Hyundai HX380AL

CONTENTS
SECTION 1 GENERAL
Group 1 Safety Hints ------------------------------------------------------------------------------------------------------ 1-1

Group 2 Specifications --------------------------------------------------------------------------------------------------- 1-10
SECTION 2 STRUCTURE AND FUNCTION
Group 1 Pump Device ---------------------------------------------------------------------------------------------------- 2-1

Group 2 Main Control Valve ------------------------------------------------------------------------------------------- 2-22
Group 3 Swing Device ---------------------------------------------------------------------------------------------------- 2-56
Group 4 Travel Device ---------------------------------------------------------------------------------------------------- 2-68
Group 5 RCV Lever -------------------------------------------------------------------------------------------------------- 2-81
Group 6 RCV Pedal -------------------------------------------------------------------------------------------------------- 2-88
SECTION 3 HYDRAULIC SYSTEM
Group 1 Hydraulic Circuit ----------------------------------------------------------------------------------------------- 3-1

Group 2 Main Circuit ------------------------------------------------------------------------------------------------------- 3-3
Group 3 Pilot Circuit -------------------------------------------------------------------------------------------------------- 3-6
Group 4 Single Operation ---------------------------------------------------------------------------------------------- 3-15
Group 5 Combined Operation --------------------------------------------------------------------------------------- 3-25
SECTION 4 ELECTRICAL SYSTEM
Group 1 Component Location --------------------------------------------------------------------------------------- 4-1

Group 2 Electric Circuit -------------------------------------------------------------------------------------------------- 4-3
Group 3 Electrical Component Specification --------------------------------------------------------------- 4-23
Group 4 Connectors ------------------------------------------------------------------------------------------------------- 4-36
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 System --------------------------------------------------------------------- 5-9
Group 7 Engine Overheat Prevention System ------------------------------------------------------------ 5-10
Group 8 Variable Power Control System ---------------------------------------------------------------------- 5-11
Group 9 Attachment Flow Control System ------------------------------------------------------------------- 5-12
Group 10 Boom floating control system ----------------------------------------------------------------------- 5-13
Group 11 Intelligent Power control system ------------------------------------------------------------------- 5-14
Group 12 Anti-Restart System ---------------------------------------------------------------------------------------- 5-16
Group 13 Self-Diagnostic System ----------------------------------------------------------------------------------- 5-17
Group 14 Engine Control System ----------------------------------------------------------------------------------- 5-62
Group 15 EPPR (Electro Proportional Pressure Reducing) Valve ------------------------------ 5-63
Group 16 Monitoring System ------------------------------------------------------------------------------------------- 5-68
Group 17 Fuel Warmer System --------------------------------------------------------------------------------------- 5-108
SECTION 6 TROUBLESHOOTING
Group 1 Before Troubleshooting ------------------------------------------------------------------------------------ 6-1

Group 2 Hydraulic and Mechanical System ----------------------------------------------------------------- 6-4
Group 3 Electrical System --------------------------------------------------------------------------------------------- 6-25
Group 4 Mechatronics System -------------------------------------------------------------------------------------- 6-44
Group 5 Air con & Heater System --------------------------------------------------------------------------------- 6-74
SECTION 7 MAINTENANCE STANDARD
Group 1 Operational Performance Test ------------------------------------------------------------------------ 7-1

Group 2 Major Components ------------------------------------------------------------------------------------------ 7-21
Group 3 Track and Work Equipment ----------------------------------------------------------------------------- 7-36
SECTION 8 DISASSEMBLY AND ASSEMBLY
Group 1 Precaution --------------------------------------------------------------------------------------------------------- 8-1

Group 2 Tightening Torque --------------------------------------------------------------------------------------------- 8-4
Group 4 Main Control Valve ------------------------------------------------------------------------------------------- 8-31
Group 6 Travel Device ----------------------------------------------------------------------------------------------------- 8-74
Group 7 RCV Lever -------------------------------------------------------------------------------------------------------- 8-106
Group 8 Turning Joint ----------------------------------------------------------------------------------------------------- 8-120
Group 9 Boom, Arm and Bucket Cylinder -------------------------------------------------------------------- 8-125
Group 10 Undercarriage -------------------------------------------------------------------------------------------------- 8-147
Group 11 Work Equipment ---------------------------------------------------------------------------------------------- 8-159
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.
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 will When a manual is revised, an edition mark is
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
8 - 4 are necessary when performing
8-4-1 the work because it is under
Added pages internal pressure.
8-4-2
8-5 Special technical precautions or
other precautions for preserving
※ Caution
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 55 mm into inches.
(1) Locate the number 50 in 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, 55 mm = 2.165 inches.
2. Convert 550 mm 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 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) 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 550 mm = 21.65 inches.
Millimeters to inches ⓑ
1 mm = 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 1 mm = 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
Kilogram to Pound 1 kg = 2.2046 lb
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 1 kgf·m = 7.233 lbf·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 1 kgf / cm2 = 14.2233 lbf / 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 ----------------------------------------------------------------------------------------------------- 1-10
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 「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. 13031GE03
Be careful of slippery conditions on platforms,

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 13031GE14
dust.
Wear an approved respirator.
·If you use solvent or paint stripper, remove
stripper with soap and water before welding.
Remove solvent or paint stripper containers
and other flammable material from area.
Allow fumes to disperse at least 15 minutes
before welding or heating.
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 13031GE20
heat goes beyond the immediate flame area.

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 volt-meter or
hydrometer.
Do not charge a frozen battery; It may explode.
Warm battery to 16˚C (60˚F ). 13031GE21
1-7
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 immediate-
ly. 13031GE22
If acid is swallowed:
1. Drink large amounts of water or milk.
2. Then drink milk of magnesia, beaten eggs,
or vegetable oil.
3. Get medical attention immediately.
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 manual.)
1-8
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.
1-9
GROUP 2 SPECIFICATIONS
1. MAJOR COMPONENT
Tool box DEF/AdBlue R tank Fuel tank Hydraulic tank Main pump
After
treatment
device
Engine
Charge air cooler
Radiator
Tooth Bucket Turning joint Swing motor Oil cooler Main control valve
Arm Arm cylinder Boom Boom cylinder Cab Handrail Counterweight
Swing
bearing
Bucket cylinder Connecting link Idler Carrier roller Sprocket
Side cutter Connecting rod Track roller Track Travel motor
380A2SP01
1-10
2. SPECIFICATIONS
1) HX380A L, MONO BOOM (1/2)

I(I')
D
G'
C
E
G
F
H
J M
K N
A B(L)
380A2SP02
Unit Specification
Boom 6.50 (21' 4")
Description m (ft-in)
Arm 3.20 (10' 6") 3.20 (10' 6") 3.90 (12' 10") 2.50 (8' 2")
mm (in) Shoe 800 (32) 600 (24)
Operating weight kg (lb) 40000 (88000) 39100 (86020) 39200 (86240) 38960 (85712)
Bucket capacity (SAE heaped), standard m³ (yd³) 1.62 (2.10) 1.62 (2.10) 1.62 (2.10) 1.62 (2.10)
Overall length A 11400 (37' 5") 11400 (37' 5") 11400 (37' 5") 11450 (37' 7")
Overall width B 3540 (11' 7") 3340 ( 9' 10") 3340 ( 9' 10") 3340 ( 9' 10")
Overall height of boom C 3630 (11' 11") 3630 (11' 11") 3740 (12' 3") 3740 (12' 3")
Superstructure width D 2980 (9' 8") 2980 (9' 8") 2980 (9' 8") 2980 (9' 8")
Overall height of cab E 3240 (10' 6") 3240 (10' 6") 3240 (10' 6") 3240 (10' 6")
Ground clearance of counterweight F 1295 (4' 3") 1295 (4' 3") 1295 (4' 3") 1295 (4' 3")
Overall height of engine hood G 2830 (9' 3") 2830 (9' 3") 2830 (9' 3") 2830 (9' 3")
Overall height of handrail G' 3470 (11' 5") 3470 (11' 5") 3470 (11' 5") 3470 (11' 5")
mm (ft-in)
Minimum ground clearance H 550 (1' 10") 550 (1' 10") 550 (1' 10") 550 (1' 10")
Rear-end distance I 3555 (11' 8") 3555 (11' 8") 3555 (11' 8") 3555 (11' 8")
Rear-end swing radius I' 3620 (11' 11") 3620 (11' 11") 3620 (11' 11") 3620 (11' 11")
Distance between tumblers J 4340 (14' 3") 4340 (14' 3") 4340 (14' 3") 4340 (14' 3")
Undercarriage length K 5270 (17' 3") 5270 (17' 3") 5270 (17' 3") 5270 (17' 3")
Undercarriage width L 3540 (11' 7") 3340 (10' 11") 3340 (10' 11") 3340 (10' 11")
Track gauge M 2740 (9' 0") 2740 (9' 0") 2740 (9' 0") 2740 (9' 0")
Track shoe width, standard N 800 (32") 600 (24") 600 (24") 600 (24")
Travel speed (low/high) km/hr (mph) 3.5/5.7 (2.2/3.5) 3.5/5.7 (2.2/3.5) 3.5/5.7 (2.2/3.5) 3.5/5.7 (2.2/3.5)
Swing speed rpm 10.4 10.4 10.4 10.4
Gradeability Degree (%) 35 (70) 35 (70) 35 (70) 35 (70)
Ground pressure kgf/cm² (psi) 0.54 (7.65) 0.70 (9.97) 0.70 (10.0) 0.70 (9.93)
Max traction force kg (lb) 32517 (71688) 32517 (71688) 32517 (71688) 32517 (71688)
1-11
HX380A L, MONO BOOM (2/2)
I(I')
D
G'
C
E
G
F
H
J M
K N
A B(L)
380A2SP02
Unit Specification
Boom 6.15 (20' 2")
Arm 2.50 (8' 2")
mm (in) Shoe 600 (24)
Operating weight kg (lb) 38860 (85492)
Bucket capacity (SAE heaped), standard m³ (yd³) 1.62 (2.10)
Overall length A 11100 (36' 5")
Overall width B 3340 ( 9' 10")
Overall height of boom C 3830 (12' 7")
Superstructure width D 2980 (9' 8")
Overall height of cab E 3240 (10' 6")
Ground clearance of counterweight F 1295 (4' 3")
Overall height of engine hood G 2830 (9' 3")
Overall height of handrail G' 3470 (11' 5")
mm (ft-in)
Minimum ground clearance H 550 (1' 10")
Rear-end distance I 3555 (11' 8")
Rear-end swing radius I' 3620 (11' 11")
Distance between tumblers J 4340 (14' 3")
Undercarriage length K 5270 (17' 3")
Undercarriage width L 3340 (10' 11")
Track gauge M 2740 (9' 0")
Track shoe width, standard N 600 (24")
Travel speed (low/high) km/hr (mph) 3.5/5.7 (2.2/3.5)
Swing speed rpm 10.4
Gradeability Degree (%) 35 (70)
Ground pressure kgf/cm² (psi) 0.70 (9.91)
Max traction force kg (lb) 32517 (71688)
1-12
2) HX380A NL, MONO BOOM
I(I')
D
G'
C
E
G
F
H
J M
K N
A B(L)
380A2SP03
Unit Specification
Boom 6.50 (21' 4") 6.15 (20' 2")
Arm 3.20 (10' 6") 3.90 (12' 10") 2.50 (8' 2") 2.50 (8' 2")
mm (in) Shoe 600 (24)
Operating weight kg (lb) 38890 (85558) 38990 (85778) 38750 (85250) 38650 (85030)
Bucket capacity (SAE heaped), standard m³ (yd³) 1.62 (2.10) 1.62 (2.10) 1.62 (2.10) 1.62 (2.10)
Overall length A 11400 (37' 5") 11400 (37' 5") 11450 (37' 7") 11100 (36' 5")
Overall width B 2990 (9' 10") 2990 (9' 10") 2990 (9' 10") 2990 (9' 10")
Overall height of boom C 3630 (11' 11") 3740 (12' 3") 3740 (12' 3") 3830 (12' 7")
Superstructure width D 2980 (9' 8") 2980 (9' 8") 2980 (9' 8") 2980 (9' 8")
Overall height of cab E 3240 (10' 6") 3240 (10' 6") 3240 (10' 6") 3240 (10' 6")
Ground clearance of counterweight F 1295 (4' 3") 1295 (4' 3") 1295 (4' 3") 1295 (4' 3")
Overall height of engine hood G 2830 (9' 3") 2830 (9' 3") 2830 (9' 3") 2830 (9' 3")
Overall height of handrail G' 3470 (11' 5") 3470 (11' 5") 3470 (11' 5") 3470 (11' 5")
mm (ft-in)
Minimum ground clearance H 550 (1' 10") 550 (1' 10") 550 (1' 10") 550 (1' 10")
Rear-end distance I 3555 (11' 8") 3555 (11' 8") 3555 (11' 8") 3555 (11' 8")
Rear-end swing radius I' 3620 (11' 11") 3620 (11' 11") 3620 (11' 11") 3620 (11' 11")
Distance between tumblers J 4340 (14' 3") 4340 (14' 3") 4340 (14' 3") 4340 (14' 3")
Undercarriage length K 5270 (17' 3") 5270 (17' 3") 5270 (17' 3") 5270 (17' 3")
Undercarriage width L 3340 (10' 11") 3340 (10' 11") 3340 (10' 11") 3340 (10' 11")
Track gauge M 2740 (9' 0") 2740 (9' 0") 2740 (9' 0") 2740 (9' 0")
Track shoe width, standard N 600 (24") 600 (24") 600 (24") 600 (24")
Travel speed (low/high) km/hr (mph) 3.5/5.7 (2.2/3.5) 3.5/5.7 (2.2/3.5) 3.5/5.7 (2.2/3.5) 3.5/5.7 (2.2/3.5)
Swing speed rpm 10.4 10.4 10.4 10.4
Gradeability Degree (%) 35 (70) 35 (70) 35 (70) 35 (70)
Ground pressure kgf/cm² (psi) 0.70 (9.92) 0.70 (9.94) 0.70 (9.88) 0.69 (9.86)
Max traction force kg (lb) 32517 (71688) 32517 (71688) 32517 (71688) 32517 (71688)
1-13
3. WORKING RANGE
1) HX380A L/NL, MONO BOOM
A
A'
F
D
E
C
B'
B
8ft
380A2SP05
Boom 6.15 (20' 2") 6.50 (21' 4")

Arm 2.50 (8' 2") 2.50 (8' 2") 3.20 (10' 6") 3.90 (12' 10")
Max digging reach A 10300 (33' 10") 10650 (34' 11") 11160 (36' 7") 11820 (38' 9")
Max digging reach on ground A' 10060 (33' 0") 10410 (34' 2") 10930 (35' 10") 11620 (38' 1")
Max digging depth B 6560 (21' 6") 6820 (22' 5") 7520 (24' 8") 8220 (27' 0")
Max digging depth (8 ft level) B' 6380 (20' 11") 6640 (21' 9") 7360 (24' 2") 8080 (26' 6")
mm (ft-in)
Max vertical wall digging depth C 4780 (15' 8") 5030 (16' 6") 5480 (18' 0") 6300 (20' 8")
Max digging height D 10000 (32' 10") 10330 (33' 11") 10270 (33' 8") 10610 (34' 10")
Max dumping height E 6870 (22' 6") 7190 (23' 7") 7190 (23' 7") 7500 (24' 7")
Min swing radius F 4310 (14' 2") 4490 (14' 9") 4490 (14' 9") 4350 (14' 3")
kN 228.5 [249.3] 201.0 [219.3] 201.0 [219.3] 201.0 [219.3]
kgf SAE 23300 [25420] 20500 [22360] 20500 [22360] 20500 [22360]
lbf 51370 [56040] 45190 [49300] 45190 [49300] 45190 [49300]
Bucket digging force
kN 259.9 [283.5] 228.5 [249.3] 228.5 [249.3] 228.5 [249.3]
kgf ISO 26500 [28910] 23300 [25420] 23300 [25420] 23300 [25420]
lbf 58420 [63740] 51370 [56040] 51370 [56040] 51370 [56040]
kN 192.2 [209.7] 192.2 [209.7] 160.8 [175.4] 137.3 [149.7]
kgf SAE 19600 [21380] 19600 [21380] 16400 [17890] 14000 [15270]
lbf 43210 [47130] 43210 [47130] 36160 [39440] 30860 [33660]
Arm digging force
kN 200.1 [218.2] 200.1 [218.2] 165.7 [180.8] 141.2 [154.1]
kgf ISO 20400 [22250] 20400 [22250] 16900 [18440] 14400 [15710]
lbf 44970 [49050] 44970 [49050] 37260 [40650 ] 31750 [34630]
[ ] : Power boost
1-14
4. WEIGHT
HX380A L HX380A NL
Item
kg lb kg lb
Upperstructure assembly 16,190 35,692 16,190 35,692
Main frame weld assembly 3,130 6,900 3,130 6,900
Engine assembly 680 1,499 680 1,499
Aftertreatment assembly 100 220 100 220
Main pump assembly 170 375 170 375
Main control valve assembly 380 838 380 838
Swing motor assembly 440 970 440 970
Hydraulic oil tank WA 410 904 410 904
Fuel tank WA 340 750 340 750
Counterweight 6,500 14,330 6,500 14,330
Cab assembly 980 2,161 980 2,161
Lower chassis assembly 14,450 31,856 14,240 31,394

Track frame weld assembly 5,150 11,354 4,940 10,891
Swing bearing 547 1,206 547 1,206
Travel motor assembly (2EA) 760 1,675 760 1,675
Turning joint 50 110 50 110
Sprocket (2EA) 170 375 170 375
Track recoil spring (2EA) 455 1,004 455 1,004
Idler (2EA) 522 1,146 520 1,146
Upper roller (2EA) 160 353 160 353
Lower roller (18EA) 1,431 3,155 1,431 3,155
Track-chain assembly
4,723 10,413 4,723 10,413
(600 mm triple grouser shoe) (2EA)
Track-chain assembly
5,621 12,392 - -
(800 mm triple grouser shoe) (2EA)
Front attachment assembly 8,450 18,629 8,450 18,629

6.50 m boom assembly 3,150 6,944 3,150 6,944
3.20 m arm assembly 1,450 3,197 1,450 3,197
1.62 m³ SAE heaped bucket 1,470 3,241 1,470 3,241
Boom cylinder assembly (2EA) 720 1,587 720 1,587
Arm cylinder assembly 450 992 450 992
Bucket cylinder assembly 300 661 300 661
Bucket control linkage total 360 794 360 794
1-15
5. LIFTING CAPACITIES
Model Type Boom Arm Counterweight Shoe Wheel Dozer Outrigger
MONO Length [mm] Length [mm] weight [kg] width [mm] width [mm] Front Rear Front Rear
HX380A L
BOOM 6500 3200 6500 600 - - - - -
余 : Rating over-front 余 : Rating over-side or 360 degree A
Lift-point radius (B) At max. reach

Lift-point 1.5 m (4.9 ft) 3.0 m (9.8 ft) 4.5 m (14.8 ft) 6.0 m (19.7 ft) 7.5 m (24.6 ft) 9.0 m (29.5 ft) Capacity Reach
height (A)
m (ft)
7.5 m kg *7790 *7790 *7050 *7050 7.80

(24.6 ft) lb *17170 *17170 *15540 *15540 (25.6)
6.0 m kg *8000 *8000 *6910 6290 8.64
(19.7 ft) lb *17640 *17640 *15230 13870 (28.4)
4.5 m kg *12530 *12530 *9960 *9960 *8720 7770 *8150 5760 *7020 5580 9.17
(14.8 ft) lb *27620 *27620 *21960 *21960 *19220 17130 *17970 12700 *15480 12300 (30.1)
3.0 m kg *16270 15710 *11750 10320 *9660 7420 *8570 5600 *7360 5200 9.42
(9.8 ft) lb *35870 34630 *25900 22750 *21300 16360 *18890 12350 *16230 11460 (30.9)
1.5 m kg *17950 14680 *13320 9750 *10570 7110 8960 5440 *7970 5070 9.43
(4.9 ft) lb *39570 32360 *29370 21500 *23300 15670 19750 11990 *17570 11180 (30.9)
0.0 m kg *18930 14280 *14290 9390 *11200 6880 8840 5330 8580 5180 9.19
(0.0 ft) lb *41730 31480 *31500 20700 *24690 15170 19490 11750 18920 11420 (30.1)
-1.5 m kg *12410 *12410 *19670 14220 *14520 9260 *11370 6780 9280 5580 8.68
(-4.9 ft) lb *27360 *27360 *43360 31350 *32010 20410 *25070 14950 20460 12300 (28.5)
-3.0 m kg *15020 *15020 *20150 *20150 *18480 14370 *13910 9310 *10750 6850 *10070 6460 7.85
(-9.8 ft) lb *33110 *33110 *44420 *44420 *40740 31680 *30670 20530 *23700 15100 *22200 14240 (25.7)
-4.5 m kg *21800 *21800 *15950 14760 *11940 9590 *10520 8480 6.57
(-14.8 ft) lb *48060 *48060 *35160 32540 *26320 21140 *23190 18700 (21.6)
Note 1. Lifting capacity are based on ISO 10567.

