can only be used for repair
solution when single wheel bolts are
replaced with the hub mounted-on.
20W78RX746
¤Ł Press in both of the bearing outer rings

until contact.
Driver 5870 051 031
20W78RX747
¤Ø Adjust the rolling moment of the wheel

bearing 1.0...1.5kgf m (without cassette-
type seal) (Figure ¤Ø...¤ )
Heat the roller bearing and assemble it
until contact to the hub carrier.
20W78RX748
¤Œ Assemble the bush(e.g.s = 26.29mm,

empirical value) until contact.
¡ If the hub as well as both of the roller
bearings were not replaced, we
recommend to reinstall the spacer ring
which had been available for disassembly.
However, a later checking of the rolling
momet is absolutely necessary.
20W78RX749
8-265
¤º Assemble the hub (without cassette-type
seal).
¡ The cassette-type seal will be installed
after setting of the bearing rolling
moment.
20W78RX750
¤ Heat the roller bearing and assemble it

until contact.
20W78RX751
¤ Assemble the ring gear and screw on the

slotted nut by hand.
¡ Thread of the slotted nut is to be provided
with lubricant (Molykote 1000).
20W78RX752
¤ Tighten the slotted nut (Figure ¤ ...¤ )

parts of the special tool for tightening of
the slotted nut.
1 Slotted nut wrench 5870 401 105
2 Centering disc cpl. 5870 912 011
20W78RX753
8-266
retaining ring.
20W78RX754
¤ Tighten the slotted nut.

Tightening torque
143+20.4kgf¡⁄m
¡ During the tightening have the hub
rotated in both directions for several
times.
¡ The high tightening torque of the slotted
nut makes it absolutely necessary to
20W78RX755
support the axle and the assembly truck
¤æ Check the rolling moment of the wheel

bearing and tractive force respectively by
means of spring balance.
Spring balance 5870 230 007
¡ T = 1.0~1.5kgf¡⁄m corresponds to a
tractive force from 5.7 to 8.6kgf, assuming
357mm on the hub diameter.
For new bearings the max. value should
be achieve. 20W78RX756
¡ If the required rolling moment is not

obtained, correct it with an adequate
spacer ring(Figure ¤Œ/ Page 8-265)-repeat
setting procedure (Figure ¤Œ~¤æ)
¡ Rolling moment too low - install a thinner
spacer ring
Rolling moment too high - install a thicker
spacer ring
8-267
¤ Then loosen the slotted nut and remove
the ring gear and the hub again.
¡ Inner roller bearing and spacer ring
remain on the hub carrier.
¤ Install the cassette-type seal.

Driver 5870 051 055
Handle 5870 260 004
¡ Exact installation position of the cassette-
type seal will be obtained by use of the
specified driver.
¡ Wet outer diameter of the cassette-type
seal with loctite No. 574.
Fill the space between the sealing lips 20W78RX757
with grease.
¤ Install the preassembled hub until

contact.
20W78RX758
¤ı Heat the roller bearing and assemble it

until contact.
20W78RX759
8-268
(3) Reassembly of the ring gear
¤ Place the support shim into the ring gear.
¡ Observe the radial location.
20W78RX760
¤Ł Fasten the support shim by means of

circlip.
20W78RX761
¤Ø Heat both support rings in the oil bath and

place it into the recesses of the piston.
Then install the U-rings with the sealing
lip showing to the pressure cavity.
1 Piston
2 Support ring
3 U-ring
X Pressure cavity
¡ After cooling down, oil the support and U- 20W78RX762
rings(use W-10 oils).
¤Œ Assemble the piston into the ring gear

and press it until contact.
¡ Observe the radial location.
¡ To avoid any shearing or tipping over of
the U-rings, install the pistons with
extreme caution (by means of hand
press).
20W78RX763
8-269
¤º Assemble the spring sleeves and
compression springs as well as the
piston with hexagon screws.
20W78RX764
¤ Turn in the hexagon screws until

dimension X = 0.5~1.0mm results -
measured from the plane face of the
piston up to the end of the screw - (also
see below sketch).
20W78RX765
1 Ring gear
2 Piston
3 Compression spring
4 Hexagon screw
5 Spring sleeve
X Setting dimension 0.5~1.0mm
20W78RX766
¤ Hold hexagon screws in place and

secure them by means of locking nuts.
¡ It is only allowed to use new locking
screws.
20W78RX767
8-270
¤ Place the support and O-ring into the
annular groove of the ring gear.
¡ Oil the support and O-ring (use W-10
oils).
¡ Observe the location, install the concave
side of the support ring showing to the O-
ring (also see below sketch).
20W78RX768
1 Support ring
2 O-ring
3 Ring gear
20W78RX769
¤ Place the split support ring as well as the

O-ring into the annular groove of the hub
carrier.
¡ Oil the support and O-ring (use W-10
oils).
¡ Observe the location, install the concave
side of the support ring showing to the O-
ring (also see below sketch).
Both ends of the support ring must 20W78RX770
contact (use assembly grease) allowing

a perfect installation of the ring gear.
1 Hub carrier
2 O-ring
3 Support ring
20W78RX771
8-271
¤ Put the ring gear over the teeth of the hub
carrier and screw on the slotted nut by
hand.
¡ Thread of the slotted nut is to be provided
with lubricant (Molykote 1000).
For assembling of the ring gear the exact
¡ contact of the oil bores(hub carrier / ring
gear) must be observed (also see below
figure). 20W78RX772
¤æ Then pull the ring gear by means of the

slotted nut - cautiously over the sealing
elements - until contact.
Opposite figure shows the position of the
two oil bores on the hub carrier.
20W78RX773
¤ Tighten the slotted nut (Figure ¤ ~¤ )

parts of the special tool for tightening of
the slotted nut.
1 Slotted nut wrench 5870 401 105
2 Centering disc cpl. 5870 912 011
20W78RX774

