Location and Components

Location of components
Figure 1
Location of components
1Boom 13Muffler 25Undercarraige
2Arm cylinder 14Cowl 26Spring package
3Boom cylinder 15Counterweight 27Cab
4Switch board 16Hydraulic pump 28Idler
5Control lever 17Track motor 29Remote control
and gearbox lever (Travel)
6Operator seat 18Radiator and oil 30Arm
cooler
7Slew gearbox 19Main control 31Bucket cylinder
valve
8Slew motor and 20Turning joint 32Connecting rod
gearbox
9Battery 21Top roller 33Link
10Fuel tank 22Air cleaner 34Bucket
11Engine 23Track link
12Hydraulic tank 24Bottom roller
GEARBOX
Gearbox, specifications
Item Unit EC210 EC240
Track Type – 2–Stage, differential planetary 3–Stage, differential planetary
gearbox Max. revolution rpm 48.1/28.2 47.3/27.7
Reduction ratio – 50.5 59.05
Gear oil Liter 5.8 5.2
Slew Model RGS100/20-00 RGS150/23-00
gearbox Type – 2–stage, differential planetary 2–stage, differential planetary
Reduction ratio 20.01 23.04
Theoretical output kgf·m (lbf·ft) 1045 (7545) 1045 (7545)
torque
RPM rpm 82 68.4
Gear oil Liter 6.0 12
Weight, Dry kg(lbs) 189 (416) 253 (557)
Weight, Wet kg(lbs) 195 (429)
Track gearbox (EC240), assembly

Preparation
· Clean all parts with cleaning solvent and dry with compressed air.
· Rework damaged parts and before assembling, prepare all replacement parts.
· Coat the sliding parts, bearings and gears with clean gear oil.
· Coat the motor assembly sliding parts and bearings with clean hydraulic oil.
· Replace the o-rings, oil seal and seals.
· Replace screws (8). DO NOT REUSE THESE SCREWS!
· Use a torque wrench to tighten the screws and plugs to the specified torque.
Tightening torque
Tightening torque, unit : kgf·m (lbf·ft)
Item No. Description Thread size Torque
4 Screw M 12 38 (274)
8 Screw M 16 11.5 (83)
43 Screw M 10 6.5 (47)
44 Plug PT 1/2 6.6 (48)
Assembly, track gearbox (EC240)

No. Procedure Remark Tool
1 Angular bearing. · The outer races of the angular bearing must be Plastic
· Press-fit the angular bearing (2) into properly aligned and fully seated. hammer
housing (1). · Press-fit using a press or hammer. Bench press
2 Ring gear. · Coat the mating surface of ring gear (3) with liquid Plastic
· Mount housing (1) on ring gear (3) and gasket, loctite #5699. hammer
tighten screws (4). · Apply loctite #277 onto the threads of screws (4). L wrench
14mm (M18)
Torque
wrench
3 Seal. · After assembling the seal, check if the o-ring is

· Press–fit seal (5) lightly into housing (1). properly seated on the motor housing.
· Press–fit lightly seal (5) onto the motor. · Apply thin coat of grease (NLG1#2) to the o-ring.
4 Rotate housing 180°. Take care not to damage the mating surface of the
· Rotate housing (1) with angular bearing seal.
(2) and seal (5) so the seal faces
downward.
5 Retainer. Shim is : 0.1, 0.3, 0.5, and 1.0 mm 19mm socket
· Assemble housing (1) onto the motor Tightening torque : 4.5 kgf·m (32 lbf·ft) Torque
aligning the angular bearing inner race to wrench
the motor housing. Depth gauge
Shim adjusting method :
· Measure the step on retainer (7) as shown.
Dimension “B”
· Install retainer (7) with four screws (8), and
tighten to the specified torque.
· Remove retainer (7) and measure from the
top of the outer bearing race to the motor as
shown.
Dimension “A”
Shim thickness S=A–B–0.4mm
· Select a shim (6) of the appropriate
thickness, align the retainer (7) correctly,
and tighten screws (8) to the specified
torque.
Tightening torque : 11.5 kgf·m (83 lbf·ft)

· Apply loctite #277 onto the thread of screws (8).
6 No. 3 planetary gear assembly. · Check if No. 3 planetary gears rotate Staking
· Place No. 3 carrier (10) with its spline smoothly. method
downward. · Align the spring pin holes of the carrier and Plastic
· Install thrust washers (13), No. 3 planetary gear No. 3 pins. hammer
(11) and needle bearing (12) into No. 3 carrier.
· Insert No. 3 pin (14). A Stake
· Tap spring pin (15) into the pin holes of the No.
3 carrier (10), and pin (14), then stake two
points on No. 3 carrier (10).
7 No. 3 planetary gear assembly. The parts are heavy. Take appropriate safety Eye bolt
· Fit No. 3 planetary gear assembly (9) into the precautions. (M10)
spline of the motor correctly
8 No. 2 planetary gear assembly. · Align the spring pin holes of the carrier and No. 2 Plastic
· Install thrust ring (18) into No. 3 sun gear (19). pins. hammer
· Install thrust washers (24), No. 2 planetary gear · Staking method
(22) and needle bearing (23) into No. 2 carrier.
· Insert No. 2 pin (25). A. Stake
· Tap spring pin (26) into the pin holes of the No. · Check if No. 2 planetary gears rotate smoothly.
2 carrier (17) and pin (25), then stake two
points on No. 2 carrier (17).
· Insert thrust ring (20) into No. 2 carrier (17).
· Install assembled No. 2 carrier onto No. 3 sun
gear (19), and mount retaining ring (21).
9 Insert No. 2 planetary gear assembly into No. 3 The parts are heavy. Take appropriate safety Eye bolt
planetary gear assembly. precautions. (M10)
10 No. 1 planetary gear assembly. · Align the spring pin holes of the carrier and No. 1 Plastic
· Press–fit No. 1 pin (29) into No. 1 carrier (28), pins. hammer
and tap spring pin (30) into the pin holes of No. · Staking method. Snap ring
1 carrier and pin (29), then stake two points on pliers φ 34
No. 1 carrier (28). A. Stake
· Insert thrust washer (36), needle bearing (34), · Check if No. 1 planetary gears rotate smoothly.
No. 1 planetary gear (33) and thrust washer
(35) onto No. 1 pin (29). Mount snap ring (37).
· Install assembled No. 1 carrier onto No. 2 sun
gear (31), and mount retaining ring (32).
11 Assembly of No. 3 planetary gear assembly The parts are heavy. Take appropriate safety Eye bolt
· Insert No. 2 planetary gear assembly into No. 3 precautions. (M10)
planetary gear assembly.
12 No. 1 sun gear.
· Insert thrust ring (38) into No. 2 sun gear (31), A. Loctite #5699
and then No. 1 sun gear (39) onto the motor
shaft.
13 Thrust ring. Plastic
1. Shim adjusting method : hammer
1. Measure dimension “L” of cover Depth gauge
(40).
2. Measure dimension “H” from the
end of No. 1 sun gear (39) to the contact
surface of ring gear (3).
3. Measure the thickness “T” of
thrust ring (38).
4. Shim thickness s = L – H – T –
(1.0 ~ 2.0 mm)
2. Select a shim of the appropriate
thickness, and mount shim (41) and thrust ring
(38) on cover (40).
14 Cover. · Coat the mating surface of ring gear (3) with liquid Eye bolt
· Screw an eye bolt into the oil level port and gasket, loctite #5699. (PT 1/2)
install cover (40) on ring gear (3). Install spring · Apply loctite #277 onto the threads of screws (43). L wrench
washer (42), screws (43), and tighten to Tightening torque : 6.5 kgf·m (47 lbf·ft) 8mm (M10)
specified torque. Torque
A. Eye bolt wrench
Plastic
hammer
15 Plug. · Apply loctite #577 onto the threads of Torque

· Install plugs (44) into cover (40) and plugs (44). wrench
tighten to specified torque. · Tightening torque : 6.6 kgf·m (48 lbf·ft) L wrench 10
mm (PT1/2)
A. Fill port
B. Level port
C. Drain port
Track gearbox (EC240), description

Principle of operation
The gearbox consists of a three stage planetary mechanism that converts the high speed rotation of the hydraulic
motor, into low speed, high torque rotating force at the sprocket hub.
The power transmitted from the hydraulic motor output shaft is transmitted to the 1st stage sun gear (39) → spline
of 1st carrier (28) → 2nd sun gear (31) → 2nd planetary gear (22) → spline of 2nd carrier → 3rd sun gear (19) →
3rd planetary gear (10) → ring gear (3). At this time, the reduction ratio of reduction gear is as follows : (1) 1st
reduction ratio i 1 = (Zs1+Zr1) · (Zs2+Zr) · (Zs3+Zr) / Zs1·Zs2·Zs3 – 1
Zs1 = No. of tooth of 1st sun gear
Zs2 = No. of tooth of 2nd sun gear
Zs3 = No. of tooth of 3rd sun gear
Zr1 = No. of tooth of 1st ring gear
Zr= No. of tooth of ring gear
Figure 1 Track gearbox (EC240), torque flow
Track gearbox, sectional view

Figure 2 Track gearbox (EC240), sectional view
1Housing 17No. 2 carrier 33No. 1 planetary gear
2Angular bearing 18Thrust ring 34Needle bearing
3Ring gear 19No. 3 sun gear 35Thrust washer
4Screw 20Thrust ring 36Thrust washer
5Seal 21Retaining ring 37Snap ring
6Shim 22No. 2 planetary gear 38Thrust ring
7Retainer 23Needle bearing 39No. 1 sun gear
8Screw 24Thrust washer 40Cover
9No. 3 planetary gear assembly 25No. 2 pin 41Shim
10No. 3 carrier 26Spring pin 42Spring washer
11No. 3 planetary gear 27No. 1 planetary gear assembly 43Screw
12Needle bearing 28No. 1 carrier 44Plug
13Thrust washer 29No. 1 pin 45Name plate
14No. 3 pin 30Spring pin 46Screws
15Spring pin 31No. 2 sun gear
16No. 2 planetary gear assembly 32Retaining ring
Track gearbox (EC240), disassembly

Precautions
· Thoroughly clean the gearbox assembly prior to disassembly.
· Select a clean work area.
· Match mark attached components to indicate proper positioning during reassembly.
· Take care not to mix parts of sub assemblies i.e. planetary bearings, gears and thrust washers.
· Thoroughly clean all parts and the inside of the casings.
· Inspect and analyze all failures. – Determine the root cause!
Disassembly
No. Procedure Remark Tool
1 Drain oil Drain oil into a clean container and check L wrench 10 mm (PT
· Place the oil fill port and the oil thoroughly for contamination. 1/2)
drain port on the vertical axis. 8 liter pan
Remove plug (44) and drain the
gear oil.
A. Fill port
B. Level port
C. Drain port
2 Remove cover. Install an eye bolt in the oil level port A (PT Socket 8mm eye bolt
· Remove screws (43) and remove 1/2) and carefully lift the cover off. (PT 1/2)
cover (40).
3 Remove No. 1 sun gear

· Remove No. 1 sun gear (39).
4 No. 1 planetary gear assembly. · Match mark gears (33), pins (29) Snap ring pliers (φ
· Remove No. 1 planetary gear and carrier (28). 34)
assembly (27) from No. 2 · Do not mix the gears, bearings, (–) screwdriver
planetary gear assembly (16). thrust washers, and pin
assemblies.
· Do not remove pins (29), if not
worn or damaged.
· Do not reuse spring pins (30).
· Disassemble No. 1 planetary
gear assembly
1. Remove snap ring (37), then thrust
washer (36), No. 1 planetary gear
(33), needle bearing (34) and thrust
washer (35).
1. Remove retaining ring (32), and

then No. 2 sun gear (31).
2. Remove thrust ring (38).
3. Remove spring pin (30) from No. 1
carrier (28), and then No. 1 pin (29).
5 No. 2 planetary gear assembly. The parts are heavy. Take appropriate Eye bolt (M10)
· Remove No. 2 planetary gear safety precautions. Plastic hammer
assembly (16) from No. 3 · Match mark gears (22), pins (25)
planetary gear assembly (9). and carrier (17).
· Do not mix the gears, bearings,
thrust washers, and pin
assemblies.
3. Disassemble No. 2 planetary gear

assembly.
1. Tap spring pin (26) into No.
2 pin (25).
2. Remove thrust washer (24),
No. 2 planetary gear (22) and needle
bearing (23) from No. 2 carrier (17).
4. Remove retaining ring (21),
then No. 3 sun gear (19).
6 No. 3 planetary gear assembly. The parts are heavy. Take appropriate Eye bolt (M10)
· Remove No. 3 planetary gear safety precautions. Plastic hammer
assembly (9) from the motor.
· Match mark gears (11), pins (14)
and carrier (10).
· Do not mix the gears, bearing,
thrust washers, and pin
assemblies.
4. Disassembling No. 3 planetary gear

assembly
1. Tap spring pin (15) into No. 3 pin (14).
2. Remove thrust washer (13), No. 3
planetary gear (11) and needle
bearing (12) from No. 3 carrier (10).
7 Remove retainer. Do not reuse the screws. 19mm socket (M12)

· Remove screws (8), retainer (7)
and shim (6).
8 Screw the eye bolts into ring gear (3), and The parts are heavy. Take appropriate Eye bolt (M10)
remove ring gear (3), housing (1), screws safety measures. Plastic hammer
(4), angular bearing (2) and seal (5) as an · When difficult to remove, lift the body
assembly. vertically and tap lightly with a plastic
After removal, place the entire assembly hammer.
facing downward.
9 Remove seal. Be careful not to damage the o-ring and
1. Remove seal (5) from housing (1). seal surface.
2. Remove seal (5) from motor.
10 Remove housing. Eye bolt (M20)
Remove screws (4), screw the eye bolt into Plastic hammer
housing (1), lift the housing, tap lightly with a
plastic hammer, and separate ring gear (3)
and housing (1).
11 Remove angular bearing Since the bearing is shrink-fitted and is Bearing fixture
Remove the angular bearing (2) from difficult to remove, use a press and a Plastic hammer
housing (1). bearing disassembling fixture, or tap with a
hammer.
Track gearbox (EC240), maintenance standard