2. Lifting capacity of the HX series does not exceed 75% of tipping load with the machine on firm,
level ground or 87% of full hydraulic capacity.
3. The Lift-point is bucket pivot mounting pin on the arm (without bucket mass).
4. *Indicates load limited by hydraulic capacity.
侍 Lifting capacities are based upon a standard machine conditions.
Lifting capacities will vary with different work tools, ground conditions and attachments.
The difference between the weight of a work tool attachment must be subtracted.
Consult your Hyundai dealer regarding the lifting capacities for specific work tools and
attachments.
Failure to comply to the rated load can cause possible personal injury or property damage.
Make adjustments to the rated load as necessory for non-standard configurations.
1-16
HX380A L
BOOM 6500 2500 6500 600 - - - - -

Lift-point 3.0 m (9.8 ft) 4.5 m (14.8 ft) 6.0 m (19.7 ft) 7.5 m (24.6 ft) Capacity Reach
height (A)
m (ft)
7.5 m kg *8970 8610 7.16
(24.6 ft) lb *19780 18980 (23.5)
6.0 m kg *9570 *9570 *8920 7920 *8920 6950 8.08
(19.7 ft) lb *21100 *21100 *19670 17460 *19670 15320 (26.5)
4.5 m kg *14460 *14460 *11020 10780 *9500 7680 *9030 6110 8.64
(14.8 ft) lb *31880 *31880 *24290 23770 *20940 16930 *19910 13470 (28.3)
3.0 m kg *12690 10160 *10330 7380 *9240 5680 8.91
(9.8 ft) lb *27980 22400 *22770 16270 *20370 12520 (29.2)
1.5 m kg *14020 9690 *11090 7110 9120 5560 8.91
(4.9 ft) lb *30910 21360 *24450 15670 20110 12260 (29.2)
0.0 m kg *14720 14400 *14660 9450 *11510 6950 9450 5730 8.66
(0.0 ft) lb *32450 31750 *32320 20830 *25380 15320 20830 12630 (28.4)
-1.5 m kg *19240 14470 *14510 9400 *11360 6920 *10230 6260 8.12
(-4.9 ft) lb *42420 31900 *31990 20720 *25040 15260 *22550 13800 (26.6)
-3.0 m kg *22870 *22870 *17520 14710 *13390 9540 *10550 7460 7.22
(-9.8 ft) lb *50420 *50420 *38620 32430 *29520 21030 *23260 16450 (23.7)
-4.5 m kg *14070 *14070 *10500 10480 5.80
(-14.8 ft) lb *31020 *31020 *23150 23100 (19.0)
attachments.
1-17
HX380A L
BOOM 6500 3900 6500 600 - - - - -

height (A)
m (ft)
9.0 m kg *5580 *5580 7.43

(29.5 ft) lb *12300 *12300 (24.4)
7.5 m kg *6800 *6800 *5240 *5240 8.59
(24.6 ft) lb *14990 *14990 *11550 *11550 (28.2)
6.0 m kg *7180 *7180 *6500 6030 *5130 *5130 9.36
(19.7 ft) lb *15830 *15830 *14330 13290 *11310 *11310 (30.7)
4.5 m kg *8930 *8930 *7990 7950 *7510 5900 *5200 5030 9.85
(14.8 ft) lb *19690 *19690 *17610 17530 *16560 13010 *11460 11090 (32.3)
3.0 m kg *14540 *14540 *10830 10620 *9040 7580 *8060 5700 *5420 4720 10.08
(9.8 ft) lb *32060 *32060 *23880 23410 *19930 16710 *17770 12570 *11950 10410 (33.1)
1.5 m kg *17770 15140 *12620 9970 *10080 7230 *8650 5500 *5810 4600 10.09
(4.9 ft) lb *39180 33380 *27820 21980 *22220 15940 *19070 12130 *12810 10140 (33.1)
0.0 m kg *7060 *7060 *19500 14470 *13900 9520 *10910 6950 8860 5350 *6450 4670 9.87
(0.0 ft) lb *15560 *15560 *42990 31900 *30640 20990 *24050 15320 19530 11790 *14220 10300 (32.4)
-1.5 m kg *7760 *7760 *11450 *11450 *19920 14240 *14490 9290 *11330 6790 8770 5270 *7490 4970 9.39
(-4.9 ft) lb *17110 *17110 *25240 *25240 *43920 31390 *31940 20480 *24980 14970 19330 11620 *16510 10960 (30.8)
-3.0 m kg *12390 *12390 *16990 *16990 *19280 14280 *14310 9250 *11160 6760 *9290 5610 8.63
(-9.8 ft) lb *27320 *27320 *37460 *37460 *42510 31480 *31550 20390 *24600 14900 *20480 12370 (28.3)
-4.5 m kg *17960 *17960 *24770 *24770 *17460 14540 *13090 9410 *9810 6940 7.50
(-14.8 ft) lb *39590 *39590 *54610 *54610 *38490 32060 *28860 20750 *21630 15300 (24.6)
-6.0 m kg *18940 *18940 *13630 *13630 *10220 *10220 5.76
(-19.7 ft) lb *41760 *41760 *30050 *30050 *22530 *22530 (18.9)
attachments.
1-18
HX380A L
BOOM 6500 3200 7000 800 - - - - -

height (A)
m (ft)
7.5 m kg *7790 *7790 *7050 *7050 7.80

(24.6 ft) lb *17170 *17170 *15540 *15540 (25.6)
6.0 m kg *8000 *8000 *6910 6650 8.64
(19.7 ft) lb *17640 *17640 *15230 14660 (28.4)
4.5 m kg *12530 *12530 *9960 *9960 *8720 8200 *8150 6100 *7020 5910 9.17
(14.8 ft) lb *27620 *27620 *21960 *21960 *19220 18080 *17970 13450 *15480 13030 (30.1)
3.0 m kg *16270 *16270 *11750 10890 *9660 7850 *8570 5950 *7360 5530 9.42
(9.8 ft) lb *35870 *35870 *25900 24010 *21300 17310 *18890 13120 *16230 12190 (30.9)
1.5 m kg *17950 15530 *13320 10320 *10570 7530 *9030 5780 *7970 5400 9.43
(4.9 ft) lb *39570 34240 *29370 22750 *23300 16600 *19910 12740 *17570 11900 (30.9)
0.0 m kg *18930 15130 *14290 9960 *11200 7310 *9310 5670 *8980 5510 9.19
(0.0 ft) lb *41730 33360 *31500 21960 *24690 16120 *20530 12500 *19800 12150 (30.1)
-1.5 m kg *12410 *12410 *19670 15070 *14520 9830 *11370 7210 *9570 5940 8.68
(-4.9 ft) lb *27360 *27360 *43360 33220 *32010 21670 *25070 15900 *21100 13100 (28.5)
-3.0 m kg *15020 *15020 *20150 *20150 *18480 15220 *13910 9880 *10750 7270 *10070 6870 7.85
(-9.8 ft) lb *33110 *33110 *44420 *44420 *40740 33550 *30670 21780 *23700 16030 *22200 15150 (25.7)
-4.5 m kg *21800 *21800 *15950 15610 *11940 10160 *10520 8990 6.57
(-14.8 ft) lb *48060 *48060 *35160 34410 *26320 22400 *23190 19820 (21.6)

attachments.
1-19
HX380A L
BOOM 6150 2500 6500 600 - - - - -

height (A)
m (ft)
7.5 m kg *9240 *9240 *9470 *9470 6.71
(24.6 ft) lb *20370 *20370 *20880 *20880 (22.0)
6.0 m kg *9720 *9720 *9360 7940 *9400 7600 7.69
(19.7 ft) lb *21430 *21430 *20640 17500 *20720 16760 (25.2)
4.5 m kg *14000 *14000 *11060 10960 *9770 7760 *9530 6610 8.27
(14.8 ft) lb *30860 *30860 *24380 24160 *21540 17110 *21010 14570 (27.1)
3.0 m kg *12720 10380 *10540 7500 *9770 6130 8.55
(9.8 ft) lb *28040 22880 *23240 16530 *21540 13510 (28.1)
1.5 m kg *14120 9910 *11290 7250 9800 6000 8.56
(4.9 ft) lb *31130 21850 *24890 15980 21610 13230 (28.1)
0.0 m kg *20360 14680 *14840 9650 *11690 7090 10180 6200 8.29
(0.0 ft) lb *44890 32360 *32720 21270 *25770 15630 22440 13670 (27.2)
-1.5 m kg *14540 *14540 *19660 14710 *14710 9590 *11390 7090 *10910 6830 7.72
(-4.9 ft) lb *32060 *32060 *43340 32430 *32430 21140 *25110 15630 *24050 15060 (25.3)
-3.0 m kg *24010 *24010 *17760 14950 *13350 9750 *11280 8310 6.77
(-9.8 ft) lb *52930 *52930 *39150 32960 *29430 21500 *24870 18320 (22.2)
-4.5 m kg *13520 *13520 *11150 *11150 5.23
(-14.8 ft) lb *29810 *29810 *24580 *24580 (17.2)
attachments.
1-20
HX380A NL
BOOM 6500 2500 6500 600 - - - - -

height (A)
m (ft)
7.5 m kg *8970 7470 7.16
(24.6 ft) lb *19780 16470 (23.5)
6.0 m kg *9570 *9570 *8920 6860 *8920 6020 8.08
(19.7 ft) lb *21100 *21100 *19670 15120 *19670 13270 (26.5)
4.5 m kg *14460 14130 *11020 9290 *9500 6630 *9030 5260 8.64
(14.8 ft) lb *31880 31150 *24290 20480 *20940 14620 *19910 11600 (28.3)
3.0 m kg *12690 8690 *10330 6340 9190 4880 8.91
(9.8 ft) lb *27980 19160 *22770 13980 20260 10760 (29.2)
1.5 m kg *14020 8240 *11090 6080 9050 4760 8.91
(4.9 ft) lb *30910 18170 *24450 13400 19950 10490 (29.2)
0.0 m kg *14720 12010 *14660 8000 *11510 5920 9370 4890 8.66
(0.0 ft) lb *32450 26480 *32320 17640 *25380 13050 20660 10780 (28.4)
-1.5 m kg *19240 12070 *14510 7960 *11360 5900 *10230 5350 8.12
(-4.9 ft) lb *42420 26610 *31990 17550 *25040 13010 *22550 11790 (26.6)
-3.0 m kg *22870 *22870 *17520 12300 *13390 8090 *10550 6370 7.22
(-9.8 ft) lb *50420 *50420 *38620 27120 *29520 17840 *23260 14040 (23.7)
-4.5 m kg *14070 12770 *10500 8930 5.80
(-14.8 ft) lb *31020 28150 *23150 19690 (19.0)
attachments.
1-21
HX380A NL
BOOM 6500 3200 6500 600 - - - - -

height (A)
m (ft)
7.5 m kg *7790 7100 *7050 6610 7.80

(24.6 ft) lb *17170 15650 *15540 14570 (25.6)
6.0 m kg *8000 6990 *6910 5440 8.64
(19.7 ft) lb *17640 15410 *15230 11990 (28.4)
4.5 m kg *12530 *12530 *9960 9490 *8720 6720 *8150 4960 *7020 4800 9.17
(14.8 ft) lb *27620 *27620 *21960 20920 *19220 14820 *17970 10930 *15480 10580 (30.1)
3.0 m kg *16270 13240 *11750 8830 *9660 6380 *8570 4810 *7360 4450 9.42
(9.8 ft) lb *35870 29190 *25900 19470 *21300 14070 *18890 10600 *16230 9810 (30.9)
1.5 m kg *17950 12270 *13320 8290 *10570 6070 8890 4650 *7970 4330 9.43
(4.9 ft) lb *39570 27050 *29370 18280 *23300 13380 19600 10250 *17570 9550 (30.9)
0.0 m kg *18930 11880 *14290 7950 *11200 5850 8760 4540 8510 4410 9.19
(0.0 ft) lb *41730 26190 *31500 17530 *24690 12900 19310 10010 18760 9720 (30.1)
-1.5 m kg *12410 *12410 *19670 11830 *14520 7810 *11370 5760 9210 4740 8.68
(-4.9 ft) lb *27360 *27360 *43360 26080 *32010 17220 *25070 12700 20300 10450 (28.5)
-3.0 m kg *15020 *15020 *20150 *20150 *18480 11970 *13910 7860 *10750 5820 *10070 5500 7.85
(-9.8 ft) lb *33110 *33110 *44420 *44420 *40740 26390 *30670 17330 *23700 12830 *22200 12130 (25.7)
-4.5 m kg *21800 *21800 *15950 12340 *11940 8140 *10520 7220 6.57
(-14.8 ft) lb *48060 *48060 *35160 27210 *26320 17950 *23190 15920 (21.6)

attachments.
1-22
HX380A NL
BOOM 6500 3900 6500 600 - - - - -

height (A)
m (ft)
9.0 m kg *5580 *5580 7.43

(29.5 ft) lb *12300 *12300 (24.4)
7.5 m kg *6800 *6800 *5240 *5240 8.59
(24.6 ft) lb *14990 *14990 *11550 *11550 (28.2)
6.0 m kg *7180 *7180 *6500 5220 *5130 4830 9.36
(19.7 ft) lb *15830 *15830 *14330 11510 *11310 10650 (30.7)
4.5 m kg *8930 *8930 *7990 6890 *7510 5090 *5200 4320 9.85
(14.8 ft) lb *19690 *19690 *17610 15190 *16560 11220 *11460 9520 (32.3)
3.0 m kg *14540 13890 *10830 9120 *9040 6540 *8060 4900 *5420 4030 10.08
(9.8 ft) lb *32060 30620 *23880 20110 *19930 14420 *17770 10800 *11950 8880 (33.1)
1.5 m kg *17770 12700 *12620 8500 *10080 6190 *8650 4710 *5810 3920 10.09
(4.9 ft) lb *39180 28000 *27820 18740 *22220 13650 *19070 10380 *12810 8640 (33.1)
0.0 m kg *7060 *7060 *19500 12070 *13900 8070 *10910 5920 8780 4550 *6450 3970 9.87
(0.0 ft) lb *15560 *15560 *42990 26610 *30640 17790 *24050 13050 19360 10030 *14220 8750 (32.4)
-1.5 m kg *7760 *7760 *11450 *11450 *19920 11850 *14490 7850 *11330 5760 8700 4480 *7490 4220 9.39
(-4.9 ft) lb *17110 *17110 *25240 *25240 *43920 26120 *31940 17310 *24980 12700 19180 9880 *16510 9300 (30.8)
-3.0 m kg *12390 *12390 *16990 *16990 *19280 11880 *14310 7810 *11160 5740 9270 4770 8.63
(-9.8 ft) lb *27320 *27320 *37460 *37460 *42510 26190 *31550 17220 *24600 12650 20440 10520 (28.3)
-4.5 m kg *17960 *17960 *24770 23970 *17460 12130 *13090 7960 *9810 5910 7.50
(-14.8 ft) lb *39590 *39590 *54610 52840 *38490 26740 *28860 17550 *21630 13030 (24.6)
-6.0 m kg *18940 *18940 *13630 12670 *10220 8900 5.76
(-19.7 ft) lb *41760 *41760 *30050 27930 *22530 19620 (18.9)

attachments.
1-23
HX380A NL
BOOM 6150 2500 6500 600 - - - - -

height (A)
m (ft)
7.5 m kg *9240 *9240 *9470 8350 6.71
(24.6 ft) lb *20370 *20370 *20880 18410 (22.0)
6.0 m kg *9720 *9720 *9360 6890 *9400 6590 7.69
(19.7 ft) lb *21430 *21430 *20640 15190 *20720 14530 (25.2)
4.5 m kg *14000 *14000 *11060 9460 *9770 6720 *9530 5710 8.27
(14.8 ft) lb *30860 *30860 *24380 20860 *21540 14820 *21010 12590 (27.1)
3.0 m kg *12720 8900 *10540 6460 *9770 5280 8.55
(9.8 ft) lb *28040 19620 *23240 14240 *21540 11640 (28.1)
1.5 m kg *14120 8450 *11290 6220 9720 5150 8.56
(4.9 ft) lb *31130 18630 *24890 13710 21430 11350 (28.1)
0.0 m kg *20360 12280 *14840 8200 *11690 6070 10100 5310 8.29
(0.0 ft) lb *44890 27070 *32720 18080 *25770 13380 22270 11710 (27.2)
-1.5 m kg *14540 *14540 *19660 12310 *14710 8150 *11390 6060 *10910 5850 7.72
(-4.9 ft) lb *32060 *32060 *43340 27140 *32430 17970 *25110 13360 *24050 12900 (25.3)
-3.0 m kg *24010 *24010 *17760 12540 *13350 8300 *11280 7110 6.77
(-9.8 ft) lb *52930 *52930 *39150 27650 *29430 18300 *24870 15670 (22.2)
-4.5 m kg *13520 13080 *11150 10580 5.23
(-14.8 ft) lb *29810 28840 *24580 23320 (17.2)
attachments.
1-24
6. BUCKET SELECTION GUIDE
1) GENERAL BUCKET
General bucket Heavy duty

(with side cutter) Rock heavy duty
MONO
Capacity Width
Recommendation mm (ft-in)
Without Weight Tooth 6.15 m 6.5 m
SAE CECE
Type side (20' 2") (21' 4")
Heaped heaped
cutter Boom Boom
2.50 m 2.50 m 3.20 m 3.90 m
m3 m3 mm kg
EA (8' 2') (8' 2') (10' 6') (12' 10')
(yd3) (yd3) (in) (lb)
Arm Arm Arm Arm
1.46 1.28 1,305 1,400
4 侑侑侑侑
(1.91) (1.67) (51.4'') (3,090)
1.62 1.42 1,415 1,500
5 侑侑侑俗
(2.12) (1.86) (55.7'') (3,310)
General 1.90 1.65 1,600 1,610
5 侑侑俗侖
bucket (2.49) (2.16) (63.0'') (3,550)
2.10 1.84 1,735 1,690
(2.75) (2.41) (68.3'') (3,730)
5 侑俗侖侘
2.32 2.02 1,885 1,800
(3.03) (2.64) (74.2'') (3,970)
6 俗侖侖侘
侑 Applicable for materials with density of 2100 kg/m3 (3500 lb/yd3) or less
俗 Applicable for materials with density of 1800 kg/m3 (3000 lb/yd3) or less
侖 Applicable for materials with density of 1500 kg/m3 (2500 lb/yd3) or less
侘 Applicable for materials with density of 1200 kg/m3 (2000 lb/yd3) or less
X Not recommended
侍#These recommendations are for general conditions and average use.
Work tools and ground conditions have effects on machine performance.
Select an optimum combination according to the working conditions and the type of work that is
being done.
Consult your Hyundai dealer for information on selecting the correct boom0arm0bucket
combination.
1-25
2) HEAVY DUTY AND ROCK-HEAVY DUTY BUCKET
General bucket Heavy duty

(with side cutter) Rock heavy duty
MONO
Capacity Width
Recommendation mm (ft-in)
Without Weight Tooth 6.15 m 6.5 m
SAE CECE
Type side (20' 2") (21' 4")
Heaped heaped
cutter Boom Boom
2.50 m 2.50 m 3.20 m 3.90 m
m3 m3 mm kg
EA (8' 2') (8' 2') (10' 6') (12' 10')
(yd3) (yd3) (in) (lb)
Arm Arm Arm Arm
1.46 1.28 1,305 1,560
4 侑侑侑侑
(1.91) (1.67) (51.4'') (3,440)
1.62 1.42 1,415 1,660
5 侑侑侑俗
Heavy (2.12) (1.86) (55.7'') (3,660)
duty 1.90 1.65 1,600 1,790
5 侑侑俗侖
(2.49) (2.16) (63.0'') (3,950)
2.10 1.84 1,735 1,880
(2.75) (2.41) (68.3'') (4,140)
5 俗俗侖侘
1.46 1.28 1,305 1,750
4 侑侑侑俗
(1.91) (1.67) (51.4'') (3,860)
Rock
1.62 1.42 1,415 1,850
heavy 5 侑侑侑俗
(2.12) (1.86) (55.7'') (4,080)
duty
1.90 1.65 1,600 1,990
5 侑俗侖侖
(2.49) (2.16) (63.0'') (4,390)
侑 Applicable for materials with density of 2100 kg/m3 (3500 lb/yd3) or less
俗 Applicable for materials with density of 1800 kg/m3 (3000 lb/yd3) or less
侖 Applicable for materials with density of 1500 kg/m3 (2500 lb/yd3) or less
侘 Applicable for materials with density of 1200 kg/m3 (2000 lb/yd3) or less
X Not recommended
侍#These recommendations are for general conditions and average use.
Work tools and ground conditions have effects on machine performance.
Select an optimum combination according to the working conditions and the type of work that is
being done.
Consult your Hyundai dealer for information on selecting the correct boom0arm0bucket
combination.
1-26
7. UNDERCARRIAGE
1) TYPES OF SHOES
Description Unit Triple grouser Double grouser

Model
width mm (in) 600 (24) 700 (28) 800 (32) 900 (36) 600 (24)
Operating weight kg (lb) 39100 62020 39550 87010 40000 88000 40460 89012 39520 86944
HX380A L Ground pressure kgf/cm² (psi) 0.7 9.97 0.61 8.64 0.54 7.65 0.48 6.88 0.71 10.07
Link quantity EA 51 51 51 51 51
Operating weight kg (lb) 38890 85558 - - - - - - - -
HX380 NL Ground pressure kgf/cm² (psi) 0.7 9.92 - - - - - - - -
Link quantity EA 51 - - - -
2) 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
600 mm triple grouser Standard A
600 mm HD triple grouser Option A
600 mm double grouser Option A
700 mm triple grouser Option B
800 mm triple grouser Option C
900 mm triple grouser Option C
1-27
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 or a wide range of general civil engineering work
normal soil
Normal soil, · These shoes cannot be used on rough ground with large obstacles
soft ground such 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 ground · 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
C such 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
1-28
8. SPECIFICATIONS FOR MAJOR COMPONENTS
1) ENGINE
Item Specification
Model Cummins L9
Type 4-cycle turbocharged, charge 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 114×145 mm (4.49"×5.69")
Piston displacement 8900 cc (543 cu in)
Compression ratio 16.72 : 1
Rated net horse power (SAE J1349) 359 Hp at 2100 rpm (268 kW at 2100 rpm)
Rated gross horse power (SAE J1995) 365 Hp at 2100 rpm (272 kW at 2100 rpm)
Maximum torque 183 kgf·m (1325 lbf·ft) at 1400 rpm
Engine oil quantity 30ℓ(7.9 U.S. gal)
Wet weight 778 kg (1560 lb)
Starting motor Denso PA90L 24 V-7.8 kW
Alternator Denso 24 V-95 A
Battery 2×12 V×160 Ah
2) MAIN PUMP
Item Specification
Type Variable displacement tandem axis piston pumps
Capacity 2×200 cc/rev
Maximum pressure 330 kgf/cm2 (4690 psi) [360 kgf/cm2 (5120 psi)]
Rated oil flow 2×340ℓ/min (89.8 U.S. gpm/74.8 U.K. gpm)
Rated speed 1700 rpm
[ ] : Power boost
1-29
3) GEAR PUMP
Item Specification
Type Fixed displacement gear pump single stage
Capacity 15 cc/rev
Maximum pressure 40 kgf/cm2 (570 psi)
Rated oil flow 25.5ℓ/min (6.7 U.S. gpm/5.6 U.K. gpm)
4) MAIN CONTROL VALVE

Item Specification
Type 9 spools
Operating method Hydraulic pilot system
Main relief valve pressure 330 kgf/cm2 (4690 psi) [360 kgf/cm2 (5120 psi)]
Boom 390 kgf/cm2 (5550 psi)
Port relief valve pressure Arm 390 kgf/cm2 (5550 psi)
Bucket 390 kgf/cm2 (5550 psi)
[ ] : Power boost
5) SWING MOTOR
Item Specification
Type Axial piston motor
Capacity 240 cc/rev
Relief pressure 290 kgf/cm2 (4120 psi)
Braking system Automatic, spring applied hydraulic released
Braking torque 134 kgf·m (969 lbf·ft) over
Brake release pressure 26 kgf/cm2 (370 psi) below
Reduction gear type 2 - stage planetary
6) TRAVEL MOTOR
Item Specification
Type Variable displacement axial piston motor
Capacity 185/114 cc/rev
Relief pressure 360 kgf/cm2 (5120 psi)
Braking system Auto matic, spring applied hydraulic released
Braking torque 57.1 kgf·m (413 lbf·ft)
Brake release pressure 10.6 kgf/cm2 (151 psi)
Reduction gear type 3-stage planetary
1-30
7) CYLINDER
Item Specification
Bore dia×Stroke Ø160 × 1500 mm
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.
1-31
9. RECOMMENDED OILS
HYUNDAI genuine lubricating oils have been developed to offer the best performance and service life for
your equipment. These oils have been tested according to the specifications of HYUNDAI and, therefore, will
meet the highest safety and quality requirements.
We recommend that you use only HYUNDAI genuine lubricating oils and grease officially approved by
HYUNDAI.
Service Ambient temperature˚C(˚F)

