Hyundai R360lc-7a S

MANUAL SERVICE
HYUNDAI R360LC-7A
CONTENTS
SECTION 1 GENERAL
Group 1 Safety Hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1
Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-9
SECTION 2 STRUCTURE AND FUNCTION

Group 1 Pump Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1
Group 2 Main Control Valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-22
Group 3 Swing Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-50
Group 4 Travel Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-62
Group 5 RCV Lever - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-75
Group 6 RCV Pedal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-82
SECTION 3 HYDRAULIC SYSTEM

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

Group 1 Component Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1
Group 2 Electrical Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-3
Group 3 Electrical Component Specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-21
Group 4 Connectors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-29
SECTION 5 MECHATRONICS SYSTEM

Group 1 Outline - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1
Group 2 Mode selection System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-3
Group 3 Automatic Deceleration System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-6
Group 4 Power Boost System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-7
Group 5 Travel Speed Control System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-8
Group 6 Automatic Warming Up Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-9
Group 7 Engine Overheat Prevention Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-10
Group 8 Anti-Restart System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-11
Group 9 Self-Diagnostic System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-12
Group 10 Engine Control System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-24
Group 11 EPPR(Electro Proportional Pressure Reducing) Valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-26
Group 12 Monitoring System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-29
SECTION 6 TROUBLESHOOTING
Group 1 Before Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1
Group 2 Hydraulic and Mechanical System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-4
Group 3 Electrical System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-24
Group 4 Mechatronics System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-40
SECTION 7 MAINTENANCE STANDARD

Group 1 Operational Performance Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1
Group 2 Major Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21
Group 3 Track and Work Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-32
SECTION 8 DISASSEMBLY AND ASSEMBLY

Group 1 Precaution - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1
Group 2 Tightening Torque - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-4
Group 3 Pump Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-7
Group 4 Main Control Valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-31
Group 5 Swing Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-51
Group 6 Travel Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-72
Group 7 RCV Lever - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-104
Group 8 Turning Joint - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-119
Group 9 Boom, Arm and Bucket Cylinder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-124
Group 10 Undercarriage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-141
Group 11 Work Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-153
SECTION 9 COMPONENT MOUNTING TORQUE

Group 1 Introduction guide - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-1
Group 2 Engine system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-2
Group 3 Electric system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-4
Group 4 Hydraulic system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-6
Group 6 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-10
Group 7 Work equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-14
FOREWORD
1. STRUCTURE
This service manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to
full effect at every opportunity.
This service manual mainly contains the necessary technical information for operations performed in
a service workshop.
For ease of understanding, the manual is divided into the following sections.
SECTION 1 GENERAL
This section explains the safety hints and gives the specification of the machine and major
components.
This section explains the structure and function of each component. It serves not only to give an
understanding of the structure, but also serves as reference material for troubleshooting.
This section explains the hydraulic circuit, single and combined operation.
This section explains the electrical circuit, monitoring system and each component. It serves not
only to give an understanding electrical system, but also serves as reference material for trouble
shooting.
This section explains the computer aided power optimization system and each component.
This section explains the troubleshooting charts correlating problems to causes.
This section gives the judgement standards when inspecting disassembled parts.
This section explains the order to be followed when removing, installing, disassembling or assembling
each component, as well as precautions to be taken for these operations.
This section shows bolt specifications and standard torque values needed when mounting
components to the machine.
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Contact your HYUNDAI distributor for the latest information.
0-1
2. HOW TO READ THE SERVICE MANUAL
Distribution and updating Revised edition mark(①②③…)
Any additions, amendments or other changes When a manual is revised, an edition mark is
will be sent to HYUNDAI distributors. recorded on the bottom outside corner of the
Get the most up-to-date information before you pages.
start any work.
Revisions
Filing method Revised pages are shown at the list of revised
1. See the page number on the bottom of the pages on the between the contents page and
page. section 1 page.
File the pages in correct order.
2. Following examples shows how to read the Symbols
page number. So that the shop manual can be of ample
Example 1 practical use, important places for safety and
2-3 quality are marked with the following symbols.
Item number(2. Structure and
Function)
Consecutive page number for Symbol Item Remarks
each item.
Special safety precautions are
3. Additional pages : Additional pages are necessary when performing the
indicated by a hyphen(-) and number after the work.
Safety
page number. File as in the example. Extra special safety precautions
10 - 4 are necessary when performing
the work because it is under
10 - 4 - 1
Added pages internal pressure.
10 - 4 - 2
Special technical precautions or
10 - 5
※ Caution
other precautions for preserving
standards are necessary when
performing the work.
0-2
3. CONVERSION TABLE
Method of using the Conversion Table
The Conversion Table in this section is provided to enable simple conversion of figures. For details of
the method of using the Conversion Table, see the example given below.
Example
1. Method of using the Conversion Table to convert from millimeters to inches
Convert 55mm into inches.
(1) Locate the number 50in the vertical column at the left side, take this as ⓐ, then draw a
horizontal line from ⓐ.
(2) Locate the number 5in the row across the top, take this as ⓑ, then draw a perpendicular line
down from ⓑ.
(3) Take the point where the two lines cross as ⓒ. This point ⓒ gives the value when converting
from millimeters to inches. Therefore, 55mm = 2.165 inches.
2. Convert 550mm into inches.

(1) The number 550 does not appear in the table, so divide by 10(Move the decimal point one place
to the left) to convert it to 55mm.
(2) Carry out the same procedure as above to convert 55mm to 2.165 inches.
(3) The original value(550mm) was divided by 10, so multiply 2.165 inches by 10(Move the decimal
point one place to the right) to return to the original value.
This gives 550mm = 21.65 inches.
Millimeters to inches ⓑ 1mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
ⓒ
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
ⓐ
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
0-3
Millimeters to inches 1mm = 0.03937in
0 1 2 3 4 5 6 7 8 9
0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound 1kg = 2.2046lb
0 1 2 3 4 5 6 7 8 9
0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.5. 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
0-4
Liter to U.S. Gallon 1ℓ = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.631 25.625 25.889 26.153
Liter to U.K. Gallon 1ℓ = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
0-5
kgf・m to lbf・ft 1kgf・m = 7.233lbf・ft
0 1 2 3 4 5 6 7 8 9
7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 396.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 10005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
0-6
kgf/cm2 to lbf/in2 1kgf / cm2 = 14.2233lbf/in2
0 1 2 3 4 5 6 7 8 9
14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 2863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 5603 2617 2631 2646 2660 2674 2688
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
0-7
TEMPERATURE
Fahrenheit-Centigrade Conversion.
A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice verse
is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
°
C °
F °
C °
F °
C °
F °
C °
F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 35 95.0 21.1 70 158.0 51.7 125 257.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 172 347.0
0-8
SECTION 1 GENERAL
Group 1 Safety Hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1

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

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

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

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

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

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

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

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

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

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

Before working on the machine:
·Park machine on a level surface.
·Lower bucket to the ground.
·Turn auto idle switch off.
·Run engine at 1/2 speed without load for 2 minutes.
·Turn key switch to OFF to stop engine.
Remove key from switch.
·Move pilot control shutoff lever to locked position.
·Allow engine to cool.
1-3
SUPPORT MACHINE PROPERLY
Always lower the attachment or implement to
the ground before you work on the machine. If
you must work on a lifted machine or
attachment, securely support the machine or
attachment.
Do not support the machine on cinder blocks,
hollow tiles, or props that may crumble under
continuous load. 13031GE10
Do not work under a machine that is supported

solely by a jack. Follow recommended
procedures in this manual.
SERVICE COOLING SYSTEM SAFELY

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

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

Do not incinerate or puncture pressurized
containers.
Make sure machine is clean of trash, grease,
and debris.
Do not store oily rags; They can ignite and
burn spontaneously.
13031GE13
1-4
BEWARE OF EXHAUST FUMES
Prevent asphyxiation. Engine exhaust fumes
can cause sickness or death.
If you must operate in a building, be positive
there is adequate ventilation. Either use an
exhaust pipe extension to remove the exhaust
fumes or open doors and windows to bring
enough outside air into the area.
REMOVE PAINT BEFORE WELDING OR
HEATING
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint
is heated by welding, soldering, or using a torch.
Do all work outside or in a well ventilated area.
Dispose of paint and solvent properly.
Remove paint before welding or heating:
· If you sand or grind paint, avoid breathing the
dust.
Wear an approved respirator.
·If you use solvent or paint stripper, remove
stripper with soap and water before welding.
Remove solvent or paint stripper containers
and other flammable material from area.
Allow fumes to disperse at least 15 minutes
13031GE14
before welding or heating.
ILLUMINATE WORK AREA SAFELY

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

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

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

other materials.
PREVENT BATTERY EXPLOSIONS

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

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

Parts catalogue.)
DISPOSE OF FLUIDS PROPERLY

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

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

Before returning machine to customer, make
sure machine is functioning properly, especially
the safety systems. Install all guards and shields.
1-8
GROUP 2 SPECIFICATIONS
1. MAJOR COMPONENT
Tool box Fuel tank Hydraulic oil tank Main pump
Engine
Radiator
Tooth Bucket Turning joint Swing motor Main control valve Battery Oil cooler
Arm Arm cylinder Boom Boom cylinder Cab Precleaner Muffler
Bucket cylinder Connecting link Idler Carrier roller Sprocket Counterweight
Side cutter Connecting rod Track roller Track Travel motor
3607A2SP00
1-9
2. SPECIFICATIONS
I(I') D
C
E
G
F
H
J M
K N
A B(L)
36072ASP01
Description Unit Specification
Operating weight kg(lb) 36100(79590)

Bucket capacity(SAE heaped), standard m3(yd3) 1.62(2.12)
Overall length A 11120(36' 6")
Overall width, with 600mm shoe B 3340(10' 11")
Overall height C 3440(11' 3")
Superstructure width D 2980( 9' 9")
Overall height of cab E 3175(10' 5")
Ground clearance of counterweight F 1290( 4' 3")
Engine cover height G 3190(10' 6")
Minimum ground clearance H mm(ft-in) 550( 1' 10")
Rear-end distance I 3350(11' 1")
Rear-end swing radius I' 3415(11' 2")
Distance between tumblers J 4340(14' 3")
Undercarriage length K 5280(17' 4")
Undercarriage width L 3340(11' 0")
Track gauge M 2740( 9' 0")
Track shoe width, standard N 600(24")
Travel speed(Low/high) km/hr(mph) 3.2/4.5(2.0/2.8)
Swing speed rpm 9.0
Gradeability Degree(%) 35(70)
Ground pressure(600mm shoe) kgf/cm2(psi) 0.64(9.10)
1-10
3. WORKING RANGE
1) 6.5m(21' 4") BOOM
A
A'
F
D
E
B'
C
B
8ft
3607A2SP04
Description 2.5m(8' 2") Arm *3.2m(10' 6") Arm 3.9m(12' 10") Arm 4.3m(14' 1") Arm
Max digging reach A 10720mm (35' 2") 11250mm (36'11") 11870mm (38'11") 12380mm (40' 7")
Max digging reach on ground A' 10490mm (34' 5") 11000mm (36' 1") 11670mm (38' 3") 12180mm (40' 0")
Max digging depth B 6800mm (22' 4") 7500mm (24' 7") 8200mm (26'11") 8600mm (28' 3")
Max digging depth (8ft level) B' 6620mm (21' 9") 7350mm (24' 1") 8070mm (26' 6") 8480mm (27'10")
Max vertical wall digging depth C 5940mm (19' 6") 6340mm (20'10") 7040mm (23' 1") 7550mm (24' 9")
Max digging height D 10470mm (34' 4") 10430mm (34' 3") 10650mm (34'11") 11210mm (36' 9")
Max dumping height E 7270mm (23'10") 7290mm (23'11") 7510mm (24' 8") 8030mm (26' 4")
Min swing radius F 4630mm (15' 2") 4560mm (15' 0") 4550mm (14'11") 4570mm (15' 0")
201.0[219.3] kN 201.0[219.3] kN 201.0[219.3] kN 201.0[219.3] kN
SAE 20500[22360] kgf 20500[22360] kgf 20500[22360] kgf 20500[22360] kgf
45190[49300] lbf 45190[49300] lbf 45190[49300] lbf 45190[49300] lbf
Bucket digging force
228.5[249.3] kN 228.5[249.3] kN 228.5[249.3] kN 228.5[249.3] kN
ISO 23300[25420] kgf 23300[25420] kgf 23300[25420] kgf 23300[25420] kgf
51370[56040] lbf 51370[56040] lbf 51370[56040] lbf 51370[56040] lbf
184.4[201.1] kN 152.0[165.8] kN 135.3[147.6] kN 124.5[135.9] kN
SAE 18800[20510] kgf 15500[16910] kgf 13800[15050] kgf 12700[13850] kgf
41450[45220] lbf 34170[37280] lbf 30420[33190] lbf 28000[30550] lbf
Arm crowd force
192.2[209.7] kN 156.9[171.2] kN 139.3[151.9] kN 128.5[140.1] kN
ISO 19600[21380] kgf 16000[17450] kgf 14200[15490] kgf 13100[14290] kgf
43210[47140] lbf 35270[38480] lbf 31310[34160] lbf 28880[31510] lbf
[ ] : Power boost
* : STD
1-11
·6.15m(20' 2") BOOM
A
A'
F
D
E
B'
C
B
8ft
3607A2SP04
Description 2.5m(8' 2") Arm
Max digging reach A 10330mm (33'11")

Max digging reach on ground A' 10100mm (33' 2")
Max digging depth B 6440mm (21' 2")
Max digging depth (8ft level) B' 6260mm (20' 6")
Max vertical wall digging depth C 5500mm (18' 1")
Max digging height D 10200mm (33' 6")
Max dumping height E 7020mm (23' 0")
Min swing radius F 4320mm (14' 2")
201.0[219.3] kN
SAE 20500[22360] kgf
45190[49300] lbf
228.5[249.3] kN
ISO 23300[25420] kgf
51370[56040] lbf
184.4[201.1] kN
SAE 18800[20510] kgf
41450[45220] lbf
Arm crowd force
192.2[209.7] kN
ISO 19600[21380] kgf
43210[47140] lbf
[ ] : Power boost
1-12
·8.6m(28' 3") BOOM
A
A'
F
D
E
B'
C
B
8ft
3607A2SP04
Description 5.1m(16' 9") Arm
Max digging reach A 15300mm (50' 2")

Max digging reach on ground A' 15120mm (49' 7")
Max digging depth B 11210mm (36' 9")
Max digging depth (8ft level) B' 11100mm (36' 5")
Max vertical wall digging depth C 10070mm (33' 0")
Max digging height D 13160mm (43' 2")
Max dumping height E 9990mm (32' 9")
Min swing radius F 6040mm (19'10")
202[220.4] kN
SAE 20600[22470] kgf
45420[49550] lbf
229.5[250.3] kN
ISO 23400[25530] kgf
51590[56280] lbf
109.8[119.8] kN
SAE 11200[12220] kgf
24690[26930] lbf
Arm crowd force
112.8[123.0] kN
ISO 11500[12550] kgf
25350[27650] lbf
[ ] : Power boost
1-13
4. WEIGHT
R360LC-7A
Item
kg lb
Upperstructure assembly 11620 25620
Main frame weld assembly 2810 6200
Engine assembly 740 1630
Main pump assembly 190 420
Main control valve assembly 250 550
Swing motor assembly 360 790
Hydraulic oil tank assembly 230 510
Fuel tank assembly 240 530
Counterweight 6500 14330
Cab assembly 310 680
Lower chassis assembly 5270 11620
Track frame weld assembly 14140 31170
Swing bearing 560 1230
Travel motor assembly 380 840
Turning joint 50 110
Track recoil spring and idler 420 930
Idler 180 400
Carrier roller 40 90
Track roller 80 180
Track-chain assembly(600mm standard triple grouser shoe) 2360 5200
Front attachment assembly(6.5m boom, 3.2m arm,
7660 16890
1.62m3 SAE heaped bucket)
6.5m boom assembly 3020 6660
3.2m arm assembly 1280 2820
1.62m3 SAE heaped bucket 1280 2820
Boom cylinder assembly 340 750
Arm cylinder assembly 460 1010
Bucket cylinder assembly 290 640
Bucket control linkage assembly 350 770
1-14
5. LIFTING CAPACITIES
1) 6.5m(21' 4") boom, 3.2m(10' 6") arm equipped with 1.62m3(SAE heaped) bucket and 600mm (24")
triple grouser shoe with 6500kg(14,330lb) counterweight.
· : Rating over-front · : Rating over-side or 360 degree
Load radius At max. reach

Load point 1.5m(5ft) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) 7.5m(25ft) 9.0m(30ft) Capacity Reach
height
m(ft)
9.0m kg *6020 *6020 7.97
(30ft) lb *13270 *13270 (26.1)
7.5m kg *4590 *4590 *6110 4650 9.12
(25ft) lb *10120 *10120 *13470 10250 (29.9)
6.0m kg *6710 6590 *6140 3860 9.87
(20ft) lb *14790 14530 *13540 8510 (32.4)
4.5m kg *8350 *8350 *7420 6290 *4490 4440 6020 3410 10.32
(15ft) lb *18410 *18410 *16360 13870 *9900 9790 13270 7520 (33.9)
3.0m kg *13690 13640 *10100 8600 *8370 5930 *6400 4260 5710 3180 10.50
(10ft) lb *30180 30070 *22270 18960 *18450 13070 *14110 9390 12590 7010 (34.4)
1.5m kg *16650 12420 *11760 7980 *9330 5590 7260 4080 5670 3120 10.45
(5ft) lb *36710 27380 *25930 17590 *20570 12320 16010 8990 12500 6880 (34.3)
Ground kg *13060 *13060 *18210 11800 *12930 7540 9560 5320 7100 3930 5900 3240 10.14
Line lb *28790 *28790 *40150 26010 *28510 16620 21080 11730 15650 8660 13010 7140 (33.3)
-1.5m kg *13680 *13680 *17490 *17490 *18550 11600 *13460 7330 9400 5170 6480 3590 9.57
(-5ft) lb *30160 *30160 *38560 *38560 *40900 25570 *29670 16160 20720 11400 14290 7910 (31.4)
-3.0m kg *17850 *17850 *22770 *22770 *17870 11660 *13210 7310 9400 5180 7700 4320 8.65
(-10ft) lb *39350 *39350 *50200 *50200 *39400 25710 *29120 16120 20720 11420 16980 9520 (28.4)
-4.5m kg *22570 *22570 *22590 *22590 *16000 11960 *11870 7510 *8000 5980 7.25
(-15ft) lb *49760 *49760 *49800 *49800 *35270 26370 *26170 16560 *17640 13180 (23.8)
-6.0m kg *11900 *11900
(-20ft) lb *26230 *26230
Note 1. Lifting capacity are based on SAE J1097 and ISO 10567.
2. Lifting capacity of the ROBEX series does not exceed 75% of tipping load with the machine
on firm, level ground or 87% of full hydraulic capacity.
3. The load point is a hook located on the back of the bucket.
4. *indicates load limited by hydraulic capacity.
1-15
2) 6.5m(21' 4") boom, 2.50m(8' 2") arm equipped with 1.62m3(SAE heaped) bucket and 600mm (24") triple
grouser shoe with 6500kg(14,330lb) counterweight.
Load point 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) 7.5m(25ft) Capacity Reach
height
m(ft)
9.0m kg *6900 *6900 7.22

(30ft) lb *15210 *15210 (23.7)
7.5m kg *6870 5190 8.49
(25ft) lb *15150 11440 (27.9)
6.0m kg *8050 *8050 *7580 6370 *6970 4240 9.29
(20ft) lb *17750 *17750 *16710 14040 *15370 9350 (30.5)
4.5m kg *11980 *11980 *9400 8990 *8180 6110 6550 3720 9.77
(15ft) lb *26410 *26410 *20720 19820 *18030 13470 14440 8200 (32.1)
3.0m kg *15410 12960 *11030 8330 *9020 5790 6210 3470 9.97
(10ft) lb *33970 28570 *24320 18360 *19890 12760 13690 7650 (32.7)
1.5m kg *17780 12000 *12460 7780 9750 5490 6180 3430 9.91
(5ft) lb *39200 26460 *27470 17150 21500 12100 13620 7560 (32.5)
Ground kg *18570 11650 *13320 7450 9520 5280 6490 3610 9.59
Line lb *40940 25680 *29370 16420 20990 11640 14310 7960 (31.5)
-1.5m kg *17800 *17800 *18280 11630 *13480 7340 9440 5210 7260 4070 8.97
(-5ft) lb *39240 *39240 *40300 25640 *29720 16180 20810 11490 16010 8970 (29.4)
-3.0m kg *23550 *23550 *17040 11830 *12770 7430 *8130 5070 7.97
(-10ft) lb *51920 *51920 *37570 26080 *28150 16380 *17920 11180 (26.1)
-4.5m kg *19520 *19520 *14370 12280 *7460 7460 6.39
(-15ft) lb *43030 *43030 *31680 27070 *16450 16450 (21.0)
height
m(ft)
9.0m kg *5290 5130 8.81
(30ft) lb *11660 11310 (28.9)
7.5m kg *5420 4000 9.85
(25ft) lb *11950 8820 (32.3)
6.0m kg *5890 *5890 *3660 *3660 *5590 3360 10.54
(20ft) lb *12990 *12990 *8070 *8070 *12320 7410 (34.6)
4.5m kg *6660 6330 *5450 4440 5380 2980 10.95
(15ft) lb *14680 13960 *12020 9790 11860 6570 (35.9)
3.0m kg *19900 *19900 *12040 *12040 *9120 8690 *7660 5930 *6860 4230 5120 2780 11.13
(10ft) lb *43870 *43870 *26540 *26540 *20110 19160 *16890 13070 *15120 9330 11290 6130 (36.5)
1.5m kg *12660 *12660 *15330 12590 *10910 7990 *8710 5540 7200 4000 5060 2720 11.07
(5ft) lb *27910 *27910 *33800 27760 *24050 17610 *19200 12210 15870 8820 11160 6000 (36.3)
Ground kg *13680 *13680 *17420 11750 *12310 7470 9470 5220 6990 3820 5230 2800 10.79
Line lb *30160 *30160 *38400 25900 *27140 16470 20880 11510 15410 8420 11530 6170 (35.4)
-1.5m kg *12590 *12590 *16830 *16830 *18250 11390 *13100 7170 9240 5020 6870 3710 5670 3060 10.26
(-5ft) lb *27760 *27760 *37100 *37100 *40230 25110 *28880 15810 20370 11070 15150 8180 12500 6750 (33.7)
-3.0m kg *16200 *16200 *21040 *21040 *18030 11340 *13170 7080 9170 4960 6560 3600 9.42
(-10ft) lb *35710 *35710 *46390 *46390 *39750 25000 *29030 15610 20220 10930 14460 7940 (30.9)
-4.5m kg *20270 *20270 *24240 *24240 *16700 11540 *12330 7180 *9270 5080 *7640 4710 8.17
(-15ft) lb *44690 *44690 *53440 *53440 *36820 25440 *27180 15830 *20440 11200 *16840 10380 (26.8)
-6.0m kg *19460 *19460 *13690 12040
(-20ft) lb *42900 *42900 *30180 26540
1-16
Load point 1.5m(5ft) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) 7.5m(25ft) 9.0m(30ft) 10.5m(35ft) Capacity Reach
height
m(ft)
9.0m kg *5050 4420 9.45
(30ft) lb *11130 9740 (31.0)
7.5m kg *2740 *2740 *4810 3510 10.42
(25ft) lb *6040 *6040 *10600 7740 (34.2)
6.0m kg *4460 *4460 *4700 2980 11.07
(20ft) lb *9830 *9830 *10360 6570 (36.3)
4.5m kg *6110 *6110 *5620 4490 *4730 2650 11.46
(15ft) lb *13470 *13470 *12390 9900 *10430 5840 (37.6)
3.0m kg *17000 *17000 *10840 *10840 *8410 *8410 *7160 6000 *6460 4250 *2660 *2660 4680 2480 11.63
(10ft) lb *37480 *37480 *23900 *23900 *18540 *18540 *15790 13230 *14240 9370 *5860 *5860 10320 5470 (38.2)
1.5m kg *13680 *13680 *14340 12850 *10300 8090 *8270 5580 *7120 4000 *2990 2920 4630 2430 11.58
(5ft) lb *30160 *30160 *31610 28330 *22710 17840 *18230 12300 *15700 8820 *6590 6440 10210 5360 (38.0)
Ground kg *13030 *13030 *16790 11840 *11850 7500 *9250 5220 6970 3790 4770 2500 11.31
Line lb *28730 *28730 *37020 26100 *26120 16530 *20390 11510 15370 8360 10520 5510 (37.1)
-1.5m kg *11080 *11080 *15420 *15420 *17980 11350 *12820 7140 9210 4980 6810 3650 5140 2710 10.81
(-5ft) lb *24430 *24430 *34000 *34000 *39640 25020 *28260 15740 20300 10980 15010 8050 11330 5970 (35.5)
-3.0m kg *14380 *14380 *19060 *19060 *18090 11210 *13120 6990 9090 4870 *6650 3610 5870 3160 10.02
(-10ft) lb *31700 *31700 *42020 *42020 *39880 24710 *28920 15410 20040 10740 *14660 7960 12940 6970 (32.9)
-4.5m kg *18170 *18170 *24050 *24050 *17140 11340 *12590 7040 9150 4930 *6970 4020 8.87
(-15ft) lb *40060 *40060 *53020 *53020 *37790 25000 *27760 15520 20170 10870 *15370 8860 (29.1)
-6.0m kg *22830 *22830 *21250 *21250 *14730 11750 *10720 7330 *6830 6040 7.15
(-20ft) lb *50330 *50330 *46850 *46850 *32470 25900 *23630 16160 *15060 13320 (23.5)
height
m(ft)
9.0m kg *7640 *7640 6.65

(30ft) lb *16840 *16840 (21.8)
7.5m kg *7520 5970 8.02
(25ft) lb *16580 13160 (26.3)
6.0m kg *8660 *8660 *6540 6530 *7580 4800 8.88
(20ft) lb *19090 *19090 *14420 14400 *16710 10580 (29.1)
4.5m kg *18380 *18380 *12260 *12260 *9890 9350 *8740 6330 7200 4190 9.38
(15ft) lb *40520 *40520 *27030 *27030 *21800 20610 *19270 13960 15870 9240 (30.8)
3.0m kg *15570 13710 *11460 8720 *9500 6030 6790 3890 9.58
(10ft) lb *34330 30230 *25260 19220 *20940 13290 14970 8580 (31.4)
1.5m kg *18030 12630 *12850 8150 10010 5730 6750 3830 9.52
(5ft) lb *39750 27840 *28330 17970 22070 12630 14880 8440 (31.2)
Ground kg *13370 *13370 *18930 12120 *13670 7770 9760 5500 7090 4010 9.19
Line lb *29480 *29480 *41730 26720 *30140 17130 21520 12130 15630 8840 (30.2)
-1.5m kg *20990 *20990 *18580 11990 *13710 7610 9650 5410 7990 4540 8.53
(-5ft) lb *46270 *46270 *40960 26430 *30230 16780 21270 11930 17610 10010 (28.0)
-3.0m kg *23670 *23670 *17040 12100 *12670 7650 *8470 5730 7.47
(-10ft) lb *52180 *52180 *37570 26680 *27930 16870 *18670 12630 (24.5)
-4.5m kg *18590 *18590 *13590 12520
(-15ft) lb *40980 *40980 *29960 27600
1-17
height
m(ft)
9.0m kg *7640 *7640 6.65

(30ft) lb *16840 *16840 (21.8)
7.5m kg *7520 6120 8.02
(25ft) lb *16580 13490 (26.3)
6.0m kg *8660 *8660 *6540 *6540 *7580 4940 8.88
(20ft) lb *19090 *19090 *14420 *14420 *16710 10890 (29.1)
4.5m kg *18380 *18380 *12260 *12260 *9890 9560 *8740 6490 7410 4310 9.38
(15ft) lb *40520 *40520 *27030 *27030 *21800 21080 *19270 14310 16340 9500 (30.8)
3.0m kg *15570 14040 *11460 8930 *9500 6190 6990 4010 9.58
(10ft) lb *34330 30950 *25260 19690 *20940 13650 15410 8840 (31.4)
1.5m kg *18030 12960 *12850 8370 *10240 5890 6950 3950 9.52
(5ft) lb *39750 28570 *28330 18450 *22580 12990 15320 8710 (31.2)
Ground kg *13370 *13370 *18930 12450 *13670 7990 10030 5670 7300 4140 9.19
Line lb *29480 *29480 *41730 27450 *30140 17610 22110 12500 16090 9130 (30.2)
-1.5m kg *20990 *20990 *18580 12310 *13710 7820 9920 5570 8220 4680 8.53
(-5ft) lb *46270 *46270 *40960 27140 *30230 17240 21870 12280 18120 10320 (28.0)
-3.0m kg *23670 *23670 *17040 12430 *12670 7870 *8470 5900 7.47
(-10ft) lb *52180 *52180 *37570 27400 *27930 17350 *18670 13010 (24.5)
-4.5m kg *18590 *18590 *13590 12850
(-15ft) lb *40980 *40980 *29960 28330
height
m(ft)
9.0m kg *6900 *6900 7.22

(30ft) lb *15210 *15210 (23.7)
7.5m kg *6870 5330 8.49
(25ft) lb *15150 11750 (27.9)
6.0m kg *8050 *8050 *7580 6530 *6970 4360 9.29
(20ft) lb *17750 *17750 *16710 14400 *15370 9610 (30.5)
4.5m kg *11980 *11980 *9400 9200 *8180 6280 6740 3840 9.77
(15ft) lb *26410 *26410 *20720 20280 *18030 13850 14860 8470 (32.1)
3.0m kg *15410 13290 *11030 8540 *9020 5950 6390 3590 9.97
(10ft) lb *33970 29300 *24320 18830 *19890 13120 14860 7910 (32.7)
1.5m kg *17780 12320 *12460 8000 *9830 5650 6370 3550 9.91
(5ft) lb *39200 27160 *27470 17640 *21670 12460 14040 7830 (32.5)
Ground kg *18570 11980 *13320 7670 9790 5450 6690 3730 9.59
Line lb *40940 26410 *29370 16910 21580 12020 14750 8220 (31.5)
-1.5m kg *17800 *17800 *18280 11960 *13480 7560 9710 5370 7480 4200 8.97
(-5ft) lb *39240 *39240 *40300 26370 *29720 16670 21410 11840 16490 9260 (29.4)
-3.0m kg *23550 *23550 *17040 12150 *12770 7640 *8130 5220 7.97
(-10ft) lb *51920 *51920 *37570 26790 *28150 16840 *17920 11510 (26.1)
-4.5m kg *19520 *19520 *14370 12600 *7460 *7460 6.39
(-15ft) lb *43030 *43030 *31680 27780 *16450 *16450 (21.0)
1-18
height
m(ft)
9.0m kg *6020 *6020 7.97
(30ft) lb *13270 *13270 (26.1)
7.5m kg *4590 *4590 *6110 4780 9.12
(25ft) lb *10120 *10120 *13470 10540 (29.9)
6.0m kg *6710 *6710 *6140 3970 9.87
(20ft) lb *14790 *14790 *13540 8750 (32.4)
4.5m kg *8350 *8350 *7420 6460 *4490 *4490 6200 3520 10.32
(15ft) lb *18410 *18410 *16360 14240 *9900 *9900 13670 7760 (33.9)
3.0m kg *13690 *13690 *10100 8820 *8370 6100 *6400 4390 5890 3290 10.50
(10ft) lb *30180 *30180 *22270 19440 *18450 13450 *14110 9680 12990 7250 (34.4)
1.5m kg *16650 12750 *11760 8190 *9330 5750 7470 4210 5850 3240 10.45
(5ft) lb *36710 28110 *25930 18060 *20570 12680 16470 9280 12900 7140 (34.3)
Ground kg *13060 *13060 *18210 12130 *12930 7760 9840 5480 *7120 4060 6080 3360 10.14
Line lb *28790 *28790 *40150 26740 *28510 17110 21690 12080 *15700 8950 13400 7410 (33.3)
-1.5m kg *13680 *13680 *17490 *17490 *18550 11930 *13460 7550 9670 5340 6680 3710 9.57
(-5ft) lb *30160 *30160 *38560 *38560 *40900 26300 *29670 16640 21320 11770 14730 8180 (31.4)
-3.0m kg *17850 *17850 *22770 *22770 *17870 11990 *13210 7530 9670 5340 7930 4460 8.65
(-10ft) lb *39350 *39350 *50200 *50200 *39400 26430 *29120 16600 21320 11770 17480 9830 (28.4)
-4.5m kg *22570 *22570 *22590 *22590 *16000 12290 *11870 7730 *8000 6150 7.25
(-15ft) lb *49760 *49760 *49800 *49800 *35270 27090 *26170 17040 *17640 13560 (23.8)
-6.0m kg *11900 *11900
(-20ft) lb *26230 *26230
height
m(ft)
9.0m kg *5290 5260 8.81
(30ft) lb *11660 11600 (28.9)
7.5m kg *5420 4120 9.85
(25ft) lb *11950 9080 (32.3)
6.0m kg *5890 *5890 *3660 *3660 *5590 3470 10.54
(20ft) lb *12990 *12990 *8070 *8070 *12320 7650 (34.6)
4.5m kg *6660 6500 *5450 4580 5550 3090 10.95
(15ft) lb *14680 14330 *12020 10100 12240 6810 (35.9)
3.0m kg *19900 *19900 *12040 *12040 *9120 8910 *7660 6100 *6860 4360 5280 2880 11.13
(10ft) lb *43870 *43870 *26540 *26540 *20110 19640 *16890 13450 *15120 9610 11640 6350 (36.5)
1.5m kg *12660 *12660 *15330 12920 *10910 8210 *8710 5700 7410 4140 5230 2820 11.07
(5ft) lb *27910 *27910 *33800 28480 *24050 18100 *19200 12570 16340 9130 11530 6220 (36.3)
Ground kg *13680 *13680 *17420 12070 *12310 7680 *9600 5380 7200 3950 5400 2910 10.79
Line lb *30160 *30160 *38400 26610 *27140 16930 *21160 11860 15870 8710 11900 6420 (35.4)
-1.5m kg *12590 *12590 *16830 *16830 *18250 11710 *13100 7390 9520 5180 7080 3840 5850 3170 10.26
(-5ft) lb *27760 *27760 *37100 *37100 *40230 25820 *28880 16290 20990 11420 15610 8470 12900 6990 (33.7)
-3.0m kg *16200 *16200 *21040 *21040 *18030 11670 *13170 7290 9450 5120 6770 3720 9.42
(-10ft) lb *35710 *35710 *46390 *46390 *39750 25730 *29030 16070 20830 11290 14930 8200 (30.9)
-4.5m kg *20270 *20270 *24240 *24240 *16700 11870 *12330 7400 *9270 5250 *7640 4860 8.17
(-15ft) lb *44690 *44690 *53440 *53440 *36820 26170 *27180 16310 *20440 11570 *16840 10710 (26.8)
-6.0m kg *19460 *19460 *13690 12360
(-20ft) lb *42900 *42900 *30180 27250
1-19
Load point 1.5m(5ft) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) 7.5m(25ft) 9.0m(30ft) 10.5m(35ft) Capacity Reach
height
m(ft)
9.0m kg *5050 4540 9.45
(30ft) lb *11130 10010 (31.0)
7.5m kg *2740 *2740 *4810 3620 10.42
(25ft) lb *6040 *6040 *10600 7980 (34.2)
6.0m kg *4460 *4460 *4700 3080 11.07
(20ft) lb *9830 *9830 *10360 6790 (36.3)
4.5m kg *6110 *6110 *5620 4620 *4730 2750 11.46
(15ft) lb *13470 *13470 *12390 10190 *10430 6060 (37.6)
3.0m kg *17000 *17000 *10840 *10840 *8410 *8410 *7160 6170 *6460 4380 *2660 *2660 4830 2580 11.63
(10ft) lb *37480 *37480 *23900 *23900 *18540 *18540 *15790 13600 *14240 9660 *5860 *5860 10650 5690 (38.2)
1.5m kg *13680 *13680 *14340 13180 *10300 8310 *8270 5740 *7120 4140 *2990 *2990 4790 2520 11.58
(5ft) lb *30160 *30160 *31610 29060 *22710 18320 *18230 12650 *15700 9130 *6590 *6590 10560 5560 (38.0)
Ground kg *13030 *13030 *16790 12170 *11850 7720 *9250 5380 7180 3920 4930 2600 11.31
Line lb *28730 *28730 *37020 26830 *26120 17020 *20390 11860 15830 8640 10870 5730 (37.1)
-1.5m kg *11080 *11080 *15420 *15420 *17980 11680 *12820 7360 9480 5140 7030 3780 5310 2820 10.81
(-5ft) lb *24430 *24430 *34000 *34000 *39640 25750 *28260 16230 20900 11330 15500 8330 11710 6220 (35.5)
-3.0m kg *14380 *14380 *19060 *19060 *18090 11540 *13120 7210 9360 5040 *6650 3750 6050 3270 10.02
(-10ft) lb *31700 *31700 *42020 *42020 *39880 25440 *28920 15900 20640 11110 *14660 8270 13340 7210 (32.9)
-4.5m kg *18170 *18170 *24050 *24050 *17140 11670 *12590 7250 9430 5090 *6970 4160 8.87
(-15ft) lb *40060 *40060 *53020 *53020 *37790 25730 *27760 15980 20790 11220 *15370 9170 (29.1)
-6.0m kg *22830 *22830 *21250 *21250 *14730 12070 *10720 7550 *6830 6220 7.15
(-20ft) lb *50330 *50330 *46850 *46850 *32470 26610 *23630 16640 *15060 13710 (23.5)
11) 8.6m(21' 4") boom, 5.1m(14' 1") arm equipped with 1.62m3(SAE heaped) bucket and 600mm (24")
triple grouser shoe with 10,700kg(23,590lb) counterweight.
Load point 1.5m(5ft) 3.0m(10.0ft) 4.5m(15.0ft) 6.0m(20.0ft) 7.5m(25.0ft) 9.0m(30.0ft) 10.5m(35.0ft) 12.0m(40.0ft) 13.5m(45.0ft) Capacity Reach
height
m(ft)
9.0m kg *3080 *3080 *3130 *3130 12.91

(30ft) lb *6790 *6790 *6900 *6900 (42.4)
7.5m kg *3180 *3180 *2670 *2670 *3200 2740 13.61
(25ft) lb *7010 *7010 *5890 *5890 *7050 6040 (44.7)
6.0m kg *3450 *3450 *3400 *3400 *3290 2440 14.10
(20ft) lb *7610 *7610 *7500 *7500 *7250 5380 (46.3)
4.5m kg *4190 *4190 *3830 *3830 *3630 3420 *3410 2250 14.40
(15ft) lb *9240 *9240 *8440 *8440 *8000 7540 *7520 4960 (47.2)
3.0m kg *11100 *11100 *7540 *7540 *5830 *5830 *4870 *4870 *4280 4260 *3910 3260 *1760 *1760 *3540 2130 14.53
(10ft) lb *24470 *24470 *16620 *16620 *12850 *12850 *10740 *10740 *9440 9390 *8620 7190 *3880 *3880 *7800 4700 (47.7)
1.5m kg *10860 *10860 *9180 *9180 *6870 *6870 *5560 5250 *4750 4010 *4230 3090 *1940 *1940 *3690 2090 14.49
(5ft) lb *23940 *23940 *20240 *20240 *15150 *15150 *12260 11570 *10470 8840 *9330 6810 *4280 *4280 *8140 4610 (47.5)
Ground kg *10370 *10370 *10430 9120 *7750 6560 *6180 4930 *5180 3800 *4520 2960 *3860 2120 14.28
Line lb *22860 *22860 *22990 20110 *17090 14460 *13620 10870 *11420 8380 *9960 6530 *8510 4670 (46.9)
-1.5m kg *7950 *7950 *11690 *11690 *11210 8750 *8400 6250 *6670 4700 *5540 3630 *4760 2860 *4040 2230 13.90
(-5ft) lb *17530*17530 *25770 *25770 *24710 19290 *18520 13780 *14700 10360 *12210 8000 *10490 6310 *8910 4920 (45.6)
-3.0m kg *8870 *8870 *10240*10240 *13850 13680 *11570 8600 *8790 6090 *6990 4570 *5770 3540 *4870 2810 *4230 2440 13.31
(-10ft) lb *19550 *19550 *22580*22580 *30530 30160 *25510 18960 *19380 13430 *15410 10080 *12720 7800 *10740 6190 *9330 5380 (43.7)
-4.5m kg *11060 *11060 *12770 *12770 *15780 13820 *11540 8610 *8880 6050 *7090 4530 *5800 3530 *4430 2790 12.50
(-15ft) lb *24380 *24380 *28150 *28150 *34790 30470 *25440 18980 *19580 13340 *15630 9990 *12790 7780 *9770 6150 (37.4)
-6.0m kg *13500 *13500 *15760*15760 *14940 14100 *11120 8750 *8630 6130 *6880 4600 *5490 3630 *4600 3390 11.41
(-20ft) lb *29760 *29760 *34740 *34740 *32940 31090 *24520 19290 *19030 13510 *15170 10140 *12100 8000 *10140 7470 (37.4)
-7.5m kg *16400 *16400 *19240*19240 *13480 *13480 *10160 9040 *7890 6350 *6120 4820 *4700 4480 9.94
(-25ft) lb *36160 *36160 *42420*42420 *29720 *29720 *22400 19930 *17390 1400 *13490 10630 *10360 9880 (32.6)
-9.0m kg *15380*15380 *11020 *11020 *8300 *8300 *6130 *6130
(-30ft) lb *33910*33910 *24290 *24290 *18300 *18300 *13510 *13510
1-20
6. BUCKET SELECTION GUIDE
1) GENERAL BUCKET
1.15m3 SAE 1.46m3 SAE ※1.62m3 SAE 1.86m3 SAE 2.10m3 SAE 2.32m3 SAE
heaped bucket heaped bucket heaped bucket heaped bucket heaped bucket heaped bucket
6.5m (21' 4") 6.15m(20'2") 8.6m(28' 3")

Capacity Width boom boom boom
Weight
SAE CECE Without With 2.5m arm 3.2m arm 3.9m arm 4.3m arm 2.5m arm 5.1m arm
heaped heaped side cutter side cutter (8' 2") (10' 6") (12' 10") (14' 1") (8' 2") (16' 9")
1.15m3 1.0m3 1090mm 1220mm 1030kg

(1.5yd3) (1.3yd3) (42.9") (48.0") (2270lb)
1.46m3 1.27m3 1380mm 1510mm 1170kg

(1.91yd ) (1.66yd3)
3
(54.3") (59.4") (2580lb)
※1.62m3 1.40m3 1440mm 1570mm 1280kg

(2.12yd3) (1.8yd3) (56.7") (61.8") (2820lb)
1.86m3 1.60m3 1620mm 1750mm 1390kg

(2.43yd3) (2.1yd3) (63.8") (68.9") (3060lb)
2.10m3 1.80m3 1810mm 1940mm 1520kg

(2.75yd3) (2.4yd3) (71.3") (76.4") (3350lb)
2.32m3 2.0m3 1990mm 2120mm 1760kg

(3.03yd3) (2.6yd3) (78.3") (83.5") (3880lb)
※ : Standard bucket
Applicable for materials with density of 2000kgf/m3 (3370lbf/yd3) or less

1-21
2) ROCK AND HEAVY DUTY BUCKET
ľ1.62m3 SAE Ľ1.44m3, 1.62m3, 1.86m3 SAE

heaped bucket heaped bucket
6.15m (20'
Capacity Width 6.5m (21' 4") boom 2") boom
Weight
SAE CECE Without With 2.5m arm 3.2m arm 3.9m arm 4.3m arm 2.5m arm
heaped heaped side cutter side cutter (8' 2") (10' 6") (12' 10") (14' 1") (8' 2")
ľ1.62m3 1.40m3 1540mm 1570kg

-
(2.12yd3) (1.8yd3) (60.6") (3460lb)
Ľ1.44m3 1.27m3 1280mm 1565kg

-
(1.88yd3) (1.66yd3) (50.4") (3450lb)
Ľ1.62m3 1.40m3 1545mm 1610kg

(2.12yd3) (1.8yd3) (60.8") - (3550lb)
Ľ1.86m3 1.60m3 1725mm 1710kg

-
(2.43yd3) (2.1yd3) (67.9") (3770lb)
ľ : Heavy duty bucket

Ľ : Rock bucket

1-22
7. UNDERCARRIAGE
1) TRACKS
X-leg type center frame is integrally welded with reinforced box-section track frames. The design
includes dry tracks, lubricated rollers, idlers, sprockets, hydraulic track adjusters with shock
absorbing springs and assembled track-type tractor shoes with triple grousers.
2) TYPES OF SHOES
Triple grouser
Model Shapes
Shoe width mm(in) 600(24) 700(28) 750(30) 800(32) 900(36)

Operating weight kg(lb) 36100(79590) 36500(80600) 36725(81000) 36950(81500) 37400(82500)
R360LC-7A
Ground pressure kgf/cm2(psi) 0.64(9.10) 0.56(7.96) 0.52(7.39) 0.49(6.97) 0.44(6.26)
Overall width mm(ft-in) 3340(10' 11") 3440(11' 3") 3490(11' 5") 3540(11' 7") 3640(11' 11")
3) NUMBER OF ROLLERS AND SHOES ON EACH SIDE
Item Quantity
Carrier rollers 2EA

Track rollers 9EA
Track shoes 51EA
4) SELECTION OF TRACK SHOE

Suitable track shoes should be selected according to operating conditions.
Method of selecting shoes
Confirm the category from the list of applications in table 2, then use table 1 to select the shoe.
Wide shoes(Categories B and C) have limitations on applications. Before using wide shoes, check
the precautions, then investigate and study the operating conditions to confirm if these shoes are
suitable.
Select the narrowest shoe possible to meet the required flotation and ground pressure. Application
of wider shoes than recommendations will cause unexpected problem such as bending of shoes,
crack of link, breakage of pin, loosening of shoe bolts and the other various problems.
※ Table 1
Track shoe Specification Category
600mm triple grouser Standard A

700mm triple grouser Option B
750mm triple grouser Option B
800mm triple grouser Option C
900mm triple grouser Option C
1-23
※ Table 2
Category Applications Precautions
Rocky ground, · Travel at low speed on rough ground with large obstacles such as
A river beds, boulders or fallen trees
normal soil
Normal soil, · These shoes cannot be used on rough ground with large obstacles such
soft ground as boulders or fallen trees
B · Travel at high speed only on flat ground
· Travel slowly at low speed if it is impossible to avoid going over
obstacles
Extremely soft gound · Use the shoes only in the conditions that the machine sinks and it is
(Swampy ground) impossible to use the shoes of category A or B
· These shoes cannot be used on rough ground with large obstacles such
C as boulders or fallen trees
· Travel at high speed only on flat ground
· Travel slowly at low speed if it is impossible to avoid going over
obstacles
1-24
8. SPECIFICATIONS FOR MAJOR COMPONENTS
1) ENGINE
Item Specification
Model Cummins QSL

Type 4-cycle turbocharged charger air cooled diesel engine
Cooling method Water cooling
Number of cylinders and arrangement 6 cylinders, in-line
Firing order 1-5-3-6-2-4
Combustion chamber type Direct injection type
Cylinder bore×stroke 114×144.5mm(4.49"×5.69")
Piston displacement 8900cc(540cu in)
Compression ratio 17.8 : 1
Rated gross horse power(SAE J1995) 296Hp at 1850rpm(221kW at 1850rpm)
Maximum torque 138.3kgf·m(1000lbf·ft) at 1400rpm
Engine oil quantity 31.7ℓ(8.4U.S. gal)
Dry weight 738kg(1630lb)
Low idling speed 700±100rpm
High idling speed 1850+50rpm
Rated fuel consumption 164.8g/Hp·hr at 1850rpm
Starting motor Denso 24V-7.5kW
Alternator Delco Remy 24V-50A
Battery 2×12V×160Ah
2) MAIN PUMP
Item Specification
Type Variable displacement tandem axis piston pumps

Capacity 2×160cc/rev
Maximum pressure 330kgf/cm2 (4690psi)[360kgf/cm2 (5120psi)]
Rated oil flow 2×288ℓ/min (76.1U.S. gpm/ 63.3U.K. gpm)
Rated speed 1800rpm
[ ]: Power boost
1-25
3) GEAR PUMP
Item Specification
Type Fixed displacement gear pump single stage

Capacity 15cc/rev
Maximum pressure 35kgf/cm2(500psi)
Rated oil flow 27˶/min(7.1U.S. gpm/5.9U.K. gpm)
4) MAIN CONTROL VALVE
Item Specification
Type 7 spools
Operating method Hydraulic pilot system
Main relief valve pressure 330kgf/cm2(4690psi)[360kgf/cm2(5120psi)]
Overload relief valve pressure 390kgf/cm2(5550psi)
[ ]: Power boost
5) SWING MOTOR
Item Specification
Type Axial piston motor

Capacity 250cc/rev
Relief pressure 260kgf/cm2(3700psi)
Braking system Automatic, spring applied hydraulic released
Braking torque 107kgfÂm(773lbfÂft)
Brake release pressure 30~50kgf/cm2(427~711psi)
Reduction gear type 2 - stage planetary
Swing speed 9.0rpm
6) TRAVEL MOTOR
Item Specification
Type Variable displacement axial piston motor

Relief pressure 360kgf/cm2(5120psi)
Capacity(max / min) 185.2/114.2cc/rev
Reduction gear type 3-stage planetary
Braking system Automatic, spring applied hydraulic released
Brake release pressure 8.5kgf/cm2(121psi)
Braking torque 44.4kgfÂm(321lbfÂft)
1-26
7) REMOTE CONTROL VALVE
Item Specification
Type Pressure reducing type

Minimum 6.5kgf/cm2(92psi)
Operating pressure
Maximum 26kgf/cm2(370psi)
Lever 61mm(2.4in)
Single operation stroke
Pedal 123mm(4.84in)
8) CYLINDER
Item Specification
Bore dia×Rod dia×Stroke Ø160×Ø110×1500mm

Boom cylinder
Cushion Extend only
Arm cylinder
Cushion Extend and retract
Bucket cylinder
Cushion Extend only
※ Discoloration of cylinder rod can occur when the friction reduction additive of lubrication oil spreads on
the rod surface.
※ Discoloration does not cause any harmful effect on the cylinder performance.
9) SHOE
Item Width Ground pressure Link quantity Overall width
Standard 600mm(24") 0.64kgf/cm2(9.10psi) 51 3340mm(10' 11")

700mm(28") 0.56kgf/cm (7.96psi)
2
51 3440mm(11' 3")
R360LC-7A
Option 750mm(30") 0.52kgf/cm2(7.39psi) 51 3490mm(11' 5")
800mm(32") 0.49kgf/cm (6.97psi)
2
51 3540mm(11' 7")
900mm(36") 0.44kgf/cm2(6.26psi) 51 3640mm(11' 11")
1-27
10) BUCKET
Capacity Tooth Width
Item quantity
SAE heaped CECE heaped Without side cutter With side cutter
Standard 1.62m3(2.12yd3) 1.40m3(1.8yd3) 5 1440mm(56.7") 1570mm(61.8")
1.15m (1.50yd )
3 3
1.0m (1.3yd )
3 3
4 1090mm(42.9") 1220mm(48.0")
1.46m3(1.91yd3) 1.27m3(1.66yd3) 4 1380mm(54.3") 1510mm(59.4")
◈1.62m (2.12yd )
3 3
1.40m (1.8yd )
3 3
5 1540mm(60.6") -
R360LC-7A Option
⊙1.44m3(1.88yd3) 1.27m3(1.66yd3) 5 1280mm(50.4") -
⊙1.62m (2.12yd )
3 3
1.40m (1.8yd )
3 3
5 1545mm(60.8") -
⊙1.86m3(2.43yd3) 1.60m3(2.1yd3) 5 1725mm(67.9") -
1.86m (2.43yd )
3 3
1.60m (2.1yd )
3 3
5 1620mm(63.8") 1750mm(68.9")
2.10m3(2.75yd3) 1.80m3(2.4yd3) 6 1810mm(71.3") 1940mm(76.4")
2.32m (3.03yd )
3 3
2.0m (2.6yd )
3 3
6 1990mm(78.3") 2120mm(83.5")
◈ : Heavy duty bucket
⊙ : Rock bucket(Esco type)
1-28
9. RECOMMENDED OILS
Use only oils listed below or equivalent.
Do not mix different brand oil.
Ambient temperature 。
C (。
F)
Capacity
Service point Kind of fluid -20 -10 0 10 20 30 40
ℓ(U.S. gal)
(-4) (14) (32) (50) (68) (86) (104)
SAE 30
SAE 10W
Engine
oil pan Engine oil 31.7(8.4)
SAE 10W-30
SAE 15W-40
Swing drive 8.0(2.1)

Gear oil SAE 85W-140
5.5×2
Final drive (1.5×2)
Tank; ISO VG 32
230(61)
Hydraulic tank Hydraulic oil ISO VG 46
System;
380(100) ISO VG 68
ASTM D975 NO.1

Fuel tank Diesel fuel 520(137)
ASTM D975 NO.2
NLGI NO.1
Fitting
Grease As required
(Grease nipple)
NLGI NO.2
Mixture of
Radiator antifreeze
45(12) Ethylene glycol base permanent type
(Reservoir tank) and water
50 : 50
SAE : Society of Automotive Engineers
API : American Petroleum Institute
ISO : International Organization for Standardization
NLGI : National Lubricating Grease Institute
ASTM : American Society of Testing and Material
1-29
Group 1 Pump Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1

Group 2 Main Control Valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-22
Group 3 Swing Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-50
Group 4 Travel Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-62
Group 5 RCV Lever - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-75
Group 6 RCV Pedal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-82
GROUP 1 PUMP DEVICE
1. STRUCTURE
The pump device consists of main pump, regulator and gear pump.
Port Port name Port size
A1,2 Delivery port SAE6000psi 1"

B1 Suction port SAE2500psi 3"
Dr Drain port PF 3/4 - 23
Pi1,i2 Pilot port PF 1/4 - 15
Pm1,m2 Qmax cut port PF 1/4 - 15
Psv1,sv2 Servo assist port PF 1/4 - 15
a1,2,3,4,5 Gauge port PF 1/4 - 15
A3 Gear pump delivery port PF 1/2 - 19
B3 Gear pump suction port PF 3/4 - 20.5
PB Gauge port PT1/8
36072MP01
2-1
1) MAIN PUMP(1/2)
The main pump consists of two piston pump(front & rear) and valve block.
36072MP02
04 Gear pump 271 Pump casing 710 O-ring

111 Drive shaft(F) 311 Valve cover(F) 717 O-ring
113 Drive shaft(R) 312 Valve cover(R) 719 O-ring
114 Spline coupling 313 Valve plate(R) 724 O-ring
123 Roller bearing 314 Valve plate(L) 725 O-ring
124 Needle bearing 401 Hexagon socket bolt 728 O-ring
127 Bearing spacer 402 Hexagon socket bolt 732 O-ring
130 Booster 406 Hexagon socket bolt 774 Oil seal
012 Cylinder block 466 VP Plug 789 Back up ring
151 Piston 468 VP Plug 792 Back up ring
152 Shoe 490 Plug 808 Hexagon head nut
153 Set plate 492 Plug 824 Snap ring
156 Bushing 531 Tilting pin 885 Pin
157 Cylinder spring 532 Servo piston 886 Spring pin
211 Shoe plate 534 Stopper(L) 901 Eye bolt
212 Swash plate 535 Stopper(S) 953 Set screw
214 Bushing 548 Feedback pin 954 Adjust screw
251 Support plate 702 O-ring
261 Seal cover(F) 706 O-ring
2-2
2) FRONT REGULATOR(1/2)
Pi1,Pi2 Pilot port PF 1/4-15

Psv1,Psv2 Servo assist port Psv1,Psv2
36072RE01
2-3
FRONT REGULATOR(2/2)
36072RE02
408 Hexagon socket bolt 628 Adjust screw(C) 724 O-ring

412 Hexagon socket bolt 629 Cover(C) 725 O-ring
413 Hexagon socket bolt 630 Lock nut 728 O-ring
436 Hexagon socket bolt 631 Sleeve, pf 730 O-ring
438 Hexagon socket bolt 641 Pilot cover 732 O-ring
466 Plug 642 Adjust screw(QMC) 733 O-ring
496 Plug 643 Pilot piston 734 O-ring
541 Seat 644 Spring seat(Q) 735 O-ring
543 Stopper 645 Adjust stem(Q) 755 O-ring
545 Steel ball 646 Pilot spring 756 O-ring
601 Casing 647 Stopper 763 O-ring
611 Feedback lever 648 Piston(QMC) 801 Hexagon nut
612 Lever(1) 651 Sleeve 814 Snap ring
613 Lever(2) 652 Spool(A) 836 Stop ring
614 Center plug 653 Spring seat 858 Snap ring
615 Adjust plug 654 Return spring 874 Pin
621 Compensator piston 655 Set spring 875 Pin
622 Piston case 696 Port cover 887 Pin
623 Compensator rod 697 Check valve plate 897 Pin
624 Spring seat(C) 708 O-ring 898 Pin
625 Outer spring 722 O-ring 924 Set screw
626 Inner spring 723 O-ring 925 Adjust screw(QI)
627 Adjust stem(C)
2-4
3) REAR REGULATOR(1/2)
Pi1,Pi2 Pilot port PF 1/4-15

Psv1,Psv2 Servo assist port PF 1/4-15
36072RE03
2-5
REAR REGULATOR(2/2)
36072RE04
079 EPPR valve 627 Adjust stem(C) 724 O-ring

601 Casing 647 Stopper 801 Hexagon nut
611 Feedback lever 648 Piston(QMC) 814 Snap ring
612 Lever(1) 651 Sleeve 836 Stop ring
613 Lever(2) 652 Spool(A) 858 Snap ring
614 Center plug 653 Spring seat 874 Pin
622 Piston case 697 Check valve plate 897 Pin
623 Compensator rod 699 Port cover 898 Pin
624 Spring seat(C) 708 O-ring 924 Set screw
625 Outer spring 722 O-ring 925 Adjust screw(QI)
626 Inner spring 723 O-ring
2-6
4) GEAR PUMP
36072GP01
307 Poppet 353 Drive gear 466 Plug

308 Seat 354 Driven gear 700 Ring
309 Ring 355 Filter 710 O-ring
310 Spring 361 Front case 725 O-ring
311 Screw 433 Flange socket 732 O-ring
312 Lock nut 434 Flange socket 850 Snap ring
351 Gear case 435 Flange socket
2-7
2. FUNCTION
1) MAIN PUMP
The pumps may classified roughly into the rotary group performing a rotary motion and working as
the major part of the whole pump function: the swash plate group that varies the delivery rates: and
the valve cover group that changes over oil suction and discharge.
(1) Rotary group

The rotary group consists of drive shaft
(F)(111), cylinder block(012),piston
shoes(151,152), set plate(153), spherical
bush(156), spacer(158) and cylinder 124
313
spring(157). The drive shaft is supported 012
by bearing(123,124) at its both ends. 158
156
The shoe is caulked to the piston to form 153
152
a spherical coupling. It has a pocket to 151
111
relieve thrust force generated by loading 157
pressure and to take hydraulic balance so 801
211
that it slides lightly over the shoe plate
(211). The sub group composed by a
piston and a shoe is pressed against the
shoe plate by the action of the cylinder
spring via a retainer and a spherical bush.
Similarly, the cylinder block is pressed 3607A2MP03
against valve plate(313) by the action of

the cylinder spring.
(2) Swash plate group
The swash plate group consists of swash 531
548
plate(212), shoe plate(211), swash plate
214
support(251), tilting bush(214), tilting
pin(531) and servo piston(532).
251
The swash plate is a cylindrical part
211
formed on the opposite side of the sliding
212
surface of the shoe and is supported by
the swash support.
If the servo piston moves to the right and
532 α
left as hydraulic force controlled by the
regulator is admitted to hydraulic chamber
located on both sides of the servo piston,
the swash plate slides over the swash α
plate support via the spherical part of the
tilting pin to change the tilting angle(α).
3607A2MP10
2-8
(3) Valve cover group
The valve cover group consists of valve
cover(F, 311), valve cover(R, 312), valve
plate (313, 314), spline coupling (114),
booster (130) and valve plate pin (885).
The valve plate having two melon-shaped
314
ports is fixed to the valve block and feeds 312
and collects oil to and from the cylinder
block. 130
The oil changed over by the valve plate is 114
connected to an external pipeline by way 885
311
of the valve block.
Now, if the drive shaft is driven by a prime
mover(electric motor, engine, etc), it
rotates the cylinder block via a spline
linkage at the same time. If the swash
plate is tilted as in Fig(previous page) the 885
313
pistons arranged in the cylinder block
make a reciprocating motion with respect
36072MP03
to the cylinder block, while they revolve
with the cylinder block.
If you pay attention to a single piston, it
performs a motion away from the valve
plate(oil sucking process) within 180
degrees, and makes a motion towards the
valve plate(or oil discharging process) in
the rest of 180 degrees. When the swash
plate has a tilting angle of zero, the piston
makes no stroke and discharges no oil.
2-9
2) REGULATOR
Regulator consists of the negative flow control, total horse power control, power shift control and
cut-off function.
(1) Negative flow control

By changing the pilot pressure Pi, the
pump tilting angle(delivery flow) is
regulated arbitrarily, as shown in the
figure.
This regulator is of the negative flow
Delivery flow, Q
control in which the delivery flow Q
decreases as the pilot pressure Pi rises.
With this mechanism, when the pilot
pressure corresponding to the flow
required for the work is commanded, the
pump discharges the required flow only,
and so it does not consume the power Pilot pressure, Pi
uselessly.
2-10
① Flow reducing function
643 654 651 652 613 646
P1 CL
B(E)
874
897
C
A
875
611
Servo piston Small diameter

Large diameter D chamber
chamber 548
531
R210LC-7 (2-10)
As the pilot pressure Pi rises, the pilot piston(643) moves to the right to a position where the force
of the pilot spring(646) balances with the hydraulic force.
The groove(A) in the pilot piston is fitted with the pin(875) that is fixed to lever 2(613). Therefore,
when the pilot piston moves, lever 2 rotates around the fulcrum of point B [fixed by the fulcrum
plug(614) and pin(875)]. Since the large hole section(C) of lever 2 contains a protruding
pin(897) fixed to the feedback lever(611), the pin(897) moves to the right as lever 2 rotates.
Since the opposing-flat section(D) of the feedback lever is fitted with the pin(548) fixed by the
tilting pin(531) that swings the swash plate, the feedback lever rotates around the fulcrum of point
D, as the pin(897) moves.
Since the feedback lever is connected with the spool(652) via the pin(874), the spool moves to
the right.
The movement of the spool causes the delivery pressure P1 to connect to port CL through the
spool and to be admitted to the large diameter section of the servo piston. The delivery
pressure P1 that is constantly admitted to the small diameter section of the servo piston moves
the servo piston to the right due to the area difference, resulting in decrease of the tilting angle.
When the servo piston moves to the right, point D also moves to the right. The spool is fitted
with the return spring(654) and is tensioned to the left at all times, and so the pin(897) is pressed
against the large hole section(C) of lever 2.
Therefore, as point D moves, the feedback lever rotates around the fulcrum of point C, and the
spool is shifted to the left. This causes the opening between the sleeve(651) and spool(652) to
close slowly, and the servo piston comes to a complete stop when it closes completely.
2-11
② Flow increasing function
643 654 651 652 613 646
P1 CL
B(E)
874
897
C
875
611
Small diameter
Servo piston D chamber
Large diameter 548
chamber
531
R210LC-7 (2-11)
As the pilot pressure Pi decreases, the pilot piston(643) moves to the left by the action of the pilot
spring(646) and causes lever 2(613) to rotate around the fulcrum of point B. Since the pin(897)
is pressed against the large hole section(C) of lever 2 by the action of the return spring(654) via
the spool(652), pin(874), and feedback lever(611), the feedback lever rotates around the fulcrum
of point D as lever 2 rotates, and shifts the spool to the left. Port CL opens a way to the tank port
as the spool moves. This deprives the large diameter section of the servo piston of pressure,
and shifts the servo piston to the left by the discharge pressure P1 in the small diameter section,
resulting in an increase in the flow rate.
As the servo piston moves, point D also moves to the left, the feedback lever rotates around the
fulcrum of point C, and the spool moves to the right till the opening between the spool and sleeve
is closed.
2-12
③ Adjustment of flow control characteristic
The flow control characteristic can be
adjusted with the adjusting screw.
Adjust it by loosening the hexagon 801
nut(801) and by tightening(or loosening) 924
the hexagonal socket head screw(924).