The parts are precision finished and must be handled carefully. Keep the parts of the planetary carrier (s)
together, do not mix the bearings, gears, pins and thrust washers.
Seals
Replace the seals, oil seal and o-ring, although they appear not damaged.
Part replacement criteria
Replace all parts that appear damaged or are not within the allowable value.
Replace some parts in sets, i.e. gears, bearings, pins and thrust washers.
Wear limits
Item No. Part Condition Standard Allowable value
value
3 Ring gear The tooth surface is pitted or Area rate :
11 No. 3 planetary gear nonuniformly worn. within 5%
19 No. 3 sun gear The gear is cracked.
22 No. 2 planetary gear
31 No. 2 sun gear
12 Needle bearing Fitting/flaking of the balls, rollers
23 Needle bearing or races.
34 Needle bearing Does not rotate smoothly by
2 Angular bearing hand.
5 Seal Rust or damage on sliding face.
O–ring distorted or damaged.
14 No. 3 pin The pin is cracked, galled or
25 No. 2 pin pitted.
29 No. 1 pin
13 Thrust washer Excessively worn on the face
24 area.
35
Track gearbox (EC240), tools

No. Description Size Quantity
1 Socket wrench 8mm 1
10mm
2 L wrench 10mm 1
14mm
3 Torque wrench 400 ~ 1800 kgf·cm 1
3000 ~ 5000 kgf·cm
4 Snap ring pliers φ 34 1
5 Eye bolt PT 1/2 2
M 10
M 20
6 Press 1 ton 1
7 Plastic hammer Approximately L = 300 ~ 500 mm 1
8 (–) Screwdriver Approximately L = 200 mm 1
9 Depth gauge Range approximately 300 mm 1
(Vernier caliper) Min. scale 0.01 mm
Special tools
1 Bearing shim adjust fixture See the diagram below 1
Shim thickness measuring fixture
Figure 1 Fixture, shim thickness measuring

Shim thickness measuring position
Part nr. : 8933-00330
Track gearbox (EC240), troubleshooting
Figure 1 Troubleshooting, track gearbox (EC240)
Track gearbox (EC240), precautions for operation

Installation
Check that the mating mount surfaces are clean.
Check that the motor is positioned correctly in the frame.
If the gearbox to frame fit is tight, draw the assembly into the frame evenly with the mounting screws.
Tighten the screws in a crisscross pattern in several stages to the specified torque.
Apply these same precautions when mounting the sprocket.
Figure 1 Installation, track gearbox (EC240)
(A) ··· Main body mounted area
(B) ··· Sprocket mounted area.
Tightening torque
Quantity Thread size Torque, kgf·m (lbf·ft)
Screw (A) 30 M16 (P2.0) 26 ~ 29 (188 ~ 209)
Screw (B) 18 M18 (P2.5) 34 ~ 42 (245 ~ 303)
NOTE!
The screws must be 10.9 strength classification or above.
Lubrication oil
Prior to operating the travel function, fill the gearbox with the specified oil to the correct level.
Gear oil replacement
First (initial) oil replacement : 500 operating hours
Subsequent oil replacement : 1000 operating hours
After maintenance (initial) : 250 operating hours
NOTE!
Regardless of the operating hours the gear oil must be replaced at least once per year.
Do not mix different types, classifications or brands of oil!
Drain the gear oil while it is still warm to flush out any contaminants.
Gear oil replacement procedure
Rotate the gearbox until the drain plug and the fill plug are on the vertical axis.
Remove the 3 plugs in the end cover and drain the oil into a suitable container.
Ensure that the drain plug o-ring is not damaged, then install the plug and torque to specification.
Refill the gearbox through the fill port until oil exits from the level check port.
Oil capacity : 5.2 Liter (1.3 gal)
Ensure that the o-ring on each plug is not damaged, then install the plugs and torque to specification.
Figure 2 Position, gear oil replacement

A. Fill port
B. Level port
C. Drain port
Operating checks
Check the oil level prior to operating the track function.
Check for oil leakage on the gearbox assembly.
Check for loose mounting screws.
Check for abnormal sound or vibration while rotating.
Check for any abnormal temperature increase after operating for a short time.
The temperature of the case is high just after running. Use a thermometer to measure. Do not touch
directly by hand to prevent a burn injury.
The temperature of the case must be lower than 80 °C, during continuous operation.
Track gearbox, installation

Carefully check the mating surface of the undercarriage and the gearbox for burrs, dirt and rust scale.
1. Pass a wire rope around the gearbox, lift and install the gearbox to the undercarriage.
Figure 1 Install, track gearbox

1. Apply Loctite 277 to the gearbox mounting screws, and tighten them to the specified torque.
Tightening torque : 25.5 ~ 31.5 kgf·m (184 ~ 227 lbf·ft)
1. Connect the hydraulic hoses at the track motor.
2. Install the gearbox cover.
3. Check the gear oil level of gearbox. If necessary, replace or refill the oil.
A – Drain port
B – Level port
C – Filling port
Figure 2 Checking, oil level

Track gearbox, removal
1. Remove cover screw (2) of track gearbox, and remove cover (1).
Figure 1 Removal, cover

1. Remove the track.
2. Place a wooden block on the track, and place the lower roller on the block to raise the sprocket off the
track.
3. Disconnect the hydraulic hoses at the track motor. Plug the pipe ends and ports to prevent the outflow of
oil and the entry of contamination.
Figure 2 Removal, hydraulic hoses and screws
1. Remove the track motor mounting screws from the undercarriage.
2. Pass a wire rope around the gearbox, and lift it. Remove the track motor as an assembly. Then, using
screws in the threaded holes of the undercarriage, force out the gearbox.
Figure 3Removal, track gearbox

NOTE!
Lift the gearbox as close to the sprocket as possible to maintain balance.
NOTE!
The gearbox mounting screws may be used in the threaded frame holes.
NOTE!
Putting match–marks on the track frame and track gearbox will facilitate reassembly.
Slew gearbox (EC240), assembly

Precautions
When mounting the gearbox assembly to the superstructure, position it on the dowel pin located in the mounting
plate to ensure that the drain / fill ports are properly positioned.
Mount the hydraulic motor on the gearbox assembly so that the oil level gauge and plumbing connections are
positioned as shown in the construction drawings.
Use a torque wrench to tighten the mounting screws to the specified torque.
Clean all parts with cleaning solvent and dry with compressed air.
Rework damaged parts and before assembling, prepare all replacement.
Coat the sliding parts, bearings,and gears with clean gear oil.
Replace the oil seal.
Use a torque wrench to tighten the screws and plugs to the specified torque.
Item No. Description Thread Torque
34 Screw M12 12~13 (87~94)
20 Screw M16 34~35 (245~252)
39 Pipe PT 1/2 6.5~7 (47~50)
40 Plug PT 1/2 6.5~7 (47~50)
36 Pipe PT 3/4 10~11 (72~79)
Assembly, slew gearbox (EC240)
Procedure Remark Tool
1 2nd planetary gear assembly. Heat spherical bearings (8, 10) in oil to 110 °C (230 – Plastic
Press spherical bearing (8) onto °F) prior to installation. hammer
crankshaft (2). Apply a dab of grease to hold thrust washers (6) to – Spring pin
Insert thrust button (9). gear (3). disassembly/
Dimension L =135 mm. Install spring (7) with the slit facing the end of pin assembly jig
Insert needle bearing (5) into gear (3), (4).
install thrust washers (6) on the gear, Ensure that the gears rotate smoothly.
then insert the assembly into Align the spring pin hole in pin (4) and crankshaft
crankshaft (2). (2).
Insert pin (4). Do not reuse the spring pins.
Tap spring pin (7) into the pin hole of
crankshaft (2).
After inserting, stake both sides of spring
pin (7).
Press spherical bearing (10) onto
crankshaft (2).
Stake
2 Oil seal. Pay attention to the oil seal assembling direction. Oil seal
– Press–fit oil seal (12) into front casing Apply grease (NLGI 2) in the seal chamber of oil assembly jig
(11) using the seal assembly jig. seal (12).
Coat the outer seal diameter with loctite #680.
3 Plate Apply loctite #243 onto the thread of screws (14). (+) Driver
– Tighten screws (14) after aligning plate
(13) exactly to front casing (11).
4 2nd ring gear. Coat the mating surface of front casing (11) with Plastic hammer
– Press–fit 4 dowels (16) into front casing liquid gasket #5699.
(11) and assemble No.2 ring gear (15). Apply molycoat on dowel pins (16).
Align the match marks on casing (11) and ring
gear (15).
5 2nd planetary gear assembly. Plastic hammer

Block the collar of front casing (11) 180mm
from the bench top, and insert The shaft is heavy. Take appropriate safety
crankshaft/planetary assembly (2) into precautions when handling.
front casing (11). Take care not to damage the oil seal lip.
Tap the assembly with a hammer to fully After 2nd gear assembly is installed, check if the
seat spherical bearing (8). oil seal lip is rolled up.
6 Intermediate casing. Align the match marks on casing (17) and ring gear L wrench :
Assemble casing (17) onto ring gear (15). 14 mm (m16)
(15) and install the screws (20). Coat the mating surface of casing (17) with liquid Torque wrench.
gasket loctite #5699.
Apply loctite #277 onto the threads of screws (20).
7 2nd sun gear. Snap ring pliers

Insert C–type snap (19) into 2nd sun (expansion φ85)
gear (18) and install it into 2nd
planetary assembly (1).
8 1st ring gear. Coat the mating surface of casing (17) with liquid
Assemble ring gear (30) to gasket loctite #5699.
intermediate casing (17).
9 1st planetary assembly. Snap ring pliers
Press–fit pins (24) to carrier (22) and (expansion φ 40)
install spring pins (29). After
inserting, stake both sides of
spring pins (29).
Onto pin (24), install thrust washer
(27), gear (23), including bearing
(25), thrust washer (26) and snap A Stake
ring (28).
Check if planetary gears (23) rotate smoothly.
Stake
10 1st planetary gear assembly. Coat the mating surface of ring gear (30) with liquid
– Install planetary gear assembly (21) onto gasket loctite #5699.
2nd sun gear (18) and 1st ring gear (30).
11 1st sun gear.

– Put thrust washer (31) on 2nd sun gear
(18) then install 1st sun gear (32).
12 Motor assembly Align the match marks on ring gear (30) and the Snap ring pliers
Install C–type snap ring (33) onto the motor. (expansion φ 40)
motor shaft, install the motor onto Coat the mating surface of ring gear (30) with Torque wrench
ring gear (30). liquid gasket loctite #5699. L wrench : 10
And install screws(34). Apply loctite #277 onto the threads of screws mm (M12)
(34).
13 Drain pipe and level gauge. Face the oil drain port of pipe downward. Spanner 24 × 27
Tighten plug (40) to pipe (39) and pipe Coat with teflon tape or loctite #577 on the pipe mm
(39) to case (11). and plug thread. Torque wrench
Install pipe (36) onto the motor, and
insert level gauge (35).
Slew gearbox (EC240), description

Model code
Figure 1 Model code

The gearbox is comprised of the following components.
Hydraulic motor M2×146B
Gearbox RGS 150/23–00
The gearbox consists of the crankshaft as a group including the 1st planetary gear assembly, the 2nd planetary
gear assembly and the 1st and 2nd sun gear pinions, the housing supporting the crankshaft, and the ring gear
including the planetary gear.
Figure 2
Slew gearbox (EC240)
A. Motor assembly
B. Intermediate
C. No. 1 planetary
D. No. 2 planetary
E. Crankshaft
Figure 3
Slew gearbox (EC240), sectional view
1No.2 planetary gear assembly 15No.2 ring gear 29Spring pin
2Crankshaft 16Dowel pin 30No.1 ring gear
3No.2 planetary gear 17Intermediate casing 31Thrust washer
4No.2 pin 18No.2 sun gear 32No.1 sun gear
5Needle bearing 19C–type snap ring 33C–type snap ring
6Thrust washer 20Screw 34Screw
7Spring pin 21No.1 planetary gear assembly 35Level gauge
8Spherical bearing 22No.1 carrier 36Pipe
9Thrust button 23No.1 planetary gear 37Name plate
10Spherical bearing 24No.1 pin 38Screw
11Front casing 25Needle bearing 39Pipe
12Oil seal 26Thrust washer 40Plug
13Plate 27Thrust washer
14Screw 28C–type snap ring
Slew gearbox (EC240), disassembly

General tools
1 Spanner 17 × 19 mm 1
24 × 27 mm 1
2 Socket wrench 1
3 Allen wrench 10 mm 1
14 mm 1
4 Torque wrench (kgf·cm) 400 ~ 1800 1
1200 ~ 4800 1
5 Snap ring pliers φ35 1
φ42
6 Plastic hammer L = 300 1
7 Eye bolt M 10 2
M 12 2
M 16 2
M 18 2
8 Drive (–) 150 mm 1
Drive (+)
Special tools
No. Description Quantity
1 Spherical bearing disassembly jig 1
2 No.2 pin assembly jig 1
3 Spring pin disassembly jig 2
4 Oil seal assembly jig 1
Spherical bearing disassembly jig (unit : mm)
Figure 1or spherical bearing disassembly

Part nr. : 8932-00080
No. 2 pin disassembly jig (unit : mm)
Figure 2 Jig for No.2 pin disassembly