Capacity
Kind of fluid
point ℓ (U.S. gal) -50 -30 -20 -10 0 10 20 30 40
(-58) (-22) (-4) (14) (32) (50) (68) (86) (104)
★SAE 5W-40
SAE 30
Engine
Engine oil 30 (7.9) SAE 10W
oil pan
SAE 10W-30
SAE 15W-40
DEF/ Mixture of urea
AdBlue® and deionized 70 (18.5) ISO 22241, High-purity urea + deionized water (32.5:67.5)
tank water
Swing
8.0 (2.1) ★SAE 75W-90
drive
Gear oil
Final 5.5×2 SAE 80W-90
drive (1.5×2)
★ISO VG 15
Tank : 210
(55.5) ISO VG 32
Hydraulic
Hydraulic oil
tank ISO VG 46, HBHO VG 46★3
System : 414
(109) ISO VG 68
★ASTM D975 NO.1

Fuel tank Diesel fuel★1 600 (159)
ASTM D975 NO.2
Fitting ★NLGI NO.1

(grease Grease As required
nipple) NLGI NO.2
Mixture of
Radiator Ethylene glycol base permanent type (50 : 50)
antifreeze
(reservoir 55 (14.5)
and soft ★Ethylene glycol base permanent type (60 : 40)
tank)
water★2
SAE : Society of Automotive Engineers ★ : Cold region (Russia, CIS, Mongolia)
API : American Petroleum Institute ★1 : Ultra low sulfur diesel
ISO : International Organization for Standardization - sulfur content ≤ 15 ppm

★2 : Soft water
NLGI : National Lubricating Grease Institute
City water or distilled water
ASTM : American Society of Testing and Material
★3 : Hyundai Bio Hydraulic Oil
DEF : Diesel Exhaust Fluid DEF compatible with AdBlue®
※ Using any lubricating oils other than HYUNDAI genuine products may lead to a deterioration of performance
and cause damage to major components.
※ Do not mix HYUNDAI genuine oil with any other lubricating oil as it may result in damage to the systems of
major components.
※ Do not use any engine oil other than that specified above, as it may clog the diesel particulate filter(DPF).
※ For HYUNDAI genuine lubricating oils and grease for use in regions with extremely low temperatures, please
contact HYUNDAI dealers.
1-32

Group 2 Main Control Valve ------------------------------------------------------------------------------------------ 2-22
Group 3 Swing Device --------------------------------------------------------------------------------------------------- 2-56
Group 4 Travel Device --------------------------------------------------------------------------------------------------- 2-68
Group 5 RCV Lever -------------------------------------------------------------------------------------------------------- 2-81
Group 6 RCV Pedal -------------------------------------------------------------------------------------------------------- 2-88
GROUP 1 PUMP DEVICE
1. STRUCTURE
The pump device consists of main pump, regulator and gear pump.
Pi1
A3
B3
Dr Psv Pi2
a4
Qmin adjusting screw Qmax adjusting screw Qmin adjusting screw
Regulator Regulator
Pi1 Pi2
a4
Dr Psv
B3
B1
a3
Dr3
a1 a2
Front pump Port block Rear pump Gear pump
A1 Psv a4 A2
Port Port name Port size
a1 a2 A1, 2 Delivery port SAE6000 psi 1"

B1 Suction port SAE2000 psi 3"
Dr Drain port PF 3/4 - 23
Pi1 Pi2 Pi1, i2 Pilot port PF 1/4 - 15
Psv Servo assist port PF 1/4 - 15
Dr
M a1, 2, 4 Gauge port PF 1/4 - 15
a3
B1 B3 Dr3 A3
a3 Gauge port PF 1/4 - 14
380A2MP01 A3 Gear pump delivery port PF 1/2 - 19
B3 Gear pump suction port PF 3/4 - 20.5
Dr3 Gear pump drain port PF 3/8 - 15
2-1
1) MAIN PUMP (1/2)
The main pump consists of two piston pumps (front & rear) and valve block.
497 312 956 401
380A2MP02
04 Gear pump 261 Seal cover (F) 717 O-ring

111 Drive shaft (F) 271 Pump casing 719 O-ring
113 Drive shaft (R) 312 Valve block 724 Square ring
114 Spline coupling 313 Valve plate (R) 725 O-ring
123 Roller bearing 314 Valve plate (L) 728 O-ring
124 Needle bearing 401 Hexagon socket screw 732 O-ring
127 Bearing spacer 406 Hexagon socket screw 774 Oil seal
012 Cylinder block 466 VP Plug 789 Back up ring
151 Piston 468 VP Plug 792 Back up ring
152 Shoe 497 Plug 808 Hexagon head nut
153 Set plate 531 Tilting pin 824 Snap ring
156 Bushing 532 Servo piston 885 Pin
157 Cylinder spring 534 Stopper (L) 886 Spring pin
211 Shoe plate 535 Stopper (S) 901 Eye bolt
212 Swash plate 548 Feedback pin 953 Set screw
214 Bushing 702 O-ring 954 Adjust screw
251 Support plate 710 O-ring 956 Set screw

2-2
MAIN PUMP (2/2)
544
545
541
543
079
VIEW A
380A2MP03
079 Proportional reducing valve 543 Stoper 1 545 Steel ball

541 Seat 544 Stoper 1
2-3
2) REGULATOR (1/2)
412 876 874 656 735 413 497 438 413

755
A 858
897 B 614
612
615 Pi
613
A 875
B 611
438 722 724 725 436
VIEW C
641
P2
Pf
438
Pi1
801
924
B
730 643 708 644 645 646 728 Hydraulic circuit
SECTION B-B 380A2MP04
412 Hexagon socket screw 708 O-ring Port Port name Port size
413 Hexagon socket screw 722 O-ring
Pi Pilot port PF 1/4-15
Pf Power shift port -
P2 Companion delivery port -
497 Plug 728 O-ring
611 Feed back lever 730 O-ring
612 Lever (1) 735 O-ring
614 Fulcrum plug 801 Nut
615 Adjust plug 858 Snap ring
643 Pilot piston 874 Pin
644 Spring seat (Q) 875 Pin
645 Adjust stem (Q) 876 Pin
646 Pilot spring 897 Pin
656 Block cover 924 Set screw
2-4
REGULATOR (2/2)
SECTION A-A 380A2MP05
601 Casing 630 Lock nut 734 O-ring

621 Compensator piston 631 Sleeve, pf 753 O-ring
622 Piston case 641 Pilot cover 756 O-ring
623 Compensator rod 651 Sleeve 763 O-ring
624 Spring seat (C) 652 Spool 802 Nut
625 Outer spring 653 Spring seat 814 Snap ring
626 Inner spring 654 Return spring 836 Stop ring
627 Adjust stem (C) 655 Set spring 887 Pin
628 Adjust screw (C) 732 O-ring 898 Pin
629 Cover (C) 733 O-ring
2-5
3) GEAR PUMP
700 354 351

887 433
B3
434 A3
311
Dr3 850
312 a3 355
732
710 435 361 353 307 310 308 309 434 466, 725
380A2MP06
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 Adjusting screw 433 Flange socket 732 O-ring
312 Nut 434 Flange socket 850 Snap ring
351 Gear case 435 Flange socket 887 Pin
2-6
4) EPPR VALVE AND CASING SUB
A1 P2
P1
a Psv
Hydraulic circuit
466,725 490 407
079
725 079 EPPR valve assy
325 Valve casing
407 Hexagon socket head screw
466 VP plug
490 Plug
P2
725 O-ring
Psv 732 O-ring
T P1
A1
380A2MP07
725 325 732

Psv Servo assist port PF 1/4-15
P1, P2 Internal assist port -
A1 Power shift port -
a Gauge port PF 1/4-15
2-7
5) EPPR VALVE ASSY
351 311 324
312 361 362 363 801 901 Seal nut
380A2MP08
311 Spool 351 Orifice 363 O-ring

312 Sleeve 361 O-ring 801 Solenoid
324 Spring 362 O-ring 901 Name plate
2-8
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 set (151,152), set plate (153),
spherical bush (156) and cylinder spring
(157). The drive shaft is supported by 124
313
bearing (123,124) at its both ends. 012
157
The shoe is caulked to the piston to from 156
153
a spherical coupling. It has a pocket to 211
relieve thrust force generated by loading 151
pressure and the take hydraulic balance 111
152
so that it slides lightly over the shoe plate
(211). The sub group composed by a
piston and a shoe is pressed against the 123
shoe plate by the action of the cylinder
spring via a retainer and a spherical bush.
Similarly, the cylinder block is pressed
against valve plate (313) by the action of
the cylinder spring. 32092MP03
(2) Swash plate group 531

The swash plate group consists of swash 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, α
the swash plate slides over the swash
plate support via the spherical part of the
tilting pin to change the tilting angle (α)
3607A2MP10
2-9
(3) Valve block group
The valve block group consists of valve
block (312), valve plate (313) and valve
plate pin (885).
The valve plate having two melon-shaped
312
ports is fixed to the valve block and feeds
and collects oil to and from the cylinder 313
block.
The oil changed over by the valve plate is
connected to an external pipeline by way 885
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 380A2MP09
plate is tilted as in Fig (previous page) the

pistons arranged in the cylinder block
make a reciprocating motion with respect
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.
2-10
2) REGULATOR
Regulator consists of the negative flow control, total horse power control and power shift control
function.
(1) Negative flow control

By changing the pilot pressure Pi, the
pump tilting angle (delivery flow) is
regulated arbitrarily, as shown in the
figure.
This regulator is of the negative flow
Delivery flow, Q
control in which the delivery flow Q
decreases as the pilot pressure Pi rises.
With this mechanism, when the pilot
pressure corresponding to the flow
required for the work is commanded, the
pump discharges the required flow only,
and so it does not consume the power Pilot pressure, Pi
uselessly.
2-11
① Flow reducing function
643 654 651 652 613 646
P1 CL
B(E)
874
897
C
A
Pi(from MCV)
875
611
Small diameter
Large diameter Servo piston 531 chamber
chamber
848
D
380A2MP10
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.
2-12
② Flow increasing function
643 654 651 652 613 646
P1 CL
B(E)
874
897
C
A
Pi
875
611
Small diameter
Large diameter Servo piston 531 chamber
chamber
848
D
380A2MP11
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.
2-13
③ Adjustment of flow control characteristic
The flow control characteristic can be
adjusted with the adjusting screw. 801
Adjust it by loosening the hexagon nut 924

(801) and by tightening (or loosening)
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
Speed 380A2MP12
Tightening Flow Flow

amount of control change
adjusting starting amount
screw pressure
Delivery flow, Q
(924) change
amount
(min -1) (Turn) (kgf/cm2) (ℓ/min)
1800 +1/4 +1.0 +18.9
Pilot pressure, Pi
2-14
(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 simultaneous
Delivery pressure, (P1+P2)
total horsepower type that operates by the
sum of load pressures of the two pumps
in the tandem double-pump system, the
prime mover is automatically prevented
from being overloaded, irrespective of the
load condition of the two pumps, when
horsepower control is under way.
Since this regulator is of the simultaneous
total horsepower type, it controls the tilting
angles (displacement volumes) of the two
pumps to the same value as represented
by the following equation :
Tin = P1×q / 2 π + P2×q / 2 π
= (P1+P2)×q / 2 π
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).
2-15
① Overload preventive function
621 651 652 623 612 601 625 626
P1 CL
B(E)
897
F
Pf
P2 P1
875
611
Large diameter Servo piston Small diameter

chamber chamber
380A2MP13
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 (652) and sleeve (651) is closed.
2-16
② Flow reset function
621 651 652 623 612 601 625 626
P1 CL
B(E)
897
F
P2 P1
875
Large diameter Small diameter

chamber chamber
Servo piston
380A2MP14
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.
2-17
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 nut
625 626 630 628
the adjusting screw C (628). Tightening
the screw shifts the control chart to the 802
right and increases the input horsepower

as shown in the figure. Since turning
the adjusting screw C by N turns
changes the setting of the inner spring
(626), return the adjusting screw QI
627
(627) by N×A turns at first. (A=1.85)
※ Adjusting values are shown in table.
Adjustment of outer spring 380A2MP15
Speed
Tightening Compensating Input torque
amount of control change
adjusting starting amount
Delivery flow, Q
screw (C) pressure

(628) change
amount
(min -1) (Turn) (kgf/cm2) (kgf·m)
1800 +1/4 +17.8 +6.7

2
2-18
b. Adjustment of inner spring
the adjusting screw QI (627). 802
Tightening the screw increases the flow
and then the input horsepower as
shown in the figure.
※ Adjusting valves are shown in table.
627
Adjustment of inner spring
Speed
Tightening Flow change Input torque
amount of amount change 380A2MP16
adjusting amount
screw (QI)
(627)
Delivery flow, Q
(min -1) (Turn) (lpm) (kgf·m)
1800 +1/4 +16.7 +7.2
2-19
(3) Power shift control
621 651 652 623 612 601 625 626
P1 CL
B(E)
897
F
Pf
P2 P1
875
611
Large diameter Servo piston Small diameter

chamber chamber
380A2MP17
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 shift .
Pf=
pressure) is admitted to the horsepower control M AX
.
section of each pump regulator through the
pump's internal path to shift it to the same set
horsepower level. Delivery pressure, (P1+P2)
This function permits arbitrary setting of the
pump output power, thereby providing the optimum power level according to the operating
condition.
The power shift pressure Pf controls the set horsepower of the pump to a desired level, as shown
in the figure.
As the power shift pressure Pf rises, the compensating rod (623) moves to the right via the pin
(898) and compensating piston (621).
This decreases the pump tilting angle and then the set horsepower in the same way as explained
in the overload preventive function of the horsepower control. On the contrary, the set
horsepower rises as the power shift pressure Pf falls.
2-20
(4) Adjustment of maximum and minimum flows
808
① Adjustment of maximum flow
the set screw (954).
The maximum flow only is adjusted
without changing other control
characteristics. R290RE08(5)
Speed Adjustment of max flow spring
Delivery flow, Q
Tightening Flow change
amount of adjusting amount
screw
(954)
(min -1) (Turn) (ℓ/min)

1800 +1/4 -6.9
Delivery pressure, Pi
② Adjustment of minimum flow

Adjust it by loosening the hexagon nut
(808) and by tightening (or loosening) 808
the hexagonal socket head set screw
(953). Similarly to the adjustment of the 953
maximum flow, other characteristics are
not changed.
However, remember that, if tightened too
much, the required horsepower during 380A2MP18
the maximum delivery pressure (or

during relieving) may increase.
Speed Adjustment of min flow spring

Delivery flow, Q
Tightening Flow change

amount of adjusting amount
screw
(953)
(min -1) (Turn) (ℓ/min)

1800 +1/4 +6.9 Delivery pressure, Pi
2-21
GROUP 2 MAIN CONTROL VALVE
1. STRUCTURE (1/2)
XBp2 (Pd)
TRAVEL XBa1
(PTb) XBtr STRAIGHT Mark Port name Port size Tightening torque
CT1
(PTb) (PTa)
CMR1 CMR2 PaL,Dra (P3) -
CP1 (P4) -
R3 PG TRAVEL 20.4~25.5 kgf·m
XBtL XAtL (R4) - PF1
BtL AtL
LEFT (148~184 lbf·ft)
Rs1 Make up port
Pns,Dr4 PbL,Drb
LCb Rs2 Make up port
P1 XAb1 Bb Ab BOOM 1 XBb1 CCk (P4)
(ROD) (HEAD)
XAtr Travel left (forward) pilot port
XAc PAcs
LCk (P3) XBtr Travel left (reverse) pilot port
Pna1,Dr3
XBc Bc Ac
CCo
(XAo) Optional pilot port
(HEAD) BUCKET
(XBo) Optional pilot port
(ROD)
PH Rs2 Rs1
(Ba2)
XAa2
(HEAD) XAc Bucket out pilot port
ARM 2 XBa2
LCAP2 (R4) XBc Bucket in pilot port
LCAT2 XAb1 Boom up pilot port
XBp1 P1 CUT N1 N2 P2 CUT XBp2 XBb1 Boom down pilot port
(PTa) XAtr
XAb2 Boom up pilot port
XAa1 XBb2 Boom down pilot port
XBp1
VIEW B XAa2 Arm out confluence pilot port
VIEW A XBa2 Arm in confluence pilot port
XAtL Travel right (forward) pilot port
XBtL Travel right (reverse) pilot port
(PTa)
CT2 XBtr (PTb) 7.8~8.0 kgf·m
XAtr CP2 Px XAs Swing right pilot port PF3/4
TRAVEL
Atr Btr (50.1~57.9 lbf·ft)
XAtr RIGHT XBtr XBs Swing left pilot port
Py
MR LCs Pns XAa1 Arm out pilot port
Pz As Bs XBtL
Pns Pns XBa1 Arm in pilot port
XAs SWING XBs
XAtL Dr4 Dr4
Drb
XAs Dr4 XBs Dr1 Drain port
A XBb2 BOOM 2 XAb2 XAb1 Dr2 Drain port
CCb LCb2 Dr2
PbL
XBb2 XAb2 (PTa) -
Hvb
XBb1 AbR
OPTION BbR (PTb) -
(Ao) LCo BoR BcR
(Pa) AoR (Bo)
(XAo) PAcs Bucket in stroke limit pilot port
(XBo)
(Pd)
AcR XBc
N1 Nega-con pressure pilot port (boom 1 side)
(XAo) Dr3 (XBo)
Dra N2 Nega-con pressure pilot port (arm 1 side)
HVa Ba1 XAa2 BaR
Dr1 Dra Dr3 LCa Dr3
XBa ARM 1 XAa1 PG Pilot port
Pna1 Pna1
XBa2 XBa1
PaL
PaL
(HEAD) XAa1 PH Pilot port
Aa Pna1
ARC XBp1
Px Pressure port for attachment
R1 (R2)
AaR
(ROD) Py Pressure port for travel
XBp2 XBp1
B
380F2MC02
2-22
STRUCTURE (2/2)
XBp2 (Pd)
TRAVEL XBa1
(PTb) XBtr STRAIGHT Mark Port name Port size Tightening torque
CT1
(PTb)
CMR1 CMR2
(PTa) PaL,Dra XBp1 Bypass cut spool pilot port (P1 side)
CP1 XBp2 Bypass cut spool pilot port (P2 side)
R3 PG
XBtL
TRAVEL
XAtL
PaL Lock valve pilot port (arm rod side)
LEFT
BtL AtL PbL Lock valve pilot port (boom head side)
Pns,Dr4 LCb PbL,Drb Dra Drain port
P1 XAb1 Bb Ab BOOM 1 XBb1 CCk (P4) Drb Drain port 3.5~3.9 kgf·m
PF1/4
(ROD) (HEAD)
XAc PAcs Pna1 Arm regeneration cut pilot port (25.3~28.2 lbf·ft)
LCk (P3)
Pna1,Dr3 Pns Swing priority pilot port
XBc Bc Ac
CCo
(HEAD) (ROD)
BUCKET Dr3 Drain port
PH (Ba2)
Rs2 Rs1 Dr4 Drain port
XAa2
(HEAD)
ARM 2 XBa2 Pz Main relief pilot pressure port
LCAP2 (R4)
LCAT2
(Pd) Option relief pilot pressure port
XBp1 P1 CUT N1 N2 P2 CUT XBp2 Atr Travel motor left side (reverse) port
(PTa) XAtr
Btr Travel motor left side (forward) port
XAa1 As Swing motor right port
XBp1
VIEW B
Bs Swing motor left port
8.5~11.2 kgf·m
VIEW A AtL Travel motor right side (reverse) port M12
(61.5~81.0 lbf·ft)
BtL Travel motor right side (forward) port
R1 Return port
CT2 XBtr (PTb)
(PTa) (R2) -
XAtr CP2 Px
Atr Btr
TRAVEL
XAtr RIGHT XBtr R3 Return port
Py
MR LCs Pns
Pz As Bs P1 Pump port (A1 side)
Pns Pns XBtL
XAtL
XAs SWING XBs P2 Pump port (A2 side)
Dr4 Dr4
XAs Dr4 XBs
Drb (Ao) Optional port
A XBb2 BOOM 2 XAb2 XAb1
CCb LCb2 Dr2 (Bo) Optional port
PbL
XBb2 XAb2 Aa Arm out port
XBb1 AbR BbR 14.3~18.4 kgf·m
Hvb OPTION LCo BcR Ba1 Arm in port M14
(Pa) AoR (Ao) (Bo) BoR (103~133 lbf·ft)
(XAo)
(XBo) Ab Boom up port
(Pd)
AcR (XAo) Dr3 (XBo) XBc Bb Boom down port
Dra
Dr1 Dra Dr3
HVa Ba1
Dr3
XAa2 BaR Ac Bucket out port
LCa
XBa ARM 1 XAa1
Pna1 Pna1 Bc Bucket in port
XBa2 PaL (HEAD) XAa1
XBa1 PaL Aa Pna1 (Ba2) -
ARC XBp1
R1 (R2)
(ROD)
AaR
XBp2 XBp1
B
380A2MC01
2-23
1) RELIEF VALVE SIDE VIEW
B A
(PTa)
XAtr
101
Py
C MR C
Pz
Pns
XAtL Dr4
XAs
Drb
D D 101 Casing A
XBb2 103
P PbL P 102 Casing B
XBb1 AbR
103 Casing C
E Hvb E
(Pa) AoR
252 Lock valve selector sub assy
991 Name plate
AcR (XAo)
F F 992 Pin
Dr1 Dra Dr3
Pna1
XBa2 PaL
G XBa1 G
103
AaR
H XBp2 H
A
B 380A2MC03
2) BACK SIDE VIEW

XBp2 (Pd)
XBa1
M PaL,Dra
971
211 Plate
273 Hexagon socket screw
273 CCk (P4)
211
Pna1,Dr3
(P3)
CCo
Rs2 Rs1
(R4)
XAa1
XBp1
VIEW B
380A2MC04
2-24
3) P2 SPOOL SECTION
351 152 168 169 153
PH P2 PG
XAtr XBtr
271
XAs XBs
152 ROH plug

XBa2 XAb2 153 ROH plug
168 O-ring
(XAo) (XBo) 169 O-ring
341 271 Hexagon socket screw
168
341 Plug
XBa1 XAa1
351 Orifice
551 Plug
561 O-ring
(P4) Rs1 Rs2
153 169 551 561 380A2MC05
4) P1 SPOOL SECTION
271 R3 P1
(PTb) (PTa)
XBtL XAtL
162 O-ring
163 O-ring
XAb1 XBb1 271 Hexagon socket screw
XBc 551 Plug
561 O-ring
XAa2 XBb2
XBp1 XBp2
162 561 551 561 551 163 162