retaining ring.
20W78RX775
8-272
¤ Tighten the slotted nut.
Tightening torque
143+20.4kgf¡⁄m
¡ During the tightening have the hub
rotated in both directions for several
times.
¡ The high tightening torque of the slotted
nut makes it absolutely necessary to
20W78RX776
support the axle and the assembly truck
¤ı Lock the securing lugs(2x) which have to

be beaded by locating of the lock plate to
the slotted nut preliminarily.
Then bead the securing lugs in the vice.
20W78RX777
§ Fasten the slotted nut by means of lock

plate.
20W78RX778
8-273
(4) Reassembly of the multi-disc brake
¤ Adjust the clearance or piston stroke to
the following table.
Number of Number of Piston stroke or
inner discs outer discs clearance
2 3 1.6~2.0mm
3 4 2.4~2.8mm
¡ The following measuring procedure
(Figure ¤Ł~ Example B) describes the
version with 3 inner discs and 4 outer
discs.
¤Ł Measure Dim. I, from the front of the ring

gear to the plane face of the piston.
Dim. I, e.g 91.00mm
Depth gauge 5870 200 051
20W78RX779
¤Ø Snap in the retaining ring and place it

until contact on the outer surface of the
recess.
Measure Dim. II, from the front of the ring
gear to the internal surface of the
retaining ring.
Dim. II, e.g 58.00mm
Then unsnap the retaining ring again.
20W78RX780
¤Œ Determine Dim. III, overall height of the

disc set incl. end shim.
¡ 2 Outer discs s = 2.00mm = 4.00mm
2 Outer discs s = 2.50mm = 5.00mm
¡
3 Inner discs s = 4.00mm = 12.00mm
1 End shim s = 9.40mm = 9.40mm
Results in overall height or Dim. III = 30.40mm
20W78RX781
8-274
¤Œ EXAMPLE B :
Dim. I e.g 91.0mm
Dim. II e.g -58.0mm
Difference 33.0mm
Dim. III e.g -30.4mm
Result = Piston stroke 2.6mm
¡ If the required piston stroke is not
obtained (see table page 8-274), it has to
be corrected with adequate outer discs
(s=2.0mm, s=2.5mm or s=3.0mm).
¤º Place the thrust washer with grease into

the recess of the hub carrier.
¡ If no perfect contact of the thrust washer
is obtained, both lugs of the lock plate
(inside) have to be installed subsequently.
20W78RX782
¤ Grease the O-ring and place it into the

annular groove of the disc carrier.
20W78RX783
¤ Assemble the sun gear into the disc

carrier until contact.
Then place the disc carrier over the teeth
of the stub shaft until contact.
20W78RX784
8-275
¤ Assemble the stub shaft with disc carrier
and sun gear until contact into the axle
casing and into the teeth of the axle bevel
gear respectively.
20W78RX785
¤ Install the outer and inner discs

alternately, starting with an outer disc.
¡ Oil the discs to list of lubricants TE-ML
05.
¡ When installing outer discs of different
strength, the thinner outer discs have
always to be installed at the piston and
end shim side.
20W78RX786
¤ Install the end shim into the ring gear.

picture.
20W78RX787
¤æ Fasten the disc set and the end shim by

means of the retaining ring.
20W78RX788
8-276
Check brake hydraulics for leakage
¤ Install the pressure connection.
HP-Pump 5870 287 007
Mini-measuring hub 5870 950 102
Venting bottle 5870 286 072
¡ Prior to start the test, ventilate the brake
and then actuate it several times(min. 10
times).
Test media : 20W78RX789
Motor oils SAE-10 W corresponding with,

MIL-L 2104 C, MIL-L 46152,
API-CC, CD, SC, SD, SE
ATF oils Type A, Suffic A
Dexron of II D
High-pressure test :
Build up a test pressure of p = 120bar
and close shut-off valve of the HP-pump.
During a 5 minute testing time a pressure
drop of max. 2% (p = 2bar) is allowed.
Low-pressure test :
Build up test pressure p =5bar and close
shut-off valve of the HP-pump.
During a 5 minute testing time no
pressure drop is allowed.
8-277
(5) Reassembly of the planet carrier
¤ Adjust the axial play of the sun gear shaft
0.4~0.6mm (Figure ¤ ~¤Ø)
Measure Dim. I, from the mounting face
of the planet carrier to the mounting face
of the thrust washer.
Dim. I, e.g 204.6mm
Straightedge 5870 200 022
20W78RX790
¤Ł Determine Dim. II, from the front of the

sun gear to the mounting face of the hub.
Dim. II, e.g 202.40mm
EXAMPLE C :
Dim. I e.g. 204.6mm
Dim. II e.g. -202.4mm
Difference 2.2mm
Required axial play e.g. -0.5mm
Result = Thrust washer e.g. s = 1.7mm 20W78RX791
¤Ø Place the thrust washer(e.g. s = 1.7mm)

into the planet carrier and press it until
contact.
Driver 5870 048 263
20W78RX792
¤Œ Install the planet gear as shown in the

opposite figure.
1 Planet gear
2 Roller bearing
3 Shim
4 Circlip
20W78RX793
8-278
¤º Heat the bearing inner ring and install the
preassembled planet gear until contact.
¡ Install the planet gear and bearing inner
ring respectively with the big radius
showing to the planet carrier
(downwards).
20W78RX794
¤ Fasten the planet gear by means of

