7 Hydraulic System, Digging, Handling, Grading Equipment, Misc Equipment

Service Information
Document Title: Function Group: Information Type: Date:

Description, general 900 Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Description, general
The machine is equipped with a negative flow control system with variable flow. With this system, the working pump can
deliver flow according to demand. A variable flow from the pump allows precision work even with high engine speed.
The hydraulic system, also known as the “Automatic Sensing Work Mode,” is designed for high-productivity, high-digging
capacity, high-maneuvering precision and excellent fuel economy. The summation system, boom, arm and swing priority
along with boom and arm regeneration provides optimum performance.
The following important functions are included in the system:
 Summation system: Combines the flow of both hydraulic pumps to ensure quick cycle times and high productivity.
 Boom priority: Gives priority to the boom operation for faster raising when loading or performing deep excavations.
 Swing priority: Gives priority to swing functions for faster simultaneous operations.
 Regeneration system: Prevents cavitation and provides flow to other movements during simultaneous operations
for maximum productivity.
 Power boost: All digging and lifting forces are increased.
 Holding valves: Boom and arm holding valves prevent the digging equipment from creeping.
The following functions are included in the main control valve :
 Boom
 Dipper arm
 Bucket
 Slew
 Travel
 Optional equipment, X1
The optional control valve has the following functions:
 Adjustable boom, X2
 Optional equipment, X3
 line rupture for boom and arm
Service Information

Hydraulic system, 900 Service Information 2014/10/29
description
Profile:
EXC, EC290B LC [GB]
Hydraulic system, description

The machine's hydraulic system is divided into two subsystems - the working hydraulic system and servo hydraulic system.
All power transmission is via hydraulic oil in the working hydraulic system.
A working pump supplies the main valve block with oil. The main valve block distributes the oil to the digging equipment's
four (five split boom) hydraulic cylinders and the two hydraulic motors for travel and slew. The flow of oil to the different
movements is controlled with valve spools in directional valves.
The servo hydraulic system is used for control.
A servo pump supplies the control levers and pedals with servo pressure. When the machine is operated, the control
pressure valves reduce the servo pressure to a control pressure, which activates the directional valves.
Service Information

Hydraulic oil, description 900 Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Hydraulic oil, description

The oil contains selected additives that provide good oxidation stability, corrosion protection and good lubricating
characteristics as well as compatibility with bearings containing lead alloys.
The ester base gives the oil a very high viscosity index and good characteristics at low temperatures.
Service Information

Hydraulic system, repair of 900 Service Information 2014/10/29
hydraulic components in
workshop
Profile:
EXC, EC290B LC [GB]
Hydraulic system, repair of hydraulic components in workshop

 Always wear clean coveralls and be strict about personal cleanliness.
 Work on hydraulic components should be performed separate from other work in a so-called "clean room". The
room must have good ventilation and the floor must be coated with a binding material. Machining, grinding and
similar work is not allowed in the "clean room".
 The workplace must be equipped with thoroughly cleaned tools and suitable containers for cleaning hydraulic
components.
 Containers for cleaning hydraulic components must not be used for other cleaning. The containers must be cleaned
frequently and filled with new fluid. The containers must be equipped with a removable grating on the bottom,
which separates the component from any sludge on the bottom.
 Always clean components that are going to be handled in the "clean room". If an alkaline detergent is used, it
should contain anti-corrosion agent.
 Always plan work on the hydraulic system so that it can be completed without any longer interruptions.
 When cleaning during repairing – use dry and clean compressed air for drying, do not use cotton waste or rags.
 Always plug a component when work is completed, use clean plastic plugs of the correct dimensions, and pack the
component.
 When cleaning in the "clean room" – use methods that do not stir up dust or dirt.
Service Information

Hydraulic oil, storage and 900 Service Information 2014/10/29
handling
Profile:
EXC, EC290B LC [GB]
Hydraulic oil, storage and handling

 Hydraulic oil should be stored in tightly sealed tanks or barrels.
 Only containers used for transporting hydraulic oil should be used for this purpose.
 Oil should be stored under cover or in temperature-controlled premises. If oil is stored outdoors, the barrels should
be stored horizontally so that water cannot enter and the barrel markings are not eradicated.
 Oil must not be stored at temperatures exceeding 60 °C, or be exposed to direct sunlight or freezing temperatures.
Service Information

Hydraulic system, 900 Service Information 2014/10/29
cleanliness when handling
hydraulic components
Profile:
EXC, EC290B LC [GB]
Hydraulic system, cleanliness when handling hydraulic components

WARNING
Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries
NOTICE
It is very important to keep the hydraulic system free from any impurities, as these can cause abnormal wear and
may lead to expensive downtime. Greatest possible cleanliness should be maintained during all handling of
hydraulic components and hydraulic oil.
NOTE!
A vacuum pump should be used for work on the hydraulic system, see 900 Vacuum pump, connection.
Service Information

Hydraulic components, 900 Service Information 2014/10/29
storage and transport
Profile:
EXC, EC290B LC [GB]
Hydraulic components, storage and transport

 All hydraulic components must be stored in plastic bags or film and they must be plugged. The packaging must not
be opened before use of the component.
 Service vehicles should be equipped with an interior which facilitates good order and cleanliness.
 Each service vehicle should carry a roll of plastic film, plastic plugs of the most common sizes and plastic containers
for components. Plugs and film should be of the disposable type.
Service Information

Hydraulic system, work 910 Service Information 2014/10/29
instructions
Profile:
EXC, EC290B LC [GB]
Hydraulic system, work instructions

 Always wear clean coveralls and be strict about personal cleanliness.
 Perform thorough troubleshooting to avoid unnecessary repair work.
 If necessary, move the machine, to as dust-free an environment as possible.
 If possible, do not dismantle components in the field. Use exchange components.
 Protect both replaced components and components that are to be reused by wrapping them in plastic film.
 If the tank is to be drained, and the oil has been found to be free of discolouration and impurities – drain the oil
into clean containers, and seal securely. Refilling of this oil or filling of new oil should always be performed by
removing the hydraulic oil filter cap and then filling through the filter.
 Use a suitable fluid when cleaning and pour it into a thoroughly cleaned container.
Service Information

Hydraulic components, 910 Service Information 2014/10/29
description
Profile:
EXC, EC290B LC [GB]
Hydraulic components, description

This machine incorporates the features and functions described below in its hydraulic circuit in order to provide easier
operation, greater safety, higher productivity, and better fuel economy.
Function of components
Purpose Component Function Feature

Ease of Travel
operation and  Controlled by servo hydraulic  Straight travel during simultaneous
safety pressure operations.
 Straight travel  Automatic shifting between low and high
 Low speed, low/high speed speed.
automatic shift
Slew
 Slew priority circuit (during  Easier digging due to the use of
simultaneous slew and arm in) simultaneous slew and arm in.
 Automatic slew parking brake
 Rebound damping function  Delayed slew parking brake application
during slew to allow for inertia.
 Damping by rebound damping valve.
Digging units
 Controlled by servo hydraulic  Fine operation.
pressure
 Boom, arm regenerating  Changing the balance between boom,
circuit arm and bucket functions.
 Holding valve (boom, arm  Decreasing the amount of natural fall of
lock) boom when the boom is at rest.
 Heavy lift and heavy duty  Increasing the working pressure by
digging increasing the pressure of main relief
valve.
Others
 Closed and semi  Contamination of hydraulic oil prevented,
automatically pressurized suction ability of pump improved.
hydraulic tank  Damage of hydraulic components
 Suction strainer prevented.
 Contamination of hydraulic oil prevented.
 Return line: filter and drain  Servo hydraulic operated circuit failure
filter prevented.
 Servo hydraulic circuit: line  Deterioration of hydraulic oil prevented.
filter  If engine stopped, movable by weight of
 Hydraulic oil cooled by oil digging units.
cooler
 Emergency circuit
Productivity Pump
increased  Full horsepower control  Effective use of engine horsepower
though action of two variable
displacement pumps.
Travel
 2–speed auto shift by the 2–  Low speed/high propel torque.
speed track motor  High speed/low propel torque.
Digging units
 Conflux for boom raising  Faster boom raising.
 Regeneration for boom  Positive bucket motion during
lowering simultaneous boom lowering and bucket
operation.
 Conflux circuit for arm in  Faster arm in under heavy load.
under heavy load
 Conflux circuit for arm in  Faster arm in under light load.
under light load
 Conflux circuit for arm out  Faster arm out.
 Pressure increasing circuit for  Improved digging, lifting under heavy
heavy load load.
Fuel economy Pump

 Negative flow control  Flow minimized when in neutral
Controller
 Mode select switch  Selecting an effective engine rpm suited
changeover for the amount of work, fuel
consumption and fine control.
 Auto idling  Engine speed decelerated during waiting
periods for reduced fuel cost and less
noise.
Service Information

Hydraulic diagram, 910 Service Information 2014/10/29
schematic
Profile:
EXC, EC290B LC [GB]
Hydraulic diagram, schematic
Figure 1
Hydraulic diagram
1 Travel spool 7 Slew spool 13 Slew motor

2 Bucket spool 8 Travel motor 14 Travel motor
3 Boom spool 9 Boom cylinder A Engine
4 Travel spool 10 Arm cylinder B Main pump
5 Arm spool 11 Bucket cylinder C Gear pump
6 Option spool 12 Center passage
The mechanical power from the engine is converted to hydraulic power by the main pumps. Hydraulic power from the main
pumps goes to the track motors, slew motor and hydraulic cylinders via the control valve, where it is converted back to
mechanical power, which actuates the travel action, slew action and digging units.
Service Information

Hydraulic tank, description Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Hydraulic tank, description
Figure 1
Structure, hydraulic oil tank
1 Hydraulic oil tank 8 Plain washer 16 Cover

2 Strainer 9 Shim 17 Cover
3 Drain plug 10 Element 18 Screw
4 O-ring 11 Strainer 19 Breather
5 Sight gauge 12 Bypass valve 21 Plug
6 Screw 13 Spring S Side door
7 Spring washer 14 Screw F Fuel tank
Tightening torque, unit : kgf·m (lbf·ft)
No. Tightening torque

6 52.2 ± 5.2 (377 ± 38)
14 6.5 ± 0.7 (47 ± 5)
18 0.3 ~ 0.5 (2.2 ~ 3.6)
 To check the oil level, park on a level surface, retract the arm cylinder, extend the bucket cylinder, lower the bucket
to the ground and stop the engine.
 Operate each control lever (for digging unit and travel) to its full stroke to release the residual pressure.
 The center line of the sight gauge is normal. Add oil when required.
– Bypass valve set pressure: 1.5 ±0.3 kgf/cm2 (21 ±4 psi)
– Air breather :
1) Relief set pressure: 0.5 ±0.1 kgf/cm2 (7 ± 1.4 psi)
2) Suction set pressure: 0.05 ±0.01 kgf/cm2 (0.7 ± 0.14 psi)
Figure 2
Oil level sight gauge
 When mounting the tank, make the bottom level with frame by use of shim (9).
 Maintain the clearance (front, rear, left, right) within 10 mm.
Oil filter bypass valve

When the filter is clogged
Bypass valve (1) is opened and the oil returns directly to the tank without passing through the filter.
NOTE!
Bypass valve set pressure : 1.5 ± 0.3 kgf/cm2 (21.33 ± 4.3 psi)
Figure 3
Oil flow, when the filter is clogged
A : From main control valve
Air breather
Preventing negative pressure inside the tank
The tank is a pressurized sealed type, so negative pressure is formed inside the hydraulic tank when the oil level drops
during operations. When this happens, the difference in pressure between the tank and the outside atmospheric pressure
opens the poppet in the breather, and air from the outside is let into the tank to prevent negative pressure.
At that time filter (2) prevents contamination from entering the tank.
Preventing excessive pressure inside the tank
When the hydraulic actuators are operated, the oil level in the hydraulic system increases as temperature rises. If the
hydraulic pressure rises exceeding the set pressure, the breather is actuated to release the hydraulic pressure inside the tank.
Hydraulic tank pressurizing
The hydraulic tank is pressurized to create a positive pressure at the hydraulic pump inlet to prevent cavitation.
If the tank cap assembly does not function or seal properly, the hydraulic pump could be damaged.
To pressurize the tank, raise the boom to maximum height, extend the arm and bucket cylinders, then lower the boom to
the ground.
Figure 4
Air breather
1 Body 3 Cap
2 Filter 4 Valve
To prevent hydraulic oil ejection due to the tank internal pressure while hydraulic system maintenance, press the inner
button several times to release the pressure until the air is all out.
Service Information

Hydraulic oil tank, vacuum- Service Information 2014/10/29
pumping, connecting and
disconnecting pump
Profile:
EXC, EC290B LC [GB]
Hydraulic oil tank, vacuum-pumping, connecting and disconnecting

pump
Op nbr 911-040
14 360 000 Vacuum pump
NOTICE
Connection of the vacuum pump must be performed with the diesel engine off. The air filter is placed above the
filtered hydraulic oil. Therefore, carefully clean the surfaces closest to the filter. Do not leave the connection to the
filter open for longer than it takes to fit the adapter.
NOTE!
There is always a risk of air entering the hydraulic system when using a vacuum pump.
NOTE!
See : 9111 Breather, replacing
1. Place the vacuum pump on the hydraulic oil tank.
Figure 1
Remove air breather
2. Remove screws (1) and air breather (2) from hydraulic oil tank (3).
3. Install adapter (2) and connect hose (1) to the adapter.

Figure 2
Connection of vacuum pump
1. Hose
2. Adapter
3. Vacuum pump
4. Connect the plug to the 24 V socket behind the operator's cab.
5. Start the vacuum pump.
6. Run the pump for 2–3 minutes until a negative pressure reading of –30 kPa (–4.35 psi) is obtained.
7. Adjust the vacuum pressure with the adjusting knob so that oil leakage will not occur during work on the hydraulic
system.
Figure 3
Vacuum pump
1. Adjusting knob
IMPORTANT! The pressure must not fall below –30 kPa (–4.35 psi), as otherwise there is a risk of damage to the
hydraulic oil tank.
8. Turn off the electric power to the vacuum pump.
9. Remove the plug from the 24V socket.
10. Remove the hose from the adapter.
11. Remove the adapter and immediately fit the air breather.
Service Information

Oil level gauge, replacing Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Oil level gauge, replacing

Op nbr 911-015
WARNING
1. Place the machine in the service position D. See 091 Service positions
2. Press the air breather cap on the hydraulic tank to release the residual pressure.
3. Connect hose (1) to the drain valve and drain the hydraulic oil into an oil container.
Disconnect hose when the hydraulic oil is lower than level gauge.
Figure 1
4. Remove mounting screws (2) and level gauge (1).
Figure 2
5. Install the new level gauge with a new O-ring.
Tightening torque : 1.5 ±0.2 kgf m (11 ±1.4 lbf ft)
6. Assemble the drain cover.
7. Refill hydraulic oil.

Service Information

Breather, replacing Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Breather, replacing
Op nbr 911-051
1. Release the internal pressure in the hydraulic oil tank via the breather.
2. Remove breather mounting screws (2).

Tool : Torx T30
Figure 1
3. Install the new breather body with a new rubber packing.

NOTE!
Observe torque when installing the breather.
Tightening torque: 2.94 N m (2.17 lbf ft) ~ 5.88 N m (4.33 lbf ft)
Service Information

Shock reducing valve, Service Information 2014/10/29
description
Profile:
EXC, EC290B LC [GB]
Shock reducing valve, description

The shock reducing valves installed in the servo hydraulic lines at the main control valve prevent shock loads at the end of
cylinder rod movements by restricting return servo hydraulic of flow the main control valve spool, thereby controlling spool
return speed from an operating to neutral position.
Circuits : Arm out.
The structure of this valve is as shown in the figure. Spool (103) and spring (105) are equipped in casing (101), and spool
(102), spring (106) are equipped in spool (103).
Fixed diaphragm (1) is installed at the center of spool (102), and diaphragm (4) is installed at the side of spool (103).
Figure 1
Shock reducing valve
Tightening torque 104, 107 (700 ~ 800 kgf·cm (50 ~ 58 lbf·ft))

B (700 ~ 800 kgf·cm (50 ~ 58 lbf·ft))
A → B (Controlled oil flow direction)

As the oil flow from port A increases, the resistance against fixed diaphragm (1) also increases, and the pressure in chamber
(2) rises.
When the oil flow in port A is over setting flow, the right directional force by the difference of pressure between chamber (2)
and (3) is stronger than spring (106) force, spool (102) is full stroke, and diaphragm (4) is closed.
When this happens, the pressure in chamber (3) rises, and the difference of pressure between chamber (2) and (3) is kept to
setting pressure. Oil flow passing fixed diaphragm (1), i.e. oil flow from port A, is kept to setting flow, regardless of the
pressure of port A or port B.
Figure 2
Controlled oil direction
B → A (Free flow direction)

When the oil flow from port B, spool (103) is full stroke, oil flows into chamber (6) through outline of spool (103) from
chamber (5), and into chamber (2) from sectional slit of spool (103), then into port A
Figure 3
Free flow direction
Shock reducing valve, troubleshooting

Troubleshooting
Trouble Cause Remedy

Oil flow (A → B) over setting flow. (Shock Spool (102) sticks, spool (103) sticks. Polish minor scratches and nicks with
is considerable as actuator stopping.) extra fine emery cloth.
Oil flow (A → B) is less than setting flow. Spool (102) sticks. Control diaphragm Disassemble, clean and polish,
(It takes a long time to stop the of spool (102) clogs. reassemble.
actuator.)
Oil flow (A → B) is low. (It takes a long Spool (103) sticks. Polish minor scratches and nicks with
time to start actuator.) extra fine emery cloth.
Service Information

Check valve, description Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Check valve, description
Figure 1
Structure, check valve
1 Screw 4 Spring 7 Split pin

2 Valve cover 5 Spring seat A Flow
3 Valve 6 Nut
Operating pressure
3.0 kgf/cm2 (43 psi) (Main control valve → Oil cooler → Oil tank)
4.5 kgf/cm2 (64 psi) (Main control valve → Oil tank)
 Creates a back pressure to prevent reverse flow in the return circuit.
NOTE!
When replacing and reassembling, the check valve must be installed to open in the direction of the flow.
NOTE!
If installed in the reverse direction, excessive back pressure will build in the return circuit.
Check valve mounting position
Figure 2
Check valve mounting position
A Check valve (4.5 kgf/cm2, 64 psi)
B Check valve (3.0 kgf/cm2, 43 psi)
C Hydraulic tank
D Main control valve mounting section
E Hydraulic oil cooler
Detaching & mounting
1. Unscrew No. 18 clamp and detach No. 3 pipe from main control valve.
2. Remove the check valve directly assembled on the machined section in A pipe → 4.5 kgf/cm2 (64 psi)
3. Remove the check valve directly assembled on the machined section in B pipe → 3.0 kgf/cm2 (43 psi)
4. When assembling the check valve, take care not to interchange the valves.
Hydraulic tank side : 4.5 kgf/cm2 (64 psi), oil cooler side : 3.0 kgf/cm2 (43 psi).
5. Pay attention to the assembling position and direction of check valve.
6. Assemble pipe and tighten the clamp.
NOTE!
(A), (B) check valves are threaded into the pipe.
Service Information

Servo hydraulic line Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Servo hydraulic line

Part Port Part Port Remark

Control lever (right) 1 Shuttle block BI Bucket curl
2 BD Boom lower
3 BO Bucket dump
4 BU Boom raise
P Servo block P3
T T3
Control lever (left) 1 Shuttle block SL Left slew
2 AO Arm out
3 SR Right slew
4 AI Arm in
P Servo block P5
T T5
Travel pedal 1 Main control valve al4 Reverse (left)
2 bl4 Forward (left)
3 ar3 Reverse (right)
4 br3 Forward (right)
P Servo block P4
T T4
Main pump Dr Filter – Drain filter
Pi1 Main control valve Fl Negative (1st pump)
Pi2 Fr Negative (2nd pump)
Psv Main pump a3
A3 Servo hydraulic filter IN Servo hydraulic line filter
B3 Suction pipe – Gear pump suction (3rd pump)
a1 Quick coupler for gauge port
Main control valve ar1 Main control valve 3Pi
Rs Slew motor M
Pa Main control valve Px1
Pg2 Servo block P1
Ps Main control valve Px1
dr2 Hydraulic tank Td7
dr3 Td1
dr4 Td5
dr5 Td8
dr6 Td6
Py Main control valve Ps
Accumulator block PS Servo hydraulic filter OUT
G Quick coupler for gauge port
Ac Accumulator –
S1 Main control valve Pg1
S2 Slew motor PG
S3 – – Conflux of 2 pump flows
Solenoid valve P1 Accumulator block Ps1
P2 – –
P3 Solenoid valve A1
A1 Servo block P1 Safety
A2 – – X1 2 pump conflux
A3 Main control valve Py Power boost
A4 Center passage B Travel speed shift
A5 – – Hammer and shear
A6 Main control valve dr1 Conflux cut-off
T Hydraulic tank Td8
Slew motor SH Shuttle block SW
Dr Drain filter In
Center passage G Slew motor Dr
Servo block P6 – – Plug
T6 – – Plug
T1 Hydraulic tank Td2
P2 – – Plug
T2 – – Plug
Block (2) 1 Main control valve Px1
2 – – Travel pressure switch
3 – – Plug
Shuttle block BU1 Main control valve br1 Boom up
BD1 ar1 Boom down
AI1 al3 Arm in
AO1 bl3 Arm out
BI1 ar2 Bucket curl
BO1 br2 Bucket dump
SL1 al1 Slew (left)
SR1 bl1 Slew (right)
BU2 b
Pb
Py
AI2 4Pi
pc
SW Pa
Shuttle block Al2
AM Main control valve a
Hydraulic tank Td3 – – Plug
Td4 – – Plug
Td9 Drain filter Out
Figure 1
Servo hydraulic lines (1)
MCV Main control valve

RCV Remote control valve
S/M Slew motor
C/P Center passage
D/F Drain filter
PS Pressure switch
AC Accumulator
Figure 2
Figure 3
Figure 4
Service Information

Return and pump line Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Return and pump line
Figure 1
Return and pump line
1. Pipe (hydraulic oil cooler → hydraulic tank)

2. Pipe (main control valve → hydraulic oil cooler)
3. Pipe (main pump → main control valve)
4. Coupling (tightening torque : 1.03 ~ 1.26 kgf·m)
(Distance between pipes : 18 ± 4 mm)
5. Check valve (main control valve → hydraulic oil cooler) : 3.0 kgf/cm2 (43 psi)
6. Bracket
8. Pipe (main control valve → hydraulic oil cooler → Tank)
9. Hose (main pump → main control valve)
10. Main pump
11. Suction pipe (hydraulic tank → main pump)
12. Hose (drain filter→ hydraulic tank)
13. Drain filter
15. Bracket
16. Check valve (main control valve → cooler) : 4.5 kgf/cm2 (64 psi)
17. Pipe
18. Bracket
19. Hydraulic oil cooler
NOTE!
Check valves (5, 16) are assembled in pipe.
Service Information

Main line Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Main line
Figure 1
Port connection (main line)
AL1 Slew left BL2 Option AR3 Forward right
AL2 Option BL3 Arm out BR1 Boom raising
AL3 Arm in BL4 Reverse left BR2 Bucket dump
AL4 Forward left AR1 Boom lowering BR3 Reverse right
BL1 Slew right AR2 Bucket curl MCV Main control valve
Service Information

Lower line Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Lower line
Figure 1
Port connection (lower line)
Port connection
Center passage Travel motor Remarks

Port Direction Port
C Left A Reverse left
D Right B Reverse right
E Left B Forward left
F Right A Forward right
G Left, right Dr Motor drain
B Left, right Pi Speed control
A Plug
Service Information

Oil cooler line bypass valve Service Information 2014/10/29
(check valve), replacing
Profile:
EXC, EC290B LC [GB]
Oil cooler line bypass valve (check valve), replacing

Op nbr 911-033
WARNING
1. Place the machine in the service position B. See 091 Service positions
WARNING
Lower the digging units to the ground and stop the engine (start switch ON position). Operate the control
levers several times to release the remaining pressure in the hydraulic piping.
NOTE!
Disconnected hoses, lines and connections must be plugged. Oil that drains from hoses, lines and connections
should be collected in a container.
3. Remove screws (1) and cover (2).
Figure 1
Removal, cover
Removal check valve (3.0k)
4. Loose clamp nuts (2) and move clamp (4) to right.

Remove screws (8) and pipe (5) from main control valve (10).
Remove check valve (6) from pipe (1).
Figure 2
Removal, check valve
1 Pipe 6 Check valve 11 Sleeve

(4.5k)
2 Nut 7 O-ring 12 Clamp
3 Clamp 8 Screw 13 Nut
4 Sleeve 9 Check valve 14 Pipe
(3.0k)
5 Pipe 10 Main control
valve
5. NOTE!
When replacing, use an E-tool ( Tool number : 8940–00400).
When replacing, use the same specifications as old bypass valve.
When replacing, the bypass valve must be installed to open in the direction of the flow. If installed in the reverse
direction, excessive back pressure will build in the return circuit.
Install check valve (6) with new O-ring (7) in reverse order of removal procedure.
6. Refill hydraulic oil and test machine.

Service Information

Pipe and hose (pump - Service Information 2014/10/29
valve), replacing
Profile:
EXC, EC290B LC [GB]
Pipe and hose (pump - valve), replacing

Op nbr 911-024
WARNING
WARNING
Lower the digging units to the ground and stop the engine (start switch ON position). Operate the control levers
several times to release the remaining pressure in the hydraulic piping.
NOTE!
Disconnected hoses, lines and connections must be plugged. Oil that drains from hoses, lines and connections should be
collected in a container.
Container capacity : 100 litres
Pipe replacing
1. Connect the vacuum pump, See : 9111 Hydraulic oil tank, vacuum-pumping, connecting and disconnecting pump
2. Remove screws (1) and cover (2).
Figure 1
3. Remove hose (1)) form pipe (2) of control valve side.

Figure 2
4. Remove screws, flanges (1, 2) and hose (3) of hydraulic oil pump side.
Figure 3
5. Install hose (3) and new O-ring, then flanges, screws (2, 1) on hydraulic pump side.
Figure 4
6. Install hose (1) and new O-ring on pipe (2) of hydraulic pump side.
Figure 5
7. Install cover (2) and screws (1).

Figure 6
8. Start the engine and check for leaks.

Service Information

Hydraulic oil cooling Service Information 2014/10/29
system, description
Profile:
EXC, EC290B LC [GB]
Hydraulic oil cooling system, description

After getting signal like hydraulic oil temperature, V-ECU controls fan speed with the control relief valve, which is necessary
at fixed pump and motor application, depending on the setting demand for each machine. Check value could be put to
prevent hydraulic motor from cavitation.
Figure 1
Hydraulic oil cooling system
1 Hydraulic oil temperature 5 Fan motor

2 Fan pump 6 Fan
3 Proportional relief valve 7 Coolant temperature
4 Check valve 8 Charge air temperature
Fan speed control curve

Basic speed control concept depending on some temperature is as the following diagram.
Here,
K ≤ 0 ↔ nᵐ
K ≥ 0 ↔ nᵐᵃ
0 < K ≤ 0 ↔ nᵐ + k (nᵐᵃ - nᵐ )
If operator requests air conditioning [ON] and the required fan speed, of which minimum speed shall be determined later, is
higher than the fan control speed according to the basic concept above, the required fan speed for air conditioning takes
the first priority. Fan speeds are converted to the working pressure of fan motor.
Figure 2
Fan speed control curve
A. Fan speed
B. Coefficient
C. Maximum fan speed
Service Information

Fan pump, description Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Fan pump, description

Machine serial no.: 80001 ~
Structure (G200 PUMP, 22.8 cc/rev)
Figure 1
Fan pump, structure (G200 PUMP, 22.8 cc/rev)
1. Suction port (1″ metric flange)

2. Discharge port (3/4″ metric flange)
3. Screw
Tightening torque:
 17 kgf·m (123 lbf·ft) - lubricated

 18.8 kgf·m (136 lbf·ft) - dry
Sectional view (G200 PUMP, 22.8 cc/rev)

Figure 2
Fan pump, sectional view (G200 PUMP, 22.8 cc/rev)
1 Cover assembly (front) 6 Channel seal 11 Screw

2 Gear housing 7 Back-up seal 12 Washer
3 Cover assembly (rear) 8 Square seal 13 Name plate
4 Drive gear 9 Seal 14 Screw
5 Thrust plate 10 Dowel pin 15 Driven gear
Exploded view (G200 PUMP, 22.8 cc/rev)

Figure 3
Fan pump, exploded view (G200 PUMP, 22.8 cc/rev)
Structure (G200 PUMP, 22.8 + 20.3 cc/rev)
Figure 4
Fan pump, structure (G200 PUMP, 22.8 + 20.3 cc/rev)
S1 Suction port
P1 Discharge port (fan motor pump)
P2 Discharge port (rotator pump)
Sectional view (G200 PUMP, 22.8 + 20.3 cc/rev)
Figure 5
Fan pump, sectional view (G200 PUMP, 22.8 + 20.3 cc/rev)
1 Cover 6 Gear shaft 11 Rubber seal 16 Washer

2 Gear housing 7 Driven gear 12 Back-up seal 17 Nut
3 Bearing carrier 8 Connecting shaft 13 Square seal 18 Name plate
4 Gear housing 9 Thrust plate 14 Dowel pin 19 Screw
5 Cover 10 Lip seal 15 Stud bolt
Tightening torque
Tightening torque
No. Unit Tightening torque Remarks

15 Nm 147
(kgf m) (15)
(lbf ft) (108)
Fan pump, principle of operation
 The fan pump is a gear pump attached to the PTO (Power Take Off) of the main pump. The fan pump consists of
gear housing (E), drive gear (A), and driven gear (B).
Figure 6
Fan pump, operation
A. Drive gear
B. Driven gear
C. Suction side (low pressure)
D. Discharge side (high pressure)
 This pump has two mating gears that are turned in a closely fitted gear housing. Rotation of the drive gear causes
the other gear to turn. External gear pumps are positive fixed displacement rotary pumps. When the pump is
turned, the oil is trapped between the teeth of the gears and gear housing. Continued rotation of the gears forces
the constant amount of oil out of the pump. On the suction side, the teeth confine and carry the oil and a vacuum
is formed in the cavity between the teeth as they unmesh, causing oil to be drawn into the pump. Pressure rise in a
gear pump is produced by squeezing action on the oil as it is expelled from between the meshing gear teeth and
the gear housing.
Service Information

Fan motor, description Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Fan motor, description

Structure
Figure 1
Structure, fan motor
Rotational direction
Inlet Outlet View from shaft end

Pin Pout Clockwise
Sectional view
Figure 2
Sectional view, fan motor
1 Case 12 Pin 23 Drive screw

2 Shaft 13 Retainer holder 24 Snap ring
3 Ball bearing 14 Retainer plate 28 Plug (for shipping)
4 Oil seal 15 Piston assembly 31 Check valve
5 Swash plate 16 Valve plate 32 Spring
6 Pin 17 Pin 33 Plug
7 Cylinder block 18 Ball bearing 34 O-ring
8 Spring seat 19 O-ring 35 Pin
9 Spring 20 Rear cover 36 Plug (for shipping)
10 Washer 21 Screw
11 Snap ring 22 Name plate
Fan motor, principle of operation

Hydraulic motor
The cylinder block incorporates 9 pistons, and at one end it is connected to the port block, and acts as a distributing valve,
via 2 half-moon shaped ports, B and C.
Torque generating principle: When oil at high pressure (pressure P) is supplied to port B, the pistons push against the swash
plate, each exerting a force of F (F = P × A, where A = cross sectional area of piston). The pistons are then subject to a
corresponding reaction force from the swash plate, so that a rotational direction component, Ft, is generated for each
piston. Together, these Ft components generate a force which rotates the cylinder block. The torque is transmitted to the
shaft via the spline, and the shaft rotates. The oil, having performed its designated function, is expelled from port C.
Conversely, if oil at high pressure is supplied to port C, the shaft will rotate in the opposite direction.
Figure 3
Operation, fan motor
1. Port block
2. Cylinder block
3. Piston assembly
4. Swash plate
5. Shaft
Check valve
The check valve helps to avoid cavitation while decelerating, to supply oil from outlet port to inlet port.
The motor outlet oil flows from Pout port, (when machine circuit stops oil supply) to Pin port. Then the motor works as a
pump because the component which is driven by motor has inertia. To stop motor completely, it needs oil supply from Pin
port. During deceleration, Pin port pressure is less than that of Pout.
This pressure balance makes the check valve open. Then the oil can return to Pin port through the check valve.
Figure 4
Check valve
A. Check valve
General precautions
Operating oil
1. Appropriate operating oil

The operating oil has a critical role to play in transmitting motive power and lubricating hydraulic components. Oil
selection and handling therefore have a critical bearing on the performance and life of the hydraulic components.
You must use an extremely good quality oil, which has excellent lubricating, oxidizing stability, corrosion resistance
and floating resistance properties. Also, it must not soak into packing / sealing materials. We recommend the oil
shown in the table below for this motor. Do not mix other types of operating oil with it.
Item In cold regions In warm/hot regions
Outside temperature 10 ~ 25 °C (50 ~ 77 °F) 0 ~ 35 °C (32 ~ 95 °F)
Hydraulic operating oil ISO VG 32 VG 56
2. Usage viscosity range for operating oil
Item Viscosity (cSt) Oil temperature, °C (°F)

ISO VG 32 VG 56
Temperature range 20 ~ 100 15 ~ 45 (59 ~ 113) 27 ~ 57 (80.6 ~
134.6)
Working range 20 ~ 500 -3 ~ 50 (26.6 ~ 122) 5 ~ 63 (41 ~ 145.4)
If it is used below the "working viscosity range" bottom limit, you must carry out unloaded warming-up prior to
usage.
For continuous operation: Install cooler or heater, as required, to keep it within the appropriate viscosity range.
3. Oil temperature control
 Circuit oil temperature range:
Normal usage oil temperature range 20 ~ 60 °C (68 ~ 140 °F)

Permitted oil temperature range -20 ~ 80 °C (-4 ~ 176 °F)
 The extent to which you can control the circuit oil temperature is extremely important. If it is too high, the
oil oxidizes more quickly and degenerates faster. If it is too low, the viscosity is too high, causing increased
motor friction loss and reducing mechanical efficiency.
Hence you should take the following measures:
 Start-up oil temperature

If the motor is operated at below 10 °C (50 °F), either carry out warming-up or use a heater to get
it above 10 °C (50 °F) before usage.
 Normal usage oil temperature
Ideally it should be kept within 20 ~ 60 °C (68 ~ 140 °F).
 Oil temperature range limits
The upper limit for the circuit oil temperature is 80 °C (140 °F). This limit has been determined
based on the effect of oil temperature on the viscosity/oxidizing resistance of the oil, and
deterioration of the O-rings and seals. Using it at above 80 °C (140 °F) will shorten the life of the
motor and the operating oil.
Filters
 The motor is comprised of precision components with extremely small clearances, so it is particularly susceptible to
contamination (sludge, iron powder, corrosion, filings, grinding dust etc.). Preventing contamination will enable you
to keep motor performance reduction (lock characteristics) and sliding component friction to a minimum.
 You need to maintain the cleanliness of the oil in the hydraulic system. This will allow you to use the motor for a
long time with minimal repairs and checks.
Piping
 You must flush the pipes out before fitting them. Make sure you remove all scale etc. inside the piping.
 When fitting the pipes, take care not to allow ingress of contamination via motor ports.
 When you have finished fitting the pipes, use a flushing pump to thoroughly clean out the whole circuit.
Shaft coupling method
 The motor shaft and slave shaft should be centred to within φ 0.1. Please treat the center of the motor shaft and
the center of the mounting flange as being one and the same.
 When fitting/removing the coupling, use the screw at the tip of the shaft or the centre hole to make sure you do
not subject it to thrust load or shock.
Starting up
 Fill the motor case with clean operating oil (minimum volume 150 cc) before starting the motor up.
 Bleed all air from the piping.
 First run it at low speed and check for abnormal noises / vibration. Then increase it to the specified speed and apply
the load.
Service Information

Fan motor, troubleshooting Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Fan motor, troubleshooting

Troubleshooting
Phenomenon Cause Remedy

Does not rotate. A hydraulic pump other than the motor, or a Check that the specified oil pressure is being
pressure control valve / direction change valve supplied at the motor inlet, then check each
is malfunctioning. component and repair if necessary.
Hydraulic pressure is being lost due to Replace worn components, then thoroughly
abnormal wear of sliding components. clean all components. Remove any
scratches / burring, and reassemble, taking
care to prevent ingress of contamination.
Malfunction caused by damage to the main Dismantle it and replace damaged
part of the motor. If this is the cause, the motor components, then thoroughly clean all
itself will make an abnormal noise. components. Remove any scratches /
burring, and reassemble, taking care to
prevent ingress of contamination.
The load on the motor is excessive, with the Check loading mechanism. Use a load
result that the relief valve is operating. appropriate for the relief valve pressure
setting.
Check valve can not close, in circuit. Disassemble and inspect the check valve, if
there is some contamination remove it.
Does not rotate quickly The correct oil flow rate is not being supplied Check that the specified oil pressure is being
enough. to the motor because of a problem with a supplied at the motor inlet, then check each
hydraulic pump or pressure control valve. component and repair if necessary.
Oil pressure is dropping significantly due to Dismantle it, replace any worn components,
wear on motor sliding components, and rpm then thoroughly clean all components.
falls off sharply when large amounts of oil leak Remove any scratches / burring, and
via the drain port. Alternatively, the bearing is reassemble, taking care to prevent ingress of
worn. contamination.
Contamination at check valve Disassemble and inspect the check valve, if
there is some contamination remove it.
Oil leak O-rings or seals are damaged. Replace damaged O-rings or seals with new
ones. Take care not to scratch lip when
inserting seals. Also, remember that the
maximum usage temperature for seals and
O-rings is 80 °C, so check the temperature of
the oil in the motor. If it is above 80 °C, you
need to take countermeasures, for example,
fitting a cooler within the hydraulic oil circuit.
The pressure inside the motor case increases, Repair the motor and replace the seals with
seals are damaged, and oil leaks (Seal new ones. Take care not to scratch lip when
withstand pressure = 1 kgf/cm2). inserting seals.
Negative pressure may have built up (because Clean out clogged drainage pipe to reduce
drainage pipe is clogged), causing damage to resistance within. Make sure that these
seals and leakage. (Seal withstand pressure = 1 measures reduce the pressure on the seals to
kgf/cm2) less than 1 kgf/cm2. Replace the seals with
new ones. Take care not to scratch lip when
inserting seals.
Service Information

Proportional relief valve, Service Information 2014/10/29
description
Profile:
EXC, EC290B LC [GB]
Proportional relief valve, description

Series DBVSA-1LG inverse-proportional pressure relief valves are two stage, spool-type units. They limit the inlet pressure in
port P to a value that is inversely proportional to the solenoid current.
The valves are screw-in cartridges and the mounting thread is the well known 3/4"-16 UNF pattern.
All exposed steel parts are corrosion protected to ISO 4042, grade A3C, and the valves are suitable for use in the harshest
operating environments.
The coils slide onto the core tubes and hydraulic envelop, even when the valve is under pressure. Coils turn through 360°
and lock at any angle.
Figure 1
Proportional relief valve, structure
Proportional relief valve characteristic curve

Figure 2
Characteristic curve
Hydraulic oil temperature Unit Specifications

60 °C Speed rpm 875
Current mA 620
90 °C Speed rpm 1750
Current mA 230
Service Information

Oil cooler, replacing Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Oil cooler, replacing

Op nbr 911-011
NOTE!
1. Park the machine on a level surface, lower the bucket to the ground and stop the engine.
Operate each control lever (for attachment and travel) to its full stroke to release the residual pressure.
2. Press the air breather cap several times to release the pressure until the air is all out.
3. Connect vacuum pump (1) to the hydraulic tank, and actuate when disconnecting the hose.
Figure 1
Connection, vacuum pump
4. Open left-hand side cover.
Figure 2
Open the side cover
5. Remove oil cooler outlet hose (1).

Figure 3
Removal, oil cooler outlet hose
 Tool: Hex bit socket 8 mm
NOTE!
At this time, there are many leakage, therefore prepare a container and plug the hose.
6. Remove oil cooler inlet hose (1).
Figure 4
Removal, oil cooler inlet hose
7. Remove mounting screws (1) for air conditioner condenser.
Figure 5
Removal, screws
 Tools: Socket 14 mm, spanner 16 mm
NOTE!
After removing mounting screws of air conditioner condenser, place air conditioner condenser (1) one side not to
damage.
8. Remove mounting screws (1) for oil cooler.
Figure 6
Removal, screws
 Tools: Socket 19 mm
9. Remove oil cooler (1) using a lifting device.
Figure 7
Lifting, oil cooler
10. Disassemble oil cooler mounting brackets (1) and install them to the new oil cooler.
Figure 8
Transfer, oil cooler mounting bracket
11. Install mounting screws (1) for oil cooler.

Figure 9
Installation, screws
12. Install the air conditioner condenser.
Figure 10
Installation, air conditioner condenser
13. Install oil cooler inlet hose (1).
Figure 11
Installation, oil cooler inlet hose
14. Install oil cooler outlet hose (1).

Figure 12
Installation, oil cooler outlet hose
15. Fill the hydraulic oil tank with hydraulic oil.

Start the diesel engine. Check for leaks and if needed.
Service Information

Fan pump, parts inspection Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Fan pump, parts inspection

Parts inspection
Part name Inspection item Remedy

Gear housing
 Existence of cut out  Replacement when the cut out of the gear
housing is more than 0.18 mm (0.0071 in)
deep.
Gear
 Existence of scoring, grooving, nicking  Replacement when damage.
and fretting etc on gear
 Existence of wear of seal contact area  Replacement when the seal contact area is
worn more than 0.05 mm (0.002 in).
Thrust plate
 Existence of wear of thrust plate  Replacement when the thrust plate is worn
more than 0.05 mm (0.002 in).
 Existence of scratch, erosion and  Replacement when damaged.
pitting
Seals
 Replacement when damaged.
Service Information

Fan pump, disassembly Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Go back to Index Page
Fan pump, disassembly

G200 PUMP, 22.8 cc/rev (Machine serial no.: 80001 ~ )
Precautions
 Thoroughly clean the pump assembly prior to disassembly.

 Select a clean area.
 Thoroughly clean all parts.
Disassembly
1. Place the pump on the work bench with the input shaft side downward.
NOTE!
Mark the pump housing and covers to indicate proper positioning during reassembly.
2. Remove screws (11).
 Tool: Socket wrench 19 mm
3. Remove rear cover assembly (3) from gear housing (2).

NOTE!
Do not draw out dowel pins (10) from rear cover assembly (3).
4. Remove thrust plate (5).

5. Pull out drive gear (4) and driven gear (15).
NOTE!
Take care not to damage the inside surfaces of gear housing (2).
6. Remove gear housing (2) and thrust plate (5).

NOTE!
Do not draw out dowel pins (4) from front cover assembly (1).
7. Turn front cover assembly (1) and remove seal (9).

NOTE!
Be careful not to damage the inside surfaces of front cover assembly (1).
Service Information

Fan pump, disassembly Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Fan pump, disassembly

G200 PUMP, 22.8 + 20.3 cc/rev (Machine serial no.: 80001 ~ )
Precautions

 Use a torque wrench to tighten the screws, fittings and plugs to the specified torque.
 If the pump was dismantled coat the gears, shafts, and sealing surfaces with clean hydraulic oil prior to assembling.
Disassembly
Figure 1
Disassembly, gear pump
A Position mark 4 Gear housing

B Mounting screw 5 Rear cover
C Work bench 15 Stud bolt
1 Front cover 16 Washer
2 Gear housing 17 Nut
3 Bearing carrier
NOTE!
2. Remove stud bolt (15), washer (16), nut (17).

 Tools: Socket wrench 19 mm
3. Remove rear cover assembly (5).

NOTE!
Do not draw out dowel pins (14) from gear housing (4) and rear cover assembly (5).

5. Pull out drive gear kit (7) from gear housing (4).
NOTE!
6. Remove bearing carrier (3) and connecting shaft (8).

NOTE!
Do not draw out dowel pins (14) from gear housing (4) and bearing carrier (3).

NOTE!
9. Pull out shaft gear kit (6) from gear housing (2).
NOTE!
Take not to damage the inside surfaces of gear housing (2).
10. Turn front cover assembly (1) and remove lip seal (10).
NOTE!
Service Information

Fan pump, assembly Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Fan pump, assembly

G200 PUMP, 22.8 + 20.3 cc/rev (Machine serial no.: 80001 ~ )
Assembly, P1 pump
1. Install new lip seal (10) to front cover assembly (1).

NOTE!
Coat the lip of the oil seal with grease. Be careful not to damage the lip of the oil seal.
2. Place the cover on the work bench with the input shaft side of front cover assembly (1) downward.
3. Install square seals (13) in the both side of gear housing (2) and assemble gear housing (2) to front cover assembly
(1) by tapping the gear housing with a plastic hammer.
NOTE!
Coat the square seal with grease.
NOTE!
Pay attention to the mounting direction of gear housing (2). Align matching mark on front cover assembly (1) and
gear housing (2) made before disassembling.
NOTE!
Check off the dowel pins.
4. Install rubber seals (11) and back-up seals (12) in thrust plate (9).
Figure 1
Installation, rubber seals and back-up seals
A. Gear side (coated side)
NOTE!
Pay attention to the mounting direction of the seals.
5. Assemble thrust plate (9) to gear housing (2).

Figure 2
Installation, thrust plate
A. Suction side
B. Discharge side
NOTE!
Pay attention to the direction of thrust plate (10). The U-shape of the thrust plate must face toward discharge side
(B).
6. Assemble shaft gear kit (6).

NOTE!
Be careful not to damage the lip of lip seal (10) by the shaft splines.
7. Apply hydraulic oil to the gear, and assemble thrust plate (9) to gear housing (2).
8. Assemble bearing carrier (4) and connecting shaft (8).
Assembly, P2 pump
1. Install rubber seals (11) and back-up seals (12) in thrust plate (9).
Figure 3
Installation, rubber seals and back-up seals
NOTE!
2. Install square seals (13) in the both side of gear housing (4) and assemble gear housing (4) to rear cover assembly
NOTE!
NOTE!
Pay attention to the mounting direction of gear housing (5). Align matching mark on bearing carrier (3) and gear
housing (4) and rear cover (5) made before disassembling.
NOTE!
Check off the dowel pins.

Figure 4
A. Suction side
B. Discharge side
NOTE!
Pay attention to the direction of thrust plate (9). The U-shape of the thrust plate must face toward discharge side
(B).
4. Assemble drive gear kit (8).

6. Assemble rear cover assembly (5).
7. Tighten stud bolt (15) and washer (16) to the specified torque.
 Tightening torque: 15 kgf·m (108 lbf·ft)
8. Check if shaft will rotate smoothly by hand. If not accordingly, disassemble and check.
Service Information

Fan pump, assembly Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Fan pump, assembly

G200 PUMP, 22.8 cc/rev (Machine serial no.: 80001 ~ )
1. Install new seal (9) to front cover assembly (1).

NOTE!
Coat the lip of the seal with grease. Be careful not to damage the lip of the seal.
2. Place the cover on the workbench with the input shaft side of front cover assembly (1) downward.
NOTE!
NOTE!
4. Install channel seals (6) and back-up seals (7) in thrust plate (5).
Figure 1
Installation, channel seals and back-up seals
NOTE!
Figure 2
A. Suction side
B. Discharge side
NOTE!
Pay attention to the direction of thrust plate (5). The U-shape of the thrust plate must face towards discharge side
(B).
6. Assemble drive gear (4) and driven gear (15).

NOTE!
Be careful not to damage the lip of seal (9) by the shaft splines.
9. Tighten screws (11) and washer (12) to the specified torque.
 Tightening torque: 17 ± 0.5 kgf·m (123 ± 4 lbf·ft)
10. Check if shaft will rotate smoothly by hand.

If not rotating accordingly, disassemble and check.
Service Information

Fan motor, tools Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Fan motor, tools

Special tools
Special tools
Description & Part no.

Jig for seal (17) assembly
Part no.: 14514415

Service Information

Fan motor, disassembly Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Fan motor, disassembly

Precautions
 Thoroughly clean the motor prior to removal from the machine.

 Use a proper bench for working, spread a paper or rubber mat on the bench, and disassemble the motor on it.
 Do not reuse the O-rings, seal and gasket.
Disassembly procedure
1. Fix the motor in a vise and remove screws (18).
Figure 1
Removal, screws
2. Remove recover (20).
Figure 2
Removal, rear cover
3. Remove O-ring (19) from cylinder block (7).
Figure 3
Removal, O-ring
NOTE!
O-ring is never used again. Change it at every disassembling.
4. Remove valve plate (16).