Part nr. : 8932-00090
Spring pin disassembly jig (unit : mm)
Figure 3 Jig for spring pin disassembly
Part nr. : 8932-00060, 8932-00070
Oil seal assembly jig (unit : mm)
Figure 4 Jig for oil seal assembly

Part nr. : 8932-00050
Disassembly
Precautions
Thoroughly clean the gearbox assembly prior to disassembly.
Select a clean work area.
Match mark attached components to indicate proper positioning during reassembly.
Take care not to mix the parts of sub assemblies i.e. planetary bearings, gears and thrust washers.
Thoroughly clean all parts and the inside of the casings.
Inspect and analyze all failures. – Determine the root cause !
Disassembly, slew gearbox (EC240)
Procedure Remark Tool
1 Removal of hydraulic motor. Make match marks on the hydraulic motor L wrench 10 mm
– Remove plug (40) and drain the gear casing, gear (30) intermediate casing (17), (M 12), 14 mm
oil. ring gear (15) and front casing (11). (PT 12)
– Remove screws (34). Make sure the match marks are permanent and
– Lift the motor off the gearbox. clearly visible.
A Match marks
2 1st sun gear.
– Remove 1st sun gear (32).
– Remove thrust washer (31).
3 1st planetary gear assembly. Match mark gears (23), pins (24), and carrier Snap ring pliers
Remove 1st planetary gear (22). (expansion φ40)
assembly (21) from 1st ring Do not mix the gears, bearings, thrust washers, Spring pin
gear (30). and pin assemblies. disassembly/asse
Disassemble the 1st planetary Do not remove pins (24) if not worn or damaged. mbly jig
gear assembly in the following Do not reuse spring pins (29).
order :
Remove C–type snap ring (28),
thrust washer (26), 1st
planetary gear (23), needle
bearing (25) and thrust washer
(27).
Remove spring pin (29) from 1st
carrier (22) to take out pin (24).
4 2nd sun gear. Snap ring pliers

– Remove 2nd sun gear (18). (expansion φ 85)
If necessary, remove C–shape snap
ring (19).
5 1st ring gear Make sure the match mark is clearly visible.
– Attach 2 (M10) eye bolts to 1st ring
gear (30), and remove it from
intermediate casing (17).
6 Intermediate casing L wrench 14mm
– Remove screws (20), use two taps (M16)
(M18) to remove casing (17).
7 2nd planetary gear assembly Match mark gears (3), pins (4), and carrier (2). Bearing
Remove 2nd planetary gear Do not mix the gears, thrust washers, bearings disassembly jig
assembly (1) and spherical and pin assemblies. Pin disassembly
bearing (8, 10) from front Do not reuse spring pins (7). jig
casing (11), attach 2 (M12) eye After removing pin (4) remove spring (7). Spring pin
bolts to crankshaft (2). disassembly jig
Disassemble in the following order:
Remove spherical bearing (10)
using the jig.
Tap spring pin (7) into pin (4).
Remove planetary gear (3).
Remove spherical bearing (8)
using the jig.
If thrust button (9) is worn, remove
it by drilling and tapping the
center for an M8×25 screw.
8 2nd ring gear Make sure the match marks on casing (11) and
Remove No. 2 ring gear from front ring gear (15) are clearly visible.
casing (11) by attaching 2 If dowel pin (16) is loose, the bores must be
(M10) eye bolts. reamed and a larger pin fitted.
9 Oil seal. Don’t reuse the oil seal. (+) Driver
Remove screws (14) and remove (–) Driver
plate (13).
Remove oil seal (12).
Slew gearbox (EC240), maintenance standard

The parts are precision finished and must be handled carefully. Keep the parts of the planetary carriers together,
do not mix the bushings, gears, pins and thrust washers.
Seals
Replace the oil seal and o-rings, although they appear not damaged.
Part replacement criteria
· Replace all parts that appear damaged or are not within the allowable value.
· Replace some parts in sets, i.e. gears, bushings, and thrust washers.
Wear limit
Item Part name Condition Allowable value
37,18 No. 1, 2 sun gear Pitting on gear teeth surface. Dia : Within φ 1 mm
23,3 No. 1, 2 planetary gear Area rate : Within 5 %
30,15 No. 1, 2 ring gear
5,25 Needle bearing Flaking on the needle bearing sliding surface. Partial
wear
8 Spherical bearing Pitting/flaking of the races or rollers.
10 Spherical bearing Does not rotate smoothly by hand.
12 Oil seal Always replace.
6,26 Thrust washer Abnormal wear on the face area.
27,31
19,28,33 C–type snap ring Abnormal wear on the face area.
Dowel pin (16) and pin hole
5. Diameter of the dowel pin is φ 18 mm.
6. Machine the pin hole on No. 2 ring gear and front casing together. If one of these has to be replaced
because of too much clearance from excessive wear do it as follows :
1. Assemble the front casing and the No. 2 ring gear together by tightening 4 screws size M18×90
mm length.
Use plain washers in order not to damage the surface of the ring gear by the screw head.
2. Ream φ19 H7 +0.021/+0 to basic hole of φ18
In case of replacing the ring gear, drill a servo hydraulic hole because the basic hole can not be seen.
3. Make a mark on the front casing and No. 2 ring gear.
4. Use a pin size φ19 P6 +0.035/+0.022 of 90 mm length.
Schedule, part replacement
Parts replacement schedule
No Description 11 15 16 18 2 3 4 5 6 9 8 10 7
11 Front casing – Note A
15 No.2 ring gear Note – A B B B B B B B B B B
16 Dowel pin –
18 No.2 sun gear – B B B B B B B B B
2 Crank shaft – B A A B A A A A
3 No.2 planetary gear B – A A B B A A A
4 No.2 pin B B – A B B A A A
5 Needle bearing B A A – B B A A A
6 Thrust washer B B A A – B A A A
9 Thrust button B B B B B – B B B
8 Spherical bearing A B A A B A – A A
10 Spherical bearing B B B B B B B – B
7 Spring pin B B A B B B B A –
A : Replaced at the same time if required.
B : Basically, these parts should be replaced together.
NOTE!
The reamer hole of the front casing and ring gear is machined together and if required to replace one of them.
Schedule, part replacement
Parts replacement schedule
Description 22 23 25 24 29
22 No.1 Carrier – A
23 No.1 B – B B B
Planetary gear A A A A
25 Needle roller bearing A A – A A
24 No. 1 pin A A A – A
29 Spring pin –
A : Replace at the same time if required.
B : Basically, these parts should be replaced together.
Slew gearbox (EC240), principle of operation

The 2–stage planetary gear reduction assembly converts the high speed / low torque output of the hydraulic motor
to low speed / high torque output, which is transmitted via the reduction drive shaft pinion gear to the slew ring
inner circumference gear to rotate the superstructure.
Operation
Power supplied to the output shaft of the hydraulic motor is transmitted to the 2nd sun gear (18) through the
splines of the 1st sun gear (32), the 1st planetary gear (23), the 1st pin (24) and the 1st carrier (22). In the same
way, power is transmitted to output shaft (2) through the splines of the 2nd planetary gear (3), the 2nd pin (4) and
the 2nd carrier.
Figure 1 Slew gearbox (EC240)

A. Torque flow
At this time, the reduction ratio of reduction gear is as follows :
· 1st reduction ratio
i1 = (Zr / ZS1) + 1
i1 = 1st reduction ratio
ZS1 = No. of gear tooth of the 1st sun gear
Zr = No. of tooth of the 1st ring gear
· 2nd reduction ratio
i2 = (Zr / ZS2) + 1
i2 = 2nd reduction ratio
ZS2 = No. of gear tooth of the 2nd sun gear
Accordingly the total reduction ratio of reduction gear is as follows : i = i1 × ι2= ((Zr / ZS 1) + 1) × ((Zr / ZS2 ) + 1)
i = Total reduction ratio
Slew gearbox (EC240), principle of operation

The 2–stage planetary gear reduction assembly converts the high speed / low torque output of the hydraulic motor
to low speed / high torque output, which is transmitted via the reduction drive shaft pinion gear to the slew ring
inner circumference gear to rotate the superstructure.
Operation
Power supplied to the output shaft of the hydraulic motor is transmitted to the 2nd sun gear (18) through the
splines of the 1st sun gear (32), the 1st planetary gear (23), the 1st pin (24) and the 1st carrier (22). In the same
way, power is transmitted to output shaft (2) through the splines of the 2nd planetary gear (3), the 2nd pin (4) and
the 2nd carrier.
Figure 1 Slew gearbox (EC240)

A. Torque flow
At this time, the reduction ratio of reduction gear is as follows :
· 1st reduction ratio
i1 = (Zr / ZS1) + 1
i1 = 1st reduction ratio
ZS1 = No. of gear tooth of the 1st sun gear
Zr = No. of tooth of the 1st ring gear
· 2nd reduction ratio
i2 = (Zr / ZS2) + 1
i2 = 2nd reduction ratio
ZS2 = No. of gear tooth of the 2nd sun gear
Accordingly the total reduction ratio of reduction gear is as follows : i = i1 × ι2= ((Zr / ZS 1) + 1) × ((Zr / ZS2 ) + 1)
i = Total reduction ratio
HYDROSTATIC DRIVER
Hydrostatic drive, specifications
Specifications
Item Unit EC210 EC240
Track motor Model – EM140V EM140V
Type – Variable swash plate Variable swash plate
piston motor piston motor
Displacement cm3/rev 82.4/140.5 82.4/140.5
(cu·in/rev) (5.03/8.57) (5.03/8.57)
Rated pressure kgf / cm2(psi) 350 (4980)
Parking brake Type – Wet disc, spring applied, hydraulic release
Input flow l pm (gpm) 200 (52) 230 (59.8)
Output speed rpm 2563/1503 2680/1604
Control pressure, Automatic kgf/cm2 (psi) 260 (3697) 260 (3697)
Parking brake release pressure kgf/cm2 (psi) 6.0 (85) 6.0 (85)
Casing pressure kgf/cm2 (psi) Max. 2 / 7 (28/100) Max. 2 / 7 (28/100)
(normal / peak)
Slew motor Model – M2X120B–CHB M2X146B–CHB
Type – Fixed swash plate, Fixed swash plate, piston
piston motor motor
Displacement cc / rev 121.6 145.9
relief pressure kgf / cm2 270 (3840) 270 (3840)
Brake release (psi) 29 (412) 27 (384)
pressure
Casing pressure(normal) Within 2 (28) Within 2 (28)
Rated speed rpm 1645 1576
Brake delay sec 5 +3-/0 5 +3/-0
Case drain (270 kgf/cm2 at 100°C) l/min (gpm) 23 (6) 25 (6.5)
Oil capacity Liter (gal) 0.9 (0.23) 0.9 (0.23)
Assembly weight kg 53 (24) 65 (29.5)
(motor only)
Track motor (EC240), description

Hydraulic motor is basically the same structure as that of the EC210. But piston and cylinder sizes are different, to
provide a greater flow rate. (Contents are not included in this manual). 3–stage planetary gear reduction assembly
has low speed/high torque structure.
Figure 1 Structure, track motor (EC240)
1. 1Motor 1. 4No. 3 planetary gear assembly
2. 2No. 1 planetary gear assembly 2. 5Ring gear
3. 3No. 2 planetary gear assembly 3.
Track motor (EC240), construction

Figure 2 Construction, track motor (EC240)
F Fill port
O Oil level check port
D Drain port
Port connection
Port symbol Port size Port
(A) (B) PF1 Oil supply (return)
(P1)~(P2) PT 1/4 Pressure check
(P) PT 1/4 Displacement changeover valve oil supply
(P3) PF 1/8 Brake release pressure
(D )~(D )
1 2
PF 1/2 Drain
Rotational direction
Inlet Outlet View from X
axis
A B Clockwise
B A Counterclockwi
se
Flexible coupling
Figure 1 Structure, flexible coupling
Figure 2 Flexible coupling, sectional view A - A

1. Insert A
2. Element
3. Insert B
4. Hub
5. Screw (M18 x 2.5 x 60L)
6. Screw (M18 x 2.5 x 55L)
7. Clamping screw (M16 x 2.0 x 16L)
8. Spring pin
Tightening torque
No. Torque kgf·m (lbf·ft)
5 31~33 (244~238)
6 31~33 (224~238)
7 10~12 (72~87)
Idler, assembly
Assemble in the reverse order of disassembly.
1. Place bushing (4) on idler wheel (1), and using jig (h), force fit with press (a).
Figure 1 Assembly, bushing
1. Install o-ring (9) on shaft (2).
Figure 2 Assembly, o-ring and etc

1. Apply a thin coat of grease to inner side of support (3), install shaft (2), and insert spring pin (7). In this
case, take care not to damage o-ring (9).
2. Insert seal ring (5) and o-ring (6) to the support and idler wheel (1), respectively.
3. Install shaft (2) to idler (1). Lightly coat engine oil on seal ring (5) contact face.
Figure 3 Assembly, shaft

1. Install support (3) with seal ring (5) and o-ring (6).
2. Insert pin (7) with hammer (k).
Figure 4 Assembly, spring pin