Tightening the screw shifts the control
chart to the right as shown in the figure.
※ Adjusting values are shown in table.
Adjustment of flow control

characteristic R290RE08(1)
Speed
Tightening Flow control Flow change
amount of control change
adjusting starting amount
Delivery flow, Q
screw(924) pressure
change
amount
(min -1) (Turn) (kgf/cm2) (ℓ/min)
1800 +1/4 +1.7 +18.9
Pilot pressure, Pi
2-13
(2) Total horsepower control
The regulator decreases the pump tilting
angle(delivery flow) automatically to limit
the input torque within a certain value with
Delivery flow, Q
a rise in the delivery pressure P1 of the
self pump and the delivery pressure P2 of
the companion pump.
(The input horsepower is constant when
the speed is constant.)
Since the regulator is of the simul taneous
total horsepower type that operates by the Delivery pressure, (P1+P2)
sum of load pressures of the two pumps
in the tandem double-pump system, the
prime mover is automatically prevented
from being overloaded, irrespective of the
load condition of the two pumps, when
horsepower control is under way.
Since this regulator is of the simultaneous
total horsepower type, it controls the tilting
angles(displacement volumes) of the two
pumps to the same value as represented
by the following equation :
Tin = P1×q/2Л + P2×q/2Л
= (P1+P2)×q/2Л
The horsepower control function is the
same as the flow control function and is
summarized in the following.(For detailed
behaviors of respective parts, refer to the
section of flow control).
2-14
① Overload preventive function
621 651 652 623 612 601 625 626
P1 CL
898
B(E)
897
FF
Pf
P2 P1
875
611
Large diameter Servo piston

chamber Small diameter
D chamber
R130RE01
When the self pump delivery pressure P1 or the companion pump delivery pressure P2 rises, it
acts on the stepped part of the compensating piston(621). It presses the compensating
rod(623) to the right till the force of the outer spring(625) and inner spring(626) balances with the
hydraulic force. The movement of the compensating rod is transmitted to lever 1 via pin (875).
Lever 1 rotates around the pin(875) (E) fixed to the casing(601).
Since the large hole section(F) of lever 1 contains a protruding pin(897) fixed to the feedback
lever(611), the feedback lever rotates around the fulcrum of point D as lever 1 rotates, and then
the spool(652) is shifted to the right. As the spool moves, the delivery pressure P1 is admitted to
the large diameter section of the servo piston via port CL, causes the servo piston move to the
right, reduces the pump delivery flow rate, and prevents the prime mover from being overloaded.
The movement of the servo piston is transmitted to the feedback lever via point D. Then the
feedback lever rotates around the fulcrum of point F and the spool is shifted to the left. The
spool moves till the opening between the spool and sleeve(651) is closed.
2-15
② Flow reset function
621 651 652 623 612 601 625 626
P1 CL
B(E)
897
P2 P1
875
Large diameter
D chamber
Servo piston
R130RE11
As the self pump delivery pressure P1 or the companion pump delivery pressure P2 decreases,
the compensating rod(623) is pushed back by the action of the springs(625 & 626) to rotate lever
1(612) around point E. Rotating of lever 1 causes the feedback lever(611) to rotate around the
fulcrum of point D and then the spool(652) to move to the left. As a result, port CL opens a way
to the tank port.
This causes the servo piston to move to the left and the pump's delivery rate to increase.
The movement of the servo piston is transmitted to the spool by the action of the feedback
mechanism to move it till the opening between the spool and sleeve is closed.
2-16
③ Low tilting angle(low flow) command preferential function
As mentioned above, flow control and horsepower control tilting angle commands are transmitted
to the feedback lever and spool via the large-hole sections(C & F) of levers 1 and 2. However,
since sections C and F have the pins(Ø4) protruding from the large hole(Ø8), only the lever
lessening the tilting angle contacts the pin(897) ; the hole(Ø8) in the lever of a larger tilting angle
command is freed without contacting the pin(897). Such a mechanical selection method permits
preference of the lower tilting angle command of the flow control and horsepower control.
④ Adjustment of input horsepower
Since the regulator is of total cumulative horsepower type, adjust the adjusting screws of both the
front and rear pumps, when changing the horsepower set values. The pressure change values
by adjustment are based on two pumps pressurized at the same time, and the values will be
doubled when only one pump is loaded.
a. Adjustment of outer spring

Adjust it by loosening the hexagon 625 626 630 628
nut(630) and by tightening(or loosening)
the adjusting screw C(628). Tightening
the screw shifts the control chart to the 801
right and increases the input 925
horsepower as shown in the figure.
Since turning the adjusting screw C by
N turns changes the setting of the inner
spring(626), return the adjusting screw
CI(925) by N×A turns at first.(A=1.9)
※ Adjusting values are shown in table.
R290RE08(2)
Adjustment of outer spring
Speed
Tightening Compens- Input torque
amount of ating control change
Delivery flow, Q
screw(C) pressure
(628) change
amount
(min -1) (Turn) (kgf/cm2) (kgf·m)
1800 +1/4 +18 +8

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

Speed
Tightening Compens- Input torque
amount of ating control change R290RE08(3)

screw(QI) pressure
(925) change
amount
Delivery flow, Q
(min -1) (Turn) (kgf/cm2) (kgf·m)
1800 +1/4 +15 +7
Delivery pressure, (P1+P2)
2-18
(3) Power shift control
621 651 652 623 612 601 625 626
P1 CL
898
B(E)
897
Pf
P2 P1
875
611
Large diameter
D chamber
Servo piston
R130RE13
The set horsepower valve is shifted by varying

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

is provided. Pf=
MIN
However, the secondary pressure Pf (power Pf= .
MA
shift pressure) is admitted to the horsepower X.
control section of each pump regulator through
the pump's internal path to shift it to the same Delivery pressure, (P1+P2)
set horsepower level.
This function permits arbitrary setting of the pump output power, thereby providing the optimum
power level according to the operating condition.
The power shift pressure Pf controls the set horsepower of the pump to a desired level, as shown
in the figure.
As the power shift pressure Pf rises, the compensating rod(623) moves to the right via the
pin(898) and compensating piston(621).
This decreases the pump tilting angle and then the set horsepower in the same way as explained
in the overload preventive function of the horsepower control. On the contrary, the set
horsepower rises as the power shift pressure Pf falls.
2-19
(4) Adjustment of maximum and minimum flows
① Adjustment of maximum flow
808
Adjust it by loosening the hexagon
954
the set screw(954).
The maximum flow only is adjusted
without changing other control
characteristics.
R290RE08(5)
Adjustment of max flow spring
Speed
Tightening amount Flow change
of adjusting screw amount
(954)
Delivery flow, Q
(min -1) (Turn) (ℓ/min)
1800 +1/4 -6.6

Delivery pressure, Pi
② Adjustment of minimum flow

808
the hexagonal socket head set screw 953
(953). Similarly to the adjustment of the
maximum flow, other characteristics are
not changed.
However, remember that, if tightened too
much, the required horsepower during
3607A2MP02
the maximum delivery pressure(or during
relieving) may increase.
Adjustment of min flow spring

Delivery flow, Q
Speed
Tightening amount Flow change
of adjusting screw amount
(953)
(min -1) (Turn) (ℓ/min)

Delivery pressure, Pi
1900 +1/4 +6.6
2-20
(5) Qmax cut control 647
The regulator regulates the maximum 648
delivery flow by inputting the pilot pressure 723
pm. Since this is a2-position control 642 43
method, the maximum delivery flow may
801
be switched in two steps by turning on/off 801
the oilot pressure Pm.(The maximum 924
control flow cannot be controlled in
intermediate level.) 641 730 643 708 644 645 646 728
① Functional explanation R360LC-7(2-4)
As shown in the figure, the pilot pressure

Pm switches the maximum flow in two
steps.
Delivery flow, Q
When the pilot pressure Pm is given, it is Pm
admitted to the lefthand side of the piston
QMC(648). The piston QMC moves the
stopper(647) and pilot piston(643) to the
right, overcoming the force of the pilot
spring(646), thereby reducing the delivery
Pilot pressure, Pi
flow of the pump.
Since the adjusting screw QMC(642) is
provided with a flange, the piston QMC
stops upon contact with the flange, and
the position of the pilot piston at this time
determines the maximum flow of the
pump.
② Adjustment of Qmax cut flow

Delivery flow, Q
the adjusting screw QMC(642).

Tightening the screw decreases the
Qmax cut flow as shown in the figure.
Pilot pressure, Pi
2-21
GROUP 2 MAIN CONTROL VALVE (-#0169)
1. STRUCTURE
Mark Port name Port size
a Arm out confluence port

b Bucketin confluenoe port
c Arm in confluence port
d Boom up confluence port
Dr/dr Drain port
dr1 Drain port
dr2 Drain port
FL Negative control signal port(PL port side)
FR Negative control signal port(PR portside) PF 1/4
Pi Pilot pressure port
3Pi Lock valve pilot port(Boom)
4Pi Lock valve pilot port(Arm)
4Pc Swing logicvalve pilot port
Px1 Signal port for attachment
Px2 Pilot pressure port for lock valve(Boom)
Py1 Signal port for travel
Py2 Main relief pilot pressure port
aF Pilot port
aF Pilot port PF 3/8
bF Pilot port
bF Pilot port
Rs Swing motor make up port PF 1
AL1 Swing motor port(RH)

AL2 Arm head side port(In)
AL3 Option port
AL4 Travel motor port(LH, Forward)
AR1 Boom rod side port(Down)
AR2 Bucket head side port(In)
AR3 Travel motor port(RH, Forward)
͚32
BL1 Swing motor port(LH)
BL2 Arm rod side port(Out)
BL3 Option port
BL4 Travel motor port(LH, Reverse)
BR1 Boom head side port(Up)
BR2 Bucket rod side port(Out)
BR3 Travel motor port(RH, Reverse)
R Return port ͚50
36072MC01
2-22
Z
A B C D E
17 18 19 1 2 3 4 5 6 55,65 55,65 9 8 7 64 63
7 8 9
J J
SW
F F 57,66
BM 67,68,69
AM 16
16 K K
BKT
OPT A (Priority valve)
G 15 G
TR 13
14 TL
14
13
H H
8
L 7 L
8 7 SECTION A-A 12 11 10 62 12 61 SECTION E-E
A B C D E
45 1 Cover assy 34 O-ring 66 O-ring

2 O-ring 35 Cap 67 Flange
26 27 28,29 23,24 94 30 31 23,24 3 O-ring 36 O-ring 68 O-ring
4 Spring 37 Cap 69 Socket bolt
5 Poppet 38 Cap 70 Poppet
21 35
6 Housing 39 Piston 71 Spring
20 7 O-ring 40 Steel ball 72 O-ring
36 43 20,28 8 Socket bolt 41 Spring 73 Back up ring
22 9 Cover 42 Spool 74 Cover assy
10 Boom plunger assy 43 Plug 75 Socket bolt
11 Bucket plunger assy 44 Cap 76 Lock washer
12 Travel plunger assy 45 Orifice 77 Manifold
15 13 Cover 46 Spool 78 O-ring
SECTION F-F VIEW Z 14 Cap 47 Spring 79 Cap
15 Cap 48 Cap 80 Piston
16 Cap 49 Main relief valve 81 Spring
17 Cover 50 O-ring 82 O-ring
18 Plug 51 Manifold 83 Sleeve
BKT - 95 BM 33 34 35 36 37 38 39 40
TR - 14 19 O-ring 52 Logic check valve 84 Spring
20 O-ring 53 O-ring 85 Check
23,24 32 31 30 23,24 15 31 30
41 21 O-ring 54 Socket bolt 86 Poppet
22 Selector assy 55 Washer 87 Cap
42 23 Back up ring 56 O-ring 88 Spring guide
24 O-ring 57 Cap 89 Spring
26 Overload relief valve 58 O-ring 90 Union
27 O-ring 59 O-ring 91 Piston
28 Back up ring 60 Socket bolt 92 Cap
29 O-ring 61 Housing 93 O-ring
30 Check 62 Option plunger assy 94 Cap
31 Spring 63 Arm plunger assy 95 Cap
SECTION G-G SECTION H-H, L-L 32 Check 64 Swing plunger assy
33 Foot relief valve 65 Socket bolt
3607A2MC02
2-23
36072MC03
2-24
2. FUNCTION
1) HYDRAULIC CIRCUIT
36072MC04
2-25
2) BASIC OPERATION
(1) Travel straight circuit
This circuit keeps straight travel in case
of simultaneous operation of other P1 P2
p
actuators (SW, AM, BKT,BM) during a
straight travel.
① During straight travel by operating
left/right travel plunger (TL, TR): FL FR
Operation of travel spool, the pilot
signal(Py1) line inside the control valve
PL
is blocked, but the pilot signal(PX1) line
is connected to the tank via orifice PR
therefore, the travel straight select valve
is not operated ; oil from pump PL is fed SW
into cylinder port BL4 only. BM
Oil from pump PR is fed into cylinder AM
port BR3 by the operation of TR
BKT
plunger.
OPT
Thus, straight travel is performed
separately with pump PL driving TR
rightward travel(TL) and pump PR TL
driving rightward travel(TR).
p
Pi
Py1
PL p PR
Px1
AL4 BL4 BR3 AR3
Px1 Py1
SW
bl4 br3
AM BM
OPT BKT TL TR
TL TR Manifold
assembly
Travel straight valve
36072MC05
2-26
② In case of a swing operation during
straight travel for instance :
P1 P2
At the beginning of swing plunger stroke p
the pilot signal(PX1) line inside the
control valve is blocked and the signal
pressure makes the connection
between the feed passages of right and FL FR
left travel plungers(TL, TR) by switching
spool of travel straight select valve. PL
When the swing plunger is switched, oil
Orifice a PR
discharged from pump PR preferentially
flows into swing motor which is
positioned upstream. SW
Thus, simultaneous operation of swing BM
and straight travel is made possible as AM
oil from pump PL is fed to swing and oil
BKT
from pump PR is fed to right travel(TR) Left parallel
OPT feed passage
and left travel (TL).
The orifice at the upstream of the TR
TL
parallel feed passage sends surplus oil
of swing to right and left travel(TL, TR)
to avoid abrupt change of the vehicle
speed.
The basic operation is same with swing
even in the case of other actuators on
upper frame of machine during straight p
travel. AL1 BL1
Pi
Py1
PL p PR
bl1 Px1
BR3 AR3
Px1 Py1
SW
SW
br3
AM BM
OPT BKT TR
AL4 BL4
TL TR
bl4
Manifold
assembly
TL
Travel straight valve
36072MC06
2-27
(2) Arm flow summation circuit
· Arm out operation
Oil from pump PL is fed into cylinder port
P1 P2
BL2 by adding pressure to arm plunger p
pilot port bl2.
Oil from pump PR flows into the center
bypass valve assembly via the center
FL FR
bypass passage. Since the same pilot
pressure of the arm plunger pilot port is
applied to the pilot signal port of the PL
center bypass valve assembly, the center PR
bypass spool is switched;pushing up the
arm flow summation check valve in the SW
manifold through center bypass passage
BM
of RH travel section. Oil flows into the
AM
high pressure feed passage, and joins to
the flow from the pump PL. BKT
· Arm in operation is same as above, OPT
summing the flow of the PL pump.(Pilot TR
signal pressure is applied a port.) TL
a
Center bypass valve
PL PR
SW BL2
Arm load
holding valve
Poppet
AM BM
AL2
TR
OPT BKT
TL TR bl2
Manifold
assembly
AM
Arm flow summation
check valve
36072MC07
2-28
(3) Boom up flow summation circuit
Oil from pump PR is fed into cylinder port
BR1 by adding pressure to boom plunger
pilot port br1.
P1 P2
Oil from pump PL flows into spool of the p
center bypass valve assembly via the
center bypass passage. Since the same
pilot pressure of the boom plunger pilot
port is applied to the pilot port(b), the FL FR
Poppet
center bypass spool assembly closes. At
Boom load
the same time, boom(up) signal works on PL holding valve
the logic check valve and the valve opens;
PR
oil flows from the center bypass passage
of swing section through the logic check SW
assembly into the boom high pressure
BM
feed passage and joins to the flow from
AM
the pump PR. BR1
BKT
OPT
TR
TL
Center bypass valve
PL PR
AR1
SW br1
SW
AM BM
BM
OPT BKT
Manifold
TL TR assembly
Logic valve
36072MC08
2-29
2) OPERATIONAL DESCRIPTION OF CONTROL VALVE
(1) Plunger operation
① Neutral position of plunger
Parallel feed passage

Load check valve
Cylinder port B Cylinder port A
Port relief Port relief
valve assy valve assy
C2
C1
Pilot port a
Pilot port b
Spring
Tank passage Center bypass Tank passage
High pressure
feed passage
360SMCV10
In neutral, spring sets the plunger at the neutral position; the high pressure feed passage is shut
off by the plunger; oil from the pump flows through the center bypass.
2-30
② Operation of plunger
Parallel feed passage

Load check valve
Cylinder port B Cylinder port A
Port relief Port relief
valve assy valve assy
C2
C1
Pilot port a
Pilot port b
Spring
Tank passage Center bypass Tank passage
High pressure
feed passage
360SMCV11
When actuated(pressure is applied to pilot port a), the plunger moves to the left; the center
bypass is shut off; oil from the center bypass pushes up the check valve C1 and flows into
cylinder port A via the high pressure feed passage. Meanwhile, oil from the parallel feed
passage pushes down check valve C2 and flows into cylinder port A via the high pressure feed
passage.
The return oil from cylinder port B flows into the tank via the tank passage.
※ Reversed when pressure is applied to pilot port b.
2-31
(2) Foot relief valve operation
① fp is lower than spring force
Spring B Orifice C
Poppet A
(fp) From center

bypass passage
Pressure signal
sent out to pump
To tank passage
360SMCV17(1)
Hydraulic oil from the center bypass passage flows into the tank via orifice(C) of poppet(A).
Pressure fp generated by orifice(C) is led to the pump, to control the pump delivery flow.
② fp is higher than spring force
Spring B
Poppet A
360SMCV17(2)
If a large amount flows due to delayed pump response, etc., and pressure fp reaches the preset
spring(B) force, then the poppet(A) is lifted and functions as a relief valve.
2-32
(3) Logic check valve operation
① Boom down or neutral
When boom up pilot pressure is not supplied.
Check C
Boom (up) Check B Orifice D
pilot signal
From 4 spool
side valve(Pa)
b d2
Z d1
To 3 spool side boom high

Piston A 1 pressure feed passage(Pb)
Tank passage
2
2
Z
360SMCV23(1)
Spring force sets piston (A) in the shown position;

Pressure in the passage a (Pa) enters chamber (Z) via passage (1) and passage(2).
Pressure in the passage b (Pb) enters chamber (Z) via orifice(D).
If Pa > Pb
Check valve (C) is seated by area d1 > d2 and passage from a to b is blocked.
If Pa < Pb
Passage from b to a is blocked by the check valve (C).
2-33
② Boom up
When boom up pilot pressure is supplied.
Piston (A) moves to right; passage (1) is shut off from passage (2).
Check C
Boom (up) Check B Orifice D
pilot signal
From 4 spool
side valve(Pa)
b d2
Z d1
To 3 spool side boom high

Piston A 1 pressure feed passage(Pb)
Tank passage
2
When Pa>Pb
360SMCV23(2)
When Pa > Pb
Check valve (C) is lifted as the shown position; oil flows through from a to b.
When Pa < Pb
Passage from b to a is blocked by the check valve (C), because d1 > d2 .
2-34
(4) Main relief valve operation
① High pressure setting pilot signal : OFF
Piston (D) is seated to the right by spring (C) force.
Pilot poppet B
Main poppet A
Spring C
Piston D
d1
d2
From pump port

(Py2)
1
Pilot signal : OFF
Tank passage
2 3 5 4
360SMCV12(1)
This relief valve is built-in between the pump port side (1) and tank passage.
Hydraulic oil from the pump port side enters chamber (3) via orifice (2) of poppet (A). Because
d1 >d2, poppets (A) is securely seated.
Pilot poppet B
Main poppet A
Spring C
Piston D
d1
d2
From pump port
Tank passage
2 3 5 4
360SMCV12(2)
When hydraulic oil reaches the pressure preset by spring (C), pilot poppet (B) opens; oil flows
around pilot poppet (B) and into the tank passage via side hole (4) and passage (5).
2-35
Main poppet A
d1
d2
From pump port
Tank passage
2 3
360SMCV13(1)
When the above oil flow is formed, pressure drops before and behind orifice (2); when pressure
of chamber (1) x area d2 is larger than pressure of chamber (3) x area d1, main poppet (A) is
lifted and hydraulic oil flows into the tank passage.
Spring C
Piston D
From pump port

(Py2)
Pilot signal : ON
Tank passage
360SMCV13(2)
② High pressure setting pilot signal : ON

Piston (D) moves to left; set pressure of spring (C) rises, making high pressure setting.
2-36
(5) Overload relief valve operation
① Overload working operation
Piston A
(Front end orifice) Main poppet B
Cylinder port
Pilot poppet C
(Front end orifice)
d2 d1
Spring D
1 Tank passage 2 Passage E

360SMCV14(1)
Hydraulic oil from cylinder port enters chamber (2) via orifice of piston (A). Because d1 >d2,
main poppet (B) is securely seated.
Piston A
Cylinder port
Pilot poppet C
(Front end orifice)
Spring D
1 To tank passage 2 Passage E

360SMCV14(2)
When hydraulic pressure reaches the preset force of spring (D), pilot poppet (C) opens; oil flows
around poppet (C) and into the tank passage via side hole and passage (E).
2-37
Piston A
Cylinder port
Pilot poppet C
(Front end orifice)
Spring D

360SMCV15(1)
Oil flow is formed; pressure drops before and behind orifice of piston (A); piston (A) moves to
right and seats at the tip of pilot poppet (C).
Hydraulic oil from chamber (1) flows into the tank passage via orifice of piston (A) and pilot
poppet (C), side hole and passage (E).
Pilot poppet C Main poppet B

(Front end orifice)
Cylinder port
Pilot poppet C
(Front end orifice)
Spring D

36072MCX
Pressure drops before and behind orifice of pilot poppet (C), making pressure of chamber
(1)>pressure of chamber (2); poppet (B) is lifted and hydraulic oil flows into the tank passage.
2-38
② Make up operation
Main poppet B
Cylinder port
d2 d1
From tank passage

360SMCV16
Poppet (B) is securely seated because the cylinder port pressure is normally higher than the tank
pressure and d1 > d2.
When the cylinder port pressure drops(closer to negative pressure) until the cylinder port
pressure is lower than the tank pressure, poppet (B) opens receiving the tank pressure for the
difference in area between d1 and d2; oil flows from the tank passage to the cylinder port in order
to prevent cavitation.
2-39
(6) Arm regeneration circuit
① Arm in operation
36072MC11
When pressure is applied to pilot port al2 of the arm plunger, the plunger moves to right as
shown; the center bypass passage is shut off; oil from the center bypass pushes up check valve
(C1) and flows into cylinder bottom port via the high pressure feed passage.
② PA is lower than PB
(PB)
BL2
(PA)
AL2
C2
C1
al2
High pressure feed passage Center bypass passage Tank passage

36072MC12
Return oil from cylinder rod side pushes up check valve (C2) in the plunger; it flows into cylinder
bottom side after returning to the high pressure feed passage.
2-40
③ PA is higher than PB
(PB)
BL2
(PA)
AL2
C2
C1
al2
High pressure feed passage Center bypass passage Tank passage
36072MC13
The check (C2) is seated by the pressure (PA) of cylinder bottom side, the return oil from cylinder
rod side flows into the tank passage.
2-41
(7) Boom load holding valve operation
① When the plunger is in neutral (3Pi pilot signal : OFF)
5
Check D
Poppet C 6
Poppet E
Piston B
1
d1
2(Pc) 4
Y
3(Pv) To boom
bottom
Px2 d2
dr 7 Boom plunger
3Pi Piston A
Pilot signal : OFF
VIEW Z
High pressure feed passage
Tank passage
36072MC14
The piston(A) is in the status as shown and the passage from pilot signal(Px2) to chamber(Y) is
blocked.
Therefore, piston (B) and poppet (C) are in the status as shown; passages (5) and (6) are shut
off by poppet (C).
Therefore, the pressure of chamber (1) becomes PC as it is connected with chamber (2) via
orifice (4). Since d1 >d2, check (D) is seated, chambers (2) and (3) are completely blocked.
2-42
② When the plunger is operated (3Pi pilot signal : OFF)
A. When PC is lower than PV (in the case of Boom up)
5
Check D
Poppet C 6
Poppet E
Piston B
1
d1
4
2(Pc)
Y
3(Pv) To boom
bottom
Px2 d2
dr 7 Boom plunger
3Pi Piston A
Pilot signal : OFF
VIEW Z
High pressure feed passage
Tank passage
36072MC15
Because check valve (D) is seated, passages (6) and (7) are shut off. Therefore, the pressure of
chamber (1) becomes PC as it is connected to chamber (2) via orifice (4); poppet (E) is pushed
up; oil from high pressure feed passage flows into the cylinder port.
2-43
③ When the plunger is operated (3Pi pilot signal : ON)
B. When PC is higher than PV (In case of Boom down)
36072MC16
The piston(A) moves up and then the pilot passage(Px2) and chamber(Y) are connected.
Therefore, piston (B) moves to right; poppet (C) opens; passages (5) and (6) are connected.
If pressure PC of cylinder port chamber (2) is higher than pressure PV of chamber (3), oil from
chamber (1) pushes up check valve (D) via passages (5) and (6) and enters chamber (3) through
passage (7). Chamber (3) is connected with the tank passage because the boom plunger is
moved to left. Therefore, pressure PC is applied to (area d1 - area d2), pushing up check (E),
and oil from the cylinder port flows into the tank passage.
2-44
(8) Boom priority valve operation
① When swing is operated only (4Pc pilot signal : OFF)
A. When Po is lower than Ph
Piston 1 Piston 2 Poppet 3

dr1
Check 4
4Pc
Pilot signal From P port
(Po)
Spring A Spring B Spring C High pressure feed

passage(Ph)
36072MC17
The piston(1) and (2) are in the position as shown by the spring (A) force, and the poppet(3) and
the check(4) are seated to hold the pressure of Ph.
B. When Po is higher than Ph
36072MC18
Oil from the P port pushes up the poppet(3) and the check(4), and flows into the high pressure
feed passage connecting to the cylinder port.
2-45
② Combined swing and boom up operation(4Pc pilot signal : ON)
36072MC19
As the poppet(3) is forced to the body by the piston(1) and (2), oil from the P port pushes up the
check(4) and flows into the high pressure feed passage of the swing through the orifice put on
the poppet(3). Then oil from P port flows into the boom section prior to the swing section.
2-46
(9) Arm load holding valve operation
① When the plunger is in neutral (4Pi pilot signal : OFF)
36072MC21
The spool(A) is in the status as shown. The passage from the chamber(1) to the drain port(dr2)
is shut off by the spool(A). Therefore, the pressure of the chamber(1) is same to the pressure of
Arm cylinder(rod); (equals to Pc), as it is connected with the core(2) through the orifice(4) of the
main poppet(B).
Since d1>d2, the main poppet(B) is seated and the core(2) and (3) are completely blocked.
2-47
② When the plunger is operated
A. When PC is lower than PV (in the case of Arm out, 4Pi pilot signal : OFF)
36072MC22
The pressure of the chamber(1) is same to the pressure of Arm cylinder(rod); (equals to Pc), as it
is connected with the core(2) through the orifice(4).
The main poppet(B) is pushed up and oil from the high pressure feed line flows into the Arm
cylinder port.
2-48
B. When PC is higher than PV (In case of Arm in, 4Pi pilot signal : ON)
36072MC23
The spool(A) is switched by the pilot pressure, the chamber(1) is connected to the drain
port(dr2).
Then the pressure of the chamber(1) comes to lower than that of the core(2), and the pressure of
the core(2) acts on the differential area(d1-d2) to push up the main poppet(B).
Return oil from Arm cylinder flows into the tank passage through the core(3) and around the
main plunger.
2-49
GROUP 2 MAIN CONTROL VALVE (#0170-)
1. STRUCTURE (1/4)
Mark Port name Port size Tightening torque
(R3) -
R4 Make up port
15~18 kgfÂm
(P3) - G-1
(108.5~130 lbfÂft)
(P4) -
P (Ck2) -
P2 P1
PAa Arm 1 (in) pilot port
(PTb) (PTa)
T1 Pa PBa Arm 1 (out) pilot port
CP1 BL
(P2g) Dr4 PAb Boom (down) pilot port
Pns PAL AL PBL
Dr3' N2 Dr3
P2c1 PBb Boom (up) pilot port
(R3) HV
(P1g) PAb Ab LCb1
(Pcb) PAc Bucket (in) pilot port
(P3)
Bb PBb PAbs PBc Bucket (out) pilot port
Pns
PAc LCc
Dr3' Pca PAL Travel right (reverse) pilot port
Ac (P4)
Bc PBc PAcs PBL Travel right (forward) pilot port
PAa2 PBa2 PAr Travel left (reverse) pilot port
N1
PBr Travel left (forward) pilot port
(Pcb)
PAs Swing (left) pilot port
(Ck2)
VIEW B PBs Swing (right) pilot port
(P4) PAa2 Arm 2 (in) pilot port
VIEW A PBa2 Arm 2 (out) pilot port 7~8 kgfÂm
G-3/8
PBb2 Boom (up) confluence pilot port (50.6~57.8 lbfÂft)
(PAo) Optional pilot port
(PBo) Optional pilot port
R4 Px
PL1 CP2 PAbs Boom (down) stroke limitter pilot port
Pa
PBr Br Ar PAr (PTb)
PAcs Bucket (in) stroke limitter pilot port
(PTa) PBr Dr4 Dr4 PAr
Pca Bypass cut spool (P2 side) pilot port
Py
Pns PBs PAs Pns (Pcb) Bypass cut spool (P1 side) pilot port
PAL
PBL PBs Bs
CCb Pns As PAs
Drb LCs Dra Drain port
PBb2 Csp Dra PSp Drb Drain port
A PBb2 PAb
Dr3' (PL2) PSp
(Bo) (PTa) -
(PL2) (Ao)
LCo (PAo)
(PBo) (PTb) -
(PBo) HV PAc
(PAo)
P2c2 (P1g) Quick clamp solenoid valve supply port
PBa LCa1
PAa
PBa2 PBa
PAa
PAa2 (P2g) -
Aa
Dr3 Dr3 Ba
(Psp) Swing priority
P Pilot port
N2 Pca (P3) (P3) (P4) Pa Pilot port
B Px Pressure port for attachment
Py Pressure port for travel
3.5~4.0 kgfÂm
(PL2)Option(Bo) port relief valve pilot port for G-1/4
(25.3~29 lbfÂft)
switching to high pressure
Pns Boom priority valve pilot port
P2c1 Lock valve (boom head side) pilot port
3607A2MC12
P2c2 Lock valve (arm rod side) pilot port
2-49-1
STRUCTURE (2/4) Mark Port name Port size Tightening torque
N1 Nega-con pressure (boom1 side) port

N2 Nega-con pressure (arm1 side) port
3.5~4.0 kgfÂm
Dr3 Drain port G-1/4
(25.3~29 lbfÂft)
Dr3' Drain port
Dr4 Drain port
P
Main relief valve pilot port for switching to high 1.5~1.9 kgfÂm
P2 P1 PL1 G-1/8
pressure (10.8~13.7 lbfÂft)
(PTb) (PTa)
T1 Pa
CP1
Aa Arm cylinder head side port (in)
BL
(P2g) Dr4
Pns PAL AL PBL
Ba Arm cylinder rod side port (out)
Dr3' N2 Dr3
P2c1 Ab Boom cylinder rod side port (down)
(R3) HV
(P1g) PAb Ab LCb1
(Pcb) Bb Boom cylinder head side port (up)
(P3)
Bb PBb PAbs Ac Bucket cylinder head side port (in)
Pns
Dr3' Pca
PAc LCc (P4)
Bc Bucket cylinder rod side port (out) 14~18 kgfÂm
Ac M14
Bc PBc PAcs Ar Travel left motor (reverse) (101~130 lbfÂft)
PAa2 PBa2 Br Travel left motor (forward)
N1 AL Travel right motor (reverse)
(Pcb) BL Travel right motor (forward)
(Ck2) (Ao) Optional port
VIEW B
(P4)
(Bo) Optional port
VIEW A
P1 Pump port (A1 side)
8.5~11 kgfÂm
P2 Pump port (A2 side) M12
(61.5~80 lbfÂft)
T1 Return port
R4 Px As Swing motor port (left) 5~6.5 kgfÂm
PL1 CP2 M10
Pa Bs Swing motor port (right) (36~47 lbfÂft)
PBr Br Ar PAr (PTb)
(PTa) PBr Dr4 Dr4 PAr
Py
Pns PBs PAs Pns
PAL
PBL PBs Bs
CCb Pns As PAs
Drb LCs
PBb2 Csp Dra PSp
A PBb2 PAb
Dr3' (PL2) PSp
(Bo) (Ao)
(PL2) LCo (PAo)
(PBo) PAc
(PBo) HV
P2c2 (PAo)
PBa LCa1
PAa PAa
PBa2 PBa PAa2
Aa
Dr3 Dr3 Ba
N2 Pca (P3) (P3) (P4)
3607A2MC12
2-49-2
STRUCTURE (3/4) D
E
C F G H
992 991
603
273 551
101 Casing-A 373 Spring
102 Casing-B 391 Travel straight spool assy
561 151 Plug 392 Bypass cut spool
155 Plug 393 Boom confluence spool
A A 158 Plug 394 Arm confluence spool
159 Plug 395 Swing priority spool
161 O-ring 511 Poppet
352 163 O-ring 513 Poppet
B B 168 O-ring 515 Boom priority valve assy
351 201 Cover 522 Spring
L 202 Cover 523 Spring
P 168 158 551 203 Cover 524 Spring
561 204 Cover 525 Spring
SECTION K - K SECTION L - L 273 205 Cover assy 541 Steel ball
206 Cover 542 Spring seat
159 212
208 Cover 543 Spring
C D E 603 F G H
L 211 Plug 550 Plug
212 O-ring 551 Plug
BOOM 1 BUCKET 251 Plug 552 Plug
102 101 972 972 BOOM 972 252 Lock valve assy 553 Plug
TRAVEL TRAVEL CONFLUENCE
TRAVEL 262 O-ring 554 Plug
STRAIGHT LEFT ARM 2 RIGHT SWING OPTION ARM 1 263 O-ring 557 Plug assy
264 O-ring 558 Plug
265 O-ring 561 O-ring
267 O-ring 562 O-ring
273 Bolt 563 O-ring
K K 274 Bolt 601 Main relief valve
275 Bolt 603 Port relief valve
165
158 551 301 Travel spool 604 Port relief valve
168 302 Arm 1 spool assy 605 Port relief valve
165 561 303 Boom 1 spoo; assy 611 Nagative control relief valve
155 155
304 Bucket spool 652 Plug
155 165
165 973 305 Swing spool 663 O-ring
155 165 308 Option spool 664 O-ring
165 313 Plug 665 Backup ring
155 155 326 Spring 751 Flange
155
165 165 327 Spring 752 Flange
155 972 332 Spring seat 754 Flange
165 335 Shim 761 O-ring
165
155 336 Bolt 762 Bolt
155 337 Rod 763 O-ring
752 351 Orifice 764 Bolt
762 352 Orifice 972 Bolt
761 355 Piston 973 Bolt
356 Piston 974 Bolt
155 165 371 Spring 991 Name plate
372 Spring 992 Pin
974 973 973
SECTION B - B
SWING SECTION A - A
PRIORITY 3607A2MC10
2-49-3
STRUCTURE (4/4)
155 TRAVEL TRAVEL TRAVEL SWING BOOM 1 BOOM
201 165 STRAIGHT RIGHT 201 LEFT 561 558 CONFLUENCE
201 201 355 554
336 336 165
336 336 206
332 332 201
332 332 336 336
373 371
371 371 332 332
332 332 371 263 372
163 332 332
263 263 332 335
263 263
601 158 161 158 161 332 562
168 168 393
652
550 252 511
553
562 522
161 351 665
543 561
562 151 664
542 513 551
541 162 524
563 161 515 205 553
561 161
561 561
551
552 551 203
523
512 264
522
552 522 274
511 161
563 511 552
523 511 161
512 161
664 395
391 161 665
763 301
754 161 262 301 305 303
262 263
764 202 262 603
202 273 332
202 273 663 263
165 155 273 335
202 262 652 273
313 372
SECTION C - C SECTION D - D 211 332
558 212 336
561 208 201
BUCKET OPTION SECTION E - E
356 201 201 165
155 165 201 ARM 2 ARM 1
206 159 336 336 554
336 212 332 332
332 336 372 335 371 CUT
371 332 332 332
332 263 326 327 251 337
161 371 263 158
263 332 265 551
562 168 252 561
603 263 562 557
605 162 522
751 514 511
611
163 762 525 561
162 553 551 162
761 267
524
264 264 204 561 392
274 203 513
155
274 165
274 162
264
522 392 511
275 264
511 522
522 522 522
511 302 557
511 511 611
304 761 394
762
162
751 562
262 603
161 308
603 262
604 202 273 561 551 326 327 251 337 265
262 202
273 262
202
155 165 202
SECTION F - F SECTION G - G SECTION H - H
3607A2MC11A
2-49-4
2. FUNCTION
1) HYDRAULIC CIRCUIT
(P3) (P4)
PS
N2 PS
N1
Pca
Dr3
(OPEN)
P2c2 Pcb
Ba (CLOSE)
Aa ARM 2
P2c2 PAa2
PAa PBa2
ARM 1 PAa2
PBa
PBa2
Bo
Ao
Ac
PL2 Bc
PAo PAcs
BUCKET Pca
OPTION
PAc
LCc PBc
PBo Dr3'
LCo
(Ck2) P2c1
Ccb
Bb
Drb
BOOM 2 BOOM 1 Ab
PBb2 PABs
PAcs
P2c1 PBb
SWING PRIORITY PAb PBb2
PSp LCb
Dra
CP1 TRAVEL(LH) AL
Bs AL
As SWING BL BL
PAs PAL
PBs
Dr4 PBL
SH Pns (Px) LCs
P Br CP2
Ar TRAVEL(RH)
PAr (PTa) (PTb)
PBr
PL1
PS
CMR1
Py PBr
CMR2
P2g P1g R4
R3 Pa T1 P2 P1
3607A2MC13
2-49-5
2) OPERATION
(1) Neutral positions of spools
When all spools are in the neutral positions, the pressurized oil discharged from the hydraulic
pump (A1) passes through Port P1, the main path (1), the bypass circuit (2) passing the spools
for boom1, bucket and arm 2, and boom 1 side negative control orifice, and returns to the
hydraulic oil tank through the tank port (T1).
The pressure upstream the boom 1 side negative control orifice (the negative control signal
pressure) is led from port N1 to the regulator on the hydraulic pump (A1) side, and controls the
pump discharge flow rate to its minimum value.
The oil discharged from the hydraulic pump (A2) passes through port P2, the main path (3), the
bypass circuit (2) passing the spools for swing, boom confluence (boom 2 ), option and arm 1,
and the arm 1 side negative control orifice, and returns to the hydraulic oil tank through the tank
port (T1).
The pressure upstream the arm 1 side negative control orifice (the negative control signal
pressure) is led from port N2 to the regulator on the hydraulic pump (A2) side, and controls the
pump discharge flow rate to its minimum value.
When any of nine main spools is changed over, the bypass circuit (2) is cut off and the hydraulic
oil at port N1 or N2 in the negative control circuit is shut off.
2-49-6
BOOM
TRAVEL CONFLUENCE
RIGHT SWING PBb2 OPTION ARM 1
PBr PBs (PBo) PBa
CUT
(R3)
3
2
PAr PAs (PAo) PAa
SWING
PRIORITY
PSp
TRAVEL TRAVEL BOOM 1 BUCKET

STRAIGHT LEFT
ARM 2
(PTa) PBL PBa2
CUT
(PTb) PAL PAc PAa2
PAb
3607A2MC14
2-49-7
(2) Travel operation
When pilot port PBL of the travel left spool is pressurized, the bypass circuit (2) in the arm 2 side
is shut off and pressurized oil from port P2 passes through port BL and flows to the travel motor.
On the other hand, the return oil from the travel motor passes through port AL and returns to the
PBL
PAL
AL BL
FROM TRAVEL MOTOR TO TRAVEL MOTOR
3607A2MC15
2-49-8
(3) Arm
Η Arm out operation
During the arm out operation the pilot pressure enters through ports PBa and PBa2. When the
pressure enters through port PBa, the spool transfers in the left direction in figure. The hydraulic
oil entering through port P2 Passes through the main path (3) and flows to the bypass circuit (2),
but the bypass circuit is shut off due to transfer of the arm 1 spool. Therefore, the hydraulic oil
from the parallel circuit pushes open the check valve (511) and flows through the U-shaped path
to the arm1 spool (302). Then, it flows around the periphery of the arm 1 spool (302) to port Ba,
and is supplied to the arm cylinder rod side (R).
On the other hand, the oil entering through port P1 passes in the main path (1), and flows into
the bypass circuit (2), and the bypass circuit is shut off due to transfer of the arm 2 spool (394).
Oil from the parallel circuit pushes open the check valve (514) and oil from the bypass circuit
pushes open the check valve (511) and flows through the U-shaped path to the arm 2 spool
(394). Then, it flows around the periphery of arm 2 spool in the inside path and joins into port Ba.
Besides, the return oil from the arm cylinder head side (H) passes through port Aa, flows into
tank line in arm 1 side and in arm 2 side and returns to the hydraulic oil tank through the tank
port (T1).
511 514
394
PBa2
PAa2
302
PBa
PAa
U-shaped path
Parallel circuit
Aa Ba
511
LCa1
3607A2MC16
2-49-9
Θ Arm in operation
During the arm in operation, the pilot pressure enters through ports PAa and PAa2. When the
pressure enters through port PAa, the spool transfers in the right direction in figure MC17A. The
hydraulic oil entering through port P2 passes through the main path (3) and flows to the bypass
circuit (2), but the bypass circuit is shut off due to transfer of the arm 1 spool. Therefore, the
hydraulic oil from the parallel circuit pushes open the check valve (511) and flows through the
U-shaped path to the arm 1 spool (302). Then, it flows around the periphery of the arm1 spool to
port Aa, and is supplied to the arm cylinder head side (H).
Besides, the oil entering through port P1 passes in the main path (1), and flows into the bypass
circuit (2), and the bypass circuit is shut off due to transfer of the arm 2 spool (394). Oil from the
parallel circuit pushes open the check valve (514) and oil from the bypass circuit pushes open
the check valve (511) and flows through the U-shaped path to the arm 2 spool (394). Then, it
flows around the periphery of arm 2 spool in the inside path and joins into port Aa.
On the other hand, the return oil from the arm cylinder rod side (R) is pressurized by self-weight
of the arms and so on, and returns to port Ba. The pressurized oil returning to Port Ba enters
into the spool through the outside hole (a) of the arm1 spool (302). During a light load only, it
pushes open the sleeve check valve and part of oil flows the U-shaped path reversely from the
spool hole (c), and joins into port Aa. The rest of oil returns to the hydraulic oil tank through the
tank port (T1).
This is called the arm regeneration function.
When the pressure in the arm cylinder head side (H) increases, the piston (d) and sub-spool (e)
are transferred in the right direction, and at the same time the sleeve check valve (f) is closed by
its backpressure. This shuts off the arm regeneration function, and the return oil from the arm
cylinder rod side (R) enters from port Ba through the periphery hole (a) of the arm1 spool into
the spool, flows out through the periphery hole (b) of the spool, and returns through the tank port
(T1) to the hydraulic oil tank.
On the other hand, the pressurized oil entering through port P1 joins into port Aa through the
inside path similarly to the case of the arm stretching operation.
2-49-10
ÂDuring light load only
511 514
394
PAa2
PBa2
302
c a
PAa
PBa
U-shaped path
Parallel circuit
Aa Ba
511
LCa1
Arm self weight
3607A2MC17A
ÂThe pressure in the arm cylinder head side (H) increases.
511 514
394
PAa2
PBa2
302
(d) (e)
(f) (a)
PAa
PBa
(b)
Aa Ba
511
LCa1
3607A2MC17B
2-49-11
(4) Boom
Η Boom up operation
During the boom up operation, the pilot pressure enters through port PBb and moves the boom
1 spool in the left direction in figure. The pressurized oil entering through port P1 passes through
the main path (1) and flows to the bypass circuit (2), but the bypass circuit is shut off due to
transfer of the boom 1 spool. Therefore, the pressurized oil flows into the parallel circuit, pushes
open the check valve (511), and flows through U-shaped path to the boom1 spool (303). When
the stroke of the boom 1 spool is small, the oil enters through the periphery hole (d) of the spool
to the inside of the spool, and flows out to port Bb through the periphery hole (e). When the
stroke of the boom 1 spool is large, the oil flows out to port Bb through the periphery of the
spool.
At the same time, the pilot pressure enters also through Port PBb2 to transfer the boom 2 spool
(393) in the left direction in figure. Though the pressurized oil enters into port P2, the bypass is
shut off due to transfer of the boom 2 spool. Therefore, the oil flows in the parallel circuit and
flows through the U-shaped path to the boom 2 spool. Then, the oil passes through the
periphery of the boom 2 spool, pushes open the check valve (511), joins into port Bb in the
inside path, and is supplied to the boom cylinder head side (H). (Boom confluent flow)
On the other hand, the return oil from the boom cylinder rod side (R) enters through port Ab and
returns to the hydraulic oil tank through the tank port (T1).
LCb1
Ab
511 Bb
303
PBb PAbs
Parallel circuit
PAb (Bbs)
(d) (e)
393
PBb2
PSp To Port Bb
Dra Drb
Ccb 511
Csp
3607A2MC18
2-49-12
Θ Boom down operation
During the boom down operation, the pilot pressure enters through port PAb and transfers the
boom1 spool in the right direction in figure. The pressurized oil entering through port P1 passes
through the main path (1) and flows to the bypass circuit (2), but the bypass circuit is shut off due
to transfer of the boom 1 spool. Therefore, the pressurized oil flows into the parallel circuit,
pushes open the check valve (511), and flows through the U-shaped path to the boom 1 spool
(303). Then, it flows around the periphery of the boom 1 spool to port Ab and is supplied to the
boom cylinder rod side (R).
On the other hand, the return oil from the boom cylinder head side (H) passes to the notch of the
boom 1 spool.
Since this return oil has a sufficient pressure caused by the weight of the boom, it passes
through the path inside the spool, pushes the poppet A in the spool in the left direction shown in
the figure, flows around the outside of the spool. Then, it is supplied again to the boom cylinder
rod side (R) as hydraulic oil to lower the boom. (Boom regeneration)
Besides, a part of the return oil from the boom cylinder flows from the check valve B (boost
check) into the tank.
The boost check boosts the hydraulic oil flowing to the tank to secure the sufficient regeneration
flow rate.
During the boom down and arm stretching operation, the pilot pressure enters through port
PAbs and the boom 1 spool transfers in the half stroke not full stroke.
LCb1
511
Ab Bb
303
PBb PAbs
PAb (Bbs)
3607A2MC19
2-49-13
(5) Bucket
Η Bucket in operation
During the bucket in operation, the pilot pressure enters through port PAc and transfers the
bucket spool in the right direction in figure. The pressurized oil entering through port P1 passes
through the main path (1) and flows through the bypass circuit (2), but the bypass circuit is shut
off due to transfer of the bucket spool. Therefore, the pressurized oil flows into the parallel circuit,
pushes open the check valve (511), and flows through the U-shaped path to the bucket spool
(304). Then, it flows through the periphery of the spool to port Ac and is supplied to the bucket
cylinder head side (H).
On the other hand, the return oil from the bucket cylinder rod side (R) enters through port Bc,
passes around the periphery of the spool, and returns to the hydraulic oil tank through the tank
port (T1).
During the boom up and bucket in operation, the pilot pressure enters through Port PAcs and the
bucket spool transfers in the half stroke not full stroke. Therefore, the most of pressurized oil
entering through Port P1 flows to the boom 1 spool (304) than the bucket spool (304) to make
the boom up operation most preferential.
511
Ac Bc
U-shaped
path
304
PBc PAcs
Parallel circuit
PAc
3607A2MC20
2-49-14
Θ Bucket out operation
During the bucket out operation, the pilot pressure enters through port PBc and transfers the
bucket spool in the left direction in figure. The pressurized oil entering through port P1 passes
through the main path (1) and flows through the bypass circuit (2), but the bypass circuit is shut
off due to transfer of the bucket spool. Therefore, the pressurized oil flows into the parallel circuit,
pushes open the check valve (511), and flows through the U-shaped path to the bucket spool
(304). Then, it flows through the periphery of the spool to port Bc and is supplied to the bucket
cylinder rod side (R).
On the other hand, the return oil from the bucket cylinder head side (H) enters through port Ac,
passes around the periphery of the spool, and returns to the hydraulic oil tank through the tank
port (T1).
511
Ac Bc
U-shaped
path
PBc PAcs
304
Parallel circuit
PAc
3607A2MC21
2-49-15
(6) Swing
Η Independent swing operation
During the swing operation, the pilot pressure enters through port PAs (or PBs) and transfers the
swing spool. The pressurized oil entering through Port P2 flows to Port As (or Bs) and is supplied
to the swing motor. The return oil from the swing motor enters Port Bs (or As) and returns to the
Θ Swing operation preference function

[Pilot Circuit]
The pilot pressure enters through Port PSp to transfer the swing priority spool (395).
[Main Circuit]
Due to transfer of the swing priority spool, the open area of the swing priority spool decreases,
and the most of the pressurized oil entering through port P2 flows to the swing side to make the
swing operation most preferential.
SWING PRIORITY SPOOL
PSp
from port P2
the open area decreases
3607A2MC22
2-49-16
(7) Travel straight operation
Simultaneous operating of both travel spools and other spool.
A case where both travel spools and swing spool are changed over will be considered.
(The pilot ports PAL, PAr and PAs are pressurized.)
[Pilot Circuit]
Since the side bypass sections of both travel spools close and the side bypass section of the
downstream-side swing closes, the pilot pressure from the port Pa enters through the port PTa
to transfer the travel straight spool.
[Main Circuit]
After changeover of the travel straight spool, the port P2 and both travel spools are connected
preferentially and the port P1 and the parallel paths of swing, boom 2, option and arm 1 / boom
1, bucket and arm 2 are connected preferentially. Therefore, the pressurized oil entering through
port P2 passes through mainly ports AL and Ar, and flows to both travel motors separately.
On the other hand, the pressurized oil entering through port P1 flows to port As and is supplied
to the swing motor.
When the pressure of port P2 is lower than the pressure of port P1, part of oil entering through
port P1 flows into port P2 side. Therefore, it prevents the rapid slowdown of travel.
P2g P1g
P1
P2 to travel
left to boom 1
side
to swing
side
(PTb) PTa
to travel
right
PAL PBL
3607A2MC23
2-49-17
(8) Function of lock valve
The lock valve is fitted between the arm cylinder rod side (R) and the arm1 spool (302). It
decreases the leakage by the pressure of the cylinder.
Another lock valve is similarly fitted between the boom cylinder head side (H) and the boom1
spool (303). It decreases the leakage by the pressure of the cylinder.
Η Neutral positions of spools
The following is the case of the boom 1 spool.
(The case of the arm 1 spool is in the same way.)
During the boom 1 spool is in neutral position, the lock valve is kept in the position shown in
figure. The spool (511) in lock valve is pushed to the seat of the bush (541) by the force of the
spring (512).
In this position, pressurized oil from the boom cylinder head side (H) enters through hole (a), the
periphery of the spool and hole (b), and it pushes the poppet to the casing seat, and the leakage
is decreased.
511 512
P2cl
Boom cylinder Dr3'

LCb1 head side(H)
HV (a) (b)
541
PBb PAbs
(Bbs)
3607A2MC24
2-49-18
Θ Boom down operation
During the boom down operation, pilot pressure enters through port P2c1 and PAb. Pilot
pressure transfers the spool (511) in lock valve assy in the right direction in figure. By the transfer
of the spool, firstly the hole (a) is blocked and pressurized oil from the boom cylinder head side
(H) does not enter to spring chamber (RH). Secondly, oil in spring chamber (RH) enters through
hole (b) and flows to port Dr3'.
Therefore, the poppet is lifted by the pressure of the boom cylinder head side (H) and the
function of the lock valve is released.
511
P2c1
Dr3'
LCb1 Boom cylinder
head side(H)
HV (a) (b)
(RH)
PBb PAbs
(Bbs)
3607A2MC25
Ι Boom up operation
During the boom up operation, the pilot pressure enters through port PBb. The oil flowing from
the boom 1 spool pushes open the poppet (513) and flows to Port Bb.
2-49-19
(9) Function of boom priority valve
During both the swing operation and the boom hoisting operation, the pilot pressure enters
through ports PAs(or PBs), PBb and Pns. The pressure Pns transfers the piston (356) and the
spool (107) to the down direction, and the path from (a) to (b) is closed. Hereby, the pressurized
oil pushes open the poppet (102), passes in the path (c) and (d), enters into the chamber (e),
and the poppet (101) is pushed to the casing seat. Therefore, the most of pressurized oil
entering through port P2 flows to the boom priority spool (393) than the swing spool (305) to
make the boom hoisting operation most preferential.
On the other hand, in the independent swing operation, the pilot pressure does not enter through
ports Pns, and the path from (a) to (b) is not closed, and oil of chamber (e) flows to the path (a)
and (b). The pressurized oil entering through port P2 pushes open the poppet (101) and flows to
the swing spool (305).
Pns
356
107
(b) (e)
Bs As
(d)
(a)
102
(c)
from PZ
PBs (Bbs)
SWING
3607A2MC26
2-49-20
(10) Function of main relief valve
The main relief valve is fitted in the casing B and functions as follows :
Η The hydraulic oil is filled up in the inside space chamber (A) from the path (P) through a hole of
the body (101) and a restriction of the plunger (511), and seats the plunger (511) against body
(101) securely.
Θ When the pressure in the path (P) becomes equal to the set load of the spring (512), the poppet
(401) opens to make the hydraulic oil flow through a hole of the seat (2) (641), around the
poppet (401) and into the low pressure path (R).
Ι Opening of the poppet (401) causes the pressure in the chamber (A) to fall and the plunger
(511) to open. As the result the pressurized oil in the path (P) runs into the low pressure path (R)
directly.
Κ When the pressurized oil higher than pressure 2.2MPa enters through the port PL1, it pushes
the piston (302) to change the relief set pressure of the spring (512) to the high pressure.
302 512 401 511 (A) 101
PL1 P
641
3607A2MC27
2-49-21
(11) Function of port relief valve
The port relief valve is fitted between the cylinder port and low-pressure path.
In addition to the relief valve, this serves also as an anti-cavitation check valve, and functions as
follows:
(1) Function as relief valve
Η The pressurized oil passes through hole A of the piston (301), is filled up in chamber B of the
inside space, and seat the plunger (511) against the seat (541) securely.
A B
R
301
511 541
3607A2MC28
A B
301
P PL
511 541
3607A2MC29
2-49-22
Θ When the pressure in the path (P) becomes equal to the set pressure of the spring (621 or 622),
the pressurized oil pushes open the poppet (611), flows around it, and flows to the low pressure
path (R) through Hole C.
611 621
3607A2MC30
P PL
611 622 106
3607A2MC31
2-49-23
Ι Opening of the poppet (611) causes the pressure in chamber B to fall and the plunger (511) to
open. As the result the pressurized oil in the path (P) runs into the low pressure path (R) directly.
511 B
611
3607A2MC32
511 B
P PL
611 622 624 105
3607A2MC33
Κ When the pressurized oil higher than pressure 1.5MPa enters through the port PL, it pushes the
piston (614) to change the relief set pressure of the spring (622) to the high pressure.
2-49-24
(2) Function as anti-cavitation check valve
When any negative pressure exists in the path (p), the oil is supplied through the path (R). When
the pressure at (R) becomes higher than that in the path (P), the seat (541) moves in the right
direction.
Then, sufficient oil passes around the seat (541) from the path (R) to the path (P) and prevents
cavitation.
541
3607A2MC34
541
R
PL
3607A2MC35
2-49-25
(12) Function of negative control relief valve
The negative control relief valve is fitted between the downstream of the center bypass path and
low-pressure path, and functions as follows :
Η When the pressure in the path (P) falls
below the set level of the spring (621),the 611 621
poppet (611) is in the condition shown in R
the figure. The pressure acting area of
the poppet (611) is reduced to
A
P
(͚B-͚A), as the area ͚B is cancelled
by the area ͚A of the damping rod
(631). 631
3607A2MC36
Θ In this condition, the pressurized oil in

the path (P) runs out to the path (R)
through the orifice (c). R
C
3607A2MC37
Ι When the pressure in the path (P) goes

over the set pressure of the spring(621), 621
the poppet (611) opens. Then, the R
pressurized oil in the path (P) passes
around the outside of the poppet (611) P
and flows to the low-pressure path (R).
611
3607A2MC38
The relation between the flow rate Q and

pressure P of the hydraulic oil that flows P
from the path (P) to the low-pressure
path (R) is as shown in the diagram.
0 Q
3607A2MC39
2-49-26
GROUP 3 SWING DEVICE
1. STRUCTURE
Swing device consists swing motor, swing reduction gear.
Swing motor include mechanical parking valve, relief valve, make up valve and time delay valve.
AGr SGo SH PG Am Mu Dr
SGr Dr(RG) A,B GA A B GB

Reduction gear Swing motor Time delay valve

SGr AGr
Dr(RG) A Main port SAE 1"
SGo SH
B Main port SAE 1"
PG Dr Drain port PF 1/2
Mu Make up port PF 1 1/4
Am SH Brake release port PF 1/4
PG Stand by port PF 1/4
dr5
GA, GB Gauge port PF 1/4
GB GA
Am Motor air bleed port PF 1/4
AGr R/G air bleed port PT 1/8
B Mu A SGr Grease filling port PT 1/8
Hydraulic circuit Dr(R/G) Gear oil drain port PT 3/8
SGo Gear oil filling port PT 3/4
3607A2SM01
2-50
1) SWING MOTOR
7 36 5 8 12 11 10 9 20 21 6 24 23 26 34 30
27
A A
2 1 3 4 14 13 16 15 17 35 19 18 22 25 31,32 29 28 33
SECTION A-A
3607A2SM02
1 Body 13 Set plate 25 Wrench bolt

2 Oil seal 14 Piston assy 26 Poppet
3 Roller bearing 15 Friction plate 27 Spring
4 Snap ring 16 Plate 28 Plug
5 Shaft 17 Brake piston 29 O-ring
6 Pin 18 O-ring 30 Relief valve assy
7 Stop ring 19 Spring 31 Time delay valve
8 Shoe plate 20 Valve plate 32 Wrench bolt
9 Cylinder block 21 Pin 33 Plug
10 Spring 22 Needle bearing 34 O-ring
11 Ball guide seat 23 Rear cover 35 O-ring
12 Ball guide 24 Wrench bolt 36 Bushing
2-51
2) REDUCTION GEAR
28,36 27 26 25 5 4 3 1 40 2 6 7 13 14 10 12 11 33 24
15
38
* * 43
16
17
29
18
37
35 34 31 30 23 8 21 32 19 20
3607A2SM03
1 Casing 15 Carrier 1 29 Stop ring

2 Drive shaft 16 Sun gear 1 30 Plug
3 Roller bearing 17 Planetary gear 1 31 Plug
4 Cover plate 18 Pin 1 32 Side plate 1
5 Hex bolt 19 Needle cage 33 Spring pin
6 Oil seal 20 Side plate 2 34 Gauge bar
7 Roller bearing 21 Spring pin 35 Gauge pipe
8 Carrier 2 22 Ring gear 36 Lock washer
9 Sun gear 2 23 Knock pin 37 Cover
10 Planetary gear 2 24 Socket bolt 38 Socket bolt
11 Pin 2 25 Spacer 39 Socket plug
12 Bushing 2 26 Pinion gear 40 Ring spacer
13 Spring pin 27 Lock plate 42 Air breather assy
14 Washer 28 Hex bolt 43 Thrust ring
2-52
2. FUNCTION
1) ROTARY PART
When high pressurized oil enters a cylinder through port(a), which is the inlet of balance plate(1),
hydraulic pressure acting on the piston causes axial force F. The pressure force F works via the
piston(2) upon the return plate(3) which acts upon the swash plate(4) via an hydrostatic bearing.
Force F1 perpendicular to swash plate(4) and force F2 perpendicular to cylinder center.
Being transferred to the cylinder block(5) through piston, force F2 causes rotational moment at
surroundings of cylinder.
Since cylinder block has 9 equidistantly arrayed pistons, rotational torque is transmitted to cylinder
shaft in order by several pistons connected to the inlet port of high pressurized oil. When the
direction of oil flow is reversed, rotational direction of cylinder is also reversed. Output torque is
given by the equation.
p×q F
T= , q=Z·A·PCD·tanθ , F1 = , F2=F tanθ, S=PCD×tanθ
2Л COSθ
Where p : Effective difference of pressure(kgf/cm2)
q : Displacement(cc/rev)
T : Output torque(kgf·cm)
Z : Piston number
A : Piston area(cm2)
θ: Tilting angle of swash plate(degree)
S : Piston stroke(cm)
F
F1 F2
S
PCD
a a
4 3 2 5 1 High pressure oil High pressure oil Low pressure oil
36072SM04
2-53
2) MAKE UP VALVE
In the system using this type of motor, there is no counter balance functioning valve and there
happens the case of revolution exceeding hydraulic supply of motor. To prevent the cavitation
caused by insufficient oil flow there is a make up valve to fill up the oil insufficiency.
A make up valve is provided immediately before the port leading to the hydraulic oil tank to secure
feed pressure required when the hydraulic motor makes a pumping action. The boost pressure
acts on the hydraulic motor's feed port via the make up valve.
Pressurized oil into the port B, the motor rotate counterclockwise.
If the plunger of MCV moves neutral position, the drain oil from Mu port run into motor via right
make up valve, which prevent the cavitation of motor.
A B
36072SM05
2-54
3) RELIEF VALVE
1 Body
5 9 2 Seat
3 Plunger
6 4 Spring
8
5 Adjusting screw
6 Piston
3
7 7 Sleeve
8 O-ring
10 9 Back up ring
10 O-ring
36072SM06
(1) Construction of relief valve

The valve casing contains two cartridge type relief valves that stop the regular and reverse
rotations of the hydraulic motor. The relief valves relieve high pressure at start or at stop of swing
motion and can control the relief pressure in two steps, high and low, in order to insure smooth
operation.
(2) Function of relief valve
Figure illustrates how the pressure acting
on the relief valve is related to its rising P=pressure, T=time
process. Here is given the function, P
referring to the figure following page. Ps
4
P2
3
P1
1 T
2-51(2) [360-7]
2-55
① Ports (P, R) at tank pressure.
36072SM07
② When hydraulic oil pressure(P×A1) reaches the preset force(FSP) of spring(4), the plunger(3)
moves to the right as shown.
P1×A1 =FSP+Pg×A2
Fsp+Pg×A2
P1 =
A1
A2 4 3 g
A1
P=P1
36072SM08
2-56
③ The oil flow chamber g via orifice m and n. When the pressure chamber g reaches the preset
force(Fsp) of spring(4), the piston(6) moves left and stop the piston(6) hits the bottom of
sleeve(7).
4 m n g
P=P2
R
7 6
36072SM09
④ When piston(6) hits the end of sleeve(7), it stops moving to the left any further. As the result, the
pressure in chamber(g) equals (PS ).
PS ×A1=FSP+Ps×A2
Fsp
PS=
A1-A2
P=Ps
R g
7 6
36072SM10
2-57
4) BRAKE SYSTEM
(1) Control valve swing brake system
This is the brake system to stop the swing motion of the excavator for during operation.
In this system, the hydraulic circuit is throttled by the swing control valve, and the resistance
created by this throttling works as a brake force to slow down the swing motion.
Work Deceleration
Stop
A B A B A B
MCV MCV MCV
MCV A,B opened MCV A,B throttled MCV A,B closed
R130SM05
(2) Mechanical swing parking brake system

The mechanical swing parking brake system is installed to prevent the upper structure from
swinging downhill because of its own weight when the excavator is parked on a slope since it
completely eliminates the hydraulic drift of swing motion while the excavator is on a slop, work can
be done more easily and safely.
① Brake assembly
Circumferential rotation of separate
plate(12) is constrained by the groove
located at housing (5). When housing is
pressed down by brake spring(16)
through friction plate(11), separate
plate(12) and brake piston(13), friction
16
force occurs there.
13
Cylinder(9) is constrained by this friction
force and brake acts, while brake 12
releases when hydraulic force exceeds 11
spring force. 9
36072SM11
5 Housing 12 Separate plate

9 Cylinder 13 Brake piston
11 Friction plate 16 Brake spring
2-58
② Operating principle
a. When one of the RCV lever (1) is set to the operation position, the each spool is shifted to left or
right and the pilot oil flow is blocked. Then the pilot oil go to SH of the time delay valve (3).
This pressure moves spool (5) to the leftward against the force of the spring(8), so pilot pump
charged oil (P3) goes to the chamber G through port PG.
This pressure is applied to move the piston (6) to the upward against the force of the spring (9).
Thus, it releases the brake force.
3 10 7
PG
P4=P3
11
G
9
6 D
PG SH
1 Swing control lever

2 Main control valve
3 Time delay valve 4
4 Pilot pump P3
5 Spool
6 Piston
2
7 Poppet
8 Spring
9 Spring
10 Orifice
11 Spring
36072SM12
2-59
b. When all of the RCV lever (1) are set the neutral position, the spool (5) returns to right.
Then, the piston (6) is moved lower by spring force and the return oil from the chamber G flows
back to tank port.
At this time, the brake works.
3 10 7
PG
P4=D
11
G
9
6 D
PG SH
1 Swing control lever

2 Main control valve
3 Time delay valve
4
4 Pilot pump
P3
5 Spool
6 Piston
2
7 Poppet
8 Spring
9 Spring
10 Orifice
11 Spring
36072SM13A
2-60
GROUP 4 TRAVEL DEVICE
1. CONSTRUCTION
Travel device consists travel motor and gear box.
Travel motor include counter balance valve, cross over relief valve.
Pr Pa A N B Pb
Dr Dr
Pi
Manual negative Pi Pi
Reduction gear Travel motor brake release port
(PT 1/4)
L
GIN
FILL
GOUT LEVEL
DRAIN
VIEW X 3607A2TM01
Dr Dr A Main port SAE 6000 psi 1"

Hi B Main port SAE 6000 psi 1"
Lo Pr Pi Pilot port PF 1/4
Pi Dr Drain port PF 1/2
Pi
N N Negative brake release port NPTF 1/16
Pa, Pb Pressure gauge port PF 1/4
Pa Pb
Pr Brake release pressure gauge port PF 1/4
L Level gauge PF 1/2
GIN Gear oil inlet port PF 1/2
AB GOUT Gear oil drain port PF 1/2
Hydraulic circuit
2-62
1) TRAVEL MOTOR(1/2)
101 491 107 102 435 504 113 201 122 741 742 121 703 545 705 461 704 351
352
802
801
451
303
131
103
111
114
472
502 503 123 272 707 702 708 546 547

3607A2TM02
101 Drive shaft 303 Valve casing 547 O-ring

102 Roller bearing 351 Reducing valve 702 Brake piston
103 Needle bearing 352 Cover 703 Orifice
107 Snap ring 435 Snap ring 704 Orifice
111 Cylinder block 451 Pin 705 Brake spring
113 Spherical bushing 461 Plug 707 O-ring
114 Cylinder spring 472 O-ring 708 O-ring
121 Piston 491 Oil seal 741 Separation plate
122 Shoe 502 Piston 742 Friction plate
123 Set plate 503 Shoe 801 Name plate
131 Valve plate 504 Pivot ball 802 Rivet
201 Swash plate 545 Orifice
272 Shaft casing 546 Orifice
2-63
TRAVEL MOTOR(2/2)
402 366 364 564 022 361 365 362

571
572
531
533
464 509
SECTION E-E
485
350 401 567 541 543 542 570 569
3607A2TM03
022 Counterbalance spool 402 Hex socket bolt 543 Steel ball
350 Relief valve 464 VP plug 564 Plug
361 Washer 485 O-ring 567 VP plug
362 Counterbalance spring 509 O-ring 569 RO plug
364 Counterbalance cover 531 Tilting spool 571 RO plug
365 O-ring 533 Tilting spring 572 O-ring
366 Hex socket bolt 541 Seat
401 Hex socket bolt 542 Stopper
2-64
2) REDUCTION GEAR
1 16 19 22 13 36 54 2
30
4
18
44
46 52
A
27
9 51
10
26
53
32
83
45
11
5
24
21 37 20 25 14 23 17
12
81 6 29 82 47 35 33 34 SECTION VIEW A
3607A2TRG01
1 Ring gear 19 Side plate 35 Shim

2 Housing 20 Side plate 36 Spring pin
4 Side cover 21 Needle cage 37 Snap ring
5 Carrier 1 22 Needle cage 44 Snap ring
6 Carrier 2 23 Needle cage 45 Clip
9 Sun gear 1 24 Inner ring 46 W clip
10 Sun gear 2 25 Floating bushing 47 Nut ring
11 Sun gear 3 26 Thrust ring 51 Name plate
12 Planetary gear 1 27 Thrust ring 52 Rivet
13 Planetary gear 2 29 Socket bolt 53 Washer
14 Planetary gear 3 30 Socket bolt 54 Set screw
16 Pin 2 32 RO plug 81 O-ring
17 Pin 3 33 Angular bearing 82 O-ring
18 Side plate 34 Floating seal 83 O-ring
2-65
2. FUNCTION
1) GENERATION OF TORQUE
(Y1)
F3
303 131 111 201 101
F3
ri
F3
F3
Low pressure High pressure

P (Y2)
F1
A P
121 F3
F2
3607A2TRG02
The pressurized oil delivered from the hydraulic pump flows to valve casing(303) of the motor,
passes through the brake valve mechanism, and is introduced into cylinder block(111) via valve
plate(131). This oil constructively introduced only to one side of (Y1)-(Y2) connecting the upper and
lower dead points of stroke of piston(121). The pressurized oil led to one side in cylinder block(111)
pushes each piston(121) four or five and generates a forec [F(kgf) = P(kgf/cm2) ×A(cm2)].
This force acts on swash plate(201), and is resolves into components(F2 and F3) because swash
plate(201) is fixed at an angle(α) with the axis of drive shaft(101).
Radial component(F3) generates respective torques(T=F3×ri) for (Y1)-(Y2). This residual of
torque[T=S(F3×ri)] rotates cylinder block(111) via piston(121).
Since the cylinder block(111) is spline coupled with drive shaft(101).
So the drive shaft(101) rotates and the torque is transmitted.
2-66
2) RELIEF VALVE
The relief valve mainly has the following two functions :
(1) To keep the starting pressure of the hydraulic motor at a constant value and bypass to the
return line excessive oil generated at the motor inlet depending upon the acceleration speed
of the driven inertia.
(2) To generate a brake pressure at the outlet during stopping of the driven inertia, and stop it
forcedly.
Port A Port B
Poppet A
Seat A Chamber A
3607A2TM06
The chamber A is always connected to the port A of the motor.

When the pressure at port A increases and the force pushing poppet A is higher than the set
pressure of the spring, then poppet A is pushed up from the contact surface of seat A, and oil
flows from chamber A to port B.
2-67
3) NEGATIVE BRAKE
The negative brake is released applying to the brake piston(702) the pressure led through the built-
in counterbalance spool sub-assembly(022).
With no pressure working, the brake force is always ensured.
272 741 742 702 703 545 705 704 351
022
111
101
303
Counterbalance Reducing valve Orifice A Brake piston Orifice B

spool(022) (351) (545) chamber (703)
Pa Dr
Position 1
Hi
A
Position 2 Lo
B
Position 3
Pb N Pi Pi Pr Dr
3607A2TM07
The brake force is the friction force generated on the surfaces of the friction plates(742) spline-
coupled with the cylinder block(111), when their rotation is restricted by the shaft casing(272),
separation plate(741), and brake piston(702).
Without pressure being applied to the brake piston, the brake piston is pushed by fourteen brake
springs(705), and the friction plate and separation plate are held between the brake and shaft
casing. This holding force functions as the friction force. This friction force restrains the shaft(101)
spline-coupled with the cylinder block, and this function is the brake.
2-68
4) PRESSURE RELEASE VALVE (Flow control valve)
During running During stop
3607A2TM08
This brake is of a backpressure-insensitive type. In other words, since the counterbalance spool
used be overlapped at the neutral position, the pressure release valve prevents the circuit
backpressure from working into the brake chamber when the machine stops traveling and works,
and so the specified brake torque is available even on a slope.
During normal traveling, the pressure coming through the counterbalance valve is applied to the
brake chamber to release the break, and is also applied to the pressure release valve section.
This pressure release valve is of a constant differential pressure type, and irrespective of the
working pressure, the passing flow is constant and approximately 1 to 2 ℓ/ min.
When the condition changes from traveling to stop, the counterbalance spool returns to its neutral
position. The brake piston is pushed by the brake spring, and the oil in the brake chamber flow to
the motor drain line via the pressure release valve. Then the brake torque is generated.
2-69
5) RELEASING METHOD OF NEGATIVE BRAKE
In releasing the negative brake without applying the brake releasing pressure, follow the procedures
shown below.
Details of work Tools

Remove two plugs(564) from the valve casing(303).
(For their position, see the attached installation dimension)
Tighten an M10 screw of 135mm in length into a tapped hole of Socket wrench
the brake piston(702). Then the condition having the brake 6mm
release pressure is attained and the brake is released. 8mm
Note : Even with the negative brake released, the hydraulic motor will not turn. When it is difficult to
generate the working pressure due to failure of the pump or so, and the whole machine is to
be pulled for transportation without removing the hydraulic motor, connect pressure
measurement ports AM and BM with a short hose or something. Then the machine can be
pulled slowly.
2-70
6) COUNTERBALANCE VALVE
Am P Bm
L K
Dv Cv
N
D' C' M
DH CH
1' 1
F E
G' G
Av Bv
3607A2TRG03
Suppose port Bv is connected to the hydraulic pump and Port Av, to the tank. The oil supplied from
the hydraulic pump passes through Bv, Cv and C' in sequence, pushes up the poppet of the check
valve, passes through K to Port Bm, and is supplied to the hydraulic motor to turn it.
Therefore, the pump discharge oil pressure increases, and the pressure is led via passage G to
spring room E and via the ball check valve to dumping room M. When the pressure in rooms E and
M exceeds the value equivalent to the force of the spring which holds the spool at its neutral
position, the spool begins to move left. Since the working oil in room N flows into room F via throttle
1' or clearance 2' and that in room F is discharged via passage G' through port Av to the tank, the
spool moves left to have passage L-Dm-D'-Dv composed. In addition, passage Cv-H-P is also
composed, and the pump discharge pressure in port Bv is led to port P.
Because of the throttle or clearance provided for the working oil flow from room N, this changeover
motion of the spool is comparatively slow.
When the pump discharge pressure is higher, the spool movement is larger and the above opening
area of the spool is larger.
When the pump discharge pressure falls, pressures in rooms E and M fall and the spool will move
right due to the spring on the room F side.
Since working oil in room M flows to room E via throttle 1 and that in room E, to port Bv via passage
G, the spool moves right.
When the pressure at port Bv falls down to the tank pressure, the pressure in room E also falls to
the tank pressure and becomes equal to that in room F, and so the spool returns to its neutral
position.
2-71
7) DISPLACEMENT CHANGEOVER SECTION
As a supporting mechanism for the swash plate(201) on which the shoes(122) slide, the pillar
system is adopted to support the load with semi-cylindrical sliding bearings provided at both ends of
the mechanism.
The capacity is changed by changing the tilting angle of this swash plate.
This is a mechanism that swash plate was pushed by tilting position, and the tilting angle of the
swash plate is decided in two positions (Large and Small) by controlling the flows to and from these
piston rooms with the displacement changeover valve section.
(1) External pilot pressure : Pi = 0 Large displacement
303
C
External pilot pressure
502 504 201 122 Stopper S Pi=0
533 531 571
High pressure selector valve

3607A2TM04
By means of the built-in high pressure selector mechanism in the valve casing(303), the high
pressure oil working on the motor functions to port P of the displacement-changeover valve. This
pressure becomes the servo pressure. Since the spool(531) assembled in the displacement
changeover valve is pressed to plug(571) by thy spring(533), the high pressure oil at port P is
enclosed.
2-72
(2) External pilot pressure : Pi 20kgf/cm2 small displacement
303
Paggage B
C External pilot pressure
Pi >
= 20kgf/cm
2
502 504 201 122 Stopper S
533 531 571
High pressure selector valve
3607A2TM05
The force working on the spool(531) of the displacement-changeover valve becomes higher than
that of the spring(533), and the spool moves left. The high pressure oil flows from port P of the
displacement-changeover valve through port S and passage B to room C where it works.
The displacement changeover piston(502) is pushed light by the high pressure oil and the swash
plate moves in the arrowed direction. The swash plate moves until it touched stopper S, and then
is fixed there.
2-73
8) REDUCTION GEAR
The reduction gear is composed of a three-stage planetary gear mechanism shown in the following
figure. Since the sun gear is designed to have a floating mechanism, errors of the gears and
carrier pin hole pitches will not affect the gears' lives heavily.
R3 R2 R1
C3 C2 C1
P3 P2 P1
S3 S2
S1
3607A2TRG04
The input rotation of the hydraulic motor is transmitted to No. 1 sun gear (S1) and this drives No. 1
planetary gears (P1). This No. 1 planetary gears (P1) drive No.1 ring gear (R1) with the same
force as the meshing tangential force with No. 1 sun gear (S1), and also No. 1 carrier (C1) with the
same force as the meshing reaction force. In other words, No. 1 planetary gears (P1) revolve
rotating. This rotation of No. 1 carrier (C1) becomes the output of the 1st stage, and is transmitted
directly to No. 2 sun gear (S2).
(No. 1 carrier is spline-coupled with No. 2 sun gear.) Similarly the revolution of No. 2 planetary gear
(P2) are transmitted via No.2 carrier (C2) to No. 3 sun gear (S3). Since No. 3 carrier (C3)
supporting No. 3 planetary gears (P3) are fixed, No. 3 planetary gears (P3) do not revolve, but
rotates to drive No. 3 ring gear (R3).
Therefore, the rotating case is driven by the overall driving torque of No1, 2 and 3 ring gears.
This reduction ratio is expressed as shown below:
(ZS1 + ZR1) (ZS2 + ZR2) (ZS3 + ZR3)
i= -1
ZS1·ZS2 ·ZS3
where Z : Number of teeth of each gear
The direction of rotation is reverse to that of the input shaft.
2-74
GROUP 5 RCV LEVER
1. STRUCTURE
The casing has the oil inlet port P(Primary pressure) and the oil outlet port T(Tank). In addition the
secondary pressure is taken out through ports 1, 2, 3 and 4 provided at the bottom face.
23.3
19
25
Single
operation Simultaneous
operation
Handle bending direction

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

T Pilot oil return port Pilot oil return port
1 Left swing port Bucket out port
PF 1/4
2 Arm in port Boom down port
3 Right swing port Bucket in port
4 Arm out port Boom up port
25032RL01
2-75
CROSS SECTION
The construction of the pilot valve is shown in the attached cross section drawing. The casing has
vertical holes in which reducing valves are assembled.
The pressure reducing section is composed of the spool(5), spring(7) for setting secondary pressure,
return spring(10), stopper(9), spring seat(8) and shim(6). The spring for setting the secondary
pressure has been generally so preset that the secondary pressure is 5 to 20.5kgf/cm2(Depending on
the type). The spool is pushed against the push rod(14) by the return spring.
When the push rod is pushed down by tilting the handle, the spring seat comes down simultaneously
and changes setting of the secondary pressure spring.
1 Case 12 Rod seal 23 Nut

2 Plug 13 O-ring 24 Insert
3 Plug 14 Push rod 25 Boot
4 O-ring 15 Plate 26 Handle
5 Spool 16 Bushing 27 Switch assembly
6 Shim 17 Joint assembly 28 Screw
7 Spring 18 Swash plate 29 Switch assembly
8 Spring seat 19 Adjusting nut 30 Switch cover
9 Stopper 20 Lock nut 40 Boot
10 Spring 21 O-ring
11 Plug 22 Handle connector
2-76
CROSS SECTION
14072SF80
2-77
2. FUNCTIONS
1) FUNDAMENTAL FUNCTIONS
The pilot valve is a valve that controls the spool stroke, direction, etc of a main control valve. This
function is carried out by providing the spring at one end of the main control valve spool and
applying the output pressure(Secondary pressure) of the pilot valve to the other end.
For this function to be carried out satisfactorily, the pilot valve is composed of the following
elements.
(1) Inlet port(P) where oil is supplied from hydraulic pump.
(2) Output ports(1, 2, 3 & 4) to apply pressure supplied from inlet port to ends of control valve spools.
(3) Tank port(T) necessary to control the above output pressure.
(4) Spool to connect output port to inlet port or tank port.
(5) Mechanical means to control output pressure, including springs that work on the above spools.
2) FUNCTIONS OF MAJOR SECTIONS
The functions of the spool(5) are to receive the supply oil pressure from the hydraulic pump at its
port P, and to change over oil paths to determine whether the pressure oil of port P is led to output
ports 1, 2, 3 & 4 or the output port pressure oil to tank port T.
The spring(7) works on this spool to determine the output pressure.
The change the deflection of this spring, the push rod(14) is inserted and can slide in the plug(11).
For the purpose of changing the displacement of the push rod through the switch plate(19) and
adjusting nut(20) are provided the handle(27) that can be tilted in any direction around the fulcrum
of the universal joint(18) center.
The spring(10) works on the case(1) and spring seat(8) and tries to return the push rod(14) to the
zero-displacement position irrespective of the output pressure, securing its resetting to the center
position.
This also has the effect of a reaction spring to give appropriate control feeling to the operator.
2-78
3) OPERATION
The operation of the pilot valve will be described on the basis of the hydraulic circuit diagram shown
below and the attached operation explanation drawing.
The diagram shown below is the typical application example of the pilot valve.
5 6
3
1
3
P T
2 4
36072RL01
1 Pilot valve 3 Main pump 5 Hydraulic motor

2 Pilot pump 4 Main control valve 6 Hydraulic cylinder
2-79
(1) Case where handle is in neutral position
7
10
P 5
1 3
25032RL03
The force of the spring(7) that determines the output pressure of the pilot valve is not applied to
the spool(5). Therefore, the spool is pushed up by the spring(10) to the position of port(1, 3) in
the operation explanation drawing. Then, since the output port is connected to tank port T only,
the output port pressure becomes equal to tank pressure.
2-80
(2) Case where handle is tilted
15
1 3
25032RL04
When the push rod(14) is stroked, the spool(5) moves downwards.

Then port P is connected with port(1) and the oil supplied from the pilot pump flows through
port(1) to generate the pressure.
When the pressure at port(1) increases to the value corresponding to the spring force set by tilting
the handle, the hydraulic pressure force balances with the spring force. If the pressure at port(1)
increases higher than the set pressure, port P is disconnected from port(1) and port T is
connected with port(1). If it decreases lower than the set pressure, port P is connected with
port(1) and port T is disconnected from port 1.
In this manner the secondary pressure is kept at the constant value.
Besides, in some type, when the handle is tilted more than a certain angle, the upper end of the
spool contacts with the inside bottom of the push rod and the output pressure is left to be
connected with port P.
2-81
GROUP 6 RCV PEDAL
1. STRUCTURE
The casing(Spacer) has the oil inlet port P(Primary pressure), and the oil outlet port T(Tank). In
addition the secondary pressure is taken out through ports 1,2, 3 and 4 provided at the bottom face.
° 12.4
12.4 °
1 2
3 4
Port Port Port size
P Pilot oil inlet port

T Pilot oil return port
1 Travel(LH, Forward)
PF 1/4
T 2 Travel(LH, Backward)
P 3 Travel(RH, Forward)
1 23 4 4 Travel(RH, Backward)
Hydraulic circuit
14072SF73
2-82
CROSS SECTION
The construction of the RCV pedal is shown in the below drawing. The casing has vertical holes in
which reducing valves are assembled.
The pressure reducing section is composed of the spool(8), spring(6) for setting secondary pressure,
return spring(10), stopper(9), and spring seat(7). The spring for setting the secondary pressure has
been generally so preset that the secondary pressure is 5 to 19kgf/cm2 (depending on the type). The
spool is pushed against the push rod(14) by the return spring.
When the push rod is pushed down by tilting pedal, the spring seat comes down simultaneously and
changes setting of the secondary pressure spring.
27 31 30 29 28 33
32 25,26
24
23 3
22 36
14 15
16
21
17
13
18
12
19
11
9 20
5 6
4 7
10
3 8
37 1 35 34 2
14072SF70
1 Body(1) 13 Snap ring 25 Cover

2 Body(2) 14 Push rod 26 Socket bolt
3 Plug 15 Spring pin 27 Cam
4 Plug 16 Seal 28 Bushing
5 Spring seat 17 Steel ball 29 Cam shaft
6 Spring 18 Spring 30 Set screw
7 Spring seat 19 Plate 31 Set screw
8 Spool 20 Snap ring 32 Nut
9 Stopper 21 Plug 33 Bellows
10 Spring 22 O-ring 34 Space
11 Rod guide 23 Rod seal 35 O-ring
12 O-ring 24 Dust seal 36 O-ring
37 Socket bolt
2-83
2. FUNCTION
1) FUNDAMENTAL FUNCTIONS
The pilot valve is a valve controls the spool stroke, direction, etc of a main control valve. This
function is carried out by providing the spring at one end of the main control valve spool and
applying the output pressure(Secondary pressure) of the pilot valve to the other end.
For this function to be carried out satisfactorily, the pilot valve is composed of the following elements.
(1) Inlet port(P) where oil is supplied from hydraulic pump.
(2) Output port(1, 2, 3 & 4) to apply pressure supplied from inlet port to ends of control valve spools.
(3) Tank port(T) necessary to control the above output pressure.
(4) Spool to connect output port to inlet port tank port.
(5) Mechanical means to control output pressure, including springs that work on the above spools.
2) FUNCTIONS OF MAJOR SECTIONS
The functions of the spool(8) are to receive the supply oil pressure from the hydraulic pump at its
port P, and to change over oil paths to determine whether the pressure oil of port P is led to output
ports 1, 2, 3 & 4 or the output spool to determine the output pressure.
The spring(6) works on this spool to determine the output pressure.
The change the deflection of this spring, the push rod(14) is inserted and can slide in the plug(21).
For the purpose of changing th displacement of the push rod through the cam(27) and adjusting
nut(32) are provided the pedal that can be tilted in any direction around the fulcrum of the cam(27)
center.
The spring(10) works on the casing(1) and spring seat(7) and tries to return the push rod(14) to the
zero-displacement position irrespective of the output pressure, securing its resetting to the center
position.
This also has the effect of a reaction spring to give appropriate control feeling to the operator.
2-84
3) OPERATION
The operation of the pilot valve will be described on the basis of the hydraulic circuit diagram shown
below and the attached operation explanation drawing.
The diagram shown below is the typical application example of the pilot valve.
36072SF01
1 Pilot valve 3 Main pump 5 Hydraulic motor

2 Pilot pump 4 Main control valve 6 Hydraulic cylinder
2-85
(1) Case where pedal is in neutral position
T 8
10
P
1 2
14072SF74
The force of the spring(6) that determines the output pressure of the pilot valve is not applied to
the spool(8). Therefore, the spool is pushed up by the spring(10) to the position of port 2 in the
operation explanation drawing. Then, since the output port is connected to tank port T only, the
output port pressure becomes equal to tank pressure.
2-86
(2) Case where pedal is tilted
14
1 2
14072SF75
When the push rod(14) is stroked, the spool(8) moves downwards.

Then port P is connected with port 1, and the oil supplied from the pilot pump flows through port 1
to generate the pressure.
When the pressure at port 1 increases to the value corresponding to the spring force set by tilting
the handle, the hydraulic pressure force balances with the spring force. If the pressure at port 1
increases higher than the set pressure, port P is disconnected from port 1 and port T is connected
with port 1. If it decreases lower than the set pressure, port P is connected with port 1 and port T
is disconnected from port 1.
In this manner the secondary pressure is kept at the constant value.
Besides, in some type, when the handle is tilted more than a certain angle, the upper end of the
spool contacts with inside bottom of the push rod and the output pressure is left to be connected
with port P.
2-87
Group 1 Hydraulic Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1

Group 2 Main Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-2
Group 3 Pilot Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-5
Group 4 Single Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-13
Group 5 Combined Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-23
GROUP 1 HYDRAULIC CIRCUIT
4
Dr
Px2
11 8 9 10
3Pi dr Py2 PL 2
Hi Hi
Lo Pr Lo Rs
PR
Pi
N 4Pc
dr1
BR1
Pa Pb al1
bl1
ar1
BL1
AL1
br1
al2
A B B A
AR1 bl2
ar2
12 dr2 1 Main pump

br2
4Pi 2 Main control valve
BR2
(al3)
Pk BL2
AR2 3 Swing motor
(bl3) AL2
(BL3) 4 Travel motor
ar3 (AL3)
3 br3 5 RCV lever(LH)
SGr AGr
BR3 al4
Dr(RG)
6 RCV lever(RH)
AR3 bl4
SGo SH
BL4 7 RCV pedal
a
PG AL4 8 Boom cylinder(LH)
b 9 Boom cylinder(RH)
Am
10 Arm cylinder
dr5
c Fr dr3 Pi R Fl d 11 Bucket cylinder
Py1 Px1
GB GA
25 12 Turning joint
A Mu B
13 Check valve
14 Check valve
15 Hydraulic tank
SWING ARM 5 BUCKET BOOM 6 7 TRAVEL

16 Oil cooler
17 Air breather
Psv1 A1 A2 Psv2 a5
18 Return filter
14 13 1
dr~dr5 T a1 a2
19 Bypass valve
(1) (3) (2) (4) (3) (1) (2) (4) 16
20 Strainer
26 bl4 al4 ar3 br3
(2) (1) (4) (3) 17 21 Spin filter
al1 bl1 bl2 al2 ar2 br2 br1 ar1
15 Pm1 Pm2 22 Line filter
24
27 21 Pi1 Pi2
23 Solenoid valve
23 4Pc Pk Pm1 Pm2 Py2 Px2
18 (Fl) (Fr)
A5 A4 A3 A2 A1
19 24 Accumulator
M
P4 PG(S/Motor)
20 25 Pressure switch
P3 Pi(MCV) 22 Dr1,Dr2 Dr3,Dr4 A3
P2 26 Terminal
T P1
27 Last guard filter
3607A3HC01
3-1
GROUP 2 MAIN CIRCUIT
The main hydraulic circuit consists of suction circuit, delivery circuit, return circuit and drain circuit.
The hydraulic system consists of one main pump, one control valve, one swing motor, four cylinders
and two travel motors.
The swash plate type variable displacement tandem axial piston pump is used as the main pump and
is driven by the engine at ratio 1.0 of engine speed.
1. SUCTION AND DELIVERY CIRCUIT
To cylinders To motors
Main control valve To oil cooler
To hydraulic oil tank
Main pump
Suction filter
Hydraulic oil tank
36073MC01
The pumps receive oil from the hydraulic tank through a suction filter. The discharged oil from the
pump flows into the control valve and goes out the tank ports.
The oil discharged from the main pump flows to the actuators through the control valve.
The control valve controls the hydraulic functions.
The return oil from the actuators flows to the hydraulic tank through the control valve and the oil
3-2
2. RETURN CIRCUIT
Check valve(2)
Full flow filter Oil cooler 1.5kgf/cm 2
Main control valve Actuators
Check valve(1)
3.0kgf/cm 2
Check valve(3)
1.5kgf/cm 2
36073CI01
All oil from each actuator returns to the hydraulic tank through the control valve.
The bypass check valves are provided in the return circuit.
The setting pressure of bypass check valves are 3.0kgf/cm2(43psi) and 5.0kgf/cm2(71psi). Usually, oil
returns to the hydraulic tank from the left side of control valve through oil cooler.
When oil temperature is low, viscosity becomes higher and flow resistance increases when passing
through the oil cooler. The oil pressure exceeds 5.0kgf/cm2(71psi), the oil returns directly to the
hydraulic tank, resulting in the oil temperature being raised quickly at an appropriate level.
When the oil cooler is clogged, the oil returns directly to the hydraulic tank through bypass check
valve(1).
The full-flow filter and bypass relief valve are provided in the hydraulic tank.
The oil from right and left side of control valve is combined and filtered by the return filter. A bypass
relief valve is provided in the full-flow filter.
When the filter element is clogged, the bypass relief valve opens at 1.5kgf/cm2(21psi) differential
pressure.
3-3
3. DRAIN CIRCUIT
Travel motor Swing motor
Turning Main pump

joint From return line
dr2 ~ dr8
Hydraulic Spin filter

oil tank
dr1
Check valve
1.5kgf/cm2
29073CI02
Besides internal leaks from the motors and main pump, the oil for lubrication circulates. These oil
have to be fed to the hydraulic tank passing through spin filter and full flow filter in the hydraulic tank.
When the drain oil pressure exceed 1.5kgf/cm2(21psi), the oil returns to the hydraulic tank directly.
1) TRAVEL MOTOR DRAIN CIRCUIT
Oil leaking from the right and left travel motors comes out of the drain ports provided in the
respective motor casing and join with each other. These oils pass through the turning joint and
return to the hydraulic tank after being filtered by full flow filter in the hydranlic tank.
2) SWING MOTOR DRAIN CIRCUIT
Oil leaking from the swing motor come out and return to the hydraulic tank passing through a spin
filter.
3) MAIN PUMP DRAIN CIRCUIT
Oil leaking from main pump come out and return to the hydraulic tank passing through spin filter.
3-4
GROUP 3 PILOT CIRCUIT
Remote control valve RCV pedal Remote control valve

(LH lever) (RH lever)
Swing parking brake

Control valve Safety lock
solenoid valve
Travel speed solenoid valve
Power boost solenoid valve
Main pump Max flow cut off solenoid valve
Line filter
Boom priority valve
Relief valve
35kgf/cm 2
Pilot pump Suction filter
36073CI03
The pilot circuit consists of suction circuit, delivery circuit and return circuit.
The pilot pump is provided with relief valve, receives the oil from the hydraulic tank through the
suction filter.
The discharged oil from the pilot pump flows to the remote control valve through line filter, EPPR
valve, solenoid valve assemblies, swing parking brake, main control valve and safety lock solenoid
3-5
1. SUCTION, DELIVERY AND RETURN CIRCUIT
BUCKET CYLINDER BOOM CYLINDER ARM CYLINDER
TRAVEL MOTOR
Px2
3Pi dr Py2 PL
PR Rs
4Pc
dr1
BR1
al1
bl1
ar1
BL1
SWING
AL1
br1
BOOM al2
AR1 bl2
ar2
ARM dr2
br2
4Pi
BR2 BUCKET
SWING MOTOR (al3) BL2
AR2
(bl3) AL2
(BL3)
ar3 OPTION (AL3)
br3
BR3 al4
TRAVEL
AR3 (RH) bl4
TRAVEL BL4
a (LH)
AL4
c Fr dr3 Pi R Fl d
RCV PEDAL
RCV LEVER(LH) TRAVEL RCV LEVER(RH)
SWING ARM BUCKET BOOM
HYD
TANK
PILOT PUMP
SAFETY
SOLENOID VALVE
LINE
FILTER STRAINER
RELIEF VALVE
36073HC02
The pilot pump receive oil from the hydraulic tank. The discharged oil from the pilot pump flows to
the safety solenoid valve through the line filter. The oil is filtered by the line filter. The pilot relief
valve is provided in the pilot pump for limiting the pilot circuit pressure.
The oil filtered by line filter flows remote control valve through safety solenoid valve.
The return oil from remote control valve returned to hydraulic tank.
3-6
2. SAFETY SOLENOID VALVE(SAFETY LEVER)
TRAVEL MOTOR
Px2
3Pi dr Py2 PL
PR Rs
4Pc
dr1
BR1
al1
bl1
ar1
BL1
SWING
AL1
br1
BOOM al2
AR1 bl2
ar2
ARM dr2
br2
4Pi
BR2 BUCKET
AR2
(bl3) AL2
(BL3)
ar3 OPTION (AL3)
br3
BR3 al4
TRAVEL
AR3 (RH) bl4
TRAVEL BL4
a (LH)
AL4
c Fr dr3 Pi R Fl d
RCV PEDAL
HYD
TANK
PILOT PUMP
LEVER DOWN SAFETY
LEVER UP SOLENOID VALVE
LINE
FILTER STRAINER
RELIEF VALVE
36073HC03
When the lever of the safety solenoid valve is moved downward, oil flows into the remote control valve
through solenoid valve and line filter.
When the lever of the safety solenoid valve moved upward, oil does not flows into the remote control
valve, because of blocked by the spool.
3-7
3. MAIN RELIEF PRESSURE CHANGE CIRCUIT
TRAVEL MOTOR
MAIN RELIEF VALVE

Px2
3Pi dr Py2 PL
PR Rs
4Pc
dr1
BR1
al1
bl1
ar1
BL1
SWING
AL1
br1
BOOM al2
AR1 bl2
ar2
ARM dr2
br2
4Pi
BR2 BUCKET
AR2
(bl3) AL2
(BL3)
ar3 OPTION (AL3)
br3
BR3 al4
TRAVEL
AR3 (RH) bl4
TRAVEL BL4
a (LH)
AL4
c Fr dr3 Pi R Fl d
RCV PEDAL
HYD
TANK
PILOT PUMP
POWER MAX SAFETY
SOLENOID VALVE Py2
SOLENOID VALVE
LINE
FILTER STRAINER
RELIEF VALVE
36073HC04
When the power max switch on the left control lever is pushed ON, the power max solenoid valve is
actuated, the discharged oil from the pilot pump into Py2 port of the main relief valve of main control
valve ; then the setting pressure of the main control valve is raises from 330kgf/cm2 to 360kgf/cm2 for
increasing the digging power. And even when pressed continuously, it is canceled after 8 seconds.
3-8
4. SWING PARKING BRAKE RELEASE
TRAVEL MOTOR
Px2
3Pi dr Py2 PL
PR Rs
4Pc
dr1
BR1
al1
bl1
ar1
BL1
d SWING
AL1
br1
BOOM al2
AR1 c
bl2
ar2 a
b
ARM
br2
BR2 BUCKET
SWING MOTOR DEVICE
(al3) BL2
AR2
(bl3) AL2
(BL3)
SH ar3 OPTION (AL3)
br3
PG BR3
TRAVEL al4
AR3 (RH) bl4
TRAVEL BL4
a (LH)
AL4
dr5
b
GA
B Mu A c Fr dr3 Pi Px1 R Fl d
RCV PEDAL
HYD
TANK
PILOT PUMP
SAFETY
SOLENOID VALVE
PG LINE
Pi FILTER STRAINER
RELIEF VALVE
3607A3HC05
When the swing control lever is operated, the pilot oil flows to SH port, this pressure move spool so,
discharged oil from pilot pump flows to PG port.
This pressure is applied to swing motor disc cylinder, thus the brake released.
When the swing control lever is set neutral position, oil in the swing motor disc cylinder is drained,
thus the brake is applied.
3-9
5. TRAVEL SPEED CONTROL PRESSURE
TRAVEL MOTOR DEVICE
Dr
Hi Hi
Lo Pr Lo
Pi Px2
3Pi dr Py2 PL
N
Pa Pb PR
Rs
4Pc
A B B A
dr1
BR1
al1
TRAVEL SPEED bl1

CHANGE OVER ar1
BL1
VALVE d SWING
AL1
br1
BOOM al2
AR1 c
bl2
ar2 a
b BL2
ARM
br2
AL2
BR2 BUCKET
(al3)
AR2
(bl3)
(BL3)
ar3 OPTION
SWING MOTOR (AL3)
br3
BR3 al4
TRAVEL
AR3 (RH) bl4
TRAVEL BL4
a (LH)
AL4
b
c Fr dr3 Py1 Pi Px1 R Fl d
RCV PEDAL
HYD
TANK
PILOT PUMP
TRAVEL SPEED SAFETY
Pk
SOLENOID VALVE SOLENOID VALVE
PG LINE
FILTER STRAINER
RELIEF VALVE
3607A3HC06
When the travel speed solenoid valve was placed in the Hi position, the pressure oil from pilot pump
through line filter flows to port(Pk) of travel speed change over valve, and the control piston is pushed
up, thus minimizing the displacement.
When the travel speed solenoid valve was placed in the Lo position, the oil of Pk port return to the
tank and the control piston is returned, thus maximizing the displacement.
3-10
6. MAX FLOW CUT OFF SYSTEM
TRAVEL MOTOR
Px2
3Pi dr Py2 PL
PR Rs
4Pc
dr1
BR1
al1
bl1
ar1
BL1
d SWING
AL1
br1
BOOM al2
AR1 c
bl2
ar2 a
b BL2
ARM
br2
AL2
BR2 BUCKET
(al3)
AR2
(bl3)
SWING MOTOR (BL3)
ar3 OPTION (AL3)
br3
BR3 al4
TRAVEL
AR3 (RH) bl4
TRAVEL BL4
a (LH)
AL4
RCV PEDAL
Pm1 Pm2
MAX FLOW CUT OFF SAFETY

SOLENOID VALVE Pm1 Pm2 SOLENOID VALVE
HYD
M
TANK
LINE
FILTER
36073HC07
When the breaker operation mode is selected on the cluster, max flow cut off solenoid valve actuates
automatically. Thus pilot pressure(Pm1, Pm2) is sent to the regulator and pump discharge volume is
decreased.
3-11
7. BOOM PRIORITY SYSTEM
TRAVEL MOTOR
SWING SELECT SPOOL

Px2
3Pi dr Py2 PL
PR Rs
4Pc
dr1
BR1
al1
bl1
ar1
BL1
d SWING
AL1
br1
BOOM al2
AR1 c
bl2
ar2 a
b BL2
ARM
br2
AL2
BR2 BUCKET
(al3)
AR2
(bl3)
SWING MOTOR (BL3)
ar3 OPTION (AL3)
br3
BR3 al4
TRAVEL
AR3 (RH) bl4
TRAVEL BL4
a (LH)
AL4
RCV PEDAL
HYD
TANK
SWING REDUCING PILOT PUMP

SOLENOID VALVE SAFETY
4Pc SOLENOID VALVE
LINE
FILTER STRAINER
RELIEF VALVE
36073HC08
When carrying out the combined operation of swing and boom or arm, the boom or arm speed can
be lowered than operating speed of swing. When the heary duty working mode in work mode is
selected on the cluster, swing reducing solenoid valve actuates automatically.
The oil from pilot pump flows into the solenoid valve through the line filter.
4Pc pressure from solenoid valve change the swing select spool and decreases the oil flow rate to
the swing section by orifice.
This is called the boom priority system.
3-12
GROUP 4 SINGLE OPERATION
1. BOOM UP OPERATION
36073HC09
When the RH control lever is pulled back, the boom spool in the main control valve is moved to the up
position by the pilot oil pressure from the remote control valve.
The oil from the rear pump through boom spool of the main control valve and front pump via logic
valve goes to the large chamber of boom cylinders.
At the same time, the oil from the small chamber of boom cylinders returns to the hydraulic oil tank
through the boom spool in the main control valve. When this happens, the boom goes up.
The excessive pressure in the boom cylinder bottom end circuit is prevented by relief valve.
When the boom is up and the control lever is returned to neutral position, the circuit for the holding
pressure at the bottom end of the boom cylinder is closed by the boom holding valve.
This prevents the hydraulic drift of boom cylinders.
3-13
2. BOOM DOWN OPERATION
TRAVEL MOTOR
Px2 BOOM HOLDING VALVE

3Pi dr Py2 PL
LOGIC VALVE
PR Rs
4Pc
dr1
BR1
al1
bl1
ar1
BL1
SWING
AL1
br1
BOOM al2
AR1 bl2
RELIEF ar2
VALVE
ARM dr2
br2
MAKE UP
4Pi
VALVE
BR2 BUCKET
(al3) BL2
AR2
(bl3) AL2
(BL3)
ar3 OPTION (AL3)
SWING MOTOR br3
BR3 al4
TRAVEL
AR3 (RH) bl4
TRAVEL BL4
a (LH)
AL4
c Fr dr3 Pi R Fl d
HYD
TANK FRONT REAR PILOT
PUMP PUMP PUMP
36073HC10
When the RH control lever is pushed forward, the boom spool in the main control valve is moved to
the down position by the pilot oil pressure from the remote control valve.
The oil from the rear pump flows into the main control valve and then goes to the small chamber of
boom cylinders. At the same time, the oil from the large chamber of boom cylinders returns to the
hydraulic tank through the boom spool in the main control valve.
When the down speed of boom is faster, the oil returned from the large chamber of boom cylinders
combines with the oil from the rear pump, and flows into the small chamber of the boom cylinders.
This prevents cylinder cavitation by the negative pressure when the rear pump flow can not match the
boom down speed. And the excessive pressure in the boom cylinder rod end circuit is prevented by
the relief valve.
3-14
3. ARM ROLL IN OPERATION
TRAVEL MOTOR
Px2 BOOM HOLDING VALVE

3Pi dr Py2 PL
LOGIC VALVE
PR Rs
4Pc
dr1
BR1
al1
bl1
ar1
BL1
SWING
AL1
br1
BOOM al2
AR1 bl2
RELIEF ar2
VALVE
ARM dr2
br2
MAKE UP
4Pi
VALVE
BR2 BUCKET
(al3) BL2
AR2
(bl3) AL2
(BL3)
ar3 OPTION (AL3)
SWING MOTOR br3
BR3 al4
TRAVEL
AR3 (RH) bl4
TRAVEL BL4
a (LH)
AL4
c Fr dr3 Pi R Fl d
HYD
PUMP PUMP PUMP
36073HC11
When the LH control lever is pulled back, the arm spool in the main control valve is moved to the roll
in position by the pilot oil pressure from the remote control valve.
The center bypass valve is blocked by pilot pressure(c) and then the oil from rear pump is joint to flow
of the front pump via confluence passage.
The oil from the front and rear pump flows into the main control valve and then goes to the large
chamber of arm cylinder.
At the same time, the oil from the small chamber of arm cylinder returns to the hydraulic oil tank
through the arm spool in the main control valve. When this happens, the arm roll in.
When the roll in speed of arm is faster, the oil returned from the small chamber of arm cylinder
combines with the oil from both pump, and flows into the large chamber of the arm cylinder by a make
up valve.
The excessive pressure in the arm cylinder bottom end circuit is prevented by relief valve.
3-15
4. ARM ROLL OUT OPERATION
TRAVEL MOTOR
Px2
3Pi dr Py2 PL
PR Rs
4Pc
dr1 ARM HOLDING VALVE

BR1
al1
bl1
ar1
BL1
SWING
AL1
br1
BOOM al2
AR1 bl2
ar2
ARM dr2
br2
4Pi
BR2 BUCKET
AR2
(bl3) AL2
(BL3) MAKE UP
ar3 OPTION (AL3) VALVE
br3 RELIEF
VALVE
BR3 al4
TRAVEL
AR3 (RH) bl4
TRAVEL BL4
a (LH)
AL4
c Fr dr3 Pi R Fl d
CENTER BYPASS
VALVE
HYD
PUMP PUMP PUMP
36073HC12
When the LH control lever is pushed forward, the arm spool in the main control valve is moved to the
roll out position by the pilot oil pressure from the remote control valve. The center bypass valve is
blocked by pilot pressure(a) and then the oil from rear pump is joint to flow of the front pump via
confluence passage. The oil from the front and rear pump flows into the main control valve and then
goes to the small chamber of arm cylinder. At the same time, the oil from the large chamber of arm
cylinder returns to the hydraulic oil tank through the arm spool in the main control valve.
When this happens, the arm roll out. The excessive pressure in the arm cylinder rod end circuit is
prevented by relief valve. When the arm is rolled out and the control lever is returned to neutral
position, the circuit for the holding pressure at the rod end of the arm cylinder is closed by the arm
holding valve. This prevents the hydraulic drift of arm cylinder.
3-16
5. BUCKET ROLL IN OPERATION
TRAVEL MOTOR
Px2
3Pi dr Py2 PL
PR Rs
4Pc
dr1
BR1
al1
bl1
ar1
BL1
SWING
AL1
RELIEF br1
VALVE BOOM al2
AR1 bl2
ar2
MAKE UP
VALVE dr2
ARM
br2
4Pi
BR2 BUCKET
AR2
(bl3) AL2
(BL3)
ar3 OPTION (AL3)
br3
BR3 CENTER BYPASS
TRAVEL al4 VALVE
AR3 (RH) bl4
TRAVEL BL4
a (LH)
AL4
c Fr dr3 Pi R Fl d
HYD
PUMP PUMP PUMP
36073HC13
When the RH control lever is pulled left, the bucket spool in the main control valve is moved to the roll
in position by the pilot oil pressure from the remote control valve.
The center bypass valve is blocked by pilot pressure(b) and then the oil from front pump is joint to
flow of the rear pump via confluence passage.
The oil from the front and rear pump flows into the main control valve and then goes to the large
chamber of bucket cylinder. At the same time, the oil from the small chamber of bucket cylinder
returns to the hydraulic oil tank through the bucket spool in the main control valve. When this
happens, the bucket roll in. The cavitation which will happen to the bottom of the bucket cylinder is
prevented by the make up valve, on other hand. The excessive pressure is also prevented by an
overload relief valve in the main control valve.
3-17
6. BUCKET ROLL OUT OPERATION
TRAVEL MOTOR
Px2
3Pi dr Py2 PL
PR Rs
4Pc
dr1
BR1
al1
bl1
ar1
BL1
SWING
RELIEF AL1
br1
VALVE BOOM al2
AR1 bl2
ar2
MAKE UP
VALVE ARM dr2
br2
4Pi
BR2 BUCKET
AR2
(bl3) AL2
(BL3)
ar3 OPTION (AL3)
br3
BR3 al4
TRAVEL
AR3 (RH) bl4
TRAVEL BL4
a (LH)
AL4
c Fr dr3 Pi R Fl d
HYD
PUMP PUMP PUMP
36073HC14
When the RH control lever is pushed right, the bucket spool in the main control valve is moved to the
roll out position by the pilot oil pressure from the remote control valve.
The oil from the rear pump flows into the main control valve and then goes to the small chamber of
bucket cylinder. At the same time the oil from the large chamber of bucket cylinder returns to the
hydraulic oil tank through the bucket spool in the main control valve. When this happens the bucket
roll out.
The cavitation which will happen to the rod of the bucket cylinder is prevented by the make-up valve,
on other hand. The excessive pressure is also prevented by an overload relief valve in the main
control valve.
3-18
7. SWING OPERATION
TRAVEL MOTOR
SWING REDUCING VALVE

Px2
3Pi dr Py2 PL
PR Rs
4Pc
dr1
BR1
al1
bl1
ar1
BL1
SWING
AL1
br1
BOOM al2
AR1 bl2
ar2
ARM dr2
br2
4Pi
BR2 BUCKET
AR2
(bl3) AL2
(BL3)
ar3 OPTION (AL3)
br3
BR3 al4
TRAVEL
AR3 (RH) bl4
TRAVEL BL4
a (LH)
AL4
c Fr dr3 Pi R Fl d
RCV PEDAL
HYD
TANK
al1 bl1 FRONT REAR PILOT

SAFETY PUMP PUMP PUMP
SOLENOID VALVE
PG LINE
FILTER STRAINER
36073HC15
When the LH control lever is pushed left or right, the swing spool in the main control valve is moved to
the left or right swing position by the pilot oil pressure from the remote control valve.
The oil from the front pump flows into the main control valve and then goes to the swing motor.
At the same time, the return oil from the swing motor returns to the hydraulic oil tank through the
swing spool in the main control valve.
When this happens, the superstructure swings to the left or right.
The swing parking brake, make up valve and the motor brake valve are provided in the swing motors.
The cavitation which will happen to the swing motor is also prevented by the make up valve in the
swing motor itself.
3-19
SWING CIRCUIT OPERATION
SWING MOTOR DEVICE
PARKING BRAKE
BRAKE OFF
SH
PG
BRAKE ON
dr5
MOTOR BRAKE VALVE
MAKE UP VALVE
B A
MAKE UP
PORT(Mu)
TO / FROM MAIN CONTROL VALVE
3607A3HC15A
1) MOTOR BRAKE VALVE

Motor brake valve for the swing motor limits to cushion the starting and stopping pressure of swing
operation.
2) MAKE UP VALVE
The make up valves prevent cavitation by supplying return oil to the vacuum side of the motor.
3) PARKING BRAKE
In case that the parking, of the machine at slope is required during operation, there is the danger of
involuntary swing caused by the self weight of the machine. The brake is connected to prevent this
involuntary swing.
PARKING BRAKE "OFF" OPERATION
The parking brake is released by the pilot pressure oil from the pilot pump.
When the RCV lever placed in the operating position, the pilot oil flows into SH port through the
MCV. This pressure transferred to the brake release valve and the brake release valve is change
over. Then the pilot oil pressure PG lift the brake piston and release the parking brake.
PARKING BRAKE "ON" OPERATION
When the control lever placed in the neutral position, the pressure of the pilot oil passage down.
Then the brake release valve returned to the neutral position and the oil is returned from the brake
piston to the tank. And the brake is set to 'ON".
3-20
8. TRAVEL FORWARD AND REVERSE OPERATION
36073HC16
When the travel levers are pushed forward or reverse position, the travel spools in the main control
valve are moved to the forward or reverse travel position by the pilot oil pressure from the remote
control valve.
The oil from the both pumps flow into the main control valve and then go to the both travel motors
through the turning joint.
The return oil from both travel motors returns to the hydraulic oil tank through the turning joint and the
travel(RH, LH) spools in the main control valve.
When this happens, the machine moves to the forward or reverse.
3-21
TRAVEL CIRCUIT OPERATION
TRAVEL MOTOR DEVICE
Dr
Lo Lo
Hi Pr Hi
Pi
A B B A
OVERLOAD RELIEF CHECK VALVE COUNTER BALANCE
VALVE VALVE
TURNING JOINT
Pk
TO/FROM MAIN CONTROL VALVE
3607A3HC16
Valves are provided on travel motors to offer the following functions.

1) CHECK VALVE
Stopping the motor, this valve sucks the oil from lower pressure passage for preventing the negative
pressure and the cavitation of the motor.
2) COUNTER BALANCE VALVE
When stopping the motor or slope descending, this valve to prevent the motor over run.
3) OVERLOAD RELIEF VALVE
Relief valve limit the circuit pressure below 335kgf/cm2 to prevent high pressure generated at a time of
stopping the machine. Stopping the motor, this valve sucks the oil from lower pressure passage for
preventing the negative pressure and the cavitation of the motor.
3-22
GROUP 5 COMBINED OPERATION
1. OUTLINE
TRAVEL MOTOR
Px2
3Pi dr Py2 PL
PR Rs
4Pc
dr1
BR1
al1
bl1
ar1
BL1
SWING
AL1
br1 al2
BOOM
AR1 bl2
ar2
ARM dr2
br2
STRAIGHT
4Pi
BUCKET TRAVEL
BR2
SWING MOTOR SPOOL
(al3) BL2
AR2
(bl3) AL2
(BL3)
ar3 OPTION (AL3)
br3
BR3 al4
TRAVEL
AR3 (RH) bl4
TRAVEL BL4
a (LH)
AL4
c Fr dr3 Pi R Fl d
HYD
PUMP PUMP PUMP
36073HC17
The oil from the front and rear pump flows through the neutral oil passage, bypass oil passage and
confluence oil passage in the main control valve. Then the oil goes to each actuator and operates
them. Check valves and orifices are located on these oil passage in the main control valve. These
control the oil from the main pumps so as to correspond to the operation of each actuator and smooth
the combined operation.
STRAIGHT TRAVEL SPOOL

This straight travel spool is provided in the main control valve.
If any actuator is operated when traveling, the straight travel spool is pushed to the right by the pilot oil
pressure(pi) from the pilot pump.
Consequently, the left and right travel oil supply passage are connected, and equivalent amount of oil
flows into the left and right travel motors. This keeps the straight travel.
3-23
2. COMBINED SWING AND BOOM OPERATION
36073HC18
When the swing and boom functions are operated, simultaneously the swing and boom spools in the
main control valve are moved to the functional position by the pilot oil pressure from the remote
control valve. The oil from the front pump flows into the swing motor through the swing spool.
The oil from the rear pump flows into the boom cylinders through the boom spool in the left control
valve.
At the same time, the pressure in the boom circuits can be high while the swing pressure is low,
therefore the oil from the front pump flows into the boom cylinders through boom spool via confluence
oil passage by logic valve in case boom up operation.
3-24
3. COMBINED SWING AND ARM OPERATION
TRAVEL MOTOR
SWING REDUCING VALVE

Px2
3Pi dr Py2 PL
PR Rs
4Pc
dr1
BR1
al1
bl1
ar1
BL1
SWING
AL1
br1
BOOM al2
AR1 bl2
ar2
ARM dr2
br2
4Pi
BR2 BUCKET
AR2
(bl3) AL2
(BL3)
ar3 OPTION (AL3)
br3
BR3 al4
TRAVEL
AR3 (RH) bl4
TRAVEL BL4
a (LH)
AL4
c Fr dr3 Pi R Fl d
CENTER BYPASS
VALVE
HYD
PUMP PUMP PUMP
36073HC19
When the swing and arm functions are operated, simultaneously the swing and arm spools in the
main control valve are moved to the functional position by the pilot oil pressure from the remote
control valve.
The oil from the front pump flows into the swing motor through the swing spool.
The center bypass valve is blocked by pilot pressure(a, c) and then the oil from the rear pump flows
into the arm cylinder through the arm spool in the right control valve.
The superstructure swings and the arm is operated.
3-25
4. COMBINED SWING AND BUCKET OPERATION
36073HC20
When the swing and bucket functions are operated, simultaneously the swing and bucket spools in
the main control valve are moved to the functional position by the pilot oil pressure from the remote
control valve. The oil from the rear pump flows into the bucket cylinder through the bucket spool in
the right control valve. The oil from the front pump flows into the swing motor through the swing spool
in the right control valve.
The superstructure swings and the bucket is operated.
3-26
5. COMBINED SWING, BOOM, ARM AND BUCKET OPERATION
36073HC21
When the swing, boom, arm and bucket functions are operated, simultaneously the each spool in the
main control valve is moved to the functional position by the pilot oil pressure from the remote control
valve. The oil from the rear pump flows into the boom cylinders and bucket cylinder through the
boom spool and bucket spool in the left control valve. The oil from the front pump flows into the swing
motor and arm cylinder through the swing spool, arm spool and the parallel oil passage in the right
control valve. Then the functions to each actuators.
According to the state of each actuators functioning, center bypass valve is blocked, the oil from front
pump flows into the boom cylinders through the confluence oil passage by logic valve in case boom
up operation.
3-27
6. COMBINED SWING AND TRAVEL OPERATION
36073HC22
When the swing and travel functions are operated, simultaneously the swing spool and travel spools
in the main control valve are moved to the functional position by the pilot oil pressure from the remote
control valve. At the same time, the straight travel spool is pushed to the right by the pilot oil
pressure(pi) from the pilot pump.
The oil from the front pump flows into the swing motor through the swing spool. The oil from the
rear pump flows into the travel motors through the RH travel spool of the left control valve and the LH
travel spool of the right control valve via the straight travel spool.
The superstructure swings and the machine travels straight.
3-28
7. COMBINED BOOM AND TRAVEL OPERATION
36073HC23
When the boom and travel functions are operated, simultaneously the boom spool and travel spools
control valve. At the same time, the straight travel spool is pushed to the right by the pilot oil
pressure(Pi) from the pilot pump. The oil from the front pump flows into the boom cylinders through
the logic valve and boom spool via the parallel and confluence oil passage in case boom up
operation. The oil from the rear pump flows into the travel motors through the RH travel spool of the
right control valve and the LH travel spool of the left control valve via the straight travel spool.
When the travel circuit pressure drops lower than boom pressure, as when traveling downhill, boom
priority and smoothness are maintained because of the orifice. Thus the machine will continue to
travel straight.
3-29
8. COMBINED ARM AND TRAVEL OPERATION
36073HC24
When the arm and travel functions are operated, simultaneously the arm spool and travel spools in
the main control valve are moved to the functional position by the pilot oil pressure from the remote
control valve. At the same time, the straight travel spool is pushed to the left by the pilot oil pressure
from the pilot pump. The oil from the front pump flows into the arm cylinder through the arm spool via
the parallel and confluence oil passage. The oil from the rear pump flows into the travel motors
through the RH travel spool of the right control valve and the LH travel spool of the left control valve
via the straight travel spool.
When the travel circuit pressure drops lower than arm pressure, as when traveling downhill, arm
priority and smoothness are maintained because of the orifice. Thus the machine will continue to
travel straight.
3-30
9. COMBINED BUCKET AND TRAVEL OPERATION
36073HC25
When the bucket and travel functions are operated, simultaneously the bucket spool and travel spools
control valve. At the same time, the straight travel spool is pushed to the left by the pilot oil pressure
from the pilot pump. The oil from the rear pump flows into the bucket cylinder through the bucket
spool. The oil from the front pump flows into the travel motors through the RH travel spool of the right
control valve and the LH travel spool of the left control valve via the straight travel spool of the control
valve.
When the travel circuit pressure drops lower than bucket pressure, as when traveling downhill, bucket
priority and smoothness are maintained because of the orifice.
In either case, the machine will continue to travel straight.
3-31
Group 1 Component Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1

Group 2 Electrical Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-3
Group 3 Electrical Component Specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-21
Group 4 Connectors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-29
GROUP 1 COMPONENT LOCATION
1. LOCATION 1
7
9
B
A
C
10
Switch 11
28 panel
12
13
14
15
16
TONE 2
5 BAL
VOL
ON
BAND
17
SEEK
push
FAD
TUNE
1
4 PROG
3
PLL
SYNTHESIZE
R
TUNNING
1
6 20A
CAB
SPARE
HOLDER
LAMP
SPARE
FUSE
CABIN
LAMP
LAMP SPARE
BEACON
WORK
F/PUMP
LAMP & HEATER FUEL
AC
HEAD 3
MOTOR SOLENOID
LAMP HONE
WIPER 2
BOOM
SOL. LIGHT
18
SOLENOID
CIGAR
& HEATER SAFETY 1
AC
PANEL - HEAT SOLENOID
MOTOR PRE
SWITCH
WIPER
RY
CUT-OFF TRAVEL
FUEL
CONVERTOR HONE
PANEL
-2
2
SWITCH RY
CR
COMP
AC RY
-7
CN-92
RY ETHER
CR
POWER - 36
CR
- 35
CR
RY
SAFETY
-5
CR
19
4 CN-47
20
8 CN-16B
21
24 CN-16&16A
25 22
26
23
27
3607A4EL01
1 Horn switch 11 Travel alarm switch 21 J1939 serial connector

2 Cluster 12 Preheat switch 22 Fuse box
3 Starting switch 13 Washer switch 23 Master switch
4 Cigar lighter 14 Wiper switch 24 Aircon & heater switch panel
5 Accel dial 15 Main light switch 25 One touch decel switch
6 Breaker operation switch 16 Speaker 26 Power max switch
7 Beacon switch 17 Cassette & radio 27 Safety lever
8 Service meter 18 Prolix resistor 28 Overload switch
9 Breaker selection switch 19 MCU(Machine control unit)
10 Cab light switch 20 RS232 serial connector
4-1
2. LOCATION 2
1
ON
OF
F
1
1
CAB BOOM
3
7
2
6
1
9
10
5
11
12
3607A4EL02
1 Lamp 5 Horn 9 Travel alarm buzzer

2 Fuel sender 6 Start relay 10 Battery relay
3 Fuel filler pump 7 Heater relay 11 Battery
4 Beacon lamp 8 Alternator 12 Air cleaner pressure switch
4-2
MEMORANDUM
4-5
GROUP 2 ELECTRICAL CIRCUIT
5W 104
3R 105
103 3L
V 2
116
105
ECM
5W 104
5W 115
FUSE BOX
74
74
POWER RY POWER RY
5R
5R
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
1
5R
5R
87a 87 85
30 86
AC COMP RY
30A
10A
30A
30A
10A
10A
10A
10A
10A
10A
10A
30A
20A
10A
20A
20A
20A
10A
20A
10A
10A
10A
10A
10A
10A
10A
30A
3
1
BATTERY
5A
CN-60
CN-95
R/DRYER
CS-74
2
1
2
HORN RY
2
1
87a 87 85
30 86
60B
FUEL WARMER(OPT)
60R
CR-35
2
1
CR-45
87a
CASSETTE RADIO
Pa
30
86
85
87
1
4
2
3
FUEL FILLER P/P
87a 87 85
30 86
CIGAR LIGHTER
SWITCH PANEL
WIPER MOTOR
BEACON LAMP
AC& HEATER
CONVERTOR
AC& HEATER
SAFETY SOL
ROOM LAMP
WORK LAMP
CN-29
12V X 2
CABIN LAMP
SOLENOID 1
SOLENOID 3
HEAD LAMP
87a
START KEY
CR-7
FUSIBLE LINK
30
86
85
3L
87
Or
PRE-HEAT
W
2
R
1
B
B
CLUSTER
CS-74
WIPER+
TRAVEL
CPU B+
87a
START
CR-2
HORN
30
86
85
G42
87
G45
18E
93A
103
CN-36
ECM
ECM
CPU
18
93
G
G
V
L
L
2
CR-1
Br
Br
106
G
106
101
Y
4A
4E
G31
2RW
85
B
GrW
GOr
ROr
RW
BW
GY
2L
Gr
Or
Gr
2L
Or
Br
Br
Br
Br
W
TO:STARTER "B" TERM.
R
Y
Y
MASTER SW
5A
9
22
98
G
5
110
100
127
109
128
54
18
99
65
56
77
78
90
15
41
10
88
87
86
97
83
20
19
8
4
5
1
BATT RY
NO. DESTINATION CN-11
2B 111
1 AC CONTROLLER GND 1
2B G61
2 BLOWER MOTOR GND 2 DO-3
2L 4 9E G
3 AC 24V 3 2
2RW 65A G32 B DIODE
4 NC 4 1
2RW 65
5 AC CONTROLLER B+ 5
G 101
6 AC COMP 6
DO-2
7 AC CONDENSOR FAN 7 9A G
R 6F 2
8 ILLUMINATION 8 92 V DIODE
1
AIR-CON DO-1
9 G
2
NO. DESTINATION CN-10 16A W DIODE
V 100 1
1 CASSETTE RADIO 24V 1
R 6E
2 ILLUMINATION 2
3 NC 3
2B G51
4 GND 4 CN-25
G3 B
5 NC 5 1
Y 99 22A G
6 CASSETTE&ROOM LAMP B+ 6 2
7 NC 7 HORN
B 112 G5 B
8 CASSETTE GND 8 1
9 NC 9 22 G
2
G 96
10 BEACON LAMP 10 CN-20
Or 89
11 CABIN LIGHT 11
12 NC 12
CABIN HARNESS CN-61

G4 B
M
1
128 GOr
2
FUEL PUMP
NO. DESTINATION CN-9
B G53
1 HORN SW 1
Y 98
2 HORN SW 2 CR-62
3 NC 3 G46 B
2 1
1
Br 81 1E Or
4 INT. SIG 4 2
B 13 95 Gr
5 ACCEL DIAL(-) 5 3
W 25 121 V
6 ACCEL DIAL(SIG) 6 4 4 3
GOr 11
7 ACCEL DIAL(+) 7 BREAKER RY
8 SPARE SW 8
CN-66
CN-8 121 V
2
1 SPARE SW 1 G12 B
1
2 SPARE SW 2
Y 97 BREAKER SOL
3 BEACON LAMP 24V 3
G 96
4 BEACON LAMP SIG 4
Or 1A
5 BRAKER SW 24V 5
Gr 95
6 BRAKER SIG 6
7 SPARE SW 7
8 SPARE SW 8
Br 17
9 START KEY (START SIG) 9
R 21 CR-13
10 START KEY (ACC) 10 G43 B
V 92 1 2 1
11 START KEY (BR) 11 88A Gr
W 18A 2
12 START KEY (COM) 12 122 R
3
CN-7 6 R
4 4 3
R 122
1 HEAD LIHGT SIG 1 HEAD LAMP RY
V 91
2 WORK LIHGT SIG 2
W 82
3 WIPER DRIVE SIG 3
CL-4
4 PRE-HEAT SW 4 G1 B
L 90 2
5 SW PANEL 24V 5 6 R
Or 89 1
6 CABIN LIGHT SIG 6
Gr 88
7 HEAD LIHGT 24V 7 HEAD LAMP
Y 87
8 WORK LIHGT 24V 8
L 79
9 WASHER SIG 9
B G54
10 GND 10
OrW 28
11 TRAVEL ALARM SIG 11
RW 86 CN-12 CL-5
12 CABIN LIGHT 24V 12 G2 B B 2 2 B
2 1
13 NC 13 91 V V 1 1 V
1 2
14 NC 14
15 NC 15 WORK LAMP
2A B
RH CONSOLE 1A V
1
CN-16B 2
B 42
CN-125 CN-125 2.5k
1
W 43 HARNESS BOOM CL-6
Y 99A 2
1 1 Gr 49
108 R R 21 3
2 2 2.5k BW 50
B 119 4
3 3 LW 62
108 R R 93 5
4 4
6
GPS CONNECTOR
CN-16
13 B B 29 CN-99
1 CD-45
25 W W 32 123 Br 2 V
2 2 A A
11 GOr GOr 30 124 V 3 G
3 1 B
35 B
C
4 WIF SENSOR B
35 B
5 CN-93
9 BW
6 3 REMOTE ACCEL ON/OFF
6 LW
CN-3 34 REMOTE ACCEL RETURN
15 ROr ROr 1 14 B
1 32 RETURN
125 RW RW 10 15 W
2 26 ACCEL POSITION SIGNAL
NO. DESTINATION CN-6 126 BOr BOr 11 16 Gr
Or 1 3 21 ACCEL POSITION SUPPLY
1 QUICK COUPLING SW 24V 1 123 Br Br 21
4 00 NC
2 QUICK COUPLING SW SIG 2 53 V V 2 2 V
LW 84 5 46 J1939(+)
3 OVERLOAD SW 3 66 G G 3 3 G
G 46 6 47 J1939(-)
4 OVERLOAD SW 4 67 SH SH 4 4 SH
GrW 10 7 37 J1939 SHIELD
5 WIPER MOTOR 24V 5 124 V V 22 10 RW
B G52 8 40 AIR-HEATER OUTPUT
6 GND 6 11 BOr
Gr 83 CN-98 42 AIR-HEATER RETURN
7 CIGARLIGHTER 24V 7 V 53A 1 ROr
R 6A A A 39 POWER IG
8 CIGARLIGHTER ILL. 8 G 66A
W 82 B 00 00
9 WIPER DRIVE SIG 9 CN-92 14A B
Br 81 B C G41 B WOr 37A 28 COOLANT LEVEL
10 INT. SIG 10
00 COOLANT LEVEL RETURN
V 80 RESISTOR
11 WASHER PUMP 11
12 NC 12 CN-94
*7 7A W
4 BATT (+)
CN-5 CR-5 7E W
L 79 127 BW 3 BATT (+)
1 WASHER SIG 1 30 19 B
17 Br 87a 87 85 2 BATT (-)
2 NC 2 86 20 B
Br 77 94 BOr 1 BATT (-)
3 CLUSTER 24V 3 87
R 110 37 WOr
4 WIPER MOTOR CONT. 4
Gr 78
85 ECM EARTH
30 86
5 CONVERTOR 24V 5 87a (BATTERY (-) TERMINAL)
WOr 61
6 HOUR METER SIG 6 ANTI-RESTART RY WIF
Or 8
7 HOUR METER 24V 7 CR-36 21 Br
SH 70 1 14 WIF SIGNAL
8 NC 8 20 L 22 V
B 113 30 2 47 WIF RETURN
9 CLUSTER GND 9 125 RW 87a 87 85
Y 68 86 CUMMINS CONNECTOR
10 CLUSTER SERIAL+ (RX) 10 107 GrW
L 69 87
11 CLUSTER SERIAL- (TX) 11 126 BOr
85
12 SHIELD 12 30 86
87a
13 NC 13
CD-31 PRE-HEAT RY
14 NC 14 84 LW
2 Pa
15 NC 15 G6 B
1 CN-2
62 LW LW 6
RH SIDE OVERLOAD PS 54 2L
1
2L 7
2 CN-28
85 V V 8 8 V
CN-22 3 1
V 80 50 BW BW 9
M 1 DO-5 4
GrW 10A 10E V
2 2 5
80A GrW AC COMP
WASHER P/P 1 6
94 BOr BOr 12
DIODE 7
8
107 GrW GrW 13
NO. DESTINATION CN-4 9
B G63 42 B B 14
1 POWER MAX SW 1 10
Y 34 43 W W 15
2 POWER MAX SW 2 11
B G62 49 Gr Gr 16
3 O/T DECEL SW 3 12
Gr 45 16 W W 17
4 O/T DECEL SW 4 13
5 NC 5 14
B G64 G81 B B 18
6 SAFETY SW (Com) 6 15
CR-23 CN-45
7 SAFETY SW (NC) 7
76 12 BOr M
8 SAFETY SW (NO) 8
G
18 B
2 M
1
LH CONSOLE B+
CN-1 CD-42 START RY
14 RW RW 1 1 RW R FROM BATT.RY
CN-68 1 3 24V STARTER
G 76 3 W G
1 2 2 SIG
R 109 47 B B 2 2 B W
2 3 1 GND CN-74
38 W W 3 15R
4
SAFETY SOL 39 Br Br 4 PUMP 1 PRESS B+ G
5
40 V
6
V 5 17 W ~3
I
CD-43 U
1A RW R GND
CN-75 3 24V
75 Br 4 Br G ALTERNATOR
2 2 SIG
41A
2A B W
117
44 Or
41
58
1 1 GND
G11
117
EPPR VLV PUMP 2 PRESS
BOr
2B
2L
G
G
L
CN-19B
B G44
CD-44
CR-46
1
CN-147
Or 59 1E RW R
3
2
4
1
2
3
4
2 3 24V
5 V G
2 SIG
2E B
2
CN-19 CN-19A
4
W
75 Br Br 48 1 GND CR-24
SH 70 1 1 15R
1
Or
3
44 Or 52 PUMP 3 PRESS 13 GrW
2 2 FUEL HEATER CN-80
15R
FUEL HEATER RY
GLOW PLUG RY GLOW PLUG
8A
32
26
34
28
14
47
16
38
39
40
31
45
36
29
30
33
12
27
55
60
63
61
58
56
48
57
37
64
51
46
53
66
67
23
68
69
73
72
71
52
OrW
GrW
WOr
WOr
BrW
BrW
GOr
GOr
ROr
YOr
BOr
RW
LOr
B G22
BW
LW
SH
YOr 26
Gr
Gr
Or
Or
Br
Br
W
W
G
R
Y
B
Y
B
L
L
51
19A
59
8E
G21
31
12A
60
53E
66E
67A
CN-51
CN-50
27
12
33
3
55
63
71
72
73
57
G23
36
GOr
3E
3A
B
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
64
19
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
Or
Or
BrW
Y
B
GrW
ROr
BrW
LOr
LW
BW
SH
1
W
2
R
B
Y
B
L
G
R
B
CN-47
WATER TEMP SENDOR
GND(PRES.SENSOR)
1
2
CN-133
CN-70
CN-137
CD-1
CN-88
TRAVEL SPEED SOL

2
1
HYD TEMP SENDOR

24V(PRES.SENSOR)
CD-2
TRAVEL ALARM SW
FUEL LEVEL SENSOR
BOOM PRIORITY SOL

1
TACHO SENSOR(+)
CN-148
CN-126
2
1
1
2
TACHO SENSOR(-)
ANTI-RESTART RY
Pa
WATER LEVEL SW
BRAKE FAIL LAMP
ENG.OIL FILTER SW
AIR CLEANER SW
ENG PREHEATER
POWER MAX SOL
TRAVEL Hi/Lo SW
PROGRAM DUMP
1
2
CD-10
CD-7
1
2
TRAVEL BUZZER
POWER MAX SW
GND (POT&DIAL)
BATTERY 24V(+)
ACCEL DIAL SIG
BKT&ARM IN PS
C
HEAVY LIFT SW
MAX FLOW SOL
A
B
OVERLOAD SIG
3
4
1
2
BRAKE FAIL PS
GND (SENSOR)
P1 PRESS SIG.
P2 PRESS SIG.
P3 PRESS SIG.
O/T DECEL SW
PUMP EPPR(+)
Pa
5V (POT&DIAL)
PRE-HEAT SW
CN-81
PUMP EPPR(-)
ACCEL ACT(+)
C
HOUR-METER
T/M OIL LAMP
ACCEL ACT(-)
WORKING PS
PARKING SW
BOOM UP PS
Pa
CAN_SHIELD
RS232 (GND)
CD-6
ENG OIL PS
GND (MAIN)
TRAVEL PS
FUEL HEAT
SERIAL-RX
ALT LEVEL
T/M OIL PS
ACCEL SW
SERIAL-TX
POWER IG
WORK PS
RS232 (+)
RESISTOR
RS232 (-)
POT-SIG
C.EARTH RS232 J1939