380A2MC06
2-25
5) TRAVEL RIGHT AND TRAVEL STRAIGHT SECTION
153
169 153 ROH plug
201
201
336
336 169 O-ring
TRAVEL TRAVEL 332
332
372
STRAIGHT RIGHT 371 201 Spring cover
337
337 (PTa) XAtr 332 203 Spool cover
332
261
261 261 O-ring
601 MR
308
263 O-ring
512 Py 301 Travel spool
301
522
552 511
308 Straight travel spool sub assy
562 521 332 Spring seat
512
CMR2 Atr
551
522
336 Spacer bolt
552
562
CMR1 CT2
561 337 Stopper
CT1
CP2
561
561 551 371 Spring
551 521
521
Btr
511
372 Spring
211 511 Poppet
512 Poppet
Px
263 521 Spring
203
169 (PTb) XBtr 263 522 Spring
153 203
SECTION C-C 551 Plug
380A2MC07
552 Plug
561 O-ring
562 O-ring
601 Main relief valve assy
6) TRAVEL LEFT AND SWING SECTION
201
201 153 ROH plug
336
336
332 TRAVEL
332 161 O-ring
SWING 371
371
337
LEFT 337 165 O-ring
332
332 XAtL XAs
261 169 O-ring
261
170 O-ring
166
301 305 171 O-ring
166 162
165 172 O-ring
163
201 Spring cover
511 AtL As 203 Spool cover
521 LCs
253 Logic poppet assy
551
CP1
Pns
255 Logic control valve assy
561
255 261 O-ring
165 Bs
161
BtL
253 263 O-ring
305 Swing spool
332 Spring seat
166 336 Spacer bolt
263 XBtL XBs 263
203 203 337 Stopper
SECTION D-D
371 Spring
380A2MC08 511 Poppet
521 Spring
551 Plug
2-26
7) BOOM 1 AND BOOM 2 SECTION
201 201 201 Spring cover

336 336
332 BOOM 1 BOOM 2 332 203 Spool cover
372 371
337 337 261 O-ring
332 XBb1 332
261
XBb2
602 263 O-ring
261
553
AbR
303 Boom 1 spool sub assy
561
Hvb
307 307 Boom 2 spool
523 Py
513
511 332 Spring seat
303 Ab
521 336 Spacer bolt
337 Stopper
CCb
551
511
521
561
561
371 Spring
511 Poppet
LCb Lcb2
551
561 551
521 513 Poppet
521 Spring
Bb
511
523 Spring
Dr2 551 Plug
602 BbR XAb1 XAb2
553 Plug
263 263 561 O-ring
203 SECTION E-E 203
602 Port relief valve assy
380A2MC09
8) BUCKET AND OPTION SECTION 153 ROH plug

153 161 O-ring
555
563
169 164 O-ring
204
201
336
165 O-ring
342
336
BUCKET OPTION 332 170 O-ring
332
371
171 O-ring
371
337
PAcs
(XAo)
337 172 O-ring
332 XAc
332
261
169 O-ring
261
602
AcR
172
AoR 309 201 Spring cover
304 606 203 Spool cover
162 Py
204 Spring cover
164 275 213 Flange
165
163
(Ao)
264 261 O-ring
Ac 213
511 511 263 O-ring
521 521 264 Square ring
551 LCk LCo
561 561 304 Bucket spool
164 264
Bc 213 309 Option spool
161 (Bo)
275
332 Spring seat
336 Spacer bolt
Px
337 Stopper
172 605 371 Spring
602 BcR XBc (XBo)
BoR
511 Poppet
263 263 521 Spring
SECTION F-F
203 203
380A2MC10 551 Plug
169
153 552 Plug
555 Plug
561 O-ring
562 O-ring
563 O-ring
2-27
9) ARM 1 AND ARM 2 SECTION
151 ROH plug
201 201 167 O-ring
336 336 201 Spring cover
332 ARM 2 ARM 1 332
203 Spool cover
375 371
337 337 261 O-ring
332 XBa2 XBb1 332 263 O-ring
261 261 205 Spool cover
306
213 Flange
Dra
302 214 Load check cover
Dr1 Py 167 253 Logic poppet assy
511
521
151 255 Logic control valve assy
561
561 264 Square ring
553
551 Hva
265 O-ring
523 266 Square ring
276 LCAT2
LCa 513 275 Hexagon socket screw
265
266
CT2
CP2 Pna1
214 302 Arm 1 spool sub assy
531 255 306 Arm 2 spool
522 Ba1
253 332 Spring seat
514 Ba2
336 Spacer bolt
337 Stopper
275 371 Spring
216 375 Spring
264
602
BaR
XAa2 511 Poppet
263 513 Poppet
261
203 XAa1 514 Poppet
205
SECTION G-G 380A2MC11
521 Spring
522 Spring
523 Spring
531 Spring seat
551 Plug
553 Plug
561 O-ring
562 O-ring
10) TRAVEL LEFT AND SWING SECTION
202
333 202 Spring cover
331
324 P2 CUT ARM REGEN CUT 215 Blank flange
323 XBp2 257 Arm regen cut sub assy
334 257
331
602 262 O-ring
262
AaR
267 O-ring
551
611 310 Bypass-cut assy
311 Bypass-cut assy
N2 Aa
323 Spring
CCk
310
324 Spring
310 CCo
331 Spring seat
R1
333 Spacer bolt
N1
611 334 Stopper
551 Plug
561 (R2)
561 O-ring
267 215 277
262
331
611 Nega-con relief valve assy
334
XBp1
323
324 P1 CUT
331
333 SECTION H-H
202 380A2MC12
2-28
11) OTHER SECTION
351 152 168
167
167 151 PG
151
541
Dra 542
554
NR
PaL
166
Pz 543
151 167
151
151
167
SECTION Q-Q SECTION N-N SECTION L-L 167
PbL Drb
515
521
551
CCk
SECTION P-P 561
169
153
CCo
551
561
521
515
SECTION M-M 380A2MC13
151 ROH plug 169 O-ring 543 Spring

152 ROH plug 351 Orifice 551 Plug
153 ROH plug 515 Poppet 554 Plug
166 O-ring 521 Spring 561 O-ring
167 O-ring 541 Steel ball
168 O-ring 542 Spring seat
2-29
2. HYDRAULIC CIRCUIT
MAKE UP (R4) (P3)
Rs1 Rs2 (P4)

R1
(R2) NR2 NR1
N2
Dra BC1 N1
BC2
HVa XBp1
PaL
XBp2
[Rod] Aa CCo CCk

Dr1
AaR
BaR
[Head] Ba1 (Ba2)
XBa1 XBa2
Arm 1 Arm 2
[ARM IN]
Arm 1 Arm 2
[ARM OUT] XAa1 XAa2
ARC LCa
LCAP2 LCAT2
Pna1
Dr3
(Bo)
Bc [Head]
BoR
AoR BcR
AcR
(Ao) Ac [Rod]
PAcs
(XAo)
XAc
Option Option Bucket Bucket
XBc
(XBo)
LCo LCk Drb
Dr2 PbL
AbR CCb HVb

Ab [Head]
BbR
Bb [Rod]
XBb2 XBb1
Boom 1 Boom 1
Boom 2 Boom 2 XAb1
LCb2 LCb
XAb2
Bs
As CP1
AtL
[SW-CW] XAs BtL
Swing Swing XAtL [RH-FW]
[SW-CCW] XBs Travel RH Travel RH
LCs XBtL [RH-BW]
Pns
Dr4
CPG
Px
CP2 CT2
Btr
Atr Travel Straight Travel Straight
(PTb) (Pta)
[LH-FW] XAtr
Travel LH [LH-BW] XBtr
Travel LH CMR1 Pz
CT1
Py MR
CMR2
PH P2 PG R3 P1
380A2MC14
2-30
3. Operation
1) Neutral positions of spools
(1) P1 housing side
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 travel straight (308), travel left (301) , boom 1 (303), bucket (304), arm 2 (306) and boom 1
side negative control orifice, and returns to the hydraulic oil tank through the return port (R1),
(R3).
The negative control signal pressure of the boom 1 side negative control relief valve (611) 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.
1
R3 P1
2
(PTb) (PTa)
XBtL XAtL
XAb1 XBb1
XBc
XAa2 XBa2
XBp1 XBp2
(P3)
380A2MC15
2-31
(2) P2 housing side
The oil discharged from the hydraulic pump (A2) passes through port P2, the main path (3), the
bypass circuit (4) passing the spools for travel right (301), swing (305), boom 2 (307), option
(309), arm 1 (302) and arm 1 side negative control orifice, and returns to the hydraulic oil tank
through the return port (R1), (R3).
The negative control signal pressure of the arm 1 side negative control relief valve (611) 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) or (4) is cut off and the
control signal pressure at port N1 or N2 in the negative control circuit is changed tank pressure,
and controls the pump discharge flow rate to its maximum value.
PH P2 PG 3
4
XAtr XBtr
XAs XBs
XBa2 XAb2
(XAo) (XBo)
XBa1 XAa1
(P4) Rs1 Rs2

380A2MC16
2-32
2) TRAVEL OPERATION
(1) Pilot circuit
Since any of the travel spools (301) on the left or right transfers and shuts off the side-bypass
path, the pressure at port Py (pressure port for travel) increases.
(2) Main circuit
When pilot port XBtL of the travel left spool (301) is pressurized, the bypass circuit (2) in the
boom 1 side is shut off and pressurized oil from port P1 passes through port BtL and flows to the
travel left motor.
When pilot port XBtr of the travel right spool (301) is pressurized, the bypass circuit (4) in the arm
1 side is shut off and pressurized oil from port P2 passes through port Btr and flows to the travel
right motor.
On the other hand, the return oil from the travel left(right) motor passes through port AtL(Atr) and
travel left (right) spool , and returns to the hydraulic oil tank through the tank port (R1), (R3).
In the case of the opposite operation (when the pilot pressure is applied to ports XAtL and XAtr of
the control valve), the operation is similar.
XBtL
XAtL
AtL BtL
Travel motor
380A2MC17
2-33
3) ARM OPERATION
(1) Arm stretching operation
① Pilot circuit
Since the arm 1 spool (302) transfers and shuts off the side-bypass path, the pressure at port Px
increases.
② Main circuit
During the arm stretching operation, the pilot pressure enters through ports XAa1 and XAa2.
When the pressure enters through ports XAa1 and XAa2, the arm 1 and arm 2 spools transfer
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 (4), but the bypass circuit is shut off due to transfer of the
arm 1 spool (302).Therefore, the hydraulic oil from the parallel circuit pushes open the logic
poppet (253) and flows through the U-shaped path to the arm 1 spool (302).Then, it flows
around the periphery of the arm 1 spool (302) to port Aa, 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 (306).
The hydraulic 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 (306). Then, it flows around the periphery of arm 2 spool (306) and joins into port Aa
through the inside path.
Besides, the return oil from the arm cylinder head side (H) passes through port Ba1, flows into
tank line in arm 1 side and in arm 2 side and returns to the hydraulic oil tank through the tank
ports (R1), (R3).
2-34
511 514
Ba2
LCAT2
BaR
Dr1
XAa2
XBa2
XAa1
XBa1
Dra
Aa LCa Ba1
253
Pna1
R H
380A2MC18
2-35
(2) Arm excavating operation
① Pilot circuit
Since the arm 1 spool (302) transfers and shuts off the side-bypass path, the pressure at port Px
(pressure port for attachment) increases. Then, the pressure enters also through port PaL and
the release signal is sent to the lock valve selector (252).
② Main circuit
During the arm excavating operation, the pilot pressure enters through ports XBa1 and XBa2.
When the pressure enters through ports XBa1 and XBa2, the arm 1 and arm 2 spools transfer
in the right direction in figure. The hydraulic oil entering through port P2 passes through the main
path (3) and flows to the bypass circuit (4), but the bypass circuit is shut off due to transfer of the
arm 1 (302) spool. Therefore, the hydraulic oil from the parallel circuit pushes open the logic
poppet (253) and flows through the U-shaped path to the arm 1 spool (302). Then, it flows
around the periphery of the arm 1 spool (302) to port Ba1, and is supplied to the arm cylinder
head side (H).
On the other hand, the hydraulic 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 (306). The hydraulic 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 (306). Then, it flows around the periphery of arm 2 spool (306) and joins into
port Ba1 through the inside path.
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 Aa. The pressurized oil returning to port Aa enters into
the spool through the outside hole (a) of the arm 1 spool (302). During a light load only, it pushes
open the sleeve check valve (302-317) and joins into port Ba from the spool hole (b). This is
called the arm regeneration function.
When the pressure in the arm cylinder head side (H) and the U-shaped path increases, the arm
regeneration cut spool (257-103) is transferred in the left direction in Fig. ***, and at the same
time the check valve (302-317) 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 Aa through the periphery hole (a) of the arm 1 spool (302) into the spool, flows
to the arm regeneration cut valve (257) through the periphery hole (c) of the arm 1 spool (302),
and returns through the tank port (R1), (R3) to the hydraulic oil tank.
2-36
·During light load only
Ba2
LCAT2
BaR
Dr1
XBa2 XAa2
a 302-317
XBa1 XAa1
b
Dra
Aa LCa Ba1
Pna1
Arm self weight
R H
380A2MC19
2-37
·In case the pressure in the arm cylinder head side (H) increases.
Ba2
LCTA2
BaR
Dr1
XBa2
XAa2
a 302-317
c
XBa1
XAa1
Dra
Aa LCa Ba1
Pna1
257-103
R H
380A2MC20
2-38
4) BOOM OPERATION
(1) Boom hoisting operation
① Pilot circuit
Since the boom 2 spool (307) transfers and shuts off the side-bypass path, the pressure at port
Px (Pressure port for attachment) increases.
② Main circuit
During the boom hoisting operation, the pilot pressure enters through port XAb1 and transfers
the boom 1 spool (303) 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 (303). Therefore, the pressurized oil flows into the
parallel circuit, pushes open the check valve (511), and flows through U-shaped path to the
boom 1 spool (303). Then, it flows around the periphery of the boom 1 spool (303) to port Ab,
and is supplied to the boom cylinder head side (H).
At the same time, the pilot pressure enters also through port XAb2 to transfer the boom 2 spool
(307) in the left direction in figure. Though the pressurized oil enters into port P2, the bypass
circuit is shut off due to transfer of the boom 2 spool (307). Therefore, the oil flows in the parallel
circuit and flows through the U-shaped path to the boom 2 spool (307). Then, the oil passes
through the periphery of the boom 2 spool, pushes open the check valve (511), joins into port Ab
through 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 Bb,
passes around the periphery of the boom 1 spool (303), and returns to the hydraulic oil tank
through the tank ports (R1), (R3).
2-39
H R
513 511
LCb Bb
Ab
BbR
XAb1
XBb1
XAb2
XBb2
Dr2
AbR
511 511
380A2MC21
2-40
(2) Boom lowering operation
① Pilot circuit
Since the boom 2 spool (307) transfers and shuts off the side-bypass path, the pressure at port
Px increases. Then, the pressure enters also through port PbL and the release signal is sent to
the lock valve selector (252).
② Main circuit
During the boom lowering operation, the pilot pressure enters through port XBb1 and transfers
the boom 1 spool (303) 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 (303). 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 (303) to port Bb
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 through the
periphery hole (a) and the periphery of the boom 1 spool (303).
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 (303-317) in the spool in the right 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 function)
Besides, a part of the return oil from the boom cylinder flows from the hole (b) into the tank.
H R
513 511
Ab LCb
Bb
BbR
XBb1
XAb1
b a 303-317
380A2MC22
2-41
5) BUCKET OPERATION
(1) Bucket excavating operation
① Pilot circuit
Since the bucket spool (304) transfers and shuts off the side-bypass path, the pressure at port
Px increases. Then, the pressure enters also through port XBp2.
② Main circuit
During the bucket excavating operation, the pilot pressure enters through port XBc and transfers
the bucket spool (304) 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 (304). Therefore, the pressurized oil flows into the
bucket spool (304). Then, it flows through the periphery of the bucket spool (304) to port Bc 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 Ac,
passes around the periphery of the spool, and returns to the hydraulic oil tank through the tank
ports (R1) and (R3).
During both the boom hoisting operation and bucket excavating operation, the pilot pressure
enters through port PAcs and the bucket spool transfers in the half stroke not full stroke.
Therefore, the pressurized oil entering through port P1 flows to the boom 1 spool (303)
preferentially to the bucket spool (304) to make the boom hoisting operation most preferential.
R H
511
Ac LCk Bc
AcR
BcR
PAcs XAc
XBc
Confluence 380A2MC23
2-42
(2) Bucket releasing operation
① Pilot circuit
Since the bucket spool (304) transfers and shuts off the side-bypass path, the pressure at port
Px increases. Then, the pressure enters also through port XBp2.
② Main circuit
During the bucket releasing operation, the pilot pressure enters through port XAc and transfers
the bucket spool (304) in the right direction in figure. The pressurized oil entering through port P1
is shut off due to transfer of the bucket spool (304). Therefore, the pressurized oil flows into the
bucket spool (304). Then, it flows through the periphery of the bucket spool (304) to port Ac 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 Bc,
passes around the periphery of the spool, and returns to the hydraulic oil tank through the tank
ports (R1), (R3).
R H
511
LCk
Ac Bc
AcR
XAc BcR
PAcs
XBc
Confluence
380A2MC24
③ Bucket confluence
During the bucket excavating or releasing operation, the pilot pressure enters also through port
XBp2 and transfers the bypass-cut spool (310). The pressurized oil entering through port P2
is shut off due to transfer of the bypass-cut spool (310). Therefore, the pressurized oil pushes
open the check valve (515), and flows through inside path and the U-shaped path to the bucket
spool (304).
2-43
6) SWING OPERATION
(1) Independent swing operation
① Pilot circuit
Since the swing spool (305) transfers and shuts off the side-bypass path, the pressure at port Px
increases.
② Main circuit
During the swing operation, the pilot pressure enters through port XAs (or XBs) and transfers the
swing spool (305). The pressurized oil entering through port P2 passes through the main path
(3) and flows through the bypass circuit (4), but the bypass circuit (4) is shut off due to transfer of
the swing spool (305). Therefore, the pressurized oil flows into the parallel circuit, pushes open
the logic poppet (254-101), and flows through the U-shaped path to the swing spool (305). Then,
it flows through the periphery of the spool to port As (or Bs) and is supplied to the swing motor.
On the other hand, the return oil from the swing motor enters port Bs (or As) and returns to the
hydraulic oil tank through the tank ports (R1), (R3).
Swing motor
Pns
LCs
As Bs
254-101
XAs
XBs
380A2MC25
2-44
(2) Swing priority function
The following is the case of making the swing operation prior to the arm excavating operation.
① Main circuit
During both the arm excavating operation and the swing operation, the swing pilot pressure
enters through ports Pna1 of the logic poppet (255), and transfers the piston (255-356) and the
spool (253-107) upward in figure. Therefore, the lift of the poppet (253-101) is limited, and the
passage from the parallel circuit to the U-shaped path is restricted. As a result, the pressurized
oil flows to the swing spool preferentially to the arm 1 spool to make the swing operation prior.
Similarly, in case the pilot pressure is applied to port Pns of the logic poppet (255), the lift of the
poppet (254-101) is limited, and the boom hoisting operation is made prior to the swing
operation.
XBa1 XAa1
Aa LCa Ba1
253-101
253-107
255
255-356
Pna1
380A2MC26
2-45
(2) Swing priority function
The following is the case of making the swing operation prior to the arm excavating operation.
① Main circuit
During both the arm excavating operation and the swing operation, the swing pilot pressure
enters through ports Pna1 of the logic poppet (255), and transfers the piston (255-356) and the
spool (253-107) upward in figure. Therefore, the lift of the poppet (253-101) is limited, and the
passage from the parallel circuit to the U-shaped path is restricted. As a result, the pressurized
oil flows to the swing spool preferentially to the arm 1 spool to make the swing operation prior.
Similarly, in case the pilot pressure is applied to port Pns of the logic poppet (255), the lift of the
poppet (254-101) is limited, and the boom hoisting operation is made prior to the swing
operation.
XBa1 XAa1
Aa LCa Ba1
253-101
253-107
255
255-356
Pna1
380A2MC26
2-46
7) OPTION OPERATION
This spool is used for controlling the optional attachments like a nibbler.
(1) Option operation
① Pilot circuit
Since the side bypass sections of both travel spools (301) shut off and the side bypass section of
the downstream-side of swing spool shuts off, the pilot pressure from the port PG enters through
the port PTb to transfer the travel straight spool (308).
② Main circuit
During the swing operation, the pilot pressure enters through port XAs (or XBs) and transfers the
swing spool (305). The pressurized oil entering through port P2 passes through the main path
(3) and flows through the bypass circuit (4), but the bypass circuit (4) is shut off due to transfer of
the swing spool (305). Therefore, the pressurized oil flows into the parallel circuit, pushes open
the logic poppet (254-101), and flows through the U-shaped path to the swing spool (305). Then,
it flows through the periphery of the spool to port As (or Bs) and is supplied to the swing motor.
On the other hand, the return oil from the swing motor enters port Bs (or As) and returns to the
hydraulic oil tank through the tank ports (R1), (R3).
H R
511
Ao LCo
Bo
AoR BoR
XAo
BBo
Confluence
380A2MC27
(2) Option confluence

In order to use the option confluence, the pilot pressure enters through port XBp1 and transfers
the bypass-cut spool (310). The pressurized oil entering through port P1 passes through the main
path (1) and flows through the bypass circuit (2), but the bypass circuit (2) is shut off due to
transfer of the bypass-cut spool (310). Therefore the pressurized oil pushes open the check valve
(515), and flows through the inside path and the U-shaped path to the option spool (309).
2-47
8) TRAVEL STRAIGHT OPERATION
Simultaneous operating of both travel spools (301) and other spool makes the operation useful.
The following is the case where both travel spools (301) and swing spool (305) are changed over.
(the pilot ports XAtL, XAtr and XAs are pressurized.)
① Pilot circuit
Since the side bypass sections of both travel spools (301) shut off and the side bypass section of
the downstream-side of swing spool shuts off, the pilot pressure from the port PG enters through
the port PTb to transfer the travel straight spool (308).
② Main circuit
After changeover of the travel straight spool (308), the port P2 and both travel spools (301) 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 AtL and Atr, 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, the part of oil entering
through port P1 flows into Port P2 side. Therefore, it prevents the rapid slowdown of travel.
P1 R3
P2
PTa PTb
XAtL XBtL
380A2MC28
2-48
9) FUNCTION OF LOCK VALVE
The lock valve (252) is installed between the arm cylinder rod side (R) and the arm 1 spool (302). It
decreases the leakage by the pressure of the cylinder.
Similarly, another lock valve (252) is installed between the boom cylinder head side (H) and the
boom 1 spool (303) and decreases the leakage by the pressure of the cylinder.
The following is the case of the boom cylinder head side (H).
(the case of the arm cylinder rod side (R) is in the same way.)
(1) Neutral positions of spools
During the boom 1 spool (303), boom 2 spool (307) are in the neutral position, the spool (252-
511) in the lock valve is kept in the position shown in figure by the force of the spring (252-512).
The spool (252-511) is pushed to the seat of the lock valve (252-101).
In this position, pressurized oil from the boom cylinder head side (H) enters through hole (a), the
periphery of the spool (252-511) in the lock valve and hole (b), and it pushes the poppet (513) to
the casing seat, and the leakage is decreased.
252-512
Drb 252-511
b
252-101
a
PbL 513
Ab LCb Bb
RH
BbR
XBb1 XBb1
380A2MC29
2-49
(2) Boom lowering operation
During the boom lowering operation, pilot pressure enters through port PbL, XBb1 and XBb2.
Pilot pressure transfers the spool (252-511) in the lock valve in the top direction in figure. By the
transfer of the spool (252-511), firstly the hole (a) is blocked and pressurized oil from the boom
cylinder head side (H) does not enter to spring chamber (RH). Secondly, the oil in spring chamber
(RH) enters through hole (b) and flows to drain circuit. Therefore, the poppet (513) is lifted by the
pressure of the boom cylinder head side (H) and the function of the lock valve (252) is released.
252-512
Drb 252-511
b
252-101
513 511
PbL
Ab LCb Bb
RH
BbR
XBb1
XBb1
380A2MC30
(3) Boom hoisting operation