1. Prior to filling with oil perform a pressure leak test. – Attach a pressure regulated air line to the oil fill port,
then completely immerse the assembly in water. – Under a pressure of 2 ~ 3 kgf/cm 2 (28 ~ 43 psi), air
bubbles must not form for 15 seconds.
2. Fill with engine oil (j).
Oil amount
EC210 Series EC240 Series
365 cc (22.3 cu·in)
1. Install plug (8) with teflon tape (L), and tighten securely.
Inspection after assembly
7. Confirm that there are no oil leaks around seals (5,6) and plug (8).
8. Assemble the idler assembly and track spring. After assembling, manually confirm that idler (1) rotates to
the extent you can rotate it despite the resistance. (More than 10 times).
Figure 5 Assembly, idler and track spring
1. Apply loctite #277 to screw A
2. Tightening torque : 25.5 ~ 31.5 kgf·m(184 ~ 227 lbf·ft)
9. End play must be within 0.1 to 0.6 mm.
Idler, description
Figure 1
Structure, idler
1 Idler wheel 6 O–ring
2 Shaft 7 Pin
3 Support 8 Plug
4 Bushing 9 O–ring (shaft)
5 Seal ring
Idler, disassembly
The numbers in parentheses following each part name in the text correspond to those in figure.
1. Remove the screws, and remove the spring package.
Figure 1 Removal, spring package
1. Remove plug (8) to drain oil.
2. Put pin jig (d) on pin (7), and force out the pin by lightly tapping the jig with a hammer.
Figure 2 Removal, pin

1. Place idler (1) on idler support jig (f), put shaft removal jig (g) on shaft (2) and force out the shaft using
press(a).
Figure 3 Push with a press

1. Place idler (1) on idler support jig (f), put bushing removal jig (e) on bushing (4), and drive out the bushing
by lightly tapping the jig.
Figure 4 Removal, bushing

1. Remove seal ring (5) and o-ring (6) from idler wheel (1) and support (3), respectively.
2. Remove o-ring (9) from shaft (2).
Inspection after disassembly
1. Confirm that there is no damage or rust on the sealing face of seal (5).
2. Confirm that any wear of idler (1) is within the allowable range.
3. Confirm that any wear of shaft (2) or bushing (4) is within the allowable range.
Figure 5 Location to be inspected
Idler, installation
Installation of the idler and the spring package
1. Tighten connecting screws (1) of idler and track spring.
2. Pass a wire rope around the spring package bracket, lift the idler assembly, then fit and push the slide
block into the slide groove in the track frame.
Confirm that the boss at the piston end of the spring package is in the track frame hole.
Figure 1 Install, idler assembly

1. Install the track.
Figure 2 Installation, track

Idler, measurement of wear
Figure 1 Measurement, wear

Limit of wear, unit : mm (in)
No. Check item Standard size Repair limit Remedy
1 Outer diameter of 540 (21.3) – Reinforcement
flange welding or replace
2 Outer diameter of tread 500 (19.7) 488 (19.2)
2-1 Tread height 20 (0.79) 26 (1.02)
3 Width of flange 83 (3.3) 75 (3.0)
4 Total width of tread 170 (6.7) –
5 Width of tread 43.5 (1.7 50 (2.0)
6 Clearance between Standard size Tolerance Clearance Replace bushing
shaft and bushing Shaft Hole Standard size Repair limit
70 –0.03 +0.35 1.5
–0.09 +0.30 ~0.44
7 Clearance between 78 +0.15 +0.03 – Replace bushing
shaft and support +0.12 0 ~0.15
Idler, removal
Removal of the idler and the spring package
2. Pass a wire rope around the track spring bracket, lift the idler assembly, and push the bracket out of the
track frame using a pry bar.
Figure 1 Removal, idler assembly

1. Remove connecting screws (1) of idler and spring package.
Figure 2 Removal, connecting screw

Idler, tools for disassembly and assembly
Prepare the following tools for disassembly and assembly.
Tools (unit : mm)
Symbol Tools Remarks
a Press 20 ton class (44000 lbs)
b Grease gun
c Torque wrench 60 kgf·m (433 lbf·ft)
d Pin jig
8920–00360
e Bushing driver jig (1)
8920–01050
f Idler support jig 400 ∗ 300 ∗ 40 (Width ∗ Height ∗ Depth)

8920–01060
g Shaft extruding jig (2)
8920–01040
h Bushing driver jig
j Engine oil SAE 10W–30

k Hammer
L Teflon tape 1 Roll
m L wrench
n Loctite #277
p Container for oil 500 cc
Measuring of flange
1. Clean the surface of measurement of the idler.
Figure 1 Flange, measurement of wear

2. Measure the width of the flange between (c) and (d) using vernier calipers (1).
3. Measure 3 places to take average value.
4. Measure right and left alternately. Repair or replace if necessary.
Measuring of tread and flange wear
Tread
1. Clean the surface of tread (a) and flange (b) of the idler.
Figure 1 Tread, measurement of wear

2. Set a scale on the surface of flange (b) horizontally.
Measure the depth (2-1) between surface of flange (b) and surface of tread (a) using depth gauge (e).
4. Measure right and left alternately. Repair or replace if necessary.
Measuring of sprocket tooth profile
Clean the sprocket.
Figure 1 Sprocket tooth, measurement of wear

1 Sprocket wear gauge
2 Sprocket new part line
3 Sprocket wear part line
A Wear of tooth profile
Align the P1, P2, P3 of sprocket wear gauge (1) and wear line (3) of the sprocket tooth.
Measure 2 places to take average value.
If the measuring value (A) is over wear limit, replace the sprocket.
Measuring of sprocket tooth width
Clean the sprocket.
Measure the width (B) of the sprocket using vernier calipers (A).
Figure 1 Sprocket, measurement of wear

A Vernier calipers
B Wear of tooth width
Measure 2 places to take average value.
If the measuring value (B) is over wear limit, replace the sprocket.
Sprocket, installation
The installation procedure is reverse order of removal.
Install the sprocket on the track gearbox.
Apply loctite #277 to the sprocket screws (C), and tighten them to the specified torque.
Figure 1 Screw in, screws
25.5 ~ 31.5 (184 ~ 227) 34 ~ 42 (245 ~ 303)
Sprocket, measurement of wear
Figure 1 Sprocket
Wear limit, unit : mm (in)
Symbol Item Wear limit Remedy
A Wear limit of sprocket tooth profile 6 (0.24) Replace
B Width of sprocket tooth Standard value 68 ± 1.5 (2.68 ± 0.06)
Allowable value 62 (2.44)
C Number of tooth 21 EA. –
Sprocket, removal
2. Place a wooden block on the track, and place the undercarriage on the block to raise the sprocket off the
track.
3. Remove the sprocket mounting screw (C), using a socket wrench.
Figure 1 Removal, sprocket

Track, adjusting track sag
1. Slew the superstructure to the side, and raise the track using boom down operation.
Figure 1 Raising the track
2. Slowly turn the track in forward and reverse direction several times. Stop the track while moving in the
reverse direction.
3. Measure the track slack (A) at the center of track frame between track shoe and track roller mounting
surface.
Figure 2 Measurement, track slack

High pressure grease in track adjuster cylinder. Do not remove grease fitting or nut and valve
assembly to release grease.
4. To decrease track sag, add multi-purpose grease to track adjuster cylinder through grease nipple (B)
using a grease gun with a maximum capacity 690 bar (10000 psi). To increase track sag, loosen valve
assembly (A) one turn so that grease in the track adjuster cylinder can be drained through rod hole (C).
Tighten the valve assembly when track sag is correct.
Figure 3 Adjusting, track sag

· Tightening torque : 7 ± 0.25 kgf·m (51 ± 2 lbf·ft)
If the piston in track adjuster cylinder does not move, replace the valve assembly, repair or replace the
cylinder.
5. Adjust the track sag according to soil condition of work site. See the following table.
Track sag according to soil condition, unit : mm (in)
Distance (A) EC210/240 Series
Normal soil 320 ~ 340 (12.6 ~ 13.4)
Rocky ground 300 ~ 320 (11.8 ~ 12.6)
Soft ground (swamp, clay, sandy soil) 340 ~ 360 (13.4 ~ 14.2)
Measuring of bushing outer diameter wear

1. Measure at direction of D1 and D2, and determine the small value between two dimension (D1 and D2).
2. Measure 2 places to take average value. Measure right and left alternately.
3. If the measuring value is over wear limit, repair or replace the bushing.
Figure 1 Bushing outer diameter, measurement of wear
1. Pin
2. Bushing
3. Shoe
4. Vernier calipers
5. Master link
Measuring of clearance between links wear
NOTE!
Measure at direction of idler (5) or sprocket (6).
1. Clean the link.
2. Measure the clearance (4) of between inner link (2) and outer link (3) using thickness gauge (1).
Measure right and left alternately.
4. If the measuring value is over wear limit, repair or replace the link.
Figure 1 Clearance between links, measurement of wear
1. Thickness gauge
2. Inner link
3. Outer link
4. Clearance between links
5. Idler
6. Sprocket
Measuring of link height wear
1. Clean the link.
2. Measure the height (4) of link (2) using vernier calipers (3).
NOTE!
Measure the height of link (2) at the center of link (2).
3. Measure at direction of D1 and D2, and determine the small value between two dimension (D1 and D2).
5. If the measuring value is over wear limit, repair or replace the track link.
Figure 1 Link height, measurement of wear

1. Shoe plate
2. Link
3. Vernier calipers
4. Height of link
Measuring of shoe grouser height wear
1. Clean the shoe grouser.
2. Measure the height (4) of shoe grouser (2) using depth gauge (3).
4. If the measuring value is over wear limit, repair or replace shoe plate (2).
Figure 1 Shoe grouser height, measurement of wear

1. Link
2. Shoe plate
3. Depth gauge
4. Height of shoe grouser
Measuring of track link pitch wear
Tape measure
Pin (ø 40 × 160 mm)
1. Put pin (3) between sprocket and frame, and then drive the machine slowly backward to tighten the track
link.
2. Measure dimension (1) of four links away three links from master pin (2).
4. If the measuring value is over wear limit, repair or replace the track link.
Figure 1 Track link pitch, measurement of wear

1. Dimension of four links
2. Master pin
3. Pin
4. Frame
10. Track chain, description
11.
12. Figure 1
Structure, track chain
1 Link (left) 8 Master bushing
2 Link (right) 9 Regular seal
3 Master link (left) 10 Spacer
4 Master link (right) 11 Pin
5 Regular pin 12 Shoe
6 Master pin 13 Shoe screw
7 Regular bushing 14 Nut
Track chain, installation
1. While an assistant drives the machine slowly, insert a bar into the master pin bore located at the track
end, and help the track engage with the sprocket tooth.
Figure 1 Insertion, a bar into the master pin bore

2. When aligning the master pin bores in the track links, use wooden blocks A and B to support the track.
Figure 2 Track, supporting

1. Master pin
Assembly of master pin
3. Install spacer (1) into bore (3) of master link (2). Take care the direction of spacer.
Figure 3 Assembly, master pin
Figure 4 Assembly, spacer

4. Connect master link (2) and general link (5), align pin bore (4) of master link (2) and the bore of master
bushing (6) press-fitted to general link (5).
5. Insert master pin (7) into aligned bores (4), (6) with a hammer.
Figure 5 Insertion, master pin

6. Push a small pin (9) into small bore (8) on master pin (7) end, and bend it more than 30°.
Figure 6 Bending, pin

1. Track link
2. After installing No. 9 pin, bend the pin. (More than 30°)
7. Assemble the removed shoe.
Tightening torque : 80 ~ 90 kgf·m (578 ~ 650 lbf·ft)
Track chain, measurement of wear
Figure 1 Dimension, track chain

No. Check item Standard Repair limit Remedy
size
1 Link pitch 190 (7.5) 194 (7.6) Turn or replace pin
2 Outer diameter of bushing 59 (2.32) 54 (2.13) and bushing
3 Height of grouser (shoe) 26 (1.02) 16 (0.63) Lug welding or
replace
4 Height of link 105 (4.13) 98 (3.68) Replace or replace
5 Clearance of link and Standard Tolerance Clearance Replace with larger
bushing size bushing
Shaft Hole Standard size Repair limit
59 (2.32) +0.04 –0.16 0.16 0.1
0 –0.23 ~0.27
6 Clearance of link and pin 38 +0.07 –0.22 0.1 Replace with larger
(1.50) 0 –0.30 ~0.37 pin
7 Clearance of link and 38 –0.26 –0.22 – –
master pin (1.50) –0.3 –0.30 ~0.04
8 Clearance of pin and 38 +0.07 +0.80 5 Turn or replace pin
bushing (1.50) 0 +0.30 ~0.80 and bushing
9 Clearance between links 1.4 (One side) 10 (Both sides)
10 Tightening torque of shoe 80 ~ 90 kgf·m (578 ~ 650 lbf·ft) Tighten
screw
Track chain, removal

1. Each track is fitted with a master pin. Move the machine so that master pin is in the position indicated by
the arrow.
Figure 1 Position, master pin

Recoil spring cylinder is filled with pressurized grease. When adjusting the track tension or
loosening the track, pay special attention.
Keep face, hands and body away from the nipple and valve.
2. Loosen track tension adjusting valve, and bleed grease from cylinder to loosen track tension.
Do not loosen valve more than 1 turn.
If loosened more than 2 turns, the valve and grease will fly out.
Figure 2 Loosen track tension adjusting valve

Do not get near the idler as the track assembly may fall on your feet.
3. Remove shoe screws and shoe from track master link.
4. Remove master pin by hammer or press. (Remove pin after detaching shoe around master pin.)
Figure 3 Removal, master pin
1. Press
2. Master pin
5. Disassemble the opposite track repeating the above procedure.
6. Drive the machine slowly backward and off the track. At this time, drive the machine onto a track or thick
steel plate.
Figure 4 Driving the machine slowly backward

Track, measurement of wear
Figure 1 Dimension, track link

Model Wear limits
D1 124.2~124.6 (5.60~4.91)
D2 160.2~160.6 (6.31~6.32)
D3 62 ± 0.1 (2.441 ± 0.004)
φF 20.2~20.4 (0.79~0.80)
Measuring of top roller flange width wear

13. Clean the top roller.
Figure 1 Top roller flange width, measurement of wear

1. Top roller flange width
2. Vernier calipers
2. Measure the width (1) of top roller flange using vernier calipers (2).
3. Measure right and left alternately.
If the measuring value is over wear limit, repair or replace the top roller.
Measuring of top roller tread outer diameter wear
Outside calipers (200 mm)
Vernier calipers (200 mm)
1. Clean the top roller.