The valve plate could be on the rear cover.
Figure 4
Removal, valve plate
NOTE!
Take care not to scratch the valve plate. If it has any damage, replace with a new one.
5. Remove cylinder block assembly.

– Cylinder block assembly consists of:
– Cylinder block (7) x 1
– Spring seat (8) x 1
– Spring (9) x 1
– Washer (10) x 1
– Snap ring (11) x 1
– Pin (12) x 3
– Retainer holder (13) x 1
– Retainer plate (14) x 1
– Piston assembly (15) x 1
Figure 5
Removal, cylinder block assembly
NOTE!
Do not lose pin (12), they are small and can easily fall out.
Any damage is not allow on mating surfaces.
When it is needed, cylinder block assembly must be changed as an assembly.
6. Remove shaft (2) with bearing (3) and swash plate (5). In case the shaft does not come out, hit the end of shaft with
a hammer as shown in the picture below.
Figure 6
Removal, shaft with bearing and swash plate
7. Remove seal (4) by pushing it from mounting flange face shown in the picture below.
Figure 7
Removal, seal
8. Remove snap ring (24) if it is needed.
Figure 8
Removal, snap ring
9. Remove plug (33) on rear cover. Then spring (32) and check valve (31) can be disassembled.
Rear cover (20) has bearing (18). If it is needed to change bearing (18), disassemble it from rear cover (20).
Figure 9
Removal, plug, spring and check valve
10. Disassemble shaft (20) with bearing (3) from the swash plate.
Figure 10
Removal, shaft with bearing
Service Information

Fan motor, assembly Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Fan motor, assembly

Precautions
 Wash all parts with treated oil and blow off oil completely.
 Be sure that the washed parts are free of dust and other foreign matter.
Handle them with care so that they will not be scratched or damaged.
 Always replace seals and bearings with new ones.
 Tighten all the tightening areas to the specified torque.
 Apply grease to the oil seals and the O-rings in advance. (In particular, the oil seal lips must be oiled.)
Assembly procedure
1. Install check valve (31) and spring (32) into rear cover (20) then install plug with O-ring.
 Tightening torque: 39.2 ± 1.9 N m (4 ± 0.2 kgf m) (29 ± 1.5 lbf ft)
Figure 1
Installation, check valve and spring
NOTE!
O-ring must be replaced to new one every disassembling.
2. Install snap ring (24)

Figure 2
Installation, snap ring
3. Install oil seal (4).
This part must be changed every disassembling to prevent oil leakage. Prior to install, put enough grease on the oil
seal and rear cover (Outer and internal diameter, also housing bore).
The position of oil seal must be as shown.
A : Grease before assembling
Figure 3
Installation, oil seal
NOTE!
Recommended grease: SHELL ALVANIA GREASE–2
4. Install shaft (2) with bearing (3) into the case.

Figure 4
Installation, shaft with bearing
5. Install swash plate (5) into the case.
Swash plate must be pushed at the end of motor case.
Figure 5
Installation, swash plate
6. Install cylinder block assembly.
The consistence of cylinder block assembly is referred in assembling procedure.
Prior to installing, all parts are oiled. Pin (12) is easy to drop. Take care not to lose it.
This part is important for motor working.
Figure 6
Installation, cylinder block assembly
7. Install O-ring (19).
This part must be changed every disassembling.
Figure 7
Installation, O-ring
8. Put rear cover (20) which is equipped with check valve and valve plate.
Take care not to drop valve plate. Greasing between valve plate and rear cover will help to assemble.
Prior to the installing, put oil into each hole of cylinder block (7). (total 9 holes)
Figure 8
Installation, rear cover
9. Tighten screws (18).
 Tightening torque : 61.2 ± 2.4 N m (6.25 ± 0.25 kgf m) (45 ± 1.8 lbf ft)
10. Reassembled motor must start slowly to confirm corrective assembling.

Service Information

Main control valve, Service Information 2014/10/29
description
Profile:
EXC, EC290B LC [GB]
Main control valve, description

This valve block consists of a 4-spool block and a 3-spool block connected by screws, main spool, main relief valve, port
relief valves, boom · arm holding valve, boom · arm regenerating valve, arm parallel valve, boom priority logic valve, foot
relief valve, straight travel valve, center bypass valve, and various check valves such as arm parallel conflux check, back
pressure check, load check etc.
1. Main relief
2. Boom raise port relief valve
3. Boom lower port relief valve
4. Arm in port relief valve
5. Arm out port relief valve
6. Bucket curl port relief valve
7. Bucket dump port relief valve
8. Option port relief valve (2 step valve)
Tightening torque (screw), 15 kgf·m (108 lbf·ft)

Tools : Allen wrench 12 mm
Figure 1
Main control valve (construction)
Port size and tightening torque
Port size Tightening torque Port name Description

kgf·cm (lbf·ft)
φ 26 P P1 pump port
(M 10 x 1.5) P P2 pump port
AL1 Slew port (left)
BL1 Slew port (right)
AL3 Arm in port
BL3 Arm out port
BR3 Right travel port (reverse)
AR3 Right travel port (forward)
BR2 Bucket dump port
AR2 Bucket curl port
BL2 Option port
AL2 Option port
BL4 Left travel port (reverse)
AL4 Left travel port (forward)
BR1 Boom raise port
AR1 Boom lower port
φ 50 R General return port
(M 12 x 1.75)
PF 1 2250 ± 250 Rs1 General return port
(162 ± 18)
PF 1/4 370 ± 20 al1 Slew port (left)
(27 ± 2) bl1 Slew port (right)
al3 Arm in port
bl3 Arm out port
br3 Right travel servo hydraulic port (reverse)
ar3 Right travel servo hydraulic port (forward)
br2 Bucket dump servo hydraulic port
ar2 Bucket curl servo hydraulic port
al2 Option servo hydraulic port
bl2 Option servo hydraulic port
al4 Left travel servo hydraulic port (forward)
bl4 Left travel servo hydraulic port (reverse)
ar1 Boom lower servo hydraulic port
br1 Boom raise servo hydraulic port
a Arm conflux port
b Boom raise conflux signal port
Fr Control signal port for P1
Fl Control signal port for P2
Dd Drain port
Ps Arm parallel conflux disconnect signal port
Main control valve, sectional view (3 spool block)
1 Main spool
2 Spool cover
3 Port relief valve
4 Orifice
5 Load check valve (Boom)
6 Load check valve (Bucket, travel)
7 Center bypass valve
8 Flow sensing valve
9 Boom holding valve
10 Boom holding valve
11 Boom back pressure check valve
12 Orifice
Figure 2
Main control valve (sectional view, 3 spool block)
Main control valve, sectional view (4 spool block)
1 Main spool
3 Port relief valve
4 Orifice
5 Load check valve (Boom)
6 Load check valve (Option, Arm, Travel)
7 Center bypass valve
8 Flow sensing valve
12 Arm holding valve
13 Main relief valve
14 Arm parallel conflux valve
15 Option conflux check valve
16 Arm conflux check valve
17 Straight travel valve
18 Arm regenerating valve/Bucket conflux check valve
19 Logic valve
20 Servo hydraulic selector valve
21 Check valve
22 Orifice
A 4 spool side
B 3 spool side
Figure 3
Figure 4
Service Information

Main control valve, Service Information 2014/10/29
description
Profile:
EXC, EC290B LC [GB]
Main control valve, description

This valve block consists of a 4-spool block and a 3-spool block connected by screws, main spool, main relief valve, port
relief valves, boom · arm holding valve, boom · arm regenerating valve, arm parallel valve, boom logic valve, foot relief valve,
straight travel valve, center bypass valve, and various check valves such as arm parallel conflux check, back pressure check,
load check etc.
1. Main relief
2. Boom raise port relief valve
3. Boom lower port relief valve
4. Arm in port relief valve
5. Arm out port relief valve
6. Bucket curl port relief valve
7. Bucket dump port relief valve
8. Option port relief valve (2 step valve)
Tightening torque (screw), 15 kgf·m (108 lbf·ft)

Figure 1
Main control valve (construction)
Port size and tightening torque
Port size Tightening torque Port name Description

N m (kgf m) (lbf
ft)
φ 26 63.7 ±6.9 (6.5 ±0.7) P P1 pump port
(M 10 x 1.5) (46.9 ±5.1) P P2 pump port
AL1 Slew port (left)
BL1 Slew port (right)
AL3 Arm in port
BL3 Arm out port
BR3 Right travel port (reverse)
AR3 Right travel port (forward)
BR2 Bucket dump port
AR2 Bucket curl port
BL2 Option port
AL2 Option port
BL4 Left travel port (reverse)
AL4 Left travel port (forward)
BR1 Boom raise port
AR1 Boom lower port
φ 50 110.8 ±10.8 (11.3 R General return port
(M 12 x 1.75) ±1.1) (81.6 ±7.9)
PF 1 205.9 ±19.6 (21 ±2) Rs1 General return port
(151.6 ±14.4)
PF 1/4 49 ±2 (5 ±0.2) (36.1 al1 Slew port (left)
±1.4) bl1 Slew port (right)
al3 Arm in port
bl3 Arm out port
br3 Right travel servo hydraulic port (forward)
ar3 Right travel servo hydraulic port (reverse)
br2 Bucket dump servo hydraulic port
ar2 Bucket curl servo hydraulic port
al2 Option servo hydraulic port
bl2 Option servo hydraulic port
al4 Left travel servo hydraulic port (reverse)
bl4 Left travel servo hydraulic port (forward)
ar1 Boom lower servo hydraulic port
br1 Boom raise servo hydraulic port
a Arm conflux port
b Boom raise conflux signal port
Fr Control signal port for P2
Fl Control signal port for P1
Dd Drain port
Ps Arm parallel conflux disconnect signal port
Main control valve, sectional view

Figure 2
Main control valve, sectional view 1
Figure 3
Main control valve, sectional view 2
1 Housing 44 Cap 87 Spring 130 Spool (boom)

2 Housing 45 Cap 88 Stopper 131 Spool (bucket)
3 Manifold 46 Cap 89 Spring guide 132 Spring guide
4 Spool 47 Cap 90 Cap 133 Cap
5 Spool 48 Cap 91 Spacer 134 Sleeve
6 Spool 49 O-ring 92 Spring 135 O-ring
7 Spool 50 O-ring 93 Spool (boom conflux) 136 Back-up ring
8 Spool 51 Back-up ring 94 O-ring 137 O-ring
9 Spool 52 Spring 95 Screw 138 Back-up ring
10 Cover 53 Spring 96 Spring 139 O-ring
11 Retainer 54 Check 97 Screw 140 Piston
12 O-ring 55 O-ring 98 O-ring 141 Sleeve
13 Screw 56 Back-up ring 99 O-ring 142 O-ring
14 Poppet 57 Poppet 100 Screw 143 Plug
15 Spring 58 Spring 101 O-ring 144 Poppet
16 O-ring 59 Sleeve 102 Back-up ring 145 Cap
17 O-ring 60 Sleeve 103 O-ring 146 Spring
18 Relief valve assembly 61 Piston 104 Back-up ring 147 Spring
19 Main relief valve 62 O-ring 105 Spool 148 Piston
assembly
20 O-ring 63 Sleeve 106 Spring 149 Cover
21 Cap 64 Piston 107 Spring 150 Cover
22 O-ring 65 Cover assembly 108 Piston 151 O-ring
23 Back-up ring 66 Screw 109 Sleeve 152 Back-up ring
24 Spring 67 Foot relief valve 110 Cap 153 Back-up ring
assembly
25 Check 68 Poppet 111 Cap 154 Cap
26 Nylon chip 69 Cap 112 Cap 155 Screw
27 Cap 70 Cap 113 O-ring 156 Cover assembly
28 O-ring 71 Spring 114 Back-up ring 157 Cap
29 Spring 72 Cover 115 Spring 158 Adjusting screw
30 Spool 73 O-ring 116 Check 159 Nut
31 Check 74 Cap 117 Manifold 160 Cap
32 Cap 75 Orifice 118 Spring 161 Back-up ring
33 Check 76 Spool (arm conflux) 119 Cover 162 O-ring
34 Spring 77 O-ring 120 Spring guide 163 Check
35 Spool 78 Back-up ring 121 Poppet 164 Orifice
36 Cap 79 O-ring 122 Screw 165 Cap
37 O-ring 80 Cap 123 Spring 166 2 stage relief valve
assembly
38 Sleeve 81 Cap 124 Spool 167 Check
39 Spool 82 O-ring 125 Plug 168 Plug
40 Spring guide 83 Spring 126 Spool (slew) 169 Check
41 Spring 84 Poppet 127 Spool (option) 170 Check
42 O-ring 85 Spool cap 128 Spool (arm)
43 Back-up ring 86 Spring guide 129 Spool (travel)
Service Information

Pressure relief valve, Service Information 2014/10/29
troubleshooting
Profile:
EXC, EC290B LC [GB]
Pressure relief valve, troubleshooting

 If an abnormal condition is detected, determine if the malfunction is in the control valve, main pump, servo
hydraulic pump or the circuit components such as: remote control valve, motor, or the center passage.
 Check the main relief, port relief, and servo hydraulic relief pressure.
 Check the P1/P2 pump flow rate.
 Check the hoses and piping for damage.
 Check the filters and hydraulic oil for contamination.
Troubleshooting
Phenomenon Cause Remark

Pressure does not rise.
 Main poppet of relief valve is  Check for contamination on the poppet.
sticking and valve is open.  Confirm that each component slides
 There is contamination on the smoothly.
poppet or seat.  Clean all the components thoroughly.
Unstable relief pressure.

 Damaged main poppet seat or  Replace damaged component.
servo hydraulic poppet seat of relief  Clean all the components thoroughly.
valve.
 Main poppet is sticking.
Relief pressure is
incorrect.  Wear due to foreign matter.  Disassemble and clean the valve.
 Damaged pilot seat due to foreign  Adjust the relief pressure.
matter.
 Loosened lock nut or adjusting
screw.
Oil leak
 Damaged main poppet seat or pilot  Replace damaged or worn component.
poppet seat due to foreign matter. Confirm that each component operates
 Worn O-ring. smoothly before reassembling.
 Sticking component due to foreign  Confirm that there are no scratches,
matter. nicks, or contamination present before
reassembling.
Service Information

Main control valve Service Information 2014/10/29
troubleshooting
Profile:
EXC, EC290B LC [GB]
Main control valve troubleshooting

 If an abnormal condition is detected, determine if the malfunction is in the control valve, main pump, servo
hydraulic pump or the circuit components such as: remote control valve, motor, or the center passage.
 Check the main relief, port relief, and servo hydraulic relief pressure.
 Check the P1/P2 pump flow rate.
 Check the hoses and piping for damage.
 Check the filters and hydraulic oil for contamination.
Troubleshooting

Travel does not Malfunctioning travel crossover relief valve. Measure travel relief valve pressure.
occur.
Slow to start up  Contamination between main poppet  Disassemble and clean the valve. If
(sluggish). and seat. damaged, replace the assembly as a unit.
Slow response.  Contamination between servo  Same as above.
hydraulic poppet and seat.
 Sticking main poppet.  Smooth sticking poppet with crocus cloth.
 Broken or fatigued spring.  Replace spring.
 Clogged main poppet orifice.  Remove contamination.
Clogged orifice in servo hydraulic circuit. Remove contamination.

Machine does not Malfunctioning straight travel valve. Measure servo hydraulic pressure.
travel straight
during  Sticking spool.  Smooth sticking spool with crocus cloth.
simultaneous travel
and digging unit
operation.
 Excessive clearance between casing  Replace spool.
block and spool.
 Clogged orifice in spool.  Remove contamination.
Malfunctioning 3 spool or 4 spool side center Measure servo hydraulic pressure.

bypass valve.
 Sticking spool.  Smooth sticking spool with crocus cloth.

 Excessive clearance between right or  Replace spool, right or left casing.
left casing and spool.
 Clogged oil passage in spool.  Remove contamination.
Malfunctioning logic valve.
 Contamination between poppet and  Disassemble and clean valve.

seat.
 Damaged poppet or seat face.  If damaged, replace poppet or seat.
Malfunctioning track motor relief valve. See 4411 Track motor, troubleshooting.
Excessive drift of Excessive clearance between casing and spool. Replace control valve section.
cylinder in neutral Spool is not completely in neutral position. Measure primary, secondary servo hydraulic
position. pressure.
 Contamination between casing and  Disassemble, clean and smooth sticking

spool, or sticking spool. part with crocus cloth.
 Broken or fatigued spring.  Replace the spring.
 Clogged servo hydraulic circuit.  Remove the contamination.
Malfunctioning port relief valve. Measure port relief valve pressure.

Malfunctioning anti-cavitation check valve.
 Contamination between poppet and  Disassemble and clean.

casing.
When extending Malfunctioning load check valve.

cylinder, at first it
retracts.  Contamination between poppet and  Disassemble and clean. If damaged,
casing. replace it.
 Sticking poppet.  Smooth sticking poppet with crocus cloth.
Bucket, boom or Malfunctioning main spool. Measure primary, secondary servo hydraulic
arm alone does not pressure.
operate.
Slow to start up  Excessive clearance between casing  Replace control valve section.
(sluggish). and spool.
Slow response.  Contamination between casing and  Disassemble and clean.
spool.
 Sticking spool.  Smooth sticking spool with crocus cloth.
 Broken or fatigued return spring.  Replace spring.
 Clogged servo hydraulic circuit.  Remove contamination.
Malfunctioning main relief valve. Measure main relief valve pressure.

Malfunctioning port relief valve. Measure port relief valve pressure.
Malfunctioning servo hydraulic relief valve. Measure servo hydraulic pressure.
Clogged screen filter of joystick. Clean filter screen.
Slew priority Malfunctioning logic valve.
function does not  Smooth sticking spool with crocus cloth.
occur.  Replace spring.
 Replace spool, right or left casing.
 Remove contamination.
Clogged orifice in servo hydraulic circuit. Remove contamination.

Slew does not Malfunctioning center bypass valve.
occur.  Disassemble and clean.
 If damaged, replace poppet or seat.
 Replace spring.
Despite lever being Malfunctioning foot relief valve. Measure foot relief valve pressure.
in neutral, negative
control does not  Contamination between poppet and  Disassemble and clean. If damaged,
occur, and fails to seat. replace the assembly as a unit.
minimize flow.  Broken or fatigued spring.  Replace spring.
 Clogged poppet orifice.  Remove contamination.
 Clogged filter.  Replace filter screen.
Service Information

Main relief valve, Service Information 2014/10/29
description
Profile:
EXC, EC290B LC [GB]
Main relief valve, description

Normal pressure (320 kgf/cm2)
Py servo hydraulic signal : OFF
Hydraulic oil supplied from the pump flows through orifice (2) of main poppet A to chamber (3).
As section area d1 > d2, main poppet A will not move.
If the pressure reaches set value of spring C, servo hydraulic poppet B will open so that the oil flows to tank passage through
hole (4). The pressure in chamber (3) will be lowered.
Figure 1
Main relief valve
A Main poppet
B Servo hydraulic poppet
C Spring
D Piston
E Servo hydraulic signal : OFF
P From pump port
T Tank passage
The oil supplied when servo hydraulic poppet B is opened (the pressure of chamber (3) is low) creates a pressure differential
between front and rear of orifice (2), so the “pressure of chamber (1) × d2” becomes larger than “pressure of chamber (3) ×
d1”. The circuit pressure is controlled to constant level as main poppet A opens to allow hydraulic oil flow to tank passage.
Figure 2
When the pressure reaches set value
Figure 3
Hydraulic oil flow to tank passage
Pressurized (350 kgf/cm2)

Py servo hydraulic signal : ON
Servo hydraulic pressure moves piston D and the set pressure of spring C is increased, so pressure setting is raised.
Figure 4
Pressure setting is raised
E. Servo hydraulic signal : ON

Service Information

Port relief valve, Service Information 2014/10/29
description
Profile:
EXC, EC290B LC [GB]
Port relief valve, description

Overload operation
Hydraulic oil from the cylinder port (P), flows through the orifice of piston A to chamber (2). Since section area d1 > d2, main
poppet B can not move.
Figure 1
Normal condition
If the pressure reaches set value of spring C, servo hydraulic poppet D will open and the oil flows to tank through the lateral
hole and circular passage, then the pressure in chamber (2) will be lowered.
Figure 2
Pressure reaches set value
The oil supplied when servo hydraulic poppet D is opened (the pressure of chamber (2) is low) creates a pressure differential
between front and rear of the orifice in piston A (chamber (1) and (2)), so piston A moves to the left and stops at the end of
servo hydraulic poppet D.
The oil in chamber (1) flows to tank passage through the orifice of piston A, through the lateral hole and circular passage.
Figure 3
Oil creates pressure differential
As the pressure is lowered front and rear of the orifice in servo hydraulic poppet D, “pressure of chamber (1) × d2” will be
higher than “pressure of chamber (2) × d1”. Therefore, poppet B opens and hydraulic oil from the cylinder port flows directly
to tank passage.
Figure 4
Oil flows to tank passage
Anti–cavitation operation
Section area of poppet B is larger than d1, and since pressure in the cylinder port is usually higher than pressure in the tank
port, the valve is closed. However if the pressure in the cylinder port decreases lower than the tank port (near to negative
pressure), poppet B is opened by tank pressure by as much as the area difference of d1 and d2. Then the tank passage
return oil will flow to the cylinder port to prevent cavitation.
Figure 5
Preventing the cavitation
NOTE!
See 9121 2 stage port relief valve, description
Service Information

2 stage port relief valve, Service Information 2014/10/29
description
Profile:
EXC, EC290B LC [GB]
2 stage port relief valve, description

Overload operation (for option)
When the normal setting [Pd Servo hydraulic signal: OFF] is used, Piston E moves to the left end due to the action of Spring
C.
Figure 1
2 stage port relief valve
A. Piston
B. Main poppet
C. Spring
D. Servo hydraulic poppet
Pressure oil from the cylinder port goes through orifice 3 in piston A, and enters chamber 2.
Because d1>d2, the main poppet (B) sits securely in its seat.
When the pressure oil reaches the pressure set by spring C, the servo hydraulic poppet (D) opens, and oil flows through
Passages 4 and 5 into the tank passage.
Figure 2
An oil flow is created, and the pressure drops before and after orifice 3 in Piston A.
This piston moves to the left, into its seat at the tip of the servo hydraulic poppet (D).
Oil from chamber 1 flows through orifice 6 in Piston A, through the side hole (4) and Passage 5, into the tank passage.
Figure 3
The pressure drops before and after Orifice 6 in Piston A. When the following condition:
Chamber 1 pressure x d2 surface area > Chamber 2 pressure x d1 surface area, is achieved, the main poppet (B) opens, and
pressure oil from the cylinder port flows into the tank passage, protecting the actuator.
Figure 4
When the high pressure setting is used [Pc Servo hydraulic signal: ON]
Piston E moves to the right, the pressure set by spring C increases, and the high pressure setting condition is achieved
Figure 5
Because d1>d2, the cylinder port pressure is normally greater than the tank pressure, and the main poppet (B) sits firmly in
its seat.
When the cylinder port pressure falls below the tank pressure (close to negative pressure), the main poppet (B) comes under
pressure corresponding to the difference between the surface areas of d1 and d2, and opens. Oil flows from the tank
passage to the cylinder port, preventing cavitation.
Figure 6
Service Information

description
Profile:
EXC, EC290B LC [GB]
2 stage port relief valve, description

Overload operation (for option)
When the high pressure setting is used [Pl servo hydraulic signal: OFF]
Piston (E) moves to the right due to the action of spring (F).
Figure 1
A. Piston
B. Main poppet
C. Spring
D. Servo hydraulic poppet
E. Piston
F. Spring
Pressure oil from the cylinder port goes through orifice (3) in piston (A), and enters chamber (2).
Because d1>d2, the main poppet (B) remains securely seated.
When the pressure oil exceeds the pressure set by spring (C), servo hydraulic poppet (D) opens, and oil flows through
passages (4) and (5) to the tank passage.
Figure 2
Due to the oil flow past poppet (D), the pressure drops before and after orifice (3) in piston (A).
The piston moves to the left, into its seat at the tip of the servo hydraulic poppet (D).
Oil from chamber (1) flows through orifice (3) in piston (A), through side hole (4) and passage (5), to the tank passage.
Figure 3
The pressure drops before and after orifice (6) in servo hydraulic poppet (D). When the following condition:
Chamber (1) pressure x d2 surface area > chamber (2) pressure x d1 surface area, is achieved, main poppet (B) opens, and
pressure oil from the cylinder port flows to the tank passage, protecting the actuator.
Figure 4
When the low pressure setting is used [Pl servo hydraulic signal: ON]
Piston (E) moves to the right because Pl servo pressure compresses spring (F), the pressure set by spring (C) decreases, and
the low pressure setting condition is achieved.
Figure 5
Because d1>d2, the cylinder port pressure is normally greater than the tank pressure, and the main poppet (B) remains
securely seated.
When the cylinder port pressure falls below the tank pressure (close to negative pressure), the main poppet (B) comes under
pressure corresponding to the difference between the surface areas of d1/d2, and opens. Oil flows from the tank passage to
the cylinder port, preventing cavitation.
Figure 6
Service Information

disassembly and assembly
Profile:
EXC, EC290B LC [GB]
2 stage port relief valve, disassembly and assembly

For assembly, reverse disassembly procedure.
Op nbr 00000
When disassembling, mark each part to make assembling easier.
Figure 1
NOTE!
It is difficult to adjust the pressure when this component is on the machine, so do not dismantle the pressure adjustment
section.
1. Remove sleeve (1), and cartridge from main control valve.
 Tools: Spanner 32 mm
2. Remove nuts (3 and 4) with spanner 30 mm.
3. Remove cap (2), and remove sub-assembly completely. Take out spring (3) and servo hydraulic poppet (4).
Figure 2
Removal, sub-assembly
4. Remove servo hydraulic seat (5), and pull out springs (6 and 7), piston (8) and main poppet (9)
Figure 3
Removal, main poppet
5. Remove adjusting screw (1), and pull out piston (2).
Figure 4
Removal, piston
Service Information

Profile:
EXC, EC290B LC [GB]
2 stage port relief valve, disassembly and assembly

(For assembly, reverse disassembly procedures)
NOTE!
It is difficult to adjust the pressure when this component is located on the machine, so do not dismantle the pressure
adjustment section.
Figure 1
1. Loosen sleeve (1), and remove cartridge completely.
 Tightening torque: 147 Nm (108 lbf ft)
2. Loosen nuts (3 and 4) with spanner 32 mm.

3. Loosen cap (2), and remove subassembly completely. Remove spring (5) and servo hydraulic poppet (6).
 Tightening torque: 98 Nm (72 lbf ft)
4. Remove servo hydraulic seat (7), and springs (8, 9), piston (10) and main poppet (11).
5. Remove adjusting screw (12), and piston (13).
Service Information

Boom holding valve, Service Information 2014/10/29
description
Profile:
EXC, EC290B LC [GB]
Boom holding valve, description

Spool in neutral
3Pi servo hydraulic signal : OFF
The position of piston A is as illustrated and servo hydraulic pressure (Pg2) is isolated from chamber Y. Therefore, the
positions of piston B and poppet C become as shown, and passage (5) and (6) will be isolated from poppet C. As chamber
(1) is connected to chamber (2) through orifice (4), pressure Pc is obtained. As poppet E is closed because section area d1 >
d2, chamber (2) and (3) are completely isolated.
Figure 1
Boom holding valve
A Piston F Boom spool

B Piston P Boom cylinder head side
C Poppet H High pressure supply passage
D Check valve T Tank passage
E Poppet
Spool operating
Boom raising [Pv > Pc] (3Pi servo hydraulic signal : OFF)
As chamber (1) is connected to chamber (2) through orifice (4), pressure (Pc) is obtained and poppet E will open. The oil in
high pressure supply passage flows to cylinder, piston side.
Figure 2
Boom raising
P Boom cylinder head side 3Pi Servo hydraulic pressure

H High pressure oil supply passage T Tank passage
E Poppet
Boom lowering [Pc > Pv] (3Pi servo hydraulic signal : ON)
When servo hydraulic pressure (3pi) is applied, piston A moves up and servo hydraulic pressure (Pg2) flows to chamber Y.
Piston B and poppet C move to the right, so passage (5) and (6) are connected.
As chamber (3) is connected to the tank passage (by spool moving to left), the oil in chamber (1) opens check valve D
through passage (5) and (6), and then flows to tank passage through passage (7). Therefore, pressure Pc is applied to (d1
area – d2 area). Poppet E is opened and the oil returned from the cylinder, piston side, now flows to tank passage.
Figure 3
Boom lowering
A Piston P Boom cylinder piston side

B Piston G Drain port
C Poppet 3Pi Servo hydraulic pressure port
D Check valve T Tank passage
E Poppet
Service Information

Boom regenerating valve, Service Information 2014/10/29
description
Profile:
EXC, EC290B LC [GB]
Boom regenerating valve, description
Figure 1
Boom regenerating valve
A Check valve H Boom holding valve

B Spring P Center bypass passage
C Back pressure check valve T Tank passage
Servo hydraulic pressure (ar1) pushes the boom spool left (boom lowering) and pressurized oil from the pump opens the
load check valve and flows through the U-shaped path, the circular notch of the spool, and port AR1 to the cylinder, rod
side.
The return oil flows from port BR1, to the circular notch of the spool, where it passes through the path inside the spool to
check valve A. As the oil pressure rises it overcomes the spring force, opens the check valve and merges with the flow
through port AR1 to the cylinder, rod side.
This process prevents cylinder cavitation during boom lowering.
Service Information

Arm holding valve, Service Information 2014/10/29
description
Profile:
EXC, EC290B LC [GB]
Arm holding valve, description

Spool in neutral
4pi servo hydraulic signal : OFF
Spool A is positioned as shown, and chamber (1) and drain (Dr2) are isolated. As chamber (1) is connected to chamber (2)
through orifice (4), the pressure in chamber (1) will be Pc. As area d1 > d2, poppet B will not move, and chamber (2) and
chamber (3) are isolated to hold the arm in position.
Figure 1
Arm holding valve
A. Spool
B. Poppet
C. Arm spool
D. Servo hydraulic signal port
R. Arm rod
H. High pressure oil supply passage
T. Tank passage
Spool operating
Arm out [Pv > Pc] (4pi servo hydraulic signal : OFF)
As chamber (1) is connected to chamber (2) through orifice (4), the pressure will be Pc and poppet B will open. The oil (Pv) in
high pressure supply passage is supplied to cylinder rod side through chamber (3).
Figure 2
Arm out
A. Spool
B. Poppet
R. Arm rod
H. High pressure oil supply passage
T. Tank passage
Arm in (Pc > Pv) [4pi servo hydraulic signal : ON]

When servo hydraulic pressure (4pi) is applied, spool A moves left. As the oil is drained when chamber (1) and drain (Dr2) is
connected, the pressure in chamber (2) becomes low. When the pressure Pc is applied by (d1 area – d2 area), poppet B will
open and the oil returned from the cylinder, rod side, flows to tank passage.
Figure 3
Arm in
A. Spool
B. Poppet
R. Arm rod
T. Tank passage
Service Information

Arm regenerating valve, Service Information 2014/10/29
description
Profile:
EXC, EC290B LC [GB]
Arm regenerating valve, description

Servo hydraulic pressure (al3) pushes the arm spool right (arm in) blocking the center bypass passage, and pressurized oil
from the pump opens the load check valve and flows through the U-shaped path, the circular notch of the spool, and port
AL3 to the cylinder, piston side.
Figure 1
Arm regenerating valve
A Check valve F Check valve

B Piston H High pressure supply passage
C Spool P Center bypass passage
D Spring R Reserve passage
E Arm holding valve T Tank passage
Pressure on rod side is high [PB > PA]

The return oil flows from port BL3, to the circular notch of the spool, to restricted passage (1) and (2) where the pressure
rises, moving spool C and opening a narrow path to check valve A. When the check valve opens the oil flows via the passage
in the spool to merge with the flow through port AL3 to the cylinder, piston side. This process prevents cylinder cavitation
during arm in operation. The oil from spring chamber Z flows to Pa (Dr) through check valve F.
Figure 2
When pressure on rod side is high
A. Check valve
C. Spool
E. Arm holding valve
F. Check valve
H. High pressure supply passage
R. Reserve passage
T. Tank passage
Pressure on piston is high [PA > PB]

When the pressure at AL3 is greater than BL3, check valve A closes. The pressurized oil acts against piston B, and if it exceeds
the force of spring D, piston B and spool C move right and passage (2) is opened wide. The return oil now flows through
unrestricted passage (1) and (2) to tank. If servo hydraulic pressure is applied to port (pa), Piston B disconnect port (Pa) and
spring chamber Z. The force of the servo hydraulic pressure multiplied by the piston area is added to the spring force and
moves spool C, closing passage (2). As the return oil pressure rises the regeneration process starts.
Figure 3
When pressure on piston is high
A Check valve F Check valve

B Piston H High pressure supply passage
C Spool P Center bypass passage
D Spring R Reserve passage
E Arm holding valve T Tank passage
Service Information

Logic valve, description Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Logic valve, description

In neutral and boom lowering
Servo hydraulic signal : OFF
Pistons A and B are positioned as shown by the force of the springs. Pressure Pa at (a) port flows to chamber Z through
passage (1) and (2) when check valve C opens. Pressure Pb‚ at (b) port flows to chamber Z from orifice E of poppet D. This
process prevents cylinder cavitation during arm in operation.
Figure 1
Logic valve, in neutral and boom lowering
A Piston F From P pump (Pa)

B Piston G Boom raise servo hydraulic oil
C Check valve H High pressure supply passage for
D Poppet 3-spool side boom (Pb)
E Orifice
In case of Pa > Pb
As area d1 > d2, poppet D remains in position and the passage between (a) and (b) is cut off. (when the boom is lowered,
some oil is leaked through orifice E).
In case of Pa < Pb
The pressure in chamber Z becomes Pb‚ through orifice E of poppet D, so check valve C is closed. Poppet D is positioned in
place due to area difference between d1 and d2, and the passage between (b) and (a) is cut off.
Boom raising
Servo hydraulic signal : ON
When the boom is raised, servo hydraulic pressure is applied to Pb‚ port. Piston A and B move left, and passage (1) and (2)
are cut off.
In case of Pa > Pb
The pressure in chamber Z becomes Pb through orifice E of poppet D, so poppet D is opened and oil flows from (a) to (b).
In case of Pa < Pb
The pressure in chamber Z becomes Pb through orifice E of poppet D. Poppet D is positioned and passage between (a) and
(b) is cut off. This process prevents cylinder cavitation during arm in operation.
Figure 2
Logic valve, boom raising
A Piston F From P pump (Pa)

B Piston G Boom raise servo hydraulic oil
C Check valve H High pressure supply passage for
D Poppet 3 spool side boom (Pb)
E Orifice
Service Information

Foot relief valve (flow Service Information 2014/10/29
sensing valve), description
Profile:
EXC, EC290B LC [GB]
Foot relief valve (flow sensing valve), description

Oil in the center bypass passage flows to tank passage through orifice C of poppet A. Pump delivery volume can be
controlled as pressure (fp) balanced with the passing flow at orifice C is fed back to the pump regulator.
Figure 1
Foot relief valve
A Poppet
B Spring
C Orifice
P From center bypass passage
T Tank passage
N Pressure signal to pump
When due to a delayed response of the pump, a large amount of oil flows, pressure (fp) exceeds the set pressure of spring B,
and poppet A will open and the hydraulic oil flows to tank. Therefore, it acts as a relief valve.
Figure 2
Act as a relief valve
Service Information

General, precautions Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
General, precautions
Removal, precautions
 Thoroughly clean the control valve prior to removal from the machine.
 Tag all hoses prior to disconnecting from the control valve.
 Cap all hoses and plug all ports to prevent contamination from entering.
 Use eye bolts to lift the control valve. Do not sling on the relief valves or spool caps.
 The control valve is heavy. Take appropriate safety precautions when handling.
Disassembly, precautions
 Do not use excessive force, sharp or high hardness tools to disassemble the control valve.
 Handle the components carefully, protect the highly polished precision finish. If the surface is damaged it will cause
internal oil leakage and malfunction.
 Match mark the parts to indicate original location and position during reassembly.
 Take care not to mix the parts of the various check valves and flow valves.
 Inspect and analyze all failures. – Determine the root cause!
Assembly, precautions
 Clean all parts with cleaning solvent and dry with compressed air.
 Rework damaged parts, polish minor burrs, nicks, score marks or sharp edges with fine emery and crocus cloth.
Prepare all replacement parts.
 Coat the sliding parts with clean hydraulic oil.
 Replace the seals, O-rings and back-up rings.
 Use a torque wrench to tighten the screws and plugs to the specified torque.
 Take care not to interchange the spools.
General, inspection
Inspection methods
Part Remark
1 Housing
 Check for flaws, cracks and corrosion, and check for  If there are score marks, rust and corrosion,
hidden cracks by use of various detection methods. correct with #2000 sand paper and crocus
i.e. magnetic flux or dyes. cloth.
 If there is damage that cannot be repaired,
replace with a new component.
 Valve housing is a non-serviceable part. If there is  Housing bore : Spool and sliding parts.
damage, replace the control valve assembly. Especially around the pressure holding areas
as applied to : Seat : Seat of check valve. Port
seal : O-ring contact surface. Seal : Main relief,
port relief bore contact surface.
Spool
2
 Check for nicks, scratches, rust, and corrosion on  If there are nicks, scratches, rust and corrosion,
the outer diameter. correct with #2000 sand paper and crocus
cloth.
 If a flaw is found on the outer diameter, check the  The spool is a non-serviceable part. If
relevant housing bore. damaged replace the control valve assembly.
 Insert the spool into its bore and operate forward/  If it binds slightly try polishing the spool with
reverse while rotating. crocus cloth.
 Check if there is a flaw on the check valve seat and  If there is a flaw or a partial contact trace on
the check valve, inside the spool. the seal face seat, replace the valve.
 Insert the check valve into the spool, and operate it  If it sticks, replace it.
forward/reverse.
 Check the spring.  If there is damage or heat discoloration

replace it.
3 Return spring, rear side.
 Check the spring, spring guide, spool cap and cover  If there is wear or damage, replace the part.
for rust, corrosion, wear, and damage.
4 Load check valve.
 Check the seat of check valve.  If there is a flaw or partial contact trace on the
seat, replace the part.
 Check the spring.  If there is damage replace it.
5 Orifice
 Check if the foot relief valve orifice is clogged.  If clogged, bore with wire.
NOTE!
Do not distort or change the orifice size.
6 Boom holding valve, servo hydraulic logic valve
 Check the poppet seat for flaws.  If there is a flaw or partial contact trace on the
seat, replace the part.
 Insert the poppet, and operate it forward/reverse.  If it sticks, replace it.
7 Main relief, port relief valve.

 Check the seat for flaws.  If there is a flaw or partial contact trace on the
seat, replace it.
 Check if the orifice is clogged.  If clogged, bore with wire.
 Insert the poppet, and move it forward/reverse.  If it sticks replace it.
 Check the spring.  If there is damage or heat discoloration,

replace it.
 It is difficult to judge the relief valve for damage by

eye, therefore check the operating condition
carefully.
Service Information

General, tools Service Information 2014/10/29
Profile:
EXC, EC290B LC, EC290B FX [GB]
General, tools
Tools
No. Tool Size Quantity

1 Vise 1
2 Socket 27 mm 1
3 32 mm 1
4 41 mm 1
5 46 mm 1
6 Allen wrench 4 mm 1
7 5 mm 1
8 6 mm 1
9 8 mm 1
10 10 mm 1
11 12 mm 1
12 14 mm 1
13 17 mm 1
14 19 mm 1
15 Torque wrench 75 ~ 4000 kgf·cm Various
(5 ~ 300 ft·lbs)
16 Loctite #262 1
Prepare the following tools, also:
 M 6 screw (to remove cut- off valve, conflux flow valve, travel priority valve)
 Magnet bar (to remove shuttle valve ball, negative control relief valve)
 Holder for main spool (to protect the spool when clamped in the vise)
Holder usages
φD Holder Application
31.2 mm 41 Main spool
Figure 1
Holder (material : Brass, unit : mm)
A. Holder (2 pieces)
Figure 2
Arm regenerating valve sleeve disassembly jig
Material : steel, unit : mm

Service Information

Main spool, disassembly Service Information 2014/10/29
and assembly
Profile:
EXC, EC290B LC, EC290B FX [GB]
Main spool, disassembly and assembly

(For assembly, reverse disassembly procedures)
Op nbr 00000
NOTE!
When disassembling, mark each part to indicate original location and position during assembly.
1. Remove screw (1), and remove cover (2).

NOTE!
When assembling, make sure that the O-ring is installed before assembling the cover.
 Tools : Allen wrench 8 mm

 Tightening torque : 5 kgf·m (36.1 lbf·ft)
Figure 1
Main spool
2. Pull out the spool subassembly.

NOTE!
Pull out the spool slowly confirming the housing condition.
Figure 2
Removal, spool
3. Hold spool with holder and vise, and loosen spool cap (3).

 Tightening torque : 6 kgf·m (43 lbf·ft)
NOTE!
Remove oil from spool and holder.
NOTE!
When assembling, take care spring guide direction.
Figure 3
Disassembly, spool
4. Remove spool cap (3) and remove spring guides (4, 7), spring (5) and spacer (6).
Figure 4
Removal, spring etc.
5. Only for AM and BM spool, remove cap (8) and pull out spring (9) and check valve (10).

Figure 5
Removal, check valve etc.
Boom spool
6. Remove plug (1).
 Tools : Spanner 19 mm
Figure 6
Removal, plug and cover

8. Remove spacer (4).

NOTE!
When assembling, make sure that the O-ring is installed before assembling the cover.
Figure 7
Removal, spacer
Service Information

adjustment
Profile:
EXC, EC290B LC [GB]
Main relief valve, adjustment

Adjustment of the limiting pressure
Op nbr 00000
Measuring condition
 Place the machine in the service position B. See091 Service positions

 Hydraulic oil temperature : 50 ±5°C (122 ±41°F)
 Working mode: “P” mode ( North America : H mode )
 Measuring location : P2 gauge ports at hydraulic main pump
 At full stroke end of bucket in/out (at 1 pump flow condition)
NOTE!
Adjustment temperature should be kept within 50 ±5°C (122 ±41°F), as unnecessary relief (valve loading) causes rapid
temperature rise.
WARNING
WARNING
Leaking high-pressure hydraulic hoses may cause severe injuries. Fine jets have high penetrating capacity on bare
skin.
Measurement
 Connect oil pressure gauge (600 kgf/cm2, 8530 psi) to the quick coupler.
 Start the engine, set to “ P ” mode, and measure the main pressure with the engine at high idle.
 Operate the bucket cylinder to the end of its stroke to check the low/high relief pressures.
 Operate the switch on the upper part of the right hand operating lever to measure the boost pressure.
Hydraulic pressure
See 9121 Main control valve, specifications
NOTE!
Operate the bucket cylinder to the end of its stroke to check the low/high relief pressures.
Figure 1
Main relief valve
1 Adjusting screw (low pressure) 4 Cartridge
2 Lock nut 5 Adjusting screw (high pressure)
3 Lock nut
Figure 2
Adjusting points
A. Main relief valve pressure adjusting points
Low pressure Adjustment
1. Remove the servo hydraulic hose connected to the relief valve, and plug the hose end.
2. Loosen lock nut (2), and turn adjusting screw (1) as follows :
To increase pressure, turn clockwise.
To decrease pressure, turn counterclockwise.
3. Hold adjusting screw (1) securely and tighten lock nut (2).
4. Reinstall the relief valve servo hydraulic hose.

High pressure adjustment
6. Loosen lock nut (2), and turn adjusting screw (1) clockwise until fully seated.
9. Readjust the low pressure setting to specification.
10. Reconfirm the high/low pressure settings.

Service Information

disassembly
Profile:
EXC, EC290B LC [GB]
Main relief valve, disassembly

(For assembly, reverse disassembly procedure)
Op nbr 00000
1. Hold adjusting screw (1) and loosen lock nut (2).
Figure 1
Main relief valve
2. Hold cap (4) and loosen lock nut (3).
3. Remove cap (4) and remove cartridge.
4. Remove sleeve (6) and pull out piston (7), spring (8) and orifice (9).
NOTE!
Do not remove servo hydraulic seat, because it is press fitted.
Figure 2
Removal, piston etc.
5. Loosen each screw and nut.
Dimensions of fastener
No. Item Dimension

1 Adjusting screw 22 mm
2 Lock nut 30 mm
3 Cap 41 mm
4 Sleeve 27 mm
Service Information

Main pressure relief valve, Service Information 2014/10/29
replacing
Profile:
EXC, EC290B LC [GB]
Main pressure relief valve, replacing

Op nbr 912-067
WARNING
WARNING
1. Remove Hose (2).

Remove main relief valve (1).
Figure 1
Removal, main relief valve
1. Main relief valve
2. Install the main relief valve.

NOTE!
Tightening torque : 147.1 ±14.7 N m (108.3 ±10.8 lbf ft)
3. Adjust the main pressure and test the machine. See : 9121 Main relief valve, adjustment
Service Information

Port relief valve pressure, Service Information 2014/10/29
measurement
Profile:
EXC, EC290B LC [GB]
Port relief valve pressure, measurement

Measurement, hydraulic pressure
Op nbr 00000
Measuring condition
 Place the machine in the service position B. See091 Service positions

 Hydraulic oil temperature : 50 ±5°C (122 ±41°F)
 Working mode: “P” mode ( North America : H mode )
 Adjusting the pump displacement
 Main relief valve pressure : 44.1 MPa (450 kgf/cm2) (6400 psi) (441.3 bar)
NOTE!
Adjustment temperature should be kept within 50 ±5°C (122 ±41°F), as unnecessary relief (valve loading) causes rapid
temperature rise.
WARNING
WARNING
Leaking high-pressure hydraulic hoses may cause severe injuries. Fine jets have high penetrating capacity on bare
skin.
Measurement
 Connect oil pressure gauge (600 kgf/cm2, 8530 psi) to the P1/P2 gauge ports.
 Start the engine, set to “P” mode, and measure the main pressure with the engine at high idle.
 Condition of digging unit to be measured.
 For the working equipment, set each cylinder to the end of its stroke.
 For slewing, put the bucket against an immovable object or put it in a trench.
 For travel, fit a pin between the sprocket and frame to lock the sprocket against the frame.
 Operate the switch on the upper part of operating lever (right) to measure the boost pressure.
1. Connect two oil pressure gauges (600 kgf/cm2 , 8530 psi) to the P1/P2 gauge ports.
2. Start the engine, set to “P” mode, and measure the main pressure with the engine at high idle.
3. Condition of digging unit to be measured.
 For the working equipment, set each cylinder to the end of its stroke.
 For slew, put the bucket against an immovable object or put it in a trench.
 For travel, fit a pin between the sprocket and frame to lock the sprocket against the frame.
 Operate the switch on the upper part of operating lever (right) to measure the boost pressure.
Hydraulic pressure
See 9121 Main control valve, specifications.
Primary pump supply to each actuator and test port location.
Port connection
Plug Pump Actuator (test port)

(1) P1 (P ) pump • Slew motor (on the motor head)
• Option digging unit
• Arm cylinder
• Left track motor (on the motor head)
(2) P2 (P ) pump • Boom cylinder
• Bucket cylinder
• Right track motor (on the motor head)
Figure 1
Pressure measuring port of hydraulic pump
1. Quick coupler
2. Cap
3. Pressure gauge
4. Hydraulic pump
Pressure measuring port of track motor

See 4411 Track motor, description
Pressure measuring port of slew motor
See 4412 Swing motor, description
Adjustment of the pump displacement
Op nbr 00000
NOTE!
For the correct setting of the limiting pressure of the valve, connect the hoses and do the procedures for adjusting the pump
displacement.
NOTE!
Do not adjust the main relief pressure and pump displacement when adjusting the slewing relief pressure only.
1. Disconnect the hose connected to the proportional solenoid valve from the gear pump.
2. Mount a tee (PF 1/4″) to the gear pump.
3. Connect the hoses to the tee as follows :
a. Connect the proportional solenoid valve hose to one tee port.

b. Disconnect the hose at the negative port (Pi1) and plug it.
c. Install a jumper hose between negative port (Pi1) and the other tee port.
4. Check the port relief pressure related to P1 pump.
5. Repeat above procedure for P2 pump.
6. Reconnect the servo hydraulic hoses to their original position upon completion of checking and adjusting
pressures.
Figure 2
Adjustment, displacement
1 Jumper hose 7 Plug

2 In 8 Jumper hose
3 Plug 9 Out
4 Main control valve (4 spool) 10 Servo hydraulic pump
5 Main control valve (3 spool) 11 Servo hydraulic filter
6 Main pump
Service Information

adjustment
Profile:
EXC, EC290B LC, EC290C L [GB]
Port relief valve, adjustment

(For boom, arm and bucket)
Op nbr 00000
NOTE!
For the correct setting of the relief pressure of the valve, connect the hoses and do the procedures for adjusting the pump
displacement.
See 9121 Port relief valve pressure, measurement.