During the boom hoisting operation, the pilot pressure enters through ports XAb1, XAb2. The oil
flowing from the boom 1 spool (303) and the boom 2 spool (307) pushes open the poppet (513)
and flows to port Ab.
2-50
10) FUNCTION OF MAIN RELIEF VALVEN
The main relief valve (601) is fitted in the casing A (101) and functions as follows.
(1) The hydraulic oil is filled up in the inside space chamber (a) from the path (P) through a hole of
the body (601-101) and a restriction of the plunger (601-511), and seats the plunger (601-511)
against body (601-101) securely.
(2) When the pressure in the path (P) becomes equal to the set load of the spring (601-512), the
poppet (601-401) opens to make the hydraulic oil flow through a hole of the seat (601-641),
around the poppet (601-401) and into the low pressure path (R).
(3) Opening of the poppet (601-401) causes the pressure in the chamber (a) to fall and the plunger
(601-511) to open. As the result the pressurized oil in the path (P) runs into the low pressure path
(R) directly.
(4) When the pressurized oil higher than pressure 3MPa enters through the port Pz, it pushes the
piston (601-302) to change the relief set pressure of the spring (601-512) to the high pressure.
601-101 601-401 601-512 601-102
601-511 a 601-302
601-641 Pz
380A2MC31
2-51
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
① 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 541
301 511
A B 541 622
Pd
P
311 511 614 380A2MC32
2-52
② When the pressure in the path (P) becomes equal to the set pressure of the spring (621), the
pressurized oil pushes open the poppet (611), flows around it, and flows to the low pressure
path (R) through hole C.
611 621
380A2MC33
③ 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.
511 611
380A2MC34
2-53
(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
380A2MC35
2-54
(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:
① When the pressure in the path (P) falls

C 621
below the set level of the spring (621),the
poppet (611) is in the condition shown in
the figure.
The pressure acting area of the poppet
(611) is reduced to ( Ø B-Ø A), as the
area ØB is cancelled by the area ØA of
the damping rod (631). P R
In this condition, the pressurized oil in
the path (P) runs out to the path (R) 631
611
through the orifice (C).
380A2MC36
② When the pressure in the path (P) goes C 621

over the set pressure of the spring (621),
the poppet (611) opens as shown in the
figure. Then, the pressurized oil in the
port P passes around the outside of the
poppet (611) and flows to the low-
pressure path (R).
P R
611 380A2MC37
The relation between the flow rate Q and

pressure P of the hydraulic oil that flows Pressure P
from the path (P) to the low-pressure
path (R) is as shown in figure.
Flow
380A2MC38
2-55
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.
SGo SH PG C Dr
SGr Dr(RG) A,B PA A B PB

Reduction gear Swing motor Time delay valve
SRG ARG
Dr(RG)
SH
SGo
PG Port Port name Port size

Dr
A Main port SAE 1"
(dr#)
B Main port SAE 1"
DB Drain port PF 1/2
C Make up port PF 1 1/4
C
PA PB SH Brake release pilot port PF 1/4
PG Brake release stand by port PF 1/4
PA, PB Gauge port PF 1/4
SGr Grease filling port PT 1/8
Dr (R/G) Gear oil drain port PT 1/2
A(CCW) B(CW)
SGo Gear oil filling port PT 3/4
Hydraulic circuit
380A2SM01
2-56
1) SWING MOTOR
1 7 11 12 13 23 25 24 18 20 37 19 21
22
6
5
2
36
31 38
28 39
3 4 8 9 10 14 15 16 17 29
380A8SM05
1 Casing 12 Cylinder spring 23 O-ring

2 Valve casing 13 Cylinder block 24 O-ring
3 Drive shaft 14 Friction plate 25 O-ring
4 Roller bearing 15 Separation plate 28 Socket bolt
5 Roller bearing 16 Brake piston 29 Socket bolt
6 Oil seal 17 Brake spring 30 Socket bolt
7 Shoe plate 18 Valve plate 31 VP plug assy
8 Retainer plate 19 Plunger 36 Snap ring
9 Shoe 20 Check spring 37 Relief valve
10 Piston 21 RO plug assy 38 Brake valve
11 Thrust ball 22 Pin 39 Reactionless valve
2-57
2) REDUCTION GEAR
36,35 34 33 32 31 30 3 1 4 37 5 6 7 28 39
8 15 14 9 10
11 12 13 40
42
* *
27
41
26
46 2 47 37 45 38 29 17 25 24 21 19 18 20 22 23
49 48 16
380A2SM03
1 Casing 17 Carrier 1 33 Pinion gear

2 Drive shaft 18 Planetary gear 1 34 Lock plate
3 Taper roller bearing 19 Pin 1 35 Hexagon bolt
4 Spacer ring 20 Needle cage 36 Lock washer
5 Oil seal 21 Side plate 1 37 Plug
6 Taper roller bearing 22 Side plate 2 38 Plug
7 Carrier assy 2 23 Stop ring 39 Socket bolt
8 Carrier 2 assy 24 Spring pin 40 Cover
9 Planetary gear 2 25 Thrust ring 41 O-ring
10 Pin assy 2 26 Sun gear 2 42 Hexagon socket bolt
11 Pin 2 assy 27 Sun gear 1 45 Air breather assy
12 Bushing 2 28 Ring gear 46 Gauge pipe
13 Spring pin 29 Knock pin 47 Gauge bar
14 Thrust washer 30 Cover plate 48 Air breather post
15 Spring pin 31 Hexagon bolt 49 Air breather cap
16 Carrier assy 1 32 Spacer
2-58
2. FUNCTION
1) ROTARY PART
When high pressurized oil enters a cylinder through port (a), which is the inlet of valve plate (1),
hydraulic pressure acting on the piston causes axial force F. The pressure force F works via the
piston (2) upon the retainer plate (3) which acts upon the shoe plate (4) via an hydrostatic bearing.
Force F1 perpendicular to shoe 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 shoe 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
36072SM04A
2-59
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
2-60
3) RELIEF VALVE
1 Body
5 9 2 Seat
3 Plunger
6 4 Spring
8
5 Adjusting screw
3
6 Piston
7 7 Sleeve
8 O-ring
10 9 Back up ring
10 O-ring
1
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]
2-61
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
2-62
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
2-63
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
(15) is constrained by the groove located
at casing (1). When housing is pressed
down by brake spring (17) through
friction plate (14), separate plate (15)
and brake piston (16), friction force
17
occurs there.
16
Cylinder block (13) is constrained by this
friction force and brake acts, while brake 15
releases when hydraulic force exceeds 14

spring force. 13
1
36072SM11
1 Casing 15 Separate plate

13 Cylinder block 16 Brake piston
14 Friction plate 17 Brake spring
2-64
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 brake 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 Brake valve 4
4 Pilot pump P3
5 Spool
6 Piston 2
7 Poppet
8 Spring
9 Spring
10 Orifice
11 Spring

36072SM12
2-65
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

3 Brake valve
4 Pilot pump 4
5 Spool P3
6 Piston
7 Poppet 2
8 Spring
9 Spring
10 Orifice
11 Spring

36072SM13A
2-66
c. When the swing control (1) lever is set the neutral position the spool (5) returns right in the
brake valve (3).
Then, the piston (6) is moved lower by spring force and the return and the return oil from the
chamber G flows back to D-port through orifice (10) of the poppet (7).
At this time, the poppet (7) works to make a time lag for 5 seconds.
3 10 7
PG
11
G
9
6 D
PG SH

3 Brake valve
4
4 Pilot pump
P3
5 Spool
6 Piston
7 Poppet 2
8 Spring
9 Spring
10 Orifice
11 Spring

38092SM04
2-67
GROUP 4 TRAVEL DEVICE
1. CONSTRUCTION
Travel device consists travel motor and reduction gear.
Travel motor include counterbalance valve, cross over relief valve.
A N B
Pr Pa Pb
Dr Dr
Pi
Manual negative
Reduction gear Travel motor brake release port Pi
(PT 1/4) Pi
L
GIN
FILL LEVEL
GOUT
DRAIN
VIEW X
3809A2TM01

Dr Dr
A Main port SAE 6000 psi 1"
Lo B Main port SAE 6000 psi 1"
Hi 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
Gout Gear oil outlet port PF 1/2
AB
Hydraulic circuit
2-68
1) TRAVEL MOTOR (1/2)
101 491 107 102 435 504 113 201 122 741 742 121 703 545 705 461 704 351
352
451
303
131
103
111
114
472
502 503 123 272 707 702 708 546 547
3809A2TM02
101 Drive shaft 272 Shaft casing 545 Orifice

102 Roller bearing 303 Valve casing 546 Orifice
103 Needle bearing 351 Reducing valve 547 O-ring
107 Snap ring 352 Cover 702 Brake piston
111 Cylinder block 435 Snap ring 703 Orifice
113 Spherical bushing 451 Pin 704 Orifice
114 Cylinder spring 461 Plug 705 Brake spring
121 Piston 472 O-ring 707 O-ring
122 Shoe 491 Oil seal 708 O-ring
123 Set plate 502 Piston 741 Separation plate
131 Valve plate 503 Shoe 742 Friction plate
201 Swash plate 504 Pivot ball

2-69
TRAVEL MOTOR (2/2)
402 366 364 564 022 361 365 362

571
572
531
533
509
464
SECTION E-E
485
E
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 570 O-ring
365 O-ring 533 Tilting spring 571 RO plug
366 Hex socket bolt 541 Seat 572 O-ring
401 Hex socket bolt 542 Stopper
2-70
2) REDUCTION GEAR
1 16 19 22 13 36 55 56 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
3809A2TRG01
1 Ring gear 20 Side plate 37 Snap ring

2 Housing 21 Needle cage 44 Snap ring
4 Side cover 22 Needle cage 45 Clip
5 Carrier 1 23 Needle cage 46 W clip
6 Carrier 2 24 Inner ring 47 Nutring
9 Sun gear 1 25 Floating bushing 51 Name plate
10 Sun gear 2 26 Thrust ring 52 Rivet
11 Sun gear 3 27 Thrust ring 53 Washer
12 Planetary gear 1 29 Socket bolt 54 Set screw
13 Planetary gear 2 30 Socket bolt 55 Nutring stopper
14 Planetary gear 3 32 RO plug 56 Hex socket bolt
16 Pin 2 33 Angular bearing 81 O-ring
17 Pin 3 34 Floating seal 82 O-ring
18 Side plate 35 Shim 83 O-ring
19 Side plate 36 Spring pin
2-71
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.
2-72
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.
2-73
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
Lo
A
Position 2 Hi
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.
2-74
4) PRESSURE RELEASE VALVE (Flow control valve)
During running During stop
3607A2TM08A
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.
2-75
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 135 mm in length into a tapped hole Socket wrench
of the brake piston (702). Then the condition having the brake 6 mm
release pressure is attained and the brake is released. 8 mm
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 Pa and Pb with a short hose or something. Then the machine can be pulled
slowly.
2-76
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' and that in room F is discharged via passage G' through port Av to the tank, the spool
moves left to have passage L-DH-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.
2-77
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.
2-78
(2) External pilot pressure : Pi＞
＝20 kgf/cm
2
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.
2-79
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.
2-80
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.
※ Refer to the parts manual for the types of the RCV lever.
1) TYPE L11, L12, L15
8
7
Null 5 5
Null
6 6
TYPE L11, L12 TYPE L15
Switches
Type No. LH RH
5 One touch decel Horn
25 19 L11, L12
Simultaneous Single 6 Power boost Breaker
operation operation
6 Power boost Null
L15
7 CCW rotation Close
8 CW rotation Open
※ Number 7 and 8 : Option attachment
P T
A A
1 3 2 4
Hydraulic circuit
Pilot ports
4 Port LH RH Port size
2 3 P 1 P Pilot oil inlet port Pilot oil inlet port
T T
T Pilot oil return port Pilot oil return port
1 P 3 2
1 Left swing port Bucket out port
4 PF 3/8
2 Arm out port Boom up port
LH RH
VIEW A-A 3 Right swing port Bucket in port
4 Arm in port Boom down port
300A2RL01
2-81
2) TYPE L13, L14, L16
8
7
Null 5
5 Null
6 6
TYPE L13, L14 TYPE L16
Switches
Type No. LH RH
25 19
Single 5 One touch decel Horn
Simultaneous L13, L14
operation
operation 6 Power boost Breaker
6 Power boost Null
L16
7 CCW rotation Close
8 CW rotation Open
※ Number 7 and 8 : Option attachment
P T
A A
1 3 2 4
Hydraulic circuit
Pilot ports
2 4
T 1 Port LH RH Port size
3 P
1 T P Pilot oil inlet port Pilot oil inlet port
P 3 T Pilot oil return port Pilot oil return port
4 2
1 Left swing port Bucket out port
LH RH PF 3/8
2 Arm out port Boom up port
VIEW A-A
3 Right swing port Bucket in port
4 Arm in port Boom down port
300A2RL05
2-82
3) CROSS SECTION
1 Case
2 Bushing
3 Spool
No. Port
4 Shim
24 P
5 Spring
25 1, 2, 3, 4 (RH) 6 Spring seat
25 2, 4 (LH) 7 Spring
26 T (RH) 8 Plug
26 1, 3, T (LH) 9 Push rod
10 O-ring
11 Rod seal
20
12 Plate
13 Spacer
14 Boot
21
15 Joint assembly
22 16 Swash plate
17 17 Adjusting nut
13 18 Bushing
15
19 Plug
20 Handle assembly
23
16 21 Handle bar
22 Nut
9
23 Boot
14 11
24 Last guard filter
12
25 Connector
18 8 26 Connector
27~34
10 27 Connector
6 28 Connector
7 29 Connector
5 30 Connector
4 31 Small guide
2 3 32 Connector
19 33 Big guide
1 34 Connector
24
25
210S2RL06
26
Item numbers are based on the type L11.

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 (3), spring (5) for setting secondary pres-
sure, return spring (7), spring seat (6) and shim (4). The spring for setting the secondary pressure
has been generally so preset that the secondary pressure is 5 to 20.5 kgf/cm2 (depending on the
type). The spool is pushed against the push rod (9) 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.
2-83
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 apply-
ing 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 ele-
ments.
(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
Item numbers are based on the type L11.
The functions of the spool (3) 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 (5) works on this spool to determine the output pressure.
The change the deflection of this spring, the push rod (9) is inserted and can slide in the plug (8).
For the purpose of changing the displacement of the push rod through the swash plate (16) and
adjusting nut (17) are provided the handle assy (20) that can be tilted in any direction around the
fulcrum of the universal joint (15) center.
The spring (7) works on the case (1) and spring seat (6) and tries to return the push rod (9) 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.
5 6
3
1
3
P T
2 4
2-70
1 Pilot valve 3 Main pump 5 Hydraulic motor

2 Pilot pump 4 Main control valve 6 Hydraulic cylinder
2-85
(1) Case where handle is in neutral position
T
5
P
3
Port 1 Port 3
300L2RL03
The force of the spring (5) that determines the output pressure of the pilot valve is not applied to
the spool (3). Therefore, the spool is pushed up by the spring (7) 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.
2-86
(2) Case where handle is tilted
Port 1 Port 3
300L2RL04
When the push rod (9) is stroked, the spool (3) 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 tilt-
ing 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 con-
nected 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 con-
nected with port P.
2-87
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 3
2 1
4 3
Port Port Port size

P T P Pilot oil inlet port
T Pilot oil return port
1 Travel (LH, Forward)
PF 1/4
2 Travel (LH, Backward)
3 Travel (RH, Forward)
1 2 3 4 4 Travel (RH, Backward)
Hydraulic circuit
130ZF2RP01
2-88
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 (7), spring (5) for setting secondary
pressure, return spring (9), stopper (8), and spring seat (6). The spring for setting the secondary
pressure has been generally so preset that the secondary pressure is 6.3±1 to 24.9±1.5 kgf/cm2
(depending on the type). The spool is pushed against the push rod (13) 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
23
22 25,26
21 2
15
20 13
34
24 16
14 17
12
18
11 19
10
8 3
4
2
1 9
5 2
6
7
130ZF2RP02
1 Body 13 Push rod 25 Cover

2 Plug 14 Spring pin 26 Wrench bolt
3 Plug 15 Seal 27 Cam
4 Spring seat 16 Steel ball 28 Bushing
5 Spring 17 Spring 29 Cam shaft
6 Spring seat 18 Plate 30 Set screw
7 Spool 19 Snap ring 31 Set screw
8 Stopper 20 Plug 32 Hex nut
9 Spring 21 O-ring 33 Bellows
10 Rod guide 22 Rod seal 34 Expand
11 O-ring 23 Dust seal 35 Name plate
12 Snap ring 24 Piston
2-89
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 (7) 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 (5) works on this spool to determine the output pressure.
The change the deflection of this spring, the push rod (13) is inserted and can slide in the plug (20).
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 (9) works on the body (1) and spring seat (6) and tries to return the push rod (13) 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.
2-90
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
2-91
(1) Case where pedal is in neutral position
7 T
9 P
130ZF2RP03
The force of the spring (5) that determines the output pressure of the pilot valve is not applied to
the spool (7). Therefore, the spool is pushed up by the spring (9) to the position of 1 and port 2.
Then, since the output port is connected to tank port T only, the output port pressure becomes
equal to tank pressure.
2-92
(2) Case where pedal is tilted
13
7 T
PORT 1 PORT 2
220F2RP04
When the push rod (13) is stroked, the spool (7) 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.
2-93
Group 1 Hydraulic Circuit ----------------------------------------------------------------------------------------------- 3-1

Group 2 Main Circuit ------------------------------------------------------------------------------------------------------- 3-3
Group 3 Pilot Circuit -------------------------------------------------------------------------------------------------------- 3-6
Group 4 Single Operation ----------------------------------------------------------------------------------------------- 3-15
Group 5 Combined Operation ---------------------------------------------------------------------------------------- 3-25
GROUP 1 HYDRAULIC CIRCUIT
1. HYDRAULIC CIRCUIT (1/2)
( 3 ,Mu) (R4) (P3)
Rs1 Rs2 2 (P4)
3 R1
SRG ARG (R2) NR2 NR1

10 11 8 9
Dr(RG) ( 2 ,Px)
SGo SH 4 4 N2
( 29 ,A(To Pi1))
Dra BC1 N1
[LH] [RH] (dr#) BC2 ( 29 ,B(To Pi2))
PG HVa
PaL XBp1
( 25 ,e)
Dr Dr ( 29 ,C)
Dr Dr Dr XBp2
[Rod] Aa
CCo CCk
Dr1
(dr#) ( 21 ,P4) (dr#)
PR PR AaR
Pi Pi
Pi Pi BaR
N N [Head] Ba1
(Ba2)
PA PA XBa2
PB PB [ARM IN] ( 25 ,e) XBa1 ( 25 ,e)
C
( 2 ,Rs1) Arm 1 Arm 2
[ARM OUT] ( 25 ,d) XAa1 XAa2
PA PB ( 25 ,d)
ARC LCa
A A Pna1 LCAP2 LCAT2
B B ( 25 ,c)
Dr3
(dr#)
P
C
A Dr D
B 12
Pk (Bo)
Bc [Head]
( 2 ,Btr) ( 2 ,AtL)
BoR
A(CCW) B(CW) ( 2 ,Atr) ( 2 ,BtL) AoR BcR
( 21 ,A4) AcR
( 2 ,As)
(dr#) Ac [Rod]
(Ao) PAcs
( 2 ,Bs) ( 25 ,h)
(XAo) XAc ( 25 ,g)
Option Bucket XBc ( 25 ,f)
(XBo)
Drb
LCo LCk (dr#)
Dr2 ( 25 ,j)
(dr#) PbL
AbR CCb HVb Ab [Head]
( 61 ,T3) BbR
( 61 ,T1) ( 61 ,P3) ( 61 ,T2)
5
( 61 ,P1) ( 61 ,P2)
1 Main pump
26 5 26 6 Bb [Rod]
[SWING] P T [ARM] [BUCKET]
P
26
T
[BOOM] 7 26 P T [TRAVEL] ( 25 ,j)
XBb2 XBb1
( 25 ,j)
Boom 1
Boom 2
XAb1
( 25 ,h) 3 Swing motor
( 25 ,h) XAb2
LCb2 LCb 4 Travel motor
(1) (3) (2) (4) (3) (1) (2) (4) (2) (1) (4) (3) ( 3 ,A)
( 3 ,B)
Bs
5 RCV lever(LH)
( 2 ,XAtr) ( 2 ,XAtL) As CP1 AtL
A B D E F G H J [SW-CW] ( 25 ,b) XAs ( 12 ,D)
( 12 ,B)
6 RCV lever(RH)
( 2 ,XBtr) ( 2 ,XBtL) BtL
25 [SW-CCW] ( 25 ,a) XBs