2. Measure the outer diameter (2) of top roller tread using outside calipers (1).
3. Read the values of vernier calipers.
Figure 1 Top roller tread outer diameter, measurement of wear

1. Outside calipers
2. Outer diameter of top roller tread
3. Vernier calipers
Top roller, assembly
Before assembling, clean the parts completely. Assemble the parts in the reverse order of disassembly.
14. Put roller shell (1) on the work bench with cover (3) facing upward, and align bushing (4) to the housing
bore. Put bushing driver jig (h) on bushing (4) and fit by press (d). Assemble bushing (5) in the same
method.

15. Fix the shaft assembly and collar into the vise vertically.
16. Install o-ring (8) and seal ring (7) to the seal groove of shaft and collar assembly (2, 14).
Figure 2 Assembly, top roller

17. Install o-ring (8) and sealing ring (7) to the seal groove of roller shell (1).
18. Clean the seal ring, contact face and coat lightly with engine oil. Assemble roller shell (1) to shaft and
collar assembly (2, 14) while taking care seals (7, 8) do not slip out.
19. Put plate (6) on shaft (2) in roller shell, align screw holes, and put lock plate (9). Tighten mounting screw
(12) as specified torque, and bend lock plate (9).
20. Install o-ring (10) to cover (3).
21. Assemble cover (3) to roller shell (1). In this case, take care not to damage o-ring (10). Then, install snap
ring (13).
22. Prior to filling with oil perform a pressure leak test.
1. Attach a pressure regulated air line to the oil fill port, then completely immerse the assembly in
water.
2. Under a pressure of 2 ~ 3 kgf/cm2 (28 ~ 43 psi), air bubbles must not form for 15 seconds.
23. Add the engine oil (SAE 10W–30, 65 cc). Install plug (11) with teflon tape (p), and tighten with an allen
wrench.
Figure 3 Apply, engine oil

1. Roller rotates smoothly by hand, and end play must be within 0.2 to 0.7 mm.
2. Top roller, description
3.
4. Figure 1 Structure, top roller
1 Roller shell 8 O–ring
2 Shaft 9 Lock plate
3 Cover 10 O–ring
4 Bushing 11 Plug
5 Bushing 12 Screw
6 Plate 13 Snap ring
7 Seal ring 14 Collar
Top roller, disassembly

The numbers in parenthesis following each part name in the text correspond to those in figure.
1. Remove plug (11), and drain the oil.
Figure 1 Disassembly, top roller
1. Remove snap ring (13) with snap ring pliers.
2. Remove cover (3) and pull out o-ring (10). Replace o-ring with a new one when assembling.
3. Straighten lock plate (9), and remove mounting screw (12).
4. Remove shaft and collar as assembly (2, 14) from roller shell (1).
Figure 2 Removal, shaft and collar

1. Remove seal ring (7) and o-ring (8) from roller shell (1) and assembly of shaft and collar (2, 14).
2. Put roller shell (1) on jig (f) with cover facing downward.
3. Put bushing driver jig (h) on bushings (4, 5), and force out them using press (d).

1. Confirm that there is no damage or rust on the sealing face of the seals.
2. Confirm that any wear of the roller is within the allowable range.
3. Confirm that any wear of the shaft and the bushing is within the allowable range.
4,5. Confirm that the interference between the bushing and the roller is within the allowable range.
Top roller, installation
1. Apply Loctite 277 to the mounting screws.
2. Tighten screw (A) of the bracket to the specified torque :
50 ~ 62 kgf·m (361 ~ 448 lbf·ft)
3. Keep the gap between roller and bracket to 3.5mm (0.14 in), and match the center of track link and roller, and
adjust top roller.
Figure 1 Gap between roller and bracket

1. Top roller lock bracket
2. Top roller
3. 0 ~ 3.5 mm
4. Top roller, measurement of wear
Figure 1 Dimension, top roller

1 Outer diameter of flange 170 (6.7) – Reinforcement
2 Outer diameter of tread 140 (5.5) 130 (5.1) welding or replace
3 Width of flange 83 (3.3) 71 (2.8)
4 Clearance between shaft Standard Tolerance Clearance Replace bushing
and bearing size Shaft Hol Standard size Repair
e limit
55 +0.030 +0. 1.5
(5.17) –0.090 35 ~0.44
+0.
30
5 Clearance between roller 63 +0.150 +0. 0 Replace bushing
and bushing (2.48) +0.120 030 ~0.18
6 Mounting screw torque 56 ± 6 kgf·m (404 ± 43 lbf·ft)
Top roller, removal

Increase the track sag and remove screw (A) at the bracket of the top roller.
Figure 1 Removal, top roller

Top roller, tools for disassembly and assembly
Prepare the following tools for disassembly and assembly.
Tools, unit : mm
a Screw driver
b Pliers
c Pliers
d Press 20 ton class (44000 lbs)
e Spanner
f Top roller support jig
h Bushing driver jig (1)
g Bushing driver jig (2)
i Torque wrench 3 ~ 10 kgf·m (22 ~ 72 lbf·ft)

j Hammer Sliding hammer
l Allen wrench 6 mm
n Engine oil SAE 10W–30
p Teflon tape 1 Roll
r Pliers for snap ring
s Container for oil 500 cc
Bottom roller, assembly

Clean the parts completely before assembly. Assemble in the reverse order of disassembly.
24. Apply a thin coat of molybdenum grease on bushing (5). Put bushing driver jig (e) on the bushing, and
press fit the bushing.

1. Press fit with a press
25. Install o-ring (7) in one side of the shaft.
Figure 2 Assembly, o-ring

26. Apply a thin coat of grease onto inner side of collar (1), and insert shaft (6). At this time, take care not to
damage o-ring (7).
27. Install o-ring (3) and seal ring (2) to the collar installed on the shaft and tap pin (8) into the bore of collar
(1) and shaft (6) with a hammer.
Figure 3 Assembly, pin
28. Install o-ring (3) and seal ring (2) to roller shell (4). Assemble shaft (6) to roller shell (4) until the seal ring
installed to the collar and the seal ring installed to roller shell (4) make contact. Apply a thin coat of engine
oil to the contact face of seal ring (2), respectively.
Figure 4 Assembly, shaft to roller shell

29. Turn over the roller so the seal ring installed faces downward. (Take care the seal ring does not fall off).
30. Install seal ring (2) and o-ring (3) on opposite side collar (1) and roller shell. Apply a thin coat of grease
onto inner side of collar (1), and install onto shaft (6) until the respective seal rings (2) make contact. At
this time, apply a thin coat of engine oil on the contact face of seal rings.
Figure 5 Assembly, collor

31. Press collar (1) completely.
32. Level the roller as collar (1) and shaft (6) are assembled. Align the bore of collar (1) and shaft (6), and
install pin (8) with a hammer.
Figure 6 Assembly, pin

33. Prior to filling with oil perform a pressure leak test. – Attach a pressure regulated air line to the oil fill port,
then completely immerse the assembly in water. – Under a pressure of 2 ~ 3 kgf/cm 2 (28 ~ 43 psi), air
bubbles must not form for 15 seconds.
34. Add engine oil (j) through the plug hole of collar (1). After filling, install plug (9) with teflon tape (i), and
tighten the plug with allen wrench (k).
Oil amount
EC210/240 Series
Oil volume 210 cc (12.8 cu·in)
Type of oil Engine oil SAE 10W–30
1. Confirm that there are no oil leaks around seal (2) and plug (9).
2. Manually confirm that bottom roller (4) turns smoothly more than 10 times (Some resistance may be felt).
3. End play must be within 0.1 to 0.9 mm (0.004 ~ 0.035 in).
4. Bottom roller, description
Figure 1 Structure, bottom roller

1 Collar (Support) 6 Shaft
2 Seal ring 7 O–ring
3 O–ring 8 Pin
4 Roller shell 9 Plug
5 Bushing
Bottom roller, disassembly

The numbers in parenthesis following each part name in the text correspond to those in figure.
1. Remove plug (9), and drain the oil.

NOTE!
Prepare a container to catch the oil flowing out of lower roller (4).
1. Using jig (c) drive out pin (8) through collar (1).
Figure 1 Removal, spring pin

1. Place bottom roller shell (4) on support jig (d), put shaft extruding jig (f) on shaft (6), and force out the
shaft with press (b).
Figure 2 Removal, shaft
1. Remove seal ring (2) and o-ring (3) from collar (1).
Figure 3 Removal, o-ring

1. Remove seal ring (2) and o-ring (3) from bottom roller shell (4).

1. Place bottom roller (4) on support jig (d), put bushing driver jig (g) on bushing (5), and force out the
bushing by tapping the jig with a hammer (a).

1. Remove o-ring (7) from shaft (6).
· Confirm that there is no damage or rust on the sealing face of the seal.
· Confirm that any wear of the roller is within the allowable range.
· Confirm that any wear of the shaft and the bushing is within the allowable range.
· Confirm that the interference between the bushing and the roller is within the allowable range.
· Confirm that the clearance between the bushing and the collar (side clearance of the roller) is within
the allowable range.
Bottom roller, installation
1. Locate the oil plug to the front of the machine.
Figure 1 Location, the oil plug

1. Front
2. Oil plug
2. Apply Loctite 277 to the threads of the lower roller mounting screws.
3. Align the screw holes in the undercarriage and lower roller (1), and temporarily tighten the screws using a
small wrench.
If any abnormal condition, such as excessive resistance of a screw is felt, remove the screw and inspect
the threads. Do not use an impact wrench for temporary tightening.
4. Tighten the screws to the specified torque with a torque wrench.
Figure 2 Screw in, screws

Tightening torque : 25.5 ~ 31.5 kgf·m (184 ~ 227 lbf·ft)
Bottom roller, measurement of wear
Figure 1 Dimensions, bottom roller

1 Outer diameter of flange 195 (7.7) – Reinforcement
2 Outer diameter of tread 160 (6.3) 148 (5.8) welding or replace
3 Width of flange 20.5 (0.8) 13.5 (0.5)
4 Clearance between shaft Standard Tolerance Clearance Replace bushing
and bushing size Shaft Hole Standard Repair
size limit
70 0 +0.30 +0.25 1.5
(2.76) –0.03 +0.25 ~0.33
5 Clearance between roller 78 +0.132 +0.046 0 Replace bushing
and bushing (3.07) +0.102 0 ~0.132
6 Mounting screw torque 28.5 ± 3 kgf·m (206 ± 22 lbf·ft)
Bottom roller, removal

1. Loosen track tension, and raise the machine about 300 mm off the ground, as shown in figure.
Figure 1 Raising, machine

1. Put a wooden block under the bottom roller, and loosen the four roller mounting screws.
2. Remove the screws, and pull out the bottom roller.
Figure 2 Removing, screws

Bottom roller, tools for disassembly and assembly
tools (unit : mm)
a Hammer
b Press 20 ton class (44000 lbs)
c Pin jig
8920–00350
d Bottom roller support jig

8920–01020
e Bushing driver jig
f Shaft extruding jig

8920–01040
g Bushing driver jig

8920–01050
h Molybdenum grease
i Teflon tape 1 Roll
j Engine oil SAE 10W–30 250 cc/EA
k Allen wrench 6 mm
L Container for oil 500 cc
Roller flange width, measurement of wear

35. Clean the bottom roller.
Figure 1 Top roller flange width, measurement of wear

1. Bottom roller flange width
2. Vernier calipers
2. Measure the width (1) of bottom roller flange using vernier calipers (2).
Roller tread diameter, measurement of wear
Outside calipers (200 mm)
Vernier calipers (200 mm)
1. Clean the bottom roller.