NOTE!
Do not adjust the port relief valve unnecessarily.
 Symptoms of faulty port relief valve :
a. Main relief valve high/low pressures can not be adjusted.

b. Digging unit hoses rupture repeatedly.
NOTE!
If pump displacement is not decreased, the port relief valve will open at lower than specified pressure.
1. Increase the main relief valve pressure to exceed 450 kgf/cm2 (6625 psi), approximate 1/2 turn.
2. Decrease the displacement of the pump.
5. After completion of adjustment, reset the main relief valve high/low pressures to specification.
Figure 1
Adjustment, port relief valve
Figure 2
Port location
Port connection
Port Digging unit Port Digging unit

ar1 Boom lowering br1 Boom raising
ar2 Bucket curl br2 Bucket dump
al2 Option bl2 Option
al3 Arm in bl3 Arm out
Track motor port relief valve pressure, adjustment

See 4411 Track motor, adjustment
Slew motor port relief valve pressure, adjustment
See 4412 Slew motor, adjustment
Service Information

disassembly
Profile:
EXC, EC290B LC [GB]
Port relief valve, disassembly

Op nbr 00000

NOTE!
Do not disassemble pressure adjusting part.
1. Remove sleeve (1) and cartridge form the main control valve.
NOTE!
Set pressure is different according to position. Be sure to assemble it to its original position.
Figure 1
Removal, sleeve
2. Remove cap (2) and pull out spring (3) and servo hydraulic poppet (4).
 Tools: Socket, spanner 27 mm

Figure 2
Removal, spring and servo hydraulic poppet
3. Remove servo hydraulic seat (5) and pull out springs (6, 7), piston (8) and main poppet (9).
Figure 3
Removal, servo hydraulic seat, spring and main poppet
Service Information

adjustment
Profile:
EXC, EC290B LC [GB]
2 stage port relief valve, adjustment

(For option)
See 9121 Main control valve, specifications
See 9121 Port relief valve pressure, measuring and adjusting
Figure 1
1. Adjusting screw (Low pressure)

2. Lock nut
3. Adjusting screw (High pressure)
4. Lock nut
5. Cap
2. Loosen lock nut (2), and turn adjusting screw (1) clockwise until fully seated.
3. Loosen lock nut (4), and turn adjusting screw (3) as follows To increase pressure, turn clockwise.
NOTE!
Tightening torque : 10kgf·m (72.2 lbf·ft)
5. Readjust the low pressure setting to specifications.

6. Reconfirm the high/low pressure settings.
Low pressure adjustment
 Remove the servo hydraulic hose connected to the relief valve, and plug the hose end.
 Loosen lock nut (2), and turn adjusting screw (1) as follows:
To increasepressure, turn clockwise.
 Hold adjusting screw (1) securely and tighten lock nut (2).
NOTE!
1/4 rotation will change it by about 89 kgf/cm2 (1266psi.)
NOTE!
Lock nut (2) tightening torque: 6 kgf·m (43 lbf·ft)
 Reinstall the relief valve servo hydraulic hose.
NOTICE
Reconfirm the low pressure setting, then check the high pressure setting using the power boost function. Do not try
to adjust the high pressure setting without proper gauges.
Service Information

adjustment
Profile:
EXC, EC290B LC [GB]
2 stage port relief valve, adjustment

(For option)
See 9121 Main control valve, specifications.
See 9121 Port relief valve pressure, measurement.
Figure 1
1 Adjusting screw (Low pressure)

2 Lock nut
3 Adjusting screw (High pressure)
4 Lock nut
5 Cap
X Piston surface
Y Screw (high pressure) surface
2. Loosen lock nut (2), and turn adjusting screw (1) clockwise until fully seated (X, Y).
3. Loosen lock nut (4), and turn adjusting screw (3) as follows.
NOTE!
Tightening torque: 98 Nm (72 lbf ft)
5. Readjust the low pressure setting to specifications.
Low pressure adjustment
1. Connect the servo hydraulic hose connected to the relief valve.

– Pl servo hydraulic signal: ON
2. Loosen lock nut (2), and turn adjusting screw (1) as follows:
NOTE!
1/4 rotation will change it by about 5.8 MPa (839 psi) (58 bar).
NOTE!
Lock nut (2) tightening torque: 98 Nm (72 lbf ft)
NOTICE
Reconfirm the low pressure setting, then check the high pressure setting using the power boost function. Do not try
to adjust the high pressure setting without proper gauges.
Service Information

Boom holding valve, Service Information 2014/10/29
disassembly
Profile:
EXC, EC290B LC [GB]
Boom holding valve, disassembly

Op nbr 00000
Figure 1
Boom holding valve
Main body check valve
1. Remove screw (1) and remove cover assembly (2).

NOTE!
When reassembling, make sure that the o-ring is installed on housing inlet before assembling the cover.
Figure 2
Main body check valve
2. Pull out spring (3) and poppet (4).

Tightening torque : 10 kgf·m (72 lbf·ft)
Selector valve
3. Remove cap (5) and pull out piston (6) and spring (7).
Figure 3
Selector valve
Cover assembly
4. Remove cap (8) and pull out spring (9) and check poppet (10)
Figure 4
Cover assembly
Figure 5
Spring etc, removal
5. Remove cap (11) and pull out piston (12).

Figure 6
Piston, removal
6. Remove cap (16) and pull out spring (15) and poppet (14).
Figure 7
Poppet, removal
7. Pull out sleeve (13) by tapping the left side of cover lightly.
NOTE!
Take care not to damage the surface edge (φ5) of sleeve.
Service Information

Boom back pressure check Service Information 2014/10/29
valve, disassembly
Profile:
EXC, EC290B LC [GB]
Boom back pressure check valve, disassembly

Op nbr 00000
NOTE!
1. Remove cap (1) and pull out spring (2) and poppet (3).
Tools : Socket wrench 32 mm
Figure 1
Boom back pressure check valve
Service Information

Servo hydraulic selector Service Information 2014/10/29
valve, disassembly
Profile:
EXC, EC290B LC [GB]
Servo hydraulic selector valve, disassembly

Op nbr 00000
Figure 1
Servo hydraulic selector valve
NOTE!
1. Remove cap (1) and pull out spring (2) spring seat (3) and spool (4).
 Tools : Socket wrench, spanner 30 mm

Figure 2
Removal, cap and spool
2. Remove sleeve (5).

Figure 3
Removal, sleeve
Service Information

Arm holding valve, Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Arm holding valve, disassembly and assembly

Op nbr 00000
NOTE!
Figure 1
Disassembly, arm holding valve
A. Arm port relief valve
1. Remove screw (1) and remove cover (2).

NOTE!
When assembling, make sure that the O-ring is installed on manifold inlet before assembling.
2. Pull out spring seat (3), spring (4) and poppet (5).
Figure 2
3. Remove cap (6) and pull out spring (7) and spool (8).

Figure 3
Removal, spool
4. Remove cap (11) and pull out sleeve (10) by tapping the left side of housing lightly.
NOTE!
Take care not to damage the surface edge (φ8) of sleeve.
Figure 4
Sleeve, removal
Service Information

Arm regenerating and Service Information 2014/10/29
bucket conflux check valve,
disassembly
Profile:
EXC, EC290B LC [GB]
Arm regenerating and bucket conflux check valve, disassembly

Op nbr 00000
Figure 1
Arm regenerating and bucket conflux check valve
NOTE!
1. Remove cap (1) and pull out spring (2), spool (3). and piston (4).
Tools : Socket wrench, spanner 41 mm
Tightening torque : 10 kgf·m (72.2 lbf·ft)
Figure 2
Removal, cap and spring
2. Assemble sleeve disassembly jig (11) to sleeve (5) and pull out sleeve (5), spring (6) and check valve (7).
Figure 3
Removal, sleeve and check valve
3. Remove cap (8) and pull out piston (9).

Tools : Socket wrench, spanner 30 mm
Tightening torque : 8 kgf·m (57.8 lbf·ft)
Figure 4
Removal, cap and piston
Figure 5
Check valve
Left: Standard (no conflux)
Right: Optional (conflux)

Service Information

Arm parallel conflux valve, Service Information 2014/10/29
disassembly
Profile:
EXC, EC290B LC [GB]
Arm parallel conflux valve, disassembly

Op nbr 00000
NOTE!
1. Remove cap (1) and pull out spring (2), and spool (3).

Figure 1
Arm parallel conflux valve
Service Information

Logic valve, disassembly Service Information 2014/10/29
and assembly
Profile:
EXC, EC290B LC [GB]
Logic valve, disassembly and assembly

Op nbr 00000
NOTE!
1. Remove cap (1) and pull out sleeve (2) and piston (3), (4) and spring (5).

Figure 1
Logic valve
2. Pull out sleeve (6) by using the horizontal hole and pull out spring (7) and check valve (8).
Figure 2
Figure 3
Removal, check valve etc.
3. Insert the round bar with threaded bolt (M 5 × 0.8) in one end into sleeve (9) and pull out sleeve (9).
Figure 4
Removal, sleeve etc.
4. Pull out spring (10) and poppet (11).
Figure 5
Removal, poppet and spring
Service Information

Load check valve, Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Load check valve, disassembly and assembly

Op nbr 00000
Figure 1
Load check valve
A. (Single) Boom, slew

B. (Double) Arm, travel, bucket, option
NOTE!

Figure 2
Removal, spool etc.
Service Information

Straight travel changeover Service Information 2014/10/29
valve, disassembly and
assembly
Profile:
EXC, EC290B LC [GB]
Straight travel changeover valve, disassembly and assembly

Op nbr 00000
Figure 1
Straight travel changeover valve
NOTE!

Figure 2
Removal, spool assembly
Service Information

Foot relief valve (flow Service Information 2014/10/29
sensing valve), disassembly
Profile:
EXC, EC290B LC [GB]
Foot relief valve (flow sensing valve), disassembly

Op nbr 00000
1. Remove cap (1) and pull out poppet (2).
Figure 1
Foot relief valve
2. Remove cap (3) and pull out shim (4) and spring (5).
 Tools: Socket wrench, spanner 30 mm

NOTE!
If shims for adjusting pressure are installed, confirm the quantity.
Figure 2
Removal, poppet etc.
Service Information

Center bypass valve, Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Center bypass valve, disassembly and assembly

Op nbr 00000
Figure 1
Center bypass valve
 Tools: Socket wrench, spanner 41 mm

NOTE!
Note that the spool notches in 3 series and 4 series side are different.
Figure 2
Removal, spring
Service Information

Line rupture valve (boom), Service Information 2014/10/29
description
Profile:
Line rupture valve (boom), description

Figure 1
Line rupture valve (boom), piping 1
Figure 2
Line rupture valve (boom), piping 2
1 Hose assembly (from left boom cylinder and 14 Spring washer 27 Flange bolt
line rupture valve P3)
2 Hose assembly (to tank T1) 15 Screw 28 Connector
3 Hose assembly 16 Tee 29 O-ring
4 Hose assembly (to main control valve ar1-1) 17 Tee 30 Plate
5 Hose assembly 18 Elbow 31 Elbow
6 Hose assembly 19 Elbow 32 O-ring
7 Copper gasket 20 Elbow 33 Pipe weld assembly
8 Pipe weld assembly 21 Elbow 34 Connector
9 Pipe weld assembly 22 Switch wire harness 35 O-ring
10 Bracket 23 O-ring 36 Plug
11 Screw with washer 24 O-ring 37 Plug
12 Pressure switch 25 O-ring
13 Connector 26 Block
MCV Main control valve

AO Arm out port relief valve
BU Boom up port relied valve
Figure 3
Line rupture valve (boom), neutral position
1 Valve block 12 Spring 23 Plug

2 Spool 13 Spring 24 Plug
3 Spring 14 Retainer 25 Plug
4 Check valve 15 Retainer 26 Screw
5 O-ring 16 Plug 27 Name plate
6 Plug 17 O-ring 28 Spring
7 Logic valve 18 Plug 29 Poppet
8 Relief valve 19 Plug 30 Plug
9 Shim 20 O-ring 31 O-ring
10 Cap 21 Plug
11 O-ring 22 O-ring
The boom line rupture valve connected between the boom cylinder and the main control valve consists of: a servo hydraulic
valve, logic valve, check valve, pressure relief valve and a housing.
The line rupture valve function is to prevent an accident caused by a sudden dropping of the boom when a pipe or hose
ruptures. It also prevents boom cylinder creep caused by internal leakage of the main control valve.
Neutral position
When the remote control valve is in neutral position, spring (28) pushes the poppet of check valve (4) forward blocking the
passage to port P1. The oil flow from P4 & P5 normally connected through orifice (a) is blocked by servo hydraulic valve
spool (2) at position (b). The spring force combined with the oil pressure acting on the sectional area difference between f &
e of logic valve (7) pushes the poppet forward blocking passage P2.
With the boom / attachment off the ground the weight pressurizes the oil on the boom cylinder piston side, the flow
connected via passage P2 is blocked by the poppet of check valve (4) and logic valve (7), trapping the oil in the hydraulic
cylinder preventing the boom from dropping.
Boom raising (P1 → P2)
When operating the remote control valve joystick to raise the boom, servo hydraulic valve spool (2) and logic valve (7) are in
the neutral position. Pressurized oil from the main control valve is routed through P1 port, pushes open check valve (4), then
flows via P2 to the piston side of the hydraulic cylinder raising the boom.
When the boom is raised and the joystick is returned to neutral position (P1 = P2), as described above check valve (4)
poppet blocks the passage and the pressurized oil on the boom piston side is trapped in the cylinder preventing the boom
from dropping.
When a pipe or hose ruptures during boom raising, pressurized oil flow will be cut off to passage P1. As a result the pressure
in passage P1 drops quickly and the poppet of check valve (4) will be pushed forward by its spring blocking passage P1, and
pressurized oil flow from the piston side of the boom cylinder is blocked.
Figure 4
Line rupture valve (boom), boom raising
Boom lowering (P2 → P1)

When operating the remote control valve joystick to lower the boom, servo (pilot) hydraulic oil is supplied to passage (Pi)
and pushes servo hydraulic valve spool (2) upward against springs (12, 13).
As spool (2) moves, passage T3 aligns with position b, and the oil in the spring chamber of logic valve (7) drains to the
hydraulic tank through passage P4 and P5.
The pressure difference of area e and f causes logic valve (7) to open and the oil from P2 flows past the poppet of logic
valve (7) to servo spool (2).
The return oil from the piston side of the boom cylinder will flow from passage P2 → P3 → P1 → main control valve → tank.
The oil passage opening from P3 to P1 will be varied because of the area of notch (C), which controls the return oil flow rate
(speed) from the boom cylinder.
When a pipe or hose ruptures during boom lowering, the pressure at port P1 will be lower than passage P3, P2, so the
poppet of logic valve (7) will be pushed forward by its spring blocking passage P3, and return oil flow from the boom
cylinder is blocked.
When the joystick is released to neutral position, pilot pressure at (Pi) is cut off, and springs (12, 13) move spool (2)
downward blocking passage P3.
Figure 5
Line rupture valve (boom), boom lowering
Overload relief valve

Normally the hydraulic oil from port P2 flows through g.
If the pressure of the boom cylinder reaches the set value, the pressure in the chamber h will open the poppet (29) and the
oil from port P2 flows to T2. So the pressure in the boom cylinder will be lowered.
Figure 6
Line rupture valve (boom), overload relief valve
Service Information

troubleshooting
Profile:
EXC, EC290B LC [GB]
Line rupture valve (boom), troubleshooting

Line rupture valve, troubleshooting

1 Excessive oil leakage in the passage P2
→ P1.  Contamination between the  Disassemble and clean.
check valve and seat. If damaged, replace.
 Contamination between the
logic valve and seat.
 Oil leakage of the servo
hydraulic valve.
 Oil leakage of the relief valve.
2 Boom lowering (or arm in) does not

occur.  Sticking spool of the servo  Disassemble and clean.
hydraulic valve. If damaged, replace.
3 External oil leakage.

 Damaged seals.  Replace damaged or
worn component.
4 Slow response in boom lowering (or

arm in).  Clogged orifice in the logic  Disassemble and clean.
valve. If damaged, replace.
 Clogged port T in the servo
hydraulic valve.
Service Information

troubleshooting
Profile:
Line rupture valve (boom), troubleshooting

Troubleshooting

1 Excessive oil leakage in the
passage P2 → P1.  Contamination between the  Disassemble and clean.
check valve and seat. If damaged, replace.
 Contamination between the logic
valve and seat.
 Oil leakage of the servo hydraulic
valve.
 Oil leakage of the relief valve.
2 Boom lowering (or arm in) does

not occur.  Sticking spool of the servo  Disassemble and clean.
hydraulic valve. If damaged, replace.
3 External oil leakage.

 Damaged seals.  Replace damaged or worn
component.
4 Slow response in boom

lowering (or arm in).  Clogged orifice in the logic valve.  Disassemble and clean.
 Clogged port T in the servo If damaged, replace.
hydraulic valve.
Service Information

Line rupture valve (arm), Service Information 2014/10/29
description
Profile:
Line rupture valve (arm), description
Figure 1
Line rupture valve (arm), piping 1
Figure 2
Line rupture valve (arm), piping 2
1 Elbow 14 U bolt
2 Pipe weld assembly 15 Clip
3 O-ring 16 Hose assembly
4 Elbow 17 Hose assembly
5 Elbow 18 Hose assembly
6 O-ring 19 Hose assembly
7 O-ring 20 O-ring
8 Connector 21 Nut
9 Tee 22 Connector
10 Nut 23 Clip
11 Plate 24 Bolt
12 Nut 25 Plug
13 Plain washer
Figure 3
Line rupture valve (arm) -1
1 Plug 12 Plug 23 Valve block

2 O-ring 13 Relief valve 24 Spool
3 Spool cover 14 Screw 25 Plug
4 O-ring 15 Spool cover 26 Plug
5 Check valve 16 Shim 27 Plug
6 Name plate 17 Spring 28 O-ring
7 Screw 18 Spring 29 Back-up ring
8 Logic valve 19 O-ring 30 Plug
9 Spring 20 Plug 31 Spring
10 O-ring 21 Retainer
11 Back-up ring 22 Retainer
Figure 4
Line rupture valve (arm) -2
The arm line rupture valve (anti-drop valve) connected between the arm cylinder and the main control valve consists of: a
servo hydraulic valve, logic valve, check valve, pressure relief valve and a housing.
The line rupture valve function is to prevent an accident caused by a sudden dropping of the boom when a pipe or hose
ruptures. It also prevents boom cylinder creep caused by internal leakage of the main control valve.
Neutral position
When the remote control valve is in neutral position, spring (31) pushes the poppet of check valve (5) forward blocking the
passage to port P1. The oil flow from P4 & P5 normally connected through orifice (a) is blocked by servo hydraulic valve
spool (24) at position (b). The spring force combined with the oil pressure acting on the sectional area difference between f
& e of logic valve (8) pushes the poppet forward blocking passage P2.
With the arm in position / attachment off the ground, the weight pressurizes the oil on the arm cylinder piston side, the flow
connected via passage P2 is blocked by the poppet of check valve (5) and logic valve (8), trapping the oil in the hydraulic
cylinder preventing the arm from dropping.
Arm out (P1 → P2)
when operating the remote control valve joystick to arm out, servo hydraulic valve spool (24) and logic valve (8) are in the
neutral position. Pressurized oil from the main control valve is routed through P1 port, pushes open check valve (5), then
flows via P2 to the rod side of the hydraulic cylinder moving the arm out.
When the arm is out and the joystick is returned to neutral position (P1 = P2), as described previously check valve (5) poppet
blocks the passage and the pressurized oil on the arm rod side is trapped in the cylinder preventing the arm from dropping.
When a pipe or hose ruptures during arm out, pressurized oil flow will be cut off to passage P1. As a result the pressure in
passage P1 drops quickly and the poppet of check valve (5) will be pushed forward by its spring blocking passage P1, and
pressurized oil flow from the rod side of the arm cylinder is blocked.
Figure 5
Line rupture valve (arm), arm out
Arm in (P2 → P1)

When operating the remote control valve joystick to arm in (lower the arm), servo (pilot) hydraulic oil is supplied to passage
(Pi) and pushes servo hydraulic valve spool (24) to the left against springs (17, 18).
As spool (24) moves, passage T3 aligns with position b, and the oil in the spring chamber of logic valve (8) drains to the
hydraulic tank through passage P4 and P5.
The pressure difference of area e and f causes logic valve (8) to open and the oil from P2 flows past the poppet of logic
valve (8) to servo spool (24).
The return oil from the rod side of the arm cylinder will flow from passage P2 → P3 → P1 →main control valve → tank.
The oil passage opening from P3 to P1 will be varied because of the area of notch (C), which controls the return oil flow rate
(speed) from the arm cylinder.
When a pipe or hose ruptures during arm lowering, the pressure at port P1 will be lower than passage P3, P2, so the poppet
of logic valve (8) will be pushed forward by its spring blocking passage P3, and return oil flow from the arm cylinder is
blocked.
When the joystick is released to neutral position, pilot pressure at (Pi) is cut off, and springs (17, 18) move spool (24) to the
right blocking passage P3.
Figure 6
Line rupture valve (arm), arm in
Overload relief valve

See 9123 Line rupture valve (boom), description.
Service Information

troubleshooting
Profile:
Line rupture valve (arm), troubleshooting

See 9123 Line rupture valve (boom), troubleshooting.
Service Information

Line rupture valve, Service Information 2014/10/29
adjustment
Profile:
Line rupture valve, adjustment

NOTE!
Adjustment temperature should be kept within 50 ~ 60 °C (122 ~ 140 °F), unnecessary relief valve loading causes rapid
temperature rise. If pump displacement is not decreased, the port relief valve will open at lower than specified pressure.
Adjustment of the pressure for boom and arm port relief valve
When installing the line rupture valve to the machine in the field or dismantling from the machine, adjust port relief valve
pressure for boom and arm as follows:
When installing the line rupture valve,
 Holding adjusting screw (2) securely, loosen lock nut (1) counterclockwise, approximately 1 turn.
 Tools
Adjusting screw (2): Allen wrench 4 mm
Lock nut (1): spanner 13 mm
Figure 1
Port relief valve
1. Lock nut
2. Adjusting screw
 Turn adjusting screw (2) to increase pressure clockwise, approximately 1/2 turn.
 Tools: Allen wrench 4 mm
 Holding adjusting screw (2) securely, tighten lock nut (1).
 Tightening torque (1): 2 kgf·m (14.4 lbf·ft)

When dismantling the line rupture valve,
See 9121 Port relief valve, adjustment.

Location, port relief valve
See 9121 Main control valve, description.
Service Information

disassembly
Profile:
Line rupture valve (boom), disassembly

Op nbr
a. L wrench : 4, 6, 12 and 14 mm
b. Spanner : 32 and 50 mm
c. Torque wrench : 1 ~ 15 kgf·m (7.2 ~ 108.0 lbf·ft)
d. Socket wrench : 32, 50 mm
e. Hammer
f. Rod : φ10 × 100 mm
Tightening torque
Item no. Tightening torque, kgf·m (lbf·ft)

8 6 ± 0.6 (43.3 ± 4)
6, 30 15 ± 1.5 (108 ± 11)
10 10 ± 1.0 (72 ± 7)
16, 18, 19 3 ± 0.3 (22 ± 2)
 Thoroughly clean the valves prior to removal from the machine.

 Do not use excessive force, sharp or high hardness tools to disassemble the valves.
1. Remove relief valve (8) from the line rupture valve.

Tools : Spanner 32 mm
NOTE!
Do not disassemble the pressure adjusting part.
2. Remove plug (6) of the logic valve, and pull out O-ring (5), spring (3) and logic valve (7).
Tools : L wrench 14 mm
3. Remove plug (30) of the check valve, and pull the O-ring (31), spring (28) and check valve (4).
4. Remove plug (6), and pull out O-ring (5).


7. Pull out springs (12, 13), retainer (15) and (14).
8. Remove spool (12).
9. Remove plugs (16).(6 places)


Service Information

disassembly
Profile:
Line rupture valve (arm), disassembly

Op nbr
1. L wrench : 4, 6 and 14 mm
2. Spanner : 32 mm
3. Torque wrench : 1 ~ 22 kgf·m (7.2 ~ 158.8 lbf·ft)
4. Socket wrench : 32 mm
5. Hammer
6. Rod : φ10 × 100 mm
Tightening torque
Item no. Tightening torque, kgf·m (lbf·ft)

1 3 ± 0.3 (22 ± 2)
13, 30 20 ± 2 (144 ± 14)
14 6 ± 0.6 (43.3 ± 4)

1. Remove relief valve (13) from the line rupture valve.

NOTE!
Do not disassemble the pressure adjusting part.
2. Remove plug (12) of the logic valve, and pull out O-ring (10), back-up ring (11), spring (9) and logic valve (8).
3. Remove plug (30) of the check valve, and pull the O-ring (28), back-up ring (29), spring (31) and check valve (5).
4. Remove screws (14), cover (3) and O-ring (4).

5. Remove screw (14), cover (15) and O-ring (19).

6. Remove spring (17, 18), retainer (21, 22), and take off spool (24).
7. Remove plug (20) at spool (24).
8. Remove plugs (20). (6 places)

9. Remove plug (1) and O-ring (3).

Service Information

Troubleshooting, Service Information 2014/10/29
diagnosing procedure
Profile:
EXC, EC290B LC [GB]
Troubleshooting, diagnosing procedure

If a minor fault is left intact and operation is continued, a failure may be caused, entailing considerable expense and long
hours of restoration. Therefore when a minor defect occurs, do not rely only on your intuition and experience, but look for
the cause based on the troubleshooting principle and perform maintenance and adjustments to prevent a major failure from
occurring. Keep in mind that a failure results from a combination of different causes.
These five basic steps are essential for effective troubleshooting :
1. Study the system.

2. Ask the operator.
3. Inspect the machine.
4. Operate the machine yourself.
5. Trace possible causes.
Study the system

Study the machine's technical manuals.
Know what the system is composed of, how it works, and the construction, functions and specifications of the system
components.
Figure 1
Study the machine's technical manuals
 Solve the problem by using the trouble shooting charts and hydraulic schematics!
Ask the operator

Before inspecting, get the full story of the malfunctions from the operator.
Figure 2
Ask the operator
 How is the machine being used? (Find out if the machine is being operated correctly).
 When was the trouble noticed, and what type of work was the machine doing at that time ?
 What are the details of the trouble? Is the trouble getting worse, or did it appear suddenly for the first time ?
 Did the machine have any other troubles previously? If so, which parts were repaired or replaced before ?
 Get all the facts concerning the complaint!
Inspect the machine

Before starting the troubleshooting procedure, check the machine's daily maintenance points, as shown in the operator's
manual.
Figure 3
Check the machine's daily maintenance points
Also, check the electrical system, including the batteries, as troubles in the electrical system such as low battery voltage,
loose connections and blown fuses will result in malfunctions causing an operational failure of the machine.
 Analyze the problem thoroughly!
Operate the machine yourself

Try to identify the trouble by operating the machine yourself.
If the trouble cannot be confirmed, stop the engine and obtain further details of the malfunction from the operator.
Figure 4
Operate the machine yourself
 After repairs are completed, operate the machine to ensure that the root cause of the problem has been corrected!
Trace possible causes

Before reaching a conclusion, check the most likely causes again. Try to identify the actual cause of the trouble.
Based on your conclusion, make a plan for appropriate repairs to avoid consequent malfunctions.
Figure 5
Trace all possible causes
 Do the easiest things first and double check before beginning any disassembly!
Service Information

Examples, hydraulic system Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Examples, hydraulic system

Unusual noise comes from the pump connection
Remove dust plug under engine flywheel and check if rubber pieces or particles
are present.
Yes Coupling element is broken, disassemble and replace.
No Coupling assembly spline is worn or the screws are loose.
Yes Replace the coupling assembly and retighten the screws.
No Hydraulic pump or engine is suspect, refer to the service manual on

hydraulic pump and engine.
Hydraulic oil is cloudy
Has the oil change interval been maintained?
Yes Drop hydraulic oil sample on a hot plate and check if it foams up.
Yes Water is mixed.

Replace the oil.
No Is the hydraulic oil mixed with another oil brand?
Yes Use only one brand oil.

Replace with a specified oil.
No Has the hydraulic system overheated?

Yes Clean cooler and check the hydraulic system.
No Oil is aerated.
Check suction line and return line, and eliminate the air
intruding source.
No Observe the recommended oil change interval.
Hydraulic oil overheated
Is hydraulic oil level correct?
Yes Is the oil cooler clogged and is anything blocking air circulation?
Yes Clean oil cooler.

Secure air circulation route.
No Is the oil cooling fan speed within the specified value?
No Check the shunt valve relief pressure and readjust or replace relief
valve.
Yes Is the set pressure of main relief, port relief and travel relief valve
lower than the standard value?
Yes Readjust set pressure.
No Is main relief valve popping very often?
Yes Reduce load.
No Replenish specified oil to the corrected level.
Pump cavitation
Is hydraulic oil level correct?

Yes Is the viscosity of the hydraulic oil too high?
Yes Replace oil with proper viscosity.
No Is the suction strainer clogged?
Yes Clean suction strainer.
No Is air intruding at pump suction line?
Yes Check for air intruding at suction line and

retighten or replace parts.
No Replenish specified oil to the corrected level.
Hydraulic oil contaminated
Has the hydraulic oil passed specified replacement hours?
Yes Replace hydraulic oil and filter.
If available, clean the hydraulic system.
No Had the return filter been replaced at proper intervals?
No Replace hydraulic oil and filter.
If available, clean the hydraulic system.
System does not operate when control levers are operated
Is the servo hydraulic pressure supplied to the servo hydraulic

chamber of main control valve?
Yes Repair or replace main control valve.
No Is the remote control valve connector filter clogged?
Yes Clean the connector filter.
No Does the system operate if the remote control valve’s servo hydraulic line
is interchanged with an operating circuit?
Yes Repair or replace remote control valve.
No Repair or replace main control valve.
Actuator moves when remote control valve is in the neutral position
Check if remote control valve operation is normal.
Yes Repair or replace main control valve.
Replace the digging unit cylinder seal.
No Replace or repair remote control valve.
The digging unit moves slowly
Is the speed slow only in combined operation? Ye Normal

s
No
Is the travel speed within the specified value?
Ye Is the conflux of oil flow normal at boom raising and arm extension?
s
Ye Is the speed of digging unit within the specified value?
s
Ye Is secondary servo hydraulic pressure within the

s specified value?
Ye Does the main control valve spool move Ye The control valve spool is
s lightly by hand? s stuck.
No Does the symptom change when port Ye Replace port relief valve.
relief valve is replaced? s
N
o
Replace or repair hydraulic No Remote control valve is
cylinder. faulty.
No Check if secondary servo hydraulic Ye Unclog servo hydraulic piping

pressure pipes are clogged or there is s or repair the leaking part.
leakage.
No Is primary servo hydraulic pressure within the No Servo hydraulic pump is

specified value? faulty.
No
Is servo hydraulic pump delivering oil? Ye Servo hydraulic relief valve is
s faulty.
No Is the servo hydraulic pressure of bypass or selector spool within the specified
value?
No For the above secondary servo hydraulic pressure refer to the

specified pressure table.
No Is travel speed slow? Ye Hydraulic pump is faulty.

s
No Is secondary servo hydraulic Ye Is the engine speed within N Adjust engine

pressure within specified s the specified value? o rpm.
value?
No Is the orifice in the control valve Yes Clean the orifice in the control valve.
clogged?
No
Is the servo hydraulic pipe clogged? Yes Unclog servo hydraulic piping or
Is there leakage? repair the leaking part.
No Is remote control valve normal? No Repair or replace remote
control valve.
No cylinders move when control levers are operated
1. Check if left-hand console box is lowered (unlock position).
Yes Check if the safety limit switch works properly.
Yes Check if the servo hydraulic pressure of servo solenoid valve port Pi is
set to the specified pressure.
Yes Clean or replace servo solenoid valve.
No Adjust or replace servo hydraulic relief valve.
No Adjust lever linkage.
No Lower the left-hand console box. (unlock position)
2. Does the engine sound change when remote control valve lever is operated.
Yes Is the hydraulic oil level low? Yes Add hydraulic oil.
No Check for air ingression at main pump Yes Repair the suction port of main pump.
suction port.
No Is the suction strainer clogged? Yes Clean suction strainer.
No Repair or replace main pump.
No Check if servo hydraulic pressure setting is Yes Repair or replace remote

normal. control valve.
No Check if servo hydraulic pump function is No Check if servo hydraulic pump suction
normal. is clogged.
No Replace servo hydraulic pump. Ye Clean suction strainer.

Check pump drive device, spline and s
coupling.
Boom raising speed is slow
Is the single operation slow?
Yes Is there any change during traveling or arm extension?
Yes Is boom conflux solenoid valve operating? No Clean or replace solenoid valve.
Yes Is center bypass valve (4-spool valve) No Repair or replace center bypass valve.
operating?
Yes Is oil supplied to the port b of center N Clean the connector filter of
bypass valve? o solenoid valve.
Yes Adjust oil pump regulator or repair pump.
No Is there any change when operating bucket or right Yes Replace bucket or travel load check
traveling? valve.
No Is boom raising faster when pulling arm? N Replace arm conflux check valve.
o
Yes Clean or replace servo hydraulic selector valve.
No Is the left/right traveling deviation within the specified N Adjust the main pump regulator or
value? o repair pump.
Yes Is main pressure normal? N Adjust main pressure or replace main relief
o valve.
Yes Are the other functions rather than boom N Adjust the main pump regulator or
raising normal? o repair pump.
Yes Is boom raising port relief valve N Adjust pressure or replace port
normal? o relief valve.
Yes Repair main control valve.
No digging power
Do all actuators fail to provide digging power?
Yes Does pump make abnormal noises?
Yes Is hydraulic oil level low? Yes Replenish hydraulic oil.
No Does the suction line have loose connections? Yes Repair suction line.
No Pump is abnormal or suction strainer is clogged.
No Is main relief pressure normal? Yes Repair or replace main pump.
No Repair or replace main relief valve for excavation.
No Does only one actuator fail to provide digging power?
Yes Replace port relief valve with one from a functioning actuator.
Does the problem disappear?
No Is remote control valve secondary pressure normal?
Yes Malfunction in control valve. Repair or replace cylinder.

Repair or replace.
No Servo hydraulic circuit abnormal.
Yes Replace port relief valve.

Service Information

Examples, power Service Information 2014/10/29
transmission
Profile:
EXC, EC290B LC [GB]
Examples, power transmission

Slew is not smooth
Is only slew function rough?
Ye Slew is rough in one direction only?

s
Ye Is phenomenon reversed when right and left servo No Check control valve spool.
s hydraulic hoses are interchanged?
Ye Check remote control valve.

s
Check the shuttle valve.
No Is slew parking brake release pressure No Check the servo hydraulic circuit.
normal?
Ye Is slew motor drain amount normal?

s
No Check motor and slew device.
Check slew motor.
No Check if the main relief valve pressure is adjusted to the specified value?
Ye Check the servo hydraulic pressure.

s
Repair or replace the servo pump.
No Adjust the relief valve.
Check main pump.
Abnormal noise in slew motion
Is the lubrication to slew ring gear and to pinion normal?
Yes Is the lubrication to slew bearing normal?
Yes Is the unusual sound heard from slew relief valve?
Yes Disassemble and repair or replace.
No Check that slew motor piston is not seized and bearing is not worn.
Yes Slew motor is faulty. Disassemble and repair.
No Slew gearbox is at fault. Disassemble and repair.
No If fault is minor, feed grease.

If fault is excessive, disassemble and repair or replace.
No Supply grease to grease bath.
No slew motion
Are all functions other than slew normal?
Yes Is pressure at left remote control valve ports 2 and 4 normal?

Yes Is normal pressure delivered to slew motor inlet?
Yes Is normal pressure delivered to port P of slew parking brake

release valve?
Yes Is normal pressure delivered to port SH of slew parking brake release valve
while slew lever is operated?
Yes Machine does not slew though slew Yes Repair or replace slew motor.
motor is rotating.
No Repair or replace control valve. No Slew device is abnormal.
No Check servo hydraulic circuit.
No Is slew motor drain amount normal? Ye Control valve spool sticking.

s Repair or replace.
No Repair or replace left remote control No Repair or replace slew motor.

valve.
No Only slew system and arm do not move?
Yes Is normal pressure delivered to left remote control valve port P?
Yes Is pressure normal at left remote control valve ports Yes Check slew system and arm
1,2,3 and 4? separately.
No Is filter of remote control valve clogged? No Repair or replace left remote

control valve.
Yes Clean filter.
No Repair or replace remote control valve.
Slow/weak slew power

Uphill slew on a slope can not be done.
Slew acceleration in slow.
No slew power in one direction?
Yes Both right slew acceleration and left slew brake are incorrect, or both left slew
acceleration and right brake are incorrect.
Yes Does phenomenon reverse when right and left cross-over relief valves are
interchanged?
Yes Check relief valve pressure setting. Adjust or replace slew motor relief
valves.
No Check make-up valve of slew motor.
No Acceleration force is not available, but braking force is normal.
Is phenomenon reversed when right and left servo hydraulic hoses are
interchanged?
Yes Check if servo hydraulic pressure setting is Yes Repair or replace control valve.
normal.
No Repair or replace control valve. No Repair or replace remote control

valve.
No All functions other than slew are normal.
Yes Is servo hydraulic pressure setting normal?
Yes Is normal pressure delivered to port P of slew parking brake

release valve?
Is normal pressure delivered to port SH of slew parking brake release

valve while slew lever is operated?
Yes Does slew motor drive and drain Yes Abnormal slew device.
pressure normal? Check oil level.
No Repair or replace shuttle valve. No Repair or replace slew motor.
No Repair or replace control valve.

No Check main pump.
Travel speed is slow
All working devices slow?
Yes Check if main pump delivery is normal? No Repair or replace main pump.
Yes Is the center passage by passing internally? N Repair or replace track motor.
o
Yes Replace the turning joint seal.
No Check if servo hydraulic pressure setting is normal. Yes Repair or replace remote control valve.
No Is primary pressure supplied to remote No Replace servo hydraulic filter, and clean the
control valve port P? filter screen at the remote control valve.
One side traveling
Steering force is weak on one side.
Yes Acceleration force is not available, but braking force is normal.
Yes Is limit pressure of main relief valve same?
Yes Is low/high shift available for right and left? Yes Refer to the track motor.
No Repair low/high speed valve of track motor.
No Does phenomenon reverse when right and Yes Replace relief valve.
left relief valves are interchanged?
No Repair track motor.
No Is phenomenon reversed when discharge lines of two Yes Adjust pump regulator or repair
pumps are interchanged? pump.
No Is phenomenon reversed when left and right lines at center

passage inlet are interchanged?
Yes Repair control valve. No Repair track motor.
No Is phenomenon reversed when left and Yes Replace center passage seals.
right lines at center passage outlet are
interchanged?
No All functions other than travel are normal. No Check main pump.
Yes Is travel pedal linkage normal? (pressure is normal.)
Yes Repair or replace travel pedal linkage.
No Is phenomenon reversed when left and right lines at center

passage inlet are interchanged?
Yes Repair control valve. No Repair track motor.
No Is phenomenon reversed when left and Yes Replace center passage seals.
right lines at center passage outlet are
interchanged?
Left and/or right travel motor does not work (one direction forward/reverse)
Is servo hydraulic pressure transmitted to the servo hydraulic shut off solenoid valve?
N Is servo hydraulic filter clogged? Yes Clean or replace filter.

o
No Is servo hydraulic limit valve pressure normal? N Adjust or replace servo

o hydraulic relief valve.
Ye Repair or replace servo hydraulic pump.
s
Ye Is servo hydraulic pressure transmitted to remote control N Repair or replace servo hydraulic shut
s valve? o off solenoid valve.
Ye Is servo hydraulic pressure transmitted to main control N Repair or replace remote

s valve? o control valve.
Ye Is main pump pressure transmitted to travel motor?

s
Ye Is the brake release pressure normal? N Replace brake piston seal.

s o
Ye Overloaded? Yes Remove load. Check and repair the brake plate
s sticking.
No Is there abnormal noise in Yes Check and repair Check gearbox coupling.
gearbox? gearbox.
No
No Is main relief valve pressure normal? N Adjust or repair main O Repair or replace main
o relief valve. r pump
Ye Is travel spool of main control valve operating N Repair or replace main

s normally? o control valve.
Ye Is the pressure raised when plugging the inlet port N Repair or replace main control
s of center passage? o valve.
Ye Is the pressure raised when plugging the N Replace center passage

s outlet port of center passage? o seals.
Yes
Is pressure normal when track motor line is N Check track motor, and repair
connected normally? o if necessary.
Or
Ye Overloaded? Yes Remove load. Check and replace track motor
s relief valve.
No Check and repair gearbox. Or Check and repair brake system.
NOTE!
Overload : Track or rollers jammed, or the track is bogged down in mud, swamp etc.
Actuator drops noticeably when control lever is placed in neutral
Does phenomenon change when engine is stopped?
Yes Remote control valve output pressure is improperly adjusted.

Repair or replace remote control valve.
No Replace port relief valve with one from a normal actuator.

Does the problem disappear?
Yes Replace port relief valve.
No Is control valve spool damaged, e.g. broken spring or loose bolt?
Yes Repair or replace control valve.
No Repair or replace cylinder.
Actuator drops briefly when starting operation
If you attempt to lift the digging unit, it drops slightly before raising.
This is easily checked when engine is stopped.
Yes Repair or replace load check valve.