CAN_H
TRAVEL MAX
CAN_L
BOOM POWER AIR CLEANER SW HYD TEMP

CONNECTOR
GND
TRAVEL BZ PRIORITY MAX FLOW TRAVEL PS FUEL LEVEL

NC
NC
NC
NC
NC
NC
NC
NC
NC
CPU CONTROLLER
3607A4CI01
4-3
CN-21
OVERLOAD SW
3 1 WIPER CUT SW
INLET M/ACT MODE(D/FOOT) RESISTOR RELAY(HI) RELAY(M2) R 10
2
TEMP M/ACT MODE(VENT)
8
7
9
2
CS-53
Gr 12
2 7 2 7 5 3
1 4 1 4 BLOWER R 4A
3 M M 3 M 7 M
3
7
1
4
Lo 1
4
ML 2
MH 3
5 5 4 G 8
M
5
Hi
4
2
2
9
2A B
10
L
6
5
6
7
5
6
7
5
6
7
1
2
3
4
5
6
7
1
2
3
4
1
2
3
4
1
2
3
4
6 M 2 6
CS-50
Or
1
2
3
4
10
3
7
2
6
1
4
5
8
9
1
2
1
1
4
4
2
3
2
3
GW
WR
BW
WB
BG
BG
GB
GB
GL
YB
LR
11
LB
Y
Y
WIPER MOTOR
YBr
YW
LW
LG
YW
BG
Or
Or
Gr
RY
RY
2B
YB
G
L
B
R
L
20A
L
9A
9B
21
22
17
20
18
19
23
24
25
16
15
G1
1A
36A
26
35
27
33A
32
36
6B
6A
29
33
36
28
35
7
6
7
CN-141
G 8
FEED BACK 1
W 1 CN-17
MOTOR DRIVE SIG 2
L 9
MOTOR DRIVE- 3 1
R 10 1 W W 9
MOTOR DRIVE+ 4 2
B 2 2 B B G3
GND 5 3
GrW 3 3 GrW GrW 3
VCC 6 4
R 4 4 R R 29
CONTINUE 24V 7 5 CN-156
V 5 5 V V 11 G9 B
WASHER P/P 8 6 2
L 6 6 L L 13 1F Gr
WASHER SIG. 9 7 1
CN-11 NO. DESTINATION Br 7 7 Br Br 10
1,2 BR INT. SIG 10 8 AIR SEAT
1 1 GND(CONTROLLER) Or 11
32 2B WIPER CUT SW 11
2 2 GND(BLOWER)
6 RY N.C 12
3 3 FUSE(IG) Gr 12
10 RW FEED BACK 13 CN-6 NO. DESTINATION
33 2R
4 4 NC
WIPER MOTOR CONTROLLER
WIPER MOTOR HARNESS 4 Or
1 1 FUSE
5 5 FUSE(Battery) 2 Y
30 LW 2 2 QUICK COUPLING SOL
6 6 DPS(COMPRESSOR) 5 LW
31 LY 3 3 OVERLOAD PS
7 7 CONDENSOR FAN 6 G
5 G
8
4 4 CPU CONTROLLER
8 ILLUMINATION 3 GrW
CL-2 5 5 FUSE
AIR CON B G5 G1 B
6 6 GND
Gr 1 1 Gr
7 7 FUSE
R 8 8 R
WB 15
BW 16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
GB 10
1 8 8 ILLUMINATION
BR 2
RW 3
RW 4
5
RY 6
8
GB 9
9 W
9 SWITCH PANEL
GW
BrR
9
WR
YBr
LW
BG
BG
BG
9
BR
8
GL
YB
LG
YB
LR
LB
LY
CIGARLIGHT 10 Br
G
Y
10 10 SWITCH PANEL
1.25LgB
11 V
CN-48 11 WASHER PUMP
1.25G
11
Or 16 12 GW
10
11
12
13
14
15
16
17
18
10
11
12
13
14
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
12 12 MCU
+ -
h WOr 15 CS-52
Gr 1E
10
TEMP MOTOR ACT(+)
10
DUCT SENSOR(GND)
9
TEMP MOTOR ACT(-)
BLOWER RELAY(M1)
BLOWER RELAY(M2)
COMPRESSOR(DPS)
28
BLOWER RELAY(LO)
1
2
MODE M/ACT(FOOT)
G
INLET MOTOR(REC)
BLOWER RELAY(HI)
HOUR METER
INLET MOTOR(FRE)
MODE M/ACT(PBR)
MODE M/ACT(DEF)
REVERSE FAN SIG

9
TEMP M/ACT(PBR)
MOTOR ACT(REF)
CONDENSER FAN
DUCT SENSOR(+)
MODE M/ACT(M+)
23
RH SIDE HARNESS
MODE M/ACT(M-)
LOr
8
ILLUMINATION
CN-138 8
BATTERY(+)
BATTERY(+)
Gr 14 6 7
POWER IG
24V 24V A 2 B 24
B G6 6
DUCT GND B 7 B G8
22 5
GND
GND
SENSOR Or 5
12V C
NC
NC
NC
NC
NC
12V 1
4
DC/DC CONVERTER 3
AIRCON & HEATER CONTROLLER L 12 CN-5
2
G 28 13 L
1 1 1 SWITCH PANEL
CN-139
Or 22 ECONO SWITCH 2 2 NC
2 17 Br
B G7 3 3 FUSE
1 29 R
4 4 FUSE
14 Gr
5 5 FUSE
12V SOCKET 15 WOr
6 6 CPU CONTROLLER
16 Or
CN-56 7 7 FUSE
RR Br 17 21 SH
POWER IG(24V) 1 8 8 CPU CASE EARTH
B 18 18 B
GND 2 9 9 GND
Y 19 19 Y
CS-29
RX 3 10 10 CPU CONTROLLER
L 20 20 L
B 1 TX 4 11 11 CPU CONTROLLER
1 23 LOr
Y 2 CLUSTER 12 12 MCU
2 24 B
13 13 GND
CN-4 NO. DESTINATION
POWER MAX SW 1 B 14 14 NC
1 1 GND
CS-19 2 Y 15 15 NC
2 2 CPU CONROLLER
B 3 3 B
1 3 3 GND
Gr 4 4 Gr
2 4 4 CPU CONROLLER
5 5 NC
ONE TOUCH DECEL SW G B
6 6 GND
CS-4 6 V
Or 5 7 7 NC
B C A 7 G
V 6 8 8 SAFETY SOL
B
G 7
A C LH HARNESS
SAFETY SW
CS-20
5 Or CS-26A
B G Gr 18A CS-5
1 B 8
Gr 5A 1
2 Y 9
2
SAFETY SW BREAKER PEDAL SW

HORN SW
CS-26
Gr 18
1
Gr 5 CN-9 NO. DESTINATION
CN-24 2 8 B
BW 12 1 1 GND
2 CS-54 9 Y
Gr 11 B G2 BREAKER SW 2 2 HORN RELAY
1 9 10 10
L 7A 3 3 NC
CS-1 9 10 Br
SPEAKER-RH 8 Gr Gr 14 4 4 WIPER CONTROLLER
8 11 B
CN-23 8 5 5 CPU CONTROLLER
10
6 7 12 W
BOr 2 B 19 6 6 CPU CONTROLLER
2 6 13 GOr
Or 9 7 Or 20 7 7 CPU CONTROLLER
1 DOOR SW 5 5 14 Gr
1 8 8 NC
4
SPEAKER-LH
3 CN-8
G 15 15 G
CL-1 2 1 1 NC
8 Gr L 7 7 L
CN-27 1 1 2 2 NC
4 Y 16 Y
N.C 1 2 SPARE SW 3 3 FUSE
BW 12 6 G
S.R- 2 ROOM LAMP 4 4 BEACON LAMP
17 Or
S.R- 3 CS-23 5 5 FUSE
BOr 10 B G1 18 Gr
S.L- 4 9 10 10 6 6 BRAKER SOL
G 6A 19 B
S.L- 5 CN-10 NO. DESTINATION 9 7 7 NC
1 V 20 Or
N.C 6 1 1 FUSE 8 8 8 FUSE
R 2 2 R 8 21 Br
ILL+ 7 2 2 ILLUMINATION 6 7 9 9 SAFETY RELAY
Gr 11 2 Y 16 22 R
S.R+ 8 3 3 6 10 10 POWER RELAY
3 2B 7 23 V
S.R+ 9 4 4 GND 5 5 11 11 DIODE(DO-2)
RW 16 1 24 W
ACC 10 5 5 4 12 12 FUSE
Y 4A 4 Y
B+ 11 6 6 FUSE 3 CN-7
Or 9 G 6
S.L+ 12 7 7 2 25 R
1 1 HEAD LAMP
5 B 4 V
S.L+ 13 8 8 GND 1
B 5 2 2 WORK LAMP
GND 14 9 9 BEACON LAMP SW 26 W
6 G
3 3 WIPER CONTROLLER
10 10 BEACON SW 27 Br
CN-143 4 4 CPU CONTROLLER
7 Or 28 L
L 14 11 11 SWITCH PANNEL 5 5 FUSE
R1 1 CS-27 3 Or
Y 13 12 12 B G3 6 6 CABIN LIGHT
R2 2 10 29 Gr
9 10 7 FUSE
Gr 5A 7
CASSETTE RADIO
15 CABIN HARNESS 9 2 Y
8 8 FUSE
8 30 L
CN-144 8 9 9 WIPER CONTROLLER
6 7 G1 B
NC 1 2 10 10 GND
L 14 6 31 OrW
R1 2 7 Or 17 11 11 CPU CONTROLLER
5 5 1 R
NC 3 CL-9 1 12 12 FUSE
Y 13 7 Or 4
R2 4 2 13 13 NC
3 B 3
NC 5 1 14 14 NC
RW 16 2
G4
4A
3A
2A
1A
25
26
27
28
29
30
31
10
24V OUTPUT 6 Gr 5 15 NC
1
15
11
12
13
1 CABIN LIGHT
21
22
23
24
V 1
IG 24V INPUT 7
OrW
Or
Or
Gr
Br
Br
W
BREAKER SW
R
R
V
V
Y
Y
GOr
L
L
RH HARNESS
Br
8
W
NC
R
V
W
CL-8
B
R 2A
CN-116
ILLUMINATION 9 7A Or
CS-2
2
CN-142
1
4
5
8
2
6
3
9
10
11
12
13
14
15
16
17
NC 10 3A B
5
4
1
6
2
3
C
B
A
B 5A 1
GND 11 B
WIPER MOTOR DRIVE
+
-
S
NC 12 0, I
1
CL-7
WORK LIGHT OUT

WORK LIGHT OUT
CABIN LIGHT OUT

CABIN LIGHT OUT
WORK LIGHT 24V

WORK LIGHT 24V
CABIN LIGHT 24V

HEAD LIGHT OUT
CABIN LIGHT 24V

6
HEAD LIHGT 24V

G
REMOCON
TRAVEL ALARM
3B B M
WASHER SIG
POWER 24V
H0 I
PRE-HEAT
4
3
2
6
5
ST C BR ACC H
INT. SIG
BEACON LAMP
ACCEL DIAL
GND
START KEY SW
SWITCH PANEL
3607A4CI02
4-4
1. POWER CIRCUIT
The negative terminal of battery is grounded to the machine chassis.
When the start switch is in the OFF position, the current flows from the positive battery terminal as
shown below.
1) OPERATING FLOW
Battery Battery relay Fusible link [CN-60] Master switch [CS-74]
Fuse box [No.1] l/conn [CN-8(12)] Start switch [CS-2(1)]
Power relay [CR-35(30)] GPS connector [CN-125]
Fuse box [No.2] I/conn [CN-10(6)] Room lamp [CL-1(2)] Door switch [CS-1]
Cassette radio [CN-27(11)]
Fuse box [No.3] I/conn [CN-11(5)] AC & Heater controller[3, 4]
Relay(Hi, M2)
l/conn [CN-11(4)] AC & heater controller[10]
Fuse box [No.4] I/conn[ON-2(2)] ECM earth [CN-94(4)]
Fuse box [No.5] I/conn [CN - 5(4)] I/conn [CN -17(5)] Wiper motor controller
[CN-141(7)]
Wiper motor [CN-21(4)]
Fuse box [No.6] CPU controller [CN-50(7)]
※ I/conn : Intermediate connector
2) CHECK POINT
Engine Start switch Check point Voltage
① - GND (Battery 1EA) 10~12.5V

② - GND (Battery 2EA) 20~25V
OFF OFF
③ - GND (Battery 2EA) 20~25V
④ - GND (Fusible link) 20~25V
※ GND : Ground
4-6
CR-35
CN-27 CN-10 W
30
1 1 R 87a 87 85
N.C 86
S.R- 2 2 3L
87
S.R- 3 3 B
85
B
Y
R
R
POWER RY
S.L- 4 4 87a 30 86
S.L- 5 5
4
1
3
Y Y
N.C 6 6
CN-125
4
1
3
ILL+ 7 7
S.R+ 8 8 CN-36 FUSE BOX
R
POWER CIRCUIT
GPS CONNECTOR
S.R+ 9 9 W START KEY 30A
10
1
ACC 10 Y 10A
Y ROOM LAMP
CASSETTE RADIO
B+ 11 11 2
2R AC& HEATER 30A
S.L+ 12 12 3
V ECM 30A
S.L+ 13
4
GY
GY
Y
GND 14 GY WIPER+ 10A
CN-8 5
RW 10A
2
CPU B+
1
1
CS-1
CL-1
6
3L
3R
2 CLUSTER 10A
6 7
5 CS-2 3
ST C
10A
DOOR SW
CASSETTE RADIO
6 4 8
ROOM LAMP
CONVERTOR 10A
3 5 5 9
2
B
1 4 SWITCH PANEL 10A
BR ACC
6
R 10
3 7
H
4 CPU 10A
11
0, I
2 8
W ECM 5A
1 9 12
H0 I
START KEY SW
R R 30A
10 FUEL WARMER(OPT)
13
11 START 20A
W W 14
12
WIPER MOTOR 10A
RW 15
4-7
BATTERY(+) 3 HEAD LAMP 20A
RW 16
BATTERY(+) 4 CN-11 WORK LAMP 20A
1 17
3
CABIN LAMP 20A

REVERSE FAN SIG 2 18
10
CR-1
3 BEACON LAMP 10A
AC & HEATER CONTROLLER RW 2R 19
4 AC& HEATER 20A
2R 2RW 20
5
BATTERY RY
1 2 1 HORN 10A
R 6 21
2 CIGAR LIGHTER 10A
7
22
8
7
6
3
5
4
3
1
2
8 PRE-HEAT 10A
CN-2
5W
3 4 4 23
2
TRAVEL 10A
1 2 1 24
60R
CN-95
R SOLENOID 1 10A
2 25 2
1
20
19
10A
7E
7A
3 SAFETY SOL
26
5W
B
B
3 4 4
W
W
10A
RELAY(M2) RELAY(HI)
SOLENOID 3
CN-17 27
12V X 2
FUEL FILLER P/P 30A
1
3
4
2
1
BATTERY
CN-21 CN-5 28
ECM EARTH
CN-94
1 2 1
3
2 3 2
BATT (-)
BATT (-)
60B
BATT (+)
BATT (+)
FUSIBLE LINK
3 4 3
1
(BATTERY(-) TERMINAL)
R R R V
4 5 4 2
4 1
5 6 5
CS-74
6 M 2 6 7 6
3R
MASTER SW
8 7
2
8
WIPER MOTOR 1
CN-60
CN-141 CN-50
GY
3R
R
CONTINUE 24V 7 BATTERY 24V(+) 7
4
WIPER MOTOR CONT CPU CONTROLLER
3607A4EL03
2. STARTING CIRCUIT
1) OPERATING FLOW
Battery(+) terminal Battery relay [CR-1] Fusible link [CN-60] Master switch [CS-74]
Fuse box [No.1] I/conn [CN-8(12)] Start switch [CS-2(1)]
(1) When start key switch is in ON position
Start switch ON [CS-2(2)] I/conn [CN-8(11)] Battery relay [CR-1]
Battery relay operating (All power is supplied with the electric component)
Start switch ON [CS-2(3)] I/conn [CN-8(10)] GPS connector [CN-125(2)→(4)]
Power relay [CR-35(86)→(87)] Fuse box [No.9]
(2) When start key switch is in START position
Start switch START [CS-2(5)] I/conn [CN-8(9)] Safety relay [CR-5(86)→(87)]
l/conn [CN-2(7)] Start relay [CR-23]
2) CHECK POINT
① - GND(Battery)
② - GND(Start key)
③ - GND(Battery relay M4)
OPERATING START ④ - GND(Starter B+) 20~25V
⑤ - GND(Starter M)
⑥ - GND(Start relay)
⑦ - GND(Battery relay M8)
※ GND : Ground
4-8
CR-35
W
30
6 R 87a 87 85
CS-2 86
5
ST C
3L
6 87
BR CN-8 B
5 85
3
POWER RY
BR BR 30 86
2 87a
B
1 9
BR ACC
4
R R R
3 10
H
4
V V V
START KEY SW
0, I
2 11
W W W
1 12
H0 I
CN-36 FUSE BOX
W START KEY 30A
1
ROOM LAMP 10A
STARTING CIRCUIT
2
2
AC& HEATER 30A
3
ECM 30A
4
WIPER+ 10A
5
CPU B+ 10A
6
3L
3R
CLUSTER 10A
7
CASSETTE RADIO 10A
CN-50 8
ALTI-RESTART RELAY 11 CONVERTOR 10A
9
~3
SWITCH PANEL 10A
U
CPU CONTROLLER 10
CPU 10A
M
B W/OR 11
STARTER
ECM 5A
12
ALTERNATOR
I
B+
CN-92
GND
FUEL WARMER(OPT) 30A
BR
M
B/OR
CN-74
BW
W/OR
B+
13
CN-45
BW START 20A
14
4
87
85
86
30
W
15R
10A
87a
WIPER MOTOR
CR-5
15
5
20A
4-9
HEAD LAMP
16
WORK LAMP 20A
SAFETY RY
3
30 86
87a 87 85
17
CABIN LAMP 20A
18
CR-1 BEACON LAMP 10A
19
AC& HEATER 20A
7
CR-23
20
HORN 10A
BATTERY RY
START RY
G
V
B
G
G
W
21
B
GY
CIGAR LIGHTER 10A
22
1
1
2
2
1
2
6
2
PRE-HEAT 10A
DO-3
DO-2
DO-1
5W
23
DIODE
DIODE
DIODE
TRAVEL 10A
24
60R
1
CN-95
SOLENOID 1 10A
25 2
SAFETY SOL 10A 1
26
5W
SOLENOID 3 10A
27
12V X 2
FUEL FILLER P/P 30A

BATTERY
9
8
7
5
4
1
6
3
15
14
13
12
11
10
28
CN-2
60B
FUSIBLE LINK
2
1
CS-74
3R
MASTER SW
2
1
CN-60
CN-51
W/OR
ALTERNATOR LEVEL
3R
9
CPU CONTROLLER
3607A4EL04
3. CHARGING CIRCUIT
When the starter is activated and the engine is started, the operator releases the key switch to the ON
position.
Charging current generated by operating alternator flows into the battery through the battery relay
(CR-1).
The current also flows from alternator to each electrical component and controller through the fuse box.
1) OPERATING FLOW
(1) Warning flow
Alternator "I" terminal I/conn [CN-2(13)] CPU alternator level [CN-51(9)]
Cluster charging warning lamp(Via serial interface)
(2) Charging flow

Alternator "B+" terminal Battery relay(M8) Battery(+) terminal
Fusible link [CN-60] Master switch [CS-74]
Fuse box
2) CHECK POINT
① - GND(Battery voltage)
② - GND(Battery relay)
Run ON ③ - GND(Alternator B+ terminal) 20~30V
④ - GND(Alternator I terminal)
⑤ - GND(CPU)
※ GND : Ground
4-10
TX
RX
SERIAL-TX
GND
SERIAL-RX
CLUSTER
POWER IG(24V)
CN-5
ALTERNATOR LEVEL
1
CPU CONTROLLER
RR
2 CN-36 FUSE BOX
3 START KEY 30A
30
29
4
3
2
1
1
4
CN-50
CN-51
ROOM LAMP 10A
CN-56
5 2
L
Y
30A
L
AC& HEATER
Y
CHARGING CIRCUIT
6 3
W/OR
5
7 ECM 30A
19
20
SH SH 4
69
68
16
8 WIPER+ 10A
9 5
Y Y CPU B+ 10A
10 6
3R
L L 10A
11 CLUSTER
7
12 CASSETTE RADIO 10A
10 8
CONVERTOR 10A
11 9
12 SWITCH PANEL 10A
10
CPU 10A
11
ECM 5A
12
FUEL WARMER(OPT) 30A
13
START 20A
14
WIPER MOTOR 10A
15
HEAD LAMP 20A
16
~3
4-11
WORK LAMP 20A
U
M
17
STARTER
CABIN LAMP 20A
18
CR-1
BEACON LAMP 10A
19
ALTERNATOR
M
I
B+
GND
B+
20A
CN-45
AC& HEATER
2
CN-74
20
HORN 10A
BATTERY RY
G
W
21
W
15R
CIGAR LIGHTER 10A
4
3
22
1
2
PRE-HEAT 10A
DO-1
5W
23
DIODE
TRAVEL 10A
24
60R
1
CN-95
SOLENOID 1 10A
25 2
SAFETY SOL 10A 1
CR-23
26
SOLENOID 3 10A
5W
START RY
27
12V X 2
B
FUEL FILLER P/P 30A
GY
BATTERY
28
1
2
60B
FUSIBLE LINK
2
1
CS-74
3R
MASTER SW
9
8
7
5
4
1
6
3
15
14
13
12
11
10
CN-2
1
CN-60
3R
3607A4EL05
4. HEAD AND WORK LIGHT CIRCUIT
1) OPERATING FLOW
Fuse box (No.16) I/conn [CN-7(7)] Switch panel [CN-116(9)]
Fuse box (No.17) I/conn [CN-7(8)] Switch panel [CN-116(10,11)]
(1) Head light switch ON
Head light switch ON [CN-116(1)] l/conn [CN-7(1)] Head light relay [CR-13(3)]
Head light ON〔CL-4(1)〕
l/conn [CN-10(2)] Cassette radio illumination ON [CN-27(7)]
l/conn [CN-11(8)] AC & Heater controller illumination ON(5)
l/conn [CN-6(8)] Cigarlight [CL-2]
(2) Work light switch ON
Work light switch ON〔CN-116(2,3)〕 l/conn〔CN-7(2)〕 l/conn〔CN-12(1)〕
Work light ON〔CL-5(2), CL-6(2)〕
2) CHECK POINT
① - GND(Fuse box)
② - GND(Switch power input)
STOP ON ③ - GND(Switch power output) 20~25V
④ - GND(Head light)
⑤ - GND(Head light relay)
⑥ - GND(Fuse box)
⑦ - GND(Switch power input)
STOP ON 20~25V
⑧ - GND(Switch power output)
⑨ - GND(Work light)
※ GND : Ground
4-12
CN-11
1
GND 1 CN-36
2
GND 2 START KEY 30A
3
BATTERY(+) 3
1
4 ROOM LAMP 10A
S.L-
S.L-
ILL+
S.R-
S.R-
S.L+
S.L+
B+
4
N.C
N.C
BATTERY(+) 2
S.R+
S.R+
ACC
GND
G 5 30A
ILLUMINATION 5 AC& HEATER
6 3
8
9
7
6
5
4
3
2
1
POWER IG 6 ECM 30A
14
13
12
11
10
7 4
CN-27
NC 7 R
WIPER+ 10A
CASSETTE RADIO
8
R
DUCT SENSOR(+) 8 5
CPU B+ 10A
DUCT SENSOR(GND) 9 6
REVERSE FAN SIG 10 CLUSTER 10A
7
NC 11 10A
CN-10 CASSETTE RADIO
NC 12 8
1 CONVERTOR 10A
NC 13 R 9
AC & HEATER CONTROLLER

2 10A
NC 14 SWITCH PANEL
3 10
CPU 10A
4 11
5 ECM 5A
12
6 FUEL WARMER(OPT) 30A
7 13
20A
1
START
8 14
9 WIPER MOTOR 10A
15
HEAD AND WORK LIGHT CIRCUIT
10 GY HEAD LAMP 20A

16
11
Y WORK LAMP 20A
12 17
3
CABIN LAMP 20A
18
BEACON LAMP 10A
CN-116 19
6
R
HEAD LIGHT OUT 1 AC& HEATER 20A
R 20
WORK LIGHT OUT 2 CN-7 HORN 10A
R R 21
WORK LIGHT OUT 3 1
V CIGAR LIGHTER 10A
4-13
WIPER MOTOR DRIVE 4 2 22
8
PRE-HEAT 10A
PRE-HEAT 5 3 23
POWER 24V 6 4 TRAVEL 10A
24
2
CABIN LIGHT OUT 7 5 10A
SOLENOID 1
CABIN LIGHT OUT 8 6 25
GY GY SAFETY SOL 10A
HEAD LIHGT 24V 9 7 26
Y Y
WORK LIGHT 24V 10 8 SOLENOID 3 10A
Y 27
WORK LIGHT 24V 11 9 FUEL FILLER P/P 30A
SWITCH PANEL
WASHER SIG 12 10
28
GND 13 11
B
V
7
9
TRAVEL ALARM 14 12 FUSE BOX

INT. SIG 15
CABIN LIGHT 24V 16
1
2
CABIN LIGHT 24V 17

CN-12
CN-6
1
2
5
3
4
CL-2 5
6
4
R
R
V
B
V
B
7
B
Gr
R R
8
3
2
4
1
1
2
1
2
1
2
CIGAR LIGHT
CL-4
CL-6
CL-5
CR-13
10
2
11
12
1
3
HEAD LAMP
WORK LAMP
HEAD LAMP RY
3607A4EL06
5. BEACON LAMP AND CAB LIGHT CIRCUIT
1) OPERATING FLOW
Fuse box (No.19) I/conn [CN-8(3)] Beacon lamp switch [CN-23(6)]
Fuse box (No.18) I/conn [CN-7(12)] Switch panel [CN-116(16, 17)]
(1) Beacon lamp switch ON
Beacon lamp switch ON [CS-23(2)] Switch lndicator lamp ON [CS-23(9)]
l/conn [CN-8(4)] l/conn [CN-10(10)]
Beacon lamp ON [CL-7]
(2) Cab light switch ON
Cab light switch ON [CN-116(7, 8)] I/conn [CN-7(6)] I/conn [CN-10(11)]
Cab light ON [CL-8(2), CL-9(2)]
2) CHECK POINT
① - GND(Fuse box)
STOP ON 20~25V
③ - GND(Switch power output)
④ - GND(Beacon lamp)
⑤ - GND(Fuse box)
⑥ - GND(Switch power input)
STOP ON 20~25V
⑦ - GND(Switch power output)
⑧ - GND(Cab light)
※ GND : Ground
4-14
CN-116
HEAD LIGHT OUT 1 CN-7
WORK LIGHT OUT 2 1
WORK LIGHT OUT 3 2
WIPER MOTOR DRIVE 4 3
7
PRE-HEAT 5 4
POWER 24V 6 5
CN-36
OR OR
CABIN LIGHT OUT 7 6 START KEY 30A
OR 1
CABIN LIGHT OUT 8 7 ROOM LAMP 10A
HEAD LIHGT 24V
2
9 8
AC& HEATER 30A
WORK LIGHT 24V 10 9 3
ECM 30A
WORK LIGHT 24V 11 10 4
SWITCH PANEL
WASHER SIG 12 11 WIPER+ 10A
R 5
GND 13 12 10A
CPU B+
6
TRAVEL ALARM 14 6
CLUSTER 10A
INT. SIG 15 CN-10 7
R CASSETTE RADIO 10A
CABIN LIGHT 24V 16 1
R 8
CABIN LIGHT 24V 17 2 CONVERTOR 10A
3
9
SWITCH PANEL 10A
4 10
5 CPU 10A
11
6 ECM 5A
12
7 30A
FUEL WARMER(OPT)
8 13
START 20A
9 14
BEACON LAMP AND CAB LIGHT CIRCUIT
G
10 WIPER MOTOR 10A
OR 15
11 20A
HEAD LAMP
5
12 16
WORK LAMP 20A
4-15
4
17
8
R CABIN LAMP 20A
G
B
B
B
18
OR
OR
Y BEACON LAMP 10A
19
1
2
8
7
2
1
20A
2
AC& HEATER
CL-7
CL-9
20
CL-8
HORN 10A
21
M
1
CIGAR LIGHTER 10A
CAB LIGHT
CAB LIGHT
22
5
6
10
PRE-HEAT 10A
23
BEACON LAMP
3
7
9
2
6
1
4
5
8
10
TRAVEL 10A
24
CS-23
BEACON LAMP SW
SOLENOID 1 10A
Y
B
G
G
25
SAFETY SOL 10A
26
SOLENOID 3 10A
CN-8 27
3
2
1 FUEL FILLER P/P 30A
28
2
Y
3
G FUSE BOX
4
5
6
7
8
9
10
11
12
3607A4EL07
6. WIPER AND WASHER CIRCUIT
1) OPERATING FLOW
(1) Key switch ON
Fuse box (No.10) I/conn [CN-7(5)] Switch panel [CN-116(6)]
Fuse box (No.5) I/conn [CN-5(4)] I/conn [CN-17(5)] Wiper motor controller [CN-141(7)]
Wiper motor [CN-21(4)]
Fuse box (No.15) I/conn [CN-6(5)] l/conn [CN-17(4)] Wiper motor controller [CN-141(6)]
Washer pump [CN-22(2)]
(2) Wiper switch ON : 1st step(Intermittent)
Wiper switch ON [CN-116(15)] I/conn [CN-9(4)] I/conn [CN-6(10)] I/conn [CN-17(8)]
Wiper motor controller [CN-141(10)→(3)] Wiper motor intermittently operating [CN-21(6)]
(3) Wiper switch ON : 2nd step(Low speed)
Wiper motor controller [CN-141(2)→(4)] Wiper motor operating [CN-21(2)]
(4) Washer switch ON
Washer switch ON [CN-116(12)] I/conn [CN-7(9)] I/conn [CN-5(1)] I/conn [CN-17(7)]
Wiper motor controller [CN-141(9)→(8)] I/conn [CN-17(6)] I/conn [CN-6(11)]
Washer pump [CN-22(1)] Washer operating
Wiper motor controller [CN-141(2)→(4)] Wiper motor operating [CN-21(2)]
(5) Auto parking(When switch OFF)
Switch OFF [CN-116(4)] Wiper motor parking position by wiper motor controller
2) CHECK POINT
① - GND(Fuse box)
24V
③ - GND(Switch power output)

STOP ON 0~5V
④ - GND(Wiper Power input)
⑤ - GND(Wiper power output)

24V
⑥ - GND(Wiper motor)
※ GND : Ground
4-16
CN-9
1
2
3 CN-36
BR 30A
4 START KEY
1
5 ROOM LAMP 10A
2
6 30A
1
AC& HEATER
7 3
CN-116 ECM 30A
8 4
3
HEAD LIGHT OUT 1 V WIPER+ 10A
5
WORK LIGHT OUT 2
CPU B+ 10A
WORK LIGHT OUT 3 CN-7 6
W 10A
WIPER MOTOR DRIVE
CLUSTER
4 1 7
10A
1
PRE-HEAT 5 2 CASSETTE RADIO
L W 8
POWER 24V 6 3 CONVERTOR 10A
CABIN LIGHT OUT 7 9
4
L L SWITCH PANEL 10A
CABIN LIGHT OUT 8 5 10
HEAD LIHGT 24V 9 CPU 10A
6
2
11
WORK LIGHT 24V 10 7 ECM 5A
12
WIPER AND WASHER CIRCUIT
WORK LIGHT 24V 11 8 30A
SWITCH PANEL
L L FUEL WARMER(OPT)
WASHER SIG 12 9 13
START 20A
GND 13 10 14
3
TRAVEL ALARM 14 11 GY/W WIPER MOTOR 10A
BR 15
INT. SIG 15 12 HEAD LAMP 20A
WORK LAMP 20A
1
CABIN LAMP 20A
3
18
CN-5 BEACON LAMP 10A
L
1 19
AC& HEATER 20A
2 20
4-17
CS-53
OR 3 HORN 10A
6
V 21
CN-21 4 CIGAR LIGHTER 10A
1 22
3 5
R PRE-HEAT 10A
2 6 23
GY 10A
5 3 7
TRAVEL
R 24
4 8 SOLENOID 1 10A
WIPER CUT SW
4 G 25
5 9
L SAFETY SOL 10A
6 M 2 6 10 26
WIPER MOTOR
SOLENOID 3 10A
11 27
12 FUEL FILLER P/P 30A
4
28
CN-141
G
FEED BACK 1 CN-6 FUSE BOX
W
MOTOR DRIVE SIG 2 CN-17 1
L
MOTOR DRIVE- 3 1 2
R W W
MOTOR DRIVE+ 4 2 3
B B B
GND 5 3 4
GY/W GY/W GY/W GY/W
VCC 6 4 5
R R R
CONTINUE 24V 7 5
V
6
V V V
GY/W
WASHER P/P 8 6 7
L L L
WASHER SIG. 9 7 8
2
BR BR BR BR
INT. SIG 10 8 9
CN-22
OR BR
M
WIPER CUT SW 11 10
V
N.C 12 11
WIPER MOTOR CONTROLLER

GY
12
WASHER PUMP
FEED BACK 13
3607A4EL08
-
+
S
ACCEL DIAL
A
B
C
CN-142
B
W
G/OR
5
4
3
1
8
7
6
2
CN-9
CN-36
START KEY 30A
1
ROOM LAMP 10A
CONTROLLER CIRCUIT
2
AC& HEATER 30A
3
6
5
4
3
2
1
ECM 30A
CN-16
4
WIPER+ 10A
5
B
W
G/OR
CN-51 56 GY CPU B+ 10A
B 6
GND (POT&DIAL) 20 10A
G/OR CLUSTER
5V (POT&DIAL) 21 7
CASSETTE RADIO 10A
POT-SIG 22 8
W
ACCEL DIAL SIG 23 CONVERTOR 10A
9
FUEL LEVEL SENSOR 24 SWITCH PANEL 10A
25
10
TACHO SENSOR(-)
8 OR CPU 10A
TACHO SENSOR(+) 26 11
32 ECM 5A
NC 12
WATER TEMP SENDOR 33 FUEL WARMER(OPT) 30A
13
HYD TEMP SENDOR 34 20A
START
4-18
14
CN-50 WIPER MOTOR 10A
FUEL HEAT 6 15
GR HEAD LAMP 20A
BATTERY 24V(+) 7 16
BR
PUMP EPPR(-) 8 WORK LAMP 20A
CPU CONTROLLER
17
NC 9 20A
CABIN LAMP
10 18
PROGRAM DUMP
BEACON LAMP 10A
ANTI-RESTART RY 11 19
12 AC& HEATER 20A
ACCEL ACT(+) 20
ACCEL ACT(-) 23 HORN 10A
OR 21
POWER IG 24
CIGAR LIGHTER 10A
GND (MAIN) 28 22
PRE-HEAT 10A
SERIAL-TX 29 23
SERIAL-RX 30 TRAVEL 10A
24
GND 31 SOLENOID 1 10A
RS232 (+) 32 25
SAFETY SOL 10A
RS232 (-) 33 26
10A
1
2
RS232 (GND) 34 SOLENOID 3
27
NC 35 FUEL FILLER P/P 30A
Or 28
1
1
2
2
PUMP EPPR(+) 36
CN-19B
CN-19 CN-19A
FUSE BOX
B
Or
Br
Or
Br
Or
1
2
CN-47
OR 8E
CN-75
1
EPPR VLV
OR 59
2
RESISTOR
3607A4EL09
1
2
8
7
9
B
SIG
SIG
SIG
24V
24V
24V
GND
GND
GND
CS-26
A
CS-26A
C
2
1
R
G
2
1
2
1
R
R
G
G
W
2
1
W
W
5
6
CS-29
CS-19
SAFETY SW
10
POWER MAX
A
B
C
BREAKER SW
BREAKER SW
1
2
3
1
2
3
1
2
3
Y
B
PUMP2 PRESS
PUMP3 PRESS
B
PUMP1 PRESS
Gr
Gr
Gr
Gr
GR
3
9
2
1
4
5
8
CS-4
6
7
10
CD-44
CD-43
CD-42
CS-27
V
G
OR
ONE TOUCH DECEL
B
B
B
V
BR
W
B
RW
RW
RW
BREAKER PEDAL SW
GR
OR
GR
OR
CD-6
BR/W
1
PS
Pa B
2
TRAVEL
CS-20
SAFETY SW
B
CD-7
B
ELECTRIC CIRCUIT FOR HYDRAULIC
PS
Pa Y
2
WORK
V
B
B
Y
B
G
GR
CS-50
OR
1
G
6
4
1
8
7
5
2
2
CN-4
CD-2 3
V
W
B R/W
BR
4
C
B
B
Y
B
1
GR
L/W B 1
2 5 5
FUEL
L/W 7
LEVEL
3
6
4
1
5
2
6
OVERLOAD SW
CN-1
CD-1 2
B 7 6
o 8
C 1 8
B
R/OR V
W
HYD
OR
BR
2
R/W
TEMP
GY 10 9
10
CN-51
Y/OR
WORKING PS 1
Y
POWER MAX SW 2
TRAVEL ALARM SW 3
ENG OIL PS 4
NC 5
BOOM UP PS 6
R/W
24V(PRES.SENSOR) 7
B
GND(PRES.SENSOR) 8
ALT LEVEL 9
W
P1 PRESS SIG. 10
BR
P2 PRESS SIG. 11
V
P3 PRESS SIG. 12
BR/W
TRAVEL PS 13
GR
O/T DECEL SW 14
WATER LEVEL SW 15
AIR CLEANER SW 16
HEAVY LIFT SW 17
BKT & ARM IN PS 18
TRAVEL Hi/Lo SW 19
GND (POT & DIAL) 20
5V (POT&DIAL) 21
POT-SIG 22
ACCEL DIAL SIG 23
L/W
FUEL LEVEL SENSOR 24
G
B
GY
OR
TACHO SENSOR(-)
LW
CY
25
TACHO SENSOR(+) 26
BRAKE FAIL PS 27
2
2
5
4
1
9
8
7
5
9
8
7
6
4
1
6
3
12
11
10
12
11
10
CN-8
4-19
CN-6
T/M OIL PS 28
ACCEL SW 29
B
G
LW
CY
GY
OR
NC 30
B
GND (SENSOR) 31
NC 32
WATER TEMP SENDOR 33 CN-36
R/OR
HYD TEMP SENDOR 34 START KEY 30A
NC 35 1
ROOM LAMP 10A
NC 36 2
AC& HEATER 30A
CN-50 3
GR/W ECM 30A
BOOM PRIORITY SOL 1 4
BR/W WIPER+
MAX FLOW SOL 2 10A
L/OR 5
POWER MAX SOL 3 CPU B+ 10A
6
CPU CONTROLLER
HOUR-METER 4
CLUSTER 10A
ENG PREHEATER 5 7
CASSETTE RADIO 10A
FUEL HEAT 6 8
BATTERY 24V(+) 7 CONVERTOR 10A
9
PUMP EPPR(-) 8 SWITCH PANEL 10A
NC 9 10
CPU 10A
PROGRAM DUMP 10 11
ANTI-RESTART RY 11 ECM 5A
12
ACCEL ACT(+) 12 FUEL WARMER(OPT) 30A
W 13
TRAVEL SPEED SOL 13
START 20A
T/M OIL LAMP 14 14
WIPER MOTOR 10A
BRAKE FAIL LAMP 15
G/OR 15
TRAVEL BUZZER 16 HEAD LAMP 20A
16
PRE-HEAT SW 17 WORK LAMP 20A
NC 18 17
CABIN LAMP 20A
PARKING SW 19 18
G
OVERLOAD SIG 20 BEACON LAMP 10A
19
ENG.OIL FILTER SW 21 AC & HEATER 20A
NC 20
22
HORN 10A
ACCEL ACT(-) 23 21
POWER IG GY CIGAR LIGHTER 10A
24 22
CAN_H 25 PRE-HEAT 10A
23
CAN_L 26 TRAVEL 10A
Y
CAN_SHIELD 27 24
R SOLENOID 1 10A
GND (MAIN) 28 25
SERIAL-TX 29 R SAFETY SOL 10A
26
SERIAL-RX 30 OR SOLENOID 3 10A
GND 27
31
FUEL FILLER P/P 30A
RS232 (+) 32 28
FUSE BOX
RS232 (-) 33
RS232 (GND) 34
NC 35
PUMP EPPR(+) 36
CN-70
W
1
Y
2
CN-133
GR/W
V
B
Gr
Or
1
R
TRAVEL BOOM
2
R
G
Y
1
3
2
G/OR
B
L/W
CN-88
GY
CN-62
L/OR
1
1
2
4
2
1
2
2
1
R
1
2
PRIORITY1 MAX
2
CN-81
CN-68
CD-31
1
POWER
CN-66
BREAKER RY
CN-137
Pa
BR/W
1
TRAVEL BZ
SAFETY SOL
R
BREAKER SOL
MAX
2
OVERLOAD PS
FLOW
3607A4EL10
Pa
h
CD-10
TX
RX
GND
CLUSTER
-
+
CN-48
L
B
POWER IG(24V)
HOUR METER
OR
MONITORING CIRCUIT
W/OR
RR
AIR CLEANER PRESSURE SW

4
3
2
1
CN-56
L
Y
B
BR
CD-2
B
1
LW
FUEL
2
LEVEL
CN-51
WORKING PS 1
POWER MAX SW 2
TRAVEL ALARM SW 3
ENG OIL PS 4
NC 5
BOOM UP PS 6
24V(PRES.SENSOR) 7
GND(PRES.SENSOR) 8
ALT LEVEL 9
P1 PRESS SIG. 10
P2 PRESS SIG. 11
P3 PRESS SIG. 12
TRAVEL PS 13
O/T DECEL SW 14
WATER LEVEL SW 15
L
AIR CLEANER SW 16
HEAVY LIFT SW 17
BKT & ARM IN PS 18
TRAVEL Hi/Lo SW 19
GND (POT&DIAL) 20
5V (POT&DIAL) 21
POT-SIG 22
L
Y
B
SH
OR
BR
CPU CONTROLLER
W/OR
ACCEL DIAL SIG 23

L/W
FUEL LEVEL SENSOR 24
TACHO SENSOR(-) 25
2
5
4
1
9
8
7
6
3
12
11
10
CN-5
TACHO SENSOR(+) 26
BRAKE FAIL PS 27
L
T/M OIL PS
Y
B
28
BR
OR
SH
W/OR
ACCEL SW 29
NC 30
CN-36
B
GND (SENSOR) 31 START KEY 30A
1
NC 32 ROOM LAMP 10A
WATER TEMP SENDOR 33 2
AC& HEATER 30A
HYD TEMP SENDOR 34 3
NC 35 ECM 30A
4
NC 36 WIPER+ 10A
5
4-20
CN-50 CPU B+ 10A
6
BOOM PRIORITY SOL 1 CLUSTER 10A
MAX FLOW SOL 2 7
CASSETTE RADIO 10A
POWER MAX SOL 3 8
W/OR
HOUR-METER 4 CONVERTOR 10A
9
ENG PREHEATER 5 SWITCH PANEL 10A
FUEL HEAT 6 10
CPU 10A
BATTERY 24V(+) 7 11
PUMP EPPR(-) 8 ECM 5A
12
NC 9 FUEL WARMER(OPT) 30A
B/W
PROGRAM DUMP 10 13
START 20A
ANTI-RESTART RY 11 14
ACCEL ACT(+) 12 WIPER MOTOR 10A
15
TRAVEL SPEED SOL 13 HEAD LAMP 20A
T/M OIL LAMP 14 16
WORK LAMP 20A
BRAKE FAIL LAMP 15
A
17
B
TRAVEL BUZZER 16 CABIN LAMP 20A

CN-98
18
PRE-HEAT SW 17 BEACON LAMP 10A
A
B
C
NC 18 19
RESISTOR
AC & HEATER 20A

PARKING SW 19 20
V
G
OVERLOAD SIG 20 HORN 10A

21
ENG.OIL FILTER SW 21 CIGAR LIGHTER 10A
NC 22
22
PRE-HEAT 10A
ACCEL ACT(-) 23 23
POWER IG 24 TRAVEL 10A
V 24
CAN_H 25 SOLENOID 1 10A
G
CAN_L 25
26
SH SAFETY SOL 10A
CAN_SHIELD 27 26
GND (MAIN) SOLENOID 3 10A
28
Y 27
SERIAL-TX 29 FUEL FILLER P/P 30A
L 28
SERIAL-RX 30
FUSE BOX
GND 31
R
RS232 (+) 32
G
RS232 (-) 33
V
G
B
SH
RS232 (GND) 34
NC 35
PUMP EPPR(+) 36
5
3
4
1
8
7
6
2
CN-3
V
G
SH
CN-126
B
1
G
2 CN-99
R
RS232
3 C A
B/W G
4 B
V
A B
CONNECTOR
RESISTOR
V
G
CN-148
SH
V
A
G
B
37
47
46
SH
J1939
C
SHIELD
J1939(-)
J1939(+)
ENGINE CONTROLLER
3607A4EL11
GROUP 3 ELECTRICAL COMPONENT SPECIFICATION
Part name Symbol Specifications Check
※ Check specific gravity

12V × 160Ah 1.280 over : Over charged
Battery
(2EA) 1.280 ~ 1.250 : Normal
1.250 below : Recharging
Rated load : ※ Check coil resistance(M4 to M4)

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

Start key B-ACC : 24V 10A
B-ST : 24V 40A ON : 0Ω(For terminal 1-3 and 1-2)
I I OH START : 0Ω(For terminal 1-5)
6
5
3
2
CS AC B H
Pressure
switch 1 10kgf/cm2 ※ Check contact
(Travel,
Pa (N.C TYPE)
2 Normal : 0.1Ω
working)
CD-6 CD-7
Pressure 2
Pa 3~6kgf/cm2 ※ Check contact
switch 1 (N.O TYPE) Normal : ∞Ω
(For overload)
CD-31
4-21
C 1 ※ Check resistance
Temperature
50。C : 804Ω
sensor -
(Hydraulic)
2 80。C : 310Ω
100。C : 180Ω
CD-8
CD-1
※ Check contact
Air cleaner Pa - High level : ∞Ω
pressure switch
Low level : 0Ω
CD-10
※ Check resistance
Full : 50Ω 6/12 : 350Ω
2 11/12 : 100Ω 5/12 : 400Ω
10/12 : 150Ω 4/12 : 450Ω
Fuel sender -
1 9/12 : 200Ω 3/12 : 500Ω
8/12 : 250Ω 2/12 : 550Ω
CD-2 7/12 : 300Ω 1/12 : 600Ω
Empty warning : 700Ω
3 4 4
3
Normal : About 200Ω
2
Relay 24V 20A (For terminal 1-3)
1 2 1 0Ω
CR-13,
CR-46CR-45 (For terminal 2-4)
CR-46, CR-62
30
86
87a 87 85 ※ Check resistance
87 Normal : About 160 Ω
Relay 85
30 86
24V 16A (For terminal 85-86)
87a
0Ω(For terminal 30-87a)
CR-2 CR-5 CR-7 ∞Ω(For terminal 30-87)
CR-35 CR-36
1
Solenoid valve 2 24V 1A Normal : 15~25Ω
(For terminal 1-2)
CN-66 CN-68 CN-70
CN-88 CN-133 CN-137
4-22
2
EPPR valve 700mA Normal : 15~25Ω
1 (For terminal 1-2)
CN-75
1
※Check resistance
Resistor 45Ω 20W±5%
Normal : 45Ω
2
CN-47
1
※Check resistance
Speaker 2 20W
Normal : 4Ω
CN-23(LH)
CN-24(RH)
10 9 8 7 6 5 4 3 2 1 ※Check contact
10 6 5 Normal
Switch ON : 0 Ω(For terminal 1-5, 2-6)
24V 8A
(Locking type) ∞ Ω (For terminal 5-7, 6-8)
9 8 2 7 1 OFF : ∞ Ω (For terminal 1-5, 2-6)
CS-23 CS-27 CS-50 0 Ω (For terminal 5-7, 6-8)
CS-52 CS-54
※ Check resist
Normal : About 5kΩ
A + (For terminal A-C)
Accel dial - ※ Check voltage
B S
Normal : About 5V
C -
(For terminal A-C)
CN-142 : 2~4.5V
(For terminal C-B)
2
Head lamp,
24V 70W ※ Check disconnection
Work lamp,
1 (H3 Type) Normal : 1.2 Ω
Cab lamp
CL-4 CL-5
CL-6 CL-8 CL-9
4-23
2
※ Check disconnection
Room lamp 24V 10W
1 Normal : A few Ω
CL-1
21V 70W ※Check disconnection

Beacon lamp M (H1 type) Normal : 1.1 Ω
CL-7
-
1 M
24V 10A ※Check resistance
Fuel filler pump 2 35ℓ /min Normal : 1.0Ω
CN-61
※Check operation
1
Supply power(24V) to terminal No.2
Hour meter h 16~32V
and connect terminal No.1 and
2
ground
CN-48
※Check operation
DC22~28V
Horn Supply power(24V) to each terminal
2A
and connect ground.
CN-20
CN- 20,CN-25
CN - 25
2 3 ※Check contact
1
Normal : 0Ω(For terminal 1-2)
24V 15A
Safety switch 1 2 ∞Ω(For terminal 1-3)
(N.C TYPE)
3
Operating : ∞Ω(For terminal 1-2)
1
0Ω(For terminal 1-3)
CS-4
4-24
Safety switch 2, 24V ※Check contact

wiper cut switch (N.C TYPE) Normal : 0Ω(One pin to ground)
CS-20
CS-53
1
P ※Check contact
Receiver dryer 24V 2.5A
2 Normal : ∞Ω
CN-29
N.C 1
2
S.R- 3
4
S.L- 5
N.C 6
7
※Check voltage
8
Cassette radio S.R+ 9 24V 2A 20~25V
10
11
12
(For terminal 10-14, 11-14)
S.L+ 13
14
CN-27
※Check contact
Washer pump 24V 3.8A
Normal : 10.7Ω(For terminal 1-2)
CN-22
3 1
2
5 3
4
4
※Check disconnection
Wiper motor 5 24V 2A
6 2 6
Normal : 7Ω(For terminal 2-6)
M
CN-21
A 24V
DC/DC 24V 24V(A-B)
B GND 12V 3A
Converter 12V(B-C)
C 12V 12V
CN-138
4-25
※Check coil resistance

Normal : About 1MΩ
Cigar lighter 24V 5A 1.4W ※Check contact
Normal : ∞Ω
Operating time : 5~15sec
CL-2
B G
※Check contact
3 Delco Remy
Alternator Normal : 0Ω(For terminal B+-I)
I 24V 55A
U Normal : 24~27.5V
GND
CN-74
B
M
Denso ※Check contact
Starter
24V 7.5kW Normal : 0.1Ω
M
CN-45
Travel alarm 1 ※Check contact

24V 0.5A
buzzer Normal : 5.2Ω
2
CN-81
1
Aircon ※Check contact
24V 79W
compressor Normal : 13.4Ω
CN-28
※Check contact
Start relay 24V 300A
CR-23
4-26
1 M ※Check resistance
Blower motor 24V 9.5A
2
1 Lo 1 ※Check resistance
2 MH 3 Normal : 1.12Ω(For terminal 4-2)
Aircon resistor -
3 ML 2 2.07Ω(For terminal 2-3)
4 Hi 4 3.17Ω(For terminal 3-1)
※Check resistance
2 1。C OFF Normal : 0Ω(For terminal 1-2),
Duct sensor
1 4。C ON the atmosphere temp :
Over 4。C
※Check resistance
Door switch 24V 2W
Normal : About 5MΩ
CS-1
CS-1
※Check disconnection
2
normal : 0Ω
Fusible link 60A
(Connect ring terminal and check
1
resist between terminal 1 and 2)
CN-60 CN95
Switch
(Power max, 1
※Check resistance
one touch 24V 6A
2 Normal : ∞Ω
decel, breaker,
horn) CS-5 CS-19 CS-26
CS-26A CS-29
4-27
3 24V
Transducer 2 SIG
0bar : 1V(For terminal 1-2)
500bar
(Pump 1, 2) 1
GND
CD-42 CD-43
3 24V
Transducer 2
SIG 50bar
(Pump 3) 50bar : 5V(For terminal 1-2)
1 GND
CD-44
※ Check contact
Glow plug 24V 200A Normal : 0.94Ω
relay
(For terminal 1-GND)
CR-24
Glow plug 24V 200A
0.25 ~ 0.12Ω
CN-80
C A
B ※Check resistance A-B

Resistor 4W
A B 120Ω
CN-98 CN-99
4-28
GROUP 4 CONNECTORS
1. CONNECTOR DESTINATION
Connector No. of Connector part No.
number Type Destination
pin Female Male
CN-1 Econoseal J 6 I/conn(Engine harness-Frame harness) S816-006002 S816-106002
CN-2 AMP 15 I/conn(Engine harness-Frame harness) 2-85262-1 368301-1
CN-3 Econoseal J 8 I/conn(Engine harness-Frame harness) S816-008002 S816-108002
CN-4 Econoseal J 8 I/conn(LH console harness-Frame harness) S816-008002 S816-108002
CN-5 AMP 15 I/conn(Side harness RH-Frame harness) 2-85262-1 368301-1
CN-6 Econoseal J 12 I/conn(Side harness RH-Frame harness) S816-012002 S816-112002
CN-7 AMP 15 I/conn(Console harness RH-Frame harness) 2-85262-1 368301-1
CN-8 Econoseal J 12 I/conn(Console harness RH-Frame harness) S816-012002 S816-112002
CN-9 Econoseal J 8 I/conn(Console harness RH-Frame harness) S816-008002 S816-108002
CN-10 DEUTSCH 12 I/conn(Cab harness-Frame harness) DT06-12S DT04-12P
CN-11 DEUTSCH 8 I/conn(Frame harness-Aircon harness) DT06-8S DT04-08P
CN-12 DEUTSCH 2 I/conn(Frame harness-Boom harness) DT06-2S-EP06 DT04-2P
CN-16 AMP 6 Emergency engine speed control S816-006002 S816-106002
CN-17 DEUTSCH 8 I/conn(Wiper harness) DT06-8S DT04-8P
CN-19 AMP 2 Emergency CPU controller S816-002002 S816-102002
CN-20 MOLEX 2 Horn 35215-0200 -
CN-21 AMP 6 Wiper motor 925276-0 -
CN-22 KET 2 Washer tank MG640605 -
CN-23 KET 2 Speaker-LH MG610070 -
CN-24 KET 2 Speaker-RH MG610070 -
CN-25 MOLEX 2 Horn 35215-0200 -
CN-27 AMP 14 Cassette radio 173852 -
CN-28 MWP 1 Aircon compressor NMWP01F-B -
CN-29 KET 2 Receiver dryer MG640795 -
CN-36 DEUTSCH 3 Fuse box 21N8-20020 -
CN-45 RING-TERM - Starter ST710264-2 -
CN-47 AMP 2 Resistor S810-002202 -
CN-48 AMP 2 Hour meter S810-002202 -
CN-50 AMP 36 CPU controller 3441110 -
CN-51 AMP 36 CPU controller 346189-5 -
CN-56 DEUTSCH 4 Cluster - DT04-4P-E004
CN-60 YAZAKI 2 Fusible link 21N4-01320 7122-4125-50
CN-61 DEUTSCH 2 Fuel filler pump DT06-2S -
CN-66 DEUTSCH 2 Breaker solenoid DT06-2S DT04-2P
CN-68 DEUTSCH 2 Safety solenoid DT06-2S DT04-2P
CN-70 DEUTSCH 2 Travel solenoid DT06-2S -
4-29
pin Female Male
CN-74 RING-TERM - Alternator "l" term S820-105000 -
CN-75 Econoseal J 2 EPPR valve S816-002002 -
CN-80 RING-TERM - Glow plug S820-306000 -
CN-81 DEUTSCH 2 Travel buzzer DT06-2S DT04-2P
CN-88 DEUTSCH 2 Power max solenoid DT06-2S -
CN-91 DEUTSCH 8 Overload switch harness DT06-2S DT04-2P
CN-92 SWF 1 Emergency engine starting connector S814-001100 S814-101100
CN-93 DEUTSCH 50 ECM DRC26-50S-04 -
CN-94 DEUTSCH 4 ECM earth DT06-4S-EP06 -
CN-95 KET 2 Fusible link 21N4-01311 S813-130200
CN-98 DEUTSCH 3 Resistor DT06-3S-P012 DT04-3P-EP10
CN-99 DEUTSCH 3 Resistor DT06-3S-EP06 DT04-3P-EP10
CN-116 PA 17 Switch panel S811-017002 -
CN-125 Econoseal J 4 GPS S816-004002 S816-104002
CN-126 DEUTSCH 4 RS 232 connector DT06-4S DT04-4P
CN-133 DEUTSCH 2 Boom priority solenoid DT06-2S-EP06 -
CN-137 DEUTSCH 2 Max flow solenoid DT06-2S-EP06 -
CN-138 DEUTSCH 3 DC/DC converter DT06-3S-P012 DT04-3P
CN-139 DEUTSCH 2 12V socket DT06-2S DT04-2P-E004
CN-141 AMP 13 Wiper motor controller 172498-1 -
CN-142 DEUTSCH 3 Accel dial DT06-3S -
CN-143 KET 2 Cassette radio(With remocon) S816-002002 -
CN-144 AMP 12 Remocon-cassette radio 174045-2 -
CN-147 PACKARD 4 Fuel heater 2-967325-3 -
CN-148 DEUTSCH 3 Data link(J1939) DT06-3S-P012 -
CN-156 Econoseal J 2 Air seat S816-002002 S816-102002
·Relay
CR-1 RING-TERM - Battery relay - S820-104002
CR-2 - 5 Horn relay - -
CR-5 - 5 Safety relay - -
CR-7 - 5 Aircon comp relay - -
CR-13 FASTEN 4 Head lamp relay S810-004202 -
CR-23 KET 2 Start relay S814-002001 S814-102001
CR-24 RING TERM 1 Glow plug relay S822-014000 -
CR-35 - 5 Power relay - -
CR-36 - 5 Pre-heat relay - -
CR-45 FASTEN 4 ECM Power relay S810-004202 -
CR-46 FASTEN 4 Fuel heater relay S810-004202 -
CR-62 FASTEN 4 Breaker relay S810-004202 -
4-30
pin Female Male
·Switch
CS-1 SHUR 1 Door switch S822-014004 S822-114004
CS-2 SWP 6 Start key switch S814-006000 S814-106000
CS-4 DEUTSCH 3 Safety switch DT06-3S DT04-3P
CS-5 DEUTSCH 2 Horn switch DT06-2S DT04-2P
CS-19 DEUTSCH 2 One touch decel switch DT06-2S DT04-2P
CS-20 AMP 1 Safety switch S822-014002 -
CS-23 SWF 10 Beacon lamp switch SWF 593757 -
CS-26 DEUTSCH 2 Breaker switch DT06-2S DT04-2P
CS-27 SWF 10 Breaker switch SWF 593757 -
CS-29 DEUTSCH 2 Powe max switch DT06-2S DT04-2P
CS-50 SWF 10 Overload switch SWF 593757 -
CS-52 AMP 10 Econo switch SWF 593757 -
CS-53 AMP 1 Wiper cut switch S822-014002 -
CS-54 SWF 10 Spare switch SWF 593757 -
CS-74 AMP 2 Master switch S813-030201 -
·Light
CL-1 KET 2 Room lamp MG 610392 -
CL-2 AMP 1 Cigar lighter S822-014002 -
CL-4 DEUTSCH 2 Head lamp DT06-2S DT04-2P
CL-5 DEUTSCH 2 Work lamp-LH DT06-2S DT04-2P
CL-6 DEUTSCH 2 Work lamp-RH DT06-2S DT04-2P
CL-7 SHUR 1 Beacon lamp S822-014004 S822-114004
CL-8 DEUTSCH 2 Cab light-LH DT06-2S DT04-2P-E005
CL-9 DEUTSCH 2 Cab light-RH DT06-2S DT04-2P-E005
·Sensor, sendor
CD-1 AMP 2 Hydraulic oil temp sender 85202-1 -
CD-2 DEUTSCH 2 Fuel sender DT06-2S DT04-2P
CD-6 KET 2 Travel pressure switch MG 640795 -
CD-7 KET 2 Working pressure switch MG 640795 -
CD-10 RING-TERM - Air cleaner switch - S820-104002
CD-16 KET 2 Water level S814-002100 S814-102100
CD-31 DEUTSCH 2 Overload pressure switch DT06-2S DT04-2P
CD-42 Econoseal J 3 Pump pressure 1 S816-003002 S816-103002
CD-45 PACKARD 2 Water in fuel sensor 12040753 -
4-31
2. CONNECTION TABLE FOR CONNECTORS
1) PA TYPE CONNECTOR
No. of
pin Receptacle connector(Female) Plug connector(Male)
2 5 1 3
1 3 2 5
S811-005002 S811-105002
3 7 1 4
1 4 3 7
S811-007002 S811-107002
4 9 1 5
1 5 4 9
S811-009002 3S811-109002
5 11 1 6
11
1 6 5 11
S811-011002 S811-111002
4-32
No. of
Receptacle connector(Female) Plug connector(Male)
pin
6 13 1 7
13
1 7 6 13
S811-013002 S811-113002
8 1 9
17
17
1 9 8 17
S811-017002 S811-117002
10
1 21
1 11
21
1 11 10
1 21
S811-021002 S811-121002
4-33
2) J TYPE CONNECTOR
No. of
pin
1 1
2
2 12
S816-002001 S816-102001
2 3 1
3 1 2
S816-003001 S816-103001
3 1 4 2
4 2 3 1
S816-004001 S816-104001
8 5 2
6 3 1
8 5 2 6 3 1
S816-008001 S816-108001
4-34
3) SWP TYPE CONNECTOR
No. of
pin
1 1
S814-001000 S814-101000
2 1
1 2
S814-002000 S814-102000
3 1
2 1 23
S814-003000 S814-103000
2 4
1 3
1 3 2 4
S814-004000 S814-104000
4-35
No. of
pin Receptacle connector(Female) Plug connector(Male)
3 6
1 4
1 4 3 6
S814-006000 S814-106000
4 8
1 5
1 5 4 8
S814-008000 S814-108000
4 12
1 9
12
4 12
1 9
S814-012000 S814-112000
3 14
1 11
14
1 11 3 14
S814-014000 S814-114000
4-36
4) CN TYPE CONNECTOR
No. of
pin
1 1
S810-001202 S810-101202
2 2
1 1
S810-002202 S810-102202
3 2
1 2 1 3
S810-003202 S810-103202
2 4 1 3
1 3 2 4
S810-004202 S810-104202
4-37
No. of
pin
3 6 1 4
1 4 3 6
S810-006202 S810-106202
4 8 1 5
1 5 4 8
S810-008202 S810-108202
4-38
5) 375 FASTEN TYPE CONNECTOR
No. of
pin
1 2 1 2
S810-002402 S810-102402
6) AMP ECONOSEAL CONNECTOR

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

No. of
pin
85202-1
4-39
8) AMP 040 MULTILOCK CONNECTOR
No. of
pin
12 1 6
7 12
174045-2
9) AMP 070 MULTILOCK CONNECTOR

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

No. of
pin
3 1
6
6 4
1
4 6 3
480003-9
925276-0
4-40
11) KET 090 CONNECTOR
No. of
pin
1
2
MG610070
12) KET 090 WP CONNECTORS

No. of
pin
1
2
MG640605
2 1
MG640795
4-41
13) KET SDL CONNECTOR
No. of
pin
14
6
14
MG610406
4-42
14) DEUTSCH DT CONNECTORS
DT 06 - 3S - ★★★★
Modifications(See below)
Number of contacts(P : Pin, S : Socket)
04 : Receptacle, 06 : Plug
Deutsch connetors
※ Modification
E003 : Standard end cap - gray
E004 : Color of connector to be black
E005 : Combination - E004 & E003
EP04 : End cap
EP06 : Combination P012 & EP04
P012 : Front seal enhancement - connectors color to black for 2, 3, 4 & 6pin
No. of
pin
1 2 2 1
2
DT06-2S DT04-2P
2 1 1 2
3 3
DT06-3S DT04-3P
4 1 1 4
3 2 2 3
DT06-4S DT04-4P
4-43
No. of
pin
6 1 1 6
4 3 3 4
DT06-6S DT04-6P
4 5 5 4
1 8 1
8
DT06-8S DT04-8P
6 7 7 6
12
1 12 12 1
DT06-12S DT04-12P
4-44
15) MOLEX 2CKTS CONNECTOR
No. of
pin
1 2
35215-0200
35215-0200
16) ITT SWF CONNECTOR

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

No. of
pin
1
1
NMWP01F-B
4-45
18) ECONOSEAL J TYPE CONNECTORS
No. of
pin
S816-001002 S816-101002
1 2 2 1
S816-002002 S816-102002
S816-003002 S816-103002
S816-004002 S816-104002
4-46
No. of
pin
S816-006002 S816-106002
S816-008002 S816-108002
10
S816-010002 S816-110002
12
S816-012002 S816-112002
4-47
No. of
pin
15
368301-1 2-85262-1
19) METRI-PACK TYPE CONNECTOR

No. of
pin
12040753
20) DEUTSCH HD30 CONNECTOR

No. of
pin
J K
K J
B
23
N T
A B
F
F Q N
Q A
HD36-24-23SN HD34-24-23PN
4-48
Group 1 Outline - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1

Group 2 Mode Selection System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-3
Group 3 Automatic Deceleration System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-6
Group 4 Power Boost System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-7
Group 5 Travel Speed Control System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-8
Group 6 Automatic Warming Up Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-9
Group 7 Engine Overheat Prevention Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-10
Group 8 Anti-Restart System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-11
Group 9 Self-Diagnostic System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-12
Group 10 Engine Control System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-24
Group 11 EPPR(Electro Proportional Pressure Reducing) Valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-26
Group 12 Monitoring System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-29
GROUP 1 OUTLINE
The NEW CAPO(Computer Aided Power Optimization) system controls engine and pump mutual power
at an optimum and less fuel consuming state for the selected work by mode selection, auto-
deceleration, power boost function, etc. It monitors machine conditions, for instance, engine speed,
coolant temperature, hydraulic oil temperature, and hydraulic oil pressure, etc.
It consists for a CPU controller, a cluster, an electronic control module (ECM), an EPPR valve, and other
components. The CPU controller and the cluster protect themselves from over-current and high voltage
input, and diagnose malfunctions caused by short or open circuit in electric system, and display error
codes on the cluster.
Engine speed control system

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

NEW CAPO
SYSTEM
Max flow control system
Anti-restart system
Controller & cluster protection

Self-diagnostic system Open-short diagnosis & error code display
ECM Fault code display
Machine condition monitoring
Machine monitoring system
Electric signal monitoring
One touch deceleration system
Boom priority system
5-1
SYSTEM DIAGRAM
Travel motor
Regulator
Auto deceleration pressure switch
Main control valve

Boom priority
valve
Main relief
valve
Swing Boom priority
solenoid valve
Boom Arm
Power boost
Bucket Option solenoid valve
Travel(RH) Travel(LH) Travel speed

solenoid valve
Max flow CO
solenoid valve
Engine
ECM
Main pump Pilot pump
Max flow Hyd temp

CO valve sensor
CAN +
CAN -
One touch
GND
Horn decel button

EPPR valve
Power boost
Option button
button
RH control LH control
lever lever signal Hyd temperature signal
signal Drive signal
Drive signal
CPU controller
Drive signal
Drive signal
Accel dial signal CN-92
Normal
Resistor
Emergency
Normal Emergency Accel dial

(optional)
Serial Communication(-)
Drive signal
Serial Communication(+)
Prolix
Resistor
Pressure switch signal
Cluster
3607A5MS01
5-2
GROUP 2 MODE SELECTION SYSTEM
1. POWER MODE SELECTION SYSTEM
Main control valve
Engine
ECM
Max flow
CO valve
CAN +
CAN -
GND
EPPR valve
Work mode switch signal
Power mode switch signal CPU controller
User mode switch signal Accel dial signal CN-92
Normal
Emergency

(optional)
Drive signal
Prolix
Resistor
50075MS02
Mode selection system(Micro computer based electro-hydraulic pump and engine mutual control
system) optimizes the engine and pump performance.
The combination of 2 power modes(H, S) and accel dial position(10 set) makes it possible to use the
engine and pump power more effectively corresponding to the work conditions from a heavy and
great power requesting work to a light and precise work.
Power shift by EPPR valve

Engine rpm
Power Ver 5.1(STD) Ver 6.1(STD)
Mode Application set
(%) Current Pressure Current Pressure
Unload Load (kgf/cm2) (kgf/cm2)
(mA) (mA)
M Maximum power 95 1850±50 1800 230±30 4 160±30 0
H High power 85 1850±50 1800 330±30 10 230±30 4
S Standard power 70 1750±50 1700 330±30 10 330±30 10
AUTO DECEL Engine deceleration - 1100±100 - 670±30 38 670±30 38
One touch decel Engine quick deceleration - 700±100 - 670±30 38 670±30 38
KEY START Key switch start position - 700±100 - 710±30 38 710±30 38
5-3
2. WORK MODE SELECTION SYSTEM
3 work modes can be selected for the optional work speed of the machine operation.
Main control valve

Boom priority
valve
Main relief
valve
Swing Boom priority

solenoid valve
Boom Arm
Bucket Option Power boost

solenoid valve
Travel(RH) Travel(LH)
Max flow CO
solenoid valve
Engine
ECM
Max flow
CO valve Hyd temp
sensor
CAN +
CAN -
GND
EPPR valve
Hyd temperature signal

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

(optional)
Serial Communication(-)
Drive signal
Serial Communication(+)
Prolix
Resistor
Cluster
3607A5MS03
1) HEAVY DUTY WORK MODE

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

General OFF OFF
Breaker OFF ON
5-4
3. USER MODE SELECTION SYSTEM
Through 2 memory sets of MI and MII, an operator can change the engine and pump power and
memorize it for his preference.
Mode Operation
High idle rpm, auto decel rpm
U
EPPR pressure can be modulated and memorized separately
HOW TO MODULATE THE MEMORY SET

1) Each memory mode has a initial set which are
mid-range of max engine speed, auto decel rpm,
and EPPR valve input current. When you select
"U", cluster LCD displays.
2) To change the engine high idle speed, press the
USER mode switch and SELECT switch at the 140W74OP03G
same time and then ACCEL blinks at 0.5 seconds
interval.
- By pressing or switch, will increase or
decrease.
3) To change DECEL rpm, press the USER mode
switch and SELECT switch once more and then
DECEL blinks at 0.5 seconds interval.
decrease.
4) To change EPPR current, press the USER mode
switch and SELECT switch one more and then
EPPR blinks at 0.5 seconds interval.
decrease.
·LCD segment vs parameter setting
Segment ACCEL DECEL EPPR
( ) (rpm) (rpm) (mA)
1 1400 Low idle(700) 150
2 1450 750 200
3 1500 800 250
4 1550 850 300
5 1600 900 350
6 1650 950 400
7 1700 1000 450
8 1750 1050 500
9 1800 Decel rpm(1100) 550
10 1850 1150 600
5) To memorize the final setting, press the USER

mode switch and SELECT switch one more time. 45074OP06
5-5
GROUP 3 AUTOMATIC DECELERATION SYSTEM
36075MS04
1. WHEN AUTO DECEL LAMP ON

If all the work equipment control levers including swing and travel levers are at neutral for at least 4
seconds, CPU controller transmits the throttle command to ECM to reduce the engine speed to
1100rpm. As the result of reducing the engine speed, fuel consumption and noise are effectively cut
down during non-operation of the control levers.
When the Auto decel lamp is turned off by pressing the switch or any control lever is operated, the
reduced engine speed rises up to the speed set before deceleration in a second.
Engine rpm
Accel dial set rpm
1100 rpm
Max Max
4sec 1.5sec 1.5sec
Lever Lever Time

neutral operation
3607A5MS05
2. WHEN AUTO DECEL LAMP OFF

The engine speed can be set as desired using the engine speed switch, and even if the control levers
are neutral, the engine speed is not reduced.
※ Auto decel function can be activated when accel dial position is over 4.
5-6
GROUP 4 POWER BOOST SYSTEM
Main control valve

Boom priority
valve
Main relief
valve
Swing
Boom Arm
Bucket Option Power boost

solenoid valve
Engine
ECM
Max flow
CO valve
CAN +
-
GND
CAN
EPPR valve
LH control
lever
Power boost
button
Power boost button signal

Drive signal
Mode switch signal Drive signal

CPU controller
36075MS05
· When the power boost switch on the left control lever knob is pushed ON, the maximum digging
power is increased by 10%.
· When the power set is at H or S and the power boost function is activated, the power boost solenoid
valve pilot pressure raises the set pressure of the main relief valve to increase the digging power.
Power boost switch

Description
OFF ON
Power set H or S H
Main relief valve set pressure 330kgf/cm2 360kgf/cm2
Even when pressed continuously,
Time of operation -
it is canceled after 8 sec.
※ Default - Power boolst solinoid valve : OFF
5-7
GROUP 5 TRAVEL SPEED CONTROL SYSTEM
Travel motor
Main control valve Regulator Regulator
Swing
Boom Arm
Bucket Option
Travel spped
solenoid valve
Engine
Max flow
CO valve
EPPR valve
Travel speed switch signal Drive signal

CPU controller
36075MS06
Travel speed can be switched manually by pressing the travel speed switch on the cluster.
Travel speed Lamp
Speed Operation
solenoid valve on cluster
Lo OFF Turtle Low speed, high driving torque in the travel motor
Hi ON Rabbit High speed, low driving torque in the travel motor
※ Default : Turtle(Lo)
5-8
GROUP 6 AUTOMATIC WARMING UP FUNCTION
Engine
ECM
Max flow
CO valve
CAN +
-
GND
CAN
EPPR valve
Drive signal
Warming up lamp signal
CPU controller
Cluster
3607A5MS07
1. CPU controller receives engine coolant temperature from the ECM, and if the coolant temperature is
less than 30。
C, it increases the engine speed from key start rpm to 1200rpm. At this time the mode
does not change.
2. In case of the coolant temperature increases up to 30。
C, the engine speed is decreased to key start
speed. And if an operator changes mode set during the warming up function, the CPU controller
cancels the automatic warming up function.
3. LOGIC TABLE
Description Condition Function

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

- Warming up time : Above 10 minutes - Default mode
- Changed mode set by operator - Changed mode
Canceled - Increase engine speed by rotating accel
dial clockwise
※ If any of the above conditions is
applicable, the automatic warming up
function is canceled
Warming up lamp - Coolant temperature : Above 30。

C - Warming up lamp : OFF
5-9
GROUP 7 ENGINE OVERHEAT PREVENTION FUNCTION
Engine
ECM
Max flow
CO valve
CAN +
-
GND
CAN
EPPR valve
Drive signal
Overheat warning signal
CPU controller
Cluster
3607A5MS08
1. CPU controller receives engine coolant temperature from the ECM and when the engine coolant boils
up to 110。 C, it sends overheat warning signal to the cluster and decrease the engine speed same as
accel dial 7 position.
2. If the coolant temperature drops less than 100。C, the CPU controller returns the mode to the mode
set before. And if mode set is changed during the function, the CPU controller cancels the function.
Even if the overheat prevention function is canceled by mode change, the overheat warning lamp
turns OFF only when the coolant temperature is less than 100。 C.
3. LOGIC TABLE
Description Condition Function
- Coolant temperature : Above 110。

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

C - Overheat warning lamp : OFF
5-10
GROUP 8 ANTI-RESTART SYSTEM
Engine
Starter
Start safety relay
Drive signal
CPU controller
CN-92a
CN-92b
21075MS10
1. ANTI-RESTART FUNCTION
After 10 seconds from the engine starts to run, CPU controller turns off the start safety relay to protect
the starter from inadvertent restarting.
2. When a replacement or taking-off of the CPU controller is needed, connect CN-92a and CN-92b to
ensure the engine start without the CPU controller.
5-11
GROUP 9 SELF-DIAGNOSTIC SYSTEM (up to #0077)
1. OUTLINE
When any abnormality occurs in the NEW CAPO system caused by electric parts malfunction and by
open or short circuit, the CPU controller diagnoses the problem and sends the error codes to the
cluster and also stores them in the memory.
The current or recorded error codes are displayed at the error display mode selected by touching
SELECT switch 2 times while pressing BUZZER STOP switch.
2. CURRENT ERROR DISPLAY
Cluster displays Co : Er and makes buzzer sound itself to warn the communication error when
communication problem caused by wire-cut or malfunction of the CPU controller occurs.
Cluster displays real time error codes received from CPU controller through communication. In case
of no problem it displays CHECK Er : 00.
If there are more than 2 error codes, each one can be displayed by pressing and switch
respectively.
Examples :
1) Communication Error
Co : Er & Buzzer sound
2) No problem
CHECK Er : 0 0
3) 4 Error codes(03, 06, 10, 43) display

CHECK Er : 0 3
Press Press Press

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

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

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

Select recorded error(TIME Er) display and press engine and select switch at the same time for
2 seconds or more. Cluster display changes to TIME Er : 00, which shows that CPU controller
deleted all the recorded error codes in the memory.
5. ECM ERROR CODES DISPLAY

If any fault lode us received from ECM, cluster turns on the "Engine check" and sound the buzzer.
The fault codes are displayed on the cluster as the same as current error display.
ex) Check Er : 143
5-12
GROUP 9 SELF-DIAGNOSTIC SYSTEM (#0078 and up)
1. OUTLINE
When any abnormality occurs in the NEW CAPO system caused by electric parts malfunction and by
open or short circuit, the CPU controller diagnoses the problem and sends the error codes to the
cluster and also stores them in the memory.
2. CURRENT ERROR DISPLAY
(Error display)
(Recorded error delete)
5-12-1
6. ERROR CODES TABLE
Error code No. Description
1 Short circuit in accel actuator system

2 Potentiometer circuit is shorted to Vcc(5V) or battery +
3 Short circuit in pump EPPR valve system
4 Short circuit in boom down EPPR valve system
5 Short circuit in travel speed solenoid system
6 Short circuit in power boost solenoid system
7 Short circuit in max flow solenoid system
10 Short circuit in hour-meter system
11 Accel dial circuit is shorted to Vcc(5V) or battery +
12 P1 pressure sensor circuit is shorted to power supply(24V) line
13 P2 pressure sensor circuit is shorted to power supply(24V) line
14 P3 pressure sensor circuit is shorted to power supply(24) line
15 Boom down pressure circuit is shorted to power supply(24V) line
16 Accel actuator circuit is open or shorted to ground
17 Potentiometer circuit is open or shorted to ground
18 Pump EPPR valve circuit is open or shorted to ground
19 Boom down EPPR valve circuit is open or shorted to ground
20 Travel speed solenoid circuit is open or shorted to ground
21 Power boost solenoid circuit is open or shorted to ground
22 Max flow solenoid circuit is open or shorted to ground
25 Hour-meter circuit is open or shorted to ground
26 Accel dial circuit is open or shorted to ground
27 P1 pressure sensor circuit is open or shorted to ground
30 Boom down pressure sensor circuit is open or shorted to ground
31 Engine preheater circuit is open or shorted to ground
32 Travel alarm buzzer circuit is open or shorted to ground
33 Alternator circuit is open or shorted to ground
34 Controller input voltage is below 18V
5-13
Error code No. Description
35 Controller input voltage is over 38V

36 Communication error with cluster
37 Engine speed sensor circuit is open or shorted to ground
38 Anti-restart relay circuit is open or shorted to ground
39 Accel actuator does not stop at a target position
40 There is more than 500rpm difference between target speed and actual speed
41 Hydraulic oil temperature sensor circuit is shorted to ground
42 Fuel level sensor circuit is shorted to ground
43 Coolant temperature sensor circuit is shorted to ground
44 Boom up pressure sensor circuit is shorted to power supply(24V) line
45 Hydraulic oil temperature sensor circuit is open or shorted to battery +
46 Fuel level sensor circuit is open or shorted to battery +
47 Coolant temperature sensor circuit is open or shorted to battery +
48 Boom up pressure sensor circuit is open or shorted to ground
49 Engine preheater circuit is shorted to battery +
51 Boom priority solenoid circuit is open or shorted to ground
56 Travel alarm buzzer circuit is shorted to battery +
58 Boom priority solenoid circuit is shorted to battery +
5-14
7. ENGINE FAULT CODE INFORMATION
Fault code No. Reason Effect (only when fault code is active)
Engine control module critical internal failure - Possible no noticeable performance effects,
Bad intelligent device or component. Error engine dying, or hard starting.
111
internal to the ECM related to memory hardware
failures or internal ECM voltage supply circuits.
Engine magnetic crankshaft speed/position lost Fueling to injectors is disabled and the engine
both of two signals - Data erratic, intermittent, or can not be started.
115 incorrect. The ECM has detected that the
primary engine speed sensor and the backup
engine speed sensor signals are reversed.
Intake manifold 1 pressure sensor circuit - Engine power derate.
Voltage above normal, or shorted to high
122
source. High signal voltage detected at the
intake manifold pressure circuit.
Intake manifold 1 pressure sensor circuit - Engine power derate.
Voltage below normal, or shorted to low Source.
123
Low signal voltage or open circuit detected at the
intake manifold pressure circuit.
Intake manifold 1 pressure - Data valid but Engine power derate.
above normal operational range - Moderately
124 severe level. Intake manifold pressure has
exceeded the maximum limit for the given
engine rating.
Accelerator pedal or lever position sensor 1 Severe derate in power output of the engine.
circuit - Voltage above normal, or shorted to high Limp home power only.
131
source. High voltage detected at accelerator
pedal position circuit.
Accelerator pedal or lever position sensor 1 Severe derate in power output of the engine.
circuit - Voltage below normal, or shorted to low Limp home power only.
132
source. Low voltage detected at accelerator
pedal position signal circuit.
Remote accelerator pedal or lever position Remote accelerator will not operate. Remote
sensor 1 circuit - Voltage above normal, or accelerator position will be set to zero percent.
133
shorted to high source. High voltage detected at
remote accelerator pedal position circuit.
Remote accelerator pedal or lever position Remote accelerator will not operate. Remote
sensor 1 circuit - Voltage below normal, or accelerator position will be set to zero percent.
134
shorted to low source. Low voltage detected at
remote accelerator pedal position signal circuit.
Engine oil rifle pressure 1 sensor circuit - Voltage None on performance. No engine protection
above normal, or shorted to high source. High for oil pressure.
135
signal voltage detected at the engine oil
pressure circuit.
Engine oil rifle pressure 1 sensor circuit - Voltage None on performance. No engine protection
below normal, or shorted to low source. Low for oil pressure.
141
signal voltage detected at engine oil pressure
circuit.
Engine oil rifle pressure - Data valid but below None on performance.
143 normal operational range - Moderately severe
level.
Engine coolant temperature 1 sensor circuit - Possible white smoke. Fan will stay ON if
Voltage above normal, or shorted to high controlled by ECM. No engine protection for
144
source. High signal voltage or open circuit engine coolant temperature.
detected at engine coolant temperature circuit.
5-15
Engine Coolant Temperature 1 Sensor Circuit - Possible white smoke. Fan will stay ON if
145 Voltage Below Normal, or Shorted to Low controlled by ECM. No engine protection for
Source. Low signal voltage detected at engine engine coolant temperature.
coolant temperature circuit.
Engine Coolant Temperature - Data Valid but Progressive power derate increasing in
Above Normal Operational Range - Moderately severity from time of alert.
146 Severe Level. Engine coolant temperature signal
indicates engine coolant temperature is above
engine protection warning limit.
Accelerator Pedal or Lever Position 1 Sensor Severe derate in power output of the engine.
Circuit Frequency - Data Valid but Below Normal Limp home power only.
147 Operational Range - Most Severe Level. A
frequency of less than 100 Hz has been
detected at the frequency throttle input to the
ECM.
Accelerator Pedal or Lever Position Sensor 1 - Severe derate in power output of the engine.
Data Valid but Above Normal Operational Limp home power only.
148 Range - Most Severe Level. A frequency of
more than 1500 Hz has been detected at the
frequency throttle input to the ECM.
Engine Coolant Temperature - Data Valid but Progressive power derate increasing in
Above Normal Operational Range - Most severity from time of alert. If Engine Protection
151 Severe Level. Engine coolant temperature signal Shutdown feature is enabled, engine will shut
indicates engine coolant temperature above down 30 seconds after Red Stop Lamp starts
engine protection critical limit. flashing.
Intake Manifold 1 Temperature Sensor Circuit - Possible white smoke. Fan will stay ON if
153 Voltage Above Normal, or Shorted to High controlled by ECM. No engine protection for
Source. High signal voltage detected at intake intake manifold air temperature.
manifold air temperature circuit.
Intake Manifold 1 Temperature Sensor Circuit - Possible white smoke. Fan will stay ON if
154 Voltage Below Normal, or Shorted to Low controlled by ECM. No engine protection for
Source. Low signal voltage detected at intake intake manifold air temperature.
manifold air temperature circuit.
Intake Manifold 1 Temperature - Data Valid but Progressive power derate increasing in
Above Normal Operational Range - Most severity from time of alert. If Engine Protection
155 Severe Level. Intake manifold air temperature Shutdown feature is enabled, engine will shut
signal indicates intake manifold air temperature down 30 seconds after Red Stop Lamp starts
above engine protection critical limit. flashing.
Sensor Supply 2 Circuit - Voltage Below Normal, Engine power derate.
187 or Shorted to Low Source. Low voltage detected
at the sensor supply number 2 circuit.
Coolant Level Sensor 1 Circuit - Voltage Above None on performance.
195 Normal, or Shorted to High Source. High signal
voltage detected at engine coolant level circuit.
Coolant Level Sensor 1 Circuit - Voltage Below None on performance.
196 Normal, or Shorted to Low Source. Low signal
voltage detected at engine coolant level circuit.
Coolant Level - Data Valid but Below Normal None on performance.
197 Operational Range - Moderately Severe Level.
Low coolant level has been detected.
Barometric Pressure Sensor Circuit - Voltage Engine power derate.
221 Above Normal, or Shorted to High Source. High
signal voltage detected at barometric pressure
circuit.
5-16
Barometric Pressure Sensor Circuit - Voltage Engine power derate.
222 Below Normal, or Shorted to Low Source. Low
signal voltage detected at barometric pressure
circuit.
Sensor Supply 2 Circuit - Voltage Above Engine power derate.
227 Normal, or Shorted to High Source. High voltage
detected at sensor supply number 2 circuit.
Engine Crankshaft Speed/Position - Data Valid Fuel injection disabled until engine speed falls
but Above Normal Operational Range - Most below the overspeed limit.
234 Severe Level. Engine speed signal indicates
engine speed above engine protection limit.
Coolant Level - Data Valid but Below Normal Progressive power derate increasing in
Operational Range - Most Severe Level. Low severity from time of alert. If Engine Protection
235 engine coolant level detected. Shutdown feature is enabled, engine will shut
down 30 seconds after Red Stop Lamp starts
flashing.
External Speed Command Input (Multiple Unit
Synchronization) - Data Erratic, Intermittent, or
237
Incorrect. Communication between multiple
engines may be intermittent.
Sensor Supply 3 Circuit - Voltage Below Normal, Possible hard starting and rough running.
or Shorted to Low Source. Low voltage detected
238
on the +5 volt sensor supply circuit to the engine
speed sensor.
Wheel-based vehicle speed - Data erratic, Engine speed limited to ,mximum engine
intermittent, or incorrect. The ECM lost the speed without VSS parameter value. Cruise
241
vehicle speed signal. control, gear-down protection, and road speed
governor will not work.
Wheel-based vehicle speed sensor circuit Engine speed limited to maximum engine
tampering has been detected - Abnormal rate of speed without VSS parameter value. Cruise
242
change. Signal indicates an intermittent control, gear-down protection, and road speed
connection or VSS tampering. g+H53overnor will not work.
Fan control circuit - Voltage below normal, or The fan may stay on continuously or not run at
shorted to low source. Low signal voltage all.
245
detected at the fan control circuit when
commanded on.
Fuel pump pressurizing assembly 1 circuit - Engine will run poorly at idle. Engine will have
Voltage below normal, or shorted to low source. low power. Fuel pressure will be higher than
271
Low signal voltage detected at the fuel pump commanded.
actuator circuit.
Fuel pump pressurizing assembly 1 circuit - Engine will not run or engine will run poorly.
272 Voltage above normal, or shorted to high
source. High signal voltage or open circuit
detected at the fuel pump actuator circuit. Engine will not run or possible low power.
Fuel pump pressurizing assembly 1 -
281
Mechanical system not responding properly or
out of adjustment.
SAE J1939 multiplexing PGN timeout error - At least one multiplexed device will not operate
Abnormal update rate. The ECM expected properly.
285
information from a multiplexed device but did not
receive it soon enough or did not receive it at all.
SAE J1939 multiplexing configuration error - At least one multiplexed device will not operate
Out of calibration. The ECM expected properly.
286
information from a multiplexed device but only
received a portion of the necessary information.
5-17
SAE J1939 multiplexed accelerator pedal or Engine may only idle or engine will not
lever sensor system - received network data In accelerate to full speed.
287 error. The OEM vehicle electronic control unit
(VECU) detected a fault with its accelerator
pedal.
SAE J1939 Multiplexing Remote Accelerator The engine will not respond to the remote
Pedal or Lever Position Sensor Circuit - throttle. Engine may only idle. The primary or
288 Received Network Data In Error. The OEM cab accelerator may be able to be used.
vehicle electronic control unit (VECU) detected a
fault with the remote accelerator.
Auxiliary temperature Sensor Input 1 - Special Possible engine power derate.
292
instructions.
Auxiliary temperature sensor input 1 circuit - None on performance.
293 source. High signal voltage or open circuit
detected at the OEM auxiliary temperature
circuit.
Auxiliary temperature sensor input 1 circuit - None on performance.
Voltage below normal, or shorted to low source.
294
Low signal voltage detected at the OEM
auxiliary temperature circuit.
Auxiliary pressure sensor input 1 - Special Possible engine power derate.
296
instructions.
Auxiliary pressure sensor input 1 circuit - Voltage None on performance.
above normal, or shorted to high source. High
297
signal voltage detected at the OEM pressure
circuit.
Auxiliary pressure sensor input 1 circuit - Voltage None on performance.
below normal, or shorted to low source. Low
298
signal voltage or open circuit detected at the
OEM pressure circuit.
Real time clock power interrupt - Data erratic, None on performance. Data in the ECM will
319 intermittent, or incorrect. Real time clock lost not have accurate time and date information.
power.
Injector solenoid driver cylinder 1 circuit - Engine can possibly misfire or run rough.
Current below normal, or open circuit. High
resistance detected on injector number 1 circuit
322 or no current detected at number 1 injector driver
or return pin when the voltage supply at the
harness is on.
harness is on.
harness is on.
harness is on.
5-18
331 resistance detected on injector number 2 circuit
or no current detected at number 2 injector driver
harness is on.
332 resistance detected on injector number 4 circuit
or no current detected at number 4 injector driver
harness is on.
Engine coolant temperature - Data erratic, The ECM will estimate engine coolant
334 intermittent, or incorrect. The engine coolant temperature.
temperature reading is not changing with engine
operating conditions.
Electronic calibration code incompatibilty - Out of Possible no noticeable performance effects,
342 calibration. An incompatible calibration has been engine dying, or hard starting.
detected in the ECM.
Engine control module warning internal No perfomance effects or possible severe
343 hardware failure - Bad intelligent device or power derate.
component. Internal ECM failure.
Injector power supply - Bad intelligent device or Possible smoke, low power, engine misfire,
351 component. The ECM measured injector boost and/or engine will not start.
voltage is low.
Sensor supply 1 circuit - Voltage below normal, Engine power derate.
352 or shorted to low source. Low voltage detected
at sensor supply number 1 circuit.
Sensor supply 1 circuit - Voltage above normal, Engine power derate.
386 or shorted to high source. High voltage detected
at sensor supply number 1 circuit.
Engine oil rifle pressure - Data valid but below Progressive power derate increasing in
normal operational range - Most severe level. Oil severity from time of alert. If engine protection
415 pressure signal indicates oil pressure below the shutdown feature is enabled, engine will shut
engine protection critical limit. down 30 seconds after red stop lamp starts
flashing.
Water in fuel indicator - Data valid but above Possible white smoke, loss of power, or hard
418 normal operational range - Least severe level. starting.
water has been detected in the fuel filter.
Water in fuel indicator sensor circuit - Voltage None on performance. No water in fuel
428 above normal, or shorted to high source. High warning available.
voltage detected at the water in fuel circuit.
Water in fuel indicator sensor circuit - Voltage None on performance. No water in fuel
429 below normal, or shorted to low source. Low warning available.
voltage detected at the water in fuel circuit.
Accelerator pedal or lever idle validation switch - Engine will only idle.
431 Data erratic, intermittent, or incorrect. Voltage
detected simultaneously on both idle validation
and off-idle validation switches.
Accelerator pedal or lever idle validation circuit - Engine will only idle.
432 Out of calibration. Voltage at idle validation on-
idle and off-idle circuit does not match
accelerator pedal position.
Engine oil rifle pressure - Data erratic, None on performance. No engine protection
435 intermittent, or incorrect. An error in the engine for oil pressure.
oil pressure switch signal was detected by the
ECM.
5-19
Battery 1 voltage - Data valid but below normal Engine may stop running or be difficult to start.
operational range - Moderately severe level.
441
ECM supply voltage is below the minimum
system voltage level.
Battery 1 Voltage - Data valid but above normal Possible electrical damage to all electrical
operational range - Moderately severe level. components.
442
ECM supply voltage is above the maximum
system voltage level.
Injector metering rail 1 pressure - Data valid but None or possible engine noise associated with
449 above normal operational range - Most severe higher injection pressures (especially at idle or
level. light load). Engine power is reduced.
Injector metering rail 1 pressure sensor circuit - Power and or speed derate.
451
source. High signal voltage detected at the rail
fuel pressure sensor circuit.
Injector metering rail 1 pressure sensor circuit - Power and or speed derate.
Voltage below normal, or shorted to low
452
source. Low signal voltage detected at the rail
fuel pressure sensor circuit.
Intake manifold 1 temperature - Data valid but Progressive power derate increasing in
above normal operational range - Moderately severity from time of alert.
488 severe level. Intake manifold air temperature
signal indicates intake manifold air temperature
is above the engine protection warning limit.
Multiple unit synchronization switch - Data
497
erratic, intermittent, or incorrect.
Auxiliary intermediate (PTO) speed switch None on performance.
523 validation - Data erratic, intermittent, or
incorrect.
Auxiliary input/output 2 circuit - Voltage above None on performance.
normal, or shorted to high source. High signal
527
voltage or open circuit has been detected at the
auxiliary input/output 2 circuit.
Auxiliary alternate torque validation switch - None on performance.
528
Data erratic, intermittent, or incorrect.
Auxiliary input/output 3 circuit - Voltage above
normal, or shorted to high source. Low signal
529
voltage has been detected at the auxiliary
input/output 2 circuit.
Injector metering rail 1 pressure - Data valid but The ECM will estimate fuel pressure and
above normal operational range - Moderately power is reduced.
553
severe level. The ECM has detected that fuel
pressure is higher than commanded pressure.
Injector metering rail 1 pressure - Data erratic, Possibly hard to start, low power, or engine
Intermittent, or incorrect. The ECM has smoke.
554
detected that the fuel pressure signal is not
changing.
Injector metering rail 1 pressure - Data Valid Either the engine will not start or the engine
but Below Normal Operational Range - will not have starter lockout protection.
559 Moderately Severe Level. The ECM has
detected that fuel pressure is lower than
commanded pressure.
Starter relay driver circuit - Voltage above The engine will not have starter lockout
normal, or shorted to high source. Open circuit protection.
584
or high voltage detected at starter lockout
circuit.
5-20
Starter relay driver circuit - Voltage below Engine power derate. The ECM uses an
585 normal, or shorted to low source. Low voltage estimated turbocharger speed.
detected at starter lockout circuit.
Turbocharger 1 speed - Data valid but above Amber lamp will light until high battery voltage
normal operational range - Moderately severe condition is corrected.
595
level. High turbocharger speed has been
detected.
Auxiliary commanded dual output shutdown - None or possible engine noise associated with
599 Special instructions. higher injection pressures (especially at idle or
light load). Engine power is reduced.
Turbocharger 1 speed - Data valid but below Engine can run rough. Possibly poor starting
normal operational range - Moderately severe capability. Engine runs using backup speed
687
level. Low turbocharger speed detected by the sensor. Engine power is reduced.
ECM.
Engine crankshaft speed/position - Data erratic, Engine power derate.
689 intermittent, or incorrect. Loss of signal from
crankshaft sensor.
Turbocharger 1 compressor inlet temperature Engine power derate.
circuit - Voltage above normal, or shorted to
691 high source. High signal voltage detected at
turbocharger compressor inlet air temperature
circuit.
Turbocharger 1 compressor inlet temperature Engine will run derated. Excessive black
circuit - Voltage below normal, or shorted to low smoke, hard start, and rough idle possible.
692
source. Low signal voltage detected at
turbocharger compressor inlet air tempera
Engine speed / position camshaft and Possible no noticeable performance effects,
crankshaft misalignment - Mechanical system engine dying, or hard starting.
not responding properly or out of adjustment.
731
mechanical misalignment between the
crankshaft and camshaft engine speed
sensors.
Electronic control module data lost - Condition Possible poor starting. Engine power derate.
757
exists. Severe loss of data from the ECM.
Engine camshaft speed / position sensor - Data Possible engine power derate.
erratic, intermittent, or incorrect. The ECM has
778
detected an error in the camshaft position
sensor signal.
Auxiliary equipment sensor input 3 - Root Possible no noticeable performance effects or
cause not known. engine dying or hard starting. Fault
779
information, trip information, and maintenance
monitor data may be inaccurate.
Power supply lost with ignition on - Data erratic, Engine will shut down.
intermittent, or incorrect. Supply voltage to the
ECM fell below 6.2 volts momentarily, or the
1117
ECM was not allowed to power down correctly
(retain battery voltage for 30 seconds after key
OFF).
OEM datalink cannot transmit - Data erratic, Engine will only idle.
1633 intermittent, or incorrect. Communications
within the OEM datalink network is intermittent.
Sensor supply 4 circuit - Voltage sbove normal, Engine will only idle.
or shorted to high source. High voltage
2185
detected at +5 volt sensor supply circuit to the
accelerator pedal position sensor.
5-21
Sensor supply 4 circuit - Voltage below normal, Possibly hard to start, low power, or engine
or shorted to low source. Low voltage detected smoke.
2186
at +5 volt sensor supply circuit to the
accelerator pedal position sensor.
Injector metering rail 1 pressure - Data valid but Engine may be difficult to start.
below normal operational range - Most severe
2249
level. The ECM has detected that fuel pressure
is lower than commanded pressure.
Electric lift pump for engine fuel supply circuit - Engine may be difficult to start.
2265
source. High voltage or open detected at the
fuel lift pump signal circuit.
Electric lift pump for engine fuel supply circuit - Possible low power.
Voltage below normal, or shorted to low
2266
source. Low signal voltage detected at the fuel
lift pump circuit.
Electronic fuel injection control valve circuit - Engine may exhibit misfire as control switches
Condition exists. Fuel pump actuator circuit from the primary to the backup speed sensor.
2311
resistance too high or too low. Engine power is reduced while the engine
operates on the backup speed sensor.
Engine crankshaft speed/position - Data erratic, Possible low power.
2321 intermittent, or incorrect. crankshaft engine
speed sensor intermittent synchronization.
Engine camshaft speed / position sensor - Data Engine power derate.
erratic, intermittent, or incorrect. Camshaft
2322 engine speed sensor intermittent
synchronization.
Turbocharger 1 Speed - Abnormal rate of Engine power derate.
2345 change. The turbocharger speed sensor has
detected an erroneous speed value.
Turbocharger turbine inlet temperature Engine power derate.
(Calculated) - Data valid but above normal
2346 operational range - Least severe level.
Turbocharger turbine inlet temperature has
exceeded the engine protection limit.
Turbocharger compressor outlet temperature Engine brake on cylinders 1, 2, and 3 can not
2347 (Calculated) - Data valid but above normal be activated or exhaust brake will not operate.
operational range - Least severe level.
Fan control circuit - Voltage above normal, or Variable geometry turbocharger will go to the
2377 shorted to high source. Open circuit or high open position.
voltage detected at the fan control circuit.
VGT actuator driver circuit - Voltage below Variable geometry turbocharger may be in
2384 normal, or shorted to low source. Low voltage either the open or closed position.
detected at turbocharger control valve circuit.
VGT actuator driver circuit - Voltage above The intake air heaters may be ON or OFF all
normal, or shorted to high source. Open circuit the time.
2385 or high voltage detected at turbocharger control
valve circuit.
Intake air heater 1 circuit - Voltage above The intake air heaters may be ON or OFF all
2555 normal, or shorted to high source. High voltage the time.
detected at the intake air heater signal circuit.
Intake air heater 1 circuit - Voltage below Can not control transmission.
2556 normal, or shorted to low source. Low voltage
detected at the intake air heater signal circuit.
Auxiliary PWM driver 1 circuit - Voltage above Can not control transmission.
2557 normal, or shorted to high source. High signal
voltage detected at the analog torque circuit.
5-22
Auxiliary PWM driver 1 circuit - Voltage below Power derate and possible engine shutdown if
2558 normal, or shorted to low source. Low signal engine protection shutdown feature is enabled.
voltage detected at the analog torque circuit.
Intake manifold 1 pressure - Data erratic,
intermittent, or incorrect. The ECM has
2973 detected an intake manifold pressure signal
that is too high or low for current engine
operating conditions.
5-23
GROUP 10 ENGINE CONTROL SYSTEM
1. CPU CONTROLLER AND ECM(Engine control module)
TON
EBA
L
VOL
ON BAND
SEEK
push
FAD
TUNE
1
2
4 PRO
3
5 G
6
PLL
SYNT
HESI
ZER
TUNN
ING
SPARE
20A
SPARE
RE
CAB
10A 10A 20A 10A

HOLDER
SPARE
10A
FUSE
LAMP
SPARE
CABIN
5A
10A
LAMP
LAMP SPARE
BEACON
WORK
10A 10A 20A

F/PUMP
5A
20A
LAMP & HEATER FUEL
KEY AC
5A
HEAD 3
START
20A
5A
MOTOR SOLENOID
LAMP HONE
5A
WIPER 2
BOOM
5A
LIGHT
5A
SOL. SOLENOID
CIGAR
10A
& HEATER SAFETY 1
5A
AC
5A
- HEAT
5A
PANEL SOLENOID
MOTOR PRE
SWITCH
5A
WIPER
5A
10A 20A
TRAVEL RY
CUT-OFF CONVERTOR
FUEL HONE
10A
PANEL
CLUSTER
SWITCH
RY -2
CR
5A
COMP
C/RADIO AC RY
-7 ETHER
RY CR
POWER - 36
CR
- 35
CR
RY
SAFETY
-5
CR
1
ECM(Engine control module)
3
3607A5MS09
2. CPU CONTROLLER ASSEMBLY

1) Remove four pieces of bolt(3) of electric box(2).
2) Disconnect 2 connectors from CPU controller.
3) Remove 6 pieces of screw and open the cover of CPU controller.
4) Inspection : Check PCB(Printed Circuit Board)
(1) If any damage is found, replace CPU controller assembly.
(2) If not, but CAPO system does not work please report it to HHI dealer or A/S department.
5-24
3. EXCHANGE METHOD OF THE ROM IN
1
THE CLUSTER
1) Disassemble the ash tray(2).
2) Disassemble the wiper motor cover(3).
3) Disassemble the cluster(1).
3
2
21075MS12
4) Loosen the screws(6EA) located back of

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

and assmelbe the cluster in the reverse
order to removal).
Same
direction
21075MS15
5-25
GROUP 11 EPPR VALVE (up to #0077)
1. COMPOSITION OF EPPR VALVE

EPPR(Electro Proportional Pressure Reducing) valve consists of electro magnet and spool valve
installed at main hydraulic pump.
1) ELECTRO MAGNET VALVE
Receive electric current from CPU controller and move the spool proportionally according to the
specific amount of electric current value.
2) SPOOL VALVE
Is the two way direction control valve for pilot pressure to reduce hydraulic pump flow.
When the electro magnet valve is activated, pilot pressure enters into flow regulator of hydraulic pump.
So, pump flow decreases to prevent engine stall.
3) PRESSURE AND ELECTRIC CURRENT VALUE FOR EACH MODE
Pressure Electric current Engine rpm
Mode
kgf/cm2 psi (mA) (At accel dial 10)
M 4Ü3 57 Ü 40 230 Ü 30 1850 Ü 50

Standard
H 10 Ü 3 142 Ü 40 330 Ü 30 1850 Ü 50
(Ver : 5.1)
S 10 Ü 3 142 Ü 40 330 Ü 30 1750 Ü 50
M 0 0 160 Ü 30 1850 Ü 50
Option
H 4Ü3 57 Ü 40 230 Ü 30 1850 Ü 50
(Ver : 6.1)
S 10 Ü 3 142 Ü 40 330 Ü 30 1750 Ü 50
ø 17 Ü 3 242 Ü 40 440 Ü 30 -
ø Manually operated condition when prolix switch resistor is connected with CN-47.
2. HOW TO SWITCH THE VERSION(5.1 Ĉ 6.1) ON THE CLUSTER

You can switch the EPPR valve pressure set by selecting the version(5.1 Ĉ 6.1).
Step 1. Turn the key switch ON.
Step 2. Press the SELECT switch 3 times.
Step 3. While 7 segment on the cluster shows the version of the CPU controller program, for example
36C5.1 press the buzzer stop switch( ) + travel speed control switch( ) at the same
time for 2 seconds.
The display changes to 36C6.1, and it indicates that version 6.1(Option) is selected.
ö If you want to get back to ver:5.1, go to step 1~3.
5-26
GROUP 11 EPPR VALVE (#0078 and up)
1. COMPOSITION OF EPPR VALVE

EPPR(Electro Proportional Pressure Reducing) valve consists of electro magnet and spool valve
installed at main hydraulic pump.
1) ELECTRO MAGNET VALVE
Receive electric current from CPU controller and move the spool proportionally according to the
specific amount of electric current value.
2) SPOOL VALVE
Is the two way direction control valve for pilot pressure to reduce hydraulic pump flow.
When the electro magnet valve is activated, pilot pressure enters into flow regulator of hydraulic pump.
So, pump flow decreases to prevent engine stall.
3) PRESSURE AND ELECTRIC CURRENT VALUE FOR EACH MODE
Pressure Electric current Engine rpm
Mode
kgf/cm2 psi (mA) (At accel dial 10)
M 4Ü3 57 Ü 40 230 Ü 30 1850 Ü 50

Standard
H 10 Ü 3 142 Ü 40 330 Ü 30 1850 Ü 50
(Ver : 5.1)
S 10 Ü 3 142 Ü 40 330 Ü 30 1750 Ü 50
M 0 0 160 Ü 30 1850 Ü 50
Option
H 4Ü3 57 Ü 40 230 Ü 30 1850 Ü 50
(Ver : 6.1)
S 10 Ü 3 142 Ü 40 330 Ü 30 1750 Ü 50
ø 17 Ü 3 242 Ü 40 440 Ü 30 -
ø Manually operated condition when prolix switch resistor is connected with CN-47.
2. HOW TO SWITCH THE VERSION(3.1Ĉ 4.1) ON THE CLUSTER

You can switch the EPPR valve pressure set by selecting the version(3.1 Ĉ 4.1).
- Dual mode
ÂChanging the MCU mode
5-26-1
2. OPERATING PRINCIPLE
1) STRUCTURE
6 7
2 3 4 5
5-22(1) 360-7
1 Sleeve 4 O-ring 6 Solenoid valve

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

P A
T Return to tank
T
A Secondary pressure to flow regulator at hydraulic pump
2) AT H MODE
Pressure line is blocked and A oil returns to tank.
P A
T P T
3) AT S MODE
Secondary pressure enters into A.
P A
T P T
A
5-22(2) 360-7
5-27
3. EPPR VALVE CHECK PROCEDURE Spec : 200~450mA
1) CHECK ELECTRIC VALUE AT EPPR
VALVE
(1) Start engine.
(2) Set S-mode and cancel auto decel mode. CN-75
(3) Position the accel dial at 10.

(4) If tachometer show approx 1750±50rpm,
disconnect one wire harness from EPPR
EPPR VALVE
valve.
Multimeter
(5) Install multimeter as figure.

(6) Check electric current at bucket circuit
relief position.
5-23(1) 360-7
2) CHECK PRESSURE AT EPPR VALVE Spec : 2~25kgf/cm2(30~350psi)

(1) Remove plug and connect pressure
gauge as figure.
·Gauge capacity : 0 to 40-50kgf/cm2
(0 to 580-725psi)
(2) Start engine. Supply line, pilot press
(3) Set S-mode and cancel auto decel mode.

CN-75
(4) Position the accel dial at 10. Pressure adjusting
screw
locknut
(5) If tachometer show approx 1750±50rpm,
check pressure at relief position of bucket
circuit by operating bucket control lever.
(6) If pressure is not correct, adjust it.
(7) After adjust, test the machine. 5-23(2) 360-7
5-28
GROUP 12 MONITORING SYSTEM (up to #0077)
1. OUTLINE
Monitoring system consists of the monitor part and switch part.
The monitor part gives warnings when any abnormality occurs in the machine and informs the
condition of the machine.
Various select switches are built into the monitor panel, which act as the control portion of the machine
control system.
2. CLUSTER
1) MONITOR PANEL
Monitoring display
Fuel low level warning lamp Fuel gauge
Hyd oil temp warning lamp Hyd oil temp gauge
Engine coolant temp gauge

Overheat warning lamp
CPU controller
Air cleaner warning lamp check warning lamp
Power max pilot lamp
Engine oil pressure warning lamp
Preheat pilot lamp
Battery charging warning lamp

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

User mode switch
Buzzer stop switch

Auto deceleration switch Select switch
3607A5MS10
5-29
2) CLUSTER CHECK PROCEDURE
(1) Start key : ON
Η Check monitor initial 5 seconds
a. All lamps light up.
b. Buzzer sound.
Θ Check monitor after 5 seconds : Indicate cluster version and machine condition
a. Cluster program version : CL : 2.0 Indicates program version 2.0 for 2 seconds.
b. Tachometer : 0rpm
c. Fuel gauge : All light up below appropriate level
d. Hydraulic temperature : All light up below appropriate level
e. Engine coolant temperature gauge : All light up below appropriate level
f. Warning lamp
ö During start key ON the engine oil pressure lamp and battery charging lamp go on, but it is not
abnormal.
ö When engine coolant temperature below 30Á C, the warming up lamp lights up.
Ι Indicating lamp state
a. Work mode selection : General work
b. Power mode selection : S mode
c. User mode selection : No LED ON
d. Auto decel LED : ON
e. Travel speed pilot lamp : Low(Turtle)
(2) Start of engine
Η Check machine condition
a. Tachometer indicates at present rpm
b. Gauge and warning lamp : Indicate at present condition.
ö When normal condition : All warning lamp OFF
c. Work mode selection : General work
d. Power mode selection : S mode
e. User mode selection : No LED ON
f. Auto decel LED : ON
g. Travel speed pilot lamp : Low(Turtle)
Θ When warming up operation
a. Warming up lamp : ON
b. 10 seconds after engine started, engine speed increases to1100rpm(Auto decel LED : ON)
ö Others same as above Η
Ι When abnormal condition
a. The lamp lights up and the buzzer sounds.
b. If BUZZER STOP switch is pressed, buzzer sound is canceled but the lamp light up until
normal condition.
5-30
3. CLUSTER CONNECTOR
No. Signal Input / Output
1 Power IG(24V) Input(20~32V)

Cluster
2 GND Input(0V)
3 Serial-(RX) Input(Vpp=12V)
4 Serial+(TX) Output(Vpp=4V)
1 4
2 3
21075MS16
5-31
4. CLUSTER FUNCTION
1) Monitoring display
(1) This displays the current time and machine information such as
engine rpm, coolant/hydraulic oil temperature, hydraulic oil
pressure and also error codes.
ö Refer to the page 5-38 for details.
14073CD03
2) Fuel gauge
(1) This gauge indicates the amount of fuel in the fuel tank.
(2) Fill the fuel when the white range or warning lamp blinks.
ö If the gauge illuminates the white range or warning lamp
blinks even though the machine is on the normal condition,
White range
check the electric device as that can be caused by the poor
21073CD04
connection of electricity or sensor.
3) Hydraulic oil temperature gauge

(1) This indicates the temperature of coolant.
ÂWhite range : below 30Á C(86Á F)
ÂGreen range : 30-105Á C(86-221Á F)
Green range ÂRed range : above105Á C(221Á F)
White range
Red range (2) The green range illuminates when operating.
20W73CD05
(3) Keep idling engine at low speed until the green range
illuminates before operation of machine.
(4) When the red range illuminates, reduce the load on the system.
If the gauge stays in the red range, stop the machine and
check the cause of the problem.
4) Engine coolant temperature gauge

(1) This indicates the temperature of coolant.
ÂWhite range : below 30Á C(86Á F)
ÂGreen range : 30-105Á C(86-221Á F)
Green range ÂRed range : above 105Á C(221Á F)
White range
Red range (2) The green range illuminates when operating.
20W73CD05
(3) Keep idling engine at low speed until the green range
illuminates before operation of machine.
(4) When the red range illuminates, turn OFF the engine, check
the radiator and engine.
5-32
5) Fuel low level warning lamp
(1) This lamp blinks and the buzzer sounds when the level of fuel
is below 49˶(12.9U.S. gal).
(2) Fill the fuel immediately when the lamp blinks.
21073CD04A
6) Hydraulic oil temperature warning lamp

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

(1) This lamp blinks and the buzzer sounds when the temperature
of coolant is over the normal temperature 110Á
C 230Á
F) .
(2) Check the cooling system when the lamp blinks.
21073CD06A
8) Engine oil pressure warning lamp

(1) This lamp blinks and the buzzer sounds after starting the
engine because of the low oil pressure.
(2) If the lamp blinks during engine operation, shut OFF engine
immediately. Check oil level.
21073CD07
9) Air cleaner warning lamp

(1) This lamp blinks and the buzzer sounds when the filter of air
cleaner is clogged.
(2) Check the filter and clean or replace it.
21073CD08
5-33
10) CPU controller check warming lamp
(1) Communication problem between CPU controller and cluster
makes the lamp blink and the buzzer sounds.
(2) Check if any fuse for CPU burnt off.
(3) Check the communication line between CPU controller and
21073CD10 cluster.
11) Battery charging warning lamp

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

(1) When the machine is overload, the overload warning lamp
blinks during the overload switch ON.
21073CD15
13) Engine check warning lamp

Η This lamp blinks and buzzer sounds when the communication
between CPU controller and ECM on the engine is abnormal
or if any fault code received from ECM.
Θ Check the communication line between them. If the
commumication line is OK, then check the fault code on the
21073CD09 cluster.
14) Power max pilot lamp

(1) The lamp will be ON when pushing power max switch on the
LH RCV lever.
21073CD11
5-34
15) Decel pilot lamp
(1) Operating auto decel or one touch decel makes the lamp ON.
(2) The lamp will be ON when pushing one touch decel switch on
the LH RCV lever.
21073CD17
16) Warming up pilot lamp

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

(1) This lamp is turned ON when the preheating function is
actuated in cold weather.
(2) Start the engine as this lamp is OFF.
21073CD12
18) Work mode switch

(1) This switch is to select the machine operation mode, which
shifts from general operation mode to heavy operation mode
and breaker mode in a raw by pressing the switch.
Â : Heavy duty work mode
Â : General work mode
21073CD20 Â : Breaker operation mode
19) User mode switch

(1) This switch is to select the maximum power or user mode.
ÂM : Maximum power
ÂU : Memorizing operators preferable power setting
18073CD21
5-35
20) Auto deceleration switch
(1) This switch is used to actuate or cancel the auto deceleration
function. When actuated the engine speed is lowered
automatically when all control levers and pedals are at neutral
position to save the fuel.
ÂLight ON : Auto deceleration function is selected.
21073CD22 ÂLight OFF : Auto deceleration function is cancelled so that the
engine speed increased to previous setting value.
(2) Operating the auto deceleration function makes the decel
indicating lamp on the LCD panel ON.
21) Power mode switch

(1) The lamp of selected mode is turned ON by pressing the
switch( ).
ÂH : This is used for high power work.
ÂS : This is used for standard power work.
21073CD23
22) Travel speed control switch

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

(1) When the starting switch is turned ON first, normally the alarm
buzzer sounds for 2 seconds during lamp check operation.
(2) The red lamp lights ON and the buzzer sounds when the
machine has a problem.
In this case, press this switch and buzzer stops, but the red
21073CD25
lamp lights until the problem is cleared.
5-36
24) Select switch
(1) This switch is used to select the monitor display function.
(2) If the switch is pressed for 3 seconds in time display mode, it
moves to time adjusting function, and you can adjust the time
as below.
21073CD25A ÂHour by auto decel( )switch
ÂMinute by buzzer stop( ) switch.
(3) After time set, the switch is pressed, it returns to clock display.
5-37
5. MONITORING DISPLAY
1) OUTLINE
Information of machine performance as monitored by the CPU controller can be displayed on the
cluster when the operator selects a display mode by touching SELECT switch alone or with BUZZER
STOP switch on the cluster as below.
How to select display mode
Display group Name Display on the cluster
Group selection Display mode selection
Initial Engine rpm
Way 1 Touch SELECT 1 time Time

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

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

C)
Touch SELECT 5 times Ambient pressure(KPA)
Touch SELECT switch Default Current error

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

3 times while pressing
Group 3 BUZZER STOP.
Touch SELECT 3 times Travel oil pressure switch
(Switch input) In this group SELECT
LED blinks at 0.5sec
Touch SELECT 4 times One touch decel switch
interval
Touch SELECT 5 times Travel alarm switch
Touch SELECT 6 times Preheat switch
5-38
How to select display mode
Display group Name Display on the cluster
Group selection Display mode selection
Default Hourmeter
Neutral relay
Touch SELECT 1 time (Anti-restart relay)
Touch SELECT 2 times Travel speed solenoid

Touch SELECT switch
4 times while pressing Power boost solenoid
BUZZER STOP.
Touch SELECT 3 times (2-stage relief solenoid)
Group 4
(Output) In this group SELECT
LED blinks at 1sec Touch SELECT 4 times Boom priority solenoid
interval
Touch SELECT 5 times Travel alarm
Touch SELECT 6 times Max flow cut off solenoid
Touch SELECT 7 times Preheat relay
öBy touching SELECT switch once while pressing BUZZER STOP, display group shifts.
Example : Group 0 Ą 1 Ą 2 Ą 3 Ą 4 Ą 0
5-39
2) DESCRIPTION OF MONITORING DISPLAY
Group Display Name Description
It displays current engine speed detected by engine speed

1850 rpm Engine speed sensor from 500 to 3000rpm.
Range : 500~3000rpm by 10rpm
It displays current time(12 is hour and 30 is minute)

TIME 12 : 30 Time
Range : Hour(1~12), minute(00~59)
Power shift It shows that pump power shift pressure of EPPR valve being
EP : 10bar pressure of controlled by the CPU controller is 10bar.
EPPR valve Range : 00~50bar by 1bar
It shows that machine model(R360LC-7A) and the program

Model and CPU
36 : C5.1 version of the CPU controller is 1.0.
Group 0 program version
Version display range : 0.0~9.9 by 0.1
It displays front pump pressure of 100bar which is detected by

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

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

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

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

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

dL : 3.8V
voltage Range : 0.0~5.0V by 0.1V
Group 1
It shows that hydraulic oil temperature detected by temperature
Hydraulic oil
Á
Hd : 50Á
C sensor is 50ÁC.
temperature
Range : 0~150Á C by 1Á C
It shows that coolant oil temperature received from ECM is

Coolant
Ct : 85Á
C 50Á C.
temperature
Range : 0~150Á C by 1ÁC
Ambient It shows that ambient pressure recived from ECM is 120kpa

AP : 100
pressure Range : 0~125kpa by 1kpa
5-40
It shows that current error of 03(Short circuit in pump EPPR valve

system) is diagnosed by self diagnosis system in the CPU controller.
CHECK Er : 03 Current error If more than 2 errors, when pressing or switch, other
error codes show.
Range : 00~999
Group 2 It shows recorded error code of 03 which is diagnosed before.

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

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

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

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

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

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

PH : on or oFF Preheat switch PH : oFF Shows that preheat switch is released.
5-41
Ho : on Shows that hourmeter is activated by CPU controller.

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

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

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

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

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

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

PR : on or oFF Preheat relay PR : oFF Shows that preheat relay is released.
5-42
GROUP 12 MONITORING SYSTEM (#0078 and up)
1. OUTLINE
Monitoring system consists of the monitor part and switch part.
The monitor part gives warnings when any abnormality occurs in the machine and informs the
condition of the machine.
Various select switches are built into the monitor panel, which act as the control portion of the machine
control system.
2. CLUSTER
1) MONITOR PANEL
RPM display
Clock display
Fuel gauge
Hyd oil temp gauge
Engine coolant temp gauge
CPU controller
Air cleaner warning lamp check warning lamp
Power max pilot lamp
Engine oil pressure warning lamp Preheat pilot lamp
Battery charging warning lamp Warming up pilot lamp
Overload warning lamp

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

User mode switch
Buzzer stop switch

Auto deceleration switch Select switch
2507A5MS10
5-42-1
2) CLUSTER CHECK PROCEDURE
(1) Start key : ON
Η Check monitor initial 5 seconds
a. All lamps light up.
b. Buzzer sound.
Θ Check monitor after 5 seconds : Indicate cluster version and machine condition
a. Cluster program version :Ö1.00 × Indicates program versionÖ1.00 ×for 5 seconds.
b. Tachometer : 0rpm
c. Fuel gauge : All light up below appropriate level
d. Hydraulic temperature : All light up below appropriate level
e. Engine coolant temperature gauge : All light up below appropriate level
f. Warning lamp
ö During start key ON the engine oil pressure lamp and battery charging lamp go on, but it is not
abnormal.
ö When engine coolant temperature below 30Á C, the warming up lamp lights up.
Ι Indicating lamp state
a. Work mode selection : General work
b. Power mode selection : S mode
c. User mode selection : No LED ON
d. Auto decel LED : ON
e. Travel speed pilot lamp : Low(Turttle)
(2) Start of engine
Η Check machine condition
a. Tachometer indicates at present rpm
b. Gauge and warning lamp : Indicate at present condition.
ö When normal condition : All warning lamp OFF
c. Work mode selection : General work
d. Power mode selection : S mode
e. User mode selection : No LED ON
f. Auto decel LED : ON
g. Travel speed pilot lamp : Low(Turttle)
Θ When warming up operation
a. Warming up lamp : ON
b. 10 seconds after engine started, engine speed increases to1200rpm(Auto decel LED : ON)
ö Others same as above Η
Ι When abnormal condition
a. The lamp lights up and the buzzer sounds.
b. If BUZZER STOP switch is pressed, buzzer sound is canceled but the lamp light up until
normal condition.
5-42-2
3. CLUSTER CONNECTOR
No. Signal Input / Output
1 Power IG(24V) Input(20~32V)

Cluster
2 GND Input(0V)
3 Serial-(RX) Input(Vpp=12V)
4 Serial+(TX) Output(Vpp=4V)
1 4
2 3
21075MS16
5-42-3
2) LCD main operation display
Default screen
Default screen Option screen
Option screen 1 Time display
2 2
1 1 2 RPM display
4
4
5
3 Hydraulic oil temperature gauge
3 3
5 4 Fuel level gauge
1607A3CD02A 1607A3CD02B 5 Engine coolant temperature gauge
(1) Time display
Η This displays the current time.
ö Refer to the page 3-7 to set time for details.
1607A3CD02C
(2) RPM display

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

12th step
Η This gauge indicates the temperature of hydraulic oil in 12 step
gauge.
Â1st step : Below 30ÁC(86Á F)
Â2nd~10th step : 30-105 Á C(86-221Á F)
1st step Â11th~12th step : Above 105Á C(221Á F)
1607A3CD02D
Θ The gauge between 2nd and 10th steps illuminates when
operating.
Ι Keep idling engine at low speed until the gauge between 2nd
and 10th steps illuminates, before operation of machine.
Κ When the gauge of 11th and 12th steps illuminates, reduce the
load on the system. If the gauge stays in the 11th~12th steps,
stop the machine and check the cause of the problem.
(4) Fuel level gauge
1st step Η This gauge indicates the amount of fuel in the fuel tank.
Θ Fill the fuel when the 1st step or fuel icon blinks in red.
ö If the gauge illuminates the 1st step or fuel icon blinks in
red even though the machine is on the normal condition,
check the electric device as that can be caused by the poor
1607A3CD02E
connection of electricity or sensor.
(5) Engine coolant temperature gauge
12th step
Η This gauge indicates the temperature of coolant in 12 step
gauge.
Â1st step : Below 30ÁC(86Á F)
Â2nd~10th step : 30-105 Á C(86-221Á F)
1st step
Â11th~12th step : Above 105Á C(221Á F)
1607A3CD02F
Θ The gauge between 2nd and 10th steps illuminates when
operating.
Ι Keep idling engine at low speed until the gauge between 2nd
and 10th steps illuminates, before operation of machine.
Κ When the gauge of 11th and 12th steps illuminates, turn OFF
the engine, check the radiator and engine.
5-42-4
3) Warning of main operation screen
(1) Warning display
Η Engine coolant temperature
- This lamp blinks and the buzzer sounds
when the temperature of coolant is over
the normal temperature 105Á
C 221ÁF) .
- Check the cooling system when the lamp
blinks.
Θ Fuel level
when the level of fuel is below 49˶
(12.9U.S. gal).
- Fill the fuel immediately when the lamp
blinks.
Ι Hydraulic oil temperature
- This warning lamp operates and the
buzzer sounds when the temperature of
hydraulic oil is over 105 Á
C 221 Á
F) .
- Check the hydraulic oil level when the
lamp blinks.
- Check for debris between oil cooler and
radiator.
Κ All gauge
when the all gauge is abnormal.
- Check the each system when the lamp
blinks.
Λ Communication error
- Communication problem between CPU
controller and cluster makes the lamp
blinks and the buzzer sounds.
- Check if any fuse for CPU burnt off.
If not check the communication line
between them.
(2) Pop-up icon display
No Switch Selected mode Display No Switch Selected mode Display
1 Work mode General work 3 Auto
Light ON
switch mode deceleration
switch
Heavy duty
Light OFF
work mode
Breaker 4 Travel speed

Low speed
operation mode control
switch
2 Power mode High power
switch High speed
work mode
Standard power
work mode
5-42-5
4) LCD
SYSTEM MENU
1 : LCD
Monitoring Diagnosis Management
1 : Escape,
Settings Display User Mode 2
Return to the previous menu
3 : Down/Left Direction
4 : Up/Right Direction
2 5 : Select(Enter)
4 Activate the currently chosen item
3 5
2507A4OP95B
(1) Main menu
1 2 3 4
1 : Menu information
: Monitoring
2 Equipment, Switch, Output
: Diagnosis
3 Current error, Recorded error
5 6 7 4 : Maintenance
2507A4OP94
: Settings
5 Time set Dual mode
System lock(Reserved)
: Display
6
Operation skin, Brightness, Language
7 : User mode
5-42-6
(2) Display map
Η Monitoring
Θ Diagnosis
a. Protocol type 1
(Error display)
(Recorded error delete)
5-42-7
b. Protocol type 2
- If there are more than 2 error codes, each one can be displayed by pressing or
switch respectively.
- 3 error codes (ΗSPN200200, ΘFMI06, ΙSPN6789, ΚFMI04, Λ345) display.
Η Θ Λ No change
Η Ι Κ
Η Ι Ι
Ι Maintenance
Κ Setting
a. Time set
: Adjusting
: Setting
b. System lock - Reserved
5-42-8
c. Dual mode
- Changing the MCU mode
Λ Display
a. Operation skin
b. Brightness
c. Language
Μ User mode
Usermode(U) is not selected.
: Adjusting : Adjusting : Adjusting

: Setting : Setting : Setting
5-42-9
5) Warning and pilot lamp
(1) Engine oil pressure warning lamp
Η This lamp blinks and the buzzer sounds after starting the
engine because of the low oil pressure.
Θ If the lamp blinks during engine operation, shut OFF engine
immediately. Check oil level.
21073CD07
(2) Air cleaner warning lamp

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

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

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

Η When the machine is overload, the overload warning lamp
blinks during the overload switch is ON.
21073CD15
5-42-10
(6) Engine check warning lamp
Η This lamp blinks and the buzzer sounds when the
communication between CPU controller and ECU on the
engine is abnormal, or if any fault code received from ECU.
Θ Check the communication line between them.
If the communication line is OK, then check the fault code on
29073CD10 the cluster
(7) Power max pilot lamp

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

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

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

Η Turning the start key switch ON position starts preheating in
cold weather.
Θ Start the engine as this lamp is OFF.
21073CD12
5-42-11
Group 1 Before Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1

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

(Machine) 5-13
Fault codes
displayed on
monitor display
3 or 4 digit SEE PAGE
(Engine) 5-15
6-1
2. DIAGNOSING PROCEDURE
To carry out troubleshooting efficiently, the following steps must be observed.
STEP 1. Study the machine system

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

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

Before starting troubleshooting, check the
machine for the daily maintenance points as
shown in the operator's manual.
And also check the electrical system including
batteries, as the troubles in the electrical system ON THE
INSPECTION
such as low battery voltage, loose connections
and blown out fuses will result in malfunction of
the controllers causing total operational failures 6-2(3) 290-7
of the machine.
6-2
STEP 4. Inspect the trouble actually on the
machine
In case that some trouble cannot be confirmed,
obtain the details of the malfunction from the
operator.
Also, check if there are any in complete
connections of the wire harnesses are or not.
6-3(1) 290-7
STEP 5. Perform troubleshooting

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

Before reaching a conclusion, check the most
suspectible causes again. Try to trace what the
real cause of the trouble is.
Make a plan of the appropriate repairing
procedure to avoid consequential malfunctions.
6-3(3) 290-7
6-3
GROUP 2 HYDRAULIC AND MECHANICAL SYSTEM
1. INTRODUCTION
1) MACHINE IN GENERAL
(1) If even a minor fault is left intact and operation is continued, a fatal failure may be caused, entailing
a large sum of expenses and long hours of restoration.
Therefore when even a small trouble occurs, do not rely on your intuition and experience, but look
for the cause based on the troubleshooting principle and perform maintenance and adjustment to
prevent major failure from occurring. Keep in mind that a fault results from a combination of
different causes.
(2) The following lists up commonly occurring faults and possible causes with this machine. For the
troubleshooting of the engine, refer to the coming troubleshooting and repair.
(3) When carrying out troubleshooting, do not hurry to disassemble the components.
It will become impossible to find the cause of the problem.
(4) Ask user or operator the following.
① Was there any strange thing about machine before failure occurred?
② Under what conditions did the failure occur?
③ Have any repairs been carried out before the failure?
(5) Check before troubleshooting.
① Check oil and fuel level.
② Check for any external leakage of oil from components.
③ Check for loose or damage of wiring and connections.
6-4
2. DRIVE SYSTEM
1) UNUSUAL NOISE COMES OUT OF PUMP CONNECTION
Cause Remedy
YES
Coupling element Disassemble
is broken. and repair.
Remove dust plug
under engine
flywheel and
YES
check if rubber Replace hub or
pieces or particles retighten
are not present. Coupling hub setscrew.
spline is worn or
NO hub fastening
setscrew is slack.
If hydraulic pump or engine is
suspected as a culprit refer to this
NO
manual "Structure and function".
6-5
2) ENGINE STARTS BUT MACHINE DOES NOT OPERATE AT ALL
Cause Remedy
NO
Replenish
specified oil to
the standard
Is oil level in Abnormal noise level.
hydraulic oil YES YES
comes out of Hydraulic pump is Disassemble
tank within hydraulic pump
standard level? broken. and repair.
Do not hydraulic
pump and pump YES Abnormal noise YES
connections comes out of See item 1).
YES make abnormal
pump connection at page 6-5
noise?
Is primary pilot
pressure within ⓐ
NO standard level?
YES
Clean pilot
Is not pilot piping piping interior or
YES clogged or is not
oil leakage present repair piping.
on pilot piping?
NO
Pilot valve is Disassemble
ⓐ faulty. and repair.
YES
Pilot relief valve is Repair or
Is gear pump faulty. replace.
NO delivering oil?
NO Gear pump is Disassemble

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

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

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

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

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

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

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

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

normal?
Select valve is Repair or

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

NO
broken. and repair.
6-17
6. ATTACHMENT SYSTEM
1) BOOM OR ARM ACTION IS IMPOSSIBLE AT ALL
Cause Remedy
YES
Does the Port relief valve is Disassemble
symptom change faulty. and repair or
YES
when port relief
replace.
valve is replaced
Is MCV pilot with other valve? NO ⓐ
YES
pressure within
standard level?
Inspect if pilot
piping is not
OK
clogged or oil is Pilot valve is Disassemble
Are other NO
YES
not leaking from faulty. and repair.
attachments the piping.
operatable?
YES
Pilot relief valve is Disassemble
Is gear pump pilot YES
Is gear pump faulty. and repair or
pressure within
NO delivering oil? replace.
standard level?
NO
zzzz broken. and repair.
Are LH/RH
operations OK
possible? Hydraulic pump is Disassemble
Disassemble broken. and repair.
YES main relief valve
Remove dust plug and check if it is
under engine not irregular.
OK flywheel and Faulty
Main relief valve Disassemble
check if coupling is defective. and repair or
element particles replace.
Inspect oil are not present. Particles present Coupling at pump Disassemble
NO
volume in
hydraulic oil tank. connection is and repair.
broken.
Short Replenish
hydraulic oil.
YES
Cylinder interior is Disassemble
Does control
broken. and repair.
ⓐ valve spool move
lightly by hand?
NO Control valve Disassemble
6-18
2) BOOM, ARM OR BUCKET SPEED IS LOW
Cause Remedy
YES
Normal.
YES
Are other ⓐ
YES attachment
Is combination speeds within
Is speed low only of oil streams standard levels? NO ⓑ
in composite YES
normal at boom YES
operation? hoisting and at Flow summation Disassemble and
Does spool of flow
arm extrusion? summation check check valve spool repair.
NO valve move lightly is stuck.
Are LH/RH travel
by hand?
NO speeds within NO
standard levels?
YES
Are both LH/RH faulty. repair.
travel speeds YES ⓒ
NO
low? Is MCV pilot
pressure within
NO
standard? ⓓ
NO
OK
Does the Port relief valve is Disassemble and
symptom change faulty. repair or replace.
YES
when port relief
valve is replaced
Does control with other valve? Cylinder is faulty. Disassemble and
YES NO
valve spool move repair.
lightly by hand?
NO
Control valve spool Disassemble and
Is MCV pilot
ⓐ pressure within is stuck. repair.
standard level?
YES
Clean pilot piping
Is not MCV pilot
pressure piping interior or repair
NO clogged or is not piping.
there oil leakage? Pilot valve is Disassemble and
NO
defective. repair.
YES
Pilot relief valve is Disassemble and
Is primary pilot NO Is gear pump faulty. repair or replace.
ⓑ pressure within
delivering oil?
standard level?
NO
Gear pump is Disassemble and
broken. repair.
Is engine NO
ⓒ revolution within Adjust engine
standard level? revolution.
YES
Clean orifice in
control valve.
Is not orifice in
ⓓ control valve YES
clogged? Is pilot piping not Clean pilot piping
clogged or is oil interior or repair
NO not leaking from piping.
the piping? Is pilot valve Pilot valve is faulty. Disassemble and
NO normal? NO
repair.
6-19
3) BOOM, ARM OR BUCKET CYLINDER EXTENDS OR CONTRACTS ITSELF AND ATTACHMENT FALLS
Cause Remedy
YES
Port relief valve is Disassemble
Does the symptom faulty. and repair or
change when port
Normal replace.
relief valve is YES
replaced with ⓐ
normal valve? Is control valve
return spring
YES
Is not hydraulic NO
normal?
oil temperature Control valve's Disassemble
high? NO
return spring is and replace.
faulty.
Is genuine Abnormally high. Locate the
hydraulic oil or cause of
equivalent being
hydraulic oil
used?
temperature rise
and lower it to
proper level.
Replace with
NO
genuine
hydraulic oil or
equivalent.
OK
Pressure Disassemble
Disassemble and tightness and repair.
YES inspect check between control
valve in hydraulic
circuit and check valve casing and
for any fault. spool is poor.
Is cylinder internal Abnormal Contact surface Disassemble
ⓐ leakage within between poppet and repair.
standard level?
and seat is poor.
Cylinder is faulty. Disassemble

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

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

NO
possible? faulty. and repair.
Does the YES

Main relief valve Adjust pressure,
symptom change is faulty. repair or
Does the
when main relief
NO valves are symptom change replace.
when hydraulic YES
exchanged? Hydraulic pump is Disassemble
NO pump's discharge
hoses are broken. and repair.
exchanged?
6-21
6) BOOM MAKES A SQUEAKING NOISE WHEN BOOM IS OPERATED
Cause Remedy
YES
Frictional noise
occurs between
the sliding faces
of boom
cylinder's oil
Is boom foot pin seal and boom
greased proper.
sufficiently?
※ Frictional
noise will
disappear if
they are kept
used.
Boom foot pin Supply grease

NO
has run out of to it.
grease. ※
If seizure is in
an initial stage,
supply sufficient
grease.
If seizure is in
a grown state,
correct it by
paper lapping
or with an oil
stone.
6-22
※ HOW TO CHECK INTERNAL BOOM CYLINDER LEAKAGE
1. Lower the bucket teeth to the ground with
bucket cylinder fully retracted and arm
cylinder rod retracted almost in full.
3607A6TS01
2. Disconnect hoses(A) from rod side of boom

cylinder and drain oil from cylinders and
hose.(Put cups on piping and hose ends) A
6-20(2) 290-7
3. Raise bucket OFF the ground by retracting

the arm cylinder rod.
If oil leaks from piping side and boom
cylinder rod is retracted there is an internal
leak in the cylinder.
If no oil leaks from piping side and boom
cylinder rod is retracted, there is an internal
leak in the control valve.
29076TS01A/01
6-23
GROUP 3 ELECTRICAL SYSTEM
1. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT
APPEAR
·Before disconnecting the connector, always turn the starting switch OFF.
·Before carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No.7.
·After checking, insert the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
Defective clucter Replace
YES Check voltage
between CN-56
(1) and chassis Disconnection in Repair or
NO
wiring harness or replace
Check voltage
between CN-5(3) poor contact (After clean)
and chassis between CN-5(3)-
CN-56(1)
Starting switch : ON
Voltage : 20~32V
NO Disconnection in Repair or
wiring harness or replace
poor contact (After clean)
between CN-5(3)-
and fuse No.7
CLUSTER FUSE
POWER IG(24V) 1 3
NO.7
GND 2 9
RX
TX
CN-56 CN-5
Check voltage
YES 20 ~ 32V
NO 0V
3607A6ES01
6-24
2. COMMUNICATION ERROR "Co : Er" FLASHES ON THE CLUSTER
·Before carrying out below procedure, check all the related connectors are properly inserted.
Cause Remedy
YES
Defective controller Replace
YES Check voltage

between CN-56
(3,4) and chassis
Disconnection in Repair or replace
NO wiring harness or (After clean)
Check voltage
between CN-5 poor contact
between CN-56
(10,11)and (3,4) CN-5(10,11)
chassis
KEY ON
NO
wiring harness or (After clean)
poor contact
between CN-5
(10,11)-CN-50
(29,30)
CONTROLLER
Check voltage
29
YES *4V *12V
NO 0V 0V
30
CN-50
CLUSTER
POWER IG(24V)
GND 2 9
RX *12V
3 10
TX *4V 4 11
CN-56 CN-5
29076ES02
6-25
3. BATTERY CHARGING WARNING LAMP LIGHTS UP(Starting switch : ON)
Cause Remedy
YES
YES Check voltage
between CN-51
(9) and chassis Disconnection in Repair or replace
NO
YES Check voltage poor contact
between CN-2
(13) and chassis between CN-51(9)
-CN-2(13)
Check voltage Disconnection in Repair or replace

NO wiring harness or (After clean)
between alternator
poor contact
terminal "I" and between
chassis CN-2(13)-alternator
Voltage : 20~32V terminal "I"
Engine : Running
Defective alternator Replace

NO
Check voltage
YES 20 ~ 32V
NO 0V
CONTROLLER ALTERNATOR
B+ G
9 13 3~
I
U
GND
CN-74
CN-51 CN-2
36076MS05
6-26
4. WHEN COOLANT OVERHEAT WARNING LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
Is the CAN poor contact
YES communication between
between CPU ECM-coolant temp
and ECM OK?
sensor
Starting switch : ON YES
Does the gauge Check resistance
light up and between CN-98 or ECM
down at lamp NO (A-B) & CN-99
check? (A-B). Defective wiring Replace
NO
Starting switch : ON Spec : 120Ω harness
Defective cluster Replace

NO
RESISTOR RESISTOR
A A A A
ECM
B B
B C B C
CN-98 CN-99
CONTROLLER
25 5 48
26 6 47
27 7 37
CN-50 CN-3 CN-93
3607A6ES02
6-27
5. WHEN AIR CLEANER WARNING LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
Clogged air filter or Check filter or
defective switch replace switch
Does display go off
when disconnect YES
CD-10? Short circuit in Repair or replace
Starting switch : ON Check resistance wiring harness (After clean)
Engine : Start between CN-51
NO
(16) and chassis
Starting switch : OFF
NO
Disconnect CN-51
Check resistance
YES MAX 1Ω
NO MIN 1MΩ
CONTROLLER AIR CLEANER SWITCH
Pa
16
CD-10
CN-51
3607A6ES03
6-28
6. WHEN ENGINE OIL PRESSURE WARNING LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
between CPU ECM-engine oil
and ECM OK?
pressure switch.
check? (A- B) Defective wiring Replace
NO
Starting switch : ON Spec : 120Ω
harness

NO
RESISTOR RESISTOR
A A A A
ECM
B B
B C B C
CN-98 CN-99
CONTROLLER
25 5 48
26 6 47
27 7 37
CN-50 CN-3 CN-93
3607A6ES02
6-29
7. WHEN HYDRAULIC OIL TEMPERATURE WARNING LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
High temperature Check hydraulic
Resistance oil temperature
YES between CD-1 (100。 C±2。 C) ,
(1,2) is in range Replace
of 130~150Ω?
Starting switch : ON Defective temp Replace
Does display go Disconnect CD-1 NO
sensor
off when
disconnect CD-1? YES
Short circuit Check and repair
Engine : Start
Resistance
between CN-51
NO (31,34) is 0~1Ω?

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

TEMPERATURE SENDER
34 2
C
31 1
CN-51 CD-1
29076ES04
6-30
8. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE
Cause Remedy
YES
between CPU ECM-coolant temp
and ECM OK?
sensor
check? (A-B). Defective wiring Replace
NO
Starting switch : ON Spec : 120Ω
harness

NO
RESISTOR RESISTOR
A A A A
ECM
B B
B C B C
CN-98 CN-99
CONTROLLER
25 5 48
26 6 47
27 7 37
CN-50 CN-3 CN-93
3607A6ES02
6-31
9. WHEN FUEL GAUGE DOES NOT OPERATE(Check warning lamp ON/OFF)
Cause Remedy
YES
Disconnection in Check and repair
wiring harness
Is resistance
YES between CN-51
(24) and (31)
over 1kΩ? YES
Starting switch : OFF
Disconnect CN-51
Check resistance
Does the gauge between CD-2(1)
light up and NO and (2)
down at lamp Defective fuel Replace
NO
check? Disconnect CD-2
sensor
See Table

NO
Green range Red range

Check Table
Level White range Green range Red range
Item
Unit Resistance(Ω) 700~601 600~101 ~100
White range Tolerance(%) ±5 ±5 ±5
CONTROLLER
FUEL SENDER
24 1
CD-2
31
CN-51
29076ES06
6-32
10. WHEN SAFETY SOLENOID DOES NOT OPERATE
short of fuse No.26.
Cause Remedy
YES
Hydraulic Check hydraulic
YES Check operation malfunction system
of solenoid
Defective solenoid Replace
Safety lever : ON-OFF NO
YES
Defective switch Replace
YES Check voltage
between CS-4(C)
Check voltage and chassis
between CN- Disconnection in Repair or replace
68(1) - CN-68(2) Start switch : ON NO
YES Check voltage Voltage : 20~30V
Starting switch : ON between CN-4(8) Disconnect CN-4 poor contact
Voltage : 20~30V and chassis between
Safety state
CS-4(C)-CN-68(2)
Voltage : 20~30V
Disconnect CN-4 Disconnect in Repair or replace
Check voltage NO
between CN-68(2) wiring harness or (After clean)
NO
with chassis poor contact
between
Safety lever : OFF
Starting switch : ON CN-4(8)-CN-68(2)
Voltage : 20~30V
Disconnection in Replace
NO
fuse No. 26
SAFETY SWITCH
CS-20 FUSE
NO.26
SAFETY SWITCH
B C A 6 SAFETY SOLENOID
B 7 2
A C 8 1
CS-4 CN-4 CN-68
3607A6ES04
6-33
11. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE
short of fuse No.24 .
Cause Remedy
YES
Defective hydraulic Check hydraulic
system system
YES Check voltage YES Check operation
between CN-50 YES
of solenoid Defective controller Replace
(13) and chassis
Check resistance
Check if travel Starting switch : ON Starting switch : ON between CN-70
Voltage : 20~30V : OFF NO
speed lamps( , (1) and (2)
Disconnect CN-50 : ON
) change when Defective solenoid Replace
Starting switch : OFF NO
pressing the travel
speed switch on SPEC : 15~25Ω
Disconnect CN-70
the cluster YES
Check controller
Y R G
NO
NO
CONTROLLER
TRAVEL SOLENOID
13 1
CN-50 CN-70
FUSE
NO.24
36076ES04
6-34
12. WHEN ENGINE DOES NOT START
·Before carrying out below procedure, check all the related connectors are properly inserted. CN-8
·After checking, insert the disconnected connectors again immediately unless otherwise specified. CS-2
II I O H
1
I,O
9
2
4
H
10 3
ACC BR
4 1
B
11 2
5 3
Cause Remedy 12
6
C ST
YES 5
Defective battery Check engine 6
system charge or ECM POWER RY START SWITCH

replace(After 2 1
1
checking specific
2
gravity of battery)
3
Check operation YES
Check voltage Defective magnet Replace 4 4 3
of start motor YES between starter of start motor CR-45
magnet coil and
Starting switch : START chassis Defective start relay Replace POWER RY
NO 30
Starting switch : START YES
30 86
Check operation SPEC : 20~30V ⓐ 86
YES
Check voltage
of start relay CR- between CR-5 87 CS-74
BATTERY RY
1
NO 23 85 2 2
(30) and chassis
Defective start Repair or replace 87a 87 85 1 CN-60
NO 87a
CR-1
Starting switch : START safety relay (After clean)
Starting switch :START
Check operation SPEC : 20~30V
CR-35
of start safety FUSE
NO relay CR-5
NO.1
YES DO-2 DO-1
Check voltage Defective relay Replace
between CR-5
NO (86) and chassis Disconnection in Repair or replace
1
2
2
NO
Starting switch : ON poor contact
Voltage : 20~30V
between CR-5(86)
and CS-2(5) CN-51
YES 9
Defective start relay Replace
Check voltage
ⓐ between CR-23 CPU CONTROLLER
(2) and chassis Disconnection in Repair or replace CN-92
NO wiring harness or (After clean) 11
Voltage : 20~30V poor contact CN-50
between CR-5(87)-
CR-23(2)
START RY STARTER
ANTI-RESTART RY
M M
30 7 2
86 30
86 1
87 B+
85 CN-2 CR-23
85 87 87a CN-45
87a
CR-5
3607A6ES05
6-35
13. WHEN STARTING SWITCH ON DOES NOT OPERATE
master switch ON. CN-8
CS-2
II I O H
1
I,O
9
2
4
H
10 3
ACC BR
4 1
B
11 2
Cause Remedy 5 3
YES 12
6
C ST
5
6
poor contact ECM POWER RY START SWITCH
YES Check voltage 1 2 1
between DO-2 between DO-2(1)-
2
(1) and chassis CR-1 or defective
3
Voltage : 20~30V
battery relay
4 4 3
CR-45
YES Check voltage Disconnection in Replace
between CS-2 NO POWER RY
wiring harness or
(2) and chassis 30
30 86
poor contact
86
Voltage : 20~30V between CS-2(2)-
Check voltage Starting switch : ON 87 CS-74
BATTERY RY
YES 1
between CS-2(1) CN-8(11)- DO-2(1) 85 2 2
87a 87 85
and chassis 87a
1 CN-60
CR-1
Defective starting Replace CR-35
Voltage : 20~30V NO
switch
FUSE
Check voltage Disconnection in Replace NO.1
and specific NO
wiring harness or DO-2
gravity of battery
poor contact
Specific gravity : MIN 1.28
1
2
Voltage : MIN 24V between CS-2(1)-
CN-8(12)-CN-60-
CR-1-Battery
Battery capacity too Charge or replace

NO
low (After clean)
CPU CONTROLLER
11
CN-50
ANTI-RESTART RY
86 30 30
START RY STARTER
86
M M
87 7 2
85 1
85 87 87a
87a
B+
CR-5 CN-2 CR-23
CN-45
3607A6ES06
6-36
14. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE
·Before carrying out below procedure, check all the related connectors are properly inserted and the fuse CN-21
No.5,10 and 15 is not blown out. 3 1
2
5 3
4 4
Cause Remedy 5
NO CN-5
6 M 2 6
Defective wiper Replace 1
cut switch
WIPER MOTOR FUSE
YES 4
Check operation wiring harness or (After clean) CN-141 NO.5
wiper cut switch poor contact FEED BACK 1 CN-6
FUSE
between CN-141 MOTOR DRIVE SIG 2 CN-17 5
Front sliding door Check voltage (11)- CS-53 MOTOR DRIVE- 3 1 6 NO.15
open-close CN-22
between CN-141 YES MOTOR DRIVE+ 4 2 9
YES (11) and chassis Defective switch Replace 2 M
GND 5 3 10
panel
NO Check voltage VCC 6 4 11 1
Front sliding door-close between CN-116
Voltage : 4~5V (6) and chassis CONTINUE 24V 7 5 WASHER TANK
Check operation 1)Recheck fuse Replace WASHER P/P 8 6
NO NO.10
of switch panel Starting switch : ON WASHER SIG. 9 7
NO Voltage : 20~30V
LED ON. 2)Disconnection in Repair or replace INT. SIG 10 8
wiring harness or (After clean) WIPER CUT SW 11
Starting switch : ON ⓐ poor contact
Push wiper switch button YES N.C 12 CN-7
between CN-
116(6)-Fuse FEED BACK 13 3 FUSE
between CN- WIPER MOTOR CONTROLLER 5
116(13)-Chassis 9 NO.10
NO 10
Check voltage between Defective switch Replace WIPER CUT SW
CN-116(4) and chassis panel
Intermittent CS-53 CN-9
NO
1) Recheck fuse Replace
Check voltage CN-116 NO.5
ⓐ
(12) and chassis 2) Disconnection Repair or replace
Washing
Check operation in wiring harness (After clean) 4
CN-116
of wiper motor or poor contact HEAD LIGHT OUT 1
Check voltage CN-116 and controller between CN- WORK LIGHT OUT 2
(15) and chassis check voltage 141(7)-Fuse, WORK LIGHT OUT 3
YES CN-141(7) and
CN-21(4)-Fuse WIPER MOTOR DRIVE 4
Voltage : 0~1V
chassis, CN-21(4) PRE-HEAT 5
and chassis NO POWER 24V 6
1) Recheck fuse Replace CABIN LIGHT OUT 7
Starting switch : OFF NO.15
Voltage : 20~30V Check voltage CABIN LIGHT OUT 8
2) Disconnection Repair or replace HEAD LIHGT 24V 9
CN-141(6)-and
YES chassis CN-141(6)-Fuse (After clean) WORK LIGHT 24V 10
WORK LIGHT 24V 11
Starting switch : ON ⓑ WASHER SIG 12
Check continuity YES GND 13
Voltage : 20~30V
NO
between Disconnection in Repair or replace TRAVEL ALARM 14
CN-141(2)-CN-116(4), wiring harness or (After clean)
INT. SIG 15
CN-141(9)-CN-116(12), CABIN LIGHT 24V 16
poor contact CABIN LIGHT 24V 17
CN-141(10)-CN-116(15),
ⓑ CN-141(5)-Chassis , NO SWITCH PANEL
Check wiper Defective wiper Replace
CN-141(1)-CN-21(5), motor resistance motor
CN-141(3)-CN-21(6),
YES between CN-21
CN-141(4)-CN-21(2), (2)-CN-21(6) Defective wiper Replace
CN-141(13)-CN-21(3) YES motor controller 3607A6ES07
Resistance : 3~4Ω
6-37
15. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP
HEAD LAMP
·After checking, insert the disconnected connectors again immediately unless otherwise specified. 2
1
Cause Remedy CL-4

NO
Defective lamp Replace switch
switch HEAD LAMP RY
1 2 1
2
3
4 4 3
Check voltage CR-13
YES
between CN-116 YES
(1) and chassis Defective bulb Replace
YES
Check voltage
Starting switch : ON between CL-4(1)
Head lamp switch : ON and chassis
Voltage : 20~30V Disconnection in Repair or replace CN-7
Starting switch : ON NO CN-116
Head lamp switch : ON wiring harness or (After clean) 1 1 HEAD LIGHT OUT
Check voltage
between CN-7(1)
Voltage : 20~30V poor contact 2 WORK LIGHT OUT
YES and chassis 3 WORK LIGHT OUT
between CN-7(1)-
4 WIPER MOTOR DRIVE
CL-4(1) 5 PRE-HEAT
Starting switch : ON 6 POWER 24V
Head lamp switch : ON 7 7 CABIN LIGHT OUT
Check voltage Voltage : 20~30V Disconnection in Repair or replace
NO 8 CABIN LIGHT OUT
between CN-116 wiring harness or (After clean) 9 HEAD LIHGT 24V
(9) and chassis 10 10 WORK LIGHT 24V
poor contact 11 WORK LIGHT 24V
Starting switch : ON between 12 WASHER SIG
Head lamp switch : 13 GND
ON-OFF
CN-116(1)-CN-
14 TRAVEL ALARM
7(1) 15 INT. SIG
16 CABIN LIGHT 24V
YES 17 CABIN LIGHT 24V
Disconnection in Repair or replace SWITCH PANEL
Check voltage poor contact
between CN-7 between CN-116
NO (7) and chassis FUSE
(9)-CN-7(7)
Head lamp switch : ON NO.16
Recheck fuse Replace
NO
No. 16
3607A6ES08
6-38
16. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP
Cause Remedy WORK LAMP

NO
Defective lamp Replace switch
1
switch
2
CL-5
CN-12 WORK LAMP
Check voltage
YES
between CN-116 YES 2 1
(2, 3) and chassis Defective bulb Replace
Check voltage 1 2
YES
Starting switch : ON between CL-5(2)
Work lamp switch : ON and chassis CL-6
Voltage : 20~30V Disconnection in Repair or replace
Starting switch : ON NO
Work lamp switch : ON wiring harness or (After clean)
Check voltage Voltage : 20~30V poor contact
between CN-7(2) CN-7
YES and chassis between CN-7(1) CN-116
1 HEAD LIGHT OUT
-CL-5(2) and 2 2 WORK LIGHT OUT
Work lamp switch : ON
CL-6(2) 3 WORK LIGHT OUT
Check voltage Voltage : 20~30V
4 WIPER MOTOR DRIVE
between CN-116 5 PRE-HEAT
(10,11) and Disconnection in Repair or replace 6 POWER 24V

NO
wiring harness or (After clean) 8 7 CABIN LIGHT OUT
chassis
8 CABIN LIGHT OUT
Starting switch : ON poor contact 9 HEAD LIHGT 24V
Work lamp switch : 10 WORK LIGHT 24V
ON-OFF
between CN-116 10
11 WORK LIGHT 24V
Voltage : 20~30V (2,3)-CN-7(2) 12 WASHER SIG
13 GND
14 TRAVEL ALARM
YES 15 INT. SIG
Disconnection in Repair or replace 16 CABIN LIGHT 24V
17 CABIN LIGHT 24V
Check voltage SWITCH PANEL
poor contact
between CN-7(8) between CN-116
NO and chassis
(10,11)-CN-7(8)
Head lamp switch : ON FUSE
Voltage : 20~30V
NO Recheck fuse Replace NO.17
No. 17
36076ES09
6-39
GROUP 4 MECHATRONICS SYSTEM
1. ALL ACTUATORS SPEED ARE SLOW

※ Boom, Arm, Bucket, Swing and travel speed are slow, but engine speed is good.
※ Spec : M-mode 1850± 50rpm H-mode 1850± 50rpm S-mode 1750 ± 50rpm
※ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE
Cause Remedy
YES
Defective
YES Check pressure hydraulic system
at EPPR valve
NO
Check electric NO Defective Replace
SPEC : 5~20kgf/cm2
current at EPPR See TEST 3
EPPR valve
valve
SPEC : 200~450mA Defective CPU Replace
See TEST 2 NO
Check if Er : 03 controller
on the cluster
YES
Short circuit or Check and repair
poor connection wire harness or
Check resistance between CN-50 - between CN-50-
YES at EPPR valve CN-75 CN-75
SPEC : 17.5±1Ω(20。
C) Defective EPPR Replace
See TEST 1 NO
valve
Wiring diagram
RESISTOR
1
2 2
CN-47 1
CN-19B
CONTROLLER
8
FUSE
24
28 NO.11
36 EPPR VALVE
CN-50 1 2
2 1
CN-19 CN-75
3607A6MS01
6-40
2) TEST PROCEDURE
SPEC : 17.5±1Ω(20。
C)
(1) Test 1 : Check resistance at connector
CN-75.
① Starting key OFF.
② Disconnect connector CN-75 from EPPR
valve at main hydraulic pump.
③ Check resistance between 2 lines as
figure.
6-38(2) 290-7
(2) Test 2 : Check electric current at EPPR SPEC : 200~450mA(S mode)

valve.
① Install multimeter as figure.
② Start engine.
③ Set the accel dial at "10"(MAX)
④ Set S-mode and cancel auto decel mode.
⑤ If tachometer show approx 1750±50rpm,
check electric current.
6-38(3) 290-7
(3) Test 3 : Check pressure at EPPR valve. SPEC : 5~20kgf/cm2(70~280psi)

① Remove plug and connect pressure
gauge as figure.
·Gauge capacity : 0 to 40~50kgf/cm2
(0 to 570~710psi)
② Start engine.
③ Set the accel dial at "10"(Max).
④ Set S-mode and cancel auto decel mode.
⑤ If tachometer show approx 1750±50rpm,
check pressure.
⑥ If pressure is not correct, adjust it.
⑦ After adjust, test the machine.
6-39(1) 290-7
6-41
2. ENGINE STALL
Cause Remedy
YES
Not enough engine Contact cummins
YES Check pressure power engine dealer
at EPPR Valve
Defective EPPR Replace
SPEC:5~20kgf/cm2 NO
See TEST 5
valve
Check electric
current at EPPR YES
valve Short circuit or Check and repair
poor connection wire harness
SPEC : 200~450mA
See TEST 4 between
Check resistance CN-50 - CN-2 or
NO at EPPR valve
CN-50 - CN-75
SPEC : 17.5±1Ω(20。
C)
See TEST 1 Defective EPPR Replace
NO
valve
Wiring diagram
RESISTOR
1
2 2
CN-47 1
CN-19B
CONTROLLER
8
FUSE
24
28 NO.11
36 EPPR VALVE
CN-50 1 2
2 1
CN-19 CN-75
3607A6MS01
6-42
2) TEST PROCEDURE SPEC : 200~450mA
(1) Test 4 : Check electric current at EPPR
valve at S-mode
CN-75
① Install multimeter as figure.
② Start engine.
③ Set the accel dial at "10"(max)
④ Set S-mode with 1750±50rpm.
⑤ Check electric current. EPPR VALVE
Multimeter
6-44(1) 290-7
(2) Test 5 : Check pressure at EPPR valve at SPEC : 5~20kgf/cm2(70~280psi)

S-mode
① Connect pressure gauge at EPPR valve.
② Start engine.
③ Set the accel dial at "10"(max) Supply line, pilot press
④ Set S-mode with 1750±50rpm.
⑤ Operate bucket lever completely push or CN-75
pull. Pressure adjusting
⑥ Hold arm lever at the end of stroke. screw locknut
⑦ Check pressure at relief position.
6-44(2) 290-7
6-43
3. MALFUNCTION OF CLUSTER OR MODE SELECTION SYSTEM
Cause Remedy
YES
No power supply to Check fuse
See if all lamps the CPU controller
YES
off in the CPU
controller case YES
Y R G CPU failure Replace
Y R G
See if Co : Er
NO
on the cluster
NO Y R G
ⓐ
NO
OK
Check connection Cluster failure Replace
between CN-50
ⓐ (29) - CN-5(10) or
CN-50(30) - CN-5
(11) No connection Check and repair
NO
KEY OFF
Wiring diagram
CPU CONTROLLER
CLUSTER
24
POWER IG(24V)
GND 28
RX 3 10 29
TX 4 11 30
CN-56 CN-5 CN-50
FUSE
NO.11(CPU)
36072MS02
6-44
4. AUTO DECEL SYSTEM DOES NOT WORK
Cause Remedy
YES
Defective CPU Replace
controller
NO
Check voltage Short circuit or Replace or repair
between CN-51 poor connection
(1)-GND and vetween CN-51(1),
CN-51(13)-GND
(13)- pressure
SPEC : switches
Actuator operating :
0~1V
Actuator stop :4~5V Defective auto Replace
See TEST 6 NO
See TEST 7 decel pressure
switch
Wiring diagram
WORK PRESSURE SWITCH

CPU CONTROLLER
1
Pa
1 2
CD-7
13 1
Pa
2
CN-51 CD-6
TRAVEL PRESSURE SWITCH
3607A6MS10
6-45
2) TEST PROCEDURE SPEC : Actuator stop : 4~5V
(1) Test 6 : Check voltage at CN-51(1) and Actuator operating : 0~1V
ground. Y R G
① Prepare 1 piece of thin sharp pin, steel or CPU

CONTROLLER
copper. PIN
② Starting key ON. CN-50

CN-51
③ Insert prepared pin to rear side of

connectors : One pin to (1) of CN-51.
④ Check voltage as figure.
(2) Test 7 : Check voltage at CN-51(13) and
ground.
CN-51
① Prepare 1 piece of thin sharp pin, steel or 12
24
1
copper 36 25
② Starting key ON. Ground

③ Insert prepared pin to rear side of
connectors : One pin to (13) of CN-51
④ Check voltage as figure. Multimeter
CN-51 12 1
24 13
36 25
Ground
Multimeter
29076MS11
6-46
5. MALFUNCTION OF WARMING UP
Cause Remedy
YES
Defective CPU Repair or Replace
Check resistance controller or
YES
between CN-50 Sensor
(26) - ECM(47)
SPEC : Below10Ω NO Poor connection Repair
Check resistance KEY OFF
between CN-50
between CN -50
(25) - ECM(48) (26) - ECM(47)
SPEC : Below 10Ω
KEY OFF
NO
Poor connection Repair
between CN-50
(25) - ECM(48)
Wiring diagram
RESISTOR RESISTOR
A A A A
ECM
B B
B C B C
CN-98 CN-99
CONTROLLER
25 5 48
26 6 47
27 7 37
CN-50 CN-3 CN-93
3607A6ES02
6-47
6. MALFUNCTION OF POWER MAX
Cause Remedy
YES Check resistance
between CN-88 Defective power Repair or replace
Resistance (1) - (2) max. solenoid valve
YES
between CN-51 SPEC: 15-30Ω
(2)-GND normal? See TEST 8
NO Short circuit or poor Repair or replace

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

3 1
2
CN-50
CN-88
1
2 2
FUSE
CN-51 CN-4 NO.25
POWER MAX SWITCH
2
CS-29
3607A6MS04
6-48
2) TEST PROCEDURE SPEC : Key ON : 24±1V
Key OFF : 0V
(1) Test 8: Check voltage between connector Resistance : 15~30Ω
CN-88 - GND.
① Start key ON.
② Disconnect connector CN-88 from power Power max. switch
max solenoid valve.
③ Check voltage as figure.
LH RCV-lever
CN-88
CN-88
Power max.
solenoid valve
Multimeter
29076MS14
(2) Test 9 : Check resistance between

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

③ Check resistance as figure. CONTROLLER
CN-51
CN-50
CN-51
12 2
24 13
36 25
Ground
Multimeter
29076MS15
6-49
Group 1 Operational Performance Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1

Group 2 Major Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21
Group 3 Track and Work Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-32
GROUP 1 OPERATIONAL PERFORMANCE TEST
1. PURPOSE
Performance tests are used to check:
1) OPERATIONAL PERFORMANCE OF A
NEW MACHINE
Whenever a new machine is delivered in
parts and reassembled at a customer's site,
it must be tested to confirm that the
operational performance of the machine Working
meets Hyundai spec. condition
WORKING MACHINE
With the passage of time, the machine's
Maintenance
operational performance deteriorates, so record
that the machine needs to be serviced
periodically to restore it to its original
performance level.
Before servicing the machine, conduct
performance tests to check the extent of Operating
deterioration, and to decide what kind of
service needs to be done(by referring to the
"Service Limits" in this manual).
REPAIRED MACHINE
After the machine is repaired or serviced, it
must be tested to confirm that its
operational performance was restored by
the repair and/or service work done. 21077MS01
7-1
2. TERMINOLOGY
1) STANDARD
Specifications applied to the brand-new
machine, components and parts.
21077MS02
2) SERVICE LIMIT
The lowest acceptable performance level.
When the performance level of the machine
falls below this level, the machine must be
removed from work and repaired.
Necessary parts and components must be
replaced.
21077MS03
7-2
3. OPERATION FOR PERFORMANCE TESTS
1) Observe the following rules in order to carry
out performance tests accurately and
safely.
(1) The machine
Repair any defects and damage found,
such as oil or water leaks, loose bolts,
cracks and so on, before starting to test.
(2) Test area
① Select a hard, flat surface.
② Secure enough space to allow the
machine to run straight more than 20m,
and to make a full swing with the front
attachment extended.
③ If required, rope off the test area and
provide signboards to keep unauthorized
personnel away.
(3) Precautions
① Before starting to test, agree upon the
signals to be employed for communication
among coworkers. Once the test is 7-3 (360-7)
started, be sure to communicate with
each other using these signals, and to
follow them without fail.
② Operate the machine carefully and
always give first priority to safety.
③ While testing, always take care to avoid
accidents due to landslides or contact
with high voltage power lines. Always
confirm that there is sufficient space for
full swings.
④ Avoid polluting the machine and the
ground with leaking oil. Use oil pans to
catch escaping oil. Pay special attention
to this when removing hydraulic pipings.
(4) Make precise measurements
① Accurately calibrate test instruments in
advance to obtain correct data.
② Carry out tests under the exact test
conditions prescribed for each test item.
③ Repeat the same test and confirm that
the test data obtained can be procured
repeatedly. Use mean values of
measurements if necessary.
7-3
2) ENGINE SPEED
(1) Measure the engine speed at each power
mode
※ The engine speed at each power mode
must meet standard RPM; if not, all other
operational performance data will be
unreliable. It is essential to perform this
test first.
(2) Preparation
① Warm up the machine, until the engine
coolant temperature reaches 50。 C or
more, and the hydraulic oil is 50±5。 C.
② Set the accel dial at 10(Max) position.
③ Push the H-mode switch and confirm that
the fuel injection pump governor lever
comes into contact with the high-idle
stopper.
④ Measure the engine RPM.
(3) Measurement
① Start the engine. The engine will run at
start idle speed. Measure engine speed
with a tachometer.
② Measure and record the engine speed at
each mode(M, H, S).
③ Select the H-mode.
④ Lightly operate the bucket control lever a
few times, then return the control lever to
neutral; The engine will automatically
enter the auto-idle speed after 4
seconds.
⑤ Measure and record the auto deceleration
speed.
(4) Evaluation
The measured speeds should meet the following specifications.
Unit : rpm
Model Engine speed Standard Remarks
Start idle 700±100
M mode 1850±50
H mode 1850±50
R360LC-7A
S mode 1750±50
Auto decel 1100±50
One touch decel 700±50
Condition : Set the accel dial at 10(Max) position.
7-4
3) TRAVEL SPEED
(1) Measure the time required for the
excavator to travel a 20m test track.
(2) Preparation
① Adjust the tension of both tracks to be
equal.
② Prepare a flat and solid test track 20m in
length, with extra length of 3 to 5m on
0.3~0.5m
both ends for machine acceleration and
deceleration.
③ Hold the bucket 0.3 to 0.5m above the
ground with the arm and bucket rolled in.
④ Keep the hydraulic oil temperature at 50
±5。 C. 290LC7MS01
(3) Measurement
① Measure both the low and high speeds of
the machine.
② Before starting either the low or high
speed tests, adjust the travel mode
switch to the speed to be tested, then
select the following switch positions.
· Mode selector : M mode
③ Start traveling the machine in the
acceleration zone with the travel levers at 3 ~ 5m 20m 3 ~ 5m
full stroke.
④ Measure the time required to travel 20m.
⑤ After measuring the forward travel speed,
turn the upperstructure 180。 and
measure the reverse travel speed.
⑥ Repeat steps ④ and ⑤ three times in 290LC7MS02
each direction and calculate the average

values.
(4) Evaluation
The average measured time should meet the following specifications.
Unit : Seconds / 20m
Model Travel speed Standard Maximum allowable Remarks
1 Speed 24.0±2.0 30
R360LC-7A
2 Speed 15.0±1.0 18.8
7-5
4) TRACK REVOLUTION SPEED
(1) Measure the track revolution cycle time
with the track raised off ground.
(2) Preparation
① Adjust the tension of both side tracks to
be equal.
② On the track to be measured, mark one
90~110
shoe with chalk.
③ Swing the upperstructure 90。and lower
the bucket to raise the track off ground.
Keep the boom-arm angle between 90 to Mark
110。as shown. Place blocks under
machine frame.
21077MS06
±5。 C.
(3) Measurement
① Select the following switch positions.
· Travel mode switch : 1 or 2 speed
· Auto decel switch : OFF
② Operate the travel control lever of the
raised track in full forward and reverse.
③ Rotate 1 turn, then measure time taken
for next 3 revolutions.
④ Raise the other side of machine and
repeat the procedure.
⑤ Repeat steps ③ and ④ three times and
calculate the average values.
(4) Evaluation
The revolution cycle time of each track should meet the following specifications.
Unit : Seconds / 3 revolutions
Model Travel speed Standard Maximum allowable

1 Speed 39.5±2.0 49
R360LC-7A
2 Speed 24.5±2.0 30
7-6
5) TRAVEL DEVIATION
(1) Measure the deviation by the tracks from
a 20m straight line.
(2) Preparation
① Adjust the tension of both tracks to be
equal.
② Provide a flat, solid test yard 20m in
length, with extra length of 3 to 5m on
0.3~0.5m
both ends for machine acceleration and
deceleration.
③ Hold the bucket 0.3 to 0.5m above the
ground with the arm and bucket rolled in.
290LC7MS01
±5。 C.
(3) Measurement
① Measure the amount of mistracking at
high and low travel speeds.
② Before beginning each test, select the
following switch positions. 3~5m extra length
· Mode selector : M mode a
M
20
③ Start traveling the machine in the
acceleration zone with the travel levers at
full stroke. 3~5m extra length
④ Measure the distance between a straight
20m line and the track made by the
machine.(Dimension a)
⑤ After measuring the tracking in forward
travel, turn the upperstructure 180。and
measure that in reverse travel. 7*-7(2) 360-7
⑥ Repeat steps ④ and ⑤ three times and
(4) Evaluation
Mistrack should be within the following specifications.
Unit : mm / 20m
Model Standard Maximum allowable Remarks
R360LC-7A 200 below 240
7-7
6) SWING SPEED
(1) Measure the time required to swing three
complete turns.
(2) Preparation
① Check the lubrication of the swing gear
and swing bearing.
② Place the machine on flat, solid ground
with ample space for swinging. Do not
conduct this test on slopes.
③ With the arm rolled out and bucket rolled
in, hold the bucket so that the height of
the bucket pin is the same as the boom
foot pin. The bucket must be empty.
±5。 C.
290LC7MS03
(3) Measurement
② Operate swing control lever fully.
③ Swing 1 turn and measure time taken to
swing next 3 revolutions.
④ Repeat steps ② and ③ three time and
(4) Evaluation
The time required for 3 swings should meet the following specifications.
Unit : Seconds / 3 revolutions
Model Power selector switch Standard Maximum allowable
R360LC-7A M mode 20±1.5 25
7-8
7) SWING FUNCTION DRIFT CHECK
(1) Measure the swing drift on the bearing
outer circumference when stopping after a
360。full speed swing.
(2) Preparation
① Check the lubrication of the swing gear
and swing bearing.
② Place the machine on flat, solid ground
with ample space for swinging. Do not
conduct this test on slopes.
③ With the arm rolled out and bucket rolled
290LC7MS03
foot pin. The bucket must be empty.
④ Make two chalk marks: one on the swing
bearing and one directly below it on the
track frame.
⑤ Swing the upperstructure 360。.
⑥ Keep the hydraulic oil temperature at 50
±5。 C.
(3) Measurement
① Conduct this test in the M mode.
② Select the following switch positions.
③ Operate the swing control lever fully and
return it to the neutral position when the
mark on the upperstructure aligns with
that on track frame after swinging 360。.
④ Measure the distance between the two
marks. Drift angle
⑤ Align the marks again, swing 360。, then
test the opposite direction. 360 swing
Swing start & stop
⑥ Repeat steps ④ and ⑤ three times each
and calculate the average values.
21077MS08
(4) Evaluation
The measured drift angle should be within the following specifications.
Unit : Degree
Model Mode select switch Standard Maximum allowable Remarks
R360LC-7A M mode 90 below 112.5
7-9
8) SWING BEARING PLAY
(1) Measure the swing bearing play using a
dial gauge to check the wear of bearing
races and balls.
(2) Preparation
① Check swing bearing mounting cap
screws for loosening.
② Check the lubrication of the swing
bearing. Confirm that bearing rotation is
smooth and without noise.
③ Install a dial gauge on the track frame as
shown, using a magnetic base.
④ Position the upperstructure so that the
7-10(1) 360-7
boom aligns with the tracks facing
towards the front idlers.
⑤ Position the dial gauge so that its needle
point comes into contact with the bottom
face of the bearing outer race.
⑥ Bucket should be empty.
(3) Measurement Measurement : (h1)
① With the arm rolled out and bucket rolled
in, hold the bottom face of the bucket to
the same height of the boom foot pin.
Record the dial gauge reading(h1).
② Lower the bucket to the ground and use it
to raise the front idler 50cm.
Measurement : (h2)
Record the dial gauge reading(h2).
③ Calculate bearing play(H) from this
data(h1 and h2) as follows.
H=h2-h1
(4) Evaluation 7-10(1) 360-7
The measured drift should be within the following specifications.

Unit : mm
Model Standard Maximum allowable Remarks
R360LC-7A 0.5 ~ 1.5 3.0
7-10
9) HYDRAULIC CYLINDER CYCLE TIME
(1) Measure the cycle time of the boom,
standard arm, and standard bucket
cylinders.
(2) Preparation
① To measure the cycle time of the boom Raise
cylinders:
With the arm rolled out and the empty
bucket rolled out, lower the bucket to the
ground, as shown. Lower
② To measure the cycle time of the arm
cylinder.
With the empty bucket rolled in, position
the arm so that it is vertical to the ground.
Lower the boom until the bucket is 0.5m
above the ground. Roll out Roll in
③ To measure the cycle time of the bucket
cylinder.
90
The empty bucket should be positioned 0.5m
at midstroke between roll-in and roll-out,
so that the sideplate edges are vertical to
the ground.
±5。 C.
(3) Measurement
· Mode selector : M mode Roll out Roll in
② To measure cylinder cycle times.
0.5m
- Boom cylinders.
Measure the time it takes to raise the 21077MS10
boom, and the time it takes to lower the

boom. To do so, position the boom at
one stroke end then move the control
lever to the other stroke end as quickly as
possible.
- Arm cylinder.
Measure the time it takes to roll in the
arm, and the time it takes to roll out the
arm. To do so, position the bucket at
one stroke end, then move the control
possible.
7-11
- Bucket cylinder
Measure the time it takes to roll in the
bucket, and the time it takes to roll out the
bucket. To do so, position the bucket at
one stroke end, then move the control
possible.
- Repeat each measurement 3 times and
(4) Evaluation
The average measured time should meet the following specifications.
Unit : Seconds
Model Function Standard Maximum allowable Remarks
Boom raise 4.0±0.4 4.8

Boom lower 4.0±0.4 4.8
Arm in 3.5±0.4 4.4
R360LC-7A
Arm out 3.0±0.3 3.6
Bucket load 2.6±0.4 3.3
Bucket dump 2.7±0.3 3.3
7-12
10) DIG FUNCTION DRIFT CHECK
(1) Measure dig function drift, which can be
caused by oil leakage in the control valve
and boom, standard arm, and standard
bucket cylinders, with the loaded bucket.
When testing the dig function drift just
after cylinder replacement, slowly operate
each cylinder to its stroke end to purge air.
(2) Preparation
① Load bucket fully. Instead of loading the
bucket, weight(W) of the following
specification can be used.
· W=M3×1.5
Where :
M3 = Bucket heaped capacity(m3)
1.5= Soil specific gravity
② Position the arm cylinder with the rod 20
to 30mm extended from the fully retracted
position.
290LC7MS05
③ Position the bucket cylinder with the rod
20 to 30mm retracted from the fully
extended position.
④ With the arm rolled out and bucket rolled
foot pin.
⑤ Keep the hydraulic oil temperature at 50
±5。 C.
(3) Measurement
① Stop the engine.
② Five minutes after the engine has been
stopped, measure the changes in the
positions of the boom, arm and bucket
cylinders.
③ Repeat step ② three times and calculate
the average values.
(4) The measured drift should be within the following specifications.
Unit : mm / 5min
Model Drift to be measured Standard Maximum allowable Remarks
Boom cylinder 10 below 20

R360LC-7A Arm cylinder 10 below 20
Bucket cylinder 40 below 50
7-13
11) CONTROL LEVER OPERATING FORCE
(1) Use a spring scale to measure the
maximum resistance of each control lever
at the middle of the grip.
(2) Preparation
① Keep the hydraulic oil temperature at
50±5。C.
(3) Measurement
① Start the engine.
② Select the following switch positions.
③ Operate each boom, arm, bucket and
swing lever at full stroke and measure the
maximum operating force for each.
④ Lower the bucket to the ground to raise
one track off the ground. Operate the
travel lever at full stroke and measure the
maximum operating force required.
When finished, lower the track and then
jack-up the other track.
⑤ Repeat steps ③ and ④ three times and
(4) Evaluation
The measured operating force should be within the following specifications.
Unit : kgf
Model Kind of lever Standard Maximum allowable Remarks
Boom lever below 1.6 2.0

Arm lever below 1.6 2.0
R360LC-7A Bucket lever below 1.6 2.0
Swing lever below 1.6 2.0
Travel lever 2.1 below 3.15
7-14
12) CONTROL LEVER STROKE
(1) Measure each lever stroke at the lever top
using a ruler.
※ When the lever has play, take a half of this
value and add it to the measured stroke.
(2) Preparation
Keep the hydraulic oil temperature at 50±
5。C.
(3) Measurement
② Measure each lever stroke at the lever
top from neutral to the stroke end using a
ruler.
③ Repeat step ② three times and calculate
the average values.
(4) Evaluation
The measured drift should be within the following specifications.
Unit : mm
Model Kind of lever Standard Maximum allowable Remarks
Boom lever 87±10 109

Arm lever 87±10 109
R360LC-7A Bucket lever 87±10 109
Swing lever 87±10 109
Travel lever 142±10 178
7-15
13) PILOT PRIMARY PRESSURE
(1) Preparation
② Remove the top cover of the hydraulic
tank oil supply port with a wrench.
③ Loosen and remove plug on the pilot
pump delivery port a3 and connect
pressure gauge.
a3
④ Start the engine and check for oil
leakage from the port.
⑤ Keep the hydraulic oil temperature at 50
±5。 C.
(2) Measurement
· Auto decel switch : OFF
36077MS01
② Measure the primary pilot pressure in the
M mode.
(3) Evaluation
The average measured pressure should meet the following specifications:
Unit : kgf / cm2
Model Engine speed Standard Allowable limits Remarks
R360LC-7A M mode 35±5 -
7-16
14) FOR TRAVEL SPEED SELECTING PRESSURE
(1) Preparation
③ Push the pressure release button to
bleed air.
④ To measure the speed selecting pressure:
Install a connector and pressure gauge
assembly to turning joint P port as shown.
⑤ Start the engine and check for on
leakage from the adapter.
±5。 C.
(2) Measurement
① Select the following switch positions. 21077MS13
Travel mode switch : 1 speed

2 speed
② Measure the travel speed selecting
pressure in the Hi or Lo mode.
③ Lower the bucket to the ground to raise
the track off the ground. Operate the
travel lever at full stroke and measure the
fast speed pressure.
④ Repeat steps ② and ③ three times and
(3) Evaluation
The average measured pressure should be within the following specifications.
Unit : kgf / cm2
Model Travel speed mode Standard Maximum allowable Remarks
1 Speed 0 -
R360LC-7A
2 Speed 35±5 -
7-17
15) SWING PARKING BRAKE RELEASING PRESSURE
(1) Preparation
③ The pressure release L wrench to bleed
air.
④ Install a connector and pressure gauge
assembly to swing motor SH port, as
shown.
⑤ Start the engine and check for oil SH
leakage from the adapter.

±5。 C.
(2) Measurement
② Operate the swing function or arm roll in
function and measure the swing brake
control pressure with the brake
disengaged. Release the control lever
36077MS02
to return to neutral and measure the
control pressure when the brake is
applied.
Repeat step ② three times and calculate
the average values.
(3) Evaluation
Unit : kgf / cm2
Model Description Standard Allowable limits Remarks
Brake disengaged 30~50 26~44
R360LC-7A
Brake applied Less than 4 -
7-18
16) MAIN PUMP DELIVERY PRESSURE
(1) Preparation
a1
bleed air.
④ To measure the main pump pressure.
assembly main pump gauge port (a1, a2)
as shown.
⑤ Start the engine and check for oil
leakage from the port. a2
±5。 C.
(2) Measurement
· Mode selector : M mode 36077MS03
② Measure the main pump delivery
pressure in the M mode(High idle).
(3) Evaluation
The average measured pressure should meet the following specifications.
Unit : kgf / cm2
Model Engine speed Standard Allowable limits Remarks
R360LC-7A High ilde 40±5 -
7-19
17) SYSTEM PRESSURE REGULATOR RELIEF SETTING
(1) Preparation
bleed air.
④ To measure the system relief pressure. a1

assembly main pump gauge port(a1, a2)
as shown.
⑤ Start the engine and check for oil
leakage from the port.
±5。 C.
(2) Measurement a2
② Slowly operate each control lever of
boom, arm and bucket functions at full
stroke over relief and measure the
pressure.
③ In the swing function, place bucket
36077MS03
against an immovable object and
measure the relief pressure.
④ In the travel function, lock undercarriage
with an immovable object and measure
the relief pressure.
(3) Evaluation
Unit : kgf / cm2
Model Function to be tested Normal Over load
Boom, Arm, Bucket 330(360)±10 390±10

R360LC-7A Travel 330±10 -
Swing 260±10 -
( ) : Power boost
7-20
GROUP 2 MAJOR COMPONENT
1. MAIN PUMP
3 1 2
9 5 6 4 7 8
36077MP01
Standard Recommended
Part name & inspection item replacement Counter measures
dimension value
Clearance
between piston(1) & cylinder Replace piston
d D 0.038 0.078 or cylinder.
bore(2)
(D-d)
Play between
piston(1) & shoe caulking
0-0.1 0.35
section(3)
(δ) Replace
assembly of
Thickness of shoe piston & shoe.
δ
(t) t 5.4 5.0
Free height of cylinder Replace cylinder

spring(4) spring.
40.9 40.1
(L)
L
Combined height of set

Replace retainer
plate(5) & spherical
23.8 22.8 or set plate.
bushing(6) h H
(H-h)
Surface roughness for valve Surface roughness

necessary to be corrected 3z
plate(Sliding face)(7,8),
swash plate (shoe plate Lapping
area)(9), & Standard surface roughness 0.4z or lower
cylinder(2)(Sliding face) (Corrected value)
7-21
2. MAIN CONTROL VALVE (-#0169)
Part name Inspection item Criteria & measure

Casing ÂExistence of scratch, rusting or corrosion. ÂIn case of damage in following section,
replace part.
- Sliding sections of casing fore and spool,
especially land sections applied with
holded pressure.
- Seal pocket section where spool is inserted.
- Seal section of port where O-ring contacts.
- Seal section of each relief valve for main,
travel, and port.
- Other damages that may damage normal
functions.
Spool ÂExistence of scratch, gnawing, rusting or ÂReplacement when its outside sliding
corrosion. section has scratch(Especially on seals-
contacting section).
ÂO-ring seal sections at both ends. ÂReplacement when its sliding section has
scratch.
ÂInsert spool in casing hole, rotate and ÂCorrection or replacement when O-ring is
reciprocate it. damaged or when spool does not move
smoothly.
Poppet ÂDamage of poppet or spring ÂCorrection or replacement when sealing is

incomplete.
ÂInsert poppet into casing and function it. ÂNormal when it can function lightly without
being caught.
Around spring ÂRusting, corrosion, deformation or breaking ÂReplacement for significant damage.
of spring, spring seat, plug or cover.
Around seal ÂExternal oil leakage. ÂCorrection or replacement.

for spool
ÂRusting, corrosion or deformation of seal ÂCorrection or replacement.
plate.
Main relief valve, ÂExternal rusting or damage. ÂReplacement.

port relief valve &
ÂContacting face of valve seat. ÂReplacement when damaged.
negative control
relief valve ÂContacting face of poppet. ÂReplacement when damaged.
ÂAbnormal spring. ÂReplacement.
ÂO-rings, back up rings and seals. Â100 replacement in general.
7-22
2. MAIN CONTROL VALVE (#0170-)
Part name Inspection item Criteria & measure
Casing ÂExistence of scratches, rust or corrosion. ÂIn case of damage in following section,
replace casing.
- Sliding sections of casing hole and spool,
especially land sections applied with held
pressure.
- Seal pocket section where spool is inserted.
- Sealing section of port where O-ring
contacts.
- Sealing section of each relief valve for main
and port.
- Sealing section of plug.
- Other damages that may damage normal
function.
Spool ÂExistence of scratch, gnawing, rusting or ÂReplacement when its outside sliding
corrosion. section has scratch (especially on seals-
contacting section).
ÂO-ring seal sections at both ends. ÂReplacement when its sliding section has
scratch.
ÂInsert spool into casing hole, rotate and ÂCorrection or replacement when O-ring is
reciprocate it. damaged or when spool does not move
smoothly.
Poppet ÂDamage of spring ÂReplacement.

ÂDamage of poppet ÂCorrection or replacement when sealing is
incomplete.
ÂInsert poppet into casing and function it. ÂNormal when it can function lightly and
smoothly without sticking.
Spring and related ÂRusting, corrosion, deformation or breakage ÂReplacement for significant damage.
parts of spring, spring seat, plug or cover.
Around seal ÂExternal oil leakage. ÂCorrection or replacement.

for spool
ÂRusting, corrosion or deformation of seal ÂCorrection or replacement.
plate.
Main relief valve, ÂExternal rusting or damage. ÂReplacement.

port relief valve &
ÂContacting face of valve seat. ÂReplacement when damaged.
control relief valve
ÂContacting face of poppet. ÂReplacement when damaged.
ÂO-rings and back up rings. ÂReplacement in principle.
7-22-1
3. SWING DEVICE
Part name Inspection item Remedy
Balance plate ·Worn less than 0.03mm ·Lapping

·Worn more than 0.03mm ·Replacement
·Sliding surface has a seizure(Even ·Replacement
through small).
Shoe of piston ·Sliding surface has a damage. ·Lapping

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

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

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

Needle bearing
·Rolling surface has a damage. ·Replacement
Roller bearing
7-23
4. TRAVEL MOTOR
Replace parts in accordance with the following standards. However, if a part is damaged significantly
in terms of its appearance, replace it irrespective of the standards.
1) HYDRAULIC MOTOR
Part name & inspection item dimension value for Remedy
replacement
Clearance between piston &

0.052mm 0.077mm Replacement
cylinder bore(D-d)
Clearance caulked part

0.1mm 0.3mm Replacement
between piston and shoe(δ)
Thickness of shoe 5.5mm 5.3mm Replacement
Assembled height of spherical

23.8mm 23.3mm Replacement as a set
bush and set plate(H-h)
Free length of cylinder spring 40.9mm 40.3mm Replacement
Shaft over pin dia.

Output spline 43.91(Ø5) 43.31mm Replacement if either one
Cylinder spline 49.06(Ø5) 48.46mm reaches replacement value.
Spline over dia.

Spline in cylinder 35.25(Ø5) 35.75mm Replacement
Spline in spherical bushing
Thickness of separation plate 1.5mm 1.3mm

Replacement
Thickness of friction plate 3.9mm 3.7mm
Free length of brake spring 42.4mm 41.4mm Replacement
Displacement over teeth

50.02(7teeth) 49.42mm Replacement
Over pin dia. of friction
152.97(Ø5) 153.57mm Replacement
plate internal teeth
Roughness of sliding surfaces

Swash plate/shoe 0.4 - z 3-z Each independent lapping
Cylinder block/valve plate 0.4 - z 3-z Mutual lapping
Roller bearing Replacement if flaking is

- -
Needle bearing found on rolling surface.
O-ring Replacement at every

- -
Oil seal disassembly, in principle.
7-24
replacement
Replacement if elongation is
Bolt - -
found.
d D
δ
clearance between piston Play at caulking between piston and shoe : δ

and cylinder bore : D-d
h H
Thickness of shoe : t Assembled height of set plate

and spherical bushing : H-h
7-25
2) REDUCTION GEAR
replacement
Pitting area Replacement pitting
Pitting or crack of gear -
rate : 10% or crack is found
Motor driving gear external Overpin 43.31mm (Z=14)

spline 43.91(Ø5)
Overpin
No. 1 sun gar internal spline 30.85mm Replacement (Z=14)
30.25(Ø5)
Displacement
Reduction No. 1 sun gear 41.92mm Do. (Z=23)
42.22(4teeth)
ratio
i = 70.145 Displacement
No. 1 planetary gear 43.68mm Do. (Z=26)
43.98(4teeth)
Overpin
No. 1 carrier internal spline 82.162mm Do. (Z=23)
81.562(Ø5)
Displacement
No. 2 sun gear 31.10mm Do. (Z=23)
31.40(3teeth)
Displacement
43.67(4teeth)
Overpin
No. 2 carrier internal spline 112.84mm Do. (Z=25)
112.24(Ø10)
Displacement
No. 3 sun gear 54.62mm Do. (Z=25)
54.92(4teeth)
Displacement
54.93(3teeth)
Overpin
Ring gear (3rd stages) 349.34mm Do. (Z=71)
348.74(Ø8.5)
Crack and flaking of bearing inner/outer Replacement if crack or

- -
races and rollers flaking is found.
Crack and flaking of 1st/2nd/3rd Replacement if crack or

- -
planetary gears and pins flaking is found.
7-26
replacement
Replacement of abnormal
Radial clearance of needle bearing 0.01-0.04mm 0.07mm
parts as a set.
Replacement if such
Crack of spline contact part - - damage as crack, crevice of
chipping is found.
Dimension check and

Backlash of spline contact part 0.1-0.3mm 0.5mm replacement according to
following standards.
Thrust ring(026) 7mm thick 6.6mm Replacement if severe wear

or seizure is found on sliding
Thrust ring(027) 8mm thick 7.6mm surface.
Replacement of scratch or
rust is found in sliding
Floating seal - - surface.
Replacement if O-ring is
deformed of damaged.
1st time : 500hr

2nd time and later :
Every 2000hr After
SAE 85W-140 disassembling, fill with new
Gear oil -
(API GL-5) oil without fail.
The above times are
measured with engine
hour meter.
7-27
5. RCV LEVER
Maintenance
Criteria Remark
check item
Leakage The valve is to be replaced when the leakage Conditions :
becomes more than 1000cc/m at neutral handle Primary pressure : 30kgf/cm2
position, or more than 2000cc/m during operation. Oil viscosity : 23cSt
Spool This is to be replaced when the sliding surface has The leakage at the left condition is
worn more than 10μm, compared with the non- estimated to be nearly equal to the
sliding surface. above leakage.
Push rod
Ø7
1mm
This is to be replaced when the top end has worn

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

drop, etc. are generated during operation, and
these cannot be remedied, referring to section 6.
Troubleshooting, replace the related parts.
Notes 1. It is desirable to replace seal materials, such as O-rings, every disassembling. However,
they may be reused, after being confirmed to be free of damage.
2. When loosening the plug(3), replace the O-ring(4) without fail.
7-28
6. RCV PEDAL
Maintenance Criteria Remark
check item
Leakage The valve is to be replaced when the leakage effect Conditions :
to the system. For example, the primary pressure Primary pressure : 30kgf/cm2
drop. Oil viscosity : 23cSt
Spool This is to be replaced when the sliding surface has The leakage at the left condition is
worn more than 10μm, compared with the non- estimated to be nearly equal to the
sliding surface. above leakage.
Push rod
Ø7
1mm
This is to be replaced when the top end has worn

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

drop, etc. are generated during operation, and
these cannot be remedied, referring to section 6.
Troubleshooting, replace the related parts.
Notes 1. It is desirable to replace seal materials, such as O-rings, every disassembling. However,
they may be reused, after being confirmed to be free of damage.
7-29
7. TURNING JOINT
Part name Maintenance standards Remedy
Sliding surface with Plating worn or peeled due to seizure or contamination. Replacement
sealing sections.
Sliding surface ·Worn abnormality or damaged more than 0.1mm Replacement

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

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

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

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

(0.059in)
7-30
8. CYLINDER
Part name Inspecting section Inspection item Remedy
Piston rod ·Neck of rod pin ·Presence of crack ·Replacement

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

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

than coating
7-31
GROUP 3 TRACK AND WORK EQUIPMENT
1. TRACK
1) TRACK ROLLER
2
1
3 4
21037MS01
Unit : mm
No. Check item Criteria Remedy
Standard size Repair limit

1 Outside diameter of flange
Ø250 -
Rebuild or
2 Outside diameter of tread Ø200 Ø188 replace
3 Width of tread 54.6 60.6
4 Width of flange 34.4 -
Standard size & tolerance Standard Clearance
Clearance between shaft Shaft Hole clearance limit Replace
5
and bushing -0.25 +0.176 bushing
Ø85 -0.35 Ø85 +0.029 0.279 to 0.526 2.0
Side clearance of roller Standard clearance Clearance limit

6 Replace
(Both side) 0.12~1.3 2.0
7-32
2) CARRIER ROLLER
4 3
5
21037MS02
Unit : mm

1 Outside diameter of flange
Ø200 -
Rebuild or
2 Outside diameter of tread Ø191 Ø181 replace
3 Width of tread 51 56
4 Width of flange 20 -
5
and support 0 +0.3 0.1 bushing
Ø57.15 -0.1 Ø57.15 +0.1 to 0.4 1.2
7-33
3) IDLER
8
1
2
7
3 5
4
21037MS03
Unit : mm

1 Outside diameter of protrusion
Ø646 -
2 Outside diameter of tread Ø594 Ø580 Rebuild or
3 Width of protrusion 102 - replace
4 Total width 203 -

5 Width of tread 50.5 57.5
6
and bushing 0 +0.05 bushing
Ø85 -0.035 Ø85.35 0 0.35 to 0.435 2.0
Clearance between shaft 0 +0.09
7 and support Ø85 -0.035 Ø85 +0.036 0.036 to 0.125 1.2 Replace
Side clearance of idler Standard clearance Clearance limit

8 Replace
(Both side) 0.25 to 1.2 2.0
7-34
4) TRACK
2 1
4
3
21037MS04
Unit : mm
Standard size Repair limit Turn or

1 Link pitch replace
215.9 220.9
2 Outside diameter of bushing ͚71 ͚60.4
Rebuild or
3 Height of grouser 36 21 replace
4 Height of link 129 115
5 Tightening torque Initial tightening torque : 140Ü14kgfÂm Retighten
7-35
5) TRACK FRAME AND RECOIL SPRING
2
3
1
21037MS05
Unit : mm
Standard size Tolerance Repair limit

+2
1 Vertical width of idler guide Track frame 123 -1
127
0 Rebuild or
Idler support 120 - 1.5 116
replace
+2
Track frame 292 -1 296
2 Horizontal width of idler guide
Idler support 290 - 287

Free Installation Installation Free Installation
3 Recoil spring length length load length load Replace
Ø251×826.5 670.2 21100kg - 16880kg
7-36
2. WORK EQUIPMENT
A C D E F
B K J I H G
3607A7MS20
Unit : mm
Pin Bushing
Remedy
Measuring point Normal Recomm. Recomm.
Mark Limit Limit &
(Pin and Bushing) value service service
of use of use Remark
limit limit
A Boom Rear 120 119 118.5 120.5 121 Replacement

B Boom Cylinder Head 100 99 98.5 100.5 101 〃
C Boom Cylinder Rod 110 109 108.5 110.5 111 〃
D Arm Cylinder Head 110 109 108.5 110.5 111 〃
E Boom Front 110 109 108.5 110.5 111 〃
F Arm Cylinder Rod 110 109 108.5 110.5 111 〃
G Bucket Cylinder Head 90 89 88.5 90.5 91 〃
H Arm Link 90 89 88.5 90.5 91 〃
I Bucket and Arm Link 100 99 98.5 100.5 101 〃
J Bucket Cylinder Rod 90 89 88.5 90.5 91 〃
K Bucket Link 100 99 98.5 100.5 101 〃
7-37
Group 1
Precaution - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1
Group 2
Tightening Torque - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-4
Group 3
Pump Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-7
Group 4
Main Control Valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-31
Group 5
Swing Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-51
Group 6
Travel Device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-72
Group 7 RCV Lever - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-104
Group 8 Turning Joint - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-119
Group 9 Boom, Arm and Bucket Cylinder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-124
Group 11 Work Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-153
GROUP 1 PRECAUTIONS
1. REMOVAL WORK
1) Lower the work equipment completely to the ground.
If the coolant contains antifreeze, dispose of it correctly.
2) After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
3) When draining oil, prepare a container of adequate size to catch the oil.
4) Confirm the match marks showing the installation position, and make match marks in the
necessary places before removal to prevent any mistake when assembling.
5) To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors.
6) Fit wires and hoses with tags to show their installation position to prevent any mistake when
installing.
7) Check the number and thickness of the shims, and keep in a safe place.
8) When raising components, be sure to use lifting equipment of ample strength.
9) When using forcing screws to remove any components, tighten the forcing screws alternately.
10) Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
11) When removing hydraulic equipment, first release the remaining pressure inside the hydraulic tank
and the hydraulic piping.
12) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
number D d L
06 6 5 8
08 8 6.5 11
10 10 8.5 12
12 12 10 15
14 14 11.5 18 Taper 1/8
øD ød
16 16 13.5 20
18 18 15 22
20 20 17 25
L
22 22 18.5 28
24 24 20 30
27 27 22.5 34
8-1
2. INSTALL WORK
1) Tighten all bolts and nuts(Sleeve nuts) to the specified torque.
2) Install the hoses without twisting or interference.
3) Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
4) Bend the cotter pin or lock plate securely.
5) When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded
portion with 2-3 drops of adhesive.
6) When coating with gasket sealant, clean the surface and remove all oil and grease, check that there
is no dirt or damage, then coat uniformly with gasket sealant.
7) Clean all parts, and correct any damage, dents, burrs, or rust.
8) Coat rotating parts and sliding parts with engine oil.
9) When press fitting parts, coat the surface with antifriction compound(LM-P).
10) After installing snap rings, check that the snap ring is fitted securely in the ring groove(Check that
the snap ring moves in the direction of rotation).
11) When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then
connect securely.
12) When using eyebolts, check that there is no deformation or deterioration, and screw them in fully.
13) When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
14) When operating the hydraulic cylinders for the first time after repairing and reassembling the
hydraulic cylinders, pumps, or other hydraulic equipment or piping, always bleed the air from the
hydraulic cylinders as follows:
(1) Start the engine and run at low idling.
(2) Operate the control lever and actuate the hydraulic cylinder 4-5 times, stopping 100mm before the
end of the stroke.
(3) Next, operate the piston rod to the end of its stroke to relieve the circuit. (The air bleed valve is
actuated to bleed the air.)
(4) After completing this operation, raise the engine speed to the normal operating condition.
※ If the hydraulic cylinder has been replaced, carry out this procedure before assembling the rod to
the work equipment.
※ Carry out the same operation on machines that have been in storage for a long time after
completion of repairs.
8-2
3. COMPLETING WORK
1) If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run
the engine to circulate the water through the system. Then check the water level again.
2) If the hydraulic equipment has been removed and installed again, add engine oil to the specified
level. Run the engine to circulate the oil through the system. Then check the oil level again.
3) If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been
removed for repair, always bleed the air from the system after reassembling the parts.
4) Add the specified amount of grease(Molybdenum disulphied grease) to the work equipment related
parts.
8-3
GROUP 2 TIGHTENING TORQUE
1. MAJOR COMPONENTS
Torque
No. Descriptions Bolt size
kgfÂm lbfÂft
1 Engine mounting bolt, nut M24 Ý 3.0 90 Ü 7.0 651 Ü 51
2 Radiator mounting bolt M16 Ý 2.0 22 Ü 1.0 159 Ü 7.2
Engine
3 Coupling mounting socket bolt M20 Ý 2.5 46.5 Ü 2.5 336 Ü 18.1
4 Main pump housing mounting bolt M10 Ý 1.5 2.81 Ü 0.3 20.3 Ü 2.2
5 Main pump mounting socket bolt M20 Ý 2.5 42 Ü 4.5 304 Ü 32.5
6 Main control valve mounting bolt M16 Ý 2.0 19.5 Ü 1.3 141 Ü 9.4
Hydraulic
7 system Fuel tank mounting bolt M20 Ý 2.5 46 Ü 5.0 333 Ü 36
8 Hydraulic oil tank mounting bolt M20 Ý 2.5 46 Ü 5.0 333 Ü 36
9 Turning joint mounting bolt, nut M12Ý 1.75 12.3 Ü 1.3 88.9 Ü 9.4
10 Swing motor mounting bolt M24 Ý 3.0 100 Ü 15 723 Ü 108
11 Swing bearing upper part mounting bolt M24 Ý 3.0 97.8 Ü 10 707 Ü 72.3
Power
12 train Swing bearing lower part mounting bolt M24 Ý 3.0 97.8 Ü 10 707 Ü 72.3
system
13 Travel motor mounting bolt M20 Ý 2.5 43.8 Ü 4.0 317 Ü 29
14 Sprocket mounting bolt M20 Ý 2.5 51 Ü 4.0 369 Ü 28.9
15 Carrier roller mounting bolt, nut M16 Ý 2.0 29.7 Ü 4.0 215 Ü 28.9
16 Track roller mounting bolt M22 Ý 2.5 77.4 Ü 11 560 Ü 79.6
Under
17 carriage Track tension cylinder mounting bolt M16 Ý 2.0 29.6 Ü 3.2 214 Ü 23.1
18 Track shoe mounting bolt, nut M22 Ý 1.5 105 Ü 5.0 755 Ü 36.2
19 Track guard mounting bolt M22 Ý 2.5 77.4 Ü 11 560 Ü 79.6
20 Counterweight mounting bolt M36 Ý 3.0 308 Ü 46 2228 Ü 333
21 Others Cab mounting bolt M12 Ý 1.75 12.8 Ü 3.0 92.6 Ü 21.7
22 Operator's seat mounting bolt M 8 Ý 1.25 4.05 Ü 0.8 29.3 Ü 5.8
ö For tightening torque of engine and hydraulic components, see each component disassembly and
assembly.
8-4
2. TORQUE CHART
Use following table for unspecified torque.
1) BOLT AND NUT
(1) Coarse thread
8T 10T
Bolt size
kgf·m lbf·ft kgf·m lbf·ft
M 6 × 1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6
M 8 × 1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.73 ~ 4.12 19.7 ~ 29.8
M10 × 1.5 4.0 ~ 6.0 28.9 ~ 43.4 5.5 ~ 8.3 39.8 ~ 60
M12 × 1.75 7.4 ~ 11.2 53.5 ~ 79.5 9.8 ~ 15.8 71 ~ 114
M14 × 2.0 12.2 ~ 16.6 88.2 ~ 120 16.7 ~ 22.5 121 ~ 167
M16 × 2.0 18.6 ~ 25.2 135 ~ 182 25.2 ~ 34.2 182 ~ 247
M18 × 2.5 25.8 ~ 35.0 187 ~ 253 35.1 ~ 47.5 254 ~ 343
M20 × 2.5 36.2 ~ 49.0 262 ~ 354 49.2 ~ 66.6 356 ~ 482
M22 × 2.5 48.3 ~ 63.3 350 ~ 457 65.8 ~ 98.0 476 ~ 709
M24 × 3.0 62.5 ~ 84.5 452 ~ 611 85.0 ~ 115 615 ~ 832
M30 × 3.5 124 ~ 168 898 ~ 1214 169 ~ 229 1223 ~ 1655
M36 × 4.0 174 ~ 236 1261 ~ 1703 250 ~ 310 1808 ~ 2242
(2) Fine thread

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

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

Escaping fluid under pressure can
penetrate the skin causing serious
injury.
(4) Loosen the drain plug under the hydraulic
tank and drain the oil from the hydraulic 5
tank. 1
· Hydraulic tank quantity : 230ℓ 3

2 4
(5) Remove socket bolts(5) and disconnect
pipes(1, 2). 36078MP01A
(6) Disconnect pilot line hoses(6, 7, 8, 9, 10,

11, 12, 13, 14, 15).
(7) Remove socket bolts(4) and disconnect 8
7
pump suction tube(3).
※ When pump suction tube is disconnected,
the oil inside the piping will flow out, so 6
catch it in oil pan.
9
(8) Sling the pump assembly and remove the 10
pump mounting bolts.
· Weight : 190kg(420lb) 36078MP01B
※ Pull out the pump assembly from housing.
When removing the pump assembly,
check that all the hoses have been 11 12
disconnected.
13
14
15
36078MP01C
8-7
2) INSTALL
(1) Carry out installation in the reverse order
to removal.
(2) Remove the suction strainer and clean it.
(3) Replace return filter with new one.
(4) Remove breather and clean it.
(5) After adding oil to the hydraulic tank to the
specified level.
(6) Bleed the air from the hydraulic pump.
① Remove the air vent plug(2EA).
② Tighten plug lightly.
③ Start the engine, run at low idling, and
check oil come out from plug.
④ Tighten plug.
(7) Start the engine, run at low idling(3~5
minutes) to circulate the oil through the
system.
(8) Confirm the hydraulic oil level and check
the hydraulic oil leak or not.
8-8
2. MAIN PUMP
1) STRUCTURE
36072MP02
04 Gear pump 271 Pump casing 706 O-ring

111 Drive shaft(F) 311 Valve cover(F) 710 O-ring
113 Drive shaft(R) 312 Valve cover(R) 717 O-ring
114 Spline coupling 313 Valve plate(R) 719 O-ring
123 Roller bearing 314 Valve plate(L) 724 O-ring
124 Needle bearing 401 Hexagon socket bolt 725 O-ring
127 Bearing spacer 402 Hexagon socket bolt 728 O-ring
130 Booster 406 Hexagon socket bolt 732 O-ring
012 Cylinder block 466 VP Plug 774 Oil seal
151 Piston 468 VP Plug 789 Back up ring
152 Shoe 490 Plug 792 Back up ring
153 Set plate 492 Plug 808 Hexagon head nut
156 Bushing 531 Tilting pin 824 Snap ring
157 Cylinder spring 532 Servo piston 885 Pin
211 Shoe plate 534 Stopper(L) 886 Spring pin
212 Swash plate 535 Stopper(S) 901 Eye bolt
214 Bushing 548 Feedback pin 953 Set screw
251 Support plate 702 O-ring 954 Adjust screw
261 Seal cover(F)
8-9
2) TOOLS AND TIGHTENING TORQUE
(1) Tools
The tools necessary to disassemble/reassemble the pump are shown in the follow list.
Tool name & size Part name
Hexagon socket PT plug PO plug Hexagon socket

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

413) and remove regulator.
36078MP02
(5) Loosen hexagon socket head bolts(401)

which tighten swash plate support(251),
pump casing(271) and valve cover(F,
311).
※ If gear pump and so on are fitted to rear
face of pump, remove them before
starting this work.
(6) Loosen hexagon socket head bolts(402)

which tighten swash plate support(251),
pump casing(271) and valve cover(R,
312).
8-12
(7) Place pump horizontally on workbench
with its regulator-fitting surface down, and
separate pump casing(271) from valve
cover(F, 311).
※ Before bringing this surface down, spread
rubber sheet on workbench without fail to
prevent this surface from being damaged.
36078MP03
(8) Separate valve cover(F, 311) from valve

cover(R, 312) and pull out booster(130),
spline coupling(114).
(9) Separate valve cover(R, 312) from pump

casing and then pull out the cylinder
block(012) of pump casing(271) straightly
over drive shaft(R, 113). Pull out also
pistons(151), set plate(153), spherical
bush(156) and cylinder springs (157)
simultaneously.
※ Take care not to damage sliding surfaces
of cylinder, spherical bushing, shoes, 36078MP04
swash plate, etc.
(10) Remove hexagon socket head bolts(406)

and then seal cover(F, 261).
※ Fit bolt into pulling-out tapped hole of seal
cover(F), and cover can be removed
easily.
※ Since oil seal is fitted on seal cover(F),
take care not to damage it when removing
cover.
36078MP05
8-13
(11) Tapping lightly fitting flange section of
swash plate support(251) on its pump
casing side, separate swash plate support
from pump casing.
36078MP06
(12) Remove shoe plate(211) and swash

plate(212) from pump casing(271).
36078MP07
(13) Tapping lightly shaft ends of drive

shafts(111, 113) with plastic hammer, take
out drive shafts from swash plate supports.
36078MP08
8-14
(14) Remove valve plates(313, 314) from valve
cover(311, 312).
※ These may be removed in work 7, 9.
36078MP09
(15) If necessary, remove stopper (L, 534),

stopper(S, 535), servo piston(532) and
tilting pin(531) from pump casing(271),
and needle bearing(124) from valve
cover(311, 312).
※ In removing tilting pin, use a protector to
prevent pin head from being damaged.
※ Since loctite is applied to fitting areas of
tilting pin and servo piston, take care not
to damage servo piston.
※ Do not remove needle bearing as far as
possible, except when it is considered to
be out of its life span.
※ Do not loosen hexagon nuts of valve cover
and swash plate support.
If loosened, flow setting will be changed.
(16) This is the end of disassembling procedures.
8-15
4) ASSEMBLY
(1) For reassembling reverse the disassem-
bling procedures, paying attention to the
following items.
① Do not fail to repair the parts damaged
during disassembling, and prepare
replacement parts in advance.
② Clean each part fully with cleaning oil
and dry it with compressed air.
③ Do not fail to apply clean working oil to
sliding sections, bearings, etc. before
assembling them.
④ In principle, replace seal parts, such as
O-rings, oil seals, etc.
⑤ For fitting bolts, plug, etc., prepare a
torque wrench or so on, and tighten them
with torques shown in page 8-11, 12.
⑥ For the double-pump, take care not to
mix up parts of the front pump with those
of the rear pump.
(2) Fit swash plate support(251) to pump

casing(271), tapping the former lightly
with a hammer.
※ After servo piston, tilting pin, stopper(L)
and stopper(S) are removed, fit them
soon to pump casing in advance for
reassembling.
※ In tightening servo piston and tilting pin,
use a protector to prevent tilting pin head
36078MP10
and feedback pin from being damaged.
In addition, apply loctite(Medium strength)
to their threaded sections.
8-16
(3) Place pump casing with its regulator fitting
surface down, fit tilting bush of swash plate
to tilting pin(531) and fit swash plate (212)
to swash plate support(251) correctly.
※ Confirm with fingers of both hands that
swash plate can be removed smoothly.
※ Apply grease to sliding sections of swash
plate and swash plate support, and drive
shaft can be fitted easily.
36078MP11
(4) To swash plate support(251), fit drive

shaft(111) set with bearing(123), bearing
spacer(127) and snap ring(824).
※ Do not tap drive shaft with hammer or so
on.
※ Assemble them into support, tapping
outer race of bearing lightly with plastic
hammer.
Fit them fully, using steel bar or so on.
36078MP12
(5) Assemble seal cover(F, 261) to pump

casing(271) and fix it with hexagon socket
head bolts(406).
※ Apply grease lightly to oil seal in seal
cover(F).
※ Assemble oil seal, taking full care not to
damage it.
※ For tandem type pump, fit rear cover(263)
and seal cover(262) similarly.
36078MP13
(6) Assemble piston cylinder subassembly

[cylinder block(012), piston subassembly
(151, 152), set plate(153), spherical
bushing(156) and cylinder spring (157)].
Fit spline phases of retainer and cylinder.
Then, insert piston cylinder subassembly
into pump casing(271).
36078MP14
8-17
(7) Fit valve plate(313) to valve cover(F, 311),
and fit valve plate(314) to valve cover(R,
312), entering pin into pin hole.
※ Take care not to mistake suction / delivery
directions of valve plate.
36078MP15
(8) Fit valve block(R, 312) to pump casing

(271) and fit spline coupling(114) and
booster(130) to shaft(R, 113).
※ Take care not to mistake direction of valve
cover.
Fit valve cover with regulator up and with
delivery flange left, viewed from front side.
※ Take care not to mistake direction of
booster(130).
36078MP16
(Refer to the sectional drawing)
(9) Fit valve cover(F, 311) to valve cover(R)

and tighten hexagon socket head
bolts(402).
(10) Fit pump casing(271) with shaft(F, 111) to

valve cover(F, 311) and tighten hexagon
socket head bolts(401).
※ Mate spline phases of shaft(F) and spline
coupling, with shaft(F) been rotating.
36078MP18
8-18
(11) Putting feedback pin of tilting pin into
feedback lever of regulator, fit regulator
and tighten hexagon socket head
bolts(412,413).
※ Take care not to mistake regulator of front
pump for that of rear pump.
36078MP17
(12) Fit drain port plug(468).

This is the end of reassembling procedures.
8-19
3. REGULATOR
1) STRUCTURE(1/2)
36072RG01
8-20
REGULATOR(2/2)
36072RG02

601 Casing 647 Stopper 801 Hexagon nut
611 Feedback lever 648 Piston(QMC) 814 Snap ring
612 Lever(1) 651 Sleeve 836 Stop ring
613 Lever(2) 652 Spool(A) 858 Snap ring
614 Center plug 653 Spring seat 874 Pin
622 Piston case 696 Port cover 897 Pin
623 Compensator rod 697 Check valve plate 898 Pin
624 Spring seat(C) 708 O-ring 924 Set screw
625 Outer spring 722 O-ring 925 Adjust screw(QI)
626 Inner spring 723 O-ring
627 Adjust stem(C) 724 O-ring
8-21
(1) Tools
The tools necessary to disassemble/reassemble the pump are shown in the follow list.
Tool name & size Part name

Hexagon socket PT plug PO plug Hexagon socket
Name B head bolt (PT thread) (PF thread) head setscrew
Allen wrench 4 M 5 BP-1/16 - M 8
B
5 M 6 BP-1/8 - M10
6 M 8 BP-1/4 PO-1/4 M12, M14
Double ring spanner,
socket wrench, double(Single) Hexagon head VP plug
open end spanner - Hexagon nut
bolt (PF thread)
B
6 M 8 M 8 -
Adjustable angle wrench Small size, Max 36mm
Screw driver Minus type screw driver, Medium size, 2 sets
Hammer Plastic hammer, 1 set
Pliers For snap ring, TSR-160
Steel bar 4×100mm
Pincers -
Bolt M4, Length : 50mm
8-22
Torque Wrench size
Part name Bolt size
Hexagon socket head bolt M 5 0.7 5.1 0.16 4
(Material : SCM435) M 6 1.2 8.7 0.20 5
M 8 3.0 21.7 0.24 6
M10 5.8 42.0 0.31 8
M12 10.0 72.3 0.39 10
M14 16.0 116 0.47 12
M16 24.0 174 0.55 14
M18 34.0 246 0.55 14
M20 44.0 318 0.67 17
PT Plug(Material : S45C) PT1/16 0.7 5.1 0.16 4
※Wind a seal tape 1 1/2 to 2 PT 1/8 1.05 7.59 0.20 5
turns round the plug
PT 1/4 1.75 12.7 0.24 6
PT 3/8 3.5 25.3 0.31 8
PT 1/2 5.0 36.2 0.39 10
PF Plug(Material : S35C) PF 1/4 3.0 21.7 0.24 6
PF 1/2 10.0 72.3 0.39 10
PF 3/4 15.0 109 0.55 14
PF 1 19.0 137 0.67 17
PF 1 1/4 27.0 195 0.67 17
PF 1 1/2 28.0 203 0.67 17
8-23
3) DISASSEMBLY
Since the regulator consists of small
precision finished parts, disassembly and
assembly are rather complicated.
For this reason, replacement of a regulator
assembly is recommended, unless there is
a special reason, but in case disassembly is
necessary for an unavoidable reason, read
through this manual to the end before
starting disassembly.
(1) Choose a place for disassembly.
※ Choose a clean place.
※ Spread rubber sheet, cloth, or so on on
top of work-bench to prevent parts from
being damaged.
(2) Remove dust, rust, etc. from surfaces of
regulator with clean oil.
(3) Remove hexagon socket head screw

(412, 413) and remove regulator main
body from pump main body.
※ Take care not to lose O-ring.
36078RE01
(4) Remove hexagon socket head screw

(438) and remove cover(C,629)
※ Cover(C) is fitted with adjusting screw
(C,QI) (628, 925), adjusting stem(C, 627),
lock nut(630), hexagon nut(801) and set
screw(924).
Do not loosen these screws and nuts.
If they are loosened, adjusted pressure-
flow setting will vary.
36078RE02
8-24
(5) After removing cover(C, 629) subassembly,
take out outer spring(625), inner spring
(626) and spring seat(C, 624) from
compensating section.
Then draw out adjusting stem(Q, 645),
pilot spring(646) and spring seat(644)
from pilot section.
※ Adjusting stem(Q,645) can easily be
drawn out with M4 bolt.
36078RE03
(6) Remove hexagon socket head screws

(436, 438) and remove pilot cover(641).
After removing pilot cover, take out set
spring(655) from pilot section.
36078RE04
(7) Remove snap ring(814) and take out

spring seat(653), return spring(654) and
sleeve(651).
Sleeve(651) is fitted with snap ring(836).
※ When removing snap ring(814), return
spring(654) may pop out.
※ Take care not to lose it.
36078RE05
(8) Remove locking ring(858) and take out

fulcrum plug(614) and adjusting plug
(615).
※ Fulcrum plug(614) and adjusting plug
(615) can easily be taken out with M6 bolt.
36078RE06
8-25
36078RE07
(9) Remove lever2(613). Do not draw out

pin(875).
※ Work will be promoted by using pincers or
so on.
36078RE08
(10) Draw out pin(874) and remove feedback

lever(611).
※ Push out pin(874, 4mm in dia.) from above
with slender steel bar so that it may not
interfere with lever1(612).
36078RE09
36078RE10
8-26
(11) Remove lever1(612). Do not draw out
pin(875).
(12) Draw out pilot piston(643) and spool(652).
(13) Draw out piston case(622), compensating
piston(621) and compensating rod(623).
※ Piston case(622) can be taken out by
pushing compensating rod(623) at
opposite side of piston case.
This completes disassembly.
8-27
4) ASSEMBLY
(1) For assembly, reverse disassembly
procedures, but pay attention to the
following items.
① Always repair parts that were scored at
disassembly.
② Get replacement parts ready before-
hand.
Mixing of foreign matter will cause
malfunction.
Therefore, wash parts well with cleaning
oil, let them dry with jet air and handle
③ them in clean place.
Always tighten bolts, plugs, etc. to their
④ specified torques.
Do not fail to coat sliding surfaces with
⑤ clean hydraulic oil before assembly.
Replace seals such as O-ring with new
ones as a rule.
(2) Put compensating rod(623) into

compensating hole of casing(601).
(3) Put pin force-fitted in lever1(612) into
groove of compensating rod and fit lever 1
to pin force-fitted in casing.
(4) Fit spool(652) and sleeve(651) into hole in

spool of casing.
※ Confirm that spool and sleeve slide
smoothly in casing without binding.
※ Pay attention to orientation of spool.
Spool
Feedback lever
36078RE11
8-28
(5) Fit feedback lever(611), matching its pin
hole with pin hole in spool.
Then insert pin(874).
※ Insert pin in feedback lever a little to ease
Lever(1) side Lever(2) side
operation. (Fulcrum plug of
※ Take care not to mistake direction of adjusting plug side)
feedback lever.
36078RE12
(6) Put pilot piston(643) into pilot hole of

casing.
※ Confirm that pilot piston slides smoothly
without binding.
(7) Put pin force-fitted in lever2(613) into
groove of pilot piston.
Then fix lever2.
36078RE13
(8) Fit fulcrum plug(614) so that pin force-

fitted in fulcrum plug(614) can be put into
pin hole of lever2.
Then fix locking ring(858).
(9) Insert adjusting plug(615) and fit locking
ring.
※ Take care not to mistake inserting holes
for fulcrum plug and adjusting plug.
At this point in time move feedback lever
to confirm that it has no large play and is
free from binding. 36078RE14
(10) Fit return spring(654) and spring seat

(653) into spool hole and attach snap ring
(814).
36078RE15
8-29
(11) Fit set spring(655) to spool hole and put
compensating piston(621) and piston
case(622) into compensating hole.
Fit pilot cover(641) and tighten it with
hexagonal socket head screws(436, 438).
36078RE16
(12) Put spring seat(644), pilot spring(646) and

adjusting stem(Q, 645) into pilot hole.
Then fix spring seat(624), inner spring
(626) and outer spring(625) into
compensating hole.
※ When fitting spring seat, take care not to
mistake direction of spring seat.
36078RE17
(13) Install cover(C, 629) fitted with adjusting

screws(628, 925), adjusting stem(C, 627),
lock nut(630), hexagon nut(801) and set
screw(924).
Then tighten them with hexagonal socket
head screws(438).
This completes assembly. 36078RE18
8-30
GROUP 4 MAIN CONTROL VALVE (-#0169)

1) REMOVAL
pressure in the hydraulic piping.

BR2
injury. BR1
PR
AR2
ö When pipes and hoses are disconnected,

AR1
R
BR3
AR3
the oil inside the piping will flow out, so
BL1
catch it in oil pan. PL
BL2
(4) Remove bolts and disconnect pipes. AL1
AL2
(5) Disconnect pilot line hoses.

36078MC01A
(6) Disconnect pilot pipes.
(7) Sling the control valve assembly and
remove the control valve mounting bolts.
Px2 br1
ÂWeight : 250kg(550lb) 3Pi
br2
br3 bl1
(8) Remove the control valve assembly. bl2
When removing the control valve c

a bl4
ar1
assembly, check that all the piping have ar2
4Pi
4Pc
been disconnected. ar3
d
al1
2) INSTALL al2
al4 b
(1) Carry out installation in the reverse order 36078MC01B
to removal.
(2) Bleed the air from below items.
Η Cylinder(Boom, arm, bucket)
Θ Swing motor dr
dr1
Ι Travel motor Rs
FR
ö See each item removal and install. Dr

bl3
Pi
(3) Confirm the hydraulic oil level and recheck Py2
dr2

Px1 al3
FL
36078MC01C
8-31
2. STURCTURE (1/3)
20
22
1
65
55 21 3
18
94 4
15 23 2 19 26
24 35 5
23 36 27
24 28
31 29
30
17
14 8
95 23
37 24
36 32 13
38 31
36 30 7
39
40
41
42 33
34
45
29
28
27
26 6
10
7
9
12
8 11
30
31
24
23
15
3607A8MC02
1 Cover assy 17 Cover 33 Foot relief valve

2 O-ring 18 Plug 34 O-ring
3 O-ring 19 O-ring 35 Cap
4 Spring 20 O-ring 36 O-ring
5 Poppet 21 O-ring 37 Cap
6 Housing 22 Selector assy 38 Cap
7 O-ring 23 Back up ring 39 Piston
8 Socket bolt 24 O-ring 40 Steel ball
9 Cover 26 Overload relief valve 41 Spring
10 Boom plunger assy 27 O-ring 42 Spool
11 Bucket plunger assy 28 Back up ring 45 Orifice
12 Travel plunger assy 29 O-ring 55 Washer
13 Cover 30 Check 65 Socket bolt
14 Cap 31 Spring 94 Cap
15 Cap 32 Check 95 Cap
8-32
STURCTURE (2/3)
36078MC03
15 Cap 37 Cap 53 O-ring

19 O-ring 44 Cap 54 Socket bolt
23 Back up ring 46 Spool 55 Washer
24 O-ring 47 Spring 56 O-ring
27 O-ring 48 Cap 57 Cap
30 Check 49 Main relief valve 58 O-ring
31 Spring 50 O-ring 59 O-ring
32 Check 51 Manifold 60 Socket bolt
36 O-ring 52 Logic check valve
8-33
STURCTURE (3/3)
36078MC04
7 O-ring 31 Spring 62 Option plunger assy 78 O-ring

8 Socket bolt 32 Check 63 Arm plunger assy 79 Cap
9 Cover 33 Foot relief valve 64 Swing plunger assy 80 Piston
12 Travel plunger assy 34 O-ring 65 Socket bolt 81 Spring
13 Cover 35 Cap 66 O-ring 82 O-ring
14 Cap 36 O-ring 67 Flange 83 Sleeve
15 Cap 37 Cap 68 O-ring 84 Spring
16 Cap 38 Cap 69 Socket bolt 85 Check
20 O-ring 39 Piston 70 Poppet 86 Poppet
23 Back up ring 40 Steel ball 71 Spring 87 Cap
24 O-ring 41 Spring 72 O-ring 88 Spring guide
26 Overload relief valve 42 Spool 73 Back up ring 89 Spring
27 O-ring 43 Plug 74 Cover assy 90 Union
28 Back up ring 55 Washer 75 Socket bolt 91 Piston
29 O-ring 57 Cap 76 Lock washer 92 Cap
30 Check 61 Housing 77 Manifold 93 O-ring
8-34
3. DISASSEMBLY AND ASSEMBLY
1) GENERAL PRECAUTIONS
(1) Disassembly
① Handle the components carefully not to drop them or bump them with each other as they are
made with precision.
② Do not force the work by hitting or twisting as burred or damaged component may not be
assembled or result in oil leakaged or low performance.
③ When disassembled, tag the components for identification so that they can be re-assembled
correctly.
④ Once disassembled, O-rings and backup rings are usually not to be used again. (Remove them
using a wire with its end made like a shoehorn. Be careful not to damaged the slot.)
⑤ If the components are left disassembled or half-disassembled, they may get rust from moisture or
dust. If the work has to be interrupted, take measures to prevent rust and dust.
(2) Assembly
① Take the same precautions as for disassembly.
② When assembling the components, remove any metal chips or foreign objects and check them
for any burrs or dents. Remove burrs and dents with oil-stone, if any.
③ O-rings and backup rings are to be replaced with new ones, as a rule.
④ When installing O-rings and backup rings, be careful not to damage them. (Apply a little amount
of grease for smoothness.)
⑤ Tighten the bolts and caps with specified torque.
2) TOOLS
Before disassembling the comtrol valve, prepare the following tools beforehand.
Name of tool Quantity Size(mm)

Vice mounted on bench(Soft jaws) 1 unit
Hexagon wrench Each 1 piece 6, 8, 10, 12, 14 and 17
Socket wrench Each 1 piece 19, 30, 36, 41 and 46
8-35
3) MOUNTING AND DISMOUNTING VALVES
(1) Disassembly
1 2
4 spool valve can be removed by
loosening socket bolts (1,2), while 3 spool
valve can be removed by loosening socket
bolts (3,4).
(2) Assembly
※ Valves should be mounted after making
sure that all O-rings and cap are placed
on the assembling faces and check
spacer is placed on assembling faces of
3-plunger valve.
· Place the valve assembly on plane 3 4
surface and assemble 3 spool valve to
manifold and then assemble 4 spool Tools
valve. ·Hexagon socket : 14mm
· Tighten the socket bolts at specified ·Torque wrench
torque after making sure that the 36078MC05
assembly is leveled.
· Tightening torque : 25 kgf·m (181 lbf·ft)
8-36
4) OPERATING SECTION OF HYDRAULIC PACK
(1) Loosen socket bolt (1) to remove cover
(2). 3 2 1
※ Install cover (2) after making sure that O-
ring is placed on the edge of the valve
hole.
4 5 6
Tools
·Hexagon socket bolt: 10mm
·Torque wrench 36078MC06A
(2) Pull the plunger out while holding the

spring.
※ Do not pull it out violently, but draw it out
gently while making sure of its contact
with housing hole.
36078MC06B
(3) Place the plunger between holders and

loosen plunger cap (3) by using a vise. Holder
· Plunger cap
Hexagon socket : 10 mm
Tightening torque : 10 kgf·m(72.3 lbf·ft)
36078MC06C
(4) Remove plunger cap (3), guide (4), sleeve

(5) and spring (6) in this order.
3 4 5 6 4
36078MC06D
8-37
(5) Arm plunger only (Remove check)
Remove cap (7) and disassemble spring
(8) and check (9).
· Plunger cap
Hexagon socket : 10 mm
Tightening torque : 10kgf·m (72.3lbf·ft)
9 8 7
360SMCV26(2)
5) OVERLOAD RELIEF ASSEMBLY

Relief assembly is assembled into a single 1 Pressure
adjuster
block as a cartridge. Do not disassemble the
relief assembly as a rule.
(1) Loosen the relief sleeve(1) and remove the
cartridge.
Tools
※ Record original position for reassembly. ·Hexagon bolt: 41mm 2
(2) Loosen the relief seat(2) and remove the

sub assembly.
Sub assembly
2
Tools
·Torque wrench 36078MC07B
8-38
(3) Pull out the poppet(3) and take off the
piston(4) and springs(5,6).
3 4 5 6
36078MC08A
6) COVER ASSEMBLY(BOOM PLUNGER)

2 3
(1) Loosen socket bolt(1) to remove cover(2).
※ Install cover(2) after making sure that
O-ring is placed on the edge of the valve
hole.
Tools 1
(2) Remove plug(3).

Tools
·Hexagon bolt: 19mm
·Torque wrench 36078MC08C
8-39
7) CENTER BYPASS VALVE ASSEMBLY 1
(1) Remove cap(1).
Tightening torque : 10kgf·m (72.3lbf·ft) 2
※ Record original position for reassembly.
3
Tools
Tools
Hexagon socket
·Hexagon bolt : 41mm
bolt: 41mm
·Torque
Torque wrench
wrench 36078MC09A
(2) Remove piston(2), steel ball(3), spool(5)

and spring(4). 2
36078MC09B
8-40
8) LOAD CHECK ASSEMBLY
(1) Remove cap(1). AM, BKT, OPT, TRV
1
4 2
※ Record original position of arm
summation cap for reassembly. 3
BM,BKT summation
1
2
3
AM summation
1
4 2
3
SW
1
2
3
Tools
(2) Remove check valve(4), spring(2) and

check valve(3). 4
36078MC10B
8-41
9) BOOM PRIORITY ASSEMBLY
(1) Remove cap(1), piston(2), spring(3) and
union(4). 1
2
7
8
Tools
(2) Remove sleeve(5), spring(6), spring

2 3 4
guide(7) and poppet sub assemmbly(8).
Tools 5 6 7 8
(3) Place the poppet sub assembly(8)

between holders and cap(9) by using a
vise. Holder
Tightening torque : 3.5kgf·m (25.3lbf·ft) 9
Tools
8-42
(4) Remove cap(9).
Take off spring(10), check valve(11) and
poppet(12).
9 10 11 12
36078MC12A
10) ARM LOAD HOLDING VALVE

(1) Loosen socket volt(1) to remove cover(2) 1 2
from housing.
Tightening torque : 18kgf·m (130.2lbf·ft) O-ring Overload
relief valve
※ Install cover(2) after making sure that O-
ring is placed on the edge of the bole.
Tools
(2) Remove spring(3) and poppet(4).
4 3
36078MC12C
8-43
(3) Remove cap(5).
Take off spring(6) and spool(7). 5 6 7
5 6 7
Tools
11) LOGIC VALVE(FOR BOOM SUMMATION)

(1) Remove cap(1). 1 2 3 4 5 7
Take off piston(2) and spring(3).
5 6
Tools
8-44
(2) Pull out sleeve(4) by inner-threaded
special tool.
Take off spring(5) and check valve(6). Special tool
4 5 6
36078MC14A
(3) Pull out sleeve(7) by threaded round bar.

Take off spring(8) and check(9). M5x0.8
Round bar 7 8 9
36078MC14B
8-45
12) MAIN RELIEF ASSEMBLY
Relief assy is assembled into a single block
as a cartridge. Do not disassemble the
relief assembly as a rule.
(1) Loosen the hexagon nut(2) with a holding
adjust screw(1).
(2) Loosen the hexagon nut(3) with a holding
cap(4). 6 4 3 5 2 1
36078MC15A
(3) Loosen the cap(4) and remove the
cartridge.
(4) Pull out the sleeve(6) and take off the

main piston(7), spring(8) and orifice(9). Pilot seat
※ Can't remove the pilot seat from the
cap(4), because it was locked at the cap.
(5) Loosen each screw and remove.
Item No. Name Socket
1 Adjust screw 22mm

2 Hexagon nut 30mm 4
3 Hexagon nut 30mm
4 Cap 41mm
6 Sleeve 27mm
6 7 8 9
36078MC15B
8-46
13) FOOT RELIEF ASSEMBLY
(1) Loosen cap(1) and remove poppet(2). 1 2
Tools
1 2
36078MC16B
(2) Remove cap(3) and take off shim(4) and

spring(5).
※ Make sure adjust shim quantity.
3 4 5
Tools
8-47
14) BOOM LOAD HOLDING VALVE
Z
(1) Basic unit
① Loosen socket bolt (1) to remove cover
assembly (2).
Tightening torque : 25 kgf·m
(180.8lbf·ft) 3
※ Install cover assembly (2) after making
4
sure that O-ring is placed on the edge of
the valve hole.
7
O-ring
6
5
VIEW Z
Tools
② Take off spring (3) and check valve (4).
4 3 36078MC17B
(2) Selector unit

① Remove the cap(5), piston(6) and
spring(7).
5 6 7
Tools
8-48
(3) Cover assembly
8 9 10
① Remove cap (8).
Take off spring (9) and check valve (10).
Tightening torque : 5 kgf·m(36.2lbf·ft)
11 12 13 14 15 16
36078MC18A
8 9 10
Tools
② Remove cap (11) and take off piston(12).

Tightening torque : 6kgf·m(43.4lbf·ft)
Tools
③ Remove cap (16).

Take off spring(15) and poppet(14).
Tightening torque : 5kgf·m(36.2lbf·ft)
④ Push sleeve (13) out with a rod or the like
through the hole of cap (11).
※ Be careful not to damage the guideway
of the sleeve.
Tools
·Torque wrench 36078MC18D
8-49
15) TRAVEL STRAIGHT VALVE
(1) Remove cap(1). 3 2 1
Take off spool(3) and spring(2).
Tools
16) OVER LOAD PLUG(OPTION)

2 M8
(1) Remove cap(1).
Take off spool(2) by M8 tap.
1
2 1
Tools
(2) Install overload relief valve(3) to valve

hole.
Tools 3
8-50
GROUP 4 MAIN CONTROL VALVE (#0170-)

1) REMOVAL

penetrate the skin causing serious AL
BL
injury.
P1
R
ö When pipes and hoses are disconnected, Ab
Bb
P2
the oil inside the piping will flow out, so Bc

Br
Bs
Ac
catch it in oil pan. As

Ar
Ba
Aa
(4) Remove bolts and disconnect pipes.

(5) Disconnect pilot line hoses.
3607A8MC01
(6) Disconnect pilot pipes.
(7) Sling the control valve assembly and
PBa2
remove the control valve mounting bolts.

ÂWeight : 340 kg (750 lb) PBa
PBc
PBb
PBb2
(8) Remove the control valve assembly. PBb PBs
PAcs
PBa
When removing the control valve Dr4
assembly, check that all the piping have PAs

Psp
Pns
Drb
PAa
been disconnected.
PAc
Dra
PAb
2) INSTALL
(1) Carry out installation in the reverse order 3607A8MC03
to removal.
(2) Bleed the air from below items.
Η Cylinder (Boom, arm, bucket)
Θ Swing motor
Ι Travel motor Pa P
Py
PBL
ö See each item removal and install. Dr3'

PBr
(3) Confirm the hydraulic oil level and P2c1 N1
N2
PBo
recheck the hydraulic oil leak or not. PAa2

PCa
PAL
PAr
Dr3 P2c2
PAo
PAb
PAc
PAa
3607A8MC04
8-50-1
2. STRUCTURE (1/4)
159
212
652
605
663
603 665
664
551
554
561 158
251 155 165 611 168
265 165
201
327
972
326
273
337
974
392 263
101
551
561
155
165 973
972
972
165
155
511
522
561
561 551
551 252
761 751
513 762
524 515
561 205
553
274
511 264
522
264
203 274
274 38098MC01
101 A2 Casing A 264 O-ring 561 O-ring

155 Plug 265 O-ring 562 O-ring
158 Plug 274 Socket bolt 603 Port relief assy
159 Plug 326 Spring 605 Port relief assy
161 O-ring 327 Spring 611 Negative relief valve assy
162 O-ring 335 Shim 652 Plug
163 O-ring 337 Rod 663 O-ring
165 O-ring 392 By pass cut spool 664 O-ring
168 O-ring 511 Poppet 665 Back-up ring
201 Spring cover 513 Poppet 751 Flange
203 Spring cover 515 Boom priority valve assy 761 O-ring
205 Cover sub-B/Priority 522 Spring 762 Screw
212 O-ring 524 Spring 972 Screw
251 Plug 551 Plug 973 Screw
252 Lock valve assy 553 Plug 974 Screw
263 O-ring 554 Stopper plug
8-50-2
STRUCTURE (2/4)
A2 CASING
511
522
557
664
665
663
301 652
604
305 603
393
262
202
308 395 262
273
202
302 335 273
263
262
202 201
262 273
273
165 165
202
273 155 554
38098MC02
155 Plug 302 Arm spool kit 554 Stopper plug

165 O-ring 305 Swing spool kit 557 Plug
201 Spring cover 308 Option spool kit 603 Port relief assy
202 Spring cover 335 Shim 652 Plug
262 O-ring 393 Boom spool kit 663 O-ring
263 O-ring 395 Swing priority spool kit 664 O-ring
273 Hex screw 511 Poppet 665 Back-up ring
301 Travel spool kit 522 Spring
8-50-3
STRUCTURE (3/4)
558
561
155
355
356 165
206 201
273
201
601
158 336 263
168 332
550
603 351
158 372 562
557 168 543
542
522 541
511 335 102
332
263
562 163
562 562
161
162
561
551
165 162
155 161 163

203 562
274 252 162 159
264 158 212
275 552 168 351 158
522 563
204 267 352 168
525 523
512
514 151 155
264 511 551 165
522 561 762
522 151 155
511 553 511 165
561
524 752
513 761
551
561
155 A1 CASING
165
38098MC03
102 Casing-B 264 O-ring 542 Spring seat

151 Plug 267 O-ring 543 Spring
155 Plug 274 Socket bolt 550 Plug
158 Plug 275 Screw 551 Plug
159 Plug 335 Shim 552 Plug
161 O-ring 351 Orifice 557 Plug
162 O-ring 352 Orifice 558 Plug
163 O-ring 355 Piston 561 O-ring
165 O-ring 356 Piston 562 O-ring
168 O-ring 511 Poppet 563 O-ring
201 Spring cover 512 Poppet 601 Main relief assy
203 Spring cover 514 Poppet 603 Port relief assy
204 Cover 522 Spring 752 Blank flange
206 Spring cover 523 Spring 761 O-ring
212 O-ring 525 Spring 762 Screw
263 O-ring 541 Steel ball
8-50-4
STRUCTURE (4/4)
A1 CASING
603
611
561 763
551
754
764
391
301
303 262
202
304 273
262
165
394 313 202 155
392
263 273
262 208
337 212
202 211
262
326
273 273
202
327
273
265
251 38098MC04
155 Plug 273 Hex screw 394 A/Confluence spool kit

165 O-ring 301 Travel spool kit 551 Plug
202 Spring cover 303 Boom spool kit 561 O-ring
208 Spool cover 304 Bucket spool kit 603 Port relief assy
211 Plug 313 Plug 604 Port relief assy
212 O-ring 326 Spring 611 Negative relief valve assy
251 Plug 327 Spring 754 Flange
262 O-ring 337 Rod 763 O-ring
263 O-ring 391 Travel straight spool kit 764 Socket screw
265 O-ring 392 By pass cut spool
8-50-5
(1) All hydraulic components must be worked with precision working. Then, before disassembling
and assembling them, it is essential to select an especially-clean place.
(2) In handling a control valve, pay full attention to prevent dust, sand, etc. from entering into it.
(3) When a control valve is to be removed from the machine, apply caps and masking seals to all
ports. Before disassembling the valve, re-check that these caps and masking seals are fitted
completely, and then clean the outside of the assembly. Use a proper bench for working, spread a
paper or rubber mat on the bench, and disassemble the valve on it.
(4) Support the body section carefully in carrying, transferring and so on of the control valve. Do not
support the lever, exposed spool, end cover section or so on without fail.
(5) After disassembling and assembling of the component, it is desired to carry out various tests (for
the relief characteristics, leakage, flow resistance, etc.), but the hydraulic test equipment is
necessary to these tests.
Therefore, even when its disassembling can be carried out technically, do not disassemble such
component that cannot be tested, adjusted, and so on.
Besides, prepare clean cleaning oil, hydraulic oil, grease, etc. beforehand.
2) TOOLS
Before disassembling the control valve, prepare the following tools beforehand.
Name of tool Quantity Size (mm)
Vise bench 1 unit -
Box wrench Each 1 piece 22, 27, 32 & 36
Hexagon key wrench Each 1 piece 5, 8, 12 & 17
Loctite #262 1 pc -
Spanner 1 pc 10, 22, 24, 32 (Main relief valve), 36
8-50-6
3) DISASSEMBLING
(1) Place control valve on working bench.
ö Disassemble it in clean place and pay
attention not to damage flange face.
(2) Disassembling of main spool (travel,

bucket, swing, option, arm 2, boom 2,
swing priority):
Η Loosen hexagon socket head bolts (273)
and remove spring cover (201), (206).
ÂHexagon key wrench : 8 mm
In removing bucket spring cover (206), at
first remove plug (558) and piston (356).
ÂHexagon key wrench : 17 mm 3607A8MC05
Θ Remove spool, spring, spring seats

(shim) and spacer bolt in spool assembly
condition from casing.
ö When pulling out spool assembly from
casing, pay attention not to damage
casing.
3607A8MC06
Ι Hold spool in mouthpiece-attached vise.

Remove spacer bolt (336) and
disassemble spring (, shim) and spring
seats.
3607A8MC07
8-50-7
(3) Disassembling of arm 1 spool :
Η Loosen hexagon socket head bolts (273)
and remove spring cover (201).
Θ Remove arm 1 spool (302), spring (371),
spring seat (332) and spacer bolt (336)
in spool assembly condition from casing.
casing, pay attention not to damage 3607A8MC08
casing.
Ι Hold arm 1 spool (302) in mouthpiece-
attached vise. Remove spacer bolt (336)
and disassemble spring (371) and spring
seats (332).
Κ Do not disassemble arm 1 spool (302)
more than these conditions.
3607A8MC09
(4) Disassembling of travel straight spool :

Η Loosen hexagon socket head bolts
(273), remove spring cover, and pull out
travel straight spool (391), spring (373),
spring seat (332) and spacer bolt (336)
in spool assembly condition from casing.
casing.
Θ Hold travel straight spool (391) in
mouthpiece-attached vise, remove
spacer bolt (336) and disassemble
spring (373) and spring seats (332).
Ι Do not disassemble travel straight spool
(391) more than these conditions.
8-50-8
(5) Disassembling of boom 1 spool :
Η In removing boom1 spring cover (206),
at first remove plug (558) and piston
(355).
Loosen hexagon socket head bolts
(273), remove spring cover (206) and
pull out boom1 spool (303), plug (313),
spring (371), spring seats (332) and 3607A8MC10
spacer bolt(336) in spool assembly

condition from casing.
casing.
Θ Hold boom1 spool (303) in mouthpiece-

attached vise, remove spacer bolt (336),
and disassemble spring (371) and spring
seats (332).
Remove plug (313).
ÂSpanner : 27 mm
Ι Do not disassemble boom1 spool (303)
more than these conditions. 3607A8MC11
(6) Disassembly of covers :

Η Remove hexagon socket head bolts
(273), and remove spool cover (202) and
(208).
In removing boom1 spool cover (208), at
first remove plug (211).
ÂBox wrench : 22mm
3607A8MC12
8-50-9
(7) Removal of main relief valve and port
relief valves :
Η Remove main relief valve (601) and port
relief valve (603), (604), (605) from
casing.
ÂMain relief valve : Spanner 32 mm
ÂPort relief valve : Box wrench 36 mm,
Spanner 36mm
3607A8MC13
(8) Removal of lock valve assembly :

Η Loosen hexagon socket head bolts and
remove lock valve assembly (252).
3607A8MC14
(9) Removal of bypass cut spool :

Η Remove plug (251), spring (326 & 327),
rod (337), and bypass cut spool (392).
ÂBox wrench : 27 mm
3607A8MC15
3607A8MC16
8-50-10
(10) Disassembly of negative control relief
valve :
Η Remove plug (551).
3607A8MC17
Θ Remove poppet (611), spring (621) and

damping rod(631).
3607A8MC18
8-50-11
(11) Disassembly of check valve :
Η Remove plug (551) and take out poppet
(511) and spring (522).
Θ Loosen hexagon socket head bolts (274)
and remove load check cover (203) and
take out poppet (551) and spring (522).
Ι Remove plug (553) and take out poppet 3607A8MC19
(513) and spring (522).

Κ Remove plug (552) and take out poppet
(512) and spring (523).
Λ Remove plug sub (557) and take out
poppet (511) and spring (522).
3607A8MC20
3607A8MC21
8-50-12
(12) Disassembly of boom priority valve :
Η Loosen hexagon socket head bolts (276,
277) and remove cover sub (205) and
poppet sub (515) of boom priority valve.
Θ Hold cover sub (205) in mouthpiece-
attached vise, remove poppet sub (515).
Ι Cover sub (205) :
Hold cover in mouthpiece-attached vise, 3607A8MC22
Loosen plug (559), and remove piston

(356).
Κ Poppet sub (515) :
Remove assy of poppet (101, 102), plug
(103) and spring (104) from bush (106).
Λ Remove spring (105) and spool (107).
Μ Do not disassemble ass'y in above
Κmore than these conditions.
3607A8MC23
(13) Disassembly of casing :

Η Except when required specially, do not
disassemble tie bolts of casing A.
Θ Since plugs not described in above
disassembling procedures are blind
plugs for sacrifice holes and blind plugs
for casing sanitation, do not disassemble
them as far as not required specially.
3607A8MC24
8-50-13
(14) Inspection after disassembling :
Clean all disassembled parts with clean mineral oil fully, and dry them with compressed air. Then,
place them on clean papers or cloths for inspection.
Η Control valve:
a. Check whole surfaces of all parts for burrs, scratches, notches and other defects.
b. Confirm that seal groove faces of casing and block are smooth and free of dust, dent, rust etc.
c. Correct dents and damages on check seat faces of casing, if any, by lapping.
ö Pay attention not to leave lapping agent in casing.
d. Confirm that all sliding and fitting parts can be moved manually and that all grooves and paths
are free from foreign matter.
e. If any spring is broken or deformed, replace it with new one.
f. When relief valve do not function properly, repair it, following its disassembling assembling
procedures.
g. Replace all seats and O-rings with new ones.
Θ Relief valve:
a. Confirm that all seat faces at ends of all poppets and seats are free of defects and are uniform
contact faces.
b. Confirm manually that main poppet and seat can slide lightly and smoothly.
c. Confirm that outside face of main poppet and inside face of seat are free from scratches and so
on.
d. Confirm that springs are free from breaking, deformation, and wear.
e. Confirm that orifices of main poppet and seat section are not clogged with foreign matter.
f. Replace all O-rings with new ones.
g. When any light damage is found in above inspections, correct it by lapping.
h. When any abnormal part is found, replace it with a relief valve assembly.
8-50-14
4) ASSEMBLING
(1) In this assembling section, explanation only is shown. Refer to figures and photographs shown in
disassembling section.
(2) Figure in ( ) shown after part name in explanation sentence shows number in construction figure.
(3) Cautions in assembling seals
Η Pay attention to keep seals free from defects in its forming and damages in its handling.
Θ Apply grease, hydraulic oil or so on to seals and seal-fitting sections for full lubrication.
Ι Do not stretch seals so much to deform them permanently.
Κ In fitting O-ring, pay attention not to roll it into its position. In addition, twisted O-ring cannot
remove its twisting naturally with ease after being fitted, and causes oil leakage.
Λ Tighten fitting bolts at all sections with torque wrench to their respective tightening torques
shown in "Maintenance Standards".
(4) Assembly of check valve :

Η Assemble poppets (511,513 & 512) and
springs (522 & 523).
Put O-rings (561) onto plugs (551 & 553). 563 561
Put O-rings (563) onto plugs (552). 552 551
Put O-rings (264) on cover (203). 523
512
Tighten the latters with their specified 552 522
torques. 563 511
523
512
38098MC10
ö Use poppets, springs and plugs in

following groups. 513
524
Poppet Spring Plug or cover Remember that 553
511 522 203, 204, 551, 557 511 in 10 positions 561
512 523 552 203

512 in 2 positions
264
513 522 553 513 in 2 positions
274
514 525 204 514 in 1 positions 552
511 38098MC11
Hexagon Tightening torque

No.
key wrench kgfÂm lbfÂft
(551) 17 mm 37.7~41.8 273~302
(274) 8 mm 5.3~6.3 38.3~45.6
(553) 17 mm 37.7~41.8 273~302
(552) 12 mm 23.5~27.5 170~197
(box wrench)
(557) 20.4~25.5 148~184
32 mm
8-50-15
Θ Bucket, option confluence plug sub :
If you want bucket confluence or option
752 753 761 380 712 401
confluence effective, loosen rod (401)
and tighten lock nut (712).
If you want to cancel bucket confluence
or option confluence, tighten rod (401)
and lock nut (712).
ÂSpanner : 10 mm for (401)
ÂTightening torque : 3.0~4.0 kgfÂm
38098MC12
(21.7~28.9 lbfÂft)
ÂSpanner : 24 mm for (712)
(28.9~36.2 lbfÂft)
(5) Assemble boom priority valve :

Η Put O-ring (108) onto bush (106), and
108 107 106 105 103 101 104 102
assemble spool (107) and spring (105).
Assemble assy of poppet (101, 102),
plug (103) and spring (104) into bush
(106).
Assemble bush sub in above Θ into
cover (205) and assemble them into
casing, and tighten hexagon socket head 38098MC13
bolts (276, 277)

ÂHexagon key wrench : 8mm
(38.3~45.6 lbfÂft)
Assemble piston (356) in cover (205),
and tighten plug (559)
ÂBox wrench : 24mm
(147.5~184.4 lbfÂft)
(6) Assembling of negative control relief

valve
611 621 631 561 551
Η Assemble poppet (611), spring (621),and
damping rod (631) to casing A (101) &
casing B(102). Put O-ring (561) onto plug
(551) and tighten the latter with its
specified torque.
38098MC14
(272.7~302.3 lbfÂft)
8-50-16
(7) Assembly of bypass cut valve
326 327 251 337
Η Assemble bypass cut spool (392), spring 265
(326 & 327) and rod (337) into casing A 102
(101) & casing B(102).
392
Put O-ring (265) onto plug (251) and
tighten the latter with its specified torque. 392
ÂBox wrench : 27 mm 101
Â Tightening torque : 7.95~10.0 kgfÂm

(57.5~72.3 lbfÂft)
326 327 251 337 265 38098MC05A
(8) Assembling of lock valve assembly

Η Fit O-ring (163) to lock valve assembly 252
(252) and tighten hexagon socket head
bolts with specified torque.
(7.2~10.2 lbfÂft)
163
38098MC15A
(9) Assembling of main relief valve and port

Η relief valve :
Assemble main relief valve (601) and
port relief valves (603, 604, & 605) to
casing and tighten it with specified 601
torque.
Tightening torque
Item Size
kgfÂm lbfÂft
Main relief valve Spanner 32 mm 38098MC19
Spanner 36 mm 12.2~14.3 88.2~103

Port relief valve
Box wrench 36 mm
603,604
605
38098MC20
8-50-17
(10) Assembling of travel straight spool :
Η Hold end of travel straight spool (391) in
mouthpiece-attached vise, set spring 336
373
seat (332) and spring (373) and tighten
332
spacer bolt (336) with specified torque.
ö Before tightening spacer bolt (336), 391
apply Loctite #262 to it.
ÂHexagon key wrench : 12 mm 102
ÂTightening torque : 3.77~4.18 kgfÂm 38098MC21
(27.2~30.2 lbfÂft)
Θ Fit spool assemblies of items Η above
into casing B (102).
ö Fit spool assemblies into casing B
(102) carefully and slowly. Do not push
them forcibly without fail.
(11) Assembling of boom1 spool :

Η Hold the middle of boom 1 spool (303) in
mouthpiece-attached vise, set spring 336
seat (332) and spring (371) and tighten 332
spacer bolt (336) with specified torque, 371
303
and tighten plug(313) with specified
torque.
ö Before tightening spacer bolt (336) and
plug (313), apply Loctite #262 to them. 38098MC22
ÂSpacer bolt (336) : Hexagon key

wrench 12 mm
ÂTightening Torque : 3.77~4.18 kgfÂm
(27.2~30.2 lbfÂft)
303
ÂPlug (313) : Spanner 27mm
Â Tightening Torque : 3.77~4.18 kgfÂm
102
(27.2~30.2 lbfÂft)
Θ Fit spool assemblies of Items Η above
313
into casing B (102).
ö Fit spool assemblies into casing B
38098MC23
(102) carefully and slowly. Do not push
them forcibly without fail.
8-50-18
(12) Assembling of arm1 spool :
Η Hold end of ar m1 spool (302) in 336
332
mouthpiece-attached vise, set spring
371
seats (332) and spring (371) and tighten 332
spacer bolt (336) with specified torque. 302
ö Before tightening spacer bolt (336),

ÂTightening Torque : 3.77~4.18 kgfÂm 38098MC24
(27.2~30.2 lbfÂft)
Θ Fit spool assemblies of Items Η above
into casing A (101).
ö Fit spool assemblies into casing A
(101) carefully and slowly.
Do not push them forcibly without fail.
(13) Assembling of main spool (travel (301),

bucket (304), swing (305), option (308),
ar m 2 (394), boom 2 (393), swing 336 336
335
priority (395)
263
Η Hold end of each spool in mouthpiece- 335
attached vise, set spring seats, springs 393
(,shim(335) for arm 2, boom 2 and
swing pr ior ity spool) and tighten
spacer bolt (336) with specified torque.
38098MC09
ö Before tightening spacer bolt (336),
ÂTightening Torque : 3.77~4.18 kgfÂm
(27.2~30.2 lbfÂft)
Θ Insert spool assemblies of Items Η
above into casing.
ö Fit spool assemblies into casing A
(101) and casing B (102) carefully and
slowly.
Do not push them forcibly without fail.
8-50-19
(14) Assembling of cover :
Η Fit spool covers (202) and (208) to sides
reverse to spring sides spools, and
tighten hexagon socket head bolts (273)
with specified torque.
ö Confirm that O-rings (262) have been 263
273
fitted to spool cover (202), O-ring (263) 262 211
to boom 1 spool cover (208). 202 212
ÂHexagon key wrench : 8 mm 273 208
38098MC06
(38.3~45.6 lbfÂft)
Θ Boom1 spool cover :
Put O-ring (212) onto plug (211) and
tighten the latter onto boom 1 spool
cover (208) with its specified torque.
(25.3~29 lbfÂft)
Ι Fit spring covers (201), (206) to spring

sides of spools, and tighten hexagon
socket head bolts (273) with specified 206
torque.
ö Confirm that O-rings (263) have been 263 263
fitted. 273
(38.3~45.5 lbfÂft) 201
38098MC07
Κ Bucket spring cover :

Assemble piston (356) to bucket spring
558 558
cover (206). Put O-ring (561) onto plug 561 561
(558) and tighten the latter with specified 356
torque. 206 355
206
ÂHexagon key wrench : 17mm 263
(144.6~180.8 lbfÂft)
Λ Boom spring cover: 38098MC08
Assemble piston (355) to boom1 spring
cover (206). Put O-ring (561) onto plug
(558) and tighten the latter with specified
torque.
(144.6~180.8 lbfÂft)
8-50-20
GROUP 5 SWING DEVICE
1. REMOVAL AND INSTALL OF MOTOR

1) REMOVAL

injury. 4 5
Dr
※ When pipes and hoses are disconnected,
the oil inside the piping will flow out, so A
B

(4) Disconnect hoses (2, 3, 4, 5, 6, 7, 8, 9). 10
2
3
(5) Sling the swing motor assembly(1) and
remove the swing motor mounting bolts 1
(10).
36078SM01A
·Motor device weight : 360kg(794lb)
·Tightening torque :100±15kgf·m
(723±108lbf·ft)
(6) Remove the swing motor assembly. 6
Mu
※ When removing the swing motor
assembly, check that all the piping have
been disconnected. PG
SH
2) INSTALL
7
to removal. 8
(2) Bleed the air from the swing motor. 9

① Remove the air vent plug.
② Pour in hydraulic oil until it overflows from 36078SM01B
the port.
③ Tighten plug lightly.
④ Start the engine, run at low idling and
⑤ Tighten plug fully.
8-51
2. SWING MOTOR
1) STRUCTURE
7 36 5 8 12 11 10 9 20 21 6 24 23 26 34 30
27
A A
2 1 3 4 14 13 16 15 17 35 19 18 22 25 31,32 29 28 33
SECTION A-A
3607A2SM02
1 Body 13 Set plate 25 Wrench bolt

2 Oil seal 14 Piston assy 26 Poppet
3 Roller bearing 15 Friction plate 27 Spring
4 Snap ring 16 Plate 28 Plug
5 Shaft 17 Brake piston 29 O-ring
6 Pin 18 O-ring 30 Relief valve assy
7 Stop ring 19 Spring 31 Time delay valve
8 Shoe plate 20 Valve plate 32 Wrench bolt
9 Cylinder block 21 Pin 33 Plug
10 Spring 22 Needle bearing 34 O-ring
11 Ball guide seat 23 Rear cover 35 O-ring
12 Ball guide 24 Wrench bolt 36 Bushing
8-52
(1) Tools
Tool name Remark
Allen wrench 5
6 B
12
17
Socket for socket wrench, spanner 36
Snap ring plier(for holes, axis) Snap ring(4)
Solder hammer Needle bearing(22), pin(6, 21)
Oil seal inserting jig Oil seal(2)
Induction heating apparatus for bearing Roller bearing(3)

Torque Wrench size
Part name Item Size
Wrench bolt 24 M14 20.9 151.2 0.47 12
Wrench bolt 25 M14 20.9 151.2 0.47 12
Relief valve 30 M33 18.0 130.2 1.42 36
Wrench bolt 32 PF 1/4 6.9 49.9 0.20 5
Plug 33 PF 1/4 20.9 151.2 0.24 6
8-53
2) DISASSEMBLING
(1) Disassemble the sub of a TURNING
AXIS
① Unloosing wrench bolt(32) and dis-
assemble time delay valve assy(31) from
rear cover(23)
3607A8SM01/01A
② Hang rear cover(23) on hoist, unloose

wrench bolt(24, 25) and disassemble
from body(1).
3607A8SM02
③ Using a jig, disassemble break piston(17)

from body(1).
3607A8SM03
④ Disassemble respectively cylinder block

assy, fricktion plate(15), plate(16) from
body(1).
3607A8SM04
8-54
⑤ Disassemble shoe plate(8) from body(1).
3607A8SM05
⑥ Using a plier jig, disassemble snap ring

(4) and shaft assy(5).
3607A8SM06/06A
(2) Disassemble cylinder block assy sub

① Disassemble pistion assy(14), set plate
(13) from cylinder block assy.
3607A8SM07
② Disassemble ball guide(12), friction

plate(15), plate(16) and ball guide
seat(11) from cylinder block(9).
3607A8SM08A/08B
8-55
③ Disassemble spring(10) from cylinder
block(9).
3607A8SM09
(3) Disassemble rear cover assy sub

① Disassemble pin(6, 21) and valve plate
(20) from rear cover(23).
3607A8SM10/10A
② Using a torque wrench, disassemble

relief valve assy(30) 2 set from rear
cover(23).
3607A8SM11/11A
③ Disassemble make up check valve assy

with a torque wrench from rear cover(23).
3607A8SM12/12A
8-56
4) ASSEMBLING
(1) Assemble the sub of a turning axls
① Put roller bearing(3) on preheater and
provide heat to inner wheel(compressing
temp : 290。C for 2 minutes)
·Roller bearing ×1EA
3607A8SM21
② After assembling and compressing

preheated roller bearing(3), stop ring(7)
into shaft(5).
·Stop ring ×1EA
·Shaft× 1EA
3607A8SM22/22A
③ Using a compressing tool and steel stick,

assemble oil seal(2) into body(1).
·Oil seal ×1EA
3607A8SM23/23A
④ Insert above shaft sub into body(1) and

assemble it with a hammer.
3607A8SM24
8-57
⑤ Fix snap ring(4) to shaft with a plier jig.
·Snap ring ×1EA
3607A8SM06
⑥ Spread grease on shoe plate(8) and

assemble on the body.
·Shoe plate ×1EA
3607A8SM05
(2) Assemble the sub of cylinder block

assy
① Assemble spring(10) 9 set into cylinder
block(9).
·Spring ×9EA
3607A8SM25
② Assemble ball guide(12) and ball guide

seat(11) into cylinder block(9).
·Ball guide ×1EA
3607A8SM26
8-58
③ Assemble piston assy(14) 9 set into set
plate(13).
·Piston assy ×9EA
·Set plate ×1EA
3607A8SM27
④ Assemble above item ② and ③.
3607A8SM28
⑤ Assemble cylinder block assy into body

(1).
3607A8SM04
⑥ Assemble 4 set of lining plate(16), friction

plate(15) respectively into body.
·Lining plate ×4EA
·Friction plate ×4EA
3607A8SM29
8-59
⑦ Assemble O-ring(18) into break piston
(17).
·O-ring ×2EA
3607A8SM30
⑧ Insert break piston assy into body(1) and

assemble spring(19) into break piston
(17).
·Spring×19EA
3607A8SM31/31A
(3) Assemble the sub of rear cover assy

sub
① After assembling needle bearing(22) into
rear cover(23), with a hammer assemble
pin(6, 21).
3607A8SM32/32A
② Assemble respectively make up check

valve assy spring(27), poppet(26),
plug(28) into rear cover(23) after then
screw it torque wrench.
·Make up check sub ×2set
·Spring ×2EA
·Check ×3EA
3607A8SM33/12A
8-60
③ Assemble relief valve assy(30) 2set into
rear cover(23) with a torque wrench.
3607A8SM34/11A
④ Spreading grease on valve plate(20),

assemble into rear cover(23).
·Valve plate×1EA
3607A8SM10/10A
⑤ Lift up rear cover assy on body(1) by a

crane and assemble it with a wrench
bolt(24, 25).
3607A8SM02
⑥ Assemble time delay valve assy(31) into

rear cover(23) with a wrench bolt(32).
3607A8SM01/01A
8-61
(4) Air pressing test
Be sure of leakage, after press air into
assembled motor.
14078SM232
(5) Leakage check

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

Mounting motor test bench, test the
availability of each part.
220078SM14
8-62
3. REMOVAL AND INSTALL OF REDUCTION GEAR
1) REMOVAL
(1) Remove the swing motor assembly.
For details, see removal of swing motor
assembly.
(2) Slide reduction gear assembly(1) and
remove mounting bolts(2)
(3) Remove the reduction gear assembly
·Reduction gear : 285kg(628lb)
13031GE18
2) INSTALL
to removal.
·Mounting bolt : 100±15kgf·m
(723±108lb·ft)
2
36078SR01
8-63
4. REDUCTION GEAR
1) STRUCTURE
28,36 27 26 25 5 4 3 1 40 2 6 7 13 14 10 12 11 33 24
15
38
* * 43
16
17
29
18
37
35 34 31 30 23 8 21 32 19 20
3607A2SM03
1 Casing 15 Carrier 1 29 Stop ring

2 Drive shaft 16 Sun gear 1 30 Plug
3 Roller bearing 17 Planetary gear 1 31 Plug
4 Cover plate 18 Pin 1 32 Side plate 1
5 Hex bolt 19 Needle cage 33 Spring pin
6 Oil seal 20 Side plate 2 34 Gauge bar
7 Roller bearing 21 Spring pin 35 Gauge pipe
8 Carrier 2 22 Ring gear 36 Lock washer
9 Sun gear 2 23 Knock pin 37 Cover
10 Planetary gear 2 24 Socket bolt 38 Socket bolt
11 Pin 2 25 Spacer 39 Socket plug
12 Bushing 2 26 Pinion gear 40 Ring spacer
13 Spring pin 27 Lock plate 42 Air breather assy
14 Washer 28 Hex bolt 43 Thrust ring
8-64
2) DISASSEMBLY
(1) Removal of cover
※ Loosen the socket bolt(24) with 16mm
hexagonal socket and remove the
cover(37).
(2) Removal of sun gear 1 and thrust ring

assembly
Remove carrier 1(15), install eye bolt to
tap hole(M10) and remove carrier 1
assembly itself.
3607A8SR03
(3) Removal of sun gear 2

Remove sun gear 2(9), install eye bolt to
tap(M10) of carrier 2(8) and remove
carrier 2 assembly itself.
3607A8SR04
(4) Disassembly of 2nd carrier assembly

① Insert spring pin(13) into pin assy 2(11)
by hammering.
※ Do not reuse spring pin after removal.
3607A8SR05
8-65
② Remove pin assy 2(11) from carrier 2(8),
planetary gear 2(10) and thrust washer
(14) with hands.
3607A8SR06
(5) Removal of ring gear

Remove ring gear(22) from casing(1).
※ Fluid packing is applied on contacting
face of ring gear and gear casing.
Therefore, remove ring gear from casing
by minus screw driver.
3607A8SR07
(6) Removal of drive shaft(2) assembly

① Spread off the corners of spacer(25),
cover plate(4) and hex bolt(5) with a tool.
3607A8SR08
② Install hydraulic press at the end face of

shaft, and remove drive shaft(2), spacer
ring(40), and roller bearing(3) as
assembly.
※ Do not reuse oil seal after removal.
3607A8SR09
8-66
③ Remove roller bearing(7) from gear
casing(1).
3607A8SR10
④ Remove oil seal(6) from gear casing(1).
3607A8SR11
(7) Disassembly of shaft assembly

Insert motor side of shaft(2) into steel tube
(inner dia : Ø145mm) and push the end of
output shaft side with hydraulic press and
then remove roller bearing(3), and spacer
ring(40) as assembly from drive shaft(2).
3607A8SR12
8-67
3) ASSEMBLY
(1) Assembly of drive shaft assembly
① After assembly drive shaft (2), heat roller
bearing(3) up to 50° C plus surrounding
temperature and assemble it to shaft with
hydraulic press and then assemble
spacer ring(40) in this order.
※ Pay attention to the assembling direction
of cover plate(4).
3607A8SR13
(2) Installation of oil seal

Remove oil from assembled face of oil
seal of gear casing(1) and oil seal(6).
Apply fluid packing(three bond of white
color) on outer face of oil seal and
assemble at pressing jig of gear casing.
After inserting with press, Iubricate oil seal
with grease.
3607A8SR14
(3) Assembly of drive shaft assembly

① Be careful lest oil seal lip damage by
spline of drive shaft(2).
Assemble drive shaft assembly by using
seal guide.
② Put drive shaft of gear casing(1) upward.
Assemble drive shaft assembly to gear
casing by tightening eye bolt into tap hole
(M16) of output side of drive shaft(2).
※ Place support (approx 150mm) below of
gear case(1) for seal protector contact
with work table.
3607A8SR15
8-68
(4) Install of roller bearing
Put gear casing under output shaft and
heat roller bearing(7) up to 50°
C plus
surrounding temperature and then
assemble it to the shaft.
3607A8SR16
(5) Assembly of ring gear

① Remove oil from mating faces between
gear casing(1) and ring gear(22), and
knock pin(23). Assemble collar of gear
casing and apply fluid packing(three
bond of grey color).
3607A8SR17
② Assemble ring gear(22).
36078SR18
(6) Assembly of carrier 2 assembly

① Assemble planetary gear 2(10) to carrier
2(8) with thrust washer(14) and insert pin
assy 2(11).
※ Lubricate gear oil to inside of gear and
outside of shaft.
3607A8SR19
8-69
② Insert spring pin(13) by hammering.
※ Insert as the clearance between spring
pins toward planetary gear 2(10).
3607A8SR20
(7) Assembly of carrier 2 assembly and

sun gear 2
① Mount eye bolt into tap hole(M10) of
carrier 2(8) and lift carrier assembly and
then insert carrier assembly being
engaged with internal teeth of ring gear
(22). Rotate carrier assembly lightly so
that splines of drive shaft(2) are
engaged.
3607A8SR21
② Insert sun gear 2(9) to planetary gear 2

(10).
3607A8SR22
(8) A ssembly of sun gear 1, carrier 1

assembly
① Mount eye bolt into tap hole(M10) of lift
carrier assembly and then insert carrier
assembly being engaged with internal
teeth of ring gear(22).
Rotate holder assembly lightly so that
sun gear 2(9) is engaged with teeth of
carrier 1(15).
3607A8SR23
8-70
② Insert sun gear 1(16) to planetary gear 1
(17).
3607A8SR24
(9) Check rotation of sun gear by turning

plunge part of gear casing with hands.
(10) Assembly of cover

Remove oil from mating faces between
ring gear(22) and cover(37) and apply
fluid packing.
Assemble cover(37) and tighten socket
bolt(24) with 16mm hexagonal socket.
Tightening torque : 27kgf·m
(195.3lbf·ft)
36078SR27
This completes assembly
8-71
GROUP 6 TRAVEL DEVICE

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

E scaping fluid under pressure can
injury.
the oil inside the piping will flow out, so 1 Pi

Dr
B
(4) Remove the track shoe assembly. A
For details, see removal of track shoe 2
assembly.
(5) Remove the cover.
36078TM01
(6) Remove the hoses.