retaining ring.
20W78RX795
¤ Place O-ring (see arrow) into the annular

groove and grease it.
20W78RX796
¤ Assemble the planet carrier until contact

and fasten it by means of cap screws.
Tightening torque¡⁄¡⁄¡⁄¡⁄¡⁄¡⁄¡⁄5.6kgf¡⁄m
¡ Prior to putting into operation of the axle,
fill up oil to lubrication and maintenance
instructions.
20W78RX797
8-279
GROUP 11 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
disconnected. 21078DA06
2) INSTALL
to removal.
8-280
1) STRUCTURE
14072SF80
8-281
1 Case 11 Plug 21 O-ring
2 Plug 12 Rod seal 22 Handle connector
3 Plug 13 O-ring 23 Nut
4 O-ring 14 Push rod 24 Insert
5 Spool 15 Plate 25 Boot
6 Shim 16 Bushing 26 Handle
7 Spring 17 Joint assembly 27 Switch assembly
8 Spring seat 18 Swash plate 28 Screw
9 Stopper 19 Adjusting nut 29 Switch assembly
10 Spring 20 Lock nut 30 Switch cover
40 Boot
8-282
(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 20 M14 5.0±0.35 36.2±2.5
Lock nut 21 M14 5.0±0.35 36.2±2.5
Screw 29 M 3 0.05 0.36
8-283
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(25) from case(1) and
take it out upwards.
1408DA62
※ For valve with switch, remove cord also

through hole of casing.
1408DA63
(4) Loosen lock nut(20) and adjusting nut(19)

with spanners on them respectively, and
take out handle section as one body.
1408DA64
(5) Remove the boot(40)
1408DA61
8-284
(6) Loosen adjusting nut(19) and plate(18)
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(15), plug(11) and push rod(14) will
come up on loosening joint.
Pay attention to this.
36078RL03
36078RL04
8-285
(8) Remove plate(15).
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
8-286
(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
31).
※ 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
8-287
36078RL13
(16) Remove lock nut(20) and then boot(25).
36078RL14
25038RL02
8-288
(17) 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.
② 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.
(18) 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.
8-289
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
8-290
(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
8-291
(9) When return spring is strong in force,
assemble 4 sets at the same time,
utilizing plate(15), and tighten joint(17)
temporarily.
36078RL23
(10) Fit plate(15).
(11) Tighten joint(17) with the specified torque

to casing, utilizing jig.
36078RL24
(12) Assemble swash plate(18) to joint(17).

※ Screw it to position that it contacts with 4
push rods evenly.
※ Do not screw it over.
36078RL25
(13) Assemble adjusting nut(19), apply

spanner to width across flat of plate(18) to
fix it, and tighten adjusting nut to the
specified torque.
※ During tightening, do not change position
of disk.
36078RL26
8-292
(14) Fit boot(40) to plate.
1408DA61
(15) Fit boot(25) and lock nut(20), and handle

subassembly is assembled completely.
25038RL02(4)
36078RL27
(16) Pull out cord and tube through adjusting

nut hole provided in direction 60°to 120°
from casing hole.
1408DA66
8- 293
(17) Assemble bushing(16) to plate and pass
cord and tube through it.
※ Provide margin necessary to operation.
1408DA67
(18) Determine handle direction, tighten lock

nut(20) to specified torque to fix handle.
1408DA68
(19) Apply grease to rotating section of joint

and contacting faces of disk and push rod.
1408DA69
(20) Assemble lower end of bellows to casing.

(21) Inject volatile rust-preventives through all
ports and then put blind plugs in ports.
25038RL04
8-294
GROUP 12 TURNING JOINT

1) REMOVAL

※ When pipes and hoses are disconnected,
(4) Disconnect all hoses.
1
(5) Sling the turning joint assembly (1) and 2
remove the mounting bolt(2).
・Tightening torque : 12.2± 1.3kgf・m
20W78TJ01
(88.2± 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.
※ Take care of turning joint direction.
※ Assemble hoses to their original positions.
※ Confirm the hydraulic oil level and check
20W78TJ02
8-295
1) STRUCTURE
26
11
21
7
23
17
8 25 10
19
22 32
6
20
3 12
14
13
24
33
9 28
15
22
1 2
16
31 29
30
28
18
27 20W78TJ03
1 Main hub 12 O-ring 23 Retainer ring

2 Main shaft 13 O-ring 24 W/washer bolt
3 Top hub 14 O-ring 25 Hex bolt
4 Top shaft 15 O-ring 26 W/washer bolt
5 Adaptor 16 O-ring 27 Socket bolt
6 Main cover 17 O-ring 28 Spring pin
7 Top cover 18 O-ring 29 Plug
8 Spacer 19 Back up ring 30 Plug
9 Bracket 20 Wear ring 31 Plug
10 Slipper seal 21 Wear ring 32 Plain washer
11 O-ring 22 Wear ring 33 O-ring
8-296
2) DISASSEMBLY
※ Before the disassembly, clean the turning
joint. 24
(1) Loosen the bolt(24) and remove the 9
bracket(9).
140W78TJ04
(2) Loosen the bolt(25) and remove the

upside(A) of turning joint. A
Remove O-ring(14) 25
140W78TJ05
(3) Loosen the bolt(26) and remove top cover 26

(7).
7
140W78TJ06
(4) Remove O-ring(17), retainer ring(23) and

spacer(8). 17
23
20W78TJ07
8-297
(5) Place hub(3) on a V-block and by using a
Secure with hand
wood buffer at the shaft end, hit out
Wooden block
shaft(4) to about 1/2 from the hub with a
hammer.
Take care not to damage the shaft(4)
when remove hub(3) or rest it sideway.
Put a fitting mark on hub(3) and shaft(4).
Work bench
8-141(3)
(6) Remove eight O-rings(15), back up ring

19
(19), O-ring(16) and wear ring(22) from
hub(3).
15
22
16
3
20W78TJ08
(7) Place main hub(1) on a V-block and by

Secure with hand
using a wood buffer at the shaft end, hit
Wooden block
out main shaft(2) to about 1/2 from the
main hub with a hammer.
Take care not to damage the main shaft(2)
when remove main hub(1) or rest it
sideway.
Put a fitting mark on main hub(1) and main Work bench
shaft(2). 8-141(3)
(8) Remove wear ring(21), eight slipper

21
seal(10), O-ring(13) and wear ring(20)
from main hub(1).
10
20
13
20W78TJ09
8-298
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) Fit wear ring(21), eight slipper seal(10), O-

ring(13) and wear ring(20). 21
(2) Fit O-ring(13) to main shaft(2) 10
20
13
20W78TJ09
(3) Set main shaft(2) on block, tap main

hub(1) with a plastic hammer to install.
20W78TJ10
(4) Fit eight O-ring(15), back up ring(19), O-

19
ring(16) and wear ring(22) to hub(3) of
turning joint upside.
15
22
16
3
20W78TJ08
8-299
(5) Set shaft(4) of turning joint upside on
block, tap hub(3) with a plastic hammer to
install.
4
20W78TJ11
(6) Fit spacer(8) and retainer ring(23) to

shaft(4). 17
23
(7) Fit O-ring(17) to hub(3).
8
20W78TJ07
(8) Set turning joint upside(A) on downside,

tighten bolts(25). A
25
・Torque : 3.5±0.4kgf・m
140W78TJ05
(9) Fit O-ring(17) to hub(3). 26

(10) Install cover(7) to hub and tighten 7
bolts(26).
・Torque : 2.35±0.35kgf・m
140W78TJ06
8-300
(11) Install bracket(9) to hub and tighten bolts
(24).
・Torque : 5.5±0.6kgf・m 24
9
This completes assembling
14078TJ04
8-301
GROUP 13 BOOM, ARM, BUCKET, DOZER AND OUTRIGGER CYLINDER

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

※ Escaping fluid under pressure can Bucket Cylinder
Fit blind plugs in the hoses after
disconnecting them, to prevent dirt or dust
from entering.
① Set block between bucket cylinder and Arm
arm.
Wooden block
21078DA14
② Remove bolt(2), nut(3) and pull out pin

2
(1).
※ Tie the rod with wire to prevent it from
3
coming out.
21078DA15
③ Disconnect bucket cylinder hoses(4) and

put plugs(5) on cylinder pipe. 5
21078DA16
8-302
④ Sling bucket cylinder assembly(8) and
8
remove bolt(6) then pull out pin (5).
⑤ Remove bucket cylinder assembly(8).
6 21078DA17
(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.
8-303
2) ARM CYLINDER
(1) Removal
※ Expand the arm and bucket fully, lower
the work equipment to the ground and
stop the engine.
Loosen the breather slowly to release the 13031GE18
※ Escaping fluid under pressure can
Fit blind plugs in the hoses after Arm cylinder
disconnecting them, to prevent dirt or
dust from entering.
① Set block between arm cylinder and
boom. Block
21078DA18
② Remove bolt(2) and pull out pin(1).

coming out.
21078DA19
③ Disconnect arm cylinder hoses(4) and 5

put plugs on cylinder pipe. 4
④ Disconnect greasing pipings(5).
21078DA20
8-304
⑤ Sling arm assembly(8) and remove bolt
(7) then pull out pin(6).
⑥ Remove arm cylinder assembly(8). 8
6
7
21078DA21
(2) Install
to removal.
pin hole.
※ Bleed the air from the arm cylinder.
8-305
3) BOOM CYLINDER
(1) Removal
the engine.
Loosen the breather slowly to release the 13031GE18
※ Escaping fluid under pressure can
Fit blind plugs in the hoses after
disconnecting them, to prevent dirt or dust 1
from entering.
① Disconnect greasing hoses(1).
② Sling boom cylinder assembly.
21078DA22
③ Remove bolt(4), stop plate(5) and pull out 4

pin(2). 5
2
coming out.
5
4
21078DA23
④ Lower the boom cylinder assembly(6) on

a stand.
21078DA24
8-306
⑤ Disconnect boom cylinder hoses(7) and
put plugs on cylinder pipe.
21078DA25
⑥ Remove bolt(9) and pull out pin(8).

⑦ Remove boom cylinder assembly(6).
・Weight : 190kg(420lb) 6
8
9
21078DA26
(2) Install
to removal.
pin hole.
※ Bleed the air from the boom cylinder.
※ Conformed the hydraulic oil level and
check the hydraulic oil leak or not.
8-307
4) DOZER CYLINDER
(1) Removal
the engine.
※ Loosen the breather slowly to release the 13031GE18
※ Fit blind plugs in the hoses after
disconnecting them, to prevent dirt or
dust from entering.
① Lower the dozer blade to the ground.
Dozer cylinder
Dozer blade
20W78DZ01
② Disconnect dozer cylinder hoses(1), and

1
put plugs on cylinder pipe.
Dozer cylinder
17038DC02(2)
③ Sling dozer cylinder assembly.

④ Remove bolt(2) and pull out pin(3).
Wire
coming out.
3
2
17038DC02(3)
8-308
⑤ Lower the dozer cylinder rod side on a
wooden block. Wire
Wooden block
17038DC03(1)
⑥ Loosen the bolt(4) and remove lock 8

washer(5), hook plate(6), and spacer(7). 9
Wire
⑦ Remove bolt(8) and pull out pin(9).
10
⑧ Remove the dozer cylinder assy(10).
76
5
4
17038DC03(2)
(2) Install
to removal.
pin hole.
※ Bleed the air from the dozer cylinder.
8-309
1) STRUCTURE
(1) Bucket cylinder
9,10 6,7 8 4,5 22 27 26 3 11,12 1 2 13 14 15,16 17 18 19 20 21
Internal detail
28,29 24 23 25 28,29
21078DA27
1 Tube assembly 11 O-ring 21 Lock nut