Service Information

Hydraulic pump, 913 Service Information 2014/10/29
description
Profile:
EXC, EC290B LC [GB]
Hydraulic pump, description
Figure 1
Structure, main pump
1. Eye bolt
2. Set screw maximum flow
3. Set screw minimum flow
4. Set screw minimum flow
Port connection
Port name Port size Tightening torque: Nm (kgf m) (lbf ft)

A1,2 Delivery SAE 6000 1″ 98 (10) (72.5)
B1 Suction SAE 2500 3″ 240 (24.4) (176.6)
Dr1, Drain PF 3/4 – 23 170 (17.3) (125.8)
Dr2
Pi1,2 Servo hydraulic PF 1/4 – 15 36 (3.6) (26.6)
Psv Servo hydraulic assist PF 1/4 – 15 36 (3.6) (26.6)
a1,2, 4 Gauge PF 1/4 – 15 36 (3.6) (26.6)
A3 Gear pump delivery PF 1/2 – 19 74 (7.5) (54.7)
B3 Gear pump suction PF 3/4 – 20 53 (102) (39.2)
Pump, sectional view

Figure 2
Main pump (sectional view)
111 Driving shaft 271 Pump casing 724 O-ring

113 Driving shaft 312 Valve block 725 O-ring
114 Spline coupling 313 Valve plate 728 O-ring
123 Roller bearing 314 Valve plate 732 O-ring
124 Needle bearing 401 Screw 774 Seal
127 Bearing spacer 406 Screw 789 Back-up ring
141 Cylinder block 466 Vp plug 792 Back-up ring
151 Piston 468 Vp plug 808 Lock nut
152 Shoe 490 Plug 809 Lock nut
153 Set plate 531 Tilting pin 824 Snap ring
156 Spherical bushing 532 Servo piston 885 Valve plate pin
157 Cylinder spring 534 Stopper 886 Spring pin
211 Shoe plate 535 Stopper 901 Eye bolt
212 Swash Plate 548 Feedback pin 953 Adjusting screw
214 Tilting bushing 702 O–ring 954 Adjusting screw
251 Swash plate support 710 O–ring 981 Name plate
261 Seal cover 717 O–ring 983 Pin
262 Seal cover 719 O-ring
Pump, principle of operation
 This pump assembly consists of two pumps connected by spline coupling (114). The two pumps are driven
simultaneously as the engine rotation is transmitted to the front drive shaft (111).
The suction and delivery ports are integrated at the connecting section of the two pumps, in valve block (312) : The
common suction port serves both the front and rear pumps.
Structure and operating principle of front and rear pump is the same so front pump only will be explained. The
pump consists of rotary group, swash plate group and valve block group.
 The rotary group consists of front drive shaft (111), cylinder block (141), piston and shoe (151, 152), set plate (153),
spherical bushing (156), and cylinder spring (157). The drive shaft is supported by bearings (123, 124). The shoe is
caulked to the piston to form a spherical coupling. It has a pocket to relieve thrust force generated by loading
pressures and create a hydraulic balance so that it slides lightly over shoe plate (211).
The sub group composed of a piston and a shoe is pressed against the shoe plate by the action of the cylinder
spring through the set plate and spherical bushing. Similarly, the cylinder block is pressed against valve plate (313)
by the action of the cylinder spring.
 The swash plate group consists of swash plate (212), shoe plate (211), swash plate support (251), tilting bushing
(214), tilting pin (531) and servo piston (532). The swash plate is supported by a cylindrical part on the opposite side
of its sliding surface and swash plate support (251).
The servo piston moves to the right and the left as hydraulic oil controlled by the regulator flows to a hydraulic
chamber located on both sides of the servo piston. The force exerted on the tilting pin by the servo piston causes
the swash plate to slide on support (251) to change the tilting angle (α).
Figure 3
Moving, swash plate
1. Servo piston
2. Tilting pin
 The valve block group consists of valve block (312), valve plate (313) and valve plate pin (885). The valve plate which
has two crescent ports is attached to the valve block to feed oil to and collect oil from the cylinder block. The oil
discharged via the valve plate is routed to an external pipe line by way of the valve block.
 The pump shaft driven by the engine, rotates the cylinder block via the splined bore. If the swash plate is tilted the
pistons arranged in the cylinder block make a reciprocating motion with respect to the cylinder block, while they
revolve with the cylinder block.
A single piston will perform a 180° motion away from the valve plate (oil suction stroke) and then make another
180° motion towards the valve plate (oil discharging stroke) as the cylinder block rotates. When the swash plate
tilting angle is zero, the piston does not stroke or discharge oil.
Adjustment of maximum flow
Figure 4
Adjustment of maximum flow
X. Servo hydraulic pressure Pi
Y. Delivery flow, Q
Adjust it by loosening nut (809) and by tightening (or loosening) adjusting screw (954).
Only the maximum flow is adjusted without changing other control characteristics.
 For the location of adjusting screw and nut, .
Adjustment of minimum flow
Figure 5
Adjustment of minimum flow
X. Servo hydraulic pressure, Pi

Y. Delivery flow, Q
Similar to the adjustment of the maximum flow, other characteristics are not changed. However, if tightened too much, the
required horsepower for the maximum delivery pressure (or for relief) may increase.
Service Information

Pump, troubleshooting 913 Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Pump, troubleshooting
Troubleshooting, overload of engine
Cause Remedy Remark

Revolution and pressure are higher than Set to specification.
set values.
Regulator torque is set higher than Readjust regulator. Refer to the regulator section.
normal.
Regulator is operating abnormally.
Pump internal parts are seized or Replace faulty parts. Check filter and drain oil to see if
broken. abnormal wear particles are present.
Troubleshooting, pump oil flow is extremely low and discharge pressure is not raised
Cause Remedy Remark

Regulator is faulty. Repair regulator. Refer to the regulator section.
Pump internal parts are seized or Replace damaged parts. Check filters and drain oil.
broken.
Auxiliary pump is faulty. Replace auxiliary pump. Remove Auxiliary pump and check shaft
coupling.
Servo hydraulic relief valve is faulty. Check servo hydraulic relief valve. Refer to the servo hydraulic relief valve
Particularly poppet, seat and spring. section.
Troubleshooting, abnormal noises and abnormal vibrations
Cause Remedy Remark

Cavitation Prevent cavitation.
Check if hydraulic oil is cloudy.  Hydraulic oil is insufficient.
 Auxiliary pump is damaged.
 Suction pipe is drawing air.
 Suction ports are blocked.
Caulked part of shoe is broken. Replace piston assembly and shoe

plate.
Cylinder is cracked. Replace cylinder.
Pump is installed improperly. Correct installation.
Regulator is hunting. Repair regulator. Refer to the regulator section.
Servo hydraulic relief valve is hunting. Repair/replace valve. Refer to the servo hydraulic relief valve
section.
Service Information

Regulator, description 913 Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Regulator, description
Model code
KR3 H– 9 N 04
Regulator for K3V series For K3V 140 Total cumulative Negative flow control Design series
pump horsepower control + number
power shift control
Port connection
Port name Port size

Pi Negative servo hydraulic pressure signal port PF 1/4
P2 Companion pump servo hydraulic pressure port PF 1/4
Pf Secondary servo hydraulic pressure port on proportional solenoid valve PF 1/4
Tightening torque
No. Size Tightening torque

N·m kgf·cm lbf·ft
412, 413 M8 29.4 300 21.6
436, 438 M6 11.8 120 8.6
496 NPTF 1/16 8.8 90 6.5
630 M 30 x 1.5 156.8 1600 115.0
801 M8 15.7 160 11.5
Regulator, Sectional view

Figure 1
Structure, regulator
412 Screw 625 Outer spring 654 Return spring

413 Screw 626 Inner spring 655 Adjusting spring
436 Screw 627 Ring 656 Cover
438 Screw 628 Screw 708 ~ 763 O-ring
496 Plug 629 Cover 801 Nut
601 Casing 630 Lock nut 814 Snap ring
611 Feedback lever 631 Sleeve 836 Snap ring
612 Lever 641 Servo hydraulic cover 858 Snap ring
613 Lever 643 Servo hydraulic piston 874 ~ 898 Pin
614 Plug 644 Spring seat 924 Adjusting screw
615 Plug 645 Adjusting ring 925 Adjusting screw
621 Piston 646 Servo hydraulic spring A-A Section A-A
622 Piston case 651 Sleeve B-B Section B-B
623 Rod 652 Spool C View C
624 Spring seat (C) 653 Spring seat
Regulator, exploded view

Figure 2
Regulator (exploded view)
Regulator, principle of operation

Schematic
In-line type axial piston pump regulator consists of following controllers.
Horsepower control
As the delivery pressure of the pump P1 and mate pump P2 are raised, the delivery flow rate will be reduced automatically,
so the input torque will be regulated to a certain value.
(When the rpm is constant, the input horsepower will become constant also.)
The regulator is the total cumulative horsepower type, that operates by the sum of load pressures of the two pumps in the
tandem double pump system. Therefore the engine can be automatically prevented from being overloaded regardless of the
loading conditions on the two pumps.
Power shift control
The horsepower setting will be changed by changing the instruction current of the proportional solenoid valve attached to
the regulator. Only one proportional solenoid valve is provided. However, secondary pressure Pf (power shift pressure) flows
into the horsepower control portion of each pump regulator through the pump inner passage, and shifts it to same
horsepower setting, respectively.
Delivery flow rate of the pump can be changed, so the proper power level suitable for the work conditions can be acquired.
Negative flow control
Delivery rate of the pump can be controlled by varying the servo hydraulic pressure Pi.
This regulator is the negative flow control type which reduces delivery rate Q according to the increase of servo hydraulic
pressure Pi. If the servo hydraulic pressure corresponding to the flow required for the work is designated, the pump will
deliver only the required oil so unnecessary power consumption will be prevented.
This regulator has 3 control functions as above, however when different control functions act at the same time, low oil flow
instruction will have priority by the mechanical operation.
Figure 3
Structure, regulator
X Large end part 625 Outer spring

Y Small end part 626 Inner spring
531 Tilting pin 646 Servo hydraulic spring
548 Feedback pin 651 Sleeve
611 Feedback lever 652 Spool
612 Lever-1 654 Return spring
613 Lever-2 875 Pin
621 Compensating piston 897 Pin
623 Compensating rod 898 Pin
Regulator, negative flow control

According to the change of the servo hydraulic pressure Pi, the delivery flow is regulated, as shown.
The regulator is negative flow control type, so the delivery flow Q decreases as the servo hydraulic pressure Pi increases.
When the servo hydraulic pressure corresponding to the flow required for the work is commanded, the pump discharges the
required flow only, so it does not consume power needlessly.
Figure 4
Negative flow control chart
X. Servo hydraulic pressure, Pi

Y. Delivery flow. Q
Flow reducing function

As the servo hydraulic pressure Pi rises, servo hydraulic piston (643) moves right to a position where the force of servo
hydraulic spring (646) is balanced with the hydraulic force.
Groove “A” in the servo hydraulic piston is fitted with pin (875) that is fixed to lever 2 (613).
Therefore, when the servo hydraulic piston moves, lever 2 rotates around the fulcrum of point “B” [Fixed by fulcrum plug
(614) and pin (875)].
Since the large hole section “C” of lever 2 contains protruding pin (897) fixed to feedback lever (611), pin (897) moves to the
right as lever 2 rotates. Since the opposed flat section “D” of the feedback lever is fitted with pin (548) fixed by the tilting pin
(531) that swings the swash plate, the feedback lever rotates around the fulcrum of point “D”, as pin (897) moves.
Since the feedback lever is connected with spool (652) through pin (874), the spool moves to the right. The movement of the
spool causes the delivery pressure P1 to flow to port (C l) through the spool and 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 servo piston moves the servo piston
right due to the area difference, resulting in a decrease of the tilting angle.
When the servo piston moves to the right, point “D” also moves right. The spool is fitted with return spring (654) and is
tensioned to the left at all times, so 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 sleeve (651) and spool (652) to close slowly, and the servo piston stops when it is closed
completely.
Flow increasing function
As the servo hydraulic pressure Pi decreases, servo hydraulic piston (643) is moved to the left by the action of servo
hydraulic spring (646), and lever 2 (613) is rotated around the fulcrum of point “B”. Since pin (897) is pressed against the
large hole section “C” of lever 2 by the action of the return spring (654) through 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.
As the spool moves, port (C l) opens a path to the tank port. This cuts off the pressure to the large diameter section of the
piston, and the servo piston shifts left due to delivery pressure P1 on the small diameter section, resulting in an increase of
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 right until the opening between the spool and sleeve is closed.
Regulator, total horsepower control
The regulator decreases the swash plate tilting angle (delivery flow) when the load pressure is increased to prevent engine
overload.
Since this regulator is the total cumulative 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 x Q/2p + P2 x Q/2p = (P1 + P2) x Q/2p
The horsepower control function is the same as the flow control function and is summarized as follows:
(For details of respective parts, see the section on flow control.)
Figure 5
Total horsepower control chart
X. Delivery pressure, (P1 + P2)

Y. Delivery flow. Q
Overload preventive function

When the pump delivery pressure P1 or the mate pump delivery pressure P2 rises, it acts on the stepped part of
compensating piston (621). It presses compensating rod (623) to the right till the force of outer spring (625) and inner spring
(626) is balanced with the hydraulic force.
The movement of the compensating rod is transmitted to lever 1 through pin (875), and lever 1 rotates around pin (875) “E”
fixed to casing (601). Since the large hole section “F” of lever 1 contains protruding pin (897) fixed to feedback lever (611),
the feedback lever rotates around the fulcrum of point “D” as lever 1 rotates, and spool (652) is shifted to the right.
As the spool moves, delivery pressure P1 flows to the large-diameter section of the servo piston through port (C l), the servo
piston is moved to the right, the pump delivery flow rate is reduced, and the engine is prevented from being overloaded.
The movement of the servo piston is transmitted to the feedback lever through point “D”.
Then the feedback lever rotates around the fulcrum of point “F” and the spool moves to the left until the opening between
the spool and sleeve (651) is closed completely.
Flow reset function
As the pump delivery pressure P1 or the mate pump delivery pressure P2 decreases, compensating rod (623) is pushed back
by the action of springs (625, 626) and lever 1 is rotated around the fulcrum of point “E”.
Rotating of lever 1 causes the feedback lever to rotate around the fulcrum of point “D” and the spool moves to the left. As a
result, port (C l) opens a path to the tank port, and the servo piston moves left as the pressure to the large diameter section
is released, resulting in an increase of the pump delivery rate.
The movement of the servo piston is transmitted to the spool by the action of the feedback mechanism till the opening
between the spool and sleeve is closed.
Regulator, low tilting angle (low flow) command priority function
As mentioned, the tilting angle commands of flow control and horsepower control are transmitted to the feedback lever and
the spool through the large hole sections “C”, “E” of levers 1 and 2, respectively. However, since sections “C” and “E” have the
pins (ø4) protruding from the large hole (ø 8), the lever contacts pin (897) only when the tilting angle is lessened. If the
tilting angle command is larger, it is free without contacting pin (897) in the large hole (ø8). Such a mechanical selection
method permits priority of the low tilting angle command of flow control and horsepower control.
Regulator, power shift control
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, compensating rod (623) moves right through pin (898) and compensating piston (621).
This decreases the pump tilting angle and 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 power shift pressure Pf falls.
Figure 6
Power shift control chart

Y. Delivery flow, Q
Service Information

Proportional solenoid 913 Service Information 2014/10/29
valve, description
Profile:
EXC, EC135B LC, EC140B LC, EC140B LCM, EC160B LC, EC180B LC, EC290B FX, EC290B LC, EC290B LCD [GB]
Proportional solenoid valve, description

Model code (KDRDE 5 K - 20 / 40 C L)
Code Description
KDRDE Electric proportional pressure reducing valve
5 Nominal designation
K Cartridge type
20 Series number
40 Max. setting secondary pressure (40 kgf/cm2)
C Solenoid specifications C = 240Ω * 0.7A
L Electrical connection
The proportional solenoid valve regulates secondary pressure (pressure in port A) to be proportional to the current applied
to the solenoid coil.
If the solenoid (801) is energized, spool (311) is pushed to the right, and oil flows from P to A. The pressure in port A affects
the spring of spool (311). If the pressure reaches the set value of the solenoid, the spool moves left and reduces the flow
from P to A.
 When selecting a mode by turning the engine speed control switch, the controller outputs a current value adequate
for the pertinent mode to the proportional solenoid valve to regulate the servo hydraulic pressure to the hydraulic
pump regulator.
 The valve regulates the secondary servo hydraulic pressure to the hydraulic pump regulators to control the swash
plate angle and allowable pump output.
 The secondary servo hydraulic pressure varies in proportion to the current value to the proportional solenoid valve.
 The proportional solenoid valve spool vibrates continuously to maintain the secondary servo hydraulic pressure,
and is very sensitive to contamination due to the close tolerances of the spool/valve body. In the event of a
malfunction, always inspect the valve for contamination before replacing it.
Notes on operation
Solenoid wiring
Solenoid has no polarity.
Input current
Never add more than 0.7A to the solenoid coil.
Adjusting screw
Factory adjusted at shipment.
Port A pressure increases when the adjusting screw is turned clockwise.
Figure 1
Proportional solenoid valve
a. Proportional solenoid valve secondary pressure measuring port
Tightening torque
Tightening torque, unit: kgf·cm
No. Item Thread size Tightening torque
079 Proportional valve M22 × 1 450 ± 50
311 Spool
312 Sleeve M14 × 1 300 ± 30
324 Spring
325 Valve case
351 Orifice M3 6 ± 1 (Loctite # 24)
361 O-ring
362 O-ring
363 O-ring
407 Screw M6 120
466 Plug PF 1/4 370
490 Plug NPTF 1/16 90
725 O-ring
732 O-ring
801 Solenoid valve M22 × 1 450 ± 50
802 Seal nut M6 75 ± 5
901 Name plate
Inspection method
 Connect the adapter cable for testing between proportional solenoid valve connectors as shown.
 Start engine and measure the current value.
Figure 2
Connection, proportional solenoid valve
1. Black with red stripe (BR)

2. White
3. Tester
4. Red
5. Black
Service Information

valve, troubleshooting
Profile:
EXC, EC290B LC [GB]
Proportional solenoid valve, troubleshooting

Troubleshooting

Pressure does not rise or vary. Error in wiring. Correct wiring.
Damage of solenoid. Replace the solenoid.
Stuck piston or spool. Remove, clean and polish.
Damage of amplifier. Repair or replace the controller.
Pressure does not vary smoothly. Incorrect dither adjustment. Readjust.
 Dither frequency is high.

 Dither amplitude is low.
Stuck piston or spool. Remove, clean and polish.

Pressure is unstable. Incorrect dither adjustment. Readjust.
 Dither frequency is low.

 Dither amplitude is high.
Slow response Servo hydraulic primary pressure is low. Readjust.

Service Information

Pump, maintenance 913 Service Information 2014/10/29
standard
Profile:
EXC, EC290B LC [GB]
Pump, maintenance standard

Precautions for usage
Precautions
Item Description
• Long term storage
 Long term storage of more than 1 year is not recommended.
 If installed in a machine, operate it occasionally.
 If in stock inventory, rotate the pump shaft occasionally.
 If in storage more than 1 year consider overhaul.
• Rotating direction
 Rotating direction of pump is depicted on the name plate.
Lubrication and air purging

Precautions
Item Cautions
• Lubrication
 Fill the pump casing through P1, P2 delivery ports with the specified hydraulic oil.
 Following repair or replacement of the pump it is necessary to pre-lubricate the
internal components to prevent scoring, scuffing, seizure of the bearing and sliding
parts.
• Air purging
 Following hydraulic system repairs, purge the air from the pump circuit by
loosening the upper plug in the pump casing.
Start-up
 Check that there is no contamination in the ports or plumbing before connecting to the pump.
 Check the direction of rotation and the suction/delivery direction.
 Check the oil level in the hydraulic tank.
 At initial start-up run the engine at idle to purge the air in the circuit.
 Check for oil leakage on the pump assembly.
 Check for abnormal sound or vibration.
 Check for any abnormal temperature increase after running for a short time.
General precautions
 Determine the nature of the abnormality, before disassembling. Especially, check if the problem is in the circuit, or
caused by the regulator, auxiliary valves, defective pump, or motor.
 Read the maintenance manual thoroughly before disassembling, and then follow the procedures carefully.
 When any section is to be disassembled, pay attention not to allow contamination into the pump.
 Since the parts are precision finished, handle them carefully to prevent damage.
Check of pump for abnormalities
The pump is usually fitted with a regulator, auxiliary valves or an auxiliary pump, so it may be difficult to find the cause of
failure. Check the following principal items, to identify the abnormality.
Check of filter and drain oil
Check the filter elements for abnormal impurities. As the shoes and cylinder wear, a small quantity of metal particles may be
detected. However, if a considerable amount of metal particles are found, the shoes may be damaged. Similarly, check the
drain oil in the pump casing.
Check of abnormal sound or vibration
Check the pump for abnormal sound and vibration. If any, check if it is a noise of regular frequency, such as hunting of the
regulator or the relief valve. If it is an abnormal vibration or sound, it may result from cavitation or damage inside the pump.
Check of circuit where two pumps are used
For the circuit with two single pumps or a tandem double pump, exchange the piping of one pump with that of the other
one. With the results of this exchange, it will be determined if the trouble is with the pump or a component downstream of
the pump.
Pressure measurement at various points
If the failure is a problem in control, do not overhaul the pump needlessly, but measure pressures at various points in the
circuit.
Standard for parts service and replacement
When a part exceeds any of the following criteria, replace or readjust it. However, when a part is damaged seriously in
appearance, replace it without fail.
Standard wear limit, unit: mm (inch)
Part name and Standard dimension/Recommended replacement value Remedy

inspection item Pump type
K3V63 K3V112 K3V140 K3V180
Clearance between 0.028/0.056 0.039/0.067 0.043/0.070 0.0375/0.078 Replace piston or
piston and cylinder bore (0.0011/0.0022) (0.0015/0.0026) (0.0017/0.0027) (0.0015/0.0031) cylinder.
(D-d)
Play between piston and 0.1/0.3 0.1/0.3 0.1/0.3 0.1/0.35 Replace piston
shoe caulking section (δ) (0.004/0.012) (0.004/0.012) (0.004/0.012) (0.004/0.014) and shoe
assembly.
Thickness of shoe (t) 3.9/3.7 4.9/4.7 5.4/5.0 5.4/5.0 Replace piston
(0.153/0.146) (0.192/0.185) (0.212/0.197) (0.212/0.197) and shoe
assembly.
Free height of cylinder 31.3/30.5 41.1/40.3 47.9/47.1 40.9/40.1 Replace cylinder
spring (L) (1.232/1.200) (1.618/1.586) (1.886/1.854) (1.610/1.578) spring.
Assembled height of set 19.0/18.3 23.0/22.0 23.8/22.8 23.8/22.8 Replace set plate
plate and spherical (0.75/0.72) (0.91/0.87) (0.94/0.90)) (0.94/0.90) or spherical
bushing (H-h) bushing.
Figure 1
Wear limit of parts
D - Clearance between piston and cylinder bore L Free height of cylinder spring
d
δ Play between piston and shoe H - Assembled height of set plate and spherical bushing
d
t Thickness of shoe
Repair standards for cylinder, valve plate and swash plate

Repair standards
Surface roughness of cylinder, valve Surface roughness requiring correction 3Z

plate and swash plate Standard surface roughness (correction 0.4Z max. (lapping)
value)
NOTE!
Lap the cylinder and valve plate together to correct the surface roughness.
Tightening torque
Tightening torque
Description Size Torque B Tool

kgf · m (lbf · ft) (mm)
M5 0.7 (5.1) 4 Allen wrench
Screw (Material : SCM 435) M6 1.2 (8.7) 5
M8 3.0 (22) 6
M 10 5.8 (42) 8
M 12 10 (72) 10
M 14 17 (120) 12
M 16 24 (170) 14
M 18 34 (250) 14
M 20 44 (320) 17
PT plug PT 1/16 0.7 (5.1) 4 Allen wrench
(Material : S45C) PT 1/8 1.05 (7.6) 5
NOTE! PT 1/4 1.75 (13) 6
Apply loctite #577 PT 3/8 3.5 (25) 8
PT 1/2 5.0 (36) 10
PO plug PF 1/4 3.0 (22) 6 Allen wrench
(Material : S45C) PF 1/2 10 (72) 10
PF 3/4 15 (110) 14
PF 1 19 (140) 17
PF 1 1/4 27 (190) 17
PF 1 1/2 28 (200) 17
Service Information

Pump, tools 913 Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Pump, tools
Tools
The tools necessary to disassemble/reassemble the K3V pump are shown in the following list. The sizes of the screws and
plugs depend on the pump type.
Tools
Tool Size Necessary tool Description

(Marked with * )
Pump type
Name B mm K3V 63 K3V K3V K3V Screw PT plug (PT PO plug (PF Set screw
112 140 180 thread) thread)
Allen wrench 2 M4
2.5 M5
3 M6
4 * * * * M5 BP-1/16 M8
5 * * * * M6 BP-1/8 M10
6 * * * * M8 BP-1/4 PO-1/4 M12 M14
8 * * * * M10 BP-3/8 PO-3/8 M16 M18
10 M12 BP-1/2 PO-1/2 M20
12 M14
14 * M16 M18 BP-3/4 PO-3/4
17 * * * M20 M22 BP-1 PO-1, 1 1/4, 1
1/2
19 M24 M27
21
22 M30 PO-2
Box end spanner 19 * * * * M12 N12 VP-1/4
Open end spanner 22 VP-3/8
24 * * * M16 M16
27 * * * M18 M18 VP-1/2
30 * * * M20 M20
36 * * * VP-3/4
41 VP-1
50 VP-11/4
55 VP-11/2
Adjustable wrench * * * * Medium size.
Screwdriver * * * * Blade type screwdriver, medium size, 2 sets.
Hammer * * * * Plastic hammer.
Pliers * * * * For snap ring, TSR-160
Brass bar * * * * Approximate 10 x 8 x 200 mm
Torque wrench * * * * Capable of tightening to the specified torque.
Service Information

Pump, disassembly 913 Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Pump, disassembly
Op nbr 00000
Precautions

 Select a clean work area.
 Match mark the pump casing parts and the regulators to indicate proper positioning during re-assembly.
 Take care not to mix the parts of the front pump with the parts of the rear pump.
 Thoroughly clean all parts and the inside of the casing.
 Inspect and analyse all failures. Determine the root cause!
1. Select a place suitable for disassembly.

NOTE!
Spread a rubber sheet or cloth on the workbench to prevent parts from being damaged.
2. Remove dust, rust, etc., from pump surfaces with cleaning solvent.
3. Remove drain port plug (467) and drain oil from the pump casing
NOTE!
For tandem type pump, remove plugs from the front and the rear pumps.
4. Remove screws (412, 413) and remove the regulator.

Refer to the regulator section for disassembly.
NOTE!
Mark each regulator to match the pump.
Figure 1
Removal, regulator
5. Remove screws (401) which hold swash plate support (251), pump casing (271) and valve block (312).
NOTE!
If a gear pump is fitted to the rear face of the pump, remove it before starting this work.
6. Place the pump horizontally on a workbench with regulator-fitting surface facing down, and separate pump casing
(271) from valve block (312).
NOTE!
Spread a rubber sheet on the workbench to prevent this surface from being damaged.
Figure 2
Removal, pump casing
7. Pull cylinder (141) out of pump casing (271) straight over drive shaft (111). Pull out piston (151), set plate (153),
spherical bushing (156) and cylinder springs (157) simultaneously.
NOTE!
Take care not to damage sliding surfaces of the cylinder, spherical bushing, shoes and swash plate, etc.
NOTE!
Mark the pistons and respective cylinder bores. Pistons must be installed into the same bores because of wear
pattern.
Figure 3
Removal, cylinder
8. Remove screws (406) and front seal cover (261).

NOTE!
Fit screws into pull-out tapped holes (M 6) of seal cover (F), so it can be removed easily.
NOTE!
Since an seal is fitted to the seal cover, take care not to damage it during disassembly.
Figure 4
Removal, seal cover
10. Tap lightly the flange section of swash plate support (251) on the pump casing side to separate swash plate
support from pump casing (271).
Figure 5
Tapping, swash plate support
11. Remove shoe plate (211) and swash plate (212) from pump casing (271).
Figure 6
Removal, shoe plate and swash plate
12. Tap lightly the ends of drive shafts (111, 113) with a plastic hammer to remove them from the swash plate supports.
Figure 7
Removal, shaft
13. Remove valve plates (313, 314) from valve block (312).
Figure 8
Removal, valve plate
14. If necessary, remove stopper (534), stopper (535), servo piston (532) and tilting pin (531) from pump casing (271),
and needle bearing (124) and splined coupling (114) from valve block (312).
NOTE!
When removing the tilting pin, use a jig to prevent the pin head from being damaged.
Since loctite is applied to fitting areas of tilting pin and servo piston, take care not to damage the servo piston.
Do not remove the needle bearing except when it is to be replaced.
NOTE!
Do not loosen nuts (808) and set screws (953, 954). If loosened, the flow setting will be changed.
Service Information

Pump, assembly 913 Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Pump, assembly
Op nbr 00000
Preparation
 Rework damaged parts before assembling, and prepare all replacement parts.
 Coat the sliding parts, bearing, etc. with clean hydraulic oil.
 Replace the o-ring and seals.
 Take care not to mix the parts of the front pump with the parts of the rear pump.
 Align the match marks of the pump casing parts and the regulators.
1. Fit swash plate support (251) to pump casing (271), tapping it lightly with a hammer.
NOTE!
Fit servo piston, tilting pin, stopper (534) and stopper (535) to the pump casing in advance of assembling the swash
plate support.
NOTE!
In tightening servo piston and tilting pin, use a jig to prevent the tilting pin head and feedback pin from being
damaged.
In addition, apply loctite (medium strength) to their threaded sections.
Figure 1
Installation, swash plate support
2. Place pump casing on its regulator fitting surface, fit tilting bushing of swash plate to tilting pin (531), and fit swash
plate (212) to swash plate support (251).
NOTE!
Confirm with fingers of both hands that the swash plate can be moved smoothly.
NOTE!
Apply grease to the sliding plate and swash plate support, so the drive shaft can be fitted easily.
Figure 2
Installation, swash plate
3. Fit drive shaft (111) with bearing (123), bearing spacer (127) and snap ring (824) to swash plate support (251).
NOTE!
Do not tap the drive shaft with a hammer.
Assemble the parts into support (251) by tapping the outer bearing race lightly with a plastic hammer. Fit them fully
using a brass drift.
Figure 3
Installation, drive shaft with bearing, bearing spacer and snap ring
4. Assemble seal cover (261) to pump casing (271) and install screws (406).
NOTE!
Apply grease lightly to the seal in seal lip cover.
Assemble seal, taking care not to damage it.

Figure 4
Assembly, seal cover
5. Assemble piston cylinder block [cylinder (141), piston sub assembly (151, 152), set plate (153), spherical bushing
(156) and cylinder spring (157)]. Then, insert the cylinder block assembly into the pump casing.
NOTE!
Match the splines of spherical bushing (156) and cylinder block (141).
Then match to the splines of drive shaft (111).
NOTE!
Ensure that the pistons are installed in their original bores.
Figure 5
Assembly, piston cylinder block
6. Fit valve plate (313, 314) to valve block (312), inserting pin into pin hole.
NOTE!
Take care not to mistake suction/delivery ports of the valve plate.
Suction port is the long crescent slot.
Apply grease to the valve plate fitting face to hold it to the valve block.
Figure 6
Assembly, valve plate
7. Fit valve block (312) to pump casing (271) and tighten screw (401).
 Clockwise rotation (viewed from input shaft side). Fit block with regulator up and with delivery flange left,
viewed from the front side.
 Counterclockwise rotation (viewed from input shaft side). Fit block with regulator up and with delivery
flange left, viewed from the front side.
NOTE!
Assemble (312) to the rear pump first.
Take care not to mistake the direction of valve block (312).
Figure 7
Assembly, valve block
8. Fit feedback pin of tilting pin (531) to feedback lever of regulator. Install regulator and tighten screws (412, 413).
NOTE!
Take care not to interchange the front and rear pump regulators.
Align the match marks made prior to disassembly.

Figure 8
Tightening, screw
9. Fit drain port plug (468). This is the end of reassembling procedures.
NOTE!
After assembling, fill with hydraulic oil to prevent corrosion.
When mounting to a machine, fill with hydraulic oil and bleed the air from the pump circuit.
Service Information

Pump, installation 913 Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Pump, installation
Precautions, start–up
 Fill the pump casing with hydraulic oil.

 Vent the air from the pump circuit.
 Check that all hoses and pipes are properly connected.
 After starting the engine, operate at low idle for a while to completely vent the air from the circuit.
NOTE!
If there is air in the hydraulic system, sliding parts may be damaged.
Precautions, installation
 Keep the pump shaft horizontal during installation to the pump coupling.
 Ensure that there is neither a radial nor thrust load on the end of the pump shaft.
 When centering the pump shaft and the coupling, keep the alignment within ±0.03 mm.
 Use a torque wrench to tighten all screws and fittings to the specified torque.
Figure 1
Installation, pump
Tightening torque
Symbol Description Tightening torque Remark

A M 20 × 20 L 45 ~ 49 (325 ~ 354) Apply Loctite #277
B M 20 × 55 L
C M 20 (10.9 and more, JIS) 37.4 ~ 50.6 (270 ~ 365)
D M 20 × 25 L 20 ~ 22 (144 ~ 159)
E M 10 3.4 (24.6)
F M 10 × 50 L 4 ~ 4.5 (28.9 ~ 32.5)
Service Information

Regulator, maintenance 913 Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Regulator, maintenance
Fault and remedies
In case a functional fault probably resulting from the regulator occurs, disassemble and inspect it, referring to the section of
disassembly and assembly.
Engine is overloaded
Determine which is faulty, front pump or rear pump, by loading each pump independently.
When both pumps are found faulty, investigate the following (1) and (2). Begin investigation with (3), when only one pump is
found faulty.
1. Check the power shift signal current.

2. Power shift pressure is low.
 Check the amplifier dither.

 Replace the proportional solenoid valve.
3. The compensating piston and rod are stuck.
 Disassemble and clean.
4. Pin (898) is stuck.
 Disassemble and clean.
Maximum flow is not available
1. Check that the servo hydraulic pressure Pi is normal.

2. Servo hydraulic piston (643) is stuck. ... ... Disassemble and clean the regulator.
3. Spool (652) is stuck. ... ... Disassemble and clean the regulator.
4. Piston (621) is stuck in piston case (622) ... ... Disassemble and clean the regulator.
 Replace faulty parts that are deeply scored.

 (1) and (2) are only for cases of the servo hydraulic control.
 (4) is only for cases of the max. flow control.
Regulator, inspection and adjustment

Maximum/minimum flow, horsepower control characteristics and flow control characteristics of this regulator can be
adjusted by the adjusting screw.
(See the specified value for the regulator adjustment)
NOTE!
The adjustment of main pump regulator should be performed by qualified personnel with a proper flow meter and pressure
gauge. Before adjusting, mark the adjusting screw and lock nut. The performance of 628, 924, 925 adjusting screws are
considerably changed, so qualified personnel shall perform adjustment.
Adjustment of input horsepower

Since the regulator is the total cumulative horsepower type, adjust the adjusting screws of both front and rear pumps, when
changing the horsepower set values. The pressure change values are based on two pumps pressurized at the same time.
Adjustment of outer spring
Tightening the screw shifts the control chart to the right and increases the input horsepower as shown in the figure.
Since turning adjusting screw (628) by N turns changes the setting of inner spring, back-off adjusting screw (925) by N × A
turns.
Figure 1
Adjustment of input horsepower

Y. Delivery flow, Q
Adjustment of inner spring

Tightening the screw increases the flow and the input horsepower as shown in the figure.
Figure 2
Change of input horsepower

Y. Delivery flow, Q
Adjustment of flow control characteristic

Loosen nut (801), and tighten (or loosening) adjusting screw (924).
If the adjusting screw is tightened, the control curve will move to right as shown in the figure.
Figure 3
Change of control curve
X. Servo hydraulic pressure Pi
Y. Delivery flow, Q
Change of value by adjusting regulator

Specifications
Item Specifications
Hydraulic pump rotating speed rpm 1900
Maximum flow Turn of adjusting screw (954) +1/4
Flow, lpm (U.S.gpm) –6 (–1.6)
Minimum flow Turn of adjusting screw (953) +1/4
Flow, lpm (U.S.gpm) +6 (+1.6)
Input horsepower Adjusting of outer Turn of adjusting screw (628) +1/4
spring Pressure at compensating control start, delta P +19 (+270)
kgf/cm2 (psi)
Input torque, delta T kgf·m (lbf·ft) +7 (+50.5)
A 1.9
Adjusting of inner Turn of adjusting screw (QI, 628) +1/4
spring Pressure at compensating control start, delta P +27 (+383)
kgf/cm2 (psi)
Input torque, delta T kgf·m (lbf·ft) +6 (+36)
Flow control characteristic Turn of adjusting screw (924) +1/4
Pressure at flow control start, kgf/cm2 (psi) +1.7 (+24.2)
Flow ,lpm (U.S.gpm) +16 (+4.2)
Pump control curves

(Machine serial no.: 10001 ~ )
Figure 4
Pump control curve (According to power shift valve current)
Q Delivery flow
P Pressure
NOTE!
Actual delivery flow = Engine rpm/1900 × Q (read at curves)
Simultaneous 2-pump loading (1900 rpm)
I : Power-shift valve input current (Dither : 80 Hz, 200 mA)
Pf : Power-shift pressure (Reference)
Pd : Negative control pressure (f , f )
(Machine serial no.: 80001 ~ )
Figure 5
Pump control curve (According to power shift valve current)
Q Delivery flow
Pd Delivery pressure
Pi Servo hydraulic pressure
Tin Input torque
NOTE!
Actual delivery flow = Engine rpm/1800 × Q (read at curves)
Simultaneous 2-pump loading (1800 rpm)
I : Power-shift valve input current (Dither : 80 Hz, 200 mA)

Pf : Power-shift pressure (Reference)
Pd : Negative control pressure (f , f )

Service Information

Regulator, disassembly 913 Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Regulator, disassembly
Op nbr 00000
Precautions
 Thoroughly clean the pump prior to removing the regulators.

 Match mark the regulators to the pump casing.
 Select a clean work area.
 Take care not to mix the parts of the front regulator with the parts of the rear regulator.
 It is not necessary to loosen or remove the adjusting screws for cleaning.
 Replacement of the regulator as an assembly is recommended, since it consists of small precision finished parts and
overhaul is rather complicated.
Tools
Tools
Description Size
Allen wrench 4, 5, 6 mm (B)
Socket wrench, double ended (single ended) Compact (maximum 36 mm)
Adjustable wrench
Screwdriver-blade type
Plastic hammer
Torque wrench
Pliers snap ring
Pry bar Less than ø4, L = 100
Tweezers
Screw M4, L = approximately 50 mm
Tightening torque
Tightening torque
Description Size Tightening torque, kgf·cm B (mm) Tool

(lbf·in)
Screw M5 70 (60) 4 Allen wrench
(Material: SCM 435) M6 120 (105) 5
M8 300 (260) 6
M 10 580 (500) 8
M 12 1000 (870) 10
M 14 1600 (1390) 12
M 16 2400 (2080) 14
M 18 3400 (2945) 14
M 20 4400 (3810) 17
PT plug (Material: S45C) Apply PT 1/16 70 (60) 4 Allen wrench
loctite #577 PT 1/8 105 (90) 5
PT 1/4 175 (150) 6
PT 3/8 350 (260) 8
PT 1/2 500 (430) 10
PO plug (Material: S35C) PF 1/4 300 (260) 6 Allen wrench
PF 1/2 1000 (870) 10
PF 3/4 1500 (1300) 14
PF 1 1900 (1650) 17
PF 1 1/4 2700 (2340) 17
PF 1 1/2 2800 (2420) 17
Regulator, disassembly
1. Select a place suitable for disassembly.

NOTE!
Spread a rubber sheet or cloth on the workbench to prevent parts from being damaged.
2. Remove dust, rust, etc. from regulator surfaces with cleaning solvent.
3. Remove screws (412, 413), and remove the regulator.

NOTE!
Take care not to lose the o-ring.
Figure 1
Removal, regulator
4. Remove screws (438), and remove cover (C) (629).
 Cover (C) is fitted with adjusting screws (C), (C1) (628, 925), adjusting ring (C) (627), lock nut (630), nut
(801) and adjusting screw (924).
NOTE!
Do not loosen these screws and nuts. If they are loosened, adjusted pressure-flow setting will be changed.
NOTE!
To adjust the pressure and flow, inspection and adjustment on a test bench will be necessary.
Figure 2
Removal, cover
5. After removing cover (C) (629) sub assembly, take out outer spring (625), inner spring (626) and spring seat (C)
(624) from compensating section. Then draw out adjusting ring (Q) (645), servo hydraulic spring (646) and spring
seat (644) from servo hydraulic section.
NOTE!
Adjusting ring (Q) (645) can be easily drawn out with a M 4 screw.
NOTE!
Note direction of spring seat.
Figure 3
Removal, adjusting ring
6. Remove screws (436, 438), and remove servo hydraulic cover (641).
After removing servo hydraulic cover, take out set spring (655) from the servo hydraulic section.
Figure 4
Removal, servo hydraulic cover
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).
NOTE!
When removing snap ring (814), return spring (654) may pop out. Take care not to lose it.
Figure 5
Removal, snap ring
8. Remove snap ring (858), and take out fulcrum plug (614) and adjusting plug (615).
 Fulcrum plug (614) and adjusting plug (615) can be easily taken out with a M 6 screw.
Figure 6
Removal, snap ring
9. Remove lever (2) (613).
 Work will be promoted by using long needle nose pliers.
NOTE!
Do not draw out pin (875).
Figure 7
Removal, lever
10. Draw out pin (874), and remove feedback lever (611).
 Push out pin (874) (4 mm in diameter) with a slender steel bar so that it does not interfere with lever (1)
(612).
NOTE!
Note the direction of the feedback lever.
Figure 8
Removal, pin and feedback lever
11. Remove lever (1) (612).
NOTE!
Do not draw out pin (875).
12. Draw out servo hydraulic piston (643) and spool (652).
13. Draw out piston case (622), compensating piston (621) and compensating rod (623).
This completes the operation.
 Piston case (622) can be taken out by pushing compensating rod (623) on opposite side of piston case.
NOTE!
Since component parts are small, take care not to lose them.
Service Information

Regulator, assembly 913 Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Regulator, assembly
Op nbr 00000
Preparation
NOTE!
The parts are small and light weight. Take care not to lose them.
 Rework scored parts before assembling, and prepare all replacement parts.
 Replace the o-rings and seals.
 Align the match marks of the regulator to the pump casing.
1. Put compensating rod (623) into compensating hole of casing (601).
2. Put lever (1) (612) force-fitted pin into the compensating rod groove, then fit lever (1) to the pin in the casing.
3. Fit spool (652) and sleeve (651) into the casing spool hole.
 Confirm that spool and sleeve slide smoothly in casing without binding.
NOTE!
Pay attention to orientation of the spool.
1. Spool
2. Feedback lever
4. Fit feedback lever (611), matching its pin hole with the hole in the spool. Then insert pin (874).
 Insert pin into feedback lever a little to ease operation.
NOTE!
Take care not to mistake direction of feedback lever.
1. Lever (1) side
2. Lever (2) side (Fulcrum plug of adjusting plug side)
5. Put servo hydraulic piston (643) into negative control hole of casing.
NOTE!
Confirm that servo hydraulic piston slides smoothly without binding.
6. Put the pin force-fitted in lever (2) (613) into the groove of the servo hydraulic piston. Then fix lever (2).
Figure 1
Assembly, lever
7. Fit fulcrum plug (614) so that the pin force-fitted in fulcrum plug (614) can be put into the pin hole of lever (2).
Then fix locking ring (858).
Figure 2
Fitting, fulcrum plug
8. Insert adjusting plug (615) and fit locking ring.

NOTE!
Take care not to mistake inserting holes for fulcrum plug and adjusting plug.
At this point move feedback lever to confirm that it has no excess play and is free from binding.
9. Fit return spring (654) and spring seat (653) into the spool hole and attach snap ring (814).
NOTE!
Pay attention to the orientation of the spring seat.
Figure 3
Assembly, snap ring
10. Fit set spring (655) to spool hole and put compensating piston (621) and piston case (622) into compensating bore.
Fit servo hydraulic cover (641) and tighten it with screws (436, 438).
Figure 4
Assembly, compensating piston
11. Put spring seat (644), servo hydraulic spring (646) and adjusting ring (Q) (645) into the servo hydraulic hole.
Then fix spring seat (624), inner spring (626) and outer spring (625) into the compensating hole.
NOTE!
Pay attention to the orientation of the spring seat.
Figure 5
Assembly, spring seat, servo hydraulic spring and adjusting ring
12. Install cover (C) (629) fitted with adjusting screws (628) (925), adjusting ring (C) (627), lock nut (630), nut (801) and
adjusting screw (924).
Then install screws (438).
Figure 6
Installation, cover
Service Information

Current/pressure, 913 Service Information 2014/10/29
specifications
Profile:
EXC, EC290B LC [GB]
Current/pressure, specifications
For except North America market
Specifications
Rotary Mode Engine rpm Valve output Valve secondary Conflux cut off
switch No–load/ current (mA) pressure solenoid
loaded No–load/loaded No–load
(± 40 rpm) (± 20 mA) kgf/cm2(psi)
9 Power Max. P 2000/1900 215/variable 2.8 (39.8) OFF
Heavy H 1900/1800 260/variable 6.4 (91.0) OFF
8 General G1 1800/1700 300/variable 8.7 (123.7) OFF
7 G2 1700/1600
6 G3 1600/1500
5 Fine F1 1500 450 19.8 (281.6) ON
4 F2 1400
3 F3 1300
2 Idle I1 1000 525 25.2 (358.4) OFF
1 I2 800
For North America market

Specifications
Rotary Mode Engine rpm Valve output Valve secondary Conflux cut off
switch No–load/ current (mA) pressure solenoid
loaded No–load/loaded No–load
(± 40 rpm) (± 20 mA) kgf/cm2(psi)
9 Heavy H 2000/1900 215/variable 2.8 (39.8) OFF
8 General G1 1900/1800 260/variable 6.4 (91.0) OFF
7 G2 1800/1700 300/variable 8.7 (123.7) OFF
6 G3 1700/1600
5 Fine F1 1500 450 19.8 (281.6) ON
4 F2 1400
3 F3 1300
2 Idle I1 1000 525 25.2 (358.4) OFF
1 I2 800
NOTE!
Valve secondary pressure at various current may differ from the specifications according to the external condition.
Service Information

specifications
Profile:
EXC, EC290B LC [GB]
Specifications
Rotary Mode Engine rpm Valve output Max pump Valve Power
switch No–load/ current (mA) input torque, secondary (ps)
loaded No–load/loaded kgf m (lbf ft) pressure
(± 40 rpm) (± 20 mA) No–load
kgf/cm2(psi)
9 Power Max. P 1900/1800 210/variable 73.6 (531.4) 3.2 (45.5) 185
Heavy H 1800/1700 260/variable 70.0 (505.4) 6.2 (88.2)
8 General G1 1700/1600 310/variable 66.2 (478.0) 9.1 (129.4)
7 G2 1600/1500
6 G3 1500/1400
5 Fine F1 1400/- 490 51.5 (371.8) 23.1 (328.6)
4 F2 1300/-
3 F3 1200/-
2 Idle I1 1000/- 610 - 31.0 (440.9)
1 I2 800/-

Specifications
(± 40 rpm) (± 20 mA) No–load
kgf/cm2(psi)
9 Heavy H 1900/1800 210/variable 73.6 (531.4) 3.2 (45.5) 185
8 General G1 1800/1700 260/variable 70.0 (505.4) 6.2 (88.2)
7 G2 1700/1600 310/variable 66.2 (478.0) 9.1 (129.4)
6 G3 1600/1500
5 Fine F1 1500/- 490 51.5 (371.8) 23.1 (328.6)
4 F2 1400/-
3 F3 1300/-
2 Idle I1 1000/- 610 - 31.0 (440.9)
1 I2 800/-
NOTE!
Service Information

specifications
Profile:
EXC, EC290B LC [GB]
Specifications
(± 40 rpm) (± 20 mA) No–load
kgf/cm2(psi)
9 Power Max. P 1900/1800 210/variable 73.6 (531.4) 3.2 (45.5) 185
Heavy H 1850/1750 235/variable 71.8 (518.3) 4.7(66.8)
8 General G1 1800/1700 260/variable 70 (505.4) 6.2(88.2)
7 G2 1700/1600 310/variable 66.2 (478.0) 9.1 (129.4)
6 G3 1600/1500
5 Fine F1 1400/- 490 51.5 (371.8) 23.1 (328.6)
4 F2 1300/-
3 F3 1200/-
2 Idle I1 1000/- 610 - 31.0 (440.9)
1 I2 800/-

Specifications
(± 40 rpm) (± 20 mA) No–load
kgf/cm2(psi)
9 Heavy H 1900/1800 210/variable 73.6 (531.4) 3.2 (45.5) 185
8 General G1 1850/1750 235/variable 71.8 (518.3) 4.7(66.8)
7 G2 1800/1700 260/variable 70.0 (505.4) 6.2 (88.2)
6 G3 1700/1600 310/variable 66.2 (478.0) 9.1 (129.4)
5 Fine F1 1500/- 490 51.5 (371.8) 23.1 (328.6)
4 F2 1400/-
3 F3 1300/-
2 Idle I1 1000/- 610 - 31.0 (440.9)
1 I2 800/-
NOTE!
Service Information

valve, measuring and
adjustment
Profile:
EXC, EC290B LC [GB]
Proportional solenoid valve, measuring and adjustment

Measuring condition
 Engine speed: Corresponds to working mode

 Working mode: Select “P” (power maximum), “H”, “G”, “F”, “I” mode in sequence.
 Oil temperature when measuring: 50 ~ 60 °C (120 ~ 140 °F)
Measurement
 Connect an oil pressure gauge (60 kgf/cm2, 850 psi) to the pressure checking port to measure servo hydraulic
secondary pressure.
Adjustment
Loosen lock nut (2) and turn screw (1) to adjust by using a blade screwdriver.
 To increase pressure, turn clockwise.

 To decrease pressure, turn counterclockwise.
Figure 1
Pressure checking
1. Adjusting screw (1)

2. Lock nut (2)
3. Pressure checking port (a)
Service Information

Hydraulic pump (removed), 913 Service Information 2014/10/29
changing shaft seal
Profile:
EXC, EC290B LC [GB]
Hydraulic pump (removed), changing shaft seal

Op nbr 913-007
1. Remove screws (1) and front seal cover (3).

NOTE!
Install screws (1) into tapped pull out holes (3) of front seal cover (2), so it can be removed easily.
Figure 1
2. Remove seal (1) and O-ring (3) from seal cover (2).
Figure 2
3. Install seal (1) and O-ring (3) in seal cover (2).
4. Assemble front seal cover to pump casing and install screws.

NOTE!
Apply grease lightly to the seal lip.
Install seal, taking care not to damage it.
Service Information

Hydraulic pump, replacing 913 Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Hydraulic pump, replacing

Op nbr 913-010
WARNING
WARNING
NOTE!
Oil that drains from hoses and connections must be collected in a barrel. Disconnected hoses and connections must be
plugged.
NOTE!
Container capacity : 300 liters Drain hose : The hose for engine oil draining can be used.
WARNING
The parts are heavy. Take appropriate safety cautions when handling them.
1. Place the machine in the service position B. See : 091 Service positions
2. Connect drain hose (1) supplied with the machine to the drain valve and drain the hydraulic oil into an oil barrel
Figure 1
3. Disconnect drain hose (1), after draining hydraulic oil and fit cover (1).
NOTICE
Always handle oils and other environmentally hazardous fluids in an environmentally safe manner.
WARNING
When the last bolt has been removed, the cover plate falls down.
4. Remove screws (2) and under covers (1).
Figure 2
5. Drain hydraulic oil from drain plug (1) of the suction pipe.
Fit drain plug (1), after draining hydraulic oil.
Figure 3
6. Remove screw (1) and cover (2).
Figure 4
7. Disconnect the light wire harness (3).

Remove screws (1) and brackets (2).
Figure 5
8. Remove screws (1, 2) and covers (3, 4).
Figure 6
9. Hold Muffler (1) with hoist (2).
10. Loosen muffler coupling clamp screws (3) - engine side.
11. Remove muffler mounting bracket (4) screws (5) - hydraulic oil pump side.
Disconnect wire harness (6) of proportional valve.
12. Remove muffler (1) with muffler mounting bracket (4).
Figure 7
13. Disconnect servo hydraulic outlet hoses (1).

Disconnect servo hydraulic inlet hose (2).
Disconnect servo hydraulic hoses (6).
Remove screws (3) and disconnect outlet hoses (4) with O-rings.
Disconnect drain hose (5).
Figure 8
14. Disconnect proportional valve wire harness (1).

Disconnect servo hydraulic hoses (1, 2).
Figure 9
15. Remove screws (4) at suction pipe (4) mounting.
16. Install eye bolts (2) and a sling, hold with hoist (2) and remove mounting screws (3).
.
Figure 10
17. Remove the hydraulic pump.
18. Remove screws (1), hub (2) and insert (3) assembly from hydraulic oil pump shaft (4).
.
Figure 11
19. Remove screws (1) and flange (2).

.
Figure 12
20. Fit the flange to a new hydraulic pump.

NOTE!
O-rings disassembled should be replaced with new ones.
21. Transfer the servo hydraulic pump to the new hydraulic pump.
22. Transfer the connectors and elbows to the new hydraulic pump.
23. Fit hub (2), insert (3) assembly and tighten screws (1) to new hydraulic oil pump shaft (4).
NOTE!
Hub spline should be fully inserted onto the pump shaft.
NOTE!
Apply loctite # 277 onto the threads of screws (1). Tightening torque : 206 ±9.8 (21 ±1 kg m) (151.6 ~ ±7.2 lbf ft)
Figure 13
24. Install the hydraulic pump assembly.
25. Install the hydraulic pump mounting screws.
26. Remove the hoist sling and eye bolts.
27. Install screws (3) at suction pipe (4) mounting.
Figure 14
28. Connect servo hydraulic hoses (1, 2).
29. Connect proportional valve wire harness (1).
30. Connect servo hydraulic hoses (6).

Connect drain hose (5).
Connect outlet hoses (4) with O-rings and tighten screws (3).
Connect servo hydraulic inlet hose (2).
Connect servo hydraulic outlet hoses (1).
Figure 15
31. Hold Muffler with hoist (2) and install muffler (1).
Install muffler mounting bracket (4) screws (5) - hydraulic oil pump side.
Connect wire harness (6) of proportional valve.
32. Tighten muffler coupling clamp screws (3) - engine side.
Figure 16
33. Install cover (3, 4) and tighten screws (1, 2).
Figure 17
34. Install brackets (2) and tighten screws (1).