Swing
Travel RH XAtL
( 7 ,(4)) [RH-FW] 7 RCV pedal
d1 e2 f1 g1 h1 j1
LCs
( 7 ,(3)) [RH-BW] 8 Boom cylinder(LH)
a c b PS d PS e PS f g PS h PS j PS 24 Pns XBtL
( 2 ,XBs)
( 2 ,XAs) 24 24 24 24 24 24 PS
( 21 ,A5)
(dr#)
Dr4 9 Boom cylinder(RH)
CPG
( 2 ,Pna1)
29 A ( 2 ,XBb1) ( 2 ,XBb2) ( 2 ,PbL)
Px
CP2 CT2
10 Arm cylinder
B ( 3 ,SH) Btr
( 12 ,A)
( 12 ,C)
11 Bucket cylinder
24 PS C Atr Travel Straight
( 2 ,XAa1) ( 2 ,XAa2)
( 2 ,XBc)
[LH-FW] ( 7 ,(2)) XAtr (PTb) (Pta) 12 Turning joint
( 2 ,XAc)
( 2 ,XBp2) [LH-BW] ( 7 ,(1))
XBtr Travel LH
CT1
CMR1 Pz
( 21 ,A2) 13 Check valve
Py
14 Check valve
( 2 ,XBa1) ( 2 ,PaL) ( 2 ,XBa2) 24 PS CMR2 MR
( 2 ,XAb1) ( 2 ,XAb2) ( 2 ,PAcs)
15 Hydraulic tank
PH P2 PG R3 P1
16 Oil cooler
17 Air breather
( 21 ,P3)
18 Return filter w/bypass valve
61 ( 21 ,P2) 19 Strainer
PS 23
( 5 ,P) RCV ( 5 ,T) RCV a4 SC 62 20 Drain filter
P1 T1
( 7 ,P) PEDAL
P2 T2
( 7 ,T) PEDAL A1 Psv A2
21 4 cartridge valve
( 6 ,P) RCV ( 6 ,T) RCV a1 a2 22 Pressure sensor
P3 T3
1 22 PS PS 22
P T
( 59 ,Out)
23 Pressure sensor
60
In
24 Pressure sensor
( 55 ,A2)
( 2 ,Pz) (Td#) ( 2 ,N2)
25 Terminal block
( 12 ,P) 23 13 26 Last guard filter
( 2 ,Pns)
26 PS 14
21 A5 A4 A2 A1 A
Pi1 Pi2 A 16 Out
29 Tee shuttle
P4
( 3 ,PG) 29 C C
29 17
P3
B 26 B DR#,dr# 55 2 EPPR cartridge valve
P2
( 2 ,PH)
PS
( 2 ,N1) 59 Gear pump
23
T P1 ( 2 ,PG) ( 29 ,A)
E 60 Fan motor
( 1 ,Psv) A2 A1
a3 15 18 20 61 Cross assy
BOOM TRAVEL POWER SC
( 1 ,A3) ( 55 ,P) Out
( 60 ,In)
(Td#) PRIORITY 2ND SPEED BOOST SAFETY
55 59 62
Td#
62 Screw coupling
In
Dr B1 B3 Dr3 A3
( 21 ,P1)
19
P 21 30KA-27100-02 1OF2
T ( ,P2)
(Td#)
FC2 FC1
3-1
2. HYDRAULIC CIRCUIT (2/2)
<SINGLE ACTING> <DOUBLE ACTING> <BOOM FLOATING> <BOOM SAFETY LOCK VALVE>
2
36 36 8 9 8 9
(Bo) 37 (Td#) 41 A1 A2 A3
37 35 26 P
37 AoR
BoR
37 T ( 21 ,A1)
35 (Ao) 34 26 P1 24
GP
(XAo) 28 T P2
PS
30 30
Option (1) (2)
PEDAL BREAKER FLOW
(XBo)
(Td#)
SAFETY E
E
PS 22
T1 T1
CONFLUX
( 27 ,C) 22 30
(Td#)
39 2 46 PS 30
13 22
14 (Td#)
24 A2 27
(Bo) T
Pi1 Pi1 S1 G2 G1 S2 E PS
39 T
A1 PS
T B B1
AoR BoR
(Td#)
V2 T
V2
16 ( 41 ,P2) C (Ao)
B A 54 B A A A1 (XAo)
2
Option
T (Td#) B A PbL Pi1 Pi1 Pi1
(XBo) SC0 LC0 T
T
P
BREAKER FLOW ( 21 ,A1) BbR HVb Ab [Head] V2
T
CONFLUX
Bb [Rod] (Td#)
NR1
XBb1
XAb1
48
N2
N1 T1
Boom 1
14 13 ( 2 ,Ab)
N2 ( 2 ,Bb) ( 2 ,PbL)
BC2
XBp1 40 (Td#) 13 BC2
N1 A P
( 25 ,j)
14 XBp1 ( 2 ,XBb2) T 16
16 (Td#)
<PROPORTIONAL RCV DOUBLE ACTING & ROTATING> <2WAY ROTATING OPTION> <ARM SAFETY LOCK VALVE> <PATTERN CHANGE> ITEM
FROM
PORT ITEM
TO
PORT
1 50 5
2
4
J1
J3
36
J1 J2 J3 J4 50
37 41 10 6
2 J4
1 Main pump
4 J2
A1 A2 A3 (Td#)
37 35
A1 A2 M1 D
( 21 ,A1) T E ISO
M2 J
M1 M2 M3 M4 50 25
24
M3 E
T
P 26 P1
GP
PS
31 M4 H
3 Swing motor
28 26 P2 E
(dr#)
58 (Td#)
T
PEDAL BREAKER FLOW a3 8 Boom cylinder(LH)
T1 2
SAFETY CONFLUX
( 27 ,C) 57 Dr B1 B3 Dr3 A3 9 Boom cylinder(RH)
39 <TRAVEL STRAIGHT> 10 Arm cylinder
( 7 ,4)
27 (Bo) LS M ( 7 ,3)
13 Check valve
T B B1 BoR
T
56 ( 7 ,2) ( 7 ,1)
( 41 ,P2) C (Ao)
AoR
V2 Pi1
A1 A2 A3 A4 47 14 Check valve
P
B A A A1 (XAo) 16 Oil cooler
Option 37 14 13 ( 2 ,PaL) 3 3
B A
(XBo) B 22 Pressure sensor
T
A 16 ( 2 ,Aa)
( 2 ,Ba1)
1 2 1 2
24 Pressure sensor
37 26 Last guard filter
FL FR BL BR
NR1
( 2 ,XAtr)
27 5 shuttle assy(option)
( 2 ,XBtr)
T1
N2 ( 2 ,XAtL) ( 2 ,XBtL)
28 Tee shuttle(option)
40 (Td#) 13 BC2
N1
30 Boom safety valve(option)
<PROPORTIONAL RCV DOUBLE ACTING(With PEDAL) & ROTATING>
14 XBp1
31 Arm safety valve(option)
16 ( 65 ,G)
34 2 way pedal(option)
58 26P
(Td#)
24 <QUICK COUPLER> 35 Accumulator(option)
A1 A2 T 34 66 B A1 A2 P2 PS A3 36 Accumulator(option)
36 P
37 Stop valve(option)
37 35
T
26
37 (dr#) (1) (2)
T (Td#) ( 1 ,a2)
49 39 Proportional relief valve(option)
<SWING FINE CONTROL> <SWING PARKING BY FORCE> A B C D E P1
40 Proportional relief valve(option)
[PEDAL [EPPR [BREAKER] [FLOW
( 21 ,A1)
( 2 ,Px) ( 25 ,b) ( 25 ,a) 65 SAFETY] SAFETY] CONFLUX]
41 3 solenoid cartridge valve(option)
3 F G H 44 Solenoid valve(option)
A3 A2 A1 T1 T B
51 39
2
P A
46 Float cartridge valve(option)
GB GA
( 66 ,P2)
(Bo) 47 Solenoid valve(option)
(Td#)
T T AoR BoR 48 Solenoid valve(option)
44 B3 B2 B1 B A
(Ao)
(XAo)
49 Solenoid valve(option)
B A
(dr#) ( 3 ,SH) ( 2 ,XAs)
(Swing CW)
( 2 ,XBs)
B A
Option 50 Pattern change valve(option)
(Swing CCW) (XBo)
T
NR1 56 Proportional valve(option)
T1
N2
57 Gear pump(option)
40 (Td#) 13 BC2
N1 58 2-EPPR valve(option)
14 XBp1 65 Shuttle block(option)
16 66 Solenoid valve(option)
30KA-27100-02 2OF2
3-2
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 strainer
Hydraulic oil tank
140L3CI01
The pumps receive oil from the hydraulic tank through a suction strainer. The discharged oil from
the pump flows into the control valve and goes out the tank ports.
The oil discharged from the main pump flows to the actuators through the control valve.
The control valve controls the hydraulic functions.
The return oil from the actuators flows to the hydraulic tank through the control valve and the oil
cooler.
3-3
2. RETURN CIRCUIT
3.0
5.0
380A3CI02
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 3.0 kgf/cm2 (43 psi) and 5.0 kgf/cm2 (71 psi). 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 5.0 kgf/cm2 (71 psi), 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 1.5 kgf/cm2 (21 psi) differential
pressure.
3-4
3. DRAIN CIRCUIT
Travel motor Swing motor
From return line Main pump
Turning
joint
Dr#, dr#
Hydraulic
oil tank
R5 Drain filter
Dr
Check valve
1.5kgf/cm 2
380A3CI03
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 drain filter and full flow filter in the hydraulic tank.
When the drain oil pressure exceed 1.5 kgf/cm2 (21 psi), the oil returns to the hydraulic tank directly.
1) TRAVEL MOTOR AND SWING 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 join
with oil leak line of the swing motor and return to the hydraulic tank after being filtered by return
filter.
2) MAIN PUMP DRAIN CIRCUIT
Oil leaking from main pump come out and return to the hydraulic tank passing through drain filter.
3-5
GROUP 3 PILOT CIRCUIT
Remote control valve RCV pedal Remote control valve

(LH lever) (RH lever)
Cross assy
Swing parking brake

MCV Safety lock
solenoid valve
Travel speed solenoid valve
Power boost solenoid valve
Main pump Boom priority EPPR valve
Line filter
Relief valve
2
40 kgf/cm
Suction strainer
Pilot pump
380A3CI01
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 strainer.
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
valve.
3-6
3-5
1. SUCTION, DELIVERY AND RETURN CIRCUIT
ARM BUCKET BOOM

CYLINDER CYLINDER CYLINDER
TRAVEL MOTOR
Mu (R4)(P3)
Rs1 Rs2 (P4)
R1
(R1) NR2 NR1
N2
Dra BC1 N1
(dr#) BC2
HVa XBp1
PaL
XBp2
CCo CCk Dr1

Aa
AaR (dr#)
BaR
Ba1
(Ba2)
XBa1 XBa2
Arm 1 Arm 2
XAa1 XAa2
ARC LCa
LCAP2 LCAT2
Pna1
Dr3
(dr#)
(Bo)
BoR Bc
AoR BcR AcR
Ac
(Ao)
PAcs
(XAo)
XAc
SWING MOTOR Option Bucket XBc
(XBo) Drb
LCo LCk (dr#)
Dr2 PbL
(dr#)
AbR CCb HVb
Ab
BbR
Bb
XBb2 XBb1
Boom 1
Boom 2 XAb1
LCb2 LCb
XAb2
Bs
As CP1 AtL
XAs
BtL
Swing XAtL
XBs Travel RH
LCs XBtL
Pns
RCV PEDAL P T TRAVEL
Dr4 CPG
(dr#) Px
CP2 CT2
Btr
Atr Travel LH Travel Straight
(PTb) (Pta)
XAtr
XBtr CMR1 Pz
CT1
Py
PS CMR2 MR
(2) (1) (4) (3)
XAtr XBtr XAtL XBtL PH P2 PG R3 P1
CROSS ASSY
SWING P T ARM BUCKET P T BOOM
P1 T1
P2 T2 A1 A2
PUMP PUMP PILOT
P3 T3 PUMP
P T
(1) (3) (2) (4) (3) (1) (2) (4)
SAFETY Dr#,dr#
A B D E F G H J Pns P Pz
SOLENOID
(MCV) (T/Joint) (MCV) VALVE
PG(S/Motor)
A5 A4 A2 A1 P4
a c b d1 d e2 e f1 f g g1 h h1 j j1 PH(MCV)
ABs XAs PS PS PS PS PS PS P3 PG(MCV) Tdr#
Psv1(M/PUMP)
Pna1 P2 P(2-EPPR)
XAa1 XAa2
PS B A P1 HYDRAULIC TANK
C T
XBa1 PaL XBa2 XBc XBp2 XAc PbL LINE FILTER

XBb2
XAb1 XAb2 PAcs XBb1
380A3HC02
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 and cross assy.
The return oil from remote control valve returned to hydraulic tank thought cross assy.
3-7
2. SAFETY SOLENOID VALVE (Safety lever)
ARM BUCKET BOOM

TRAVEL MOTOR
Mu (R4)(P3)
Rs1 Rs2 (P4)
R1
(R1) NR2 NR1
N2
Dra BC1 N1
(dr#) BC2
HVa XBp1
PaL
XBp2
CCo CCk Dr1

Aa
AaR (dr#)
BaR
Ba1
(Ba2)
XBa1 XBa2
Arm 1 Arm 2
XAa1 XAa2
ARC LCa
LCAP2 LCAT2
Pna1
Dr3
(dr#)
(Bo)
BoR Bc
AoR BcR AcR
Ac
(Ao)
PAcs
(XAo)
XAc
(XBo) Drb
LCo LCk (dr#)
Dr2 PbL
(dr#)
AbR CCb HVb
Ab
BbR
Bb
XBb2 XBb1
Boom 1
Boom 2 XAb1
LCb2 LCb
XAb2
Bs
As CP1 AtL
XAs
BtL
Swing XAtL
XBs Travel RH
LCs XBtL
Pns
Dr4 CPG
(dr#) Px
CP2 CT2
Btr
(PTb) (Pta)
XAtr
XBtr CMR1 Pz
CT1
Py
PS CMR2 MR
(2) (1) (4) (3)
CROSS ASSY
SWING P T ARM BUCKET P T BOOM
P1 T1
P2 T2 A1 A2
PUMP PUMP PILOT
P3 T3 PUMP
P T
(1) (3) (2) (4) (3) (1) (2) (4)
SAFETY
SOLENOID Dr#,dr#
A B D E F G H J Pns P Pz VALVE LEVER UP
(MCV) (T/Joint) (MCV)
PG(S/Motor)
A5 A4 A2 A1
a c b d1 d e2 e f1 f g g1 h h1 j j1 P4 PH(MCV)
Psv1(M/PUMP)
Pna1 P2 P(2-EPPR)
XAa1 XAa2
C T

XBb2
LEVER DOWN
XAb1 XAb2 PAcs XBb1
380A3HC03
When the lever of the safety solenoid valve is moved upward, oil flows into the remote control valve
through solenoid valve and line filter and cross assy.
When the lever of the safety solenoid valve moved downward, oil does not flows into the remote
control valve, because of blocked by the spool.
3-8
3. BOOM PRIORITY SYSTEM
ARM BUCKET BOOM
TRAVEL MOTOR
Mu (R4)(P3)
Rs1 Rs2 (P4)
R1
(R1) NR2 NR1
N2
Dra BC1 N1
(dr#) BC2
HVa XBp1
PaL
XBp2
CCo CCk Dr1

Aa
AaR (dr#)
BaR
Ba1
(Ba2)
XBa1 XBa2
Arm 1 Arm 2
XAa1 XAa2
ARC LCa
LCAP2 LCAT2
Pna1
Dr3
(dr#)
(Bo)
BoR Bc
AoR BcR AcR
Ac
(Ao)
Boom speed (XAo)
PAcs
XAc
(XBo) Drb
LCo LCk (dr#)
Dr2 PbL
(dr#)
AbR CCb HVb
Ab
BbR
Swing reducing Bb
logic valve
XBb2 XBb1
Boom 1
Boom 2 XAb1
LCb2 LCb
XAb2
Bs
As CP1 AtL
XAs
BtL
Swing XAtL
XBs Travel RH
LCs XBtL
Pns
Dr4 CPG
(dr#) Px
CP2 CT2
Btr
(PTb) (Pta)
XAtr
XBtr CMR1 Pz
CT1
Py
PS CMR2 MR
(2) (1) (4) (3)
SWING P T ARM BUCKET P T BOOM CROSS ASSY
P1 T1 A1 A2
PUMP PUMP PILOT
P2 T2 PUMP
P3 T3
P T
(1) (3) (2) (4) (3) (1) (2) (4)
Dr#,dr#
PG(S/Motor)
A5 A4 A2 A1 P4
Psv1(M/PUMP)
Pna1 P2 P(2-EPPR)
XAa1 XAa2
C T

XBb2 BOOM PRIORITY
EPPR VALVE
XAb1 XAb2 PAcs XBb1
380A3HC04
When carrying out the combined operation of swing and boom up, the boom up operating speed is
lowered then normal operation.
To increase working efficiency, swing speed reducing system is used.
The pilot oil from pilot pump flow into Pns port in main control valve through boom EPPR valve. Pns
oil pressure moves swing reducing logic valve to upper position and oil flow rate to the swing motor
decreased.
Then, the boom up speed is increased. This is called the boom priority system.
The boom up speed can be adjusted by the cluster. Refer to page 3-21 of the operator's manual.
3-9
4. TRAVEL SPEED CONTROL system
ARM BUCKET BOOM
4 4
[LH] [RH]
Dr Dr Dr Dr
Mu (R4)(P3)
Rs1 Rs2 (P4)
PR PR
R1
Pi Pi (R1) NR2 NR1
Pi Pi
N2
N N Dra BC1 N1
(dr#) BC2
HVa XBp1
PA PA PaL
PB PB XBp2
CCo CCk Dr1

Aa
AaR (dr#)
BaR
B A A B Ba1
(Ba2)
P XBa1 XBa2
A D Arm 1 Arm 2
C
Dr
B 12 XAa1 XAa2
Pk
ARC LCa
LCAP2 LCAT2
Pna1
(dr#) Dr3
(dr#)
(Bo)
BoR Bc
AoR BcR AcR
Ac
(Ao)
PAcs
(XAo)
XAc
(XBo) Drb
LCo LCk (dr#)
Dr2 PbL
(dr#)
AbR CCb HVb
Ab
BbR
Bb
XBb2 XBb1
Boom 1
Boom 2 XAb1
LCb2 LCb
XAb2
Bs
As CP1 AtL
XAs
BtL
Swing XAtL
XBs Travel RH
LCs XBtL
Pns
Dr4 CPG
(dr#) Px
CP2 CT2
Btr
(PTb) (Pta)
XAtr
XBtr CMR1 Pz
CT1
Py
PS CMR2 MR
(2) (1) (4) (3)
P1 T1 A1 A2
PUMP PUMP PILOT
P2 T2 PUMP
P3 T3
(1) (3) (2) (4) (3) (1) (2) (4) P T
Dr#,dr#
PG(S/Motor)
A5 A4 A2 A1 P4
Psv1(M/PUMP)
Pna1 P2 P(2-EPPR)
XAa1 XAa2
C T

XBb2 TRAVEL SPEED
XAb1 XAb2 PAcs XBb1 SOLENOID VALVE
380A3HC05
When the travel speed solenoid valve was placed in the Hi position, the pressure oil from pilot pump
through line filter flows to port Pi of travel speed change over valve, and the control piston is pushed
left (RH) and right (LH), thus minimizing the displacement.
When the travel speed solenoid valve was placed in the Lo position, the oil of Pi port return to the
tank and the control piston is returned, thus maximizing the displacement.
3-10
5. MAIN RELIEF PRESSURE CHANGE CIRCUIT
ARM BUCKET BOOM
TRAVEL MOTOR
Mu (R4)(P3)
Rs1 Rs2 (P4)
R1
(R1) NR2 NR1
N2
Dra BC1 N1
(dr#) BC2
HVa XBp1
PaL
XBp2
CCo CCk Dr1

Aa
AaR (dr#)
BaR
Ba1
(Ba2)
XBa1 XBa2
Arm 1 Arm 2
XAa1 XAa2
ARC LCa
LCAP2 LCAT2
Pna1
Dr3
(dr#)
(Bo)
BoR Bc
AoR BcR AcR
Ac
(Ao)
Auto power boost (XAo)
PAcs
XAc
(XBo) Drb
LCo LCk (dr#)
Dr2 PbL
(dr#)
AbR CCb HVb
Ab
BbR
Bb
XBb2 XBb1
Boom 1
Boom 2 XAb1
LCb2 LCb
XAb2
Bs
As CP1 AtL
XAs
BtL
Swing XAtL
XBs Travel RH
LCs XBtL
Pns
Dr4 CPG
(dr#) Px
CP2 CT2
Btr
(PTb) (Pta)
XAtr
XBtr CMR1 Pz MAIN
CT1
Py RELIEF
PS CMR2 MR VALVE
(2) (1) (4) (3)
P1 T1 A1 A2
PUMP PUMP PILOT
P2 T2 PUMP
P3 T3
(1) (3) (2) (4) (3) (1) (2) (4) P T
Dr#,dr#
PG(S/Motor)
A5 A4 A2 A1 P4
Psv1(M/PUMP)
Pna1 P2 P(2-EPPR)
XAa1 XAa2
C T

XBb2
POWER MAX
XAb1 XAb2 PAcs XBb1
SOLENOID VALVE
380A3HC06
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 Pz port of the main relief valve of main control
valve ; Then the setting pressure of the main control valve is raises from 330 kgf/cm2 to 360 kgf/cm2 for
increasing the digging power. And even when press continuously, it is canceled after 8 seconds.
When the auto power boost function is selected to enable on the cluster, the pressure of the main
relief valve is automatically increased to 360 kgf/cm2 as working condition by the MCU. It is also
operated max 8 seconds.
3-11
6. SWING PARKING BRAKE RELEASE
ARM BUCKET BOOM
TRAVEL MOTOR
Mu (R4)(P3)
Rs1 Rs2 (P4)
R1
(R1) NR2 NR1
SWING MOTOR N2
Dra BC1 N1
(dr#) BC2
HVa XBp1
SRG ARG PaL
XBp2
Dr(RG) ( 2 ,Px)
SH CCo CCk
SGo Aa Dr1
AaR (dr#)
PG BaR
Ba1
(Ba2)
Dr
XBa1 XBa2
Arm 1 Arm 2
XAa1 XAa2
(dr#)
ARC LCa
LCAP2 LCAT2
Pna1
Dr3
(dr#)
(Bo)
BoR Bc
AoR BcR
C AcR
( 2 ,Rs1) Ac
(Ao)
PAcs
PA PB (XAo)
XAc
Option Bucket XBc
(XBo) Drb
LCo LCk (dr#)
Dr2 PbL
(dr#)
AbR CCb HVb
Ab
BbR
Bb
XBb2 XBb1
Boom 1
A(CCW) B(CW) Boom 2 XAb1
LCb2 LCb
XAb2
Bs
As CP1 AtL
XAs
BtL
Swing XAtL
XBs Travel RH
LCs XBtL
Pns
Dr4 CPG
(dr#) Px
CP2 CT2
Btr
(PTb) (Pta)
XAtr
XBtr CMR1 Pz
CT1
Py
PS CMR2 MR
(2) (1) (4) (3)
P1 T1 A1 A2
PUMP PUMP PILOT
P2 T2 PUMP
P3 T3
(1) (3) (2) (4) (3) (1) (2) (4) P T
Dr#,dr#
PG(S/Motor)
A5 A4 A2 A1 P4
Psv1(M/PUMP)
Pna1 P2 P(2-EPPR)
XAa1 XAa2
C T

XBb2
XAb1 XAb2 PAcs XBb1
380A3HC07
When one of the RCV lever (except travel lever) is tilted, the pilot oil flows into SH port through main
control valve.
This pressure moves spool of the time delay valve so, discharged oil from pilot valve flows to swing
motor PG port. This pressure is applied to swing motor disc, thus the brake is released.
When all of the RCV lever are set in the neutral position, oil in the swing motor disc cylinder is
drained, thus the brake is applied.
3-12
7. SWING PRIORITY SYSTEM
ARM BUCKET BOOM
TRAVEL MOTOR
Mu (R4)(P3)
Rs1 Rs2 (P4)
R1
(R1) NR2 NR1
N2
Dra BC1 N1
(dr#) BC2
HVa XBp1
PaL Swing priority
logic valve XBp2
CCo CCk Dr1