2. Measure the outer diameter (2) of bottom roller tread using outside calipers (1).
3. Read the values of vernier calipers.
Figure 1 Bottom roller tread outer diameter, measurement of wear
1. Outside calipers
2. Outer diameter of bottom roller tread
3. Vernier calipers
Spring package, assembly
36. Assemble in the reverse order of disassembly.
37. Install packing (7), back-up ring (8), and dust seal (7) to cylinder (1).
Figure 1 Assembly, spring cylinder

38. Fill cylinder (1) with grease and push piston (3) in. Release the air from the cylinder.
39. Install grease valve (12), plate (10), and screw (11) to cylinder (3).
1. Tightening torque (Grease valve) : 7 ± 0.25 kgf·m (50.5 ± 1.8 lbf·ft)
40. Install rod (17) to cylinder (1). Align the screw hole of rod (17) and cylinder (1), and tighten screw (16).
Figure 2 Spring installed length

A. Installed length
Take care that the spring not does slip out during installation.
41. Push spring (2) and yoke (5) onto cylinder (1) on which rod (17) and piston (3) is installed. Slowly
compress spring (2) until the rod thread is exposed. Install nut (6), lock plate (14) and screw (15), in order.
Installed length and load of the spring
Installed length, mm(in) 444 (1′ 6″) 468 (1′ 6″)
Installed load, kg(lbs) 13309 ± 800 (29340 ± 1764) 14916 ± 800 (32884 ± 1764)
Spring package, description

Figure 1
Structure, spring package
1Cylinder body 7Packing 13Spring washer
2Spring 8Back–up ring 14Plate
3Piston 9Dust seal 15Screw
4Grease valve 10Plate 16Screw
5Yoke 11Screw 17Rod
6Nut 12Grease nipple 18Stopper
Spring package, disassembly

A great force is applied to the spring package. Pay special attention when disassembling.
Use special tools for safety.
Figure 1 Spring package

1. Prepare a press with a capacity of more than 25 tons.
2. Slowly compress spring (2) to with press (a). Remove screw (15) and lock plate (14) connected to rod
(17).
Figure 2 Removal, screw and lock plate

While compressing or releasing the spring by press, take care that the spring does not slip out.
1. Remove nut (6). Remove yoke (5) and spring (2) while releasing the load applied to spring (2).
2. Remove screw (11), plate (10), and grease valve (12) from piston (3), in order.
Figure 3 Removal, screw and etc

1. Remove piston (3), dust seal (9), back–up ring (8), and packing (7) from cylinder (1), in order.
2. Remove lock screw (16) and rod (17).
· Confirm that there is no damage or rust on the inner side of the cylinder and the outer side of the
piston.
· Replace the packing and dust seal.
Hydraulic pressure, specifications

Specifications
Components Mode Set pressure (unit : kgf/cm2 (psi))
EC210 EC240
Main relief Standard 320 +10/–5(4550 +142/–71)
at 200 lpm(52 U.S.gpm)
Boost 350 +10/–5 (4980 +142/–71)
at 200 lpm(52 U.S.gpm)
Boom port relief Up 355 +10/–5 (5050 +142/–71)
Down at 28 lpm(7.3 U.S.gpm)
Arm port relief In 355 +10/–5 (5050 +142/–71)
Out at 28 lpm(7.3 U.S.gpm)
Bucket port relief Curl 355 +10/–5 (5050 +142/–71)
Dump at 28 lpm(7.3 U.S.gpm)
Slew motor Left 270 +10/–5 (3830 +142/–71) 270 +10/–5 (3830 +142/–71)
crossover relief Right at 200 lpm(52 U.S.gpm) at 230 lpm(60 U.S.gpm)
Travel motor relief Left 350 +10/–5 (4980 +142/–71) 350 +10/–5 (4980 +142/–71)
(Same with main relief) Right at 200 lpm(52 U.S.gpm) at 230 lpm(60 U.S.gpm)
Servo hydraulic pump relief – 40 +3/–0 (571 +42/–0) 40 +3/–0 (571 +42/–0)
at 19 lpm(4.9 U.S.gpm) at 20 lpm(5.2 U.S.gpm)
DIAGRAMS
Hydraulic diagram, schematic
Figure 1 Hydraulic diagram
1 Travel 7 Slew 13 Slew motor

2 Bucket 8 Travel motor 14 Travel motor
3 Boom 9 Boom cylinder A Engine
4 Travel 10 Arm cylinder B Main pump
5 Arm 11 Bucket cylinder C Gear pump
6 Option 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.
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
Component Function Feature
Travel Controlled by servo hydraulic pressure. Straight travel during simultaneous
Straight travel. operations.
Low speed, low/high speed automatic Automatic shifting between low and high
shift. speed.
Slew Slew priority circuit. (during Easier digging due to the use of
simultaneous slew and arm retraction) simultaneous slew and arm retraction.
Automatic slew parking brake. Delayed slew parking brake application
Rebound damping function. during slew to allow for inertia.
Damping by rebound damping valve.
Digging units Controlled by servo hydraulic pressure Fine operation.
Boom, arm regenerating circuit Changing the balance between boom,
Holding valve (boom, arm lock) arm and bucket functions.
Heavy lift and heavy duty digging Decreasing the amount of natural fall of
boom when the boom is at rest.
Increasing the working pressure by
increasing the pressure of main relief
valve.
Others Closed and semi automatically Contamination of hydraulic oil
Pressurized hydraulic tank. prevented, suction ability of pump
Suction strainer. improved.
Return line : filter and drain filter. Damage of hydraulic components
Servo hydraulic circuit : line filter. prevented.
Hydraulic oil cooled by oil cooler. Contamination of hydraulic oil prevented
Emergency circuit. Servo hydraulic operated circuit failure
prevented.
Deterioration of hydraulic oil prevented
If engine stopped, movable by weight of
digging units.
Pump Full horsepower control. Effective use of engine horsepower
though action of two variable
displacement pumps.
Travel 2–speed auto shift by the 2–speed Low speed/high propel torque.
travel motor. High speed/low propel torque.
Digging units Conflux for boom raising. Faster boom raising.
Regeneration for boom lowering. Positive bucket motion during
Conflux circuit for arm retraction under simultaneous boom lowering and
heavy load. bucket operation.
Conflux circuit for arm retraction under Faster arm retraction under heavy load.
light load. Faster arm retraction under light load.
Conflux circuit for arm extension Faster arm extension.
Pressure increasing circuit for heavy Improved digging, lifting under heavy
load. load.
Pump Negative flow control. Flow minimized when in neutral
Controller Mode select switch change over. Selecting an effective engine rpm suited
Auto idling. for the amount of work, fuel
consumption and fine control.
Engine speed decelerated during waiting
periods for reduced fuel cost and less
noise.
Hydraulic circuits, 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 (br3) and (bl4) ports, respectively. When control lever is operated to “ARM IN”, secondary servo
hydraulic oil flows to port (al3), (al31), (al32), (p31), (4Pi), and oil from (p31) port flows to (a) port through
solenoid valve A3 on block (12).
· Servo hydraulic pressure explained below, is for straight travel and related operation only.
· P1(PR) pump oil is supplied to right travel, and P2(P L) to left travel. In traveling, straight travel changeover
valve (38) is closed.
· Operating “ARM IN” during traveling, primary servo hydraulic pressure from (Pg1) is blocked by the travel
spool and arm spool at main control valve 4–spool valve, the pressure in (Px2) line connected to straight
travel changeover valve increases, pushing the spool to the left opening the valve.
· When oil lines of P1(PR) and P2(PL) are connected as straight travel valve is opened, oil in pump P1(P R) and
P2(PL) flows as follows :
{(P1-Po)+orifice(B)}+{P2-orifice(A)}/2
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.
Figure 1 Straight travel / arm (straight travel auto shift, arm in)
Hydraulic circuits, straight travel (low / auto shift)
42. When both travel pedals are operated “ FORWARD ” secondary servo hydraulic oil is
routed from the remote control valve as follows :
1. (br3) oil flows to the main control valve moving the spool to the right, routing P1
pump flow to port(B) on the right travel motor.
2. (bl4) oil flows to the main control valve moving the spool to the left, routing P2 pump flow
to port (A) on the left travel motor.
43. Travel function (as selected by rocker switch)
o 1st speed fixed : Constant low speed, primary servo hydraulic pressure (P2) to port (ph)
of the changeover valve is blocked by solenoid valve A3 on block (11).
o 1st/2nd speed auto shift : solenoid A3 activated and primary servo hydraulic oil (P2)
flows to port (ph) of the changeover valve and travel speed is automatically selected
according to the load on the motor.
1. Low speed
o Pressure of travel motor is more than 260 kgf/cm 2
o Not traveling
2. High speed : When the pressure of travel motor is less than 260kgf/cm 2, primary
servo hydraulic pressure pushes travel speed changeover valve, and travel motor pressure
reduces swash plate angle, so rpm is increased.
o (Pg1) oil is applied to switch (28) to input the signal to controller, so auto idle and
pressure boost function can be used. Circuit connected to main control valve
inside operates straight travel valve.
o The functions of travel motor are brake, anti-cavitation, low/high auto change,
and overspeed prevention. (See travel motor)
o As traveling, main pressure boost is done by controller automatically.
o Negative lines of Fr and Fl are cut off to increase oil delivery rate of P1/P2
pumps.
Figure 1 Straight travel (low / auto shift)
Figure 2 Straight travel
Hydraulic circuits, ports
Location Port Description

Pump PL, PR Discharge port
Dd Drain port (Dr1 ~ Dr5)
Pi1(Fr), Pi2(Fl) Negative control signal port
G1, 2 Gauge port
Control valve PR Pump P1 port
PL Pump P2 port
AR1 Boom lower port
BR1 Boom raise port
AR2 Bucket curl port (cylinder extend)
BR2 Bucket dump port (cylinder retract)
AL4 Left travel port (reverse)
BL4 Left travel port (forward)
AR3 Right travel port (reverse)
BR3 Right travel port (forward)
AL3 Arm in port (cylinder extend)
BL3 Arm out port (cylinder retract)
AL1 Slew port (left) (MA)
BL1 Slew port (right) (MB)
AL2, BL2 Option port
ar1 Boom lower servo hydraulic port
br1 Boom raise servo hydraulic port
ar2 Bucket curl servo hydraulic port
br2 Bucket dump servo hydraulic port
3Pi Boom lower holding valve servo hydraulic port
Pg2 Boom holding valve primary pressure source
4Pi Arm in holding valve port
al4 Left travel servo hydraulic port (reverse)
bl4 Left travel servo hydraulic port (forward)
a Arm in/out conflux signal port
al1 Slew servo hydraulic port (left)
bl1 Slew servo hydraulic port (right)
al3 Arm in servo hydraulic port (cylinder extend)
bl3 Arm out servo hydraulic port (cylinder retract)
al2, bl2 Option servo hydraulic port
ar3 Right travel servo hydraulic port (reverse)
br3 Right travel servo hydraulic port (forward)
b(br11), Pb Boom raise conflux signal port
R Main return port
RS1 Slew motor booster port
PS Arm parallel conflux servo hydraulic port
Others PG Pressure source for slew brake
pa Slew priority valve port
Pg1 Pressure source for straight travel and auto deceleration signal
(digging unit, travel)
ph Pressure source for high speed travel
Py Pressure boost servo hydraulic port (main)
pi Pressure source for remote control valve
al31,SH, SW Slew brake release signal port
Boom conflux blocking signal port
al32
Boom raise conflux signal port
br11
Po Arm conflux port
Px2 Auto deceleration pressure source (digging unit)
Px1 Auto deceleration pressure source (Travel)
P3 Arm conflux signal port
p11 Solenoid valve inlet port primary pressure
Solenoid valve inlet port secondary pressure
p21, p31
Hydraulic circuits, standard
1Pump 24Bypass valve

2Control valve 25Bypass strainer
3Slew motor 26Strainer
4Travel motor 27Air breather
5Boom cylinder 28Pressure switch
6Arm cylinder 29Screen filter
7Bucket cylinder 30Screen filter
8Servo hydraulic filter 31Screen filter
9Accumulator block 32Servo hydraulic selector valve
10Accumulator 33Shuttle valve
11Solenoid valve group 34Foot relief valve
12Solenoid valve group 35Center bypass valve - 4 series (boom conflux check valve)
13Remote control valve - left 36Center bypass valve - 3 series (arm conflux check valve)
14Remote control valve - right 37Logic valve
15Remote control valve - travel 38Straight travel change over valve
16Shuttle block 39Boom holding valve
17Shuttle block 40Arm holding valve
18Center passage 41Arm parallel conflux valve
19Hydraulic oil cooler 42Main relief valve
20Check valve 43Port (overload) relief valve
21Check valve
22Hydraulic oil tank AOrifice
23Return filter BOrifice
Figure 1 Standard hydraulic circuit
Pump, description
Model code
Figure 1 Model code

Pump, structure
Eye bolt
Set screw maximum flow
Set screw minimum flow
Set screw minimum flow
Port connection
Port name Port size
A1,2 Delivery SAE 6000 3/4″
B1 Suction SAE 2500 2 1/2″
Dr Drain PF 3/4 – 20
Pi1,2 Gauge PF 1/4 – 15
Psv Servo hydraulic PF 1/4 – 15
a1,2 Gauge PF 1/4 – 15
a3,4 Gauge PF 1/4 – 15
A3 Gear pump delivery PF 1/2 – 19
B3 Gear pump suction PF 3/4 – 20
Figure 2 Structure, main pump
Pump, sectional view
Figure 3 Main pump (sectional view)

111 Driving shaft 262Seal cover 719 O-ring
113 Driving shaft 271Pump casing 724 O-ring
114 Spline coupling 312Valve block 725 O-ring
123 Roller bearing 313Valve plate 728 O-ring
124 Needle bearing 314Valve plate 732 O-ring
127 Bearing spacer 401Screw 774 Oil seal
141 Cylinder block 406Screw 789 Back-up ring
151 Piston 466Vp plug 792 Back-up ring
152 Shoe 468Vp plug 808 Lock nut
153 Set plate 490Plug 809 Lock nut
156 Spherical bushing 531Tilting pin 824 Snap ring
157 Cylinder spring 532Servo piston 885 Valve plate pin
158 Spacer 534Stopper 886 Spring pin
211 Shoe plate 535Stopper 901 Eye bolt
212 Swash Plate 548Feedback pin 953 Adjusting screw
214 Tilting bushing 702O-ring 954 Adjusting screw
251 Swash plate support 710O-ring 981 Name plate
261 Seal cover 717O-ring 983 Pin
Pump, exploded view
Figure 4 Main pump (exploded view)

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), spacer (158), 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 (a).
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.
Figure 5 Moving, swash plate
Servo piston
Tilting pin
Adjustment of maximum flow
Adjust it by loosening hexagon 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, see [Invalid linktarget].
Figure 6 Adjustment of maximum flow

X : Servo hydraulic pressure Pi
Y : Delivery flow, Q
Adjustment of minimum flow
Adjust it by loosening hexagon nut (808) and by tightening (or loosening) adjusting screw (953).
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.
Figure 7 Adjustment of minimum flow