Connect light wire harness (3).
Figure 18
35. Install cover (2) and screws (1).

Figure 19
36. Install under covers (1) and tighten screws (2).
Figure 20
37. Remove plug (1) on cover (2).

Fill the oil tank with hydraulic oil through the return filter.
Install plug (1) on cover (2).
Figure 21
38. Start the engine and test the machine.

Service Information

Proportional solenoid valve 913 Service Information 2014/10/29
(power shift), replacing
Profile:
Proportional solenoid valve (power shift), replacing

Op nbr 914-041
NOTE!
3. Open the side cover and disconnect wire harness connector (1) for the solenoid valve.
Figure 1
Disconnection, wire harness connector
4. Disconnect hose (1) for the proportional solenoid valve.
Figure 2
Disconnection, hose
 Tool: Spanner 19 mm

Figure 3
Removal, screws
NOTE!
Prepare small container for some leakage from the pump body.
6. Transfer fitting (1) to the new proportional solenoid valve.
Figure 4
Transfer, fitting
7. Install new proportional solenoid valve (1).
Figure 5
Installation, proportional solenoid valve
NOTE!
Replace O-ring and pay attention not to pull out seat of check valve, ball , and stopper from pump body. Also take
care not to loss and faulty assembly
8. Connect hose (1) for the proportional solenoid valve.

Figure 6
Connection, hose
9. Connect wire harness connector (1) for the solenoid valve.
Figure 7
Connection, wire harness connector
10. Start the diesel engine. Check for leaks and if needed.
Service Information

Servo pump, description Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Servo pump, description

Machine serial no.: ~ 13328
Figure 1
Structure, servo pump (Machine serial no.: ~ 13328)
1 Motor case 11 Screw 21 Pin bushing

2 Cover 12 Lock nut 22 O-ring
3 Bushing 13 Adjust screw 23 Plug
4 Drive gear 14 Spring seat 24 O-ring
5 Driven gear 15 Spring A1 Suction port PF 3/4
6 Thrust plate 16 Poppet A2 Delivery port PF 1/2
7 Seal 17 Seat A3 Gauge port PF 1/4
8 O-ring 18 Coin filter P To main pump
9 O-ring 19 Retaining ring
1 Screw 20 Flange screw
0
Tightening torque
No. Size kgf·m (lbf·ft)

10, 11 M 8 x 1.25 3.3 (23.8)
12 3.0 (21.7)
22 P16 6.5 (46.9)
23 PF 1/4 2.6 (18.8)
Precautions
 Repair of this pump is not recommended.

 Replace O-ring (9) when installing a new pump.
 Check and adjust the relief valve pressure setting.
 Output shaft rotating torque 1.0 kgf·m (7 lbf·ft).
Service Information

Servo pump, description Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Servo pump, description

Figure 1
Structure, servo pump (Machine serial no.: 13329 ~ )
307 Poppet 354 Driven gear 710 O-ring

308 Seat 355 Filter 725 O-ring
309 Ring 361 Front case 732 O-ring
310 Spring 433 Screw 850 Snap ring
311 Adjusting screw 434 Screw A3 Suction port PF 1/2
312 Lock nut 435 Screw B3 Delivery port PF 3/4
351 Gear case 466 Plug a3 Gauge port PF 1/4
353 Drive gear 700 Ring
Tightening torque
No. Size N·m (kgf·m / lbf·ft)

312 M 14 x 1.5 29 (3 / 21.5)
433, 434 M8 17 (1.7 / 12.6)
435 M 10 33 (3.4 / 24.4)
466 PF 1/4 16 (1.6 / 11.8)
Precautions
 Repair of this pump is not recommended.

 Replace O-ring (9) when installing a new pump.
 Check and adjust the relief valve pressure setting.
Service Information

Servo pump, parts Service Information 2014/10/29
inspection
Profile:
EXC, EC290B LC [GB]
Servo pump, parts inspection

Inspection item

Gear housing
deep.
Gear
 Existence of scoring, grooving,  Replacement when damaged.
nicking and fretting etc on gear  Replacement when the seal contact area is
 Existence of wear of seal contact area worn more than 0.05 mm (0.002 in).
Thrust plate
 Existence of scratch, erosion and more than 0.05 mm (0.002 in).
pitting  Replacement when damaged.
Seals
Service Information

Servo hydraulic pressure, Service Information 2014/10/29
adjustment
Profile:
EXC, EC290B LC [GB]
Servo hydraulic pressure, adjustment

Measuring condition
 Engine speed : high idle

 Oil temperature when measuring: 50 ±5 °C (122 ±41 °F)
Measurement
Remove the plug (23), and install a pressure gauge 100 kgf/cm2 (1422 psi) to the pump (port A3).
Specifications of pressure checking port : PF 1/4

Tightening torque : 2.6 kgf·m (18.8 lbf·ft)
NOTE!
The material of the pump housing is aluminium. If tightened excessively, the threads can be damaged.
Adjustment
 Loosen nut (12) and turn screw (13) to adjust.

 Adjust the screw as follows.
 To increase pressure, turn clockwise.

 To decrease pressure, turn counterclockwise.
 After completion of adjustment, install the plug.

Service Information

Servo pump, replacing Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Servo pump, replacing

Op nbr 914-060
NOTE!
3. Connect vacuum pump (1) to the hydraulic tank, and actuate when disconnecting the hose.
Figure 1
Connection, vacuum pump
4. Open the side cover and then disconnect suction hose (1).
Figure 2
Disconnection, hose
5. Disconnect outlet hoses (1, 2) of the pump.

Figure 3
Disconnection, hoses
 Tools: Spanner 19 mm / 27 mm
6. Remove servo pump mounting screws (1).
Figure 4
Removal, screws
7. Remove servo pump (1).
Figure 5
Removal, servo pump
General precautions
 Rework damaged parts before assembling, and prepare all replacements.

 Replace O-rings with new ones.
 Use a torque wrench to tighten the screws to the specified torque.
8. Transfer the fittings to the new servo pump.

Figure 6
Transfer, fittings
9. Install new servo pump (1).
Figure 7
Installation, servo pump
 Tightening torque (screw) : 3.4 kgf·m (24.5 lbf·ft)
10. Connect outlet hoses (1, 2).
Figure 8
Connection, hoses
11. Connect suction hose (1).

Figure 9
Connection, hose
12. Start the diesel engine. Check for leaks and if needed.
Service Information

Pressure accumulator, Service Information 2014/10/29
description
Profile:
EXC, EC290B LC [GB]
Pressure accumulator, description

 The accumulator is installed with a check valve between the gear pump and solenoid valve, to prevent the back flow
of oil charged in the accumulator.
 The nitrogen gas in the accumulator is compressed by the oil discharged from the gear pump. When the hydraulic
pressure falls, the compressed gas volume will expand and displace the accumulated pressurized oil into the circuit.
 When the boom is left in the raised position, and the control lever is operated with the engine stopped, the
pressure of the compressed nitrogen gas inside the accumulator sends servo hydraulic pressure to the control valve
to actuate it and allow the digging unit to come down under its own weight.
NOTE!
The servo hydraulic pressure accumulated in the accumulator can be utilized only when start switch is ON and the
safety lever is released by the left control console being lowered.
Figure 1
Circuit, accumulator
1. Check valve
2. Accumulator
3. Solenoid valve
4. Control lever
Figure 2
Structure, accumulator
1 Plug
2 Seal ring
3 Diaphragm
4 Closure button
5 Housing
Accumulator block
Figure 3
Accumulator block, sectional view & circuit diagram
G : Plug
Figure 4
Accumulator block (exploded view)
1 Block 7 Plug
2 O-ring 8 Coil spring
3 Plug 9 Spring guide
6 Steel ball
Port description
Port Description Port Description

AC Accumulator S1 Main control valve
PS Servo hydraulic filter outlet S2 Slew motor PG
PS1 Solenoid valve P1 S3 Solenoid valve P2
Service Information

Accumulator, replacing Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Accumulator, replacing
Op nbr 914-051
NOTE!
3. Open the side cover.
4. Remove accumulator assembly (1).
Figure 1
Removal, accumulator
5. Remove connector (1) from accumulator (2) using a vice.

Figure 2
Removal, connector
6. Transfer the connector to the new accumulator.
7. Install accumulator (1)
Figure 3
Installation, accumulator
NOTE!
Replace O-ring and copper gasket with a new one.
Service Information

Accumulator, replacing Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Accumulator, replacing
Op nbr 914-051
NOTE!
3. Remove accumulator assembly (1).
Figure 1
Removal, accumulator
4. Remove connector (1) from accumulator (2) using a vice.
Figure 2
Removal, connector
5. Transfer the connector to the new accumulator.
6. Install accumulator (1)
Figure 3
Installation, accumulator
NOTE!
Replace O-ring and copper gasket with a new one.
Service Information

Remote control valve Service Information 2014/10/29
(Lever), description
Profile:
EXC, EC290B LC [GB]
Remote control valve (Lever), description

The servo hydraulic valve PV48K is a remote control valve of the reducing valve type and has four reducing valves controlling
the secondary pressure in one valve casing. Its secondary pressure is controlled by adjusting the tilting angle of the handle.
The casing has vertical bores in which the reducing valves are assembled.
The pressure reducing section is composed of spool (201), spring (241) for setting secondary pressure, return spring (221),
washer 1 (215), spring seat (216) and washer 2 (217). The spring for setting the secondary pressure has been preset so that
the secondary pressure is 5 ~ 10 kgf/cm2 (71 ~ 142 psi) (depending on the type).
The spool is pushed against push rod (212) by return spring (241).
Piping
For good responsiveness, piping of about 8 mm (0.31 inch) in inner diameter and 3 m (9.84 ft) in length is used. To avoid a
back pressure effect, the oil is returned directly to the tank.
Fundamental functions
The servo hydraulic valve controls the main control valve spool stroke and direction. This function is carried out by providing
a spring at one end of the main control valve spool and applying the output pressure (secondary pressure) of the servo
hydraulic valve to the other end.
To accomplish this function, the servo hydraulic valve consists of the following:
 Inlet port (P), receives oil from the servo hydraulic system hydraulic pump.
 Output ports (1, 2, 3, 4) supply oil pressure to the inlet port of the control valve spool end.
 Tank port (T) controls the above output pressure.
 Spools to connect output port to main control valve inlet port, or tank port.
 Mechanism including springs applied to the above spools to control output pressure.
Functions of major sections

Spool (201) connects the oil passages that route port (P) oil from the hydraulic pump to outlet ports 1, 2, 3, 4 or to tank port
(T). Secondary pressure setting spring (241) works on this spool to determine the output pressure.
To change the force of this spring, push rod (212) slides in plug (211) reacting on the spring.
For the purpose of changing the displacement of the push rod, disc (302) and adjusting nut (312) are provided; the handle
can be tilted in any direction around the fulcrum of universal joint (301). Spring (221) works on casing (101) and spring seat
(216) and tries to return push rod (212) to the zero displacement position irrespective of the output pressure. This ensures its
resetting to the center position.
This also has the effect of a reaction spring to give an accurate sense of control to the operator. The output pressure in
relation to the secondary pressure is directly proportional to the inclination of the remote control valve control handle.
External view (Control Lever- right)
Figure 1
Remote control valve (Lever- right), 1 switch, 3 switch and 5 switch
1 Number 1 push rod 1 Green color A Neutral adjusting position mark white paint on edge
1
2 Number 2 push rod 1 Red color B Single operating angle (19°)
2
3 Number 3 push rod 1 Yellow color Bb Single operating angle (25°)
3
4 Number 4 push rod 1 Black color C Tilting angle of handle
4
5 Rear switch 1 White color D Double operating angle (25°)
5
6 Double switch (left) 1 Orange color E Tilted direction of handle (No. 1 push rod direction)
6
7 Double switch (left) 1 Brown color F PF 1/4 (tightening torque: 29.4 ± 2.0 N·m (300 ± 20 kgf·cm, 22
7 ± 2 lbf·ft))
8 Number 1 front switch 1 Pink color
8
9 Number 2 front switch G 5 - PF 3/8 (tightening torque: 49 ± 4.9 N·m (500 ± 50 kgf·cm,
1 single switch 36 ± 3.6 lbf·ft))
0
NOTE!
Switch ON: When depressing,
Switch OFF: When releasing
NOTE!
5 switch is not available to EC700B model..
Figure 2
Remote control valve lever (sectional view)
101 Casing 211 Plug 302 Disc 454 Rubber tube

111 Plate 212 Push rod 312 Adjust nut 455 Switch
121 Washer (seal) 213 Seal 315 Lock nut 456 Wire
122 O-ring 214 O-ring 323 Handle bar 457 Bushing
125 Screw 216 Spring seat 402 Grip (handle) 458 Tube
126 Spring pin 217 Washer 2 403 Insert 459 Terminal
131 Bushing 221 Spring 404 Tube 460 Terminal
151 Plate 241 Spring 431 Screw 461 Terminal
201 Spool 301 Joint 432 Screw 501 Bellows
When the push rod is pushed down by tilting the handle, the spring seat moves down simultaneously and changes the
setting of the secondary pressure spring.
The casing has the oil inlet (primary pressure), port (P), and the oil outlet (tank), port (T). In addition the secondary pressure
is routed through ports 1, 2, 3 and 4 provided at the bottom face. An electric switch is fitted to each control valve and switch
(455) is built into the top of the handle grip. When the center of handle grip (402) at the handle head is pushed, the switch
will function. Wire lead (456) connected to the switch, is led through the handle section and casing to the outside.
Control Lever patterns
The patterns in the left and right columns are applied to the left and right control levers.
Arm out (1)

- move the lever here to move the arm out.
Slew right (2)

- move the lever here to slew the superstructure to the right.
Arm in (3)
- move the lever here to move the arm in.
Slew left (4)

- move the lever here to slew the superstructure to the left.
Boom lower (5)

- move the lever here to lower the boom.
Bucket dump (6)

- move the lever here to dump the bucket.
Boom raise (7)

- move the lever here to raise the boom.
Bucket curl (8)

- move the lever here to curl the bucket.
Figure 3
Operation, remote control valve (Lever)
A SAE system (Volvo CE Korea system)

B MHI system
C KOB system
D Standard backhoe loader system
E SCM system
Hold (9) - When the lever is released from any position, the lever will return to HOLD. Slew, arm, bucket or boom movement
will stop.
Two functions may be performed at the same time by moving the lever diagonally.
(If equipped with a hydraulic hammer) Hammer Raise (6) - Move the lever here to raise the hammer.
Hammer lower (8) - Move the lever here to lower the hammer.
 Servo hydraulic line ports of Volvo CE korea system (SAE system). – See the hydraulic circuit drawing.
WARNING
The remote control valve lever pattern decal must conform with machine control pattern. Failure to comply could
result in injury or death.
NOTE!
The remote control valve lever pattern can be changed at the connector block.
Operation
The operation of the servo hydraulic valve is described on the basis of the hydraulic circuit diagram and sectional view which
is a typical application example of the servo hydraulic valve.
Figure 4
Diagram, remote control valve (Lever)
1 Remote control valve 4 Main control valve

2 Servo hydraulic pump 5 Hydraulic motor
3 Main pump 6 Hydraulic cylinder
Handle is in neutral position

The force of spring (241) determines that the output pressure of the servo hydraulic valve is not applied to spool (201).
Therefore, the spool is pushed up by spring (221) to the position of port 3. Then since the output is connected to tank port
(T) only, the output port pressure becomes equal to tank pressure.
Figure 5
Operation, handle is in neutral position
Handle is in operating position

When push rod (212) is stroked, spool (201) moves downward.
Then port (P) is connected with port 1, and the oil supplied from the servo hydraulic 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 a constant value. In some valves, when the handle is tilted more than a
certain angle, the upper end of the spool contacts the inside bottom of the push rod and the output pressure is connected
with port (P).
Figure 6
Operation, handle is in operating position
Operating pressure
Figure 7
Operating pressure chart
SP Secondary pressure OA Operating angle

PD Push rod operating distance OT Operating torque
Service Information

(lever), replacing
Profile:
EXC, EC290B LC [GB]
Remote control valve (lever), replacing

Op nbr 914-081
1. Park the machine in the service position. (Move the operator's seat (1) and control box (2) forward.)
NOTE!
When the engine is running, the hydraulic line is under high pressure.
Stop the engine, and remove the residual pressure inside the hydraulic line by operating the control lever smoothly
for 3~4 times with the ignition switch at "ON" position. Turn the ignition key to "OFF" position.
Figure 1
Service position
2. Open the cover (3) and remove screws (4).
Figure 2
Removal, screws
3. Remove screw (5) and open the cover (6).

Figure 3
Removal, screw
4. Remove screws (7) and control box cover (7).

NOTE!
Loosen 2 mounting screws (7) and remove cover (8) from control box.
Figure 4
Removal, screws
5. Remove screws (A)-(4EA).
Figure 5
Removal, screws
6. Remove hydraulic hoses (9) and control lever (10).

NOTE!
Mark on the each hydraulic hoses (9) for identification before disassembly.
Prepare container for collecting hydraulic oil.
Figure 6
Removal, control lever
7. Remove nipples (11) and install to the new control lever.

NOTE!
Nipples (11) tightening torque : 30 ±3 Nm (22.2 ±2.2 lbf ft)
Do not reuse removed O-ring.
Figure 7
Removal and Installation, nipples
8. Install the hoses (9) to the control lever (10).

NOTE!
Hoses (9) tightening torque : 25.5 ±2.9 Nm (18.8 ±2.2 lbf ft)

Figure 8
Installation, hydraulic hoses
9. Install screws (A)-(4EA).
Figure 9
10. Install control box cover (8) and screws (7).
Figure 10
11. Install cover (6) and screw (5).

Figure 11
Installation, screw
12. Install screws (4) and cover (3).
Figure 12
13. Check the operation of the control lever and switchs.

Service Information

(Lever), troubleshooting
Profile:
EXC, EC290B LC [GB]
Remote control valve (Lever), troubleshooting

It isn’t always easy to trace a malfunction. Some general phenomenon to be considered are listed in following table. See
cause and remedy.
However, the trouble is not always caused by one faulty part only, but by its relation to other parts.
So remedies other than listed in the table may be necessary.
Troubleshooting

Secondary pressure will not
rise.  Primary pressure is low.  Adjust primary pressure.
 Spring (241) breaks or yields.  Replace it with new one.
 Clearance between spool and  Replace spool subassembly and
casing is excessive. casing.
 There is play at handle section.  Disassemble and repair handle
section or replace it.
Secondary pressure is
unstable.  Sliding part is sticking.  Repair/replace parts.
 Tank line press fluctuates.  Return oil directly to tank.
 Air in hydraulic circuit.  Carry out operation several times to
bleed air from the system.
Secondary pressure is too

high.  Tank line pressure is too high.  Return oil directly to tank.
 Sliding part is stuck.  Repair/replace defective parts.
Service Information

(pedal), description
Profile:
EXC, EC290B LC [GB]
Remote control valve (pedal), description

Remote control valve RCVD8C is a reducing valve type remote control valve. The inclination of the controller is adjusted by
pedal or lever, and in relation to secondary pressure, output pressure proportional to inclination will be generated.
The servo hydraulic valve controls the main control valve spool stroke and direction.
This function is carried out by providing a spring at one end of the main control valve spool and applying the output
pressure (secondary pressure) of the servo hydraulic valve to the other end.
To accomplish this function, the servo hydraulic valve consists of the following:
 Inlet Port (P), receives oil from the servo hydraulic system hydraulic pump.
 Outlet ports (1, 2), supply oil pressure to the inlet port, of the control valve spool end.
 Tank port (T), controls the above output pressure.
 Spools to connect the outlet port to main control valve inlet ports, or tank port.
 Mechanism including springs applied to the above spools to control the output pressure.
Principal function
Spool (301) connects the oil passages that route (P) port oil from the hydraulic pump to outlet port (1, 2) or to tank port (T).
The secondary pressure setting spring (324) works on this spool to determine the output pressure.
To change the spring force, push rod (214) slides into plug (202), reacting on the spring.
The displacement of the push rod is changed by the use of cam (420): a pedal or lever is attached and the cam can be
rotated ±12.4° over center of camshaft (413).
Return spring (335) acts on casing (101) and spring seat (311), it sets the displacement of push rod (214) to “0” regardless of
output pressure, and returns the spool to neutral.
Also, it acts as a reaction spring to give an accurate sense of control to the operator.
The damping valve installed in the servo hydraulic valve prevents hunting symptoms that may occur due to abrupt pedal
(lever) operation.
Figure 1
Structure, remote control valve (pedal)
101 Casing 221 Retaining ring 412 Bushing

151 Plug 223 Bushing 413 Camshaft
171 Screw 224 Piston 420 Cam
201 Cover 225 Ball 423 Set screw
202 Plug 271 Screw 471 Set screw
203 Grease cap 301 Spool 472 Lock nut
204 Cover 2 311 Spring seat 501 Bellows
210 NHU packing 313 Washer 3 520 Pedal
212 O-ring 324 Spring 522 Cover
214 Push rod 335 Spring 524 Screw
217 Washer 2 336 Spring
218 Spring seat 337 Spring
Tightening torque, unit: kgf·cm (lbf·in)
No. Size Tightening torque

151 NPTF 1/16 70 ± 10 (61 ± 9)
171 M8 300 ± 30 (260 ± 26)
271 M 12 800 ± 100 (693 ± 86)
423 M6 70 ± 10 (61 ± 9)
NOTE!
Apply loctite No. 241
472 M 10 340 ± 35 (295 ± 30)
Operation
The operation of the remote control valve (pedal) is explained in accordance with the hydraulic circuit diagram and sectional
view which is a typical application example of the remote control valve.
Figure 2
Diagram, remote control valve (pedal)
1 Remote control 4 Control valve

2 Servo hydraulic pump 5 Hydraulic motor
3 Main pump 6 Hydraulic cylinder
Neutral position
Spool (301), spring seat (311) and washer (215) are pushed upward, by return spring (335), and set at the position as shown
in the sectional view.
Therefore, pressure at outlet port 1, 2, will be the same as tank pressure because the outlet port is connected to tank port (T)
due to the spool conversion function.
Operating position
According to the sectional view, pedal cam (420) rotates counterclockwise and push rod (214) at port 1 side pushes spool
(301) downward through washer 1, spring nozzle and secondary pressure setting spring (314). Then port (P) and port 1 are
connected, and oil supplied from (P) port flows into port 1 and pressure is generated.
When the pressure of port (P) rises to equal the force of the secondary pressure setting spring, created by depressing the
controller, the oil pressure and spring pressure will be balanced so the output pressure can be maintained to a constant
value.
Port 2 side maintains a neutral condition and the oil returned from the control valve will be drained through port (T).
Damping valve
Neutral position
The push rod is pushed upward through piston (224) by return spring (336, 337), and set at the position as shown in the
sectional view.
Operating position
According to the sectional view below, the pedal cam rotates clockwise and the push rod at port 1 side is pushed downward.
Oil in the damping piston is drained through the piston orifice and dampened by the pressure generated at that time.
In normal operating, the push rod at port 2 moves upward through the piston by return spring.
Thereby, it draws in oil from the tank through the check ports (3 places) produced by bushing (223) and check ball (225) in
the damping piston. The oil outside the piston chamber flows through the passage connected to port (T) in the upper
casing.
Figure 3
Damping valve
1 Push rod 5 In neutral position, the oil in the right (left) side piston chamber is drained
2 Orifice through the orifice, and damped by the pressure generated.
3 Piston
4 Piston seal
Operating opposite position

According to the sectional view below, when operating the pedal to the opposite direction completely the pedal cam rotates
fully clockwise, and then rotates counterclockwise again, and push rod at port 2 side is pushed downward and the piston
moved upward.
At this point of time, as explained before, oil in the damping piston is drained through the piston orifice and damped by the
pressure generated at that time.
In normal operating, the push rod at port 1 moves upward through the piston by return spring (335) and damping spring.
Thereby, it draws in oil from the tank through the check ports (3 places) in the damping piston.
The oil outside the piston chamber flows through the passage connected to the tank port in the upper casing.
Therefore, the operation is dampened from the neutral position to the complete operating position or from the operating
position to the neutral position.
Figure 4
When operating the pedal to the opposite direction
When handing the lever reversely from ⇒ to ··· >, the left piston is immediately activated.
Always damping happens to both directions.
1. When converting to the opposite direction from neutral, the push rod is pushed upward by the damping spring.
(During operating).
2. Neutral position
3. Operating angle
4. The oil outside the piston is drained through the passage connected to T port in the upper part of casing (During
operating).
5. Oil
6. The oil in piston chamber is damped by the pressure produced when it is drained through the hole (During
operating).
7. The oil of T line flows through the ball checks (3 places) and enters the damper chamber (During operating).
Secondary pressure and operating force
Figure 5
Secondary pressure and operating force
SP Secondary pressure OA Operating angle

PD Push rod operating distance OT Operating torque
Service Information

(pedal), replacing
Profile:
EXC, EC290B LC [GB]
Remote control valve (pedal), replacing

Op nbr 914-084
1. Park the machine in the service position.

NOTE!
When the engine is running, the hydraulic line is under high pressure.
Stop the engine, and remove the residual pressure inside the hydraulic line by operating the control lever smoothly
for 3~4 times with the ignition switch at "ON" position. Turn the ignition key to "OFF" position.
Figure 1
Service position
2. Remove screws (1) - (7 EA) and under cover (2).
Figure 2
Removal, under cover
3. Remove hoses (3) and connectors (4).
NOTICE
When a hose has been disconnected, plug both the hose and the connection immediately. The hoses should
be marked for correct connection.
NOTE!
Figure 3
Removal, hoses and connectors
4. Remove travel pedal rubber pads (5).
Figure 4
Removal, rubber pads
5. Remove screws (6) and travel pedal plates (7).
Figure 5
Removal, pedals
6. Remove floor mat (8) and rubbers (9).

Figure 6
Removal, floor mat
7. Remove screws (10) and travel pedal valve (11).
Figure 7
Removal, travel pedal
8.
Figure 8
Removal, connectors
Remove connectors (13)-(4EA) from travel pedal valve (12).
9.
Figure 9
Installation, travel pedal
Mount connectors to the new travel pedal valve.
NOTE!
10. Install travel pedal valve (11) with screws (10).
11. Install rubbers (9) and floor mat (8).
Figure 10
Installation, floor mat
12. Install travel pedal plates (7) and screws (6).
Figure 11
Installation, pedals
13. Install travel pedal pads (5).
Figure 12
Installation, rubber pads
14. Install connectors (4) and hoses (3).

NOTE!
Figure 13
Installation, hoses and connectors
15. Install under cover (2) and screws (1)-(7EA).
Figure 14
Installation, under cover
16. Check the operation of the travel pedal.
Service Information

(pedal), troubleshooting
Profile:
EXC, EC290B LC [GB]
Remote control valve (pedal), troubleshooting

It isn’t always easy to trace a malfunction. Some general phenomenon to be considered are listed in following table. See
cause and remedy.
However, the trouble is not always caused by one faulty part only, but by its relation to other parts.
So remedies other than listed in the table may be necessary.
Troubleshooting

Secondary pressure will not
rise.  Lack of primary pressure.  Adjust the primary pressure.
 Damaged secondary pressure setting  Replace it with new parts.
spring.
 Clearance between spool and casing is  Replace spool subassembly and
excessive. casing.
 Play in controller.  Disassemble, and repair or replace
controller parts.
Secondary pressure is
unstable.  Related to sliding part.  Repair/replace the related parts.
 Tank line pressure fluctuates.  Return oil directly to the tank.
 Air in hydraulic circuit.  Bleed the air by repeating pedal
operation several times.
Secondary pressure is too

high.  Pressure of tank line is too high.  Return oil directly to tank.
 Related to sliding part.  Repair/replace defective part.
Damping is not done.

 Air in piston chamber.  Bleed the air by repeating
operation several times.
 Sliding parts are sticking.  Repair replace sticking part.
 Damping springs (336, 337) failure.  Replace spring.
 Excessive clearance between damping  Replace the damping piston
piston (224) and casing. assembly.
 Check valve malfunction.  Disassemble/check/repair the
check valve.
 Orifice of damping piston oversized.  Replace the damping piston.
Damping torque is heavy.

 Sliding parts malfunction.  Repair defective parts.
 The hole of damping piston is clogged.  Clean/replace the damping piston.
Service Information

(Lever), maintenance
standard
Profile:
EXC, EC290B LC [GB]
Remote control valve (Lever), maintenance standard

Maintenance standard
Maintenance Criteria Remark

check item
Leakage The valve is to be replaced when the leakage becomes Conditions:
more than 1000 cc/min at neutral handle position, or more - Primary pressure:30 kgf/cm2 (426 psi) -
than 2000 cc/min during operation. Oil viscosity: 23 cSt
Spool This is to be replaced when the sliding surface has worn The leakage is estimated to be nearly equal
more than 10 µm, compared with the non–sliding surface. to the above leakage.
Push rod
A. Worn more than 1mm
This is to be replaced when the top end has worn more

than 1mm (0.004″).
Play at The pin, shaft, and joint of the operating section are to be When the play is due to loose parts /
operating replaced when the play becomes more than screws, tighten to specifications.
section 2 mm (0.008″)
Operation When abnormal noises, hunting, primary pressure drop, etc.
stability are generated during operation, and these cannot be
remedied, see causes of troubles and countermeasures,
replace the related parts.
NOTE!
In principle, replace seals and o-rings during reassembly.
NOTE!
When loosening the screws (125), replace the seal washers (121) without fail.
Service Information

(Lever), disassembly
Profile:
EXC, EC290B LC [GB]
Remote control valve (Lever), disassembly

Op nbr 00000
8940-00200 remote control valve joint
Tools and tightening torque

Tools
Tool Size Part no. Part Thread size Tightening torque

kgf·cm (lbf·ft)
Allen wrench 6 (mm) 125 Screw M8 300 ± 30
(22 ± 2)
Spanner 22 (mm) 312 Adjusting nut M14 700 ± 50
(50 ± 4)
315 Lock nut M14 500 ± 35
(36 ± 2)
27 (mm) 302 Disc M14 700 ± 50
(50 ± 4)
Philips screwdriver About 15 cm 431 Tap screw 2 M4 5 ± 0.5
(4 ± 0.5 lbs·in)
432 Tap screw 3 M5 18 ~ 22
(16 ~ 19 lbs·in)
Blade screwdriver About 4 ~ 5 mm 211 Bushing M1
wide
Special tool 301 Joint M14 480 ± 30
(35 ± 2)
Torque wrench 100 ~ 1000 kgf·cm
(0 ~ 900 lbs·in)
(0 ~ 150 lbs·ft)
Other:
 Rust inhibitor  Cleaning solvent
 High temperature grease
(spray type recommended)
 Loctite # 241 (special # 261)  Sandpaper (# 1000, # 2000)

 Oilstone  Vise
Preparation
 Thoroughly clean the exterior of the valve prior to disassembly. Dismantle in a clean environment.
 Prepare the tools and materials.
General precautions
 All parts are precision fitted to very close tolerances therefore utmost care must be taken not to damage them
during the dismantling and assembling procedure.
 Do not strike or force any parts that may be partially seized.
 Protect the parts from rusting prior to assembling, and check all surfaces for scratches, nicks and wear. Replace any
damaged part.
Disassembly
1. Clean servo hydraulic valve with cleaning solvent.

NOTE!
Use plugs to cover all ports.
2. Fix servo hydraulic valve in a vise with copper (or lead) sheets.
Figure 1
Fixing with the vise
3. Lift the end of bellows (501) upward from casing (101).

NOTE!
Pay attention not to damage the bellows.
Figure 2
V1004864
Figure 3
Lifting, bellows
4. Loosen lock nut (315) and adjusting nut (312). Use a spanner on each nut.
Figure 4
Removal, adjusting nut
5. Remove handle (402).
Figure 5
Removal, handle
6. Remove disc (302).
Figure 6
Removal, disc
7. Turn the joint counterclockwise to loosen it, utilizing jig (special tool).
NOTE!
[Photo] shows how to fit jig.
NOTE!
Take care when loosening the joint. Plate (151), plug (211) and push rod (212) may fly out due to compresdsed
return spring (221).
Figure 7
Using special tool
Figure 8
Removal, joint
8. Remove plate (151).
Figure 9
Removal, plate
9. When return spring (221) is released plug (211) stays in the casing because of the sliding resistance of the o-ring.
Take it out with a screwdriver.
NOTE!
Take it out, utilizing the external periphery groove of the plug and pay attention not to damage it by partial
loading. During removal, the plug may fly out due to return spring (211) force. Pay attention to this.
Figure 10
Removal, spring
10. Remove push rod (212), plug (211), reducing valve subassembly and return springs (221) from the casing.
NOTE!
Record relative position of reducing valve subassembly and return springs.
Figure 11
Removal, reducing valve subassembly
11. Fix servo hydraulic valve in a vise, port plate (111) upward. Loosen screws with hexagon socket key.
Figure 12
Loosening, screws
12. Remove port plate (111) and o-ring (122) from the casing (101).
Figure 13
Removal, o-ring
13. Remove bushing (131) from the casing (101).

Figure 14
Removal, bushing
14. To disassemble the reducing valve section, push down secondary pressure spring (241) and remove the spring
(241) through large hole of the spool (201).
NOTE!
Pay attention not to damage spool surface. Do not push down spring seat more than 6mm.
Figure 15
Removal, reducing valve
15. Separate spool (201), spring seat (216), secondary pressure spring (241) and washer 2 (217).
Figure 16
Removal, spool, spring seat and spring etc.
16. Remove push rod (212) from plug (211).
Figure 17
Removal, push rod
17. Remove o-ring (214) from plug (211).
Figure 18
Removal, o-ring
18. Remove seal (213) from plug (211) using a small screwdriver.
Figure 19
Removal, seal
19. Remove bellows (501) by pulling the top from its groove in the grip.
Figure 20
Removal, bellows
20. Remove handle (402) cover. Remove tap screw (431), and take off grip (402) cover.
Figure 21
Removal, tap screws
21. Remove the switch bracket.

Figure 22
Removal, switch bracket
22. Remove switches (455).

NOTE!
Record the location relationship between the color of wire and the position at the handle.
Figure 23
Removal, switches
23. Cleaning of parts:
 Initially wash the remote control valve assembly with clean solvent to remove the heavy accumulation of
dirt.
NOTE!
Allow the parts to soak in the solvent to soften the dirt. Do not wash the internal parts with contaminated
solvent. Ensure that all parts are thoroughly cleaned prior to reassembly.
 In the final stage, wash all passages, chambers, grooves with clean solvent, to ensure the utmost
cleanliness.
Wipe off the parts with a clean cloth.
NOTE!
Do not dry parts with compressed air, since they may be damaged and/or rust may develop due to
moisture in the air.
24. Rust prevention of parts:

Apply rust inhibitor to all parts.
NOTE!
If left untreated after being cleaned, they will rust and will not function properly after being reassembled.
Service Information

(Lever), assembly
Profile:
EXC, EC290B LC [GB]
Remote control valve (Lever), assembly

Op nbr 00000
Preparation
 Prepare the workbench, tools and parts. Assemble the valve in a clean area.
General precautions
 See the general precautions during disassembling.

 Remove all contamination from the parts and check that parts are free from burrs, nicks scratches, etc.
 Replace o-rings and back-up rings with new ones.
 In fitting o-rings and back-up rings, pay attention not to damage them.
 Apply grease to the parts to hold them in place during assembly.
 Tighten screws to specified torques shown in the tightening torque table.
 After assembling, cover all ports to prevent contamination from entering the valve.
Assembly
1. Install bushing (131) into casing (101).
Figure 1
Assembly, bushing
2. Install o-ring (122) into casing (101).

Figure 2
Assembly, o-ring
3. Install port plate to casing (101) with screws (125) and seal washers (121).
NOTE!
Position the port plate so spring pin (126) can enter into the casing hole. Replace washers (121) with new ones.
Figure 3
Assembly, port plate
Figure 4
Replacement, washers with new ones
4. Tighten screws (125) to the specified torque.

NOTE!
Tighten two screws alternately and evenly.
Figure 5
Tightening, screws
5. Assemble washer (217), secondary pressure spring (241) and spring seat (216) onto spool (201) in this order.
NOTE!
Do not push down spring seat more than 6 mm.
Figure 6
Assembly, washer, secondary pressure spring and spring seat
6. To assemble the reducing valve section, push down secondary pressure spring (241) and install the spring (241)
through large hole of the spool (201).
Figure 7
7. Install return spring (221) into the casing. Install reducing valve subassembly into the casing (101).
NOTE!
Install them to their original positions.
Figure 8
Assembly, spring
8. Assemble o-ring (214) onto plug (211).
Figure 9
Assembly, o-ring
9. Assemble seal (213) to plug (211).

NOTE!
Assemble seal lip direction as shown below.
Figure 10
Assembly, seals
10. Assemble push rod (212) to plug (211).

NOTE!
Apply oil on push rod surface.
Figure 11
Assembly, push rod
Figure 12
Apply oil on push rod surface
1 Seal 3 Plug
2 Push rod 4 Apply working oil
11. Assemble plug subassembly to casing (101).

NOTE!
When return spring is relaxed, subassembly stops due to resistance of o-ring.
Figure 13
Assembly, plug subassembly
12. When return spring is compressed, assemble 4 sets at the same time, utilizing plate (151), and tighten joint (301)
temporarily.
NOTE!
The plug subassembly and plate (151) may fly out due to return spring (221) force. Pay attention to this.
Figure 14
Assembly, 4 sets of plug
13. Fit plate (151).
 E- tool part no.: 8940 - 00200
Figure 15
Fit, plate
14. Tighten joint (301) to the specified torque to casing, utilizing jig.
Figure 16
Tightening, joint
15. Assemble disc (302) to joint (301).

NOTE!
Screw it to a position that it contacts the 4 push rods evenly.
NOTE!
Do not screw it past this position.
Figure 17
Assembly, disc
16. Assemble adjusting nut (312). Tighten adjusting nut to the specified torque.
NOTE!
During tightening, do not change position of disc.
NOTE!
Hold disc (302) with a spanner when tightening the lock nut.
Figure 18
Assembly, adjusting nut
17. Place the switches and bracket at the original position, and tighten screw.
Figure 19
Assembly, switch bracket
18. Place the handle cover, and tighten tap screw (431).
Figure 20
Assembly, handle cover
19. Fix top of the bellows into the groove in the lower end of handle (402).
Figure 21
Assembly, bellow
20. Assemble adjusting nut (312) to the handle, and place it to the joint (301).
Figure 22
Assembly, handle and joint
21. Determine handle direction, and tighten lock nut (315) to specified torque.
Figure 23
Assembly, lock nut
22. Apply grease to rotating section of joint and contacting faces of disc and push rod.
NOTE!
Molybdenum based CSE 115B paste type grease is recommended, but commonly used spray type grease is also
acceptable.
Grease should be applied every six months.
Figure 24
Applying, grease
23. Install the lower end of bellows (501) onto casing (101).
Figure 25
Assembly, bellows
Service Information

(pedal), maintenance
standard
Profile:
EXC, EC290B LC [GB]
Remote control valve (pedal), maintenance standard

Maintenance standard
Check item Criteria Remark

Leakage Handle in neutral: more than 500 cc/minute. Conditions:
During operation: more than 1000 cc/minute.
 Primary pressure: 30 kgf/cm2
(426 psi)
 Oil viscosity: 23 cSt
Spool When the sliding part worn more than 10 mm compared

with the non-sliding part, replace it.
Push rod
When the top end is worn more than 1mm (0.004″),

replace it.
Set screw
When the end is worn more than 1 mm, replace it.

Play of controller When the play is more than 2 mm (0.008″) on cam, When the play is due to loose parts/
camshaft and bushing of controller due to wear, replace screws, tighten to specifications.
the parts.
Operation stability When abnormal noise, hunting and primary pressure drop
occurs and can"t be corrected in accordance with
“Troubleshooting”, replace the remote control valve.
NOTE!
In principle, replace the o-rings and seals during reassembly.
Service Information

(pedal), disassembly
Profile:
EXC, EC290B LC [GB]
Remote control valve (pedal), disassembly

Op nbr 00000
Preparation
 Prepare the tools and materials.
General precautions
 All parts are precision fitted with very close tolerances therefore utmost care must be taken not to damage them
 Protect the parts from rusting prior to assembling, and check all surfaces for scratches, nicks, and wear. Replace any
damaged part.
Tools and tightening torque

Tool and tightening torque
Tool Dimension Part no. Part name Screw Tightening torque Remark
(mm) N·m (lbf·ft), kgf·cm
Allen wrench 3 423 Screw M6 6.9 ± 1 (5 ± 1) -
70 ± 10
5 471 M 10 - -
6 271 Screw M8 29.4 ± 2.9 (22 ± 2) -
800 ± 100
Spanner 17 472 Lock nut M 10 33.3 ± 3.4 (25 ± 2) -
340 ± 35
Driver Width 1 210 Seal - - For disassembly
211 Scraper - -
(Dust seal)
Width 215 Washer - - For disassembly
2~3
Hammer Standard 412 Bushing - - -
413 Camshaft
Special tool See below 412 Bushing - - -
figure
Torque wrench 2.9 ~ 4.9 N·m (30 ~ 450 kgf·cm) (0 ~ 500 lbs·in)
Others
 Rust inhibitor
 Cleaning solvent
 Heat resisting grease (Spray type recommended)
 Loctite # 241
 Sand paper # 1000, # 2000
 Oilstone
 Vise
 Spatula for greasing
Figure 1
Jig.1 (for bushing detachment)
A. Center hole (less than φ 2)
Figure 2
Jig. 2 (for the locking ring assembly)
Disassembly
1. Clean the servo hydraulic valve with cleaning solvent.
 Block each port with blind plugs.
2. Fix servo hydraulic valve in a vise with copper (or lead) plates.
 Remove the lower part of bellows (501) from cover (201).

Figure 3
Removal, bellows
3. Loosen screw (423) using an allen wrench.
 Loctite # 242 is applied and releasing torque is high. Take care not to damage the threads.
Figure 4
Loosening, screws
4. Match the round bar (φ 8 and less) to one end of camshaft (413), and push out by tapping lightly with a hammer.
Figure 5
Matching, end of camshaft
5. Remove cam (420) as an assembly with set screw (471), lock nut (472) attached.
 Record the position relationship with casing.

Figure 6
Removal, cam
6. Remove screws (271). Loosen each screw simultaneously so the cover is kept horizontal.
NOTE!
Take care, push rod (214) can spring out due to return spring force.
Figure 7
Removal, screws
7. Remove cover (201).
 Record the position relationship with casing (101).

 When return spring (335) is relaxed, plug (202) is left inside the casing due to sliding resistance of o-ring
(212).
 Pull it out with a screwdriver.
 Prevent any damage caused by a partial load on the plug outer diameter groove.
 Take care, the plug can spring out due to return spring force.
Figure 8
Removal, cover
8. Remove the push rod from the plug. Record the location relationship between push rod and plug.
NOTE!
Be careful not to damage the surface of push rod.
NOTE!
Take care, the plug can spring out.
Figure 9
Removal, push rod
9. Remove grease cap (203) and NHU packing (210) from plug. Record the location relationship between plug and
casing.
NOTE!
Take care, the plug can spring out due to return spring force.
Figure 10
Removal, grease cap
10. Record the location relationship between piston (224), separate piston and casing, and then disassemble.
Figure 11
Disassembly, piston and casing
11. Pull out the damping springs (336, 337) from casing.
 Record the location relationship between damping spring and casing.

Figure 12
Removal, damping spring
12. Remove spring seat (218) from casing.
 Record the location relationship between spring seat and casing.
Figure 13
Removal, spring seat
13. Pull out the check ball (225) using a magnet.

NOTE!
Take care not to lose the check ball.
Figure 14
Removal, check ball
14. Pull out locking ring (221) from casing using snap pliers.
 Record the location relationship between locking ring and casing.

 Take care, the bushing can spring out due to return spring force (335).
 Take care not to damage the casing inside.
Figure 15
Removal, locking ring
15. Pull out bushing (223) from casing with needle nose pliers.
 Record the location relationship between washer and casing hole.
Figure 16
Removal, bushing
16. Pull out the reducing valve assembly and return spring (335) from casing.
 Record the location relationship between reducing valve assembly and casing bore.
Figure 17
Removal, reducing valve assembly and return spring
17. Put cover (201) on a flat plate in a horizontal position, and match the special tool to the bushing. Push out the
bushing by tapping lightly with a hammer.
Figure 18
Removal, bushing
18. Fix the cam assembly into the vise. Remove lock nut (472) and set screw (471) with a spanner.
 Set screw is required for neutral adjusting when assembling. If the set screw does not need to be replaced,
do not remove it.
Figure 19
Removal, lock nut and set screw
19. Disassembly of reducing valve. Put the lower part of spool (301) on a flat surface vertically, lower spring seat (311),
and remove the 2 semicircular washers (215) with a screwdriver.
 Take care not to damage the spool surface.

 Never lower the spring seat more than 4 mm.
Figure 20
Removal, washer
20. Remove spool (301), spring seat (311), secondary pressure spring (324), washer 3 (313) and washer 2 (217).
 Handle as an assembly before assembling.
 Washer 2 (217) is used for adjusting the preset of secondary pressure setting spring (324), and the
thickness is different for each spool assembly.
However, sometimes the washer is not factory installed.
Figure 21
Removal, spool
21. Remove grease cap (203) from plug (202).
 Take care not to damage the push rod surface.
Figure 22
Removal, grease cap
22. Remove NHU packing (210) from plug with a small blade screwdriver.
 Take care not to damage the inside of the plug.
Figure 23
Removal, NHU packing
23. Remove o-ring (212) from plug.

Figure 24
Removal, o-ring
24. Cleaning of parts:
 Initially wash the remote control valve assembly with clean solvent to remove the heavy accumulation of
dirt.
NOTE!
Allow the parts to soak in the solvent to soften the dirt. Do not wash the internal parts with contaminated
solvent. Ensure that all parts are thoroughly cleaned prior to reassembly.
 In the final stage, wash all passages, chambers, grooves etc. to ensure the utmost cleanliness.
Wipe off the parts with a clean cloth.
NOTE!
Do not dry parts with compressed air. They may be damaged and/or rust may develop due to moisture in
the air.
25. Apply rust inhibitor to all parts.

NOTE!
If left untreated after being cleaned, they will rust and will not function properly after being reassembled.
Service Information

(pedal), assembly
Profile:
EXC, EC290B LC [GB]
Remote control valve (pedal), assembly

Op nbr 00000
Preparation
 Prepare the workbench, tools and parts. Assemble the valve in a clean area.
General precautions
 See the general precautions during disassembling.

 Remove all contamination from the parts and check that parts are free from burrs, nicks scratches, etc.
 Replace o-ring and NHU packings with new ones.
 In fitting o-ring and NHU packings pay attention not to damage them.
 Apply grease to the parts, to hold them in place during assembly.
Tighten screws to specified torques shown in the tightening torque table.
 After assembling, cover all ports to prevent contamination from entering the valve.
Assembly
1. Assemble washer 3 (313), washer 2 (217), spring (324) and spring seat (311) onto spool (301) in this order. The
washer 2 is for secondary pressure adjusting, and its thickness differs with every spool assembly.
 Washer 2 is not necessarily factory installed.
Figure 1
Assembly, spool
2. Stand spool vertically with its bottom placed on a flat workbench, and with spring seat pushed down, put the two
semicircular washers 1 (215) on the spring seat without prying them on.
Figure 2
Assembly, washers
3. Assemble washer 1 (215) so that its sharp edge side will be caught by the spool head.
NOTE!
Do not push down spring seat more than 4 mm.
Figure 3
Assembly limit, washers
A. Sharp edge
4. Assemble return spring (335) into the casing.
 Assemble to original position.
Figure 4
Assembly, return spring
5. Assemble the No. 1 reducing valve into casing.

Figure 5
Assembly, No. 1 reducing valve
6. When installing the reducing valve sub assembly, take care that the lower part of the spool does not hit the casing
edge.
Figure 6
Installing the reducing valve subassembly
A. Do not strike casing edge.
7. Assemble bushing (223) onto spring seat (311) mounted in the casing.
Figure 7
Assembly, bushing
8. Carefully insert locking ring (221) into the casing bore with snap ring pliers.
 Assemble to the original position.

 Ensure the snap ring is horizontal.
 Take care not to damage the casing bore.
Figure 8
Assembly, locking ring
9. Align the locking ring assembly jig 2 with the casing bore, and press the return spring with bushing so that the
locking ring is correctly assembled.
 Take care not to damage the inside of casing.
Figure 9
Press the return spring
10. Assemble check ball (225) into the bushing.
Figure 10
Assembly, check ball
11. Assemble spring seat (218) into the bushing.