Aa
AaR (dr#)
BaR
Ba1
(Ba2)
XBa1 XBa2
Arm 1 Arm 2
XAa1 XAa2
ARC LCa
LCAP2 LCAT2
Pna1
Dr3
(dr#)
(Bo)
BoR Bc
AoR BcR AcR
Ac
(Ao)
PAcs
(XAo)
XAc
(XBo) Drb
LCo LCk (dr#)
Dr2 PbL
(dr#)
AbR CCb HVb
Ab
BbR
Bb
XBb2 XBb1
Boom 1
Boom 2 XAb1
LCb2 LCb
XAb2
Bs
As CP1 AtL
XAs
BtL
Swing XAtL
XBs Travel RH
LCs XBtL
Pns
Dr4 CPG
(dr#) Px
CP2 CT2
Btr
(PTb) (Pta)
XAtr
XBtr CMR1 Pz
CT1
Py
PS CMR2 MR
(2) (1) (4) (3)
P1 T1 A1 A2
PUMP PUMP PILOT
P2 T2 PUMP
P3 T3
(1) (3) (2) (4) (3) (1) (2) (4) P T
Dr#,dr#
PG(S/Motor)
A5 A4 A2 A1 P4
Psv1(M/PUMP)
Pna1 P2 P(2-EPPR)
XAa1 XAa2
C T

XBb2
XAb1 XAb2 PAcs XBb1
380A3HC08
When carrying out the combined operation of swing and arm of the left control valve, the swing
speed can be lowered than operating speed of arm.
Pna1 pressure from the swing shuttle block change the swing priority logic valve and decreases the
oil flow rate to the next section to make the swing operation more preferential.
This is called the swing priority system. For details, refer to page 2-45.
3-13
8. boom floating SYSTEM
ARM BUCKET
CYLINDER CYLINDER
BOOM
CYLINDER
TRAVEL MOTOR
Mu (R4)(P3)
Rs1 Rs2 (P4)
E PS
R1
(R1) NR2 NR1
N2 Pi1 Pi1
Dra BC1 N1 T
(dr#) BC2 V2
HVa XBp1
PaL
XBp2
(Td#)
CCo CCk Dr1

Aa Boom safety
AaR (dr#) lock valve
BaR
Ba1
(Ba2)
XBa1 XBa2
Arm 1 Arm 2
XAa1 XAa2
ARC LCa
LCAP2 LCAT2
Pna1
Dr3
(dr#)
Head to Rod to tank
tank solenoid solenoid
(Bo)
AoR
BoR Bc PS
BcR AcR
S1 G2 G1 S2
Ac
(Ao)
PAcs
(XAo)
XAc
(XBo) Drb
LCo LCk (dr#)
Dr2 T
PbL
(dr#)
AbR CCb HVb SC0 LC0
BbR Ab Boom floating
Bb solenoid valve
XBb1
XBb2
Boom 1
Boom 2 XAb1
LCb2 LCb
XAb2
Bs
As CP1 AtL A P
XAs
BtL T
Swing XAtL
XBs Travel RH
LCs XBtL
(Td#)
Pns
Shuttle block
Dr4 CPG (j, Boom Down)
(dr#) Px
CP2 CT2
Btr Boom down control
Atr Travel LH Travel Straight solenoid valve
(PTb) (Pta)
XAtr
XBtr CMR1 Pz
CT1
Py
PS CMR2 MR
Dr#,dr# PH P2 PG R3 P1
A1 A2
PUMP PILOT
PUMP PUMP
HYDRAULIC TANK
380A3HC09
Smooth and convenient boom movement is accomplished by only arm control lever operation.
The boom floating solenoid values are equipped in the rod and head of boom cylinder that are
controlled to act as floating mode.
"Head to tank solenoid" are active. so the hydraulic oil of head goes to tank, and floating is
accomplished. In the mode, boom down cut-off solenoid is active so that boom down pilot pressure
is cut.
For more details, refer to page 5-13.
3-14
GROUP 4 SINGLE OPERATION
1. BOOM UP OPERATION
ARM BUCKET BOOM
TRAVEL MOTOR
Mu (R4)(P3)
Rs1 Rs2 (P4)
R1
(R1) NR2 NR1
N2
Dra BC1 N1
(dr#) BC2
HVa XBp1
PaL
XBp2
CCo CCk Dr1

Aa
AaR (dr#)
BaR
Ba1
(Ba2)
XBa1 XBa2
Arm 1 Arm 2
XAa1 XAa2
ARC LCa
LCAP2 LCAT2
Pna1
Dr3
(dr#)
(Bo)
BoR Bc
AoR BcR AcR
Ac
(Ao)
PAcs
(XAo)
XAc
(XBo) Drb
LCo LCk (dr#)
Dr2 PbL
(dr#)
AbR CCb HVb
Ab
BbR Boom
holding valve Bb
Relief valve
XBb2 XBb1
Boom 1
Boom 2 XAb1
LCb2 LCb
XAb2
Bs
As CP1 AtL
XAs
BtL
Swing XAtL
XBs Travel RH
LCs XBtL
Pns
Dr4 CPG
(dr#) Px
CP2 CT2
Btr
(PTb) (Pta)
XAtr
XBtr CMR1 Pz
CT1
Py
PS CMR2 MR
A1 A2
PUMP PILOT
PUMP PUMP
HYDRAULIC TANK
380A3HC10
When the RH control lever is pulled back, the boom spools in the main control valve are moved to
the up position by the pilot oil pressure (XAb1, XAb2) from the remote control valve.
The oil from the A1 and A2 pump flows into the main control valve and then goes to the large
chamber of boom cylinders.
At the same time, the oil from the small chamber of boom cylinders returns to the hydraulic oil tank
through the boom 1 spool in the main control valve. When this happens, the boom goes up.
The excessive pressure in the boom cylinder bottom end circuit is prevented by relief valve.
When the boom is up and the control lever is returned to neutral position, the circuit for the holding
pressure at the bottom end of the boom cylinder is closed by the boom holding valve.
This prevents the hydraulic drift of boom cylinder.
3-15
2. BOOM DOWN OPERATION
ARM BUCKET BOOM
TRAVEL MOTOR
Mu (R4)(P3)
Rs1 Rs2 (P4)
R1
(R1) NR2 NR1
N2
Dra BC1 N1
(dr#) BC2
HVa XBp1
PaL
XBp2
CCo CCk Dr1

Aa
AaR (dr#)
BaR
Ba1
(Ba2)
XBa1 XBa2
Arm 1 Arm 2
XAa1 XAa2
ARC LCa
LCAP2 LCAT2
Pna1
Dr3
(dr#)
(Bo)
BoR Bc
AoR BcR AcR
Ac
(Ao)
PAcs
(XAo)
XAc
(XBo) Drb
LCo LCk (dr#)
Dr2 PbL
Relief valve
(dr#)
AbR CCb HVb
Ab
BbR
Bb
XBb2 XBb1
Boom 1
Boom 2 XAb1
LCb2 LCb
XAb2
Bs
As CP1 AtL
XAs
BtL
Swing XAtL
XBs Travel RH
LCs XBtL
Pns
Dr4 CPG
(dr#) Px
CP2 CT2
Btr
(PTb) (Pta)
XAtr
XBtr CMR1 Pz
CT1
Py
PS CMR2 MR
A1 A2
PUMP PILOT
PUMP PUMP
HYDRAULIC TANK
380A3HC11
When the RH control lever is pushed forward, the boom 1 spool in the main control valve is moved
to the down position by the pilot oil pressure (XBb1, XBb2) from the remote control valve.
The oil from the A2 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 1 and 2 spools in the main control valve.
When the down speed of boom is faster, the oil returned from the large chamber of boom cylinder
combines with the oil from the A2 pump, and flows into the small chamber of the boom cylinder.
This prevents cylinder cavitation by the negative pressure when the A2 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.
3-16
3. ARM IN OPERATION
ARM BUCKET BOOM
TRAVEL MOTOR
Mu (R4)(P3)
Rs1 Rs2 (P4)
R1
(R1) NR2 NR1
N2
Dra BC1 N1
(dr#) BC2
HVa XBp1
PaL
XBp2
Arm holding
valve CCo CCk
Aa Dr1
AaR (dr#)
Make up valve
BaR
Ba1
Relief valve
(Ba2)
XBa1 XBa2
Arm 1 Arm 2
XAa1 XAa2
ARC LCa
LCAP2 LCAT2
Pna1
Dr3
(dr#)
(Bo)
BoR Bc
AoR BcR AcR
Ac
(Ao)
PAcs
(XAo)
XAc
(XBo) Drb
LCo LCk (dr#)
Dr2 PbL
(dr#)
AbR CCb HVb
Ab
BbR
Bb
XBb2 XBb1
Boom 1
Boom 2 XAb1
LCb2 LCb
XAb2
Bs
As CP1 AtL
XAs
BtL
Swing XAtL
XBs Travel RH
LCs XBtL
Pns
Dr4 CPG
(dr#) Px
CP2 CT2
Btr
(PTb) (Pta)
XAtr
XBtr CMR1 Pz
CT1
Py
PS CMR2 MR
A1 A2
PUMP PILOT
PUMP PUMP
HYDRAULIC TANK
380A3HC12
When the LH control lever is pulled back, the arm spools in the main control valve are moved the to
roll in position by the pilot oil pressure (XBa1, XBa2) from the remote control valve.
The oil from the A1 and A2 pump flows into the main control valve and then goes to the large
chamber of arm cylinder.
At the same time, the oil from small chamber of arm cylinder returns to the hydraulic oil tank through
the arm 1 spool in the main control valve. When this happens, the arm rolls in.
The excessive pressure in the arm cylinder head side is prevented by relief valve.
The cavitation which will happen to the head side of the arm cylinder is also prevented by the make-
up valve in the main control valve.
3-17
4. ARM OUT OPERATION
ARM BUCKET BOOM
TRAVEL MOTOR
Mu (R4)(P3)
Rs1 Rs2 (P4)
R1
(R1) NR2 NR1
N2
Dra BC1 N1
(dr#) BC2
HVa XBp1
PaL
XBp2
Arm holding
valve CCo CCk
Aa Dr1
Make up (dr#)
valve AaR Relief BaR
Ba1 valve
(Ba2)
XBa1 XBa2
Arm 1 Arm 2
XAa1 XAa2
ARC LCa
LCAP2 LCAT2
Pna1
Dr3
(dr#)
(Bo)
BoR Bc
AoR BcR AcR
Ac
(Ao)
PAcs
(XAo)
XAc
(XBo) Drb
LCo LCk (dr#)
Dr2 PbL
(dr#)
AbR CCb HVb
Ab
BbR
Bb
XBb2 XBb1
Boom 1
Boom 2 XAb1
LCb2 LCb
XAb2
Bs
As CP1 AtL
XAs
BtL
Swing XAtL
XBs Travel RH
LCs XBtL
Pns
Dr4 CPG
(dr#) Px
CP2 CT2
Btr
(PTb) (Pta)
XAtr
XBtr CMR1 Pz
CT1
Py
PS CMR2 MR
A1 A2
PUMP PILOT
PUMP PUMP
HYDRAULIC TANK
380A3HC13
When the LH control lever is pushed forward, the arm spools in the main control valve are moved to
the roll out position by the pilot oil pressure (XAa1, XAa2) from the remote control valve.
The oil from the A1 and A2 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 spools in the main control valve. When this happens, the arm rolls out.
The excessive pressure in the arm cylinder rod side is prevented by relief valve.
When the arm is roll out and the control lever is returned to neutral position, the circuit for the holding
pressure at the rod side of the arm cylinder is closed by the arm holding valve.
The cavitation which will happen to the rod side of the arm cylinder is also prevented by the make-up
valve in the main control valve.
3-18
5. BUCKET IN OPERATION
ARM BUCKET BOOM

TRAVEL MOTOR
Mu (R4)(P3)
Rs1 Rs2 (P4)
R1
(R1) NR2 NR1
N2
Dra BC1 N1
(dr#) BC2
HVa XBp1
PaL
XBp2
CCo CCk Dr1

Aa
AaR (dr#)
BaR
Ba1
(Ba2)
XBa1 XBa2
Arm 1 Arm 2
XAa1 XAa2
ARC LCa
LCAP2 LCAT2
Pna1
Dr3
(dr#)
Make up valve
(Bo) Relief valve
BoR Bc
AoR BcR AcR
Ac
(Ao)
PAcs
(XAo)
XAc
(XBo) Drb
LCo LCk (dr#)
Dr2 PbL
(dr#)
AbR CCb HVb
Ab
BbR
Bb
XBb2 XBb1
Boom 1
Boom 2 XAb1
LCb2 LCb
XAb2
Bs
As CP1 AtL
XAs
BtL
Swing XAtL
XBs Travel RH
LCs XBtL
Pns
Dr4 CPG
(dr#) Px
CP2 CT2
Btr
(PTb) (Pta)
XAtr
XBtr CMR1 Pz
CT1
Py
PS CMR2 MR
A1 A2
PUMP PILOT
PUMP PUMP
HYDRAULIC TANK
380A3HC14
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 (XBc) from the remote control valve.
The oil from the A2 pump flows into the main control valve and then goes to the large chamber of
bucket cylinder. The oil from the A1 pump flows into the large chamber of bucket cylinder through
confluence oil passage in the main control valve by bypass cut pilot pressure (XBp2).
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 rolls in.
The excessive pressure in the bucket cylinder head side is prevented by relief valve.
The cavitation which will happen to the head side of the bucket cylinder is also prevented by the
make-up valve in the main control valve.
3-19
6. BUCKET OUT OPERATION
ARM BUCKET BOOM
TRAVEL MOTOR
Mu (R4)(P3)
Rs1 Rs2 (P4)
R1
(R1) NR2 NR1
N2
Dra BC1 N1
(dr#) BC2
HVa XBp1
PaL
XBp2
CCo CCk Dr1

Aa
AaR (dr#)
BaR
Ba1
(Ba2)
XBa1 XBa2
Arm 1 Arm 2
XAa1 XAa2
ARC LCa LCAT2

Pna1 LCAP2
Dr3
Make up
valve
(dr#)
Relief
(Bo) valve Bc
BoR
AoR BcR AcR
Ac
(Ao)
PAcs
(XAo)
XAc
(XBo) Drb
LCo LCk (dr#)
Dr2 PbL
(dr#)
AbR CCb HVb
Ab
BbR
Bb
XBb2 XBb1
Boom 1
Boom 2 XAb1
LCb2 LCb
XAb2
Bs
As CP1 AtL
XAs
BtL
Swing XAtL
XBs Travel RH
LCs XBtL
Pns
Dr4 CPG
(dr#) Px
CP2 CT2
Btr
(PTb) (Pta)
XAtr
XBtr CMR1 Pz
CT1
Py
PS CMR2 MR
A1 A2
PUMP PILOT
PUMP PUMP
HYDRAULIC TANK
380A3HC15
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 (XAc) from the remote control valve.
The oil from the A2 pump flows into the main control valve and then goes to the small chamber of
bucket cylinder. The oil from the A1 pump flows into the large chamber of bucket cylinder through
confluence oil passage in the main control valve by bypass cut pilot pressure (XBp2).
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 rolls out.
The excessive pressure in the bucket cylinder rod side is prevented by relief valve.
The cavitation which will happen to the rod side of the bucket cylinder is also prevented by the make-
up valve in the main control valve.
3-20
7. SWING OPERATION
ARM BUCKET BOOM
TRAVEL MOTOR
Mu (R4)(P3)
Rs1 Rs2 (P4)
R1
(R1) NR2 NR1
SWING MOTOR N2
Dra BC1 N1
(dr#) BC2
HVa XBp1
SRG ARG PaL
XBp2
Dr(RG) ( 2 ,Px)
SH CCo CCk
SGo Aa Dr1
AaR (dr#)
PG BaR
Ba1
(Ba2)
Dr
XBa1 XBa2
Arm 1 Arm 2
XAa1 XAa2
(dr#)
ARC LCa
LCAP2 LCAT2
Pna1
Dr3
(dr#)
(Bo)
BoR Bc
AoR BcR
C AcR
( 2 ,Rs1) Ac
(Ao)
PAcs
PA PB (XAo)
XAc
Option Bucket XBc
(XBo) Drb
LCo LCk (dr#)
Dr2 PbL
(dr#)
AbR CCb HVb
Ab
BbR
Bb
XBb2 XBb1
Boom 1
A(CCW) B(CW) Boom 2 XAb1
LCb2 LCb
XAb2
Bs
As CP1 AtL
XAs
BtL
Swing XAtL
XBs Travel RH
LCs XBtL
Pns
Dr4 CPG
(dr#) Px
CP2 CT2
Btr
(PTb) (Pta)
XAtr
XBtr CMR1 Pz
CT1
Py
PS CMR2 MR
(2) (1) (4) (3)
P1 T1 A1 A2
PUMP PUMP PILOT
P2 T2 PUMP
P3 T3
(1) (3) (2) (4) (3) (1) (2) (4) P T
Dr#,dr#
PG(S/Motor)
A5 A4 A2 A1 P4
Psv1(M/PUMP)
Pna1 P2 P(2-EPPR)
XAa1 XAa2
C T

XBb2
XAb1 XAb2 PAcs XBb1
380A3HC16
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 (XAs, XBs) from the remote control valve.
The oil from the A1 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 upper structure swings to the left or right.
The swing parking brake, make up valve and the motor brake valve are provided in the swing motor.
The cavitation which will happen to the swing motor is also prevented by the make up valve in the
swing motor itself. Also the swing operation preference function is operated by the pilot pressure
Pna1 (refer to page 3-12).
3-21
SWING CIRCUIT OPERATION
SWING MOTOR DEVICE

PARKING BRAKE
SRG ARG
Dr(RG) BRAKE RELEASE VALVE
SGo SH
BRAKE OFF
PG
Dr BRAKE ON
(dr#)
MAKE UP VALVE
MOTOR BRAKE VALVE

C
MAKE UP PORT
PA PB
ANTI-INVERSION VALVE
A(CCW) B(CW)
TO/FROM MAIN CONTROL VALVE
380A3HC17
1) MOTOR BRAKE VALVE

Motor brake valve for the swing motor limits to cushion the starting and stopping pressure of swing
operation and controls the swing motor operating pressure.
2) MAKE UP VALVE
The make up valves prevent cavitation by supplying return oil to the vacuum side of the motor.
3) PARKING BRAKE
This is function as a parking brake only when all of the RCV lever (except travel pedal) are not
operated.
PARKING BRAKE "OFF" OPERATION
The parking brake is released by the pilot pressure oil from the pilot pump.
When one of the RCV lever (except travel 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 all of the RCV lever placed in the neutral position, the pressure of the pilot oil passage down.
Then the brake release valve returned to the neutral position and the oil is returned from the brake
piston to the tank. And the brake is set to 'ON".
4) Anti-inversion VALVE
This anti-inversion valve absorbs shocks produced as swing motion stops and reduced oscillation
cause by swing motion.
3-22
8. TRAVEL FORWARD AND REverSE OPERATION
ARM BUCKET BOOM
4 4
[LH] [RH]
Dr Dr Dr Dr
Mu (R4)(P3)
Rs1 Rs2 (P4)
PR PR
R1
Pi Pi (R1) NR2 NR1
Pi Pi
N2
N N Dra BC1 N1
(dr#) BC2
HVa XBp1
PA PA PaL
PB PB XBp2
CCo CCk Dr1

Aa
AaR (dr#)
BaR
B A A B Ba1
(Ba2)
P XBa1 XBa2
A D Arm 1 Arm 2
C
Dr
B 12 XAa1 XAa2
Pk
ARC LCa
LCAP2 LCAT2
Pna1
(dr#) Dr3
(dr#)
(Bo)
BoR Bc
AoR BcR AcR
Ac
(Ao)
PAcs
(XAo)
XAc
(XBo) Drb
LCo LCk (dr#)
Dr2 PbL
(dr#)
AbR CCb HVb
Ab
BbR
Bb
XBb2 XBb1
Boom 1
Boom 2 XAb1
LCb2 LCb
XAb2
Bs
As CP1 AtL
XAs
BtL
Swing XAtL
XBs Travel RH
LCs XBtL
Pns
Dr4 CPG
(dr#) Px
CP2 CT2
Btr
(PTb) (Pta)
XAtr
XBtr CMR1 Pz
CT1
Py
PS CMR2 MR
(2) (1) (4) (3)
P1 T1 A1 A2
PUMP PUMP PILOT
P2 T2 PUMP
P3 T3
(1) (3) (2) (4) (3) (1) (2) (4) P T
Dr#,dr#
PG(S/Motor)
A5 A4 A2 A1 P4
Psv1(M/PUMP)
Pna1 P2 P(2-EPPR)
XAa1 XAa2
C T

XBb2 TRAVEL SPEED
XAb1 XAb2 PAcs XBb1 SOLENOID VALVE
380A3HC18
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 (XAtr, XBtr, XAtL,
XBtL) from the remote control valve.
The oil from the each pump flows into the main control valve and then goes to the each travel motor
through the turning joint.
The return oil from both travel motors returns to the hydraulic oil tank through the turning joint and
the travel spools in the main control valve.
When this happens, the machine moves to the forward or reverse.
3-23
TRAVEL CIRCUIT OPERATION
TRAVEL MOTOR DEVICE
[LH] [RH]
Dr Dr Dr Dr
PR PR
Pi Pi
Pi Pi
N N
PA PA
PB PB
OVERLOAD
RELIEF VALVE
B A A B
P COUNTER BALANCE
A
C
Dr D
B 12 VALVE
Pk
(dr#)
TO/FROM MAIN CONTROL VALVE
380A3HC19
valves are provided on travel motors to offer the following functions.
1) COUNTER BALANCE VALVE

When stopping the motor of slope descending, this valve to prevent the motor over run.
2) OVERLOAD RELIEF VALVE
Relief valve limit the circuit pressure below 370 kgf/cm2 (5260 psi) for the travel motor type 1 and 360
kgf/cm2 (5120 psi) for the travel motor type 2 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.
3-24
GROUP 5 COMBINED OPERATION
1. OUTLINE
ARM BUCKET BOOM
TRAVEL MOTOR
Mu (R4)(P3)
Rs1 Rs2 (P4)
R1
(R1) NR2 NR1
N2
Dra BC1 N1
(dr#) BC2
HVa XBp1
PaL
XBp2
CCo CCk Dr1

Aa
AaR (dr#)
BaR
Ba1
(Ba2)
XBa1 XBa2
Arm 1 Arm 2
XAa1 XAa2
ARC LCa
LCAP2 LCAT2
Pna1
Dr3
(dr#)
(Bo)
BoR Bc
AoR BcR AcR
Ac
(Ao)
PAcs
(XAo)
XAc
(XBo) Drb
LCo LCk (dr#)
Dr2 PbL
(dr#)
AbR CCb HVb
Ab
BbR
Bb
XBb2 XBb1
Boom 1
Boom 2 XAb1
LCb2 LCb
XAb2
Bs
As CP1 AtL
XAs
BtL
Swing XAtL
XBs Travel RH
LCs XBtL
Pns
Dr4 CPG
(dr#) Px
CP2 CT2
Btr
Travel Straight
Atr Travel LH (PTb) (Pta)
XAtr
XBtr CMR1 Pz
CT1
Py
PS STRAIGHT CMR2 MR
TRAVEL
SPOOL
A1 A2
PUMP PILOT
PUMP PUMP
HYDRAULIC TANK
380A3HC20
The oil from the A1 and A2 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 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.
3-25
2. COMBINED SWING AND BOOM up OPERATION
ARM BUCKET BOOM
TRAVEL MOTOR
Mu (R4)(P3)
Rs1 Rs2 (P4)
R1
(R1) NR2 NR1
N2
Dra BC1 N1
(dr#) BC2
HVa XBp1
PaL
XBp2
CCo CCk Dr1

Aa
AaR (dr#)
BaR
Ba1
(Ba2)
XBa1 XBa2
Arm 1 Arm 2
XAa1 XAa2
ARC LCa
LCAP2 LCAT2
Pna1
Dr3
(dr#)
(Bo)
BoR Bc
AoR BcR AcR
Ac
(Ao)
PAcs
(XAo)
XAc
(XBo) Drb
LCo LCk (dr#)
Dr2 PbL
(dr#)
AbR CCb HVb
Ab
BbR Boom
holding valve Bb
Relief valve
XBb2 XBb1
Boom 1
Boom 2 XAb1
LCb2 LCb
XAb2
Bs
As CP1 AtL
XAs
BtL
Swing XAtL
XBs Travel RH
LCs XBtL
Pns
Dr4 CPG
(dr#) Px
CP2 CT2
Btr
(PTb) (Pta)
XAtr
XBtr CMR1 Pz
CT1
Py
PS CMR2 MR
A1 A2
PUMP PILOT
PUMP PUMP
HYDRAULIC TANK
380A3HC21
When the swing and boom up functions are operated simultaneously, the swing spool and boom
spools in the main control valve are moved to the functional position by the pilot oil pressure (XAs,
XBs, XAb1, XAb2) from the remote control valve.
The oil from the A1 pump flows into the swing motor through swing spool and the boom cylinder
through boom 2 spool.
The oil from the A2 pump flows into the boom cylinders through the boom 1 spool in the P1 housing
side of the main control valve. The upper structure swings and the boom is operated.
Refer to page 3-8 for the boom priority system.
3-26
3. COMBINED SWING AND ARM OPERATION
ARM BUCKET BOOM

TRAVEL MOTOR
Mu (R4)(P3)
Rs1 Rs2 (P4)
R1
(R1) NR2 NR1
N2
Dra BC1 N1
(dr#) BC2
HVa XBp1
PaL
XBp2
Arm holding
valve CCo CCk
Aa Dr1
AaR (dr#)
Make up valve
BaR
Ba1
Relief valve
(Ba2)
XBa1 XBa2
Arm 1 Arm 2
XAa1 XAa2
ARC LCa
LCAP2 LCAT2
Pna1
Dr3
(dr#)
(Bo)
BoR Bc
AoR BcR AcR
Ac
(Ao)
PAcs
(XAo)
XAc
(XBo) Drb
LCo LCk (dr#)
Dr2 PbL
(dr#)
AbR CCb HVb
Ab
BbR
Bb
XBb2 XBb1
Boom 1
Boom 2 XAb1
LCb2 LCb
XAb2
Bs
As CP1 AtL
XAs
BtL
Swing XAtL
XBs Travel RH
LCs XBtL
Pns
Dr4 CPG
(dr#) Px
CP2 CT2
Btr
(PTb) (Pta)
XAtr
XBtr CMR1 Pz
CT1
Py
PS CMR2 MR
A1 A2
PUMP PILOT
PUMP PUMP
HYDRAULIC TANK
380A3HC22
When the swing and arm functions are operated simultaneously, the swing spool and arm spools in
the main control valve are moved to the functional position by the pilot oil pressure (XAs, XBs, XAa1,
XAa2, XBa1, XBa2) from the remote control valve.
The oil from the A1 pump flows into the swing motor through swing spool and the arm cylinder
through arm 1 spool.
The oil from the A2 pump flows into the arm cylinder through the arm 2 spool of the P1 housing side
of the main control valve. The upper structure swings and the arm is operated.
Refer to page 2-45 for the swing operation preference function.
3-27
4. COMBINED SWING AND BUCKET OPERATION
ARM BUCKET BOOM

TRAVEL MOTOR
Mu (R4)(P3)
Rs1 Rs2 (P4)
R1
(R1) NR2 NR1
N2
Dra BC1 N1
(dr#) BC2
HVa XBp1
PaL
XBp2
CCo CCk Dr1

Aa
AaR (dr#)
BaR
Ba1
(Ba2)
XBa1 XBa2
Arm 1 Arm 2
XAa1 XAa2
ARC LCa
LCAP2 LCAT2
Pna1
Dr3
(dr#)
(Bo)
BoR Bc
AoR BcR AcR
Ac
(Ao)
PAcs
(XAo)
XAc
(XBo) Drb
LCo LCk (dr#)
Dr2 PbL
(dr#)
AbR CCb HVb
Ab
BbR
Bb
XBb2 XBb1
Boom 1
Boom 2 XAb1
LCb2 LCb
XAb2
Bs
As CP1 AtL
XAs
BtL
Swing XAtL
XBs Travel RH
LCs XBtL
Pns
Dr4 CPG
(dr#) Px
CP2 CT2
Btr
(PTb) (Pta)
XAtr
XBtr CMR1 Pz
CT1
Py
PS CMR2 MR
A1 A2
PUMP PILOT
PUMP PUMP
HYDRAULIC TANK
380A3HC23
When the swing and bucket functions are operated simultaneously, the swing spool and bucket spool
in the main control valve are moved to the functional position by the pilot oil pressure (XAs, XBs,
XAc, XBc) from the remote control valve.
The oil from the A1 pump flows into the swing motor through the swing spool in the P2 housing side
of the main control valve.
The oil from the A2 pump flows into the bucket cylinder through the bucket spool in the P1 housing
side of the main control valve.
The upper structure swings and the bucket is operated.
3-28
5. COMBINED SWING AND TRAVEL OPERATION
ARM BUCKET BOOM
TRAVEL MOTOR
Mu (R4)(P3)
Rs1 Rs2 (P4)
R1
(R1) NR2 NR1
N2
Dra BC1 N1
(dr#) BC2
HVa XBp1
PaL
XBp2
CCo CCk Dr1

Aa
AaR (dr#)
BaR
Ba1
(Ba2)
XBa1 XBa2
Arm 1 Arm 2
XAa1 XAa2
ARC LCa
LCAP2 LCAT2
Pna1
Dr3
(dr#)
(Bo)
BoR Bc
AoR BcR AcR
Ac
(Ao)
PAcs
(XAo)
XAc
(XBo) Drb
LCo LCk (dr#)
Dr2 PbL
(dr#)
AbR CCb HVb
Ab
BbR
Bb
XBb2 XBb1
Boom 1
Boom 2 XAb1
LCb2 LCb
XAb2
Bs
As CP1 AtL
XAs
BtL
Swing XAtL
XBs Travel RH
LCs XBtL
Pns
Dr4 CPG
(dr#) Px
CP2 CT2
Btr
Atr
Travel Straight
Travel LH (PTb) (Pta)
XAtr
XBtr CMR1 Pz
CT1
Py
PS STRAIGHT CMR2 MR
TRAVEL
SPOOL
A1 A2
PUMP PILOT
PUMP PUMP
HYDRAULIC TANK
380A3HC24
When the swing and travel functions are operated simultaneously, the swing spool and travel spools
XAtr, XBtr, XAtL, XBtL) from the remote control valve and straight travel spool is pushed to the right
by the pilot oil pressure from the pilot pump.
The oil from the A1 pump flows into the travel motors through the RH travel spool of the P2 housing
side and the LH travel spool of the P1 housing side via the straight travel spool.
The oil from the A2 pump flows into the swing motor through the swing spool via the straight travel
spool.
When the pressure of the travel motors is lower than the pressure of the swing motor, some oil from
the A2 pump flows into the travel motors through the check valve and orifice in the straight travel
spool. This prevents the rapid slowdown of the travel.
The upper structure swings and the machine travels straight.
3-29
6. COMBINED BOOM AND TRAVEL OPERATION
ARM BUCKET BOOM
TRAVEL MOTOR
Mu (R4)(P3)
Rs1 Rs2 (P4)
R1
(R1) NR2 NR1
N2
Dra BC1 N1
(dr#) BC2
HVa XBp1
PaL
XBp2
CCo CCk Dr1

Aa
AaR (dr#)
BaR
Ba1
(Ba2)
XBa1 XBa2
Arm 1 Arm 2
XAa1 XAa2
ARC LCa
LCAP2 LCAT2
Pna1
Dr3
(dr#)
(Bo)
BoR Bc
AoR BcR AcR
Ac
(Ao)
PAcs
(XAo)
XAc
(XBo) Drb
LCo LCk (dr#)
Dr2 PbL
(dr#)
AbR CCb HVb
Ab
BbR
Bb
XBb2 XBb1
Boom 1
Boom 2 XAb1
LCb2 LCb
XAb2
Bs
As CP1 AtL
XAs
BtL
Swing XAtL
XBs Travel RH
LCs XBtL
Pns
Dr4 CPG
(dr#) Px
CP2 CT2
Btr
Atr
Travel Straight
Travel LH (PTb) (Pta)
XAtr
XBtr CMR1 Pz
CT1
Py
PS STRAIGHT CMR2 MR
TRAVEL
SPOOL
A1 A2
PUMP PILOT
PUMP PUMP
HYDRAULIC TANK
380A3HC25
When the boom and travel functions are operated simultaneously, the boom spools and travel spools
XAb1, XAb2, XBb1, XBb2) from the remote control valve and the straight travel spool is pushed to
the right by the oil pressure from pilot pump.
The oil from the A2 pump flows into the boom cylinders through the boom 2 spool and boom 1 spool
via the parallel and confluence oil passage in case boom up operation.
When the pressure of the travel motors is lower than the pressure of the boom cylinders, some oil
from the A2 pump flows into the travel motors through the check valve and orifice in the straight
travel spool. This prevents the rapid slowdown of the travel.
The boom is operated and the machine travels straight.
3-30
7. COMBINED ARM AND TRAVEL OPERATION
ARM BUCKET BOOM
TRAVEL MOTOR
Mu (R4)(P3)
Rs1 Rs2 (P4)
R1
(R1) NR2 NR1
N2
Dra BC1 N1
(dr#) BC2
HVa XBp1
PaL
XBp2
CCo CCk Dr1

Aa
AaR (dr#)
BaR
Ba1
(Ba2)
XBa1 XBa2
Arm 1 Arm 2
XAa1 XAa2
ARC LCa
LCAP2 LCAT2
Pna1
Dr3
(dr#)
(Bo)
BoR Bc
AoR BcR AcR
Ac
(Ao)
PAcs
(XAo)
XAc
(XBo) Drb
LCo LCk (dr#)
Dr2 PbL
(dr#)
AbR CCb HVb
Ab
BbR
Bb
XBb2 XBb1
Boom 1
Boom 2 XAb1
LCb2 LCb
XAb2
Bs
As CP1 AtL
XAs
BtL
Swing XAtL
XBs Travel RH
LCs XBtL
Pns
Dr4 CPG
(dr#) Px
CP2 CT2
Btr
(PTb) (Pta)
XAtr
XBtr CMR1 Pz
CT1
Py
PS CMR2 MR
A1 A2
PUMP PILOT
PUMP PUMP
HYDRAULIC TANK
380A3HC26
When the arm and travel functions are operated simultaneously, the arm spools and travel spools in
the main control valve are moved to the functional position by the pilot oil pressure (XAs, XBs, XAa1,
XAa2, XBa1, XBa2) from the remote control valve and the straight travel spool is pushed to the right
by the oil pressure from pilot pump.
The oil from the A2 pump flows into the arm cylinders through the arm 1 spool and arm 2 spool via
the parallel and confluence oil passage.
When the pressure of the travel motors is lower than the pressure of the arm cylinder, some oil from
the A2 pump flows into the travel motors through the check valve and orifice in the straight travel
spool. This prevents the rapid slowdown of the travel.
The arm is operated and the machine travels straight.
3-31
8. COMBINED BUCKET AND TRAVEL OPERATION
ARM BUCKET BOOM
TRAVEL MOTOR
Mu (R4)(P3)
Rs1 Rs2 (P4)
R1
(R1) NR2 NR1
N2
Dra BC1 N1
(dr#) BC2
HVa XBp1
PaL
XBp2
CCo CCk Dr1

Aa
AaR (dr#)
BaR
Ba1
(Ba2)
XBa1 XBa2
Arm 1 Arm 2
XAa1 XAa2
ARC LCa
LCAP2 LCAT2
Pna1
Dr3
(dr#)
(Bo)
BoR Bc
AoR BcR AcR
Ac
(Ao)
PAcs
(XAo)
XAc
(XBo) Drb
LCo LCk (dr#)
Dr2 PbL
(dr#)
AbR CCb HVb
Ab
BbR
Bb
XBb2 XBb1
Boom 1
Boom 2 XAb1
LCb2 LCb
XAb2
Bs
As CP1 AtL
XAs
BtL
Swing XAtL
XBs Travel RH
LCs XBtL
Pns
Dr4 CPG
(dr#) Px
CP2 CT2
Btr
(PTb) (Pta)
XAtr
XBtr CMR1 Pz
CT1
Py
PS CMR2 MR
A1 A2
PUMP PILOT
PUMP PUMP
HYDRAULIC TANK
380A3HC27
When the bucket and travel functions are operated simultaneously, the bucket spool and travel
spools in the main control valve are moved to the functional position by the pilot oil pressure (XAs,
XBs, XAc, XBc) from the remote control valve, and the straight travel spool is pushed to the right by
the oil pressure from pilot pump. The oil from the A1 pump flows into the travel motors through the
RH travel spool of the P2 housing side and the LH travel spool of the P1 housing side via the straight
travel spool of the control valve.
The oil from the A2 pump flows into the bucket cylinder through the bucket spool via the confluence
oil passage.
When the pressure of the travel motors is lower than the pressure of the bucket cylinder, some oil
from the A2 pump flows into the travel motors through the check valve and orifice in the straight
travel spool. This prevents the rapid slowdown of the travel.
The bucket is operated and the machine travels straight.
3-32
9. COMBINED BOOM UP AND BUCKET OPERATION
ARM BUCKET BOOM
TRAVEL MOTOR
Mu (R4)(P3)
Rs1 Rs2 (P4)
R1
(R1) NR2 NR1
N2
Dra BC1 N1
(dr#) BC2
HVa XBp1
PaL
XBp2
CCo CCk Dr1

Aa
AaR (dr#)
BaR
Ba1
(Ba2)
XBa1 XBa2
Arm 1 Arm 2
XAa1 XAa2
ARC LCa
LCAP2 LCAT2
Pna1
Dr3
(dr#)
Bucket in stroke
(Bo) limit spool
BoR Bc
AoR BcR AcR
Ac
(Ao)
PAcs
(XAo)
XAc
(XBo) Drb
LCo LCk (dr#)
Dr2 PbL
(dr#)
AbR CCb HVb
BbR Ab
Bb
XBb2 XBb1
Boom 1
Boom 2 XAb1
LCb2 LCb
XAb2
Bs
As CP1 AtL
XAs
BtL
Swing XAtL
XBs Travel RH
LCs XBtL
Pns
Dr4 CPG
(dr#) Px
CP2 CT2
Btr
(PTb) (Pta)
XAtr
XBtr CMR1 Pz
CT1
Py
PS CMR2 MR
A1 A2
PUMP PILOT
PUMP PUMP
HYDRAULIC TANK
380A3HC28
When the boom up and bucket functions are operated simultaneously, each spool in the main control
valve is moved to the functional position by the pilot oil pressure (XAb1, XAb2, XAc, XBc) from the
remote control valve.
The oil from the A1 pump flows into the boom cylinders through the boom 2 spool in the P2 housing
side. The oil from the A2 pump flows into the boom cylinders and bucket cylinder through the boom 1
spool, bucket spool and the parallel and confluence oil passage in the P1 housing side.
Also, when the boom up and bucket in functions are operated simultaneously, the boom up operation
preference function is operated by the pilot pressure PAcs and then the bucket spool transfers in the
half stroke not full stroke (Refer to page 2-42). Therefore, the most of pressurized oil flows into boom
1 spool than the bucket spool to make the boom up operation more preferential.
The boom and bucket are operated.
3-33
Group 1 Component Location ----------------------------------------------------------------------------------------- 4-1

Group 2 Electrical Circuit ------------------------------------------------------------------------------------------------- 4-3
Group 3 Electrical Component Specification ----------------------------------------------------------------- 4-23
Group 4 Connectors --------------------------------------------------------------------------------------------------------- 4-36
GROUP 1 COMPONENT LOCATION
1. LOCATION 1
20 19
21 24
22 25
23 26
IR
A
27
18
1
2
3
4 17
5 16
6
7
8 14
13
12
11
10
9
380A4EL01
1 Cigar lighter 10 Emergency engine stop switch 20 Lower wiper & washer switch
2 Radio & USB player 11 One touch decel switch 21 Boom floating switch
3 Jod dial module 12 RS232 & J1939 service socket 22 Swing lock switch
4 Horn switch 13 Fuse & relay box 23 Free/fine swing switch
5 Cluster 14 Master switch 24 Quick clamp switch
6 Breaker operation switch 16 Seat heater switch 25 Exhaust system cleaning switch
7 Starting switch 17 Service socket 26 Air compressor switch
8 Service meter 18 Speaker 27 Rear view camera
9 Power max switch 19 Travel straight switch
4-1
2. LOCATION 2
24 4
1
A1
A
1
11
A5 2
26 1
SOLENOID VALVE BOOM SAFETY VALVE CAB
BOOM
33 25 10
8 9
12
2-EPPR VALVE a4
2 13
a4
a2
a1
14
3
15
30
1 5
7 29
27
28
21
Py
16 17 18 23
20 32
g1
19 c
31 j1
h1 1
d1 Px
e2
f1
22
TERMINAL BLOCK MAIN CONTROL VALVE AIR CLEANER

380A4EL02
1 Lamp 12 Start relay 23 Air cleaner sensor

2 Fuel sender 13 Heater relay 24 4 cartridge valve
3 Fuel filler pump 14 Alternator 25 Pump EPPR valve
4 Beacon lamp 15 Travel alarm buzzer 26 Boom priority EPPR valve
5 Battery 16 Arm in pressure sensor 27 United MCU
6 Battery relay 17 Boom up pressure sensor 28 RMCU assy
7 Horn 18 Swing pressure sensor 29 RDU assy
8 P1 pressure sensor 19 Boom down pressure sensor 30 View controller
9 P2 pressure sensor 20 Arm out pressure sensor 31 Bucket in pressure sensor
10 EPPR pressure sensor 21 Attach pressure sensor 32 Bucket out pressure sensor
11 Overload pressure sensor 22 Travel pressure sensor 33 2 EPPR cartridge valve
4-2
N7-12
N5-24
RH-SIDE CN-5
N4-10
NC 1
N7-15
CAN 1
CAN 2
N5-9
NC 2
NC 3
NC 4
UNITED CN-51 34P/KEY-1(DOUBLE LOCK)
G 0.75 U108-1 U108-1 MCU CN-52 34P/KEY-2(SINGLE LOCK)
CAN 2_LO 5
U202
U201
U109
U108
V 0.75 U109-1 U109-1 CN-53 26P
CAN 2_HI 6
Y 0.75 U201 U201 CN-54 34P/KEY-1(SINGLE LOCK)
CAN 1_LO 7
L 0.75 U202 U202 B 0.75 U117
CAN 1_HI 8 CAN_SHIELD CAN 2 51-17 CN-126 CN-15 CD-69
B 0.75 N5-25 B 0.75 U210 U1322 U1322 0.75 Gr
CAN_SH 25 CAN_SHIELD CAN 1 52-10 10 1 A SUPPLY
B 0.75 RW U232 U232 0.75 OrW
CLUSTER_GND 9 9 J 2 B SIG
Gr 1.0 f16 G 0.75 U108 U1312 0.75 Br
CLUSTER_IG 10 CAN #2 Lo 51-08 8 H 3 C RETURN
GY 1.0 f09 V 0.75 U109
CLUSTER_BATT 11 CAN #2 Hi 51-09 7 G CN-237
RL 0.75 N5-12 Y 0.75 U201 U216 U216 0.75 OrW
(A3)
ATT.
CAM POWER 12 CAN #1 Lo 52-01 6 F 5 1
BL 0.75 N5-13 L 0.75 U202 F19 1.5 Or
Service Tool
CAM GND 13 CAN #1 Hi 52-02 5 E 4 2
V 1.0 f15 B
RADIO IG 14 4 D CN-149
GrW 1.0 f20 GrY 0.75 U211 U309 U309 0.75 YL
CAN 2
CAN 1
WIPER IG 16 RS232 #1 TX 52-11 3 C 6 1
RBr 1.0 f08 OrG 0.75 U203
WIPER BATT 18 RS232 #1 RX 52-03 2 B
ATT. PS CONFLUX SOL

2
ATT.
LW 1.0 N5-19 P 0.75 U230
WASHER PUMP 19 PROGRAM DUMP 52-30 1 A CN-150
B 1.0 N7-12 U214 U214 0.75 WG
F13
WIPER GND 21 add 9 1
Y 0.75 N5-22
<HARNESS TWOWAY>
CAM POS 22 15 10 2
(A1/B) (A1)
SOL
L 0.75 N5-23
CAM NEG 23 54-15 PWT SW(PARKING)
2WAY
GrW 0.75 N5-24 N5-241 U419 0.75 RL U208 U208 0.75 VB CN-66
QUICK COUPLING 24 54-19 BREAKER OPERATING SIG 7 1
V 1.5 f32 N5-24 U420 0.75 WL f31 1.0 BrR
DC/DC CVT_24V 26 54-20 BOOM FLOATING SELECT SW 8 2
V 0.75 N4-101 N5-9 U421 0.75 BrL
(A2)
SOL
NC 27 54-21 POWER BOOST SW
B 1.5 N4-101 L 0.75 U105
DC/DC CVT_GND 28 54-23 CRUISE SW FAN Speed (Hyd) 51-05
B 1.5 N4-10 Y 0.75 U106
CABIN_GND 54-24 TRAVEL SPEED SELECTION SW
SAFETY SELECT BREAKER

29 GND(Pulse In) 51-06
f282 WOr 0.75 U113
SOL. POWER 30 54-29 RAM LOCK SW(OFF) PUMP EPPR Pf PS 51-13
B 1.5 YR 0.75 U114
GND 31 54-30 RAM LOCK SW(AUTO) MAIN PUMP P2 PS 51-14
FLASHER B+ 32 54-31 PWT SW(WORKING) FWD PILOT