X : Servo hydraulic pressure Pi
Y : Delivery flow, Q
Wiring diagram 15, function group 9, hydraulics
Figure 1
Figure 1
Figure 1
Electrical components
Motors
Designation Wiring diagram Circuit No. Function
MO201 3 2,010 Engine start
MO202 4 2,040 Engine stop motor (EC210 only)
MO203 5 2,070 Fuel filler pump (35 L, option))
MO204 5 2,080 Fuel filler pump, auto stop(50L, option)
MO205 7 2,190 Stepping motor (with position sensor)
MO801 11 8,030 Air suspension compressor (option)
MO802 12 8,050 Washer motor
MO803 12 8,060 Wiper motor
MO804 13 8,090 Air conditioner compressor (option)
MO805 13 8,090 Air conditioner motor 1 (option)
MO809 18 Greasing motor (option)
Solenoid
valves
Designation Wiring diagram Circuit No. Type Function
MA201 4 2,050 Pulling solenoid Engine stop (EC240
only)
MA901 14 9,030 Proportional solenoid valve Pump flow control
(option)
MA902 14 9,040 Proportional solenoid valve Pump power shift
MA903 15 9,050 Hydraulic valve Hydraulic safety
MA904 15 9,060 Hydraulic valve Travel speed selection
MA905 15 9,070 Hydraulic valve Boom conflux cut-off
MA906 15 9,080 Hydraulic valve Arm conflux cut-off
MA907 15 9,090 Hydraulic valve Power boost
MA908 15 9,110 Hydraulic valve Hammer
MA909 16 9,120 Hydraulic valve Quickfit (option)
MA910 16 9,130 Hydraulic valve Rotator, left (option)
MA911 15 9,150 Hydraulic valve Rotator, right (option)
Sensor
Designation Wiring diagram Circuit No. Type of sensor Function
SE201 3 2,020 Temperature Ambient temperature
SE202 5 2,080 Level Fuel level
SE203 6 2,090 Temperature Engine cooling
temperature
SE204 6 2,100 Level Fuel level
SE205 6 2,110 Temperature Engine cooling
temperature
SE206 6 2,120 pressure Engine oil pressure
SE207 6 2,130 Pressure Air cleaner
SE208 7 2,170 Temperature Engine coolant
temperature
SE209 7 2,180 Frequency Engine speed
SE801 12 8,060 Mechanical Window front
SE802 13 8,090 Temperature Air conditioner
temperature (option)
SE901 14 9,020 Pressure Hammer port pressure
(option)
SE902 15 9,050 Mechanical Safety bar
SE903 16 9,160 Pressure Digging unit port
pressure
SE904 16 9,170 Pressure Travel port pressure
Lamps
LA301 8 3,010 Head lamp, left

LA302 8 3,020 Head lamp, right
LA303 8 3,030 Work lamp, left
LA304 8 3,040 Work lamp, right
LA305 9 3,260 Count weight amp (option)
LA306 9 3,270 Cab rear lamp, rear (option)
LA307 9 3,280 Cab lamp, front (option)
LA308 9 3,290 Cab lamp, front (option)
LA309 9 3,300 Cab room lamp
LA310 9 3,310 Hand lamp (option)
LA311 9 3,320 Beacon (option)
Control lamps
LC01 8 3,080 Beacon switch (option)
LC02 8 3,090 Overload warning switch (option)
LC03 8 3,100 Room lamp switch
LC04 8 3,110 Fuel heater switch (option)
LC05 8 3,120 Seat heater switch (option)
LC06 8 3,130 Travel alarm switch (option)
LC07 8 3,140 Cassette mute switch (option)
LC08 9 3,150 Buzzer stop & confirm switch (option)
LC09 9 3,160 Head & work lamp switch
LC10 9 3,170 Extra lamp switch (option)
LC11 9 3,180 Boost/hammer switch
LC12 9 3,190 Auto idling switch
LC13 9 3,200 Travel speed selection switch
LC14 9 3,210 Power max mode switch
LC15 9 3,220 Quickfit switch 1 (option)
LC16 9 3,230 Wiper switch
LC17 9 3,240 Washer switch
LC18 9 3,250 Quickfit switch 2 (option)
LC19 1 1,100 Charge indicator
LC20 6 2,110 Coolant temperature indicator
LC21 6 2,120 Engine oil pressure indicator
LC22 6 2,130 Air cleaner indicator
LC23 15 9,100 Power boost indicator
LC24 3 2,010 Air heater indicator
LC25 4 2,060 Fuel heater indicator (option)
LC26 18 Auto greasing indicator (option)
LC27 - - Overload indicator (option)
LC28 16 9,130 Quickfit indicator (option)
LC29 1 1,100 Central warning indicator
LC30 1 1,100 Central warning indicator
LC31 8 3,060 I-ECU illumination
LC32 8 3,070 I-ECU illumination
LC33 8 3,050 D-ECU illumination
Switches
SW101 2 1,100 Start switch
SW102 2 1,100 Master switch
SW201 6 2,060 Fuel heater switch (option)
SW202 5 2,070 / 2,080 Fuel filler pump switch (option)
SW203 5 2,080 Fuel filler pump, start (option)
SW204 5 2,080 Fuel filler pump, stop (option)
SW205 7 2,140 Engine speed control switch
SW206 7 2,150 Power max. mode switch
SW207 7 2,160 Auto idling switch
SW301 8, 9 3,010 ∼ 3,250 Head and work lamp
SW302 10 3,260 ∼ 3,290 Extra lamp (option)
SW303 10 3,300 Cab room lamp
SW304 10 3,320 Beacon (option)
SW801 11 8,010 Cassette mute (option)
SW802 11 8,020 Seat heater (option)
SW803 12 8,050 Washer
SW804 12 8,060 Wiper
SW805 12 8,070 Joystick horn, left
SW806 12 8,070 Joystick horn, right
SW807 12 8,080 Buzzer stop & confirm (option)
SW808 18 Greasing switch (option)
SW901 14 9,040 Flow control switch (option)
SW902 14 9,040 Auto/manual switch
SW903 15 9,060 Travel speed selection
SW904 15 9,110 Joystick switch, boost/hammer
SW905 15 9,110 Boost/hammer selection
SW906 16 9,120 Quickfit switch, 1 (option)
SW907 16 9,120 Quickfit switch, 2 (option)
SW908 16 9,140 Joystick switch, rotator left (option)
SW909 16 9,150 Joystick switch, rotator right (option)
Relays
RE01 2 1,100 Battery relay
RE02 3 2,010 Safety relay
RE03 4 2,040 / 2,050 Engine stop motor/fuel cut-off
RE04 5 2,060 Fuel heater (option)
RE05 12 8,070 Horn
RE06 8 3,030 / 3,040 Work and head lamp
RE07 10 3,280 / 3,290 Cab front lamp (option)
RE08 15 9,060 Travel relay
RE09 15 9,060 Travel speed selection
RE10 15 9,070 Boom/arm conflux cut-off
RE11 15 9,080 Power boost
RE12 3 2,030 Battery relay cut-off
RE13 3 2,020 Preheater
RE14 5 2,080 Fuel filler pump (option)
RE15 5 2,080 Fuel filler pump (option)
RE16 13 8,090 Air conditioner relay 1 (option)
RE21 16 9,120 Quickfit relay
RE22 16 9,120 Quickfit relay
Fuses
Designation Feed AMP Wiring Circuit No. Circuits
diagram
FU2 50 10 4 2,030 Feed head lamp
FU3 50 20 9 3,030 / 3040 Feed work lamp
FU4 50 15 12 8,060 Feed wiper front
FU6 50 10 11 8,040 Feed cigarette lighter
FU7 50 10 12 8,070 feed horn
FU8 50 20 13 8,090 Feed air conditioner
FU9 50 10 10 3,210 / 3,220 Feed cab rear lamp
FU10 50 10 14 9,040 Feed auto/manual switch
FU11 30 10 10 3,290 Feed beacon lamp
FU12 50 10 15 9,050 - 9,110 Feed travel speed selection/boom conflux cut-
off/arm conflux cut-off/power boost/power shift
FU14 50 20 10 3,230 - 3,260 Feed cab front lamp
FU16 FU51 30 2 1,100 Feed ignition switch
FU17 30 5 10 3,270 Feed cab room lamp
FU18 40 5 11 8,010 Feed radio & cassette
FU19 30 30 5 2,040 Engine stop motor / fuel cut-off solenoid
FU20 30 10 10 3,280 Feed hand lamp
FU21 30 15 6 2,070 Fuel filler pump
FU25 50 30 6 2,060 Preheating
FU26 50 10 11 8,020 Feed seat heat / air suspended seat
FU27 50 10 16 9,120 Quickfit solenoid
FU28 50 10 16 9,130 / 9,140 Rotator
FU30 50 10 18 Auto greasing
FU50 Battery 40 2 1,100 Slow blow fuse
FU51 Battery 40 2 1,100 Slow blow fuse
FU52 RE01 80 2 1,100 Slow blow fuse
FU53 FU52 80 2 1,100 Slow blow fuse
Connector, configuration
Figure 1
Connectors, configuration 1
Figure 2
Figure 3
Figure 4
Relay box, description
Figure 1 Relay box
Relay box, specifications

Relay codes of relay box 1
Relay No. Components Type Wiring diagram
R1 Horn Normally opened, NO RE05
R2 Boom conflux cut-off solenoid valve Normally opened, NO RE11
Arm conflux cut-off solenoid valve
R3 Battery power cut-off relay Normally opened, NO RE12
R4 Boost solenoid valve Normally opened, NO RE10
R6 Stop motor / fuel-cut-off solenoid valve Normally opened, NO RE03
R7 Travel speed selection solenoid valve Normally opened, NO RE09
R8 Head lamp, work lamp Normally opened, NO RE06
Relay codes of relay box 2

Relay No. Components Type Wiring
diagram
R1 Quickfit solenoid valve Normally opened, NO RE21
R2 Quickfit solenoid valve Normally opened, NO RE22
R5 Fuel heater Normally opened, NO RE04
R7 Traveling mode Normally opened, NO RE08
R8 External lamps Normally opened, NO RE09
Relay, specifications
Item Specifications
Rated voltage DC 24 V
Ambient temperature –30 ~ 90 °C
Maximum operating voltage 20 V (at 20 °C)
Coil resistance 315 Ω ± 10 %
Resistor box, description
· The resistance of resistor box make the current correspond to the 85% of the rated engine output power for
the proportional solenoid valve when the Auto/manual switch is in MANUAL status.
Figure 1 Resistor box
Resistor box, specifications

Item Specifications
Rated wattage 50 W
Rated resistance (at 25°C) EC210 : 67 Ω, EC240 : 60 Ω
Temperature -30 ~ 120 °C (-22 ~ 248 °F)
Insulation resistance 20 MΩ and more (500 V megohmmeter)
Resistor box, wire specifications

NO. Wire specifications
1 AVX 1.25 R
2 AVX 1.25 SB
Fuse box, description

· To conveniently locate and identify the fuse capacity of protecting individual circuit from overload.
Always install a fuse of the same type with the correct amperage rating to prevent electrical system damage from
overload.
Figure 1 Fuse box

Fuse box, continuity test
Fuse failure is often caused by a fine crack in the fuse, and this kind of crack is very hard to detect by visual
inspection. Checking fuse continuity with a tester is far superior to eye inspection.
Fuse, specifications
Fuse (blade-type) color codes
Amperage Color Amperage Color
rating rating
1A Black 10 A Red
3A Violet 15 A Light blue
4A Pink 20 A Yellow
5A Tan 25 A Natural (White)
7.5 A Brown 30 A Light green
Fuse, specifications
No. Specification Load name No. Specification Load name
F1 10 A I-ECU F16 30 A Start switch
F2 10 A Head lamp F17 5A Room lamp
F3 20 A Work lamp F18 5A Radio & cassette
F4 15 A Wiper & washer F19 30 A Engine stop motor (EC210) / fuel cut-
off solenoid (EC240)
F5 F20 10 A Hand lamp
F6 10 A Cigarette lighter F21 15 A Fuel filler pump
F7 10 A Horn F22
F8 20 A Air conditioner F23
F9 10 A Extra work lamp F24
F10 10 A Controller F25 30 A Fuel heater
F11 10 A Beacon F26 10 A Seat heat & air suspension
F12 10 A Safety solenoid valve F27 10 A Quickfit
F13 F28 10 A Rotator solenoid valve
F14 20 A Extra work lamp F29 10 A Travel alarm
F15 F30 10 A Auto grease
Automatic control system, description

The advanced control system (ACS) comprised of input components (sensors, switches), V-
ECU, and output components (actuators) continuously control the machine performance to
correspond to a built-in program.
The control system is manually controlled via an override switch so it can be operated on
automatic (normal position) or manual mode. MANUAL mode should only be used as an
emergency when the machine is abnormality on automatic mode.
The functions of the automatic control system are as follows :
Self diagnosing
Machine status indication
Mode selection : engine speed and work mode
Engine speed sensing power control
Automatic idling
Power boost
Safety start / stop
Travel speed selection
Automatic engine warm-up
Pump flow control
The automatic control system is sensitive to contamination and must be protected from the
penetration of moisture, lubricants and dust. The ACS electronic components must also be
protected from over-voltage, therefore it is imperative that precautions concerning the charging
system and welding procedures be strictly adhered to.
Figure 1 Automatic control system, block diagram
1 V-ECU
2 Engine speed control switch
3 Auto/manual switch
4 Start switch
5 Travel speed selection switch
6 Boost/hammer selection switch
7 Auto idling switch
8 Power max. mode switch
9 Flow control switch (option)
10 Digging unit port pressure switch
11 Travel port pressure switch
12 Hammer port pressure switch (option)
13 Engine speed sensor
14 Throttle position sensor
15 Rotator switch 1 (left joystick, option)
16 Rotator switch 2 (left joystick, option)
17 Boost/hammer switch (right joystick)
18 Coolant temperature sensor
19 Resister box
20 Stepping motor
21 Power shift proportional solenoid valve
22 Flow control proportional solenoid valve
23 Boom conflux cut-off solenoid valve
24 Arm conflux cut-off solenoid valve
25 Hammer solenoid valve
26 Power boost solenoid valve
27 Travel speed selection solenoid valve
28 Relay box
29 Battery power cut-off relay
30 D-ECU
Automatic control system, components location
Figure 2
Components location, automatic control system
1Stepping motor
2D-ECU
3Resistor box
4Auto/manual switch
5Engine speed sensor
6Digging unit port pressure switch
7Travel port pressure switch
8V-ECU
9Flow control valve (option)
10Hammer port pressure switch (option)
11Flow control switch (option)
12Engine speed control switch
Automatic idling, description
Automatic idling function is activated by pressing the auto idling switch (7).
When this function is activated, the V-ECU (1) analyzes the operating status of the hydraulic circuits with the
feedback signals of the digging unit port pressure switch (10), travel port pressure switch (11) and rotator
switches (15,16, option). If there is not any operation for 5 seconds, the V-ECU reduces engine speed to the
auto idle setting value.
After the engine has decelerated, if the operator touches one of the remote control valves (joysticks, pedals) or
turns the engine speed control switch (2) or pushes one of the rotator switches, the V-ECU increases the
engine speed to the selected speed of the engine speed control switch.
Auto idling is working when the engine speed control switch is on the 3 - 9 step.
This function reduces fuel consumption and lowers noise levels, enhancing operator comfort and machine
profitability.
Figure 1
Components related to automatic idling
1V-ECU
7Auto idling switch
10Digging unit port pressure switch
12Throttle position sensor
15Rotator switch (left joystick, option)
16Rotator switch (left joystick, option)
20Stepping motor
Auto idling operation