Figure 11
Assembly, spring seat
12. Assemble damping spring (336) into casing.
Figure 12
Assembly, damping spring
13. Assemble damping spring (337) into casing.

 Take care that damping springs (336, 337) are not entangled.
Figure 13
Assembly, damping spring
14. Assemble piston (224).

Figure 14
Assembly, piston
15. Assemble o-ring (212) onto plug (202).
Figure 15
Assembly, o-ring
16. Assemble NHU packing seal (210), scraper (211) and o-ring (212) into plug (202).
 Note the direction of seal and scraper when assembling.

 Apply grease thinly onto seal and scraper before assembling.
Figure 16
NHU packing seal
A. NHU packing
Figure 17
Assembly, NHU packing seal
17. Assemble grease cap (203) onto plug.
Figure 18
Assembly, grease cap
18. Insert push rod (214) into plug (202).
 Apply hydraulic oil onto the surface of the push rod before assembling.
 Take care not to damage the lip of the seal and scraper when assembling.
Figure 19
Assembly, push rod
19. Install the push rod subassembly of step no. 13, 14, 15, 16 into the casing.
Figure 20
Assembly, push rod subassembly
20. Attach bushing (412) to cover (201) by use of special tool, and press-fit by tapping lightly.
 Take care that the bushing edge does not protrude inside.
Figure 21
Assembly, bushing
21. Assemble the cover onto housing (101).

 Keep damping springs (336, 337) and the cover properly aligned.
Figure 22
Assembly, cover
22. Assemble the cover and tighten screws (271) to specified torque.
 Keep the cover horizontal during installation, ensure that there is no gap between the cover and casing.
Figure 23
Tightening screws to specified torque
23. Assemble set screw (471) and lock nut (472) to cam (420) temporarily.
Figure 24
Assembly, set screw and lock nut
24. Assemble cam (420) to the cover.
Figure 25
Assembly, cam
25. Insert camshaft (413) through cover (201) and cam (420).
Figure 26
Assembly, cam and cover
26. Apply loctite # 241 or equivalent onto the screw thread and tighten to the specified torque.
Figure 27
Applying, loctite
27. Tighten screw (423) to the specified torque.
Figure 28
Screw in, set screws
28. Make the upper surface of cam and lower surface of cover parallel by adjusting the height of set screw (471).
Tighten lock nut (472) to specified torque after making the clearance against push rod “0”.
 If the set screw is excessively tightened, play will occur in neutral.
Figure 29
Adjusting, the height of set screw
29. Apply grease onto top of push rod and top of plug by inclining the cam.
 When greasing, use a spatula of softer material to prevent scratching the surface of push rod and plug.
Figure 30
Applying, grease
30. Insert the upper part of bellows (501) into cam groove and then the lower part into cover groove.
 Before inserting the lower part of bellows into cover groove, spray anti-rust oil on the inner parts.
Figure 31
Spraying, anti-rust oil
31. If the bellows is inserted improperly or twisted, the anti-rust protection is significantly lowered.
Figure 32
Assembly, bellows
Service Information

Solenoid valve, description Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Solenoid valve, description

 Solenoid coil : An electronic coil to apply a force on the spool.
 Body : A main body with the flow passage and the port.
 Spool : Moved by solenoid coil and spring, and limits the flow passage of each port.
When power is supplied to a solenoid coil, an electro–magnetic force is formed and the spool in the guide is activated,
which pushes the spool and converts the oil flow passage while compressing the spring.
By the spool movements, the flow passage to each port is connected or disconnected, and if power is turned off, the spool is
returned by the spring force and each port also returns to the original condition.
These solenoid valves perform the following functions when activated.
1. Safety switch (limit switch) (A1)

2. 2-pump conflux selection for X1 (A2)
3. Main pressure boost (A3)
4. Travel speed selection (A4)
5. Optional device (A5)
6. Boom/arm conflux shut off (A6)
Machine serial number
Place of manufacture, serial number

Korea China
~ 12744 ~ 30177
Figure 1
Solenoid valve block
1 Body 6 Retainer C 11 O-ring

2 Spool A 7 Rod 12 O-ring
3 Spool B 8 Solenoid guide 13 O-ring
4 Spring C 9 Solenoid coil 14 Plug
5 Plug 10 Nut 15 Name plate

Korea China
12745 ~ 30178 ~
80001 ~
Figure 2
1 Body 7 Solenoid guide 13 Plug

2 Spool B 8 Solenoid coil 14 Pin
3 Spring C 9 Nut 15 Name plate
4 Plug 10 O-ring 16 Plug
5 Retainer C 11 O-ring 17 O-ring (A1 port only)
6 Rod 12 O-ring 18 O-ring (A1 port only)
Safety lever lock (A1)

Servo hydraulic safety lever lock function : when the left control console safety lever is moved to the operate position, the
switch is turned ON, directing the primary servo hydraulic pressure at port P1 to A1, and then to the remote control valve
control valves.
When the lever is moved to the lever lock position the switch is turned OFF, and the spring force moves the solenoid valve
spool, making it impossible to operate all the implement levers and travel system levers.
2-pump conflux selection for X1 (A2)
Activating the switch allows the servo hydraulic oil to flow to port a of main control valve and close center bypass valve, then
P1 pump oil and P2 pump oil are supplied to the option spool.
Main relief valve pressure boost (A3)
When the digging unit boost pressure switch is pressed, solenoid valve A2 is activated and port P2 is opened to port A2. The
servo hydraulic pressure from port A2 raises the relief pressure of the main relief valve.
Travel speed selection (A4)
When the 2–speed travel switch is pressed, solenoid valve A3 is activated routing primary servo hydraulic pressure at port P2
to A3, shifting to the travel valve to 1st/2nd automatic speed change position.
Optional device (A5)
When the selection switch is pressed solenoid valve A1 is activated and routes primary servo hydraulic pressure to the main
control valve to operate an optional digging unit.
Boom/arm conflux shut off valve (A6) (Fine mode)
Activating the switch allows the servo hydraulic oil to flow to port dr1 of main control valve and open center bypass valve,
then P1 pump oil is supplied to arm and P2 pump oil is supplied to boom.
 The center bypass valve opens to the negative line, and reduces the output of each pump.
Service Information

Solenoid valve, description Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Solenoid valve, description

 Solenoid coil : An electronic coil to apply a force on the spool.
 Body : A main body with the flow passage and the port.
 Spool : Moved by solenoid coil and spring, and limits the flow passage of each port.
When power is supplied to a solenoid coil, an electro–magnetic force is formed and the spool in the guide is activated,
which pushes the spool and converts the oil flow passage while compressing the spring.
By the spool movements, the flow passage to each port is connected or disconnected, and if power is turned off, the spool is
returned by the spring force and each port also returns to the original condition.
These solenoid valves perform the following functions when activated.
1. Safety switch (limit switch) (A1)

2. Main pressure boost (A2)
3. Travel speed selection (A3)
4. Boom/arm conflux shut off (A4)
5. Optional device (A5)
5 serial type
Figure 1
1 Body 7 Rod 13 O-ring

2 Spool A 8 Solenoid guide 14 Name plate
3 Spool B 9 Solenoid coil 15 O-ring
4 Spring C 10 Nut 16 O-ring
5 Plug 11 O-ring
6 Retainer C 12 O-ring
4 serial type
Figure 2
1 Body 6 Retainer C 11 O-ring

2 Spool A 7 Rod 12 O-ring
3 Spool B 8 Solenoid guide 14 Name plate
4 Spring C 9 Solenoid coil 15 O-ring
5 Plug 10 Nut 16 O-ring
Safety lever lock (A1)

Servo hydraulic safety lever lock function : when the left control console safety lever is moved to the operate position, the
switch is turned ON, directing the primary servo hydraulic pressure at port P1 to A1, and then to the remote control valve
control valves.
When the lever is moved to the lever lock position the switch is turned OFF, and the spring force moves the solenoid valve
spool, making it impossible to operate all the implement levers and travel system levers.
Activating the switch allows the servo hydraulic oil to flow to port a of main control valve and close center bypass valve, then
P1 pump oil and P2 pump oil are supplied to the option spool.
Main relief valve pressure boost (A2)
When the digging unit boost pressure switch is pressed, solenoid valve A2 is activated and port P2 is opened to port A2. The
servo hydraulic pressure from port A2 raises the relief pressure of the main relief valve.
Travel speed selection (A3)
When the 2–speed travel switch is pressed, solenoid valve A3 is activated routing primary servo hydraulic pressure at port P2
to A3, shifting to the travel valve to 1st/2nd automatic speed change position.
Boom/arm conflux shut off valve (A4) (Fine mode)
Activating the switch allows the servo hydraulic oil to flow to port dr1 of main control valve and open center bypass valve,
then P1 pump oil is supplied to arm and P2 pump oil is supplied to boom.
 The center bypass valve opens to the negative line, and reduces the output of each pump.
Optional device (A5)

When the selection switch is pressed solenoid valve A5 is activated and routes primary servo hydraulic pressure to the main
control valve to operate an optional digging unit.
Service Information

Solenoid valve, inspection Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Solenoid valve, inspection

 Use a sensory organ : By the sense of hearing or touch, check the solenoid valves for operating at switch ON.
 Coil continuity test : Check for coil damage by tester.
 Spool malfunction : In the event that the solenoid valve malfunctions and there is no electrical abnormality, the
spool may be stuck in the valve. Press the spool on the solenoid to check for spool sticking. Disassemble and clean
thoroughly, if damaged it must be replaced.
Figure 1
Inspection method
NOTE!
For hydraulic operation related information, see the hydraulic system.
Service Information

Solenoid valve, disassembly Service Information 2014/10/29
and assembly
Profile:
Solenoid valve, disassembly and assembly

Tools and torque
Tightening torque, unit : kgf·cm (lbf·ft)
Part name Tools Torque

Spring guide (5) 26 mm 1900 ± 50 (1646 ± 43)
Guide kit (8) 5 mm 70 ± 5 (61 ± 35)
Nut (10) 27 mm 55 ± 5 (61 ± 35)
Disassembly
Precautions
 All parts are precision fitted to very close tolerances therefore utmost care must be taken not to damage them
 Protect the parts from rusting prior to assembling, and check all surfaces for scratches, nicks and wear. Replace any
damaged part.
Disassembly procedure
1. Remove the spring guide and spring from the valve casing.
2. Unscrew the coil case nut and extract the solenoid coil.
3. Remove the guide kit, retainer and the spool.
4. Extract the spool slowly to avoid binding the spool lands in the valve casing.
Assembly
Precautions
 Follow the same precautions as disassembly.

 Minor scratches, nicks, and sharp edges may be polished with very fine emery or crocus cloth.
 Replace all O-rings.
 Lightly coat the O-rings with grease to hold them in place during assembly.
 Lubricate the spool prior to assembly.
 Upon completion of assembly, plug all ports to prevent contamination intruding into the valve.
Assembly procedure
1. Insert the spool and retainer.

2. Install the O-ring and guide kit.
3. Assemble the solenoid coil, O-ring and coil case.
4. Tighten the coil case nut to specified torque.
5. Install the spring and spring guide with a new O-ring.
6. Tighten the spring guide to specified torque.
Troubleshooting
For minor problems, see the following causes and corrective actions.
Troubleshooting
No. Problem Cause Remedy
1 Spool does not move. Solenoid voltage is low. Check the electric wiring.
Test the solenoid coil.
Solenoid coil is burnt. Replace the coil.
Spool spring is broken. Replace the spring.
Contamination in the casing. Check the circuit and hydraulic oil for
contamination, clean as required.
2 Leakage from coil case O-rings are damaged. Replace the O-rings.
or spring guide. Coil case nut, spring guide are loose. Tighten to specified torque.
Service Information

Solenoid valve, replacing Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Solenoid valve, replacing

Op nbr 914-091
NOTE!
WARNING
1. Place the machine in the service position B. See : 091 Service positions
Park the machine on a level surface, lower the bucket to the ground and stop the engine.
3. Connect vacuum pump. See 9111 Hydraulic oil tank, vacuum-pumping, connecting and disconnecting pump
NOTE!
Mark the solenoid valve block, wire harness connectors and hoses to indicate proper positioning during reassembly
4. Disconnect wire harnesses (1) from solenoid valve.
Figure 1
5. Remove hoses (2)
6. Remove screws (3)
7. Transfer fittings to a new solenoid valve block from the old solenoid valve block.
NOTE!
Replace O-rings with new ones.
8. Install the solenoid valve block.
9. Connect the hoses to the solenoid valve block.
10. Connect the wire harnesses.

11. Start the engine. Check for leaks and repair if needed.
Service Information

Hammer and Shears (X1 Service Information 2014/10/29
Line option), description
Profile:
EXC, EC290B LC [GB]
Hammer and Shears (X1 Line option), description

The hammer/shears equipment consists of single pedal, hammer/shears selector valve, flow control valve, solenoid valve,
shuttle and the hoses etc.
The information given in this manual shows a construction and explanation on the hammer/shears.
In regard to purchase parts and installation, contact your authorized Volvo Construction Equipment workshop.
When the machine is equipped with hammer/shears, an extra bracket must be installed. This bracket makes it possible to
gain access to the extra hydraulic controls that are required for hammer/shears. The bracket is supposed to be installed
behind the cab.
Figure 1
Hammer and shears, piping (1)
A Solenoid valve block E Shuttle valve K Block

B Remote control valve F Shuttle valve B type L Block
C Connector G Main control valve M Shuttle valve A type
D Solenoid valve and bracket I Block
Figure 2
Figure 3
Stop valve
Figure 4
Stop valve position
1. For scissors, crusher, shear, grap, titling and hammer

2. Not used
Single pedal stopper position

Figure 5
A. 2 way supply (scissors, crusher, shear, grap and titling)

B. 1 way supply (hammer)
C. Foot rest
Service Information

Solenoid valve for hammer Service Information 2014/10/29
and shear
Profile:
EXC, EC290B LC [GB]
Solenoid valve for hammer and shear
Figure 1
Solenoid valve for hammer and shear
1 Valve body 9 DC solenoid guide

2 Spool 10 Solenoid coil
3 Retainer - A 11 O-ring
4 Retainer - B 12 O-ring
5 Spacer 13 O-ring
6 Spring 14 O-ring
7 Nut 15 Name plate
8 Rod 16 Screw
Specifications, solenoid valve
Description Unit Specifications

Maximum operating pressure kgf/cm2 (psi ) 150 (2134)
Operating flow rate Liter/min (gal/min) 40 (10.6)
Internal leakage, at 50 kgf/cm2 and 20 cSt cc/min (cu·in/min) 70 (4.3)
Oil temperature ºC (ºF) -20 ~ 90 (-4 ~ 194)
Viscosity range cSt 5 ~ 500
Power source - D28G
Normal voltage DC V 28
Normal current A 1.0 at DC 28 V and 20 ºC
Service Information

2 pump flow piping Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
2 pump flow piping

Figure 1
2 pump flow piping for hammer & shear
1 From solenoid valve port "A2" 4 Pressure switch

2 To main control valve port "a" 5 From shuttle valve (1) port "5"
3 To solenoid valve "P2" 6 To shuttle valve (2) port "B"
Pressure adjustment for 2 pump flow

Figure 2
Pressure adjusting screw for 2 pump flow
1. Adjusting nut (tightening torque : 20 kgf·m, 144.4 lbf·ft)

2. Adjusting nut (tightening torque : 3.2 kgf·m, 23.1 lbf·ft)
3. Adjusting screw (tightening torque : 0.3 kgf·m, 2.2 lbf·ft)
4. Adjusting range (2 pump : 4.1 mm (0.16 "), 1 pump : -1.5 mm (-0.06"))
Service Information

Logic valve, description Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Logic valve, description
Figure 1
Logic valve for 2 pump flow
1 Valve body 10 Plug

2 Poppet 11 Spool
3 Poppet 12 Spring
4 Spring 13 O-ring
5 O-ring 14 Cover
6 O-ring 15 Screw
7 Back-up ring 16 Plug
8 Plug 17 Plug
9 O-ring
Specifications, logic valve
Description Unit Specifications

Maximum flow rate Litre/min (gal/min) 500 (132)
Maximum pressure kgf/cm2 (psi) 350 (4978)
Maximum pilot pressure kgf/cm2 (psi) 40 (569)
Operating pilot pressure range kgf/cm2 (psi) 2.8 ~ 12.3 (40 ~ 175)
Tightening torque
Item Unit Specifications

M12 kgf·m (lbf·ft) 10 ± 1 (72 ± 7)
PF 1 33 ± 2 (238 ± 14)
PF 3/8
Service Information

Hammer and Shears (X1 Service Information 2014/10/29
Line option), hydraulic
circuits
Profile:
EXC, EC290B LC [GB]
Hammer and Shears (X1 Line option), hydraulic circuits

See 990 Hydraulic diagram, with option components.
Service Information

Adjustable boom and Service Information 2014/10/29
cylinder, specifications
Profile:
EXC, EC290B LC [GB]
Adjustable boom and cylinder, specifications
Figure 1
2nd cylinder
Unit Dimension
A mm (in) 1850 (72.8)
B mm (in) 3150 (124.0)
Weight kg (lbs) 315 (694.5)
Figure 2
1st boom
Unit Dimension
A mm (in) 3150 (124.0)
Weight kg (lb) 1167 (2572.8)
Figure 3
2nd boom
Unit Dimension
A mm (in) 3150 (124)
B mm (in) 1086 (42.8)
Weight kg (lbs) 1129 (2489)
Service Information

Adjustable boom (1st Service Information 2014/10/29
boom), description
Profile:
EXC, EC290B LC [GB]
Adjustable boom (1st boom), description
Figure 1
1st boom structure (1)
1 Pin (pivot of boom cylinder rod) 5 Pin

2 Pin (pivot of boom cylinder tube) 6 2 mm gap (nut + lock pin)
3 Pin (pivot of boom rear) 7 Dust seal
4 Pin 8 Bushing
Gap and shims

Position Gap (mm) Necessary for max. gap
Min. Max. Shim part No. ( 1t ) Quantity Shim part No. ( 0.5t ) Quantity
Gap 1 + 0.25 + 0.9 – – – –
Gap 2 + 1.0 + 2.5 1173 – 02310 1 1173 – 02320 1
Gap 3 0.0 + 2.0 1173 – 01630 1 1173 – 01390 1
Gap 4 + 0.4 + 0.8 – – – –
Gap 5 + 0.5 + 2.5 1173 – 02000 2 – –
Figure 2
1st boom structure (2)
1 Pipe (1st boom rear bearing - right) 4 Pipe (1st boom cylinder rod - right)
2 Pipe (1st boom rear bearing - left) 5 Grease nipple
3 Pipe (1st boom cylinder rod - left)
Initial lubrication table (unit : cc)
Sign Initial grease amount Position

GR 1 70 × 2 = 140 Boom rear bushing
GR 2 125 × 2 = 250 Boom cylinder rod
GR 3 9 2nd boom cylinder tube
GR 4 16 × 2 = 32 1st boom cylinder tube
NOTE!
Grease hose / bearing inner space included.
NOTE!
Grease : High strength grease including MOS2 3%.
Service Information

Adjustable boom (2nd Service Information 2014/10/29
boom), description
Profile:
EXC, EC290B LC [GB]
Adjustable boom (2nd boom), description
Figure 1
2nd boom structure (1)
1 Pin
2 Dust seal
3 Bushing
4 Pin
5 Pin
Gap and shims
Position Gap (mm) Necessary for max. gap

Min. Max. Shim part No. ( 1t ) Quantity Shim part No. ( 0.5t ) Quantity
Gap 1 + 0.5 + 2.5 1173 – 02000 2 – –
Gap 2 + 0.5 + 2.5 1173 – 00180 1 1173 – 00190 1
Gap 3 + 0.4 + 0.8 – – – –
Figure 2
2nd boom structure (2)
1 Pipe (pivot bearing of 2nd boom)

2 Pipe (arm cylinder tube)
Initial lubrication table (unit : cc)
Sign Initial grease amount Position

GR 1 9 Boom bearing (right)
GR 2 9 2nd boom cylinder rod
GR 3 150 Arm cylinder tube
GR 4 9 Boom bearing (left)
NOTE!
Grease hose / bearing inner space included.
NOTE!
Grease : High strength grease including MOS2 3%.
Service Information

Adjustable boom, hydraulic Service Information 2014/10/29
line
Profile:
EXC, EC290B LC [GB]
Adjustable boom, hydraulic line

Figure 1
Hydraulic line for adjustable boom
1 Hose (to plate ’4’) 8 Adjustable boom valve ’a’ (to pedal ’2’)
2 Hose (to plate ’2’) 9 Block (1) ’P2’
3 Hose (to plate ’3’) 1 Main control valve ’Px3’
0
4 Hose (to plate ’1’) 1 Main control valve ’a’
1
5 Adjustable boom valve ’Pi’ (to main control valve ’Pg1’) 1 Shuttle valve (2) ’c’
2
6 Adjustable boom valve ’c’ (to block (3) ’2’) 1 Block (3)
3
7 Adjustable boom valve ’b’ (to pedal ’1’) 1 Plate (3)
4
Service Information

Adjustable boom valve, Service Information 2014/10/29
description
Profile:
EXC, EC290B LC [GB]
Adjustable boom valve, description
Figure 1
Adjustable boom valve, structure
1 Shuttle valve 7 Cover

2 Check valve 8 Housing
3 Boom holding check valve 9 Poppet B
4 Cover 10 Piston A
5 Spool 11 Poppet D
6 Relief valve 12 Check valve C
Spool in neutral position

NOTE!
pi (servo hydraulic signal): OFF
The position of piston A and poppet B become as shown in the following figure, and passage (5) and (6) will be isolated by
poppet B. As chamber (1) is connected to chamber (2) through orifice (4), pressure Pc is obtained. As poppet D is closed
because section area d1 > d2, chamber (2) and (3) are completely isolated.
Figure 2
Adjustable boom, valve spool in neutral position
A. Piston A
B. Poppet B
C. Check valve C
D. Poppet D
E. Servo hydraulic signal port
F. Tank port
G. From port P
Spool operating, boom raising (Pv > Pc)

NOTE!
pi (servo hydraulic signal): OFF
Main control valve spool moves to the right, the oil from the pump flows to chamber (3). As chamber (1) is connected to
chamber (2) through orifice (4), pressure (Pc) is obtained and poppet D opens. The high pressure oil is supplied to the
cylinder piston side.
Figure 3
Adjustable boom valve, boom raising
A. Piston A
B. Poppet B
C. Check valve C
D. Poppet D
F. Tank port
G. From port P
Spool operating, boom lowering (Pv < Pc)

NOTE!
pi (servo hydraulic signal): ON
As chamber (3) is connected to the tank passage by the main control valve spool moving to the left, servo hydraulic pressure
(pi) applied at signal port E, moves piston A upward and the oil opens poppet (B). The oil flows to chamber (3) through
passage (5), (6) and check valve C.
Therefore, pressure Pc is applied to the area difference (d1 - d2) and opens poppet D. The oil from the cylinder piston side
flows to the tank passage.
Figure 4
Adjustable boom valve, boom lowering
A. Piston A
B. Poppet B
C. Check valve C
D. Poppet D
F. Tank port
G. From port P
Service Information

Single pedal stopper Service Information 2014/10/29
position
Profile:
EXC, EC290B LC [GB]
Figure 1
A. Adjustable boom control

B. Foot rest
C. Screw (tightening torque : 3.4 ±0.3 kgf·m, 24.6 ±2.2lbf·ft)
Service Information

Control pattern change Service Information 2014/10/29
valve, description
Profile:
EXC, EC290B LC [GB]
Control pattern change valve, description

Control pattern change valve is mounted at the front left of the air cleaner room. This valve makes it possible to change oil
flow direction by moving lever of the valve.
Figure 1
Control pattern change valve, servo hydraulic piping
1 Remote control valve (lever) 11 D: from remote control valve (lever - left) "4"
2 Control pattern change valve 12 BD: from control pattern selector valve "1"
3 1: to shuttle valve "BD" 13 BU: from control pattern selector valve "3"
4 4: to shuttle valve "AI" 14 BU1: to main control valve "br1"
5 3: to shuttle valve "BU" 15 BD1: to main control valve "ar1"
6 2: to shuttle valve "AO" 16 AI: from control pattern selector valve "4"
7 Connector (tightening torque : 5 0/-0.5 kgf·m) 17 AO: from control pattern selector valve "2"
8 A: from remote control valve (lever - right) "2" 18 AO1: to main control valve "bl3"
9 B: from remote control valve (lever - left) "2" 19 AI1: to main control valve "al3"
10 C: from remote control valve (lever - right) "4"
Sectional view
Figure 2
Structure, control pattern selector valve
1 Name plate 8 Screw

2 Lever 9 Washer
3 Plate 10 Rivet
4 Plate 11 Pin
5 Plate 12 O-ring
6 Collar 13 O-ring
7 Screw
Pattern change mode

When lever (2) of the valve moves from position S to B, remote control valve (lever) operates as follows:
Lever position Remote control valve (lever) Remarks

Position S ISO pattern
Position B Standard backhoe loader

pattern
Service Information

Control pattern selector Service Information 2014/10/29
valve, hydraulic circuits
Profile:
EXC, EC290B LC [GB]
Control pattern selector valve, hydraulic circuits

When control pattern selector valve (73) is operated to the "ISO position"
Figure 1
Hydraulic circuits, ISO position
Right control lever (23) - Boom operation

When control lever (23) is operated to the "BOOM RAISE", secondary oil from port 4 of remote control valve (lever) (23)
flows through port C to port 3 of control pattern selector valve (78), then through port BU & BU1 of shuttle valve (25), to
port br1 of main control valve (3), moving the boom spool to the right.
Now P1/P2 pump flow is routed through main control valve (3), to the piston side of boom cylinders (4), raising the boom.
Left control lever (22) - Arm operation
When control lever (22) is operated to the "ARM IN", secondary oil from port 4 of remote control valve (lever) (22) flows
through port D to port 4 of control pattern selector valve (78), then through port AI & AI1 of shuttle valve (25), to port al3 of
main control valve (3), moving the arm spool to the left.
Now P1/P2 pump flow is routed through main control valve (3), to the piston side of arm cylinder (5), moving the arm in.
When control pattern selector valve (73) is operated to the "Backhoe loader position"
Figure 2
Hydraulic circuits, backhoe loader position
Right control lever (23) - Arm operation

When control lever (23) is operated to the "ARM IN", secondary oil from port 4 of remote control valve (lever) (23) flows to
port C and to port 4 of control pattern selector valve (73), then through port Al & Al1 of shuttle valve (25), to port al3 of
main control valve (3), moving the arm spool to the right.
Now P1/P2 pump flow is routed through main control valve (3), to the piston side of arm cylinder (5), moving the arm in.
Left control lever (22) - Boom operation
When control lever (22) is operated to the "BOOM RAISE", secondary oil from port 4 of remote control valve (lever) (22)
flows through port D to port 3 of control pattern selector valve (73), then through port BU & BU1 of shuttle valve (18), to
port br1 of main control valve (2), moving the boom spool to the right.
Now P1/P2 pump flow is routed through main control valve (3), to the piston side of boom cylinders (4), raising the boom.
Service Information

Rotator pump, description Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Rotator pump, description

Model code (P315BB17FM1007L) - Machine serial no.: 10001 ~
Symbol Description
P315 Pump model
B Drive shaft: B - SAE ″B″ 13 teeth
B Mounting flange type: B - SAE ″B″ 2 screws
17 Displacement (cc/rev)
FM1007
L- Rotational direction
R: Clockwise
L: Counterclockwise
Figure 1
Rotator pump, structure
1. Suction port (1″ metric flange)

2. Discharge port (3/4″ metric flange)
3. Screw
Tightening torque:
 17 kgf·m (123 lbf·ft) for lubricated condition

 19.6 kgf·m (142 lbf·ft) for dry condition
Figure 2
Rotator pump, sectional view
1 Cover assembly (front) 6 Channel seal 11 Screw

2 Gear housing 7 Back-up seal 12 Washer
3 Cover assembly (rear) 8 Square seal 13 Name plate
4 Drive gear 9 Seal 14 Screw
5 Thrust plate 10 Dowel pin 15 Driven gear
Figure 3
Rotator pump, exploded view
Rotator pump, principle of operation
 The rotator pump is a gear pump attached to the PTO (Power Take Off) of the main pump. The rotator pump
consists of a gear housing (E), drive gear (A), and driven gear (B).
Figure 4
Rotator motor, operation
A. Drive gear
B. Driven gear
C. Suction side (low pressure)
D. Discharge side (high pressure)
 This pump has two mating gears that are turned in a closely fitted gear housing. Rotation of the drive gear causes
the other gear to turn. External gear pumps are positive fixed displacement rotary pumps. When the pump is
turned, the oil is trapped between the teeth of the gears and gear housing. Continued rotation of the gears forces
the constant amount of oil out of the pump. On the suction side, the teeth confine and carry the oil and a vacuum
is formed in the cavity between the teeth as they unmesh, causing oil to be drawn into the pump. Pressure rise in a
gear pump is produced by squeezing action on the oil as it is expelled from between the meshing gear teeth and
the gear housing.
Model code (G200 PUMP, 22.8 + 20.3 cc/rev) - Machine serial no.: 80001 ~
See 9113 Fan pump, description
Service Information

Rotator (X3 Line option), Service Information 2014/10/29
description
Profile:
EXC, EC290B LC [GB]
Rotator (X3 Line option), description

The rotator equipment consists of rotator valve, pump and the hoses. To obtain tank and servo pressure, the hydraulic hoses
are connected between pump and tank/rotator valve. The two feed/return hoses continue from rotator valve out to the
hydraulic device, the rotator.
Figure 1
Rotator, piping
1 Hose (to rotator valve port A) 6 To rotator port B

2 Hose (to rotator valve port B) 7 To rotator port A
3 Rotator pump 8 To return pipe
4 Clip 9 Port P
5 Rotator valve
Service Information

ports
Profile:
EXC, EC290B LC [GB]
Rotator (X3 Line option), ports

See 990 Hydraulic diagram, ports.
Service Information

hydraulic circuits and
principle of operation
Profile:
EXC, EC290B LC [GB]
Rotator (X3 Line option), hydraulic circuits and principle of operation

When solenoid valve (2) sol. b is operated ON
The oil from gear pump (2) P1 port is supplied to check valve (54). The hydraulic oil is supplied to rotator (R) port B, and
returns to port (T) through port A. Therefore rotator comes to rotate.
When solenoid valve (2) sol. a is operated ON
The hydraulic oil is supplied to rotator (R) port A, and returns to port (T) through port B. Therefore throw a rotator into
reverse.
Service Information

Overload warning device, Service Information 2014/10/29
operation
Profile:
EXC, EC240B FX, EC160B NLC, EC290B F, EC140B LCM, EC180B LC, EC240B LC, EC290B LC, EC140B LC, EC240B F,
EC290B FX, EC160B LC, EC290B NLC, EC700C L, EC700B LC, EC290B LR, EC240B LR, EC240B NLC [GB]
Overload warning device, operation

1. The overload warning device must be installed in the hydraulic line between the main control valve and the boom
cylinder large chamber (boom raise circuit).
2. When lifting the load using boom raise operation the pressure in the boom cylinder large chamber will increase.
When pressure in that line reachs the preset pressure of the pressure switch, the warning lamp in the cab will light.
WARNING
If the applied pressure is above the preset pressure lighting the warning lamp, lower the load immediately to
prevent the overturn of the equipment.
Service Information

Standard of the setting Service Information 2014/10/29
pressure
Profile:
Standard of the setting pressure

NOTE!
Overload warning device pressure switch installed at factory : 26.5 MPa (270 kgf/ cm2) (3840 psi) (265 bar).
1. Lifting load = Tipping load × 0.75

2. Allowance of the setting pressure = +0/-1 MPa (+0/-10 kgf/cm2) (+0/-142 psi) (+0/-10bar)
3. Base of the lifting load
 The load point is the fulcrum of the bucket in a curled position at 2m height from the ground.
 The attachment is perpendicular with the track frame and in the fully extended position.
Service Information

Checking and Adjusting Service Information 2014/10/29
procedure
Profile:
Checking and Adjusting procedure

Measurement procedure and pressure gauge connection port
1. The adjustment range is 2.94 ~ 34.3 Mpa (30 ~ 350 kgf/cm2) (426 ~ 4978 psi) (29 ~ 343 bar)
Figure 1
Pressure switch
1 Knob 4 Micro switch

2 Lock screw 5 Rod
3 Connector assembly 6 Connector
2. Loosen lock screw (2)
 Use allen wench 2.5 mm
3. By turning knob (1) one rotation the pressure varies 5.4 Mpa (56 kgf/cm2) (797 psi) (55 bar)
 To increase turn clockwise

 To decrease turn counterclockwise
4. Check and adjust the pressure switch

5. Tighten lock screw (2)
WARNING
Adjusting the setting pressure above the specification will cause the overturn of the equipment.
Service Information

Servo hydraulic line Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]

Figure 1
Adjustable boom, servo hydraulic line (1)
1 Solenoid valve A6 4 Main control valve dr1

2 Hydraulic oil tank Td1 5 Servo hydraulic select valve(1) Pi
3 Servo hydraulic select valve
Figure 2
Adjustable boom, servo hydraulic line (2)
6 Travel pedal ’P’, ’T’ 19 Servo hydraulic select valve (2) ’Pi’
7 Block (1) 20 Slew motor ’PG’
8 Pedal for adjustable boom ’T’ 21 Block (1) ’T6’
9 Pedal for adjustable boom ’P’ 22 Main control valve ’Px3’
10 Pedal for adjustable boom ’P’, ’T’ 23 Shuttle valve (2) ’C’
11 Shuttle valve (2) 24 Main control valve ’a’
12 From solenoid valve ’A2’ 25 Plate ’3’
13 To Block (3) ’3’ 26 Pressure switch
14 Servo hydraulic valve (2) ’T’ 27 Servo hydraulic valve ’A’
15 To main control valve ’dr6’ 28 Main control valve
16 Servo hydraulic select valve (2) ’P’ 29 Main control valve ’Pg1’
17 Block (3) 30 To accumulator block (S1)
18 Servo hydraulic valve 31 Plate ’4’
Port connection
Component (From) Port Component (To) Port Remarks

Pedal for adjustable boom 1 Plate 2 2nd boom up
2 Plate 1 2nd boom down
P Block (1) P4
T Block (1) T4
Servo hydraulic valve for adjustable P Slew motor PG
boom (1) A Main control valve Px3
Pi Block (3) 1
T Block (1) T6
Main control valve Pg1 Plate 4
Block (3) 2 Plate 3
3 Main control valve a
Shuttle valve (2) C
Servo hydraulic valve for adjustable P Solenoid valve A6
boom (2) A Main control valve dr1
Pi Servo hydraulic valve (1) Pi
T Hydraulic oil tank Td1
Service Information

Boom float position, Service Information 2014/10/29
hydraulic circuits
Profile:
EXC, EC290B LC [GB]
Boom float position, hydraulic circuits

WARNING
When operating control levers after converting pattern change valve from the "ISO Position" to the "Backhoe
Position", the operation for boom and arm will be changed. Exercise extreme caution when using the control levers
until you are familiar with the control pattern.
Figure 1
Hydraulic circuits, boom float position
Boom float position

When control lever (15) is operated to the "BOOM FLOAT", secondary servo oil from port 2 of remote control valve (lever)
(23) flows to port BD & BD1 of shuttle valve (25).
Servo oil from port BD1 flows to:
– port P on solenoid valve (75)
– ports 2 & 3 of block (75A) to port Pi of line rupture valve (37).
The servo oil at port Pi of each line rupture valve (31), shifts the valve spool allowing oil flow from each boom cylinder piston
side, through the line rupture valves to port A of the boom float position valve (74).
When the boom float switch integrated into remote control valve (lever) (23) is depressed (ON position), the spool in
solenoid valve (75) moves downward and servo oil from port P, flows through port A to port Pi of boom float position valve
(74) moving the spool downward to create conflux flow at ports A, B, & T.
The hydraulic oil flow from each boom cylinder rod side is routed to port B of the boom float position valve.
The return oil flow routed to the hydraulic tank is connected to port T of the boom float position valve.
The hydraulic oil from P1/P2 pumps, flows to tank through the central passage of the boom spool in the main control valve.
Therefore, the oil from the boom cylinders piston side and rod side, and the tank return oil, merge creating conflux flow on
both sides of each cylinder piston. Since no pressurized oil is fed into the boom cylinder circuit, the free flow of oil between
the rod and piston side of the cylinder is influenced only by the up & down movement of the bucket and boom as it moves
over the ground surface following the contours of the terrain.
NOTE!
For boom raising, do not depress the boom float switch.
Service Information

Power Take Off (PTO, Service Information 2014/10/29
option), description
Profile:
Power Take Off (PTO, option), description
Figure 1
Power take off (option)
1. Tube
2. Banjo screw, tightening torque : 4 kgf·m (28.9 lbf·ft)
3. Power take off
4. Screw, tightening torque : 4.1 ±0.4 kgf·m (29.6 ±3 lbf·ft)
5. O-ring
6. Coupling tube
7. Oil pipe
8. Copper gasket
9. Screw
10. Screw
11. Copper gasket
12. O-ring
NOTE!
Rotating direction of PTO : Clockwise (view from the fan side)
Service Information

Disassembly and assembly, Service Information 2014/10/29
general
Profile:
EXC, EC290B LC [GB]
Disassembly and assembly, general

General, precautions

Assembly, precautions
 Rework damaged parts, polish minor burrs, nicks, score marks or sharp edges with fine emery and crocus cloth.
Prepare all replacement parts.
 Replace the seals, o-rings and back-up rings.
Service Information

Adjustable boom valve, Service Information 2014/10/29
disassembly
Profile:
EXC, EC290B LC [GB]
Adjustable boom valve, disassembly

Op nbr
Figure 1
Adjustable valve holder
NOTE!
Material: Brass
NOTE!
For assembly, reverse the disassembly procedures.
NOTE!
When disassembling, mark each part to indicate original location and position during assembly.
Disassembly, main spool

NOTE!
When reassembling, make sure that the o-ring is installed before assembling the cover.
 Allen wrench 8 mm
 Tightening torque: 5 kgf·m (36 lbf·ft)
Figure 2
Removal, cover
2. Pull out the spool sub assembly.

NOTE!
Pull out the spool slowly confirming the housing condition.
Figure 3
Removal, spool
3. Hold the spool with the holder and vise, and loosen spool cap (3).
NOTE!
Remove the oil from the spool and the holder.
 Tightening torque: 6 kgf·m (43.3 lbf·ft)
Figure 4
Loosen the spool cap
Figure 5
Spool cap
4. Remove spool cap (3), spring guide (4), spring (5) and spacer (6).
Figure 6
Disassembly, relief valve
5. Loosen sleeve (1) and remove the cartridge.
 Spanner 32 mm
Figure 7
Removal, cartridge
6. Remove cap (2) and pull out spring (3) and servo hydraulic poppet (4).
 Spanner 27 mm
Figure 8
Removal, servo hydraulic poppet
Figure 9
Disassembly, servo hydraulic poppet
7. Remove servo hydraulic seat (5) and pull out spring (6, 7), piston (8) and main poppet (9).
Figure 10
Removal, main poppet (1)
Figure 11
Removal, main poppet (2)
Disassembly, boom holding valve
8. Main body poppet
A. Remove screw (1) and valve assembly.

NOTE!
When reassembling, make sure that the o-ring is installed on the housing inlet before assembling the
valve.
B. Remove cap (2) and pull out spring (3) and poppet (4).
 Spanner 32 mm
Figure 12
Removal, poppet
Figure 13
Removal, valve assembly
9. Selector valve
A. Remove cap (5) and pull out spring (6) and poppet (7).
 Spanner 8 mm
Figure 14
Removal, poppet
Figure 15
Removal, spring
B. Remove cap (8) and pull out spring (9).
C. Pull out sleeve (13) by tapping the right side of the housing lightly.
10. Check valve

Remove cap (10) and pull out spring (11) and check valve (12).
Figure 16
Removal, check valve
Disassembly, shuttle valve
11. Remove screw (A) and cover (B).

NOTE!
When reassembling, make sure that the o-ring is installed on the housing inlet before assembling the cover.
Figure 17
Removal, cover
12. Remove cap (1) and pull out shuttle seat (2) and steel ball (3).
Figure 18
Shuttle valve
Figure 19
Removal, steel ball
Disassembly, check valve
13. Remove cap (1) and pull out spring (2) and check valve (3).
 Spanner 32 mm
Figure 20
Check valve
Figure 21
Removal, spring
Service Information

Tool attachment, Service Information 2014/10/29
adjustment
Profile:
EXC, EC290B LC [GB]
Tool attachment, adjustment

Remove any shims between the screw holder and mating plates.
Hook the bucket on and lock it in accordance with the instructions for installing a bucket or tool.
Check the lock wedge position and the way the attachment butts up against the mating plates. Then calculate any
adjustment to the plate shims as follows;
Put in thicker shims if the locking wedge goes too far into the hook.
Put in thinner shims if the locking wedge does not go far enough into the hook.
Remove the bucket or tool in accordance with the instructions for removing a bucket or tool.
Figure 1
Tool attachment, adjustment
1. Bucket/tool
2. Screw holder
3. Spacer
4. Tool attachment
Fit the required number of shims beneath the mating plates, then re-install the bucket or tool.
Check that the locking wedge position is in accordance with the specified tolerances.
Measure and install the required number of shims between the screw holder and the mating plates. Tension the mating
plates with the required number of fastening screws.
Figure 2
Adjustment using shims
1. Shims
2. Bucket hook
3. Lock wedge
NOTE!
All mating plates and adjustment screws must be adjusted to give a good fit.
Service Information

Rotator pump, disassembly Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Rotator pump, disassembly

Precautions

Disassembly
NOTE!
 Tool: Socket wrench 19 mm
3. Remove rear cover assembly (3) from gear housing (2).

NOTE!
Do not draw out dowel pins (10) from rear cover assembly (3).

5. Pull out drive gear (4) and driven gear (15).
NOTE!

NOTE!
7. Turn front cover assembly (1) and remove seal (9).

NOTE!
See 9113 Fan pump, disassembly
Service Information

Rotator pump, assembly Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Rotator pump, assembly

1. Install new seal (9) to front cover assembly (1).

NOTE!
Coat the lip of the seal with grease. Be careful not to damage the lip of the seal.
2. Place the cover on the workbench with the input shaft side of front cover assembly (1) downward.
NOTE!
NOTE!
4. Install channel seals (6) and back-up seals (7) in thrust plate (5).
NOTE!
Figure 1
Installation, channel seals and back-up seals

NOTE!
Pay attention to the direction of thrust plate (5). The U-shape of the thrust plate must face towards discharge side
(B).
Figure 2
A. Suction side
B. Discharge side
6. Assemble drive gear (4) and driven gear (15).

NOTE!
Be careful not to damage the lip of seal (9) by the shaft splines.
9. Tighten screws (11) and washer (12) to the specified torque.
 Tightening torque: 17 ± 0.5 kgf·m (123 ± 4 lbf·ft)
10. Check if shaft will rotate smoothly by hand.