※ Fit blind plugs to the disconnected hoses.
(7) Remove the bolts and the sprocket.
(8) Sling travel device assembly(1).
(9) Remove the mounting bolts(2), then
remove the travel device assembly.
·Weight : 380kg(840lb)
2) INSTALL
to removal.
(2) Bleed the air from the travel motor.
① Remove the air vent plug.
② Pour in hydraulic oil until it overflows from
the port.
③ Tighten plug lightly.
④ Start the engine, run at low idling, and
⑤ Tighten plug fully.
8-72
2. TRAVEL MOTOR
1) STRUCTURE(1/2)
101 491 107 102 435 504 113 201 122 741 742 121 703 545 705 461 704 351
352
802
801
451
303
131
103
111
114
472
502 503 123 272 707 702 708 546 547
3607A2TM02
101 Drive shaft 303 Valve casing 547 O-ring

102 Roller bearing 351 Reducing valve 702 Brake piston
103 Needle bearing 352 Cover 703 Orifice
107 Snap ring 435 Snap ring 704 Orifice
111 Cylinder block 451 Pin 705 Brake spring
113 Spherical bushing 461 Plug 707 O-ring
114 Cylinder spring 472 O-ring 708 O-ring
121 Piston 491 Oil seal 741 Separation plate
122 Shoe 502 Piston 742 Friction plate
123 Set plate 503 Shoe 801 Name plate
131 Valve plate 504 Pivot ball 802 Rivet
201 Swash plate 545 Orifice
272 Shaft casing 546 Orifice
8-73
STRUCTURE(2/2)
402 366 364 564 022 361 365 362

571
572
531
533
464 509
SECTION E-E
485
350 401 567 541 543 542 570 569
3607A2TM03
022 Counterbalance spool 402 Hex socket bolt 543 Steel ball
350 Relief valve 464 VP plug 564 Plug
361 Washer 485 O-ring 567 VP plug
362 Counterbalance spring 509 O-ring 569 RO plug
364 Counterbalance cover 531 Tilting spool 571 RO plug
365 O-ring 533 Tilting spring 572 O-ring
366 Hex socket 541 Seat
401 Hex socket 542 Stopper
8-74
(1) Tools
Tool name Remark

Allen wrench 2
2.5
4
6 B
8
10
17
Socket for socket wrench, spanner 19
22.4
27
42
Torque wrench Capable of tightening with the specified torques.
Plier(For hole, TPR-90) For snap ring(435)
Plier(For shaft) For snap ring(107)
( - ) Driver -
Plastic hammer Wooden hammer allowed. Nominal 1 or so
Steel rod approx 7×7×200mm, Bearing(102, 103)
Monkey wrench -
Oil seal inserting jig -
Bearing plier -
Seal tape -

Torque Wrench size
Part name Item Size
Socket bolt 366 M12×45 10 72.3 0.39 10
Socket bolt 401 M20×100 44 318 0.67 17
Socket bolt 402 M20×50 44 318 0.67 17
Plug 461 NPTF 1/16 0.9 6.5 0.16 4
VP Plug 464 PF 1/4 11 79.6 1.06 27
Orifice 545, 546 NPTF 1/16 0.7 5.1 0.16 4
Plug 564 PT 1/2 2.2 15.9 0.24 6
VP Plug 567 PF 1/4 3.7 26.8 0.75 19
Plug 569 PF 1/4 3.7 26.8 0.24 6
Plug 571 PF 3/8 7.5 54.2 0.31 8
Orifice 703 M4×0.7 0.35 2.5 0.08 2
Orifice 704 M5×0.8 0.7 5.1 0.1 2.5
8-75
3. TRAVEL REDUCTION GEAR
1) STRUCTURE
1 16 19 22 13 36 54 2
30
4
18
44
46 52
A
27
9 51
10
26
53
32
83
45
11
5
24
21 37 20 25 14 23 17
12
81 6 29 82 47 35 33 34 SECTION VIEW A
3607A2TRG01
1 Ring gear 19 Side plate 35 Shim

2 Housing 20 Side plate 36 Spring pin
4 Side cover 21 Needle cage 37 Snap ring
5 Carrier 1 22 Needle cage 44 Snap ring
6 Carrier 2 23 Needle cage 45 Clip
9 Sun gear 1 24 Inner ring 46 W clip
10 Sun gear 2 25 Floating bushing 47 Nut ring
11 Sun gear 3 26 Thrust ring 51 Name plate
12 Planetary gear 1 27 Thrust ring 52 Rivet
13 Planetary gear 2 29 Socket bolt 53 Washer
14 Planetary gear 3 30 Socket bolt 54 Set screw
16 Pin 2 32 RO plug 81 O-ring
17 Pin 3 33 Angular bearing 82 O-ring
18 Side plate 34 Floating seal 83 O-ring
8-76
(1) Tools
Tool name Remark

Allen wrench 4 B
8
10
14
Spanner 27
Torque wrench Capable of tightening with the specified torques.
Plier(For shaft) Snap ring(037, 044)
( - ) Driver For removing floating seal
Plastic hammer Wooden hammer allowed
Eye bolt M8, M10, M16, M20, For lifting-up
Press(1 ton) Angular bearing(033)
Depth gauge straight edge 100mm depth, for adjusting shins(053)
Tap M16 For removing screw lock in tapped holes
Oil stone For finishing mating faces
Punch For preventing spring pin from coming out
Loctite(Three bond 1373B) Set screw(054)
Loctite Socket bolt(029)
Nut ring inserting jig Nut ring(047)

Torque Wrench size
Part name Item Size
Socket bolt 29 M16×100 30 217 0.55 14
30 M8×20 3.5 25.3 0.24 6
Plug 32 PF 1/2 11 79.6 0.39 10
Set screw 54 M8×16 1.0 7.2 0.24 6
8-77
4. DISASSEMBLING
(1) Pay attention to not damaging contact surfaces for O-rings, oil seals, etc. and contact/sliding
surfaces for gears, pins, bearings, etc.
(2) This motor can be disassembled even in a state on the reduction gear.
However, in that case, pay full attention to preventing mud, dust, etc. from entering in it.
(3) The numerical in parentheses following each part name indicates its part number shown in the
attached assembly drawings.
(4) The piping side of the motor is referred to as the rear side, and the output side as the front side.
2) DISASSEMBLY OF REDUCTION GEAR
(1) Select a disassembling place.
※ Select a clean place.
※ Spread rubber sheet or cloth on work bench to prevent parts from being damaged.
(2) Remove dust, mud, etc. from reduction gear surfaces with washing oil or so.
(3) Place reduction gear with its gear oil drain port or level gauge at the lowest position, and drain
reduction gear oil.
※ Receive gear oil with clean vessel and check it for abnormalities.
Renew gear oil.
(4) Place reduction gear with its side cover (4)
upward, and remove socket bolt(30), and
remove side cover(4) and O-ring(81).
370078TM01
(5) Remove sun gear 1(9).
370078TM02
8-78
(6) Remove carrier 1(5), together with
planetary gears 1(12), sun gear 2(10), etc.
fitted.
370078TM03
(7) Disassembling of carrier 1 sub-

assembly
① Remove snap ring(44), and then remove
side plate (18), planetary gear 1 (12),
needle cage(21) and side plate(18).
※ If flaking is observed on the inner ring
surface replace inner ring. In this case,
replace planetary gear 1 and needle
cage simultaneously.
370078TM04
② Remove circlip(45), and then remove

carrier 1(5) from sun gear 2(10).
370078TM05
③ Remove thrust ring(26).
370078TM06
8-79
(8) Remove carrier 2(6), with planetary gears
2(13), sun gear 3(11), etc. fitted.
※ Use M10 eyebolt. In this case, thrust
ring(26) is removed simultaneously.
370078TM07
(9) Disassembling of carrier 2 sub-

assembly
① Push in spring pin(36), and remove pin
2(16), from carrier 2.
※ Carry out the following check in advance.
If any abnormality should be found, carry
out disassembling.
· Is there any crevice, crack or pitting on
tooth surface of planetary gear?
· When turning planetary gear lightly, is 370078TM08
there any abnormal noise or eccentric

clearance? Carry out check similarly to
the above for carrier 3.
② Remove side plate(20), planetary gear

2(13), and needle bearing(22) from
carrier 2.
③ Remove thrust ring(26).
370078TM09
④ Remove snap ring(46), and remove

carrier 2(6) from sun gear 3(11).
⑤ Remove thrust ring(27) from sun gear
3(11).
370078TM10
8-80
(10) Remove socket bolt(29), and then screw
two M8 eyebolts on front side of ring
gear(1), lift up ring gear with crane, and
remove O-ring(82) from housing(2).
※ It is difficult to separate them, because it is
assembled by LOCTITE.
In this case, if you can use wrench and
pipe, it is easy to separate them.
370078TM11
(11) Remove snap ring(37) and then remove

pin 3(17) from shaft casing(272).
370078TM12
370078TM13
(12) Remove side plate(20), planetary gear

3(14), needle cage(23), floating bushing
(25) from shaft casing(272).
370078TM14
8-81
(13) Remove set screw(54) from nut ring(47),
and then remove nut ring(47) from shaft
casing(272).
※ When disassembling nut ring, remove
dust, mud, etc. from set screw hole by
blasting compressed air.
And remove the nut ring by using the
special tool for removing the nut ring.
370078TM15
(14) Remove housing(2), angular bearing(33),

floating seal(34) from shaft casing(272).
※ Screw two M16 eye bolts on front side of
housing(2).
Lift up housing(2) with crane.
370078TM17
(15) Remove floating seal(34) from housing(2),

paying attention to not damaging it.
※ Pay attention to O-ring and sheet faces.
370078TM18
(16) Remove floating seal(34) from casing

(272), pay attention to not damaging it.
※ Pay attention to O-ring and sheet faces.
370078TM19
8-82
(17) Remove angular bearing(33) from
housing(2).
※ Bearing should be renewed once it is
removed.
370078TM20
3) DISASSEMBLY OF MOTOR
(1) Disassembling of motor main body
① Place hydraulic motor on bench with its
output shaft down.
370078TM21
② Loosen relief valve(350), reducing valve

(351), cover(352), plug, etc.
They are fitted to valve casing(303).
370078TM22
370078TM23
8-83
③ Remove plug(564) from valve casing
(303). And then screw two M10×135
bolts on the holes of compelent brake
release. Sub assembly(valve casing &
brake piston)
370078TM24
④ Remove socket bolts(401, 402) that

assemble valve casing(303).
370078TM25
⑤ Remove the above socket bolt, and then

separate valve casing sub-assembly and
remove valve plate(131).
370078TM26
⑥ Pull out friction plate(742) and separation

plate(741) from cylinder block(111).
※ In this case, motor should be located in
horizontally.
370078TM27
8-84
⑦ Pull out cylinder block and piston sub-
assembly.
※ After placing the motor horizontally, take
out cylinder block from casing.
※ Be careful not to damage the sliding
parts of the cylinder block, spherical
bushing and shoe.
370078TM28
⑧ Remove swash plate(201).
370078TM29
⑨ Remove pivot ball(504) and tilting piston

sub assembly.
370078TM30
⑩ Take out snap ring(435), and then hit

front side end face of shaft(101) lightly
with plastic hammer or so to remove from
casing(272).
※ Do not remove cylinderical roller bearing
(102) as far as it remains normal.
370078TM31
8-85
⑪ Take out oil seal(491) from shaft
casing(272).
※ Do not reuse the disassembling oil
seal(491).
370078TM32
(2) D isassembling of valve casing sub-

assembly
① Remove two M10×135 bolts for compe-
lling brake release. Disassemble brake
piston from valve casing.
370078TM33
② Remove plug(571), tilting spring(533),

and tilting spool(531) from valve casing.
370078TM34
③ Remove socket bolts(366), counterbalan-

ce cover(364), and counterbalance spool
assembly.
※ When any abnormality is found in
counterbalance spool, counterbalance
spring, etc. replace with the counter
balance spool sub assembly as a set.
370078TM35
8-86
④ Remove plug(569), stopper(542), steel
ball(543) and seat(541).
※ When no abnormality is found in
displacement changeover, it is not
necessary to overhaul it specifically.
And don't remove needle bearing(103)
as far as it remains normal.
370078TM36
(3) D isassembling of cylinder sub-

assembly
① Pull out set plate(123), piston(121), and
shoe(122) sub-assembly.
370078TM37
② Remove spherical bush(113) and

cylinder spring(114).
That is all of the disassembling work.
The pins(451) force-fitted to the valve
casing cannot be removed.
370078TM38
8-87
5. ASSEMBLING
1) GENERAL CAUTIONS
(1) Clean each part fully with washing oil and dry it by blasting compressed air. It is better not to use
waste cloths as much as possible.
However, if they are to be used, use clean ones, and pay attention to not leaving lint and so on.
Don't clean the friction plate with washing oil without fail.
(2) Use the torque wrench in tightening fitting screws and plugs to their respective torque shown in
page 8-75, 8-77.
(3) When hammering is required, use the plastic hammer and try to hit parts lightly.
(4) Similarly to the disassembling procedures, the numeral in parentheses following each part name
indicates its item number shown in the attached assembly drawings.
2) ASSEMBLY OF MOTOR
(1) Assembling driving shaft sub-assembly
① Put roller bearing (102) on drive shaft
(101), and assemble snap ring(107) by
using the plier.
※ Roller bearing is press fit by the heat to
drive shaft.
※ Pay attention to not damaging oil seal
sliding area of driving shaft.
※ Pay attention to not fitting snap ring the 370078TM39
other way around.
(2) Assembling of valve casing sub-

assembly
① Tighten plugs(461, 564) into valve casing
(303) with specified torque.
·Plug(461) : 0.9kgf·m(6.5lbf·ft)
·Plug(564) : 2.2kgf·m(15.9lbf·ft)
370078TM40
② Interference-fit pin(451).
370078TM41
8-88
③ Interference-fit needle bearing(103).
※ It is necessary when needle bearing was
disassembled from the valve casing.
370078TM42
④ Assemble seat(541), steel ball(543),

stopper(542) and RO plug(569) in the
order named.
·Tightening torque : 3.7kgf·m(26.8lbf·ft)
※ Pay attention to not assembling seat and
stopper the other way around.
370078TM43
⑤ Assemble counterbalance spool(360),

washer(361), spring(362) in the order
named.
370078TM44
⑥ Fit counterbalance cover(364) by

tightening socket bolt(366).
·Tightening torque : 10kgf·m(72.3lbf·ft)
※ Confirm that O-ring(365) has been
inserted in cover.
370078TM45
8-89
⑦ Assemble tilting spool(531), tilting
spring(533) and plug(571) in the order
named.
370078TM46
⑧ Assemble orifice(703) and tighten them

into brake piston(702) to specified torque.
370078TM47
⑨ Assemble brake spring(705) in brake

piston(702). And then screw two M10×
135 bolts on the holes for compelent
brake release.
Sub-assembly(valve casing & brake
piston)
※ After finishing assembly, two M10×135
bolts will be removed.
370078TM48
(3) Assembling of cylinder sub-assembly

① Fit cylinder spring(114) and spherical
bush(113) to cylinder block(111).
※ Match spline phase of cylinder block
(111) to that of spherical bush.
370078TM49
8-90
② Put piston(121), shoe(122) sub-assembly
in set plate(123) and then assemble
them to cylinder block(111).
370078TM50
(4) Assembling of motor main body

① Tighten plug(461) and orifice(545, 546)
into shaft casing(272) to specified torque.
·Plug(461) : 0.9kgf·m(6.5lbf·ft)
·Plug(545, 546) : 0.7kgf·m(5.1lbf·ft)
370078TM51
370078TM51A
② Interference-fit oil seal(491) into shaft

casing(272) by special tool.
370078TM52
8-91
③ Interference-fit the shaft sub-assembly.
And then assemble snap ring(435).
※ Interference-fit outer race of cylindrical
roller bearing(102) by hitting lightly with
hammer, utilizing key.
370078TM53
370078TM54A
④ Assemble tilting piston sub-assembly and

pivot ball(504) into shaft casing(272).
370078TM54
370078TM54A
8-92
⑤ Assemble swash plate(201) onto pivot
ball(504).
※ Apply grease on sliding area of swash
plate rear surface.
※ Confirm with finger tips of both hands if
swash plate moves smoothly.
370078TM55
⑥ Change position of shaft casing(272)

from vertical one to horizontal one.
And then mount cylinder block sub-
assembly.
※ Pay attention to not dropping swash
plate.
370078TM56
⑦ Change position of shaft casing(272)

from horizontal one to vertical one.
370078TM57
⑧ Fit separation plate(741) and friction

plate(742) into cylinder block(111).
※ Mate hole of separation plate each other.
370078TM27
8-93
⑨ Assemble O-ring(707, 708) into shaft
casing(272).
※ Do not reuse the disassembling O-ring
(707, 708).
※ Coat the O-ring with grease.
(O-ring can be protected by grease)
370078TM59
⑩ Fit valve plate(131) to valve casing(303)

sub-assembly. Assemble them to
casing, and then tighten them with socket
bolt(401, 402).
·Socket bolt(401, 402) Tightening torque
: 44kgf·m(318lbf·ft)
※ Apply grease on valve plate rear surface
and pay attention to not dropping valve
plate.
※ Use guide bolt. 370078TM60
※ Apply grease on roller of needle bearing

and pay attention to easy to assemble
with driving shaft.
※ Use crane in assembling valve casing to
shaft casing.
370078TM60A
⑪ Tighten to specified torque plugs, relief

valve(350), reducing valve(351), etc. fitted
to valve casing sub-assembly.
·Tightening torque :
- Relief valve(350) : 18kgf·m(130lbf·ft)
- Reducing valve(351) : 4.5kgf·m(32.5lbf·ft)
370078TM61
8-94
370078TM61A
⑫ Mount cover(352).
370078TM63
⑬ Disassemble two M10×135 bolts on the

holes for compelent brake release.
And then assemble plug(564).
370078TM24
3) ASSEMBLY OF REDUCTION GEAR

(1) Place housing(2) with its front side up,
and fit angular bearings(33) with their
back faces mated.
※ Fit angular bearings one by one with
press or key hammer.
※ When housing is to be reused, remove
screw lock of its tapped holes with M16
tap.
370078TM64
8-95
(2) Fit O-ring to floating seal(34) without
twisting it, and then to housing(2).
※ Apply grease to O-ring thinly.
※ Do not reuse the disassembling O-ring.
370078TM65
(3) Similarly, fit floating seal to shaft

casing(272) of hydraulic motor.
370078TM66
(4) Lift up housing sub-assembly with its

floating seal side down, and put inner
diameter of angular bearing on outer
diameter of shaft casing.
※ Pay attention to not damaging sliding
faces of floating seal.
370078TM67
(5) Assemble shim(35) to nut ring(47).

※ Apply grease between shim and nut ring.
370078TM68
8-96
(6) Insert nut ring assembled shim to shaft
casing, and then tighten it to specified
torque, utilizing special tool.
※ After tighten it to maximum torque and
then disassemble, and then tighten it to
specified torque.
·Tightening torque : 60kgf·m(434lbf·ft)
370078TM70
(7) After assemble set screw(54) affixed

LOCTITE, and punch at hole to lock it.
Pay attention to not be lifted nut ring(47).
※ Screw the set screw, until upper side of
set screw is lower than tilting side of nut
ring.
·Loctite specifications : Three bond 1373B
·Tightening torque : 1kgf·m(7.2lbf·ft)
370078TM71
(8) Assemble thrust ring(27) into shaft

casing(272).
※ Pay attention to not assembling thrust
ring(27) the other way around.
(Oil groove is located upside.)
370078TM72
(9) Put needle cage(23) into inside of plane-

tary gears 3(14), and insert them into
shaft casing, holding them between side
plates(20).
※ Mate pin hole of shaft casing with center
of planetary gear.
370078TM73
8-97
(10) Insert pin 3(17) into shaft casing, and then
assemble snap ring(37).
370078TM74
370078TM74A
(11) Assemble O-ring(82) to housing(2), and

then assemble ring gear(1).
Pay attention to its meshing planetary
gear 3(14) and ring gear(1), utilizing
crane.
※ Applying grease to O-ring thinly.
370078TM75
(12) Assemble ring gear(1) and housing(29).

(Screw socket bolt(29), and tighten it to
specified torque, with torque wrench.)
·Tightening torque : 30kgf·m(217lbf·ft)
·Loctite specifications : #636
370078TM76
8-98
(13) Assembling carrier 2 sub-assembly
① Assemble carrier 2(6) to sun gear 3(11),
and fit clip(46).
② Place carrier 2 with sun gear 3 up.
370078TM77
③ Put needle cage(22) into inside of

planetary gear 2(13), and insert them
into carrier 2, holding them between side
plates(19).
370078TM78
④ Insert pins 2(16) into carrier 2.
370078TM78A
⑤ Insert spring pin(36) into pin holes of

carrier 2 and pin 2, and punch at two
points as figure to lock it.
※ Mate pin hole of carrier 2 with center of
planetary gear.
Punching
370078TM79
8-99
(14) Screw two M10 eyebolts into carrier 2 sub-
assembly, and assemble it with crane,
paying attention to its meshing with
planetary gear 2 and ring gear.
370078TM80
(15) Assembling of carrier 1 sub-assembly

① Interference-fit inner ring(24) to carrier
1(5).
※ Inner ring is press-fit by the heat to carrier
1(5).
370078TM81
② Assemble carrier 1(5) to sun gear 2(10),

and fit clip(45).
370078TM82
③ Assemble thrust ring(26) to sun gear

2(10).
※ Pay attention to not assembling thrust
ring(26) the other way around.
(Oil groove is located upside.)
370078TM83
8-100
④ Put needle cage(21) into inside of
planetary gear 1(12), and assemble
them, holding them between side plates
(18). Then fit snap ring(44) on them.
370078TM84
(16) Assemble carrier 1(5) sub-assembly to

ring gear(1).
Paying attention to its meshing with carrier
1 sub-assembly and ring gear(1).
370078TM85
(17) Assemble sun gear 1(9) to drive shaft

(101) paying attention to its meshing with
sungear and drive shaft(101).
(18) Measure height "A" from sun gear 1 end

face to ring gear(1) mating face with
straight edge and depth gage.
370078TM87
8-101
(19) Measure height "B" from side cover(4)
mating face to center hold bottom with
straight edge and depth gage.
370078TM88
(20) Obtain optimum thickness with the

following formula.
1.5~2.0 = (B+A)
- (Thickness of thrust ring + thickness of
washer)
B
※ Keep axial clearance between sun gear
and washer 1.5~2.0mm.
370078TM89
(21) Place washer(53) of above-selected

thickness and thrust ring(26) to center of
side cover(4).
※ Pay attention to not assembling thrust ring
(26) the other way around and punch it
(Oil groove is located upside)
370078TM90
(22) Assemble O-ring(81) into ring gear.

And degrease and dry mating faces of
side cover & ring gear. Then lift side
cover(4) up, and place it on ring gear.
And tighten socket bolt(30) to specified
torque to fix side cover.
370078TM91
8-102
(23) Tighten plug(32) to specified torque at
side cover(4).
That is all of the assembling work. After

fitting the motor this reduction gear, supply
oil until overflows from the level gauge.
370078TM92
4) CHECKING FACTS AFTER ASSEMBLY

(1) Air test of reduction gear
Disassemble plug(32) of reduction gear part.
When compressed air(0.3kgf/cm2) is inserted that in water during the 2 minutes, it should be not
happened air bubble.
·Gear oil : 5.5 liter (SAE 85W-140, API GL-5 or better)
(2) Air test of hydraulic motor
One port should be opened, the others port should be closed.
When compressed air(3kgf/cm2) is inserted opened port in water during the 2 minutes, it should be
not happened air bubble.
·Working fluid : 1.5 liter
8-103
GROUP 7 RCV LEVER

1) REMOVAL

1
injury.
2
(4) Loosen the socket bolt(1).
(5) Remove the cover of the console box.
3
(6) Disconnect pilot line hoses(3).
(7) Remove the pilot valve assembly(2).
※ When removing the pilot valve assembly,
21078DA06
check that all the hoses have been
disconnected.
2) INSTALL
to removal.
8-104
1) STRUCTURE
14072SF80
8-105
1 Case 12 Rod seal 23 Nut
2 Plug 13 O-ring 24 Insert
3 Plug 14 Push rod 25 Boot
4 O-ring 15 Plate 26 Handle
5 Spool 16 Bushing 27 Switch assembly
6 Shim 17 Joint assembly 28 Screw
7 Spring 18 Swash plate 29 Switch assembly
8 Spring seat 19 Adjusting nut 30 Switch cover
9 Stopper 20 Lock nut 40 Boot
10 Spring 21 O-ring
11 Plug 22 Handle connector
8-106
(1) Tools
Tool name Remark
Allen wrench 6 B
22
Spanner
27
(+) Driver Length 150
(-) Driver Width 4~5

Torque
Part name Item Size
kgf·m lbf·ft
Plug 2 PT 1/8 3.0 21.7
Joint 17 M14 3.5 25.3
Swash plate 18 M14 5.0±0.35 36.2±2.5
Adjusting nut 19 M14 5.0±0.35 36.2±2.5
Lock nut 20 M14 5.0±0.35 36.2±2.5
Screw 28 M 3 0.05 0.36
8-107
3) DISASSEMBLY
(1) Clean pilot valve with kerosene.
※ Put blind plugs into all ports
(2) Fix pilot valve in a vise with copper(or
lead) sheets.
(3) Remove end of boot(25) from case(1) and
take it out upwards.
1408DA62
※ For valve with switch, remove cord also

through hole of casing.
1408DA63
(4) Loosen lock nut(20) and adjusting nut(19)

with spanners on them respectively, and
take out handle section as one body.
1408DA64
(5) Remove the boot(40)
1408DA61
8-108
(6) Loosen adjusting nut(19) and swash plate
(18) with spanners on them respectively,
and remove them.
36078RL01
36078RL02
(7) Turn joint anticlockwise to loosen it,

utilizing jig(Special tool).
※ When return spring(10) is strong in force,
plate(15), plug(11) and push rod(14) will
come up on loosening joint.
Pay attention to this.
36078RL03
36078RL04
8-109
(8) Remove plate(15).
36078RL05
(9) When return spring(10) is weak in force,

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

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

hexagon socket screw key.
36078RL08
8-110
(12) For disassembling reducing valve section,
stand it vertically with spool(5) bottom
placed on flat workbench. Push down
spring seat(8) and remove two pieces of
semicircular stopper(9) with tip of small
minus screwdriver.
※ Pay attention not to damage spool
surface.
※ Record original position of spring seat(8, 36078RL09
31).
※ Do not push down spring seat more than
6mm.
(13) Separate spool(5), spring seat(8),

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

plug(11).
Use small minus screwdriver or so on to
remove this seal.
36078RL12
8-111
36078RL13
(16) Remove lock nut(20) and then boot(25).
36078RL14
25038RL02
8-112
(17) Cleaning of parts
① Put all parts in rough cleaning vessel
filled with kerosene and clean them
(Rough cleaning).
※ If dirty part is cleaned with kerosene just
after putting it in vessel, it may be
damaged. Leave it in kerosene for a
while to loosen dust and dirty oil.
※ If this kerosene is polluted, parts will be
damaged and functions of reassembled
valve will be degraded.
Therefore, control cleanliness of
kerosene fully.
② Put parts in final cleaning vessel filled
with kerosene, turning it slowly to clean
them even to their insides(Finish
cleaning).
※ Do not dry parts with compressed air,
since they will be damaged and/or rusted
by dust and moisture in air.
(18) Rust prevention of parts.
Apply rust-preventives to all parts.
※ If left as they after being cleaned, they will
be rusted and will not display their
functions fully after being reassembled.
8-113
4) ASSEMBLY
(1) Tighten hexagon socket head plug(2) to
the specified torque.
※ Tighten two bolts alternately and slowly.
36078RL15
(2) Put shim(6), springs(7) and spring seat(8)

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

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

Assemble reducing valve subassembly
into casing.
※ Assemble them to their original positions.
36078RL18
8-114
(5) Assemble O-ring(13) onto plug(11).
36078RL19
(6) Assemble seal(12) to plug(11).

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

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

※ When return spring is weak in force,
subassembly stops due to resistance of
O-ring.
36078RL22
8-115
(9) When return spring is strong in force,
assemble 4 sets at the same time, utilizing
plate(15), and tighten joint(17) temporarily.
36078RL23
(10) Fit plate(15).
(11) Tighten joint(17) with the specified torque

to casing, utilizing jig.
36078RL24
(12) Assemble swash plate(18) to joint(17).

※ Screw it to position that it contacts with 4
push rods evenly.
※ Do not screw it over.
36078RL25
(13) Assemble adjusting nut(19), apply

spanner to width across flat of plate(18) to
fix it, and tighten adjusting nut to the
specified torque.
※ During tightening, do not change position
of disk.
36078RL26
8-116
(14) Fit boot(40) to plate.
1408DA61
(15) Fit boot(25) and lock nut(20), and handle

subassembly is assembled completely.
25038RL02(4)
36078RL27
(16) Pull out cord and tube through adjusting

nut hole provided in direction 60。to 120。
from casing hole.
1408DA66
8-117
(17) Assemble bushing(16) to plate and pass
cord and tube through it.
※ Provide margin necessary to operation.
1408DA67
(18) Determine handle direction, tighten lock

nut(20) to specified torque to fix handle.
1408DA68
(19) Apply grease to rotating section of joint

and contacting faces of disk and push rod.
1408DA69
(20) Assemble lower end of bellows to casing.

(21) Inject volatile rust-preventives through all
ports and then put blind plugs in ports.
25038RL04
8-118
GROUP 8 TURNING JOINT

1) REMOVAL

injury.
the oil inside the piping will flow out, so
(4) Disconnect all hoses. 1
(5) Sling the turning joint assembly (1) and

21078DA07
remove the mounting bolt(2).
·Tightening torque : 12.3± 1.3kgf·m
(88.9± 9.4lbf·ft)
(6) Remove the turning joint assembly.
※ When removing the turning joint, check
that all the hoses have been disconnected.
2) INSTALL
to removal. 1
※ Take care of turning joint direction.

※ Assemble hoses to their original positions.
※ Confirm the hydraulic oil level and check 2
21078DA08
8-119
1) STRUCTURE
14 3
15
10 6
12 4
5
11
11
9
8
21078DA09
1 Hub 6 Shim 11 Wear ring

2 Shaft 7 Slipper seal 12 Retainer ring
3 Cover 8 O-ring 13 Plug
4 Spacer 9 O-ring 14 Hexagon bolt
5 Shim 10 O-ring 15 Spring washer
8-120
2) DISASSEMBLY
14
※ Before the disassembly, clean the turning 15
joint.
3
(1) Remove bolts(14), washer(15) and
cover(3).
21078DA10
(2) Remove shim(6) and O-ring(10). 6

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

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

two ring wear(11) from hub(1).
7
11
9
1
21078DA12
8-121
3) ASSEMBLY
※ Clean all parts.
※ As a general rule, replace oil seals and O-
ring.
※ Coat the sliding surfaces of all parts with
engine oil or grease before installing.
(1) Fix seven slipper seal(7) and O-ring(9), 11

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

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

6
(12) to shaft(2). 10
12
(5) Fit O-ring(10) to hub(1).
(6) Fit shim(6) to shaft(2). 4
5
21078DA11
8-122
(7) Install cover(3) to body(1) and tighten
bolts(14). 14
·Torque : 10~12.5kgf·m(72.3~90.4lbf·ft) 15
21078DA10
8-123
GROUP 9 BOOM, ARM AND BUCKET CYLINDER

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

the pressure inside the hydraulic tank.
Bucket Cylinder
※ Escaping fluid under pressure can
penetrate the skin causing serious injury.
Fit blind plugs in the hoses after
disconnecting them, to prevent dirt or dust
from entering.
Arm
① Set block between bucket cylinder and
arm. Wooden block
21078DA14
② Remove nuts(3), bolt(2) and pull out pin 2

(1).
3
※ Tie the rod with wire to prevent it from
coming out.
21078DA15
③ Disconnect bucket cylinder hoses(4) and

put plugs(5) on cylinder pipe. 5
21078DA16
8-124
④ Sling bucket cylinder assembly, and
remove bolt(6), plate(7) then pull out pin
8
(5).
⑤ Remove bucket cylinder assembly(8).
5
6
36078CY02
(2) Install
① Carry out installation in the reverse order
to removal.
When aligning the mounting position
of the pin, do not insert your fingers in
the pin hole.
※ Bleed the air from the bucket cylinder.
※ Confirm the hydraulic oil level and check
8-125
2) ARM CYLINDER
(1) Removal
the engine.
Loosen the breather slowly to release 13031GL18

disconnecting them, to prevent dirt or
dust from entering.
① Set block between arm cylinder and
boom.
36078CY03
② Remove bolt(2) and pull out pin(1).

coming out.
36078CY04
③ Disconnect arm cylinder hoses(4) and

put plugs on cylinder pipe.
④ Disconnect greasing pipings(5).
36078CY05
8-126
⑤ Sling arm assembly(9), and remove bolt
(7), plate(8) then pull out pin(6).
⑥ Remove arm cylinder assembly(9).
36078CY06
(2) Install
to removal.
the pin hole.
※ Bleed the air from the arm cylinder.
8-127
3) BOOM CYLINDER
(1) Removal
the engine.
Loosen the breather slowly to release 13031GE18

disconnecting them, to prevent dirt or dust
from entering.
① Disconnect greasing hoses(1).
② Sling boom cylinder assembly.
36078CY07
③ Remove bolt(4), stop plate(5) and pull out

pin(2).
coming out.
36078CY08
④ Lower the boom cylinder assembly(6) on

a stand.
36078CY09
8-128
⑤ Disconnect boom cylinder hoses(7), and
put plugs on cylinder pipe.
36078CY10
⑥ Remove bolt(9) and pull out pin(8).

Remove boom cylinder assembly(6).
⑦ ·Weight : 340kg(750lb)
36078CY10A
(2) Install
to removal.
When aligning the mounting position of
the pin, do not insert your fingers in the
pin hole.
※ Bleed the air from the boom cylinder.
8-129
1) STRUCTURE
(1) Bucket cylinder
36078CY11
1 Tube assembly 11 Wear ring 21 Lock washer

2 Rod assembly 12 O-ring 22 Lock nut
3 Gland 13 Back up ring 23 Hexagon socket head bolt
4 Du bushing 14 Cushion ring 24 Band assembly
5 Snap ring 15 Piston 25 Pipe assembly(R)
6 Rod seal 16 O-ring 26 Pipe assembly(B)
7 Back up ring 17 Back up ring 27 O-ring
8 Buffer ring 18 Piston seal 28 Hexagon socket head bolt
9 Dust wiper 19 Wear ring 29 Pin bushing
10 Snap ring 20 Dust ring 30 Dust seal
8-130
(2) Arm cylinder
9,10 11 6,7 8 4 27 5 33 31 3 12,13 1 2 14 15 16,17 18 19 20 25 26
Internal detail
21,22,23,24
35,36 29 28 39 30 34 32 35,36
3607A8CY12
1 Tube assembly 14 Cushion ring 27 Hexagon socket head bolt

2 Rod assembly 15 Piston 28 Band assembly
3 Gland 16 O-ring 29 Pipe assembly(R)
4 Du bushing 17 Back up ring 30 Pipe assembly(B)
5 Snap ring 18 Piston seal 31 O-ring
6 Rod seal 19 Wear ring 32 O-ring
7 Back up ring 20 Dust ring 33 Hexagon socket head bolt
8 Buffer ring 21 Cushion spear 34 Hexagon socket head bolt
9 Dust wiper 22 Check valve 35 Pin bushing
10 Snap ring 23 Coil spring 36 Dust seal
11 Wear ring 24 Stop ring 39 Band assembly
12 O-ring 25 Lock washer
13 Back up ring 26 Lock nut
8-131
(3) Boom cylinder
36078CY13
1 Tube assembly 12 Back up ring 22 Hexagon socket head bolt

2 Rod assembly 13 Cushion ring 23 Band assembly
3 Gland 14 Piston 24 Pipe assembly(R)
4 Du bushing 15 O-ring 25 Pipe assembly(B)
5 Snap ring 16 Back up ring 26 O-ring
6 Rod seal 17 Piston seal 27 Hexagon socket head bolt
7 Back up ring 18 Wear ring 28 Pin bushing(R)
8 Buffer ring 19 Dust ring 29 Pin bushing(B)
9 Dust wiper 20 Lock washer 30 Dust seal
10 Snap ring 21 Lock nut 31 Dust seal
11 O-ring
8-132
(1) Tools
B
10
Allen wrench
19
Spanner 19
(-) Driver Small and large sizes

Torque
Part name Item Size
kgf·m lbf·ft
Bucket cylinder 23 M24 79±8 571±57.9
Socket head bolt Boom cylinder 22 M20 46±5 333±36.2
Arm cylinder 27 M27 116±12 839±86.8
Bucket cylinder 28 M12 9.4±1 68.0±7.2
Boom cylinder 27 M12 9.4±1 68.0±7.2
Socket head bolt
33 M12 9.4±1 68.0±7.2
Arm cylinder
34 M12 9.4±1 68.0±7.2
Bucket cylinder 22 M75 100±10 723±72.3
Lock nut Boom cylinder 21 M75 100±10 723±72.3
Arm cylinder 26 M90 100±10 723±72.3
Bucket cylinder 15 - 150±15 1085±109
Piston Boom cylinder 14 - 150±15 1085±109
Arm cylinder 15 - 150±15 1085±109
8-133
3) DISASSEMBLY
(1) Remove cylinder head and piston rod
※ Procedures are based on the bucket
cylinder
① Hold the clevis section of the tube in a
vise.
※ Use mouth pieces so as not to damage
the machined surface of the cylinder
tube. Do not make use of the outside
piping as a locking means.
② Pull out rod assembly(2) about 200mm

(7.1in). Because the rod assembly is
rather heavy, finish extending it with air
pressure after the oil draining operation.
m
0m
20
36078CY21A
③ Loosen and remove socket bolts(23) of

Hexagon
the cylinder head in sequence. socket wrench 23
※ Cover the extracted rod assembly(2) with
rag to prevent it from being accidentally
damaged during operation. Turn counter
clockwise
Cover here
with rag
2
36078CY21B
④ Draw out cylinder head and rod assembly

together from the tube assembly(1). Lift
※ Since the rod assembly is heavy in this
case, lift the tip of the rod assembly(2)
with a crane or some means and draw it Full straight
out. However, when rod assembly(2) sideways
has been drawn out to approximately
two thirds of its length, lift it in its center to
draw it completely. Oil pan
36078CY21C
8-134
Note that the plated surface of rod
assembly(2) is to be lifted. For this
reason, do not use a wire sling and
others that may damage it, but use a
strong cloth belt or a rope.
⑤ Place the removed rod assembly on a

wooden V-block that is set level.
※ Cover a V-block with soft rag. Rod assembly
Wooden block
36078CY22A
(2) Remove piston and cylinder head

① Remove lock nut(22). 14 17 16 15 21 22
※ Since lock nut(22) and lock washer(21) is
tightened to a high torque, use a hydraulic
and power wrench that utilizers a hydraulic
cylinder, to remove the lock nut(22) and
lock washer (21).
② Remove piston assembly(15), back up
ring(17), O-ring(16) and cushion ring(14).
36078CY22B
③ Remove the cylinder head assembly

Plastic
from rod assembly(2). hammer
※ If it is too heavy to move, move it by Lift with a crane
striking the flanged part of cylinder head
with a plastic hammer.
Pull straight
※ Pull it straight with cylinder head
assembly lifted with a crane.
Exercise care so as not to damage the lip
of rod bushing(4) and packing (6,7,8,9)
36078CY22C
by the threads of rod assembly(2).
8-135
(3) Disassemble the piston assembly
① Remove wear ring(19). 20 19 18 19 20
② Remove dust ring(20) and piston seal
(18).
※ Exercise care in this operation not to
damage the grooves.
36078CY23A
(4) Disassemble cylinder head assembly

10 9 11 7 6 8 4 12 13
① Remove back up ring(13) and O-ring
(12).
② Remove snap ring(10), dust wiper(9)
and wear ring(11).
③ Remove back up ring(7), rod seal(6) and
buffer ring(8).
※ Exercise care in this operation not to
damage the grooves. 36078CY23B
※ Do not remove seal and ring, if does not
damaged.
8-136
4) ASSEMBLY
(1) Assemble cylinder head assembly
※ Check for scratches or rough surfaces if
found smooth with an oil stone.
① Coat the inner face of gland(3) with
hydraulic oil.
21078DA37
② Coat dust wiper(9) with grease and fit Press here

dust wiper(9) to the bottom of the hole of (Straight down)
dust seal.
9 Metal
At this time, press a pad metal to the
metal ring of dust seal.
③ Fit snap ring(10) to the stop face.
36078CY24A
④ Fit wear ring(11), back up ring(7), rod

seal(6) and buffer ring(8) to
corresponding grooves, in that order.
Wrong Right
※ Coat each packing with hydraulic oil
before fitting it.
※ Insert the backup ring until one side of it
is inserted into groove.
8-157(3) (360-7)
※ Rod seal(6) has its own fitting direction.

Push bar
Therefore, confirm it before fitting them.
※ Fitting rod seal(6) upside down may
damage its lip. Therefore check the
correct direction that is shown in fig.
36078CY24B
8-137
⑤ Fit back up ring(13) to gland(3).
12
※ Put the backup ring in the warm water of 13
30~50。 C.
⑥ Fit O-ring(12) to gland(3).
36078CY25A
(2) Assemble piston assembly

※ Check for scratches or rough surfaces.
If found smooth with an oil stone.
① Coat the outer face of piston(15) with
hydraulic oil.
36078CY28
② Fit piston seal(18) to piston.

18
※ Put the piston seal in the warm water of
60~100。 C for more than 5 minutes.
※ After assembling the piston seal, press
its outer diameter to fit in.
36078CY25B
③ Fit wear ring(19) and dust ring(20) to

20 19 18 19 20
piston(15).
④ Fit back up ring(17) and O-ring(16) to
17
piston(15).
16
36078CY25C
8-138
(3) Install piston and cylinder head
① Fix the rod assembly to the work bench. Gland assembly
② Apply hydraulic oil to the outer surface of
Rod assembly
rod assembly(2), the inner surface of
piston and cylinder head.
③ Insert cylinder head assembly to rod
assembly.
36078CY26A
④ Insert cushion ring(14) to rod assembly.

※ Note that cushion ring(14) has a direction 14
in which it should be fitted.
Insert
36078CY26B
⑤ Fit piston assembly to rod assembly.

·Tightening torque : 150±15kgf·m Piston assembly
(1085±109lbf·ft)
36078CY26C
⑥ Fit lock nut(22) to piston.

·Tightening torque : 22
Item kgf·m lbf·ft

Bucket 22 100±10 723±72.3
Boom 21 100±10 723±72.3
Arm 26 100±10 723±72.3
36078CY26D
8-139
(4) Overall assemble Fix with a bar
① Place a V-block on a rigid work bench.
Mount the tube assembly(1) on it and fix
Lift
the assembly by passing a bar through
the clevis pin hole to lock the assembly.
② Insert the rod assembly in to the tube Straight
assembly, while lifting and moving the
rod assembly with a crane.
Appply liquid packing
※ Be careful not to damage piston seal by 36078CY27A
thread of tube assembly.
③ Match the bolt holes in the cylinder head
flange to the tapped holes in the tube
Apply loctite
assembly and tighten socket bolts to a Turn clockwise
specified torque.
※ Refer to the table of tightening torque.
Place rag
36078CY27B
8-140
GROUP 10 UNDERCARRIAGE
1. TRACK LINK
1) REMOVAL Master pin
(1) Move track link until master pin is over

front idler in the position put wooden block
as shown.
(2) Loosen tension of the track link.
※ If track tension is not relieved when the
grease valve is loosened, move the
Block
machine backwards and forwards.
(3) Push out master pin by using a suitable
tool.
36078UC09
(4) Move the machine slowly in reverse, and

lay out track link assembly (1).
※ Jack up the machine and put wooden
block under the machine.
※ Don't get close to the sprocket side as the
track shoe plate may fall down on your
feet. 1
36078UC10
2) INSTALL

to removal.
※ Adjust the tension of the track link.
90 ~ 110
21074OP14
8-141
2. CARRIER ROLLER
Lower frame
1) REMOVAL
(1) Loosen tension of the track link. Grease valve
36078UC11
(2) Jack up the track link height enough to

permit carrier roller removal.
Jack Carrier roller
36078UC12
(3) Loosen the lock nut (1).

1 Carrier roller
(4) Open bracket(2) with a screwdriver, push
2
out from inside, and remove carrier roller
assembly.
36078UC13
2) INSTALL
to removal.
8-142
3. TRACK ROLLER
Lower frame
1) REMOVAL
(1) Loosen tension of the track link. Grease valve
36078UC14
(2) Using the work equipment, push up track

frame on side which is to be removed.
※ After jack up the machine, set a block
under the unit. 90 ~ 110
36078UC15
(3) Remove the mounting bolts(1) and draw

out the track roller(2). 1 2
·Weight : 80kg(176.4lb)
36078UC16
2) INSTALL
to removal.
8-143
4. IDLER AND RECOIL SPRING
1) REMOVAL
(1) Remove the track link.
For detail, see removal of track link.
36078UC17
(2) Sling the recoil spring(1) and pull out idler

and recoil spring assembly from track
frame, using a pry.
1
36078UC18
(3) Remove the bolts(2), washers(3) and

separate ilder from recoil spring.
2,3
36078UC19
2) INSTALL
to removal.
※ Make sure that the boss on the end face
of the recoil cylinder rod is in the hole of
the track frame.
36078UC20
8-144
3) DISASSEMBLY AND ASSEMBLY OF IDLER
(1) Structure
36078UC01
1 Shell 4 O-ring 7 Spring pin

2 Bushing 5 Seal assembly 8 Plug
3 Shaft 6 Bracket
8-145
(2) Disassembly
Press
① Remove plug and drain oil.
② Draw out the spring pin(7), using a press.
7
36078UC21
③ Pull out the shaft(3) with a press.

Press
④ Remove seal(5) from shell(1) and bracket
(6).
⑤ Remove O-ring(6) from shaft.
3
36078UC22
⑥ Remove the bushing(2) from shell, using

a special tool.
※ Only remove bushing if replacement is
necessity.
2
36078UC23
8-146
(3) Assembly
※ Before assembly, clean the parts. Press
※ Coat the sliding surfaces of all parts with 1 2
oil.
① Cool up bushing(2) fully by some dry ice
and press it into shell(1).
Do not press it at the normal
temperature, or not knock in with a
hammer even after the cooling. 36078UC24
② Coat O-ring(4) with grease thinly, and

install it to shaft(3).
4
③ Insert shaft(3) into bracket(6) and drive in
3
the spring pin(7).
6
36078UC25
④ Install seal(5) to shell(1) and bracket(6).

5
36078UC26
⑤ Install shaft(3) to shell(1).

3 1
36078UC27
8-147
⑥ Install bracket(6) attached with seal(5).
6
36078UC28
⑦ Knock in the spring pin(7) with a

hammer. 6 7 1
36078UC29
⑧ Lay bracket(6) on its side.

Supply engine oil to the specified level, 6
and tighten plug.
36078UC30
8-148
4) DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING
(1) Structure
36078UC02
1 Body 6 Lock plate 11 Dust seal

2 Tie bar 7 Hexagon bolt 12 Rod
3 Spring 8 Spring washer 13 Grease valve
4 Bracket 9 Rod packing 14 Tube stopper
5 Lock nut 10 Back up ring 15 Spring pin
8-149
(2) Disassembly
① Apply pressure on spring(3) with a press.
※ The spring is under a large installed load.
This is dangerous, so be sure to set
properly.
· Spring set load : 21100 ± 1688kg
(46517 ± 3721lb)
② Remove bolt(7), spring washer(8) and

lock plate(6).
③ Remove lock nut(5).
Take enough notice so that the press
which pushes down the spring, should
not be slipped out in its operation.
④ Lighten the press load slowly and
remove bracket(4) and spring(3).
36078UC03
⑤ Remove rod(12) from body(1).

⑥ Remove grease valve(13) from rod(12).
36078UC04
⑦ Remove rod packing(9), back up ring(10)

and dust seal(11).
36078UC05
8-150
(3) Assembly
① Install dust seal(11), back up ring(10) and
rod packing(9) to body(1).
※ When installing dust seal(11) and rod
packing(9), take full care so as not to
damage the lip.
36078UC05
② Pour grease into body(1), then push in

rod(12) by hand.
After take grease out of grease valve
mounting hole, let air out.
※ If air letting is not sufficient, it may be
difficult to adjust the tension of crawler.
③ Fit grease valve(13) to rod(12).
·Tightening torque : 10±1kgf·m
(72.3±7.2lbf·ft) 36078UC06
④ Install spring(3) and bracket(4) to body

(1).
⑤ Apply pressure to spring(3) with a press
and tighten lock nut(5).
※ Apply sealant before assembling.
※ During the operation, pay attention
specially to prevent the press from
slipping out.
36078UC07
8-151
⑥ Lighten the press load and confirm the
set length of spring(3).
⑦ After the setting of spring(3), install lock
plate(6), spring washer(8) and bolt(7).
36078UC08
8-152
GROUP 11 WORK EQUIPMENT
1. STRUCTURE
A
A
SECTION A SECTION B SECTION C
21078DA44
8-153
1) BUCKET ASSEMBLY
(1) Removal
① Lower the work equipment completely to
A
ground with back of bucket facing down.
B
36078AT04
② Remove nuts(1), bolt(2) and draw out the

pin(A).
2
36078AT01
③ Remove nuts(3), bolt(4) and draw out the

pin(B).
36078AT02
(2) Install
to removal.
the pin hole.
※ Adjust the bucket clearance.
For detail, see operator's manual.
36078AT05
8-154
2) ARM ASSEMBLY
(1) Removal
※ Loosen the breather slowly to release the
penetrated the skin causing serious
injury.
① Remove bucket assembly. 36078AT06
For details, see removal of bucket
assembly.
② Disconnect bucket cylinder hose(1).
5
Fit blind plugs(5) in the piping at the
chassis end securely to prevent oil 1
from spurting out when the engine is
started.
③ Sling arm cylinder assembly, remove 1
spring, pin stopper and pull out pin.
36078AT03
coming out.
For details, see removal of arm cylinder
assembly.
④ Place a wooden block under the cylinder
and bring the cylinder down to it.
Crane
⑤ Remove bolt(2), plate(3) and pull out the
pin(4) then remove the arm assembly.
2,3,4
※ When lifting the arm assembly, always lift
the center of gravity.
36078AT07
(2) Install
to removal.
When lifting the arm assembly, always
lift the center of gravity.
※ Bleed the air from the cylinder.
8-155
3) BOOM ASSEMBLY
(1) Removal
① Remove arm and bucket assembly.
For details, see removal of arm and
bucket assembly.
② Remove boom cylinder assembly from
boom.
For details, see removal of arm cylinder
assembly. 36078AT08
③ Disconnect head lamp wiring.

④ Disconnect bucket cylinder hoses(2) and
1
arm cylinder hoses(1). 2
※ When the hoses are disconnected, oil
may spurt out.
⑤ Sling boom assembly(3). 1
21078DA45
⑥ Remove bolt(4), plate(5) and pull out the

pin(6) then remove boom assembly. Crane
※ When lifting the boom assembly always
4,5,6
3
36078AT09
(2) Install
to removal.
When lifting the arm assembly, always
※ Bleed the air from the cylinder.
21078DA46
8-156
Group 1 Introduction guide - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-1

Group 2 Engine system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-2
Group 3 Electric system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-4
Group 4 Hydraulic system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-6
Group 6 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-10
Group 7 Work equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-14
GROUP 1 INTRODUCTION GUIDE
1. This section shows bolt specifications and

standard torque values needed when
mounting components to the machine.
2. Use genuine Hyundai spare parts.
We expressly point out that Hyundai will not
accept any responsibility for defects resulted
from non-genuine parts.
In such cases Hyundai cannot assume
liability for any damage.
※ Only metric fasteners can be used and
incorrect fasteners may result in machine
damage or malfunction.
※ Before installation, clean all the
components with a non-corrosive cleaner.
Bolts and threads must not be worn or
29079CM00
damaged.
9-1
GROUP 2 ENGINE SYSTEM
ENGINE AND ACCESSORIES MOUNTING
Muffler 2
7
4
4
Air cleaner 7
Engine
3
7
Fan
4
7
6 1
3607A9CM01
·Tightening torque
Item Size kgf·m lbf·ft Item Size kgf·m lbf·ft

1 M10×1.5 4.4±0.9 31.8±6.5 5 M12×1.75 12.8±3.0 92.6±21.7
2 M10×1.5 5.0±1.0 36.2±7.2 6 M12×1.75 14.7±2.2 106±15.9
3 M10×1.5 6.9±1.4 49.9±10.1 7 M24×3.0 90±7.0 651±51
4 M12×1.75 10.0±2.0 72.3±14.5 - - - -
9-2
COOLING SYSTEM AND FUEL TANK MOUNTING
2 Air compressor Cooler & radiator

Hyd tank 3
Air con
Fuel tank Prefilter idle pully
Air con pully 4
DISCHARGE
Receiver drier 1
-A
UID
LIQ
Condenser
7
VIEW A
4 Needle 2
8 valve 5
L
W
O
C
5
O
T
Screen
Charge air cooler 4
Screen Radiator
4
2
Reservoir Fan guard 4

tank 2 5
Oil cooler
Shroud
6
3607A9CM02
·Tightening torque

1 M 6×1.0 1.05±0.2 7.6±1.45 5 M12×1.75 12.8±3.0 92.6±21.7
2 M 8×1.25 2.5±0.5 18.1±3.6 6 M16×2.0 29.7±4.5 215±32.5
3 M 8×1.25 4.05±0.8 29.3±5.8 7 M20×2.5 46±5.0 333±36
4 M10×1.5 6.9±1.4 49.9±10.1 8 - 2.3±0.6 16.6±4.3
9-3
GROUP 3 ELECTRIC SYSTEM
ELECTRIC COMPONENTS MOUNTING 1
Heater relay
Work lamp 1
ECM
Alternator
A/C COMP
4 1
Start relay
Travel alarm buzzer

2
Fuel filler
pump
ON
OFF
3
3 2
1
Washer tank
Battery relay
Horn
2 Battery
3607A9CM03
·Tightening torque

1 M 6×1.0 1.05±0.2 7.6±1.45 3 M10×1.5 6.9±1.4 49.9±10.1
2 M 8×1.25 2.5±0.5 18.1±3.6 4 M12×1.75 12.8±3.0 92.6±21.7
9-4
ELECTRIC COMPONENTS MOUNTING 2
Beacon lamp
3
Wiper motor
Cluster
VIEW A
2
Electric box
Prolix resistor
Fuse box CPU controller
1
2 1
1
1 YR G
Wiper motor cover

1 1
3607A9CM04
·Tightening torque

1 M 6×1.0 1.05±0.2 7.6±1.45 3 M10×1.5 5.0±1.0 36.2±7.2
2 M 8×1.25 2.5±0.5 18.1±3.6 4 M10×1.5 6.9±1.4 49.9±10.1
9-5
GROUP 4 HYDRAULIC SYSTEM
HYDRAULIC COMPONENTS MOUNTING 1
A
Main pump
4 4 8 Solenoid
valve
3
Air breather
Level gauge
4 2
5
Spin filter Main pump
housing
Suction pipe
7 10
Hydraulic tank 3 10
Coupling
9
Main control valve
4
11 Swing motor
6
RCV-RH
1
RCV-LH Terminal 4
1 Terminal
4
Cross
4
4
36079CM05
·Tightening torque

1 M 6×1.0 1.05±0.2 7.6±1.45 7 M16×2.0 35.6±7.1 257±51
2 M 8×1.25 2.5±0.5 18.1±3.6 8 M20×2.5 42±4.5 304±32.5
3 M10×1.5 2.81±0.3 20.3±2.2 9 M20×2.5 46±5.0 333±36
4 M10×1.5 6.9±1.4 49.9±10.1 10 M20×2.5 46.5±2.5 336±18.1
5 M12×1.75 14.7±2.2 106±15.9 11 M24×3.0 100±15 723±108
6 M16×2.0 19.5±1.3 141±9.4 - - - -
9-6
36079CM06
·Tightening torque

1 M 8×1.25 4.05±0.8 29.3±5.8 4 M12×1.75 9.4±1.0 68.0±7.2
2 M10×1.5 6.9±1.4 49.9±10.1 5 M12×1.75 14.7±2.2 106±15.9
3 M12×1.75 12.8±3.0 92.6±21.7 6 M20×2.5 43.8±4.0 317±29
9-7
2
Solenoid valve
7
Manual
override
7
1 3
2
Check valve
3 Coil
5
8
BOOM CYLINDER
2 2
1 1
1
2 2
1
4 1
6
ARM CYLINDER BUCKET CYLINDER
3607A9CM07
·Tightening torque

1 M12×1.75 5.5±0.6 39.8±4.3 5 M20×2.5 46±5.0 333±36.2
2 M12×1.75 9.4±1.0 68.0±7.2 6 M27×3.0 116±12 839±86.8
3 M16×2.0 29.7±4.5 215±21.7 7 M22×2.5 4.1 29.6
4 M24×3.0 79±8.0 571±57.9 8 M27×3.0 5.1 36.9
9-8
GROUP 5 UNDERCARRIAGE
ADJUST COMPONENT
Rod
3
4
Swing bearing
Idler
9
Idler
7
Carrier roller
8 Track chain
Cover
5
1
2
Adjust
component
Track roller
Track guard
Travel motor
7
Sprocket 6
36079CM08
·Tightening torque

1 M10×1.5 6.9±1.4 49.9±10.1 6 M20×2.5 51±4.0 369±28.9
2 M12×1.75 12.8±3.0 92.6±21.7 7 M22×2.5 77.4±11 560±79.6
3 M12×1.25 13.3±2.7 96.2±19.5 8 3/4-16UNF 78±3.0 564±21.7
4 M16×2.0 26.6±3.2 214±23.1 9 M24×3.0 97.8±10 707±72.3
5 M16×2.0 29.7±4.0 215±28.9 - - - -
9-9
GROUP 6 STRUCTURE
CAB AND ACCESSORIES MOUNTING
2
Sun roof
4
Sun visor
1
Latch
Cab
A Air vent cover

4
4 4
VIEW A 5
3
2
5
Door latch
6 Striker
3607A9CM09
·Tightening torque

1 M 6×1.0 0.49±0.1 3.5±0.7 4 M10×1.5 6.9±1.4 49.9±10.1
2 M 8×1.25 2.5±0.5 18.1±3.6 5 M12×1.75 12.8±3.0 92.6±21.7
3 M10×1.5 4.7±0.9 34±6.5 6 M16×2.0 29.7±4.5 215±32.5
9-10
CAB INTERIOR MOUNTING
Seat
1
1
Storage
4 box cover
Aircon upper
cover
Console 1 5
box(RH) Storage
Wiper motor box
cover 1 5
Defroster 5
hose cover Aircon lower
cover
2 Console box(LH)
6 3
Travel
lever 5 Safety lever
Slide rail 2
Seat base 7
Pedal bracket
5
Viscous
mount
5
Foot rest
Bottom plate
5
Foot rest bracket
36079CM10
·Tightening torque

1 M 6×1.0 0.49±0.1 3.5±0.7 5 M10×1.5 6.9±1.4 49.9±10.1
2 M 6×1.0 1.05±0.2 7.6±1.4 6 M10×1.5 8.27±1.7 59.8±12.3
3 M 8×1.25 3.43±0.7 24.8±5.1 7 M16×2.0 29.7±4.5 215±32.5
4 M 8×1.25 4.05±0.8 29.3±5.8 - - - -
9-11
COWLING MOUNTING
Engine hood
2
Side cover(RH)
Pump hood
2 Catch
2 1
2
2
2
A
2 2 Pump 1
screen
Air cleaner hood
Screen
2
HYD TANK
2 Engine hood
support
2
Tank cover
MCV hood
support
2
MCV hood 2 2
3
A
Air cleaner
2 bracket 2
2
2
Base plate
2
Side cover(LH)
3607A9CM11
·Tightening torque

1 M 8×1.25 2.5±0.5 18.1±3.6 3 M16×2.0 21.9±3.3 158±23.9
2 M12×1.75 12.8±3.0 92.6±21.7 - - - -
9-12
COUNTERWEIGHT AND COVERS MOUNTING
3607A9CM12
·Tightening torque

1 M10×1.5 6.9±1.4 49.9±10.1 3 M36×3.0 308±46 2228±333
2 M12×1.75 12.8±3.0 92.6±21.7 - - - -
9-13
GROUP 7 WORK EQUIPMENT
Arm cylinder
rod pin
2
Arm cylinder
2 Boom cylinder
rod pin
Bucket cylinder
head pin 1
Bucket 1 2
cylinder
Arm pin Boom
Bucket cylinder Arm cylinder
rod pin 1 Boom pin
head pin Boom cylinder
Bucket head pin
control link
2
Boom
Bucket cylinder 1
2 3 2
Side cutter(RH)
1
Bucket control
rod pin
Cover plate
Side cutter(LH)
3607A9CM13
·Tightening torque

1 M16×2.0 29.7±4.5 215±32.5 3 M30×3.5 199±30 1439±217
2 M20×2.5 57.9±8.7 419±62.9 - - - -
9-14

Hyundai R360lc-7a S

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Hyundai R360lc-7a S

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MANUAL SERVICE

SECTION 2 STRUCTURE AND FUNCTION

SECTION 3 HYDRAULIC SYSTEM

SECTION 4 ELECTRICAL SYSTEM

SECTION 5 MECHATRONICS SYSTEM

SECTION 7 MAINTENANCE STANDARD

SECTION 8 DISASSEMBLY AND ASSEMBLY

SECTION 9 COMPONENT MOUNTING TORQUE

2. Convert 550mm into inches.

Millimeters to inches ⓑ 1mm = 0.03937 in

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

Kilogram to Pound 1kg = 2.2046lb

0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

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

0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

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

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

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

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

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

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

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

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

FOLLOW SAFE PROCEDURE

WEAR PROTECTIVE CLOTHING

WARN OTHERS OF SERVICE WORK

USE HANDHOLDS AND STEPS

PROTECT AGAINST FLYING DEBRIS

PROTECT AGAINST NOISE

AVOID POWER LINES

MOVE AND OPERATE MACHINE SAFELY

OPERATE ONLY FORM OPERATOR'S SEAT

PARK MACHINE SAFELY

Do not work under a machine that is supported

SERVICE COOLING SYSTEM SAFELY

HANDLE FLUIDS SAFELY-AVOID FIRES

Store flammable fluids away from fire hazards.

ILLUMINATE WORK AREA SAFELY

STAY CLEAR OF MOVING PARTS

AVOID HIGH PRESSURE FLUIDS

Install fire resisting guards to protect hoses or

PREVENT BATTERY EXPLOSIONS

PREVENT ACID BURNS

Use only recommended replacement parts.(See

DISPOSE OF FLUIDS PROPERLY

REPLACE SAFETY SIGNS

LIVE WITH SAFETY

Tool box Fuel tank Hydraulic oil tank Main pump

Arm Arm cylinder Boom Boom cylinder Cab Precleaner Muffler

Bucket cylinder Connecting link Idler Carrier roller Sprocket Counterweight

Side cutter Connecting rod Track roller Track Travel motor

Description Unit Specification

Operating weight kg(lb) 36100(79590)

Description 2.5m(8' 2") Arm

Max digging reach A 10330mm (33'11")

Description 5.1m(16' 9") Arm

Max digging reach A 15300mm (50' 2")

· : Rating over-front · : Rating over-side or 360 degree

Load radius At max. reach

9.0m kg 6900 6900 7.22

9.0m kg 7640 7640 6.65

9.0m kg 7640 7640 6.65

9.0m kg 6900 6900 7.22

9.0m kg 3080 3080 3130 3130 12.91