2 Rod assembly 12 Back up ring 22 Hexagon socket head bolt
3 Gland 13 Cushion ring 23 Band assembly
4 DD2 bushing 14 Piston 24 Pipe assembly(R)
5 Snap ring 15 O-ring 25 Pipe assembly(B)
6 Rod seal 16 Back up ring 26 O-ring
7 Back up ring 17 Piston seal 27 Hexagon socket head bolt
8 Buffer ring 18 Wear ring 28 Pin bushing
9 Dust wiper 19 Dust ring 29 Dust seal
10 Snap ring 20 Lock washer
8-310
(2) Arm cylinder
20,21
9,10 6,7 8 4,5 26 32 31 3 11,12 1 2 13 14 15,16 17 18 19 24 25 22,23
Internal detail
34,35 27 28 34,35
29 30 33
21078DA28
1 Tube assembly 13 Cushion ring 25 Lock nut

2 Rod assembly 14 Piston 26 Hexagon socket head bolt
3 Gland 15 O-ring 27 Band assembly(R)
4 DD2 bushing 16 Back up ring 28 Band assembly(B)
5 Snap ring 17 Piston seal 29 Pipe assembly(R)
6 Rod seal 18 Wear ring 30 Pipe assembly(B)
7 Back up ring 19 Dust ring 31 O-ring
8 Buffer ring 20 Cushion spear 32 Hexagon socket head bolt
9 Dust wiper 21 Check valve 33 Hexagon socket head bolt
10 Snap ring 22 Coil spring 34 Pin bushing
11 O-ring 23 Stop ring 35 Dust seal
12 Back up ring 24 Lock washer
8-311
(3) Boom cylinder
9,10 6,7 8 4,5 22 27 26 3 11,12 1 2 13 14 15,16 17 18 19 20 21
Internal detail
28,30 24 23 25 29,30
21078DA29
1 Tube assembly 11 O-ring 21 Lock nut

2 Rod assembly 12 Back up ring 22 Hexagon socket head bolt
3 Gland 13 Cushion ring 23 Band assembly
4 DD2 bushing 14 Piston 24 Pipe assembly(R)
5 Snap ring 15 O-ring 25 Pipe assembly(B)
6 Rod seal 16 Back up ring 26 O-ring
9 Dust wiper 19 Dust ring 29 Pin bushing
10 Snap ring 20 Lock washer 30 Dust seal
8-312
(4) Dozer cylinder
27 8,9 18 3 5,6 7 10,11 4 23 21 1 2 19 12 15 13,14 16 17 20 24 22
25,26 25,26
200W38DC00
1 Tube assembly 10 O-ring 19 Pipe assembly

2 Rod assembly 11 Back up ring 20 Check valve block
3 Gland 12 Piston 21 O-ring
4 Du bushing 13 O-ring 22 O-ring
5 Rod seal 14 Back up ring 23 Hexagon socket head bolt
8 Dust wiper 17 Nylon nut 26 Dust seal
9 Snap ring 18 Hexagon socket head bolt 27 Grease nipple
8-313
(5) Outrigger cylinder
8,9 18 3 5,6 7 10,11 4 23 21 1 2 19 12 15 13,14 16 17 20 24 22
25,26 25,26
20W78OT01
1 Tube assembly 10 O-ring 19 Pipe assembly

2 Rod assembly 11 Back up ring 20 Check valve block
3 Gland 12 Piston 21 O-ring
4 Du bushing 13 O-ring 22 O-ring
5 Rod seal 14 Back up ring 23 Hexagon socket head bolt
8 Dust wiper 17 Nylon nut 26 Dust seal
9 Snap ring 18 Hexagon socket head bolt
8-314
(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 M16 23±2.0 166±14.5
22
Boom cylinder M16 23±2.0 166±14.5
Arm cylinder 26 M18 32±3.0 232±21.7
Dozer cylinder
18 M16 23±2.0 166±14.5
Outrigger cylinder
Bucket cylinder 27
Socket head bolt
Boom cylinder 27 M10 5.4±0.5 39.1±3.6
Arm cylinder 33
Dozer cylinder
23 M8 2.7±0.3 19.5±2.2
Outrigger cylinder
Dozer cylinder
24 M10 5.4±0.5 39.1±3.6
Outrigger cylinder
Bucket 26
Hexagon head bolt Boom 25 M10 3.2±0.3 23.1±2.2
Arm 29
Bucket cylinder 21 M60
Boom cylinder 21 M60 100±10.0 723±72.3
Lock nut Arm cylinder 25 M70
Dozer cylinder M56 400±40 2893±289
17
Outrigger cylinder M52 300±30 2170±217
Bucket cylinder
Boom cylinder 14 150±15.0 1085±109
Piston Arm cylinder -
Dozer cylinder
12 100±10 723.3±72.3
Outrigger cylinder
8-315
3) DISASSEMBLY
(1) Remove cylinder head and piston rod
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.
② 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 2
21078DA30
③ 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
④ 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
8-316
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.
⑤ 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). 13 16 15 14 22 21
※ Since lock nut(21) and lock washer(22)
is tightened to a high torque, use a
hydraulic and power wrench that utilizers
a hydraulic cylinder, to remove the lock
nut(21) and lock washer (22).
② Remove piston assembly(14), back up
ring(16), and O-ring(15).
21078DA34
③ Remove the cylinder head assembly Plastic

from rod assembly(2). 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
21078DA35
(5,6,7,8,9,10) by the threads of rod
assembly(2).
8-317
(3) Disassemble the piston assembly
① Remove wear ring(18). 19 18 17 18 19
② Remove dust ring(19) and piston seal
(17).
※ Exercise care in this operation not to
damage the grooves.
8-156(1) 210-7
(4) Disassemble cylinder head assembly

10 9 6 7 8 4 5 12 11
① Remove back up ring(12) and O-ring
(11).
② Remove snap ring(10), dust wiper(9).
③ Remove back up ring(7), rod seal(6) and
buffer ring(8).
※ Exercise care in this operation not to
damage the grooves.
※ Do not remove seal and ring, if does not
21078DA36
damaged.
8-318
3) 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.
21078DA37
② Coat dust wiper(9) with grease and fit Press here

dust wiper(9) to the bottom of the hole of (Straight down)
dust seal. Metal
At this time, press a pad metal to the 9
metal ring of dust seal.
③ Fit snap ring(10) to the stop face.
8-157(2) 210-7
④ 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.

Push bar
Therefore, confirm it before fitting them.
※ Fitting rod seal(6) upside down may
damage its lip. Therefore check the
correct direction that is shown in fig.
21078DA38
8-319
⑤ Fit back up ring(12) to gland(3).
※ Put the backup ring in the warm water of 11
30~50° C.
12
⑥ Fit O-ring(11) to gland(3).
21078DA39
(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
② Fit piston seal(17) to piston.

※ Put the piston seal in the warm water of 17
60~100° C for more than 5 minutes.
※ After assembling the piston seal, press its
outer diameter to fit in.
8-158(3) 210-7
③ Fit wear ring(18) and dust ring(19) to

piston(14). 19 18 17 18 19
14
8-158(4) 210-7
8-320
(3) Install piston and cylinder head
① Fix the rod assembly to the work bench. Cylinder head assembly
② Apply hydraulic oil to the outer surface of Rod assembly
rod assembly(2), the inner surface of
piston and cylinder head.
③ Insert cylinder head assembly to rod
assembly.
21078DA40
④ Insert cushion ring(13) to rod assembly.

※ Note that cushion ring(13) has a direction 13
in which it should be fitted. Insert
8-159(2) 210-7
⑤ Fit piston assembly to rod assembly.

Piston assembly
・Tightening torque : 100±10kgf・m
(723±72lbf・ft)
8-159(3) 210-7
⑥ Fit lock nut to piston.

・Tightening torque : 20
Item kgf・m lbf・ft
Bucket 21 100±10 723±72.3

Boom 21 100±10 723±72.3
Arm 25 100±10 723±72.3
Dozer 17 400±40 2893±289
Outrigger 17 300±30 2170±217 8-159(4) 210-7
8-321
(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.
② 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.
③ 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
8-322
GROUP 14 WORK EQUIPMENT
1. STRUCTURE
A
A
SECTION A SECTION B SECTION C
21078DA44
8-323
1) BUCKET ASSEMBLY
(1) Removal
① Lower the work equipment completely to
A
ground with back of bucket facing down.
B
36078AT04
② Remove nut(1), bolt(2) and draw out the

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

pin(B) then remove the bucket assembly.
36078AT02
(2) Install
to removal.
pin hole.
※ Adjust the bucket clearance.
For detail, see operation manual.
36078AT05
8-324
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.
② 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.
4
③ Sling arm cylinder assembly, remove
spring, pin stopper and pull out pin.
coming out. 4
④ For details, see removal of arm cylinder
assembly.
21078DA16
Place a wooden block under the cylinder
and bring the cylinder down to it.
⑤ Remove bolt(2), plate(3) and pull out the
pin(4) then remove the arm assembly.
※ 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.
8-325
3) BOOM CYLINDER
(1) Removal
① Remove arm and bucket assembly.
For details, see removal of arm and
bucket assembly.
② Remove boom cylinder assembly from
boom.
For details, see removal of arm cylinder
assembly. 8-176(1) 210-7
③ Disconnect head lamp wiring.

④ Disconnect bucket cylinder hose(2) and 1
arm cylinder hose(1). 2
※ When the hose are disconnected, oil
may spurt out.
⑤ Sling boom assembly(3). 1
21078DA45
⑥ Remove bolt(4), plate(5) and pull out the

Crane
pin(6) then remove boom assembly.
・Weight :1950kg(4300lb)
※ 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
8-326
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 5 Power train system 9-9
Group 6 Structure 9-11
Group 7 Work equipment 9-15
SECTION 9 COMPONENT MOUNTING TORQUE
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.
※ Only metric fasteners can be used and
incorrect fasteners may result in machine
damage or malfunction.
※ Before installation, clean all the components
with a non-corrosive cleaner. Bolts and
threads must not be worn or damaged. 20W79CM00
9-1
GROUP 2 ENGINE SYSTEM
ENGINE AND ACCESSORIES MOUNTING
2
Muffler
Air cleaner
7 Cable bracket
5
4 2
Engine
8
4
7 Engine 6
Hydraulic tank oil filter 1
D
C Speed lever
9
A
B
A
B
8
D
6 C
2 3
4 Accel Fan
actuator
6 Emergency
lever
210N79CM01
・Tightening torque
Item Size kgf・m lbf・ft Item Size kgf・m lbf・ft

1 M 6×1.0 0.92±0.2 6.7±1.4 6 M12×1.75 10.0±2.0 72.3±14.5
2 M 8×1.25 2.5±0.5 18.1±3.6 7 M12×1.75 12.8±3.0 92.6±21.7
3 M10×1.5 4.4±0.9 31.8±6.5 8 M20×2.5 55±3.5 398±25.3
4 M10×1.5 6.9±1.4 49.9±10.1 9 M24×3.0 90±7.0 651±51
5 M12×1.5 12.5±3.0 92.6±21.7 - - - -
9-2
COOLING SYSTEM AND FUEL TANK MOUNTING
2 Cooler & radiator

Water Air compressor
seperator
2
Hyd tank Air con
idle pully
Fuel tank 3
DISCHARGE
Receiver drier -A
1
UID
LIQ
Condenser
5
VIEW A
Radiator
3
6
Oil cooler 3 4
HY
UN
Reservoir DA
I
Needle valve tank

FU
LO
LL
2
Shroud
3
4
4
2
3
4
Fan guard
4
210N79CM02

1 M 6×1.0 1.05±0.2 7.6±1.45 4 M12×1.75 12.8±3.0 92.6±21.7
2 M 8×1.25 2.5±0.5 18.1±3.6 5 M20×2.5 46±5.1 333±36.9
3 M10×1.5 6.9±1.4 49.9±10.1 6 - 2.3±0.6 16.6±4.3
9-3
GROUP 3 ELECTRIC SYSTEM
ELECTRIC COMPONENTS MOUNTING 1
Work lamp
Alternator
3
Start relay
Heater relay
2
4
1
Fuel filler ON
OFF
pump
Travel alarm buzzer

3
Battery 3
2
Horn
2
A
Battery relay 2 DETAIL A
1
Washer
tank
20W79CM03

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
ELECTRIC COMPONENTS MOUNTING 2
Beacon lamp
3
Wiper motor
Cluster
VIEW A
2
Electric box
Fuse box
Prolix resistor
1
CPU controller
2
1
1 YR
G
Wiper motor cover

1 1
20W79CM04

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
HYDRAULIC COMPONENTS MOUNTING 1
2 Solenoid valve
5 Solenoid valve
6 4
2 7
Air breather
Level gauge
6
5 3
Spin filter
3
10
Main pump
Hydraulic tank 10
8
Swing motor Coupling
11 Main control valve
12
6
8
RCV-LH
6
1
Terminal
RCV-RH
1
Dozer lever
6
Cross
6
3
6
20W79CM05

1 M 6×1.0 1.05±0.2 7.6±1.45 8 M12×1.75 12.2±1.3 88.2±9.4
2 M 6×1.0 1.44±0.3 10.4±2.2 9 M12×1.75 14.7±2.2 106±15.9
3 M 8×1.25 2.5±0.5 18.1±3.6 10 M18×2.5 32±1.0 231±7.2
4 M10×1.5 0.5 3.6 11 M20×2.5 46±5.1 333±36.9
5 M10×1.5 4.8±0.3 34.7±2.2 12 M20×2.5 57.9±8.7 419±62.9
6 M10×1.5 6.9±1.4 49.9±10.1 - - - -
7 M10×1.5 8.27±1.7 59.8±12.3
9-6
Double acting attachment piping Boom safety lock system

Boom safety lock valve
Boom
cylinder
Gear pump
5
5
8
8 Travel motor
Stop
valve
Turning joint
3
8 4
D/acting
3 way joint 4 7
D/acting
hose joint
Transmission
valve Brake supply valve
9 8
1 Arm safety lock system

1
2
Arm cylinder
Accel pedal 7
Brake pedal
D/acting single pedal
Steering valve
4
Arm safety
lock valve
20W79CM06

1 M 6×1.0 1.05±0.2 7.6±1.4 6 M12×1.75 9.3±1.9 67.3±13.7
2 M 8×1.25 2.5±0.5 18.1±3.6 7 M12×1.75 12.0±1.3 86.8±9.4
3 M 8×1.25 4.05±0.8 29.3±5.8 8 M12×1.75 12.8±3.0 92.6±21.7
4 M10×1.5 6.9±1.4 49.9±10.1 9 M12×1.75 14.7±2.2 106±15.9
5 M10×1.5 8.27±1.7 59.8±12.3 10 M16×2.0 29.6±3.2 214±23.1
9-7
3
3 4
4
3 2 2 2
2
7
6
5
BOOM CYLINDER ARM CYLINDER
3
2
2
4
3 1
3 1
6
6
4
BUCKET CYLINDER DOZER & OUTRIGGER CYLINDER

20W79CM07

1 M8 ×1.25 2.7±0.3 19.5±2.2 5 M12×1.75 9.4±1.0 68.0±7.2
2 M10×1.5 3.2±0.3 23.1±2.2 6 M16×2.0 23±2.0 166±14.5
3 M10×1.5 5.4±0.5 39.1±3.6 7 M18×2.5 32±3.0 232±21.7
4 M12×1.75 5.5±0.6 39.8±4.3
9-8
GROUP 5 POWER TRAIN SYSTEM
Swing bearing
Rear axle
8 1
8
10
7 11
9
1
Oscillating 1
Tire cylinder
2 6
4 Rear 11
Pivot pin propeller shaft
10 5
1
1 Transmission
1
Front
propeller shaft
Front axle Transmission

protect cover
5 3
20W79CM08

1 M10×1.0 5.9±0.6 42.7±4.3 7 M20×2.5 39±4.2 282±30.4
2 M12×1.75 12.2±1.3 88.2±9.4 8 M20×2.5 57.8±6.4 418±46.3
3 M12×1.75 12.8±3.0 92.6±21.7 9 M22×1.5 69.4±10.4 502±75.2
4 M16×2.0 29.6±3.2 214±23.1 10 M24×2.0 100±10.7 723±77.4
5 M20×1.5 50±0.5 362±3.6 11 M24×3.0 100±10 723±72.3
6 M20×2.5 29.6±3.2 214±23.1 - - - -
9-9
COVER AND FOOT BOARD
2 2
Rear fender(RH)
Wheel chock
2 Lower frame
Front fender(RH)
Foot board(RH)
Rear fender(LH)
2
3
2
2 2
Foot board(LH)
1 3
Tool box assy
2
2
Front fender(LH)
20W79CM09

1 M10×1.5 6.9±1.4 49.9±10.1 3 M20×2.5 57.9±8.7 419±62.9
2 M12×1.75 12.8±3.0 92.6±21.7 - - - -
9-10
GROUP 6 STRUCTURE
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
210N79CM09

1 M 6×1.0 0.49±0.1 3.5±0.7 4 M10×1.5 6.9±1.4 49.9±10.1
2 M 8×1.25 2.5±0.5 18.1±3.6 5 M12×1.75 12.8±3.0 92.6±21.7
3 M10×1.5 4.7±0.9 34±6.5 6 M16×2.0 29.7±4.5 215±32.5
9-11
CAB INTERIOR MOUNTING
Seat
1
1
Storage
4 box cover
Aircon upper
cover
Console 1 5
box(RH) Storage
Wiper motor box
cover
1 1 5
Defroster 5
hose cover Aircon lower
cover
1 Console box(LH)
3
Seat base
Slide rail Safety lever
2
6
Steering column
5
Viscous
mount
Bottom plate
20W79CM10

1 M 6×1.0 0.49±0.1 3.5±0.7 5 M10×1.5 6.9±1.4 49.9±10.1
2 M 6×1.0 1.05±0.2 7.6±1.4 6 M16×2.0 29.7±4.5 215±32.5
3 M 8×1.25 3.43±0.7 24.8±5.1 - - - -
4 M 8×1.25 4.05±0.8 29.3±5.8
9-12
COWLING MOUNTING
Engine hood
Side cover(RH)
2
Pump hood
2 Catch
1
2 2
2
2
A
2 2 Pump 1
screen
Air cleaner hood
Screen
2
2
Tank cover 2
MCV hood Engine hood
support
A
2
2
2
Base plate
2
Side cover(LH)
20W79CM11
Item Size kgf・m lbf・ft

1 M 8×1.25 2.5±0.5 18.1±3.6
2 M12×1.75 12.8±3.0 92.6±21.7
9-13
COUNTERWEIGHT AND COVERS MOUNTING
Handle pipe
2
Handle pipe
1
Fuel tank
Fuel tank Counterweight

2 cover
2
2
Tool box
Handle
2
Upper frame
Pump under cover
Engine under cover

Hyd tank under cover
Fuel under cover Radiator under cover
1
1
Swing bearing grease 1

drain cover
MCV under cover
1
Cab under cover(C)
Cab under cover(B)

Cab under cover(A) 1
20W79CM12

1 M10×1.5 6.9±1.4 49.9±10.1 3 M36×3.0 308±46 2228±333
2 M12×1.75 12.8±3.0 92.6±21.7 - - - -
9-14
GROUP 7 WORK EQUIPMENT
Arm cylinder
rod pin
2
Arm cylinder
Stop plate
Bucket cylinder
head pin
Bucket 3 2 1
cylinder
Arm pin Boom
Bucket cylinder Arm cylinder
rod pin Boom pin
head pin Boom cylinder
Bucket head pin
control link 1
3
Boom
Bucket cylinder 2
3 4 2
Side cutter(RH)
2
Bucket control
rod pin
Cover plate
Side cutter(LH)
20W79CM13

1 M12×1.75 12.8±3.0 92.6±21.7 3 M20×2.5 57.9±8.7 419±62.9
2 M16×2.0 29.7±4.5 215±32.5 4 M22×2.5 55.8±7.5 404±54.2
9-15

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SECTION 1 GENERAL

Group 1 Safety Hints 1-1

FOLLOW SAFE PROCEDURE

WEAR PROTECTIVE CLOTHING

WARN OTHERS OF SERVICE WORK

「Do Not Operate」tag on the right side control lever. DO

USE HANDHOLDS AND STEPS

PROTECT AGAINST FLYING DEBRIS

PROTECT AGAINST NOISE

AVOID POWER LINES

MOVE AND OPERATE MACHINE SAFELY

OPERATE ONLY FORM OPERATOR'S SEAT

PARK MACHINE SAFELY

SERVICE COOLING SYSTEM SAFELY

HANDLE FLUIDS SAFELY-AVOID FIRES

Store flammable fluids away from fire hazards. Do not

REMOVE PAINT BEFORE WELDING OR HEATING

ILLUMINATE WORK AREA SAFELY

STAY CLEAR OF MOVING PARTS

AVOID HIGH PRESSURE FLUIDS

fluid injected into the skin must be surgically removed

PREVENT BATTERY EXPLOSIONS

PREVENT ACID BURNS

DISPOSE OF FLUIDS PROPERLY

REPLACE SAFETY SIGNS

LIVE WITH SAFETY

Bucket Tire Turning joint Swing motor Main control valve

Arm Arm cylinder Boom Boom cylinder Cab Muffler Counterweight

Description Unit Specification

Operating weight kg(lb) 20500(45290)

・ : Rating over-front ・ : Rating over-side or 360 degree

Load radius At max. reach

7.5m kg *3810 *3810 6.85

7.5m kg *3810 2550 6.85

7.5m kg *3830 *3830 6.85

7.5m kg *3830 2550 6.85

0.51m3 0.45m3 700mm 820mm 580kg

※0.80m3 0.70m3 1000mm 1120mm 650kg

0.87m3 0.75m3 1090mm 1210mm 660kg

0.92m3 0.80m3 1130mm 1250mm 710kg

1.20m3 1.00m3 1400mm 770kg

1.34m3 1.15m3 1550mm 800kg

◈0.74, 0.90, 1.05m3 SAE

◈0.74m3 0.65m3 915mm 750kg

◈0.90m3 0.80m3 1070mm 790kg

◈1.05m3 0.92m3 1220mm 870kg

0.87m3 0.75m3 1140mm 860kg

▣0.75m3 0.65m3 1810mm 880kg

◈ : Heavy duty bucket : Rock bucket(Heavy) ▣ : Slope finishing bucket

Applicable for materials with density of 2000kgf/m3 (3370lbf/yd3) or less

Model Cummins B5.9-C

Type Variable displacement axial piston pump

Type Fixed displacement gear pump single stage

4) MAIN CONTROL VALVE

Type 9 spools double-block

Type Fixed displacement axial piston motor

Type Variable displacement bent-axis axial piston motor

Item Description Specification

8) REMOTE CONTROL VALVE

Type Pressure reducing type

Bore dia×Rod dia×Stroke Ø120×Ø85×1290mm

2 Piece boom Bore dia×Rod dia×Stroke Ø160×Ø100×425mm

STD 0.80m (1.05yd )

7.5m kg 3810 3810 6.85

7.5m kg 3830 3830 6.85