If not rotating accordingly, disassemble and check.
See 9113 Fan pump, assembly
Service Information

Rotator pump, parts Service Information 2014/10/29
inspection
Profile:
EXC, EC290B LC [GB]
Rotator pump, parts inspection

Parts inspection

Gear housing
deep.
Gear
 Existence of scoring, grooving,  Replacement when damage.
nicking and fretting etc on gear
 Existence of wear of seal contact area  Replacement when the seal contact area is
worn more than 0.05 mm (0.002 in).
Thrust plate
more than 0.05 mm (0.002 in).
 Existence of scratch, erosion and  Replacement when damaged.
pitting
Seals
Service Information

Rotator valve, adjustment Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Rotator valve, adjustment

Measuring condition
 Engine speed: high idle

 Oil temperature when measuring: 50 ~ 60 °C (122 ~ 140 °F)
WARNING
Main relief valve, adjustment
 Stop the machine on even ground and block the rotator of the left and right rotation.
 Remove the plug from port (G) and connect oil pressure gauges (600 kgf/cm2, 8530 psi) to the gauge port (G).
 Start the engine, and operate the hydraulic rotator (left or right rotation).
 Loosen lock nut (2), and turn adjusting screw (1) as follows: To increase pressure, turn clockwise.
 Set the main relief valve pressure to 150 ± 2 kgf/cm2 (2134 ± 28 psi).
Figure 1
1. Adjusting screw
2. Lock nut
3. Main relief valve
4. Port relief valve (A port)
5. Port relief valve (B port)
6. Solenoid valve
 Stop the machine on even ground and block the rotator of the left and right rotation.
 Remove the plug from port (G) and connect oil pressure gauges (600 kgf/cm2, 8530 psi) to the gauge port (G).
 Start the engine, and operate the hydraulic rotator (left or right rotation).
 Adjust the main relief pressure higher than port relief valve pressure (180 ± 2 kgf/cm2, 2560 ± 28 psi).
 Loosen lock nut (2), and turn adjusting screw (1) as follows: To increase pressure, turn clockwise.
 Set the port relief valve pressure to 180 ± 2 kgf/cm2 (2560 ± 28 psi).
 After completion of adjustment, reset the main relief valve (3) pressure (150 ± 2 kgf/cm2, 2134 ± 28 psi).
Service Information

Control pattern selector Service Information 2014/10/29
valve, ports
Profile:
EXC, EC290B LC [GB]
Control pattern selector valve, ports

Hydraulic ports
Component Port Component Port Remarks

Control pattern selector valve A Remote control valve (lever) - right 2
B Remote control valve (lever) - left 2
C Remote control valve (lever) - right 4
D Remote control valve (lever) - left 4
1 Shuttle valve BD Boom lower
2 AO Arm out
3 BU Boom raise
4 AI Arm in
Service Information

Hydraulic quickfit, 924 Service Information 2014/10/29
description
Profile:
EXC, EC290B LC [GB]
Hydraulic quickfit, description

The quickfit attachment consists of a flat assembly plate, which is fitted to the arm end and bucket link. There are two hooks
(6) on the plate, for the front shafts (2) on the bucket.
There is a lifting hook (3) on the quickfit attachment. With the bucket removed, the permitted load increases and the
operator’s field of vision is improved.
The quickfit attachment is equipped which a double acting hydraulic cylinder. The quickfit lock wedge (4) is fitted to its
piston rod. Servo pressure acts on the piston side of the lock cylinder, locking the bucket in place against the rear hook (5).
This means that the lock wedge adjust itself and provides gap-free locking.
When the lock wedge (4) is released, the servo pressure is transferred to the piston rod side. If necessary, the release
pressure can be increased by loading the bucket cylinder in its end position.
Figure 1
Hydraulic quickfit, install
1. The red marker

2. Bucket shaft
3. Lifting hook
4. Locking wedge
5. Bucket rear hook
6. Tool attachment hook
There is a red marker (1) on the left side of the quickfit attachment, which is folded in when the lock wedge is in the locked
position and folded in when the lock wedge is in the locked position and folded out when the lock wedge is released.
Figure 2
Quickfit, structure (1)
1 Quickfit bucket assembly (1.2 m3) 6 Spacer

2 Screw 7 Shim
3 Special screw 8 Shim
4 Shim 9 Spacer
5 Shim
Figure 3
1 Quickfit weld assembly 12 Copper gasket

2 Hydraulic cylinder 13 Copper gasket
3 Lock wedge 14 Hose assembly
4 Pin 15 Hose assembly
5 Split pin 16 Elbow
6 Stay 17 Elbow
7 Screw 18 Nut
8 Nut 19 Nut
9 Plain washer 20 Quickfit cover
10 Connector 21 Screw
11 Connector 22 Spring washer
Figure 4
1 Connector (to quickfit valve ’B’) 10 Hose assembly (to main control valve ’Po’)
2 Connector (to quickfit valve ’A’) 11 O-ring
3 Nut 12 Connector
4 Nut 13 Hose assembly (to return pipe ’T2’)
5 Connector 14 Connector
6 Connector 15 Hose assembly ((to quickfit cylinder ’B’)
7 Connector 16 Hose assembly (to servo block ’P6’)
8 Copper gasket 17 Hose assembly (to quickfit cylinder ’A’)
9 Copper gasket
NOTE!
P6 : from the quickfit valve ’PS’.
Figure 5
1. Pipe assembly (to quickfit valve A)

2. Pipe assembly (to quickfit valve B)
Figure 6
1 Pipe assembly (to quickfit valve B) 6 O-ring
2 Pipe assembly (to quickfit valve A) 7 Pipe assembly (to quickfit valve B)
3 Hose assembly (to quickfit valve A) 8 Pipe assembly (to quickfit valve A)
4 Hose assembly (to quickfit valve B) 9 Connector
5 Connector 10 O-ring
Figure 7
Clearance for fixing pin
1 2 mm clearance (nut + locking pin)

Gap1 Below 2.5 mm maximum
Figure 8
Quickfit valve
1. Screw
2. Quickfit valve
3. Solenoid valve
4. Plate
5. Screw
Service Information

Quickfit system, operation 924 Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Quickfit system, operation

Solenoid valve: OFF
In the case of solenoid valve (6) is turned OFF,
 The hydraulic oil from servo pump (7) flows

Pi of safety solenoid valve (9) → PS of quickfit valve (5) → check valve (8) → shuttle valve (3) → solenoid valve (6) →
port A of quickfit valve (5) → check valve (2) → piston side of quickfit cylinder (1)
 The hydraulic oil from the piston rod side flows
Port B of solenoid valve → solenoid valve (6) → hydraulic oil tank (T)
Figure 1
Quickfit system, solenoid valve : OFF
X ON Y OFF
Solenoid valve: ON
In the case of solenoid valve (6) is turned ON,
 The hydraulic oil from servo pump (7) flows
1. Pi of safety solenoid valve (9) → PS of quickfit valve (5) → check valve (8) → shuttle valve (3) → solenoid
valve (6) → press up servo valve (4)
2. Quickfit valve (B) → open the check valve (2) → rod side of the quickfit cylinder (1)
 The oil of the piston side of the quickfit cylinder flows

Check valve (2) → port A of quickfit valve (5) → solenoid valve (6) → hydraulic oil tank (T)
 The oil from the main pump flows (as the servo valve (4) was moved upward):
Port P3 of quickfit valve (5) → servo valve (4) → shuttle valve (3) → solenoid valve (6) → port B of quickfit valve (5) →
rod side of quickfit cylinder (1)
Figure 2
Quickfit system, solenoid valve: ON
X ON Y ON
Service Information

Cylinder, description 970 Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Cylinder, description
Figure 1
Cylinder (With both cushion, sectional view)
Figure 2
Cylinder (exploded view)
1 Tube 8 Retaining ring 15 Seal 22 O-ring
2 Bushing 9 Expander ring 16 Back-up ring 23 Seal
3 Rod 10 Piston 17 Seal 24 Wear ring
4 Bushing 11 Lock washer 18 Seal 25 Seal
5 Head 12 Lock nut 19 Back-up ring 26 Seal
6 Bushing 13 Screw 20 O-ring 27 Pin
7 Retaining ring 14 Grease nipple 21 Back-up ring 28 Cushion spool
NOTE!
Coat the screws of the head with Three Bond 1360K (or equivalent).
By construction the hydraulic cylinder consists largely of cylinder tube (1), piston (10) that reciprocates in it, piston rod (3)
that takes the movement of the piston, and head (5) that serves as a head/guide. The cylinder tube (1) and the piston rod (3)
has a clevis, a trunnion or a flange to mount the cylinder assembly.
Packing, seals and bushing are used in the moving part or on the mounting part between piston (10) and cylinder tube (1),
between piston rod (3) and head (5) and between cylinder tube (1) and head (5).
Figure 3
Structure, cylinder
Operation of cylinder with cushion

If pressurized oil is fed alternatively to the oil inlet and outlet provided in the cylinder, force acts on the piston which in turn
causes piston rod (3) to extend and retract.
Cushion on rod side
If moving piston (10) strikes head (5) without deceleration, impact results. A cushioning mechanism is provided to prevent it,
as shown in following figure.
When the piston is in its intermediate stroke with the head side under pressure, the oil in chamber “A” passes through path
“B” at a constant velocity and returns to the tank. Then if expander ring (7) plunges into path “B” before the stroke end, the
oil in chamber “A” goes through clearance “D”.
As a result the oil flow returning to the tank decreases sharply which in turn reduces the moving speed of the piston.
Figure 4
Cushion action on rod side
A Chamber T Tank
C Expander ring 5 Head
D Clearance 7 Expander ring
S Stroke
Cushion on piston side

In the same way as the construction of the rod side cushion, the oil passes through path “B” at a constant velocity and goes
back to the tank when the piston is at its intermediate stroke with the rod side under pressure.
Next, if cushion spool (9) plunges into path “B” before the stroke end, the oil goes only through clearance (A) between pass
“B” and cushion spool (9). As a result the oil flow returning to the tank decreases sharply which in turn reduces the speed of
the piston.
Figure 5
Cushion action on piston side
9 Cushion spool
A Clearance
T Tank
Service Information

Cylinder, troubleshooting 970 Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Cylinder, troubleshooting
Troubleshooting
Trouble Faulty part Cause Remedy

Oil leaks past the sliding Rod packing
surface of piston rod. (Oil  Contamination caught in  Remove contamination.
ring forms on piston rod the bore.
and drips).
 Flaw on the inner face,  Replace packing.

outer face and lip of
packing.
A. Oil leaks from

here  Other irregularity of  Replace packing as
packing. required.
Buffer ring
 Contamination caught in  Remove contamination.
the bore of buffer ring.
 Flaw on the bore of buffer  Replace buffer ring.

ring.
 Other irregularity of buffer  Replace buffer ring.

ring.
Dust seal
 Contamination caught on  Remove contamination.
the bore of dust seal.
 Flaw on the bore of dust  Replace dust seal.

seal.
 Other irregularity on dust  Replace dust seal.

seal.
Piston rod
 Flaw on the sliding surface  Smooth the sliding surface
of piston rod. with fine emery cloth. If
the leakage persists the
piston rod may be
damaged.
Disassemble and inspect
the rod. If damaged
replace the piston rod.
 Hard chromium plating has  Replate

peeled off.
O-ring
 O-ring is damaged.  Replace o-ring.
Back-up ring
A. Oil leaks from  Back-up ring is damaged.  Replace back-up ring.
here
Oil leaks from welds Cylinder tube

 Welds of cylinder are  Replace cylinder tube.
fractured.
A. Welds
Cylinder drift Piston packing

 Contamination is caught on  Remove contamination.
the sliding surface of slide
ring. NOTE!
Replace the seal kit to prevent
repeated maintenance due to
different durability of parts.
 Flaw on the sliding surface  Replace slide ring.

of slide ring.
 Other irregularity of slide  Replace slide ring.
ring.
Service Information

Cylinder, troubleshooting 970 Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Cylinder, troubleshooting
Troubleshooting
Trouble Faulty part Cause Remedy

Oil leaks past the sliding Rod packing
surface of piston rod. (Oil  Contamination caught in  Remove contamination.
ring forms on piston rod the bore.
and drips).
 Flaw on the inner face,  Replace packing.

outer face and lip of
packing.
A. Oil leaks from

here  Other irregularity of  Replace packing as
packing. required.
Buffer ring
 Contamination caught in  Remove contamination.
the bore of buffer ring.
 Flaw on the bore of buffer  Replace buffer ring.

ring.
 Other irregularity of buffer  Replace buffer ring.

ring.
Dust seal
 Contamination caught on  Remove contamination.
the bore of dust seal.
 Flaw on the bore of dust  Replace dust seal.

seal.
 Other irregularity on dust  Replace dust seal.

seal.
Piston rod
 Flaw on the sliding surface  Smooth the sliding surface
of piston rod. with fine emery cloth. If
the leakage persists the
piston rod may be
damaged.
Disassemble and inspect
the rod. If damaged
replace the piston rod.
 Hard chromium plating has  Replate

peeled off.
O-ring
 O-ring is damaged.  Replace o-ring.
Back-up ring
A. Oil leaks from  Back-up ring is damaged.  Replace back-up ring.
here
Oil leaks from welds Cylinder tube

 Welds of cylinder are  Replace cylinder tube.
fractured.
A. Welds
Cylinder drift Piston packing

 Contamination is caught on  Remove contamination.
the sliding surface of slide
ring. NOTE!
Replace the seal kit to prevent
repeated maintenance due to
different durability of parts.
 Flaw on the sliding surface  Replace slide ring.

of slide ring.
 Other irregularity of slide  Replace slide ring.
ring.
Service Information

Digging unit, maintenance 970 Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Digging unit, maintenance

Clearance between pins and bushing
Figure 1
Clearance, pin and bushing
Wear limits (unit : mm)
Check item Standard Pin diameter Bushing bore Remedy

Recommended service Recommended service
limit limit
A Boom mounting 100 99 101 Replace
B Boom cylinder mounting pin 90 89 91 Replace
C Boom cylinder rod end pin 90 89 91 Replace
D Arm cylinder mounting pin 80 79 81 Replace
E Boom–arm coupling pin 100 99 101 Replace
F Arm cylinder rod end pin 80 79 81 Replace
G Bucket cylinder mounting pin 80 79 81 Replace
H Arm–link coupling pin 90 89 91 Replace
I Bucket–arm coupling pin 90 89 91 Replace
J Bucket cylinder rod end pin 90 89 91 Replace
K Bucket–link coupling pin 90 89 91 Replace
Greasing
Lubricating point
Figure 2
Lubricating position
Lubricating period
Lubricating period
Standard Option
Every 50 hours (A) Every 50 hours (A)
Every 50 hours (B, C, D) Every 500 hours (B, C, D)
NOTE!
In swamp working condition, oil film may be destroyed due to submersion. Shorten the lubrication hours by 1/5.
NOTE!
Lubricating period is affected by the external working environment. Lubricate pin and bushing with grease as soon as
possible when abnormal noise occurs.
NOTE!
Failure to do this may damage bushing and pin.
Service Information

Cylinder, disassembly and 970 Service Information 2014/10/29
assembly
Profile:
EXC, EC290B LC [GB]
Cylinder, disassembly and assembly

Precautions
 When reinstalling a hydraulic cylinder it is essential to bleed the air from the cylinder.
 Observe the following procedure :
1. Run engine at low idle speed.

2. Operate cylinder retraction and extension 4 ~ 5 times.
Do not operate to the end of the stroke, but stop about 100 mm (4 in) from the end of the stroke.
(Do not relieve at the end of stroke.)
3. Operate cylinder 4 ~ 5 times to the end of stroke. After completing above procedure, run the
engine for normal working conditions and start actual work operation.
 When storing the hydraulic cylinder for more than 1 month, coat the cylinder rod with grease to protect the chrome
plated area from rust (Oxidization).
 Clean the packing with hydraulic oil.
Other oils shorten packing life.
 Coat grease on pins and bushings.
 Excessive temperatures of a paint drying booth can affect cylinder packing and seals, resulting in cylinder failure or
oil leaks.
 Paint overspray on a cylinder rod can damage the wiper seal, allowing contamination into the cylinder assembly.
Prior to painting wrap the exposed chrome plating and after completion of painting clean the rod thoroughly.
 Salt water and materials containing chlorides or acids can cause the chrome plating to peel, pit or rust.
Daily, upon completion of work, clean the cylinder rod and apply an anti–corrosive.
 Traverse loading of a cylinder rod (bending) or excessive vibration can damage the cylinder head dry bushing, wiper
seal and the rod chrome plating, resulting in an oil leak and the ingression of contamination.
 High pressure washers can force dirt and water under the wiper seal lip, contaminating the cylinder. Always keep
the spray nozzle at an angle of 45° or greater to the rod.
General tools
Tools and jigs
Tool/Jig Remark
Hammer Steel hammer
Wooden or plastic mallet
Screwdriver Large and small sizes
Chisel Flat chisel, Punch
Vise One having an opening wide enough to hold the tube mounting pin (clevis).
Wrench Hook wrench
Allen wrench
Torque wrench
Extension pipe for wrenches
Spatula Metallic one with rounded corners.
Gimlet A sharp–point tool may be used in place of a gimlet.
Jig For fitting seal ring
For holding seal ring
For inserting piston rod bushing
For pressing in seal.
Rust remover Sand paper
Measuring Slide calipers
instruments Micrometer
Cylinder gauge
V-block
Special tools
Dust wiper seal
Dust wiper seal, unit : mm
Part No. φA φB φC φD N M L Application

8920–01310 121 109 0/-0.5 104 95 depth 35 5 45 50 Boom
8920–01320 133 121 0/-0.5 116 105 depth 35 5 45 50 Arm
8920–01330 121 109 0/-0.5 104 95 depth 35 5 45 50 Bucket
Figure 1
Dimension, dust wiper seal
Cylinder dry bushing (head)

Cylinder dry bushing , unit : mm
Part No. φA φB φC φD φE O N M L Application

8920–01250 125 101 95 80 depth 137 100 40 72 45 157 Boom
8920–01260 135 111 105 90 depth 137 110 40 72 45 157 Arm
8920–01270 125 101 95 80 depth 137 100 40 72 45 157 Bucket
Figure 2
Dimension, cylinder dry bushing
Preparation before disassembly

Before disassembly, clean working area and facilities.
Work area
The following working area is required for disassembly :
Sufficient space
For disassembly of the hydraulic cylinder, the cylinder head and the piston rod must be extracted.
Therefore, the first prerequisite is that the working area must have sufficient space for such work. It is also necessary that the
area have ample space widthwise to accommodate disassembly, cleaning and measuring facilities.
Suitable working environment
The hydraulic cylinder is a precision machined product incorporating seals and packing made of rubber and plastic materials.
For this reason, care should be used so that the hydraulic cylinder is free from dust, dirt, sand, metal chips, weld slag and
other contaminants. If the hydraulic cylinder is assembled with hard particles stuck on the cylinder tube and piston rod, the
tube inner surface and the rod surface will be scratched as the cylinder operates, thereby disabling it. Damage to the piston
seals and the rod seals will result in oil leaks. For this reason, grinding and welding should be avoided near the working area
to keep it clean.
Apparatus
The following equipment is required for disassembly :
Hoist or crane
The hoist or crane must be capable of carrying the cylinder in an assembled condition. It must also be capable of making
level and linear movement under load for inserting and extracting the piston rod.
Work bench
The work bench must have strength and rigidity capable of accommodating the total length of the cylinder in its most
retracted condition and of withstanding the rotary force of the tightening torques of the cylinder head and the piston nut.
Support stand
If the piston rod is fully extended in a free condition, the bushing and the seals may be damaged as the bushing and the
piston are twisted due to the weight of the rod. A stand is required to support the rod to prevent such damage.
Hydraulic source
A hydraulic source is required for disassembly and assembly of the rod, piston nut and for oil leak tests after completion of
assembly.
Compressed air source
It is used for drying after oil draining and cleaning of the cylinder.
Cleaning tank, cleaning solvent
Oil pan and oil reservoir
An oil pan is necessary to contain oil drained from the cylinder and spilt during work. An oil reservoir is required to collect oil
spilt on the floor and waste oil.
Others
Oil extracting hoses, wooden skids, rags and absorbent for absorbing oil are also necessary.
External cleaning
Prior to bringing a hydraulic cylinder into the workshop thoroughly steam clean it to remove all mud, grease etc.
NOTE!
The cylinder described below is the cushion type, however, check the construction of the cylinder with the parts catalogue
when disassembling and servicing the cylinder.
Discharging oil
Place wooden blocks on the workbench to support the cylinder, and clamp it in a vise to prevent it from rotating.
Push/pull the piston rod till all hydraulic oil in the cylinder is drained out. At this time, connect a suitable hose to each port
to drain the hydraulic oil into a container.
Figure 3
Discharging, oil
1 V - Block 4 Oil pan

2 Port B 5 Port A
3 Wood
Cylinder, disassembly
Op nbr 00000
Disassembly of piston rod and cylinder head assembly
1. Disassemble the cylinder head assembly from the cylinder tube.
1. Remove mounting screws of cylinder head assembly.

2. Disassemble piston rod and cylinder head assembly from cylinder.
 When piston rod and cylinder head unit are removed, hydraulic oil in the cylinder will drain out.
Place a proper container under the cylinder head.
 If it is difficult to remove, pull the piston rod from the cylinder by rotating it slightly.
Figure 4
Disassembly, cylinder head
1. Cylinder head assembly

2. Mounting screw
2. Place the piston rod and cylinder head assembly on the supporting block and remove the piston nut with driver
and hook wrench.
NOTE!
Unscrew lock nut clockwise.
Figure 5
Disassembly, piston rod from cylinder
1. Cylinder
2. Sling
3. Piston rod
3. After removing the piston nut, remove the piston assembly, cushion spool and cylinder head assembly.
NOTE!
Be careful not to damage the rod seal, or the piston rod thread when removing the cylinder head assembly. Rotate
the piston assembly counterclockwise to disassemble.
Figure 6
Disassembly, cylinder head assembly
1. Cylinder head
2. Piston assembly
3. Piston nut
4. Expander ring
Disassembly of piston assembly

NOTE!
Do not remove contami, seal, wear ring and packing, if not damaged.
4. Remove wear ring from the piston.
Figure 7
Disassembly, piston
1 O-ring 4 Wear ring

2 Piston 5 Seal
3 Seal
5. Remove O-ring, seal, packing and expander ring.

NOTE!
Do not reuse wear ring and, seal after removal.
Disassembly of cylinder head assembly

NOTE!
Do not remove seal, back-up ring and dust wiper, if not damaged.
6. Do not reuse removed seals. When reassembling, replace the bushing with a new one if worn.
NOTE!
Do not remove bushing if not damaged. If removed, replace the bushing with a new one when reassembling.
Figure 8
Disassembly, cylinder head
1 Dust wiper 5 Seal

2 Seal 6 Back-up ring
3 Dry bushing 7 Snap ring
4 Cylinder head
Inspection after disassembly

Visually inspect all parts after cleaning for excessive wear, cracks and other faults.
Inspection item
Part Section Fault Remedy

Piston rod Neck of rod eye. Presence of crack. Replace.
Weld on rod eye. Presence of crack. Replace.
Stepped part to which piston Presence of crack. Replace.
is attached.
Threads. Presence of seizure. Recondition or replace.
Bend. Measure degree of bend
Plated surface. Check that :
Plating is not worn off to base Replace or replate.
metal.
Rust is not present on plating. Replace or replate.
Scratches are not present. Recondition, replate or replace.
Rod. Wear of outer diameter. Recondition, replate or replace.
Bushing at mounting part Wear of outer diameter. Replace.
Cylinder tube Weld on bottom. Presence of crack. Replace.
Weld on head. Presence of crack. Replace.
Weld on hub. Presence of faults. Replace if oil leakage or bypassing
is evident.
Tube interior. Wear on inner surface. Replace.
Cylinder head Bushing. Wear on inner surface. Replace.
Flaw on inner surface. Replace if flaw is deeper than
coating.
Repair method
Check all seals and parts to see that they do not show excessive damage and wear.
For correction of faults on the piston rod, observe the following procedure:
 Correct fine longitudinal scratches with an oilstone. Replace the piston rod if the scratch is so deep that it may be
caught by your nail.
 In case of a smooth indentation, recondition by removing the sharp area around the indentation with an oilstone : if
the flaw or the indentation is excessive, replace or replate the piston rod.
NOTE!
Always regrind after replating. The thickness of the plating must be minimum 0.25 mm (0.010 in).
NOTE!
If the plating is removed to the base metal during reconditioning with an oilstone, the rod must be replated.
Limit of serviceability
Clearance between piston rod and rod bushing
Replace the bushing if the clearance between the piston rod and rod bushing exceeds 0.25 mm (0.010 in).
Bend of piston rod
The allowable bend of the rod is maximum 1mm/m (0.040″).
For measurement, support both ends of the parallel section of the piston rod with V-blocks, set a dial indicator in the center
between the two V-blocks, turn the piston rod, and read the difference between the maximum and minimum oscillations on
the dial indicator
Figure 9
Measurement, bend
Bend limit
Spacing between V–blocks Intermediate value in dial indicator readings × 1/2 Remedy
1 m (3′3″) 1 mm (0.040″) Replace
NOTE!
If the bend is within the above limit, the cylinder may not operate smoothly because of localized bend. Beware of it during
function test after assembly. Replace the rod if the cylinder makes an abnormal sound or does not operate smoothly.
Cylinder, assembly
Installation of cylinder head seals.
Op nbr 00000
NOTE!
To prevent damage of the seal when inserting it, check for sharp edges on the mounting grooves for the seal and dust
wiper. If any, remove sharp edges with an oilstone.
Figure 10
Removal, sharp edge
1. Splinter
2. Oilstone
1. Press the dry bushing into the head and install the retaining ring.
Figure 11
Assembly, dry bushing
1. Dry bushing
2. Press
3. Jig
2. Apply hydraulic oil on the inner diameter of cylinder head and mounting grooves.
Figure 12
Applying, grease
A. Apply grease
3. Install the step seal with care to the direction.
Figure 13
Assembly, step seal
1. Seal
2. Back-up ring
3. Seal
4. Install the seal with care to the direction.
Figure 14
Assembly, seal
1 Retaining ring 6 Back-up ring

2 Wiper seal 7 Retaining ring
3 Back-up ring 8 Back-up ring
4 Seal 9 O-ring
5 Dry bushing
5. Install back-up ring to groove B by pressing against inner diameter D. Make sure that the bias edge of installed
back-up ring is not overlapped.
Figure 15
Assembly, back-up ring
1. Back-up ring
6. Using the jig, assemble the dust wiper seal into head.
Figure 16
Assembly, dust wiper seal
1. Jig
2. Dust wiper seal
7. Install retaining ring into the head.

NOTE!
Use jig made of copper, aluminium or plastic, and be careful of sharp edges on the jig. Insert the packing by hand
not with the jig, if possible.
Figure 17
Assembly, retaining ring
1. Retaining ring
8. Install O-rings and back-up rings.

NOTE!
Take care to the position of back-up ring.
Figure 18
Assembly, O-ring and back-up ring
1. O-ring
2. Back-up ring
Assembly of piston unit

NOTE!
Check for sharp edges at piston ring groove.
If any, remove sharp edge with an oilstone.
Figure 19
Assembly, piston unit
1 Back-up ring 4 Wear ring

2 Piston 5 Seal
3 Seal
Figure 20
Removal, sharp edges
1. Splinter
2. Oilstone
9. Apply hydraulic oil to locations A.

Figure 21
Applying, hydraulic oil
10. Assemble the cushion ring into the center groove of piston.
(A piston packing set consists of one cushion ring and one piston packing).
Figure 22
Assembly, cushion ring
11. Assemble the piston packing on the cushion ring.
Figure 23
Assembly, piston packing
12. Assemble wear ring to piston.
Figure 24
Assembly, wear ring
1 O-ring 4 Back-up ring

2 Wear ring 5 Seal
3 Seal
13. Assemble seal to piston.
14. Assemble O-ring into the inner side of piston.

Replacement of piston rod and cylinder tube bushing
Figure 25
Removal, bushing
1 Bushing 4 Base
2 Metal piece X Push with press
3 Piston rod
NOTE!
If necessary to replace bushing, remove the bushing in the same method as figure, and replace with new one.
15. Mount the piston rod on the work table and press–fit the bushing using a press.
Figure 26
Assembly, bushing
1 Seal 3 Press jig

2 Grease nipple 4 Bushing
16. Assemble seal in the both ends of bushing.
17. Assemble the grease nipple.
Figure 27
Assembly, seal and grease nipple
1 Hammer 3 Grease nipple
2 Press jig 4 Seal
18. Assemble the cylinder tube in the same method.
Figure 28
Assembly, cylinder tube
1. Grease nipple
2. Tube
Assembly of piston rod and head assembly
19. Mount the piston rod on the work table and be careful not to damage chrome plated sliding surface of rod.
Figure 29
Assembly, head
1. Head
20. Install head assembly to piston rod using a head guide.

NOTE!
Be careful not to damage the rod seal on the piston rod thread.
21. Assemble expander ring to piston rod.
Figure 30
Assembly, expander ring
1. Head
2. Expander ring
22. Assemble piston assembly to piston rod.

NOTE!
Take care not to damage the O-ring inside the piston.
Figure 31
Assembly, piston assembly
1 Head 3 Piston
2 Expander ring 4 Hook wrench
23. Tighten the piston using a hook wrench to the specified torque.
NOTE!
For the cylinder with cushion spool (ex : Arm cylinder), see the cushion valve mounting cylinder.
Figure 32
Tightening, piston
1 Head 3 Lock nut

2 Lock washer 4 Expander ring
24. Assemble the lock washer, and tighten the lock nut.
NOTE!
Be careful of the tightening direction of lock nut (left hand thread). See tightening torque.
25. After tightening lock nut, bend the lock washer to both directions to be fixed at the groove of the piston and lock
nut.
NOTE!
Tighten the piston clockwise and the piston lock nut counterclockwise to specified torques.
Assembly of piston rod and cylinder tube
26. Insert the piston rod assembly into the cylinder tube.
 Take care not to damage the piston seal when assembling.

 The piston rod and cylinder tube must be kept parallel.
Figure 33
Insertion, piston rod assembly
1. Tube
 Carefully insert the head so as not to damage the O-rings.
Figure 34
Insertion, head
1. head
 Align the screw holes of cylinder tube and head, and tighten to the specified torque.
Cushion valve mounted cylinder
27. Assemble the cushion spool and lock pin in the end groove of piston rod.
 Place the hole of lock pin upward and install the lock pin.
Figure 35
Assembly, cushion spool
1 Cushion spool 4 Piston

2 Expander ring 5 Lock pin
3 head
28. Assemble the lock washer and tighten lock nut to the specified torque.
Figure 36
Assembly, lock nut
1 Cushion spool 4 Head

2 Lock nut 5 Piston
3 Expander ring 6 Lock washer
29. Bend the lock washer to the left and right direction into the groove of the piston and lock nut.
30. Check the cushion spool for movement.

Play : 0.2 mm (0.0079″)
Figure 37
Playing limit
Inspection after assembly

No load functional test
Place the cylinder level under no load.
NOTE!
Do not raise the hydraulic pressure above the maximum pressure of the machine circuit.
NOTE!
Grease coated on the O-rings and seals of the head may ooze out. Wipe it off and retest the cylinder.
Leak test
1. Apply a test pressure to the retracting and extending sides of the cylinder for three minutes independently, and
check that the rod section and the welds have no external leaks. For an internal leak test, connect the cylinder as
shown in Figure.
Figure 38
External leak test
A. Hydraulic cylinder
B. Control valve
C. Pump
2. After completing the test, install a plug to each port.
Figure 39
Internal leak test
A. Measure the internal leak

B. From main control valve
NOTE!
For storage, place the cylinder on wooden V-blocks and bring the cylinder to the most retracted position.
Figure 40
Storage method
A. Plug
B. Cylinder assembly
C. Plug
Service Information

Boom, description Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Boom, description
Figure 1
Structure, boom (unit : mm)
1 Shim (φ150 × φ82 × 1.0t) 10 Shim (φ165 × φ92 × 1.0t) 19 Washer

2 Shim (φ150 × φ82 × 0.5t) 11 Shim (φ165 × φ92 × 0.5t) 20 Seal (φ115 × φ100 × 8t)
3 Bushing (φ150 × φ100 × 100L) 12 Pin (φ90 × 215L) 21 Pin (φ100 × 585L)
4 Shim (φ200 × φ102 × 1.0t) 13 Screw 22 Pin (φ100 × 952L)
5 Lock (φ150 × φ90 × 40t) 14 Screw 23 Plate
6 Pin (φ90 × 898L) 15 Screw 24 Spacer (φ140 × φ90 × 10t)
7 Pin (φ80 × 252L) 16 Nut P1 Pivot of boom cylinder rod
8 Shim (φ150 × φ92 × 0.5t) 17 Washer P2 Pivot of boom cylinder tube
9 Shim (φ150 × φ92 × 1.0t) 18 Washer P3 Pivot of boom rear
Gap and shims
Items Gap Necessary shims for maximum gap

Position Minimum Maximum Quantity (1t) Quantity (0.5t)
GAP 1 +0.25 +0.9 – 1
GAP 2 +1.0 +2.5 1 1
GAP 3 0.0 +2.0 1 1
GAP 4 +0.5 +2.5 1 1
GAP 5 0.4 +0.8 – –
Initial lubricating table (unit : cc)
Position Initial grease amount Location

GR 1 70 × 2 = 140 Boom rear bushing
GR 2 125 × 2 = 250 Boom cylinder rod
GR 3 150 Arm cylinder tube
GR 4 16 × 2 = 32 Boom cylinder tube
NOTE!
Grease hose/bearing inner space included.
Service Information

Boom, removal Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Boom, removal
Op nbr 97413
WARNING
When the engine is running, the hydraulic line is under high pressure. Stop the engine, and release the residual
pressure by operating the control lever.
1. Hold boom cylinder with hoist (27), remove lock screw (28) and cylinder rod pin lock collar (29). Disconnect
lubrication hose (30), and remove pin (31).
Figure 1
Removal, lock screw and cylinder rod pin lock collar
2. Put boom cylinder on wooden block (A).
Figure 2
Position, block
3. Disconnect working lamp connector.

Disconnect arm and bucket cylinder connecting hoses (25), and plug the hoses.
4. Remove boom mounting pin lock screw (26).
Figure 3
Removal, boom mounting pin lock screw
5. Hold boom with hoist, and remove boom mounting pin (34) with sliding hammer (B). Raise the boom, travel
machine backward, and lower boom safely.
Figure 4
Removal, boom mounting pin
Service Information

Boom, installation Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Boom, installation
Op nbr 97414
1. Align superstructure hole with boom mounting pin hole using hoist, and install boom mounting pin (34) with
hammer.
Figure 1
Installation, boom
2. Tighten boom mounting pin lock screw (26).
3. Insert new O-rings (35) to the arm and bucket cylinder connecting hoses (25), and tighten.
4. Connect the working lamp connector.
Figure 2
Installation, boom
Service Information

Boom lifting cylinder, Service Information 2014/10/29
description
Profile:
EXC, EC290B LC [GB]
Boom lifting cylinder, description

See 970 Cylinder, description.
Machine serial number: 10001 ~
Figure 1
Boom lifting cylinder, sectional view
1 Tube 8 Screw 15 Rod seal 22 Back-up ring

2 Rod 9 Retaining ring 16 Back-up ring 23 Piston seal
3 Head cover 10 Lock washer 17 Buffer seal 24 Wear ring
4 Bushing 11 Lock nut 18 Back-up ring 25 Contamination seal
5 Piston 12 Set screw 19 O-ring
6 Cushion ring 13 Pellet pad 20 Back-up ring
7 Retaining ring 14 Wiper seal 21 O-ring
Figure 2
Boom lifting cylinder, sectional view
1 Tube 7 Retaining ring 13 Wiper seal 19 Back-up ring

2 Rod 8 Screw 14 Rod seal 20 O-ring
3 Head cover 9 Retaining ring 15 Back-up ring 21 Back-up ring
4 Bushing 10 Lock washer 16 Buffer seal 22 Piston seal
5 Piston 11 Lock nut 17 Back-up ring 23 Wear ring
6 Cushion ring 12 Set screw 18 O-ring 24 Contamination seal
NOTE!
Coat the screws of the head with Three Bond 1360K (or equivalent).
Service Information

Profile:
EXC, EC290B LC [GB]
Boom lifting cylinder, disassembly and assembly

Precautions
See 970 Cylinder, disassembly and assembly.
General tools
Special tools
Tightening torque
Figure 1
Tightening torque
A B C D
Piston nut, to tighten turn Lock nut, to tighten turn Set screw Screw
clockwise counterclockwise
M 70 M 65 M8 M 16
35 ± 5 (253 ± 36) 15 ± 3 (108 ± 22) 1.0 ± 0.2 (7.2 ± 1.4) 26.7 ± 2.7 (193 ± 19)
Figure 2
Tightening torque
A B C D
Piston nut, to tighten turn Lock nut, to tighten turn Set screw Screw
M 70 M 65 M8 M 16
97 ± 9.7 (703 ± 70) 61 ± 6.1 (444 ± 44) 1.2 ± 0.12 (8.9 ± 0.9) 26.7 ± 2.7 (193 ± 19)
NOTE!
Apply three bond 1360K or loctite #242 to the rod and screw thread before tightening.
Volume of oil leakage

Oil leakage
Volume of internal oil leakage

5.6 cc (0.34 cu·in) or less / 10 min.
Maintenance standards
Figure 3
Wear limit
Wear limit, unit : mm
Item Standard Tolerance Standard Clearance limit

value Shaft Hole clearance
Clearance between piston rod 95 – 0.036 – 0.195 0.096 0.585

and bushing (1) ~ – 0.090 ~ – 0.060 ~ 0.285
Clearance between piston rod 90 – 0.036 – 0.257 0.206 1.0
pin and bushing (2) ~ – 0.090 ~ – 0.170 ~ 0.347
Clearance between rear end pin 90 – 0.036 – 0.257 0.206 1.0
and bushing (3) ~ – 0.090 ~ – 0.070 ~ 0.347
Disassembly
Assembly
Service Information

troubleshooting
Profile:
EXC, EC290B LC [GB]
Boom lifting cylinder, troubleshooting

See 970 Cylinder, troubleshooting.
Service Information

Boom cylinder, replacing Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Boom cylinder, replacing

Op nbr 974-021
1. Park the machine on level, firm ground. Secure enough space around the machine.
WARNING
When the engine is running, the hydraulic line is under high pressure. Stop the engine, and release the
residual pressure by operating the control lever.
NOTE!
Disconnect hose, and stop with plug for preventing oil leakage and contamination.
2. Disconnect grease hose (30) of boom cylinder rod.
3. Hold one boom cylinder with hoist (27).
4. Remove lock screw (28) and lock collar (29). And then push pin (31) to opposite side and remove it from cylinder
rod.
Figure 1
Removal, pin
5. Retract boom cylinder rod fully.
6. Lower boom cylinder (34) on block (A) with hoist (27).
7. Disconnect boom cylinder hose (32).
8. Remove lock plate of boom cylinder mounting pin and pin (33).
Figure 2
Removal, boom cylinder
9. Lift boom cylinder (34), and lower to work bench safely.
10. Remove boom cylinder pipe and clamp, and install them to new boom cylinder.
NOTE!
B: 93 ±9.8 Nm (9.5 ±1 kgf m) (69 ±7 lbf ft), Lotite 275
11. Install boom cylinder (34).
12. Connect boom cylinder hose (32).
13. Push pin (31) of boom cylinder rod, and install lock collar (29) and lock screw (28).
14. Connect boom cylinder grease hose (30).
Figure 3
Installation, boom cylinder
Service Information

Dipper arm, description Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Dipper arm, description
Figure 1
Structure, dipper arm (unit : mm)
1 Shim 10 Spring washer

2 Shim 11 Bushing (φ100 × φ125 × 100L)
3 Pin with bracket (φ80 × 252L) 12 Bushing (φ90 × φ105 × 80L)
4 Pin with lock (φ90 × 485L) 13 Bushing (φ90 × φ110 × 100L)
5 Pin with bracket (φ80 × 242L) 14 Seal
6 Plate 15 Seal
7 Screw 16 Seal
8 Screw 17 Shim
9 Nut 18 Shim
Gap and shims

Position Minimum Maximum Shim part No.(1t) Quantity Shim part No.(0.5t) Quantity
GAP 1 0.0 +1.0 – – – –
GAP 2 +0.5 +2.5 1173–00180 1 1173–00190 1
GAP 3 +0.5 +2.5 1173–01210 1 1173–01330 1
Initial lubricating table
Position Location Initial grease amount (cc)

GR 1 Boom bearing (left) 64
GR 2 Arm cylinder rod 66
GR 3 Boom bearing (right) 122
GR 4 Bucket cylinder tube 28
GR 5 Front bearing (yoke) 1200
GR 6 Front bearing (bucket) 5
NOTE!
Service Information

Dipper arm, removal Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Dipper arm, removal

Op nbr 97511
WARNING
When the engine is running, the hydraulic line is under high pressure. Stop the engine, and release the residual
pressure by operating the control lever.
1. Roll in arm (15) completely, and put blocks at points (A).
Figure 1
Removal, arm cylinder lock plate
2. Remove arm cylinder lock plate (16), and pin (17).
3. After starting the engine, retract arm cylinder rod (18).
Figure 2
Removal, boom-arm connecting pin
4. Remove lock screw (19) and boom-arm connecting pin (20).
5. Start the engine and slowly raise the boom.

NOTE!
Ensure the arm is securely blocked. Take appropriate safety measures.
Service Information

Dipper arm, installation Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Dipper arm, installation

Op nbr 97512
1. Move arm (15) with hoist, and put a block at point (A).
Figure 1
Installation, dipper arm
2. Align boom and arm pin hole. Insert pin (20), and install lock screw (19).
3. Extend arm cylinder (18) to align with rod pin hole.
4. Insert pin (17), and install lock plate (16).

Service Information

Bucket operation Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Bucket operation
Bucket pin direction, description
NOTE!
Be advised that Yoke, Connecting, Yoke pin, Bucket cylinder rod pin, Bucket pin and Bucket link direction shouldn’t be
switched.
Figure 1
Bucket pin direction, structure
1. Bucket pin
2. Bucket link pin
3. Yoke pin
4. Bucket cylinder rod pin
The Pin (A, B, C and D) should be assembled as shown In the picture (Pin has to be assembled from left to right side).
Service Information

Bucket operation Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Bucket operation
Bucket pin direction, description
NOTE!
Be advised that Yoke, Connecting, Yoke pin, Bucket cylinder rod pin, Bucket pin and Bucket link direction shouldn’t be
switched.
Figure 1
Bucket pin direction, structure
1. Bucket pin
2. Bucket link pin
3. Yoke pin
4. Bucket cylinder rod pin
The Pin (A, B, C and D) should be assembled as shown In the picture (Pin has to be assembled from right to left side).
Service Information

Link, description Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Link, description
Figure 1
Link, structure
1. Screw
2. Nut
3. Shim
4. Shim
5. Pin with lock
Gap and shims

GAP1 +1.0 +2.5 1173–00180 1 1173–00190 1
GAP2 +2.0 +3.0 1173–00180 2 1173–00190 1
NOTE!
Maximum gap : 1.0 mm
Initial lubricating table (unit : cc)
Nipple Initial grease amount Location

GR1 12 Bucket cylinder rod
GR2 12 × 2 Connecting rod + yoke
GR3 12 × 2 Connecting rod + bucket
NOTE!
Service Information

Dipper arm connecting rod, Service Information 2014/10/29
replacing
Profile:
EXC, EC290B LC [GB]
Dipper arm connecting rod, replacing

Op nbr 975-024
Figure 1
Removal, link pin
2. Lower attachment for bottom of bucket reaching to ground fully.
3. Remove lock screw (1) of bucket link pin, and remove link pin (2) and code ring (3).
4. Retract bucket cylinder rod fully, and fix cylinder rod.

Figure 2
Replacing, connecting rod
5. Hold connecting rod (6) with hoist.
6. Remove lock screw (4) of connector link pin, and remove link pin (5) and connecting rod (6).
7. Mount new connecting rod (6) with link pin (5), and tighten lock screw (4).
8. Install code ring (3), link pin (2) and lock screw (1).
NOTE!
Clearance between lock screw nut and yoke plate is approximately 2 mm (0.079 inch).
Service Information

Connecting rod yoke, Service Information 2014/10/29
replacing
Profile:
EXC, EC290B LC [GB]
Connecting rod yoke, replacing

Op nbr 975-028
Figure 1
Replacing, connecting rod yoke
3. Hold connecting rod (1) with hoist.
4. Remove lock screw (2) of connector link pin, and remove link pin (3) and yoke (4).
5. Mount new yoke (4) with link pin (3), and tighten lock screw (2).
NOTE!
Clearance between lock screw nut and yoke plate is approximately 2 mm (0.079 inch).
Service Information

Dipper arm cylinder, Service Information 2014/10/29
description
Profile:
EXC, EC290B LC [GB]
Dipper arm cylinder, description


Korea China
~ 12927 ~ 30177
Figure 1
Dipper arm cylinder (With both cushion, sectional view)

5 Head cover 12 Lock nut 19 Back-up ring 26 Seal
6 Bushing 13 Screw 20 O-ring 27 Pin
NOTE!
Apply the screws (13) of the head cover (5) with "Three bond 1360K" (or equivalent).

Korea China
12928 ~ 30178 ~
Figure 2
Dipper arm cylinder (With both cushion, sectional view)
1 Tube 8 Pin 16 Wiper seal 23 O-ring

2 Rod 9 Retaining ring 17 Rod seal 24 Back-up ring
3 Bushing 10 Screw 18 Back-up ring 25 Piston seal
4 Head cover 11 Retaining ring 19 Buffer seal 26 Wear ring
5 Cushion ring 12 Lock washer 20 Back-up ring 27 Contamination seal
6 Piston 13 Lock nut 21 O-ring
7 Cushion plunger 14 Set-screw 22 Back-up ring
NOTE!
Apply the screws (10) of the head cover (4) with "Loctite #277".
Service Information

replacing
Profile:
EXC, EC290B LC [GB]
Dipper arm cylinder, replacing

Op nbr 975-025
WARNING
NOTE!
2. Disconnect grease hose (1) of arm cylinder rod.
Figure 1
Removal, pin of arm cylinder rod
3. Remove lock plate (3) of arm cylinder rod pin and pin (2).
4. Retract arm cylinder rod (4) fully, and fix cylinder rod (4).
Figure 2
Fixing, arm cylinder rod
5. Hold arm cylinder (10) with hoist (9).
6. Disconnect arm cylinder grease hose (5).
7. Disconnect arm cylinder hoses (6).
8. Remove arm cylinder lock plate (7), and mounting pin (8).
Figure 3
Removal, arm cylinder hoses and pin
9. Lift arm cylinder (10), and lower to work bench safely.
10. Remove arm cylinder pipe and clamp, and install them to new arm cylinder.
11. Install arm cylinder (10).
12. Connect arm cylinder hoses (6).
13. Connect arm cylinder grease hose (5).
14. Install pin (2) of arm cylinder rod, and lock plate (3).
Figure 4
Installation, pin of arm cylinder rod
15. Connect grease hose (1) of arm cylinder rod.

Service Information

Profile:
EXC, EC290B LC [GB]
Dipper arm cylinder, disassembly and assembly

Precautions
General tools
Special tools
Tightening torque

Korea China
~ 12927 ~ 30177
Figure 1
Tightening torque
A B C
Piston nut, to tighten turn clockwise Lock nut, to tighten turn Screw
counterclockwise
35 ± 5 (253 ± 36) 15 ± 3 (108 ± 22) 26.7 ± 2.7 (193 ± 19)
Apply "Three bond 1360K" or "Loctite #242" to the rod and screw thread before tightening.

Korea China
12928 ~ 30178 ~
Figure 2
Tightening torque
A B C D
Piston nut, to tighten turn Lock nut, to tighten turn Screw Set-screw
96.9 ± 9.7 (703 ± 70.3) 61.2 ± 6.1 (444 ± 44.4) 26.7 ± 2.7 (193 ± 19) 1.7 ± 0.2 (13 ± 1.3)
NOTE!
Apply "Loctite #277" to the rod and screw thread before tightening.
NOTE!
Caulk 2 places in set-screw after assembling set-screw to apply "Loctite #277".

Oil leakage

6.0 cc (0.37 cu·in) or less / 10 minutes
Figure 3
Wear limit
Item Standard Tolerance Standard Clearance

value Shaft Hole clearance limit
Clearance between piston rod and 105 – 0.036 + 0.195 0.096 0.585
bushing (1) ~ – 0.090 ~ + 0.060 ~ 0.285
Clearance between piston rod pin 80 – 0.030 + 0.168 0.180 1.0
and bushing (2) ~ – 0.076 ~ + 0.079 ~ 0.300
Clearance between rear end pin and 80 – 0.030 + 0.168 0.180 1.0
bushing (3) ~ – 0.076 ~ + 0.079 ~ 0.300
Disassembly
Assembly
Service Information

troubleshooting
Profile:
EXC, EC290B LC [GB]
Dipper arm cylinder, troubleshooting

Service Information

Bucket, description Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Bucket, description
Figure 1
Structure, bucket
1. Pin with lock

2. Screw
3. Nut
4. Shim
5. Shim
Gap and shims

GAP 1 +1.0 +2.5 1173–01630 1 1173–01390 1
GAP 2 0.0 +1.0 – – – –
Initial lubricating table

Position Location Initial grease amount (cc)
GR 1 Bucket cylinder rod 13
GR 2 Connecting rod + yoke 15 × 2
GR 3 Connecting rod + bucket 15 × 2
NOTE!
Service Information

Bucket cylinder, description Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Bucket cylinder, description

Figure 1
Bucket cylinder (With both cushion, sectional view)
Figure 2
Bucket cylinder (exploded view)
5 head 12 Lock nut 19 Back-up ring 26 Seal
6 bushing 13 Screw 20 O-ring 27 Pin
NOTE!
Coat the screws of the head with "Three Bond 1360K" (or equivalent).
Service Information

Bucket, adjustment of Service Information 2014/10/29
bucket clearance
Profile:
EXC, EC290B LC [GB]
Bucket, adjustment of bucket clearance

Op nbr 00000
1. Park the machine on a level, firm surface and lower the bucket (A) to the ground.
Figure 1
Bucket clearance
1. No gap
2. Slide code rings (G) out of the way.
3. Slowly operate the slew control lever until the right arm boss and bucket boss are in full face to face contact (no
gap).
4. Engage the safety control lever to prevent the digging unit moving and stop the engine.
5. Measure clearance (D) between bushing (B) and bucket bracket (I).
6. Loosen screws (H) and ADD or REMOVE shims to obtain the correct clearance. (Use the same quantity of split shims
on each half.)
7. After the shim adjustment, tighten screws (H) to specified torque. 52.2 kgf·m (377 lbf·ft)
8. Recheck clearance (D), readjust if required.
9. Slide code rings (G) back into position.
NOTE!
Original shim quantity (E) is 12 (= 6 × 2).
NOTE!
Keep removed shims in the tool box as spares. Adjust clearance (D) each time a bucket is installed on the machine.
NOTE!
If the specified clearance can not be achieved after removing all shims, change bushing (B) with new one.
NOTE!
Bucket clearance standard (D) = 0.5 ~ 1.0 mm (0.02 ~ 0.04 in)
NOTE!
Lubricate bushing (B) outer diameter with an anti–seize compound or grease.
Service Information

Bucket assembly, replacing Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Bucket assembly, replacing

Op nbr 925-011
Figure 1
Removal, link pin
3. Remove lock screw (2) of bucket link pin, and remove link pin (3) and code ring (1).
4. Remove lock screw (2) of bucket pin, and remove bucket pin (4) and code ring (5).
Figure 2
Removal, bucket pin
5. Remove bucket from arm.

Figure 3
Installation, bucket
6. Remove bucket pin cover (6) and shims (7) from removed bucket, and install them to new bucket.
7. Install code ring (5), bucket pin (4) and lock screw (2).
8. Install code ring (1), link pin (3) and lock screw (2).
NOTE!
Check a gap between arm and bucket, and if required, insert shim.
Service Information

Bucket cylinder, replacing Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Bucket cylinder, replacing

Op nbr 975-061
WARNING
NOTE!
2. Remove lock screw (1) of connector link pin, and remove link pin (2).
Figure 1
Removal, link pin
3. Retract bucket cylinder rod (3) fully, and fix cylinder rod (3).
4. Disconnect bucket cylinder hose (4).