Mode Switch Work status Auto idle ON Auto idle OFF
F - G - H - P step 3-9 5 seconds lapse in work cycle Engine speed is decelerated to auto Engine speed remains
idle speed (Step 2). at the speed set by the
Work cycle restarted or change engine speed control
the step of the engine speed Engine speed accelerates to the speed switch.
control switch set by the engine speed control switch.
I step 1 Work cycle started Engine speed remains at low idle.
Engine speed remains at auto idle
step 2 Work cycle started speed.
Machine status indication
V-ECU continuously sends the signals of the current machine operating condition to the D-ECU.
Indicating the operating condition facilitates troubleshooting and repairs.
The D-ECU display the value that the V-ECU receives or outputs. Especially, for items based on the V-
ECU output value, the value may differ from the actual operating value of machine components. When
the operating condition of the equipment is abnormal, confirm by actually measuring the machine, then
compare with the value displayed on the D-ECU, and judge whether it is normal or abnormal.
D-ECU, indication contents

No. Item Status Display Unit Remark
code example
0 Mode G1 rpm Default
1 Engine speed 1900
2 Engine speed control switch step SC SC 9 1-9
3 Power max. mode switch status P P ON ON/OFF
4 Auto idling switch status A A ON ON/OFF
5 Boost/hammer switch status A. A.ON ON/OFF
6 Power shift current D D 400 mA
7 Boost relay status E E ON ON/ OFF
8 Boom/arm conflux cut-off relay status E. E.ON ON/OFF
9 Travel speed selection relay status F F ON ON/OFF
10 V-ECU power supply voltage G G26.5 V
11 Digging unit port pressure switch status H H. ON ON/ OFF
12 Travel port pressure switch status H. H ON ON/ OFF
13 Throttle position sensor value J J 4.2 V
14 Rotator switch status R R ON ON/OFF
15 Engine start switch (ACC) status S S ON ON/OFF
16 Auto warming up function status WARM WARM/NOWM
17 Hammer port pressure switch status M M ON ON/OFF
18 Flow control switch step FC FC 9 1~9
19 Setting pump flow L L100 Display for 10 seconds whenever
changes the setting pump flow
20 Flow control current L. L.300 mA
21 Fault code ER ER11
Mode selection & engine speed sensing power control, description
The engine speed control switch (2) allows the operator to select the engine speed and work mode according to the
working condition and environment to optimize the machine performance and fuel efficiency.
This is accomplished by turning the engine speed control switch to vary its output voltage to the V-ECU (1),
0.5~+4.5V. The V-ECU then establishes an appropriate pulse signal value to rotate the stepping motor (20), to
the correct rotary angle, to position the fuel injection pump lever, to obtain the engine speed to match mode
speed requirement. the throttle position sensor (14, potentiometer) confirms the angle to the V-ECU for greater
accuracy.
The V-ECU continuously receives the current engine speed from engine speed sensor (13). It balances engine
output horsepower and hydraulic pump drive horsepower by changing the pump swash angle with driving the
power shift proportional solenoid valve (21) to keep pump torque below the engine torque developed at the
selected engine speed. this is called engine speed sensing power control (ESSPC) and working P, H and G
modes.
P mode (Full duty operation)
P (Power max.) mode functions on the power max. mode switch (8) ON with step-9 of the engine speed control
switch (2) to maximize the working capacity and working speed by utilizing 100% of the rated engine output
horsepower.
This mode is for heavy duty excavating operation which require powerful digging and lifting force.
H mode (Heavy duty operation)
H mode functions on step-9 of the engine speed control switch (2) and the power max. mode switch (8) OFF to
increase the working capacity and working speed by utilizing 95% of the rated engine output horsepower.
This mode is for slightly heavy duty excavating operation which require powerful digging and lifting force.
G mode (General duty operation)
G mode functions over a 3 step range as follows : Step 6/7/8 utilize 90% of the rated engine output horsepower
and is recommended for general duty operations that are below the level which require maximum engine output.
These positions provide the most efficient, fuel saving, economical machine performance for general excavating
and loading operations.
F mode (Fine duty operation)
F mode functions over a 3 step range as follows : Step 3/4/5 utilize 70% of the rated engine output horsepower,
however at each step this mode outputs a constant current to the power shift proportional solenoid valve (21) on
the hydraulic pump to set and hold the swash plate angle for consistent pump discharge. At the same time, the V-
ECU activates the boom and arm conflux cut-off solenoid valves (23, 24) and shut off summation of the two
hydraulic pumps when operating the boom or arm. Also, the V-ECU activates the boost solenoid valve (26). It
provides fine controllability for precise smooth movements and maximum lifting force at mid-range engine speeds.
This mode is recommended for finishing/levelling work and when fine precision control of the boom and arm is
essential.
I mode (Idling operation)
I mode functions over a 2 step range as follows : Both steps minimize the output of the pumps.
Step-1 is the low idle speed set at engine starting. Step-2 is the auto idle speed and is available if the auto idling
switch (7) is in the ON position.
Figure 1
Components related to mode selection
1V-ECU
3Auto/manual switch
8Power max. mode switch
14Throttle position sensor
20Stepping motor
21Power shift proportional solenoid valve
23Boom conflux cut-off solenoid valve
24Arm conflux cut-off solenoid valve
28Relay box
Mode selection & engine speed sensing power control, specification

Engine speed and work mode
Switch Mode Engine speed Maximum Current Remarks
steps (±40 rpm) pump input (±20 mA)
(unload / load) torque
EC210 EC240 EC210 EC240
9 Power P 2070 / 2170 / 100% 200 / 200 / - Power max. mode
max. above 1900 above 2000 variable variable switch : ON
- ESSPC
Heavy H 1950 / 2050 / 95% 240 / 240 / - Power max. mode
above 1750 above 1850 variable variable switch : OFF
- ESSPC
8 General G1 1800 / 1900 / 90% 280/ 280/ - ESSPC
above 1600 above 1700 variavle variavle
7 G2 1700 / 1800 /
above 1500 above 1600
6 G3 1700 /
above 1500
5 Fine F1 1600 / - 1600 / - 70% 470 450 - Automatic power
4 F2 1500 / - 1500 / - boost
3 F3 1400 / - 1400 / - - Boom / arm conflux
cut-off
- Travel low speed
mode
2 Idle I1 1100 / - 1100 / - - 555 570 - Auto idling
1 I2 850 / - 850 / - - Engine start
MANUAL condition Manual - 314 342
linkage cable
Travel speed selection, description
High speed mode
Travel speed modes can be selected according to the soil condition and the type of work.
If the travel speed selection switch (5) is in the high (travel symbol) position, 1st and 2nd automatic speed
change position, the swash plate of the travel motor will be automatically changed. the traveling speed is
controlled automatically to the 1st (low) or 2nd (high) speed according to load on motor.
Low speed mode
If the travel speed selection switch (5) is on the low (no symbol) or the engine speed control switch (2) is on the F
mode position (3 - 5 steps), the travel speed is held in 1st speed, regardless of the load on the travel motor.
When loading the machine onto a transport, or when precise travel operation is required the travel mode
switch must be in the low position to prevent an abrupt change of travel speed, since it could result in an
accident.
Travel speed selecting operation
Switch position Feature
Low speed mode Traveling locked in 1st speed.
(1st speed fixed) Fine control mode, speed is fixed.
High speed mode Traveling Automatic speed change to between 1st and 2nd according to the effort required
(automatic 1st/2nd to move the machine.
speed change) Stopped Automatically sets the swash angle to 1st speed.
The low speed / high torque position provides more stability on a slope as it
requires greater external forces to rotate the motor.
Although the auto/manual switch (3) is in the MANU position, the travel speed selection function is available using
the travel speed selection switch (5) and operate as described when the machine is traveling. When the machine
is stopped the swash angle is NOT automatically set to 1st speed position.
Figure 1
Components related travel speed selection

1V-ECU
5Travel speed selection switch
27Travel speed selection solenoid valve
28Relay box
Vehicle electronic control unit (V-ECU), description

The vehicle electronic control unit (V-ECU) receives information on the operating status from sensors installed in
the machine and then outputs signals to the appropriate actuators to control major component functions for
optimum performance.
Figure 1 V-ECU, connector pin specifications 1
Connector IN01-S Connector IN03-S
No. Description No. Description
1 TX 1 Rotator switch
2 RX 2 Power max. mode switch
3 AGND 3 -
4 D-ECU (+24 V) 4 -
5 AGND 5 -
6 - 6 Automatic idling switch
7 DGND 7 Boost/hammer selection switch
8 - 8 Start switch (ACC)
9 Digging unit port pressure switch
10 Travel port pressure switch
11 Battery ground (GND)
12 Battery power supply (+24 V)
V-ECU, connector pin specifications 2
Connector IN02-S Connector IN04-S
No. Description No. Description
1Engine speed sensor output (SIG) 1Stepping motor A
2Engine speed sensor ground (GND) 2Stepping motor A’
3Coolant temperature sensor output (SIG) 3Stepping motor B
4Coolant temperature sensor power (VCC) 4Stepping motor B’
5Throttle position sensor power (VDD) 5-
6Throttle position sensor output (SIG) 6-
7Throttle position sensor ground (GND) 7-
8- 8-
9- 9Flow control switch output (SIG)
10- 10Flow control switch power (24 V)
11Engine speed control switch power (24V) 11Flow control switch ground (GND)
12Engine speed control switch output (SIG) 12Power boost relay
13Engine speed control switch ground (GND) 13Boom/arm conflux cut-off relay
14Power shift proportional solenoid valve output (SIG) 14Travel speed selection relay
15Power shift proportional solenoid valve ground (GND) 15Battery power cut-off relay
16Flow control proportional solenoid valve output (SIG) 16Battery power (24 V)
17Flow control proportional solenoid valve ground (GND) 17Relay power (24 V)
18Hammer port pressure switch 18Battery power (24 V)
19Battery ground (GND)
20Battery ground (GND)

Location and Components

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Track gearbox (EC240), assembly

Assembly, track gearbox (EC240)

3 Seal. · After assembling the seal, check if the o-ring is

Tightening torque : 11.5 kgf·m (83 lbf·ft)

15 Plug. · Apply loctite #577 onto the threads of Torque

Track gearbox (EC240), description

Figure 1 Track gearbox (EC240), torque flow

Track gearbox, sectional view

Track gearbox (EC240), disassembly

3 Remove No. 1 sun gear

1. Remove retaining ring (32), and

3. Disassemble No. 2 planetary gear

4. Disassembling No. 3 planetary gear

7 Remove retainer. Do not reuse the screws. 19mm socket (M12)

Track gearbox (EC240), maintenance standard

Track gearbox (EC240), tools

Figure 1 Fixture, shim thickness measuring

Figure 1 Troubleshooting, track gearbox (EC240)

Track gearbox (EC240), precautions for operation

Figure 2 Position, gear oil replacement

Track gearbox, installation

Figure 1 Install, track gearbox

Figure 2 Checking, oil level

Figure 1 Removal, cover

Figure 3Removal, track gearbox

Slew gearbox (EC240), assembly

5 2nd planetary gear assembly. Plastic hammer

7 2nd sun gear. Snap ring pliers

11 1st sun gear.

Slew gearbox (EC240), description

Figure 1 Model code

Slew gearbox (EC240), disassembly

Figure 1or spherical bearing disassembly

Figure 2 Jig for No.2 pin disassembly

Figure 4 Jig for oil seal assembly

4 2nd sun gear. Snap ring pliers

Slew gearbox (EC240), maintenance standard

Slew gearbox (EC240), principle of operation

Figure 1 Slew gearbox (EC240)

Slew gearbox (EC240), principle of operation

Figure 1 Slew gearbox (EC240)

Track motor (EC240), description

Track motor (EC240), construction

Figure 1 Structure, flexible coupling

Figure 2 Flexible coupling, sectional view A - A

Figure 2 Assembly, o-ring and etc

Figure 3 Assembly, shaft

Figure 4 Assembly, spring pin

Figure 2 Removal, pin

Figure 3 Push with a press

Figure 4 Removal, bushing

Figure 1 Install, idler assembly

Figure 2 Installation, track

Figure 1 Measurement, wear

Figure 1 Removal, idler assembly

Figure 2 Removal, connecting screw

f Idler support jig 400 ∗ 300 ∗ 40 (Width ∗ Height ∗ Depth)

h Bushing driver jig

j Engine oil SAE 10W–30

Figure 1 Flange, measurement of wear

Figure 1 Tread, measurement of wear