Figure 2
Replacing, bucket cylinder
5. Disconnect bucket cylinder grease hose.
6. Remove lock plate (5) of bucket cylinder pin, and remove cylinder by removing pin (6).
7. Lift bucket cylinder, and lower to work bench safely.
8. Remove bucket cylinder pipe and clamp, and install to new bucket cylinder.
9. Install bucket cylinder.
10. Connect bucket cylinder grease hose.
11. Connect bucket cylinder hose (4)
12. Install pin (2) and lock screw (1) of bucket cylinder rod.
Service Information

Bucket cylinder, Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Bucket cylinder, disassembly and assembly

Precautions
See 970 Cylinder, disassembly and assembly
General tools
Special tools
Tightening torque
Figure 1
Tightening torque
A B C
Piston nut, to tighten turn clockwise Lock nut, to tighten turn Screw
counterclockwise
M 64 M 60 M 16
35 ± 5 (253 ± 36) 35 ± 5 (108 ± 22) 26.7 ± 2.7 (193 ± 19)
Apply three bond 1360K or loctite #242 to the rod and screw thread before tightening.
Oil leakage

5.6 cc (0.34 cu·in) or less / 10 minutes
Figure 2
Item Standard Tolerance Standard Clearance

value Shaft Hole clearance limit
Clearance between piston rod 95 – 0.036 + 0.195 0.096 0.585

and bushing (1) ~ – 0.090 ~ + 0.060 ~ 0.285
Clearance between piston rod 90 – 0.036 + 0.257 0.206 1.0
pin and bushing (2) ~ – 0.090 ~ + 0.170 ~ 0.347
Clearance between rear end pin 80 – 0.030 + 0.168 0.180 1.0
and bushing (3) ~ – 0.076 ~ + 0.079 ~ 0.300
Disassembly
Assembly
Service Information

Bucket cylinder, Service Information 2014/10/29
troubleshooting
Profile:
EXC, EC290B LC [GB]
Bucket cylinder, troubleshooting

Service Information

Explanations to hydraulic 990 Service Information 2014/10/29
diagram
Profile:
EXC, EC210B NLC, EC460B LC, EC235C NL, EC460C L, EC210C L, EC360C NL, EC140B LCM, FC2121C, EW145B, EC240B
FX, EC140C, EC240B LC, EC700C L, EC290B LC, FC2924C, FC3329C, EC360B LC, EC290B FX, EC360B LCD, EC290B LCD,
EC290C NL, EC290C LR, EC240C LR, EC240C NL, EC160C NL, EC460B LCD, EC210C N, EC180B LC, EC210B LC, EC700B
LC, EC140B LC, EC160B LC, EC135B LC, FC2421C, EC210B FX, EC160C L, EC330B LC, EC180C L, EC360C L, EC330C L,
EC290C L, EC210C NL, EC240C L, EC210C LR [GB]
Explanations to hydraulic diagram

Symbols
Symbol Explanation
Line
Servo line / Pilot line

Line junction
Crossing lines not connecting
Outlet, plugged
Quick-action coupling (e.g. checking point)
Restriction
Restriction, insignificantly viscosity-dependent
Adjustable restriction
Reservoirs and accumulators

Atmospheric (open) reservoir
Accumulator
Filter
Filter, strainer
Filter with magnetic element
Heat exchanger
Cooler without representation of lines for the coolant
Control devices
Manual control by push button
Manual control by lever
Manual control by pedal
Mechanical control by spring, neutral position spring, return spring
Electromagnetic control (one winding)
Hydraulic pressure control
Hydraulic pressure control, two pressure levels
Control via hydraulic pressure drop
Pneumatic control
Control via pneumatic pressure drop
Sources of energy
Combustion engine
Electric motor
Pumps
Hydraulic pump with fixed displacement and one direction of flow
Hydraulic pump with variable displacement and one direction of flow
Hydraulic pump with variable displacement and two directions of flow
Hydraulic pump with variable displacement, pressure controlled
Hydraulic pump with variable displacement, pressure controlled with

pressure-compensated control
Motors
Hydraulic motor with fixed displacement and one direction of flow
Hydraulic motor with fixed displacement and two directions of flow
Cylinders
Single-acting cylinder with return stroke by spring
Double-acting cylinder with single piston rod
(The piston end is called plus side and the piston rod end is called
minus side)
Valves
Non-return valve which requires very low opening pressure
Non-return valve which requires a certain opening pressure
Shuttle valve
Pressure-limiting valve
Pressure-limiting valve with adjustable opening pressure
Pressure-reducing valve
Pressure-reducing valve with adjustable closing pressure
Pressure-reducing valve, pressure controlled
Three-position valve, lever-controlled and spring-centred
Lines parallel with the long sides of the valve symbol show that the
valve can take up any position between its end positions (stepless
movement)
Shut-off valve / Breather valve
Application
The symbols in a diagram show connections, flow paths and function of the components in the system, but does not show
the design of the components.
NOTE!
In a hydraulic diagram the valve symbols are always drawn in neutral position.
Valve symbols
The basic element of a valve symbol is a square box. One box is shown for each position that the moving part of a valve
(spool or similar) can take up.
Figure 1
Valve symbol
If the valve does not have fixed positions, but can be operated steplessly, this is shown with parallel lines along the valve
symbol.
Figure 2
Valve symbol, steplessly controlled valve
Internal flow paths and flow directions are drawn in the boxes. Line connections to the valve are drawn to the box that
shows the valve position when other components are actuated according to the diagram.
Figure 3
Closed valve
Figure 4
Open valve
Interpretation of valve symbols

In a three-position valve the spool can be placed in three positions, which in the symbol are represented by one box for
each position. The box that represents the intended position is drawn between the line connections, which means that the
appropriate connecting paths in the valve are shown in the diagram.
The position in the diagram
Figure 5
Neutral position
1. Inlet
2. Outlet
The spool is centred in neutral position by the springs. The inlet is connected to the outlet through the spool.
Imagined position for piston movement outwards
Figure 6
The piston rod is pressed out
1. Inlet
2. Outlet
The spool is actuated with the lever so that the plus side of the cylinder is connected to the inlet at the same time as the
minus side is connected to the tank.
Imagined position for piston movement inwards
Figure 7
The piston rod is pressed in
1. Inlet
2. Outlet
The spool is actuated with the lever so that the minus side of the cylinder is connected to the inlet at the same time as the
plus side is connected to the tank.
Service Information

Hydraulic diagram, neutral 990 Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Hydraulic diagram, neutral

Servo hydraulic circuit (safety lever in unlocked position)
Servo hydraulic pressure circuit
Oil discharged by the gear pump passes through the relief valve and servo hydraulic filter (16) and enters the following
components, completing the servo hydraulic pressure circuit :
 Remote control valve for operating digging units (22, 23)

 Remote control valve for travel (24)
 Slew brake valve (PG)
 Proportional solenoid valve (for pump control)
 Straight travel circuit and auto idle circuit (Pg1)
 Solenoid valve for main pressure boost
 Solenoid valve for 2–speed travel signal
 Solenoid valve for breaker (Option)
Negative control signal circuit

The advantage of this circuit is minimizing pump discharge under no–load, thereby eliminating wasteful energy
consumption (for energy conservation), and reducing fuel costs.
The operating principle is the negative control type in which the increase in main return oil pressure (Fl, Fr) reduces the
discharge from the pump.
Negative control pressure (Fl, Fr) rises when in neutral because all the oil discharged from the pump is directed through the
throttle of the flow sensing valve (58), increasing the flow through it.
In the negative control circuit for the P1 pump, oil from port Fl of the control valve passes and enters port Pi1 (Fl) of the
pump.
In the negative control circuit for the P2 pump, oil from port Fr of the control valve passes and enters port Pi2 (Fr) of the
pump.
Main circuit
Hydraulic oil cleaned by tank strainer (34) is drawn in by the variable displacement pumps. This oil is then discharged by P1,
P2 pump and enters control valve. When the flow sensing valve in the control valve is actuated, the oil drains through tank
port (R).
The returning oil passes through the oil cooler and return filter (30) where any contaminates are removed as it is drained to
tank.
Service Information

Hydraulic diagram, ports 990 Service Information 2014/10/29
Profile:
EXC, EC290B LC [GB]
Hydraulic diagram, ports

Hydraulic ports
Item no. Component Port Item no. Port Description

1 Main pump P1 3 P Discharge port
P2 3 P Discharge port
A3 16 In Servo hydraulic line filter
B3 - - Suction port (gear pump)
Dr 35 DR1 Drain filter
Pi1 3 Fl Negative control signal port (P1 pump)
46 A Negative control signal port
Pi2 3 Fr Negative control signal port (P2 pump)
a1 - - Quick coupler for gauge port
a3 - Psv Power shift valve signal port
Psv - a3 Power shift valve primary pressure port
2 Rotator pump Out 52 P X3 line option check valve
3 Main control valve P 1 P1 Pump P1 port
P 1 P2 Pump P2 port
AR1 4 S Boom lower port (small chamber)
BR1 4 L Boom raise port (large chamber)
AR2 6 L Bucket curl port (cylinder extend) - large chamber
BR2 6 S Bucket dump port (cylinder retract) - small chamber
BL4 13 C Left travel port (reverse)
AL4 13 E Left travel port (forward)
BR3 13 D Right travel port (reverse)
AR3 13 F Right travel port (forward)
AL3 5 L Arm in port (cylinder extend) - large chamber
BL3 5 S Arm out port (cylinder retract) - small chamber
AL1 9 B Slew port (left)
BL1 9 A Slew port (right)
AL2 51 A Option port
BL2 48 B Option port
al1 25 SL1 Slew servo hydraulic port (left)
bl1 25 SR1 Slew servo hydraulic port (right)
al2 44 2 Option servo hydraulic port
bl2 44 1 Option servo hydraulic port
ar1 25 BD1 Boom lower servo hydraulic port
37 Pi Line rupture valve release signal port (Boom)
3 3Pi Boom holding valve release signal port
br1 25 BU1 Boom raise servo hydraulic port
ar2 25 B11 Bucket curl servo hydraulic port
br2 25 BO1 Bucket dump servo hydraulic port
4Pi 25 AI2 Arm holding valve release signal port
bl4 24 1 Left travel servo hydraulic port (reverse)
al4 24 2 Left travel servo hydraulic port (forward)
br3 24 3 Right travel servo hydraulic port (reverse)
ar3 24 4 Right travel servo hydraulic port (forward)
a 25 AM Arm conflux signal port
b 25 BU Boom raise conflux signal port
3 Main control valve al3 25 Al1 Arm in servo hydraulic port (cylinder extend)
39 Pi Line rupture valve release signal port (Arm)
bl3 25 AO1 Arm out servo hydraulic port (cylinder retract)
R 27, 28 - Main return port
Rs 9 M Slew motor boost port
Pa 25 SW Slew priority valve port
Py 20 A3 Pressure boost servo hydraulic port (main)
Px1 10 - Auto deceleration pressure source (travel)
Px3 10 - Auto deceleration pressure source (attachment)
Po 55 P3 Quickfit valve port
Pz 43 4 Option 2 step relief valve signal port
dr1 20 A6 Drain port
dr2 36 Td7 Drain port
Fr 1 pi2 Negative pump control signal port
Fl 1 pi1 Negative pump control signal port
Ps 45 - Boom priority raise servo hydraulic port
Pb 25 BU2 Boom raise conflux signal port
Pc 25 AI2 Boom raise conflux cut-off signal port
Pg1 17 S1 Pressure source for straight travel and auto deceleration
signal (digging unit, travel)
Pg2 26 P1 Boom holding valve primary pressure source
4 Boom cylinder L 3 BR1 Boom cylinder piston side inlet port (large chamber)
S 3 AR1 Boom cylinder rod side inlet port (small chamber)
5 Arm cylinder L 3 AL3 Arm cylinder piston side inlet port (large chamber)
S 3 BL3 Arm cylinder rod side inlet port (small chamber)
6 Bucket cylinder L 3 AR2 Bucket cylinder piston side inlet port (large chamber)
S 3 BR2 Bucket cylinder rod side inlet port (small chamber)
7 Slew motor A 3 BL1 Slew motor inlet port (right)
B 3 AL1 Slew motor inlet port (left)
M 3 Rs Slew motor boost port
SH 25 AI2 Slew brake valve release signal port (arm in position)
PG 17 S2 Pressure source port for slew brake release
Dr 13 G Drain port
35 In Drain port
11 Track motor A (left) 13 C Left track port (forward)
B (left) 13 E Left track port (reverse)
A (right) 13 F Right track port (reverse)
B (right) 13 D Right track port (forward)
13 Center passage C 3 BL4 Left track port (reverse)
D 3 BR3 Right track port (reverse)
E 3 AL4 Left track port (forward)
F 3 AR3 Right track port (forward)
B 20 A4 Primary pressure source low speed signal
G 9 Dr Drain port
17 Accumulator block AC 19 - Accumulator
PS 16 - Accumulator inlet port
PS1 20 P1 Safety solenoid valve inlet port primary pressure
S1 3 Pg1 Pressure source for straight travel and auto deceleration
signal (attachment, travel)
S2 9 PG Pressure source for slew brake release port
S3 46 P Pressure source for proportional valve
20 Solenoid valve A1 26 P1 Pressure source for remote control valve
20 P3 Pressure source for option solenoid valve
A2 3 a Arm in/out conflux signal port
A3 3 Py Pressure boost servo hydraulic port (main)
A4 13 B Pressure source for low speed travel
A5 44 6 Pressure source for shuttle valve
A6 3 dr1 Drain port
P1 17 PS1 Safety solenoid valve inlet port primary pressure
P2 44 5 Pressure source for shuttle valve
P3 46 P Option proportional solenoid valve inlet port
22 Remote control 1 25 SL Left slew servo hydraulic port
valve (left control 2 25 AO Arm out servo hydraulic port (cylinder retract)
lever)
3 25 SR Right slew servo hydraulic port
4 25 Al Arm in servo hydraulic port (cylinder extend)
P 26 P5 Pressure source for remote control valve
T 26 T5 Hydraulic tank return port
23 Remote control 1 25 Bl Bucket curl servo hydraulic port (cylinder extend)
valve (right control 2 25 BD Boom lower servo hydraulic port (cylinder retract)
lever)
3 25 BO Bucket dump servo hydraulic port (cylinder retract)
4 25 BU Boom raise servo hydraulic port (cylinder extend)
24 Remote control 1 3 al4 Left travel servo hydraulic port (reverse)
valve (pedal) 2 3 bl4 Left travel servo hydraulic port (forward)
3 3 ar3 Right travel servo hydraulic port (reverse)
4 3 br3 Right travel servo hydraulic port (forward)
25 Shuttle block Al 22 4 Secondary pressure inlet port (arm in)
Al1 3 al3 Secondary pressure source for arm in
Al2 3 4Pi Arm holding valve release signal port
3 Pc Boom raise conflux shut off signal port
9 SH Slew brake valve release signal port
AO 22 2 Secondary pressure inlet port (arm out)
AO1 3 bl3 Arm out servo hydraulic port
SR 22 3 Secondary pressure inlet port (slew right)
SR1 3 bl1 Secondary pressure source for slew right
SL 22 1 Secondary pressure inlet port (slew left)
SL1 3 al1 Secondary pressure source for slew left
BO 23 3 Secondary pressure inlet port (bucket dump)
BO1 3 br2 Secondary pressure source for bucket dump
Bl 23 1 Secondary pressure inlet port (bucket curl)
Bl1 3 ar2 Secondary pressure source for bucket curl
BD 23 2 Secondary pressure inlet port (boom lower)
BD1 3 ar1 Secondary pressure source for boom lower
BU 23 4 Secondary pressure inlet port (boom raise)
BU1 3 br1 Secondary pressure source for boom raise
BU2 3 Py Boom priority raise servo hydraulic port
3 b Pressure source for boom raise conflux
3 Pb Boom raise conflux signal port
AM 3 a Arm in/out conflux signal port
SW 3 Pa Slew priority valve port
9 SH Slew brake valve release signal port
26 Servo hydraulic P1 20 A1 Primary pressure inlet port
block 3 Pg2 Boom holding valve primary pressure source
P2 41 P Primary pressure source for hammer and shear
P3 23 P Primary pressure source for remote control valve (right)
P4 24 P Primary pressure source for remote control valve (pedal)
P5 22 P Primary pressure source for remote control valve (left)
P6 55 PS Quickfit cylinder oil source
T1 36 Td2 Tank return
T2 41 T Tank return (hammer & shear valve)
T3 23 T Tank return (remote control valve)
42 T Tank return (remote control valve - single pedal)
T6 - - Close
35 Drain filter DR1 1 Dr Tank return (main pump)
DR2 - - Oil leak
9 Dd Tank return (track motor)
36 Hydraulic tank Td1 3 dr3 Tank return
Td2 26 T1 Tank return
Td3 - - Close
Td4 - - Close
Td5 3 dr4 Tank return
48 dr Tank return
46 T Tank return
Td8 20 T Tank return
3 dr5 Tank return
Td9 35 Out Filter drain
37 Line rupture valve P1 3 BR1 Line rupture valve inlet port (boom raise)
(boom) P2 4 L Cylinder piston side inlet port
Pi 3 PAb Line rupture valve release servo hydraulic signal port
(boom lower)
T 30 t1 Tank return port
39 Line rupture valve P1 3 BL3 Line rupture valve inlet port
(arm) P2 5 S Cylinder rod side inlet port
Pi 25 AI1 Line rupture valve release servo hydraulic signal port
(arm in)
T1 30 t2 Tank return port
T2 30 t3 Tank return port
41 Solenoid valve A 43 1 Outlet port for shuttle valve
(Hammer & shear) B 43 2 Outlet port for shuttle valve
P 26 P2 Primary pressure inlet port
T 26 T2 Tank return port
42 Single pedal 1 44 6 Inlet port for shuttle valve
2 44 4 Inlet port for shuttle valve
P 43 5 Primary pressure source for single pedal inlet port
43 Shuttle - B 1 41 A Shuttle valve inlet port
2 41 B Shuttle valve inlet port
3 48 Pi Pressure source for 3 way selector valve release
4 3 Pz 2 step relief valve control signal
5 42 P Primary pressure source for single pedal inlet port
44 Shuttle - A 1 3 bl2 Pressure source for option servo hydraulic signal port
2 3 al2 Pressure source for option servo hydraulic signal port
3 - - Close
4 42 2 Inlet port from single pedal
5 20 P2 Pressure source for solenoid valve
21 - Pressure switch port
6 20 A5 Inlet port from solenoid valve
42 1 Inlet port from single pedal
46 Proportional valve A 1 Pi1 Negative control signal port
P 17 S3 Primary pressure inlet port
T 36 Td7 Tank return port
48 3 way selector valve Pi 43 3 Primary pressure inlet port
A 50 - Outlet port
B 3 BL2 Inlet port from option port
dr 36 Td5 Drain port
T 49 In Return port
50 Stop valve - 48 A Inlet port from 3 way selector valve
52 Rotator valve A, B - - To rotator motor port
G - - Gauge port
T 30 t5 Tank return port
54 Check valve P 2 Out Rotator valve inlet port from gear pump
55 Quickfit valve A, B - - Quickfit cylinder port
P3 3 Po Quickfit valve inlet port
PS 26 P6 Quickfit valve inlet port
68 Adjustable boom 1 69 b Adjustable boom lower signal port
control valve 2 69 a Adjustable boom raise signal port
P 26 P4 Primary pressure inlet port
69 Adjustable boom a 68 2 Adjustable boom raise signal inlet port
valve b 68 1 Adjustable boom lower signal inlet port
C 71 Pi Pressure source for adjustable boom selector valve
P 3 P Flow source for adjustable boom cylinder
R - t7 Return pipe port
Pi 3 Pg1 Primary pressure inlet port
73 Control pattern A 23 2 Secondary pressure inlet port (boom lower)
selector valve B 22 2 Secondary pressure inlet port (arm out)
C 23 4 Secondary pressure inlet port (boom raise)
D 22 4 Secondary pressure inlet port (arm in)
1 25 BD Secondary pressure for boom lower
2 25 AO Secondary pressure for arm out
3 25 BU Secondary pressure for boom raise
4 25 AI Secondary pressure for arm in
74 Boom float valve A 3 BR1 Boom float valve hydraulic oil inlet port
B 3 AR1 Boom float valve hydraulic oil inlet port
T 3 R Tank return port
Pi 75 A Boom float valve servo hydraulic signal port
Dr 36 Td1 Drain port
75 Boom float solenoid P 25 BD1 Servo hydraulic pressure inlet port
valve A 74 Pi Boom float valve servo hydraulic signal port
B 3 ar1 Boom lower servo hydraulic signal port
Service Information

standard
Profile:
EXC, EC290B LC [GB]
Hydraulic diagram, standard

1 Main pump 27 Check valve

3 Main control valve 28 Check valve
4 Boom cylinder 29 Hydraulic oil cooler
5 Arm cylinder 30 Return filter
6 Bucket cylinder 31 Bypass valve
7 Slew motor 32 Bypass strainer
8 Slew gearbox 33 Air breather
9 Slew motor 34 Strainer assembly
10 Pressure switch (20 ±1.5 kgf/cm2 ) 35 Drain filter
11 Track gearbox 36 Hydraulic oil tank
12 Slew ring gear 45 Shuttle valve
13 Center passage 47 Shuttle valve
14 Filter connector 56 Boom holding valve
15 Filter connector 57 Center bypass valve
16 Servo hydraulic filter 58 Flow sensing valve
17 Accumulator block 59 Arm parallel conflux valve
18 Quick coupler 60 Servo hydraulic selector valve
19 Accumulator 61 Logic valve
20 Solenoid valve 62 Arm regenerating valve
22 Remote control valve - Left lever 63 Slew brake valve
23 Remote control valve - Right lever 64 Shock reducing valve
24 Remote control valve - Pedal 65 Arm holding valve
25 Shuttle block 66 Straight travel valve
26 Servo hydraulic block
Figure 1
Service Information

standard
Profile:
EXC, EC290B LC [GB]

1 Main pump 28 Bypass valve

2 Main control valve 29 Bypass valve
3 Slew motor 30 Hydraulic oil tank
4 Track drive unit (Track motor + Track gearbox) 31 Air breather
5 Boom cylinder 33 Bypass valve
6 Arm cylinder 34 Strainer
7 Bucket cylinder 35 Strainer assembly
8 Center passage 36 Drain valve
9 Slew ring gear 37 Quick coupler
10 Radiator 38 Filter connector
11 Fan motor 39 Filter connector
12 Proportional relief valve 40 Filter connector
13 Gear pump 41 Filter connector
14 Servo hydraulic filter 42 Filter
15 Accumulator block 43 Connector
16 Accumulator 90 Center bypass valve
17 Solenoid valve 91 Flow sensing valve
18 Servo hydraulic block 92 Straight travel valve
19 Remote control valve (pedal) 93 Arm regenerating valve
20 Remote control valve (lever) - left 94 Logic valve
21 Remote control valve (lever) - right 95 Servo hydraulic selector valve
22 Shuttle valve 96 Arm parallel conflux valve
23 Shuttle valve 97 Boom holding valve
24 Shuttle valve 98 Arm holding valve
25 Shock reducing valve
27 Drain filter
Figure 1
Service Information

standard
Profile:
EXC, EC290B LC [GB]

1 Main pump 11 Solenoid valve (4 row) 21 Return filter
2 Main control valve 12 Remote control valve (lever), left 22 Bypass valve
3 Slew motor 13 Remote control valve (lever) - right 23 Bypass strainer
4 Track motor 14 Remote control valve (travel) 24 Suction strainer
5 Boom cylinder 15 Center passage 25 Hydraulic oil tank
6 Arm cylinder 16 Shuttle valve (attachment) 26 Air breather
7 Bucket cylinder 17 Shuttle valve 27 Drain filter
8 Servo hydraulic oil filter 18 Hydraulic oil cooler 28 Slow return valve
9 Accumulator block 19 Check valve : 0.29 MPa (3 kgf/cm2) 51 Servo hydraulic block
(43 psi) (2.9 bar)
1 Accumulator 20 Check valve : 0.44 MPa (4.5 kgf/ 52 Drain block
0 cm2) (64 psi) (4.4 bar)
Figure 1
Service Information

Hydraulic diagram, with 990 Service Information 2014/10/29
option components
Profile:
EXC, EC290B LC [GB]
Hydraulic diagram, with option components

1 Main pump 40 3 way selector valve

2 Gear pump for X3 (rotator) 41 Solenoid valve
3 Main control valve 42 Remote control valve - Pedal (Single)
4 Boom cylinder 43 Shuttle valve (B type)
5 Arm cylinder 44 Shuttle valve (A type)
6 Bucket cylinder 45 Shuttle valve
7 Slew motor 46 Proportional solenoid valve
8 Slew gearbox 47 Shuttle valve
9 Slew motor 48 3 way selector valve
10 Pressure switch (20 ± 1.5 kgf/cm2 ) 49 Filter for hammer
11 Travel gearbox 50 Stop valve
12 Slew ring gear 51 Connector
13 Center passage 52 Rotator valve
14 Filter connector 53 Solenoid valve
15 Filter connector 54 Check valve
16 Pilot filter 55 Quickfit valve
17 Accumulator block 56 Boom holding valve
18 Quick coupler 57 Center bypass valve
19 Accumulator 58 Flow sensing valve
20 Solenoid valve 59 Arm parallel conflux valve
21 Pressure switch (7 ±1 kgf/cm2 ) 60 Servo hydraulic selector valve
22 Remote control valve - Left lever 61 Logic valve
23 Remote control valve - Right lever 62 Arm regenerating valve
24 Remote control valve - Pedal 63 Slew brake valve
25 Shuttle block 64 Shock reducing valve
26 Servo hydraulic block 65 Arm holding valve
27 Check valve 66 Straight travel valve
28 Check valve 67 Solenoid valve
29 Hydraulic oil cooler 68 Adjustable boom control pedal
30 Return filter 69 Adjustable boom valve
31 Bypass valve 70 Adjustable boom cylinder
32 Bypass strainer 71 Servo hydraulic valve
33 Air breather 72 Servo hydraulic valve
34 Strainer assembly 73 Pattern change valve
35 Drain filter 74 Boom float valve
36 Hydraulic oil tank 75 Boom float solenoid valve
37 Boom hose rupture valve 76 Non leak valve (Large chamber)
38 Pressure switch 77 Non leak valve (Small chamber)
39 Arm hose rupture valve 78 Shuttle valve
Figure 1
Hydraulic diagram with option components
Service Information

option components
Profile:
EXC, EC290B LC [GB]

1 Main pump 34 Strainer 67 Filter connector

2 Main control valve 35 Strainer assembly 68 Pressure switch
3 Slew motor 36 Drain valve 69 Shuttle
4 Track motor 37 Quick coupler 70 Filter connector
5 Boom cylinder 38 Filter connector 71 Solenoid valve
6 Arm cylinder 39 Filter connector 72 X1 pedal
7 Bucket cylinder 40 Filter connector 73 Filter connector
8 Center passage 41 Filter connector 74 Shuttle
9 Slew ring gear 42 Connector 75 Pattern change valve
10 Radiator 43 Connector 76 Float position valve
11 Fan motor 44 Pressure switch 77 Float position solenoid valve
12 Proportional relief valve 45 Line rupture valve (Boom) 78 Filter connector
13 Gear pump 46 Overload warning device switch 79 Pressure switch
14 Servo hydraulic filter 47 Line rupture valve (Arm) 80 X1 pedal
15 Accumulator block 48 Adjustable boom valve 81 Shuttle valve
16 Accumulator 49 Adjustable boom cylinder 82 Filter connector
17 Solenoid valve 50 Adjustable boom control pedal 83 Solenoid valve
18 Servo hydraulic block 51 Servo hydraulic selector valve 84 Rotator valve
19 Remote control valve (pedal) 52 Servo hydraulic selector valve 85 Check valve
20 Remote control valve (lever) - left 53 Shuttle 86 Quick coupler
21 Remote control valve (lever) - right 54 Filter connector 87 Quickfit valve
22 Shuttle valve 55 Non leak valve 88 Quickfit
23 Shuttle valve 56 Non leak valve 89 Block
24 Shuttle valve 57 X1 selector valve 90 Center bypass valve
25 Shock reducing valve 58 Stop valve 91 Flow sensing valve
26 Block 59 Filter for X1 92 Straight travel valve
27 Drain filter 60 Solenoid valve 93 Arm regenerating valve
28 Bypass valve 61 Hammer/Shear selector shuttle 94 Logic valve
valve
29 Bypass valve 62 Servo hydraulic selector valve 95 Servo hydraulic selector valve
30 Hydraulic oil tank 63 Shuttle valve 96 Arm parallel conflux valve
31 Air breather 64 Flow control valve 97 Boom holding valve
32 Return element 65 Shuttle 98 Arm holding valve
33 Bypass valve 66 Filter connector
Figure 1
Service Information

option components
Profile:
EXC, EC290B LC [GB]

1 Main pump 19 Check valve : 0.29 MPa (3 kgf/cm2) 38 Shuttle valve (X1)
(43 psi) (2.9 bar)
2 Main control valve 20 Check valve : 0.44 MPa (4.5 kgf/ 39 Solenoid valve (Hammer & Shear)
cm2) (64 psi) (4.4 bar)
3 Slew motor 21 Return filter 40 Shuttle valve (Hammer & Shear)
4 Track motor 22 Bypass valve 41 3-way selector valve (X 1)
5 Boom cylinder 23 Bypass strainer 42 Return filter (X1)
6 Arm cylinder 24 Suction strainer 43 Solenoid valve (X1 2 pump flow)
7 Bucket cylinder 25 Hydraulic oil tank 44 Proportional solenoid valve (X1 flow
control)
8 Servo hydraulic oil filter 26 Air breather 45 Pressure switch
9 Accumulator block 27 Drain filter 46 Pressure switch
1 Accumulator 28 Slow return valve 51 Servo hydraulic block
0
1 Solenoid valve (5 row) 30 Quickfit valve 52 Drain block
1
1 Remote control valve (lever), left 31 Quickfit cylinder 53 Shuttle valve
2
1 Remote control valve (lever) - 32 Gear pump (X3) 54 Boom line rupture valve (left)
3 right
1 Remote control valve (pedal) 33 Check valve (X3) 55 Boom line rupture valve (right)
4
1 Center passage 34 Solenoid valve (X3) 56 Boom float position valve
5
1 Shuttle valve (attachment) 35 Control valve (X3) 57 Boom float position solenoid valve
6
1 Shuttle valve (Acc) 36 Remote control valve (X1 pedal)
7
1 Hydraulic oil cooler 37 Solenoid valve (X1 2 switch)
8
Figure 1
Hydraulic diagram with option components
Service Information

reversible cooling fan
Profile:
EXC, EC290B LC [GB]
Hydraulic diagram, with reversible cooling fan

Hydraulics diagram, Waste Handler
1 Main pump 36 Drain valve 71 Solenoid valve

2 Main control valve 37 Quick coupling 72 Remote control valve pedal X1
3 Slew motor & gearbox 38 Filter 73 Connector filter
4 Travel motor & gearbox 39 Filter 74 Shuttle tee
5 Boom cylinder 40 Filter 75 Pattern change valve
6 Arm cylinder 41 Filter 76 Float position valve
7 Bucket cylinder 42 Connector 77 Float position solenoid valve
8 Center passage 43 Connector 78 Connector filter
9 Swing gear 44 Pressure switch 79 Pressure switch
10 Radiator 45 Boom holding valve 80 Remote control valve pedal X1
11 Fan motor 46 Overload warning device switch 81 Shuttle valve
12 Proportional relief valve 47 Arm holding valve 82 Connector filter
13 Gear pump 48 Valve 83 Solenoid valve
14 Pilot filter 49 Boom cylinder 84 Rotator valve block valve
15 Accumulator block 50 2pcs pedal valve 85 Check valve
16 Accumulator 51 Pilot valve 86 Quick coupling
17 Solenoid valve 52 Pilot valve 87 Quickfit valve
18 Block 53 Shuttle tee 88 Quickfit
19 Remote control valve pedal 54 Connector filter 89 Block
20 Remote control valve - left 55 Valve 90 Reverse fan valve
21 Remote control valve - right 56 Valve
22 Shuttle valve 57 Selector valve
23 Shuttle valve 58 Stop valve
24 Shuttle valve 59 X1 filter
25 Valve 60 Solenoid valve
26 Block 61 Select valve
27 Drain filter 62 Pilot selection valve
28 By pass valve 63 Shuttle valve
29 By pass valve 64 Control flow valve
30 Hydraulic oil tank 65 Shuttle tee
31 Air breather 66 Control filter
32 Return filter element 67 Control filter
33 By pass valve 68 Pressure switch
34 Strainer 69 Shuttle tee
35 Strainer 70 Control filter
Figure 1
Hydraulic diagram
1 Main pump 36 Drain valve 71 Solenoid valve

2 Main control valve 37 Quick coupling 72 Remote control valve pedal X1
3 Slew motor & gearbox 38 Filter 73 Connector filter
4 Travel motor & gearbox 39 Filter 74 Shuttle tee
5 Boom cylinder 40 Filter 75 Pattern change valve
6 Arm cylinder 41 Filter 76 Float position valve
7 Bucket cylinder 42 Connector 77 Float position solenoid valve
8 Center passage 43 Connector 78 Connector filter
9 Swing gear 44 Pressure switch 79 Pressure switch
10 Radiator 45 Boom holding valve 80 Remote control valve pedal X1
11 Fan motor 46 Overload warning device switch 81 Shuttle valve
12 Proportional relief valve 47 Arm holding valve 82 Connector filter
13 Gear pump 48 Valve 83 Solenoid valve
14 Pilot filter 49 Boom cylinder 84 Rotator valve block valve
15 Accumulator block 50 2pcs pedal valve 85 Check valve
16 Accumulator 51 Pilot valve 86 Quick coupling
17 Solenoid valve 52 Pilot valve 87 Quickfit valve
18 Block 53 Shuttle tee 88 Quickfit
19 Remote control valve pedal 54 Connector filter 89 Block
20 Remote control valve - left 55 Valve 90 Reverse fan valve
21 Remote control valve - right 56 Valve
22 Shuttle valve 57 Selector valve
23 Shuttle valve 58 Stop valve
24 Shuttle valve 59 X1 filter
25 Valve 60 Solenoid valve
26 Block 61 Select valve
27 Drain filter 62 Pilot selection valve
28 By pass valve 63 Shuttle valve
29 By pass valve 64 Control flow valve
30 Hydraulic oil tank 65 Shuttle tee
31 Air breather 66 Control filter
32 Return filter element 67 Control filter
33 By pass valve 68 Pressure switch
34 Strainer 69 Shuttle tee
35 Strainer 70 Control filter
Figure 2
Hydraulic diagram
Service Information

Hydraulic diagram, boom 990 Service Information 2014/10/29
raise conflux (internal)
Profile:
EXC, EC290B LC [GB]
Hydraulic diagram, boom raise conflux (internal)

 When control lever (23) is operated to “ BOOM RAISE ”, secondary servo hydraulic oil from the remote control
valve flows to ports BU1 (3-br1), BU2 (3-Py, 3-Pb, 3-b) on shuttle block (25).
 BU1 (3-br1) flows to the main control valve servo hydraulic port (3-br1), moving the boom spool to the right,
routing P2 pump flow (P ) to the piston side of the cylinders extending the rods raising the boom.
 BU2 (3-Py) flows through shuttle valve to arm conflux valve (59) servo hydraulic port (3-Ps), closing the valve
blocking P2 pump flow (P ) to the arm cylinder.
 BU2 (3-Pb) flows to servo hydraulic selector valve (60) port (3-Pb), then through the servo hydraulic valve to the
logic valve spool servo hydraulic port, moving the spool blocking P1 flow to the upper side of logic valve (61).
 BU2 (3-b) flows to center bypass valve (57) servo hydraulic port (3-b), moving the spool blocking P1 pump flow to
tank, therefore P1 pump flow (P ) opens logic valve (61) and combines with P2 pump flow (P ) in the main control
valve, then is routed to the piston side of the cylinders raising the boom.
 The oil from the rod side flows to the hydraulic filter and oil cooler, then is drained to tank.
Negative signal (Fr) of P2 pump is disconnected by the boom spool and negative signal (Fl) of P1 pump is
disconnected by the spool of center bypass valve (57). So P1, P2 pump discharge is increased.
Line color index

Red High pressure oil
Blue Low pressure, servo hydraulic primary pressure oil
Brown Servo hydraulic secondary pressure oil
Green Drain circuit, pump suction oil
Figure 1
Hydraulic diagram, boom raise conflux
Service Information

Hydraulic diagram, arm in 990 Service Information 2014/10/29
conflux
Profile:
EXC, EC290B LC [GB]
Hydraulic diagram, arm in conflux

 When control lever (22) is operated to “ARM IN” secondary servo hydraulic oil from the remote control valve flows
to ports AI1 (3-al3), AI2 (3-Pc, 3-4Pi, 9-SH), AM (3-a) on shuttle block (25).
 AI1 (3-al3) oil flows to the main control valve moving the arm spool (3-al3) to the right, routing P1 pump flow to
the arm cylinder piston side, moving the arm in.
 AI2 (3-Pc) oil flows to servo hydraulic selector valve (60) shifting the spool, draining servo hydraulic signal at the
spool valve of logic valve (61). Then P1 pump oil flows through the check valve and spool valve to the logic valve
upper side. Due to the surface area differential valve (61) is held closed.
 AI2 (3-4Pi) oil flows to the arm holding spool valve (65), shifting the spool, draining the oil from the upper side of
arm holding valve (65). This enables return oil from the cylinder rod side to open the holding valve and flow
through the main control valve, hydraulic filter and oil cooler to tank.
 AI2 (9-SH) oil flows to slew brake valve (63) shifting the brake valve spool, routing primary servo hydraulic oil (PG)
to release the slew brake.
 AM (3-a) oil flows to port (3-a) at center bypass valve (57) moving the spool, blocking P2 pump flow to tank and
the negative flow signal (Fr); therefore P2 pump flow increases and is routed through arm conflux valve (59) to
merge with P2 pump flow in the main control valve, and is routed to the cylinder piston side moving the arm in
(confluent flow).
 When supply flow is sufficient, regenerating valve (62) is pushed to the left and the return circuit is unrestricted.
 When the engine rotates at low rpm or the supply flow isn’t sufficient due to combined operation, the pressure
will drop. In this case, regenerating valve (62) is pushed to the right and the return circuit is restricted. Arm
regenerating check valve in the center of the arm spool is opened and some return oil is merged with supply flow,
to the arm cylinder.
 This prevents cavitation and any sudden change of cylinder speed.
Line color index

Figure 1
Hydraulic diagram, arm in conflux
Service Information

Hydraulic diagram, arm in / 990 Service Information 2014/10/29
boom raise
Profile:
EXC, EC290B LC [GB]
Hydraulic diagram, arm in / boom raise

Arm in, boom raise simultaneous operation (Priority and fine control)
 When the control levers are operated to “ARM IN” and “BOOM RAISE” secondary servo hydraulic oil flows to ports
AI1 (3-al3), AI2 (3-Pc, 3-4Pi, 9-SH), AM (3-a), BU1 (3-br1), BU2 (3-Ps, 3-Pb, 3-b) on shuttle block (25) for the arm
and boom respectively.
 When arm in and boom raise are operated simultaneously, operation speed depends on the lever control angle.
Each circuit is explained according to the priority function.
 Arm lever and boom lever at full stroke :
 When the arm lever is fully stroked, maximum secondary servo hydraulic pressure applied to port Pc (25-
AI2) on servo hydraulic selector valve (60) pushes the spool to the upside, blocking Pb (25-BU2) flow and
draining the servo hydraulic signal so the spool of logic valve (61) moves to the downside.
 Since P1 pump flow is blocked by the arm spool the pressure rises, and flows through the check valve,
spool valve, to the logic valve upper side holding it closed, preventing P1 flow from merging with P2 flow
for boom raising (boom conflux).
 When the boom lever is fully stroked, maximum secondary servo hydraulic pressure applied to port (Ps)
on arm conflux valve (59) pushes the spool to the left, preventing P2 flow from merging with P1 flow for
arm in (arm conflux).
 Therefore P2 flow is dedicated to boom raise and P1 flow is dedicated to arm in.
 Boom raise priority (Arm fine control)

Boom lever at full stroke and Arm lever at half stroke :
 Since secondary pressure applied to port (Ps) is high (boom lever full stroke) the arm conflux flow is cut
off and P2 flow is dedicated to boom raise.
 However secondary pressure applied to port Pc (25-AI2) is low (arm lever 1/2 stroke) so the spool of
servo hydraulic selector valve (60) is partially stroked and Pb (25-BU2) oil flows to moving the spool of
logic valve (61) partially to the upside, reducing P1 flow to the upper side of logic valve (61).
Now P1 pump flow (P ) at the lower side opens the logic valve and merges with P2 pump flow to the
boom cylinders (boom conflux), to increase boom raise speed.
 Port b (25-BU2) is also pressurized, closing center bypass valve (57), blocking P1 flow so it is routed
through the logic valve.
 Therefore confluent flow is regulated according to the pressure applied to port Pc (25-AI2) via the lever
control angle.
 Arm in priority (Boom fine control)

Arm lever at full stroke and boom lever at half stroke :
 Since secondary pressure applied to port Pc (25-AI2) is high (arm lever full stroke) the spool of
servo hydraulic selector valve (60) is fully stroked, blocking Pb (25-BU2) oil flow and draining
servo hydraulic signal at the spool valve of logic valve (61). Then P1 pump oil flows through the
check valve and spool valve to the logic valve upper side, closing the valve so P1 flow is
dedicated to arm in.
 However secondary pressure applied to port (Py) is low (boom lever 1/2 stroke) so the spool of arm
conflux valve (59) is partially stroked and some P2 pump flow (P ) is routed to merge with P1 pump flow
to the arm cylinder to increase arm in speed.
 Port a (25-AM) is also pressurized, closing center bypass valve (57), blocking P2 flow so it is routed
through the arm conflux valve.
 Therefore confluent flow is regulated according to the pressure applied to port (Ps) via the lever control
angle.
Figure 1
Hydraulic diagram, arm in / boom raise
Service Information

Hydraulic diagram, slew 990 Service Information 2014/10/29
priority (slew right / arm
in)
Profile:
EXC, EC290B LC [GB]
Hydraulic diagram, slew priority (slew right / arm in)

 When the control lever is operated to “SLEW RIGHT” and “ARM IN” secondary servo hydraulic oil from the remote
control valve (22) flows to ports AI1 (3-al3), AI2 (3-Pc, 3-4Pi, 9-SH), AM (3-a), SR1 (3-bl1), SW (3-pa, 9-SH) on
shuttle block (25).
 During the combined operation some P1 pump flow (P ) is supplied to the arm cylinder through orifice (A),
however sharing the pump flow reduces the slew speed. To prevent this (pa) oil at arm regenerating valve (62)
moves the spool to the right restricting the return flow from the arm cylinder rod side. This raises the return circuit
pressure, and opens the regenerating check valve in the center of the arm spool, allowing some return oil to
merge with the supply flow to the arm cylinder.
Therefore more P1 pump flow is directed to the slew function to maintain slew priority.
 All of P2 pump flow (P ) and some of P1 pump flow (P ) is confluently supplied to the arm cylinder. As the supply
flow pressure to the cylinder piston side increases the arm regenerating valve spool (62) is pushed to the left by
the high pressure signal, and the regenerating check valve in the center of the arm spool closes.
 If the bucket is operated in conjunction with the arm and slew operation, P2 pump flow is divided between the
arm and bucket functions. Due to a rapid decrease of flow to the arm cylinder (pressure drop in high pressure
signal to regenerating valve spool) and (pa) pressure applied to regenerating valve (62), the spool is pushed to the
right reactivating the arm regeneration cycle to maintain arm speed.
 Negative lines Fr and Fl are cut off, and the oil delivery rate of P1/P2 pumps are increased.
Line color index

Figure 1
Hydraulic diagram, slew priority (slew right / arm in)
Service Information

Hydraulic diagram, straight 990 Service Information 2014/10/29
travel / arm (straight travel
auto shift, arm in)
Profile:
EXC, EC290B LC [GB]
Hydraulic diagram, straight travel / arm (straight travel auto shift,

arm in)
 When the left, right travel pedals are operated to “FORWARD” secondary servo hydraulic oil flows to main control
valve (3-ar3) and (3-al4) ports, respectively. When control lever is operated to “ARM–IN”, secondary servo
hydraulic oil flows to port AI1 (3-al3), AI2 (3-Pc, 3-4Pi, 9-SH), AM (3-a) on shuttle block (25).
 Servo hydraulic pressure explained below, is for straight travel and related operation only.
 P2 (P ) pump oil is supplied to right travel, and P1 (P ) to left travel. In travelling, straight travel changeover valve
(66) is closed.
 While travel operation primary servo hydraulic pressure, from Pg1 (17-S1) is blocked by the travel spool, the
pressure in (3-Px1) line connected to arm conflux valve (59) disconnecting arm conflux flow and arm regenerating
valve (62) increasing arm regeneration flow to maintain arm in speed.
 Operating “ARM–IN” during travelling, primary servo hydraulic pressure from Pg1 (17-S1) is blocked by the travel
spool and arm spool at main control valve 4–spool valve, the pressure in (3-Px2) line connected to straight travel
changeover valve increases, pushing the spool to the right opening the valve.
 When oil lines of P1 (P ) and P2 (P ) are connected as straight travel valve is opened, so equal flow is supplied to
both motors to maintain straight travel.
 Negative lines Fr and Fl are cut off, so oil delivery rate of P1/P2 pumps are increased.
Line color index

Figure 1
Hydraulic diagram, straight travel / arm (straight travel auto shift, arm in)
Service Information

Hydraulic diagram, straight 990 Service Information 2014/10/29
travel (low / auto shift)
Profile:
EXC, EC290B LC [GB]
Hydraulic diagram, straight travel (low / auto shift)

 When both travel pedals (24) are operated “FORWARD” secondary servo hydraulic oil is routed from the remote
control valve as follows :
 (Port 4) oil flows to the main control valve (3-ar3) moving the travel spool to the left, routing P2 pump
flow to port (11-B) on the right travel motor.
 (Port 2) oil flows to the main control valve (3-al4) moving the travel spool to the right, routing P1 pump
flow to port (11-A) on the left travel motor.
 Travel function (as selected by rocker switch)
 1st speed fixed : Constant low speed, primary servo hydraulic pressure (P3) to port (Pi) of the change
over valve is blocked by solenoid valve (14-A4).
 1st/2nd speed auto shift : Solenoid A4 activated and primary servo hydraulic oil (P2) flows to port (Pi) of
the changeover valve and travel speed is automatically selected according to the load on the motor.
 Low speed : When pressure of travel motor is more than 265 kgf/cm2 or while not traveling (by
controller).
 High speed : When the pressure of travel motor is less than 265 kgf/cm2, primary servo hydraulic
pressure pushes travel speed changeover valve, and travel motor pressure reduces swash plate angle, so
rpm is increased.
 Pg1 (17-S1) oil is applied to switch (10) to input a signal to the controller, so auto idle and pressure boost function
can be used. Circuit connected to remote control valve inside operates straight travel valve.
 The functions of travel motor are brake, anti–cavitation, low/high auto change, and over-speed prevention. (See
the travel motor section)
 As travelling, main pressure boost is done by controller automatically.
 Negative lines of Fr and Fl are cut off to increase oil delivery rate of P1/P2 pumps.
Line color index

Figure 1
Hydraulic diagram, straight travel (low / auto shift)
Thank you for your purchase.
Have a nice day.
file:///C|/Users/app/Documents/yeqiwen-END.txt[2014/10/29 9:31:24]

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Service Information

Document Title: Function Group: Information Type: Date:

The following functions are included in the main control valve :

The optional control valve has the following functions:

Document Title: Function Group: Information Type: Date:

Hydraulic system, description

Document Title: Function Group: Information Type: Date:

Hydraulic oil, description

Document Title: Function Group: Information Type: Date:

Hydraulic system, repair of hydraulic components in workshop

Document Title: Function Group: Information Type: Date:

Hydraulic oil, storage and handling

Document Title: Function Group: Information Type: Date:

Hydraulic system, cleanliness when handling hydraulic components

Document Title: Function Group: Information Type: Date:

Hydraulic components, storage and transport

Document Title: Function Group: Information Type: Date:

Hydraulic system, work instructions

Document Title: Function Group: Information Type: Date:

Hydraulic components, description

Purpose Component Function Feature

Fuel economy Pump

Document Title: Function Group: Information Type: Date:

Hydraulic diagram, schematic

1 Travel spool 7 Slew spool 13 Slew motor

Document Title: Function Group: Information Type: Date:

Hydraulic tank, description

1 Hydraulic oil tank 8 Plain washer 16 Cover

Tightening torque, unit : kgf·m (lbf·ft)

No. Tightening torque

Oil filter bypass valve

A : From main control valve

Document Title: Function Group: Information Type: Date:

Hydraulic oil tank, vacuum-pumping, connecting and disconnecting

14 360 000 Vacuum pump

1. Place the vacuum pump on the hydraulic oil tank.

3. Install adapter (2) and connect hose (1) to the adapter.

4. Connect the plug to the 24 V socket behind the operator's cab.

5. Start the vacuum pump.

8. Turn off the electric power to the vacuum pump.

9. Remove the plug from the 24V socket.

10. Remove the hose from the adapter.

Document Title: Function Group: Information Type: Date:

Oil level gauge, replacing

4. Remove mounting screws (2) and level gauge (1).

6. Assemble the drain cover.

7. Refill hydraulic oil.

Document Title: Function Group: Information Type: Date:

2. Remove breather mounting screws (2).

3. Install the new breather body with a new rubber packing.

Document Title: Function Group: Information Type: Date:

Shock reducing valve, description

Tightening torque 104, 107 (700 ~ 800 kgf·cm (50 ~ 58 lbf·ft))

A → B (Controlled oil flow direction)

B → A (Free flow direction)

Shock reducing valve, troubleshooting

Trouble Cause Remedy

Document Title: Function Group: Information Type: Date:

Check valve, description

1 Screw 4 Spring 7 Split pin

 Creates a back pressure to prevent reverse flow in the return circuit.

Check valve mounting position

Detaching & mounting

Document Title: Function Group: Information Type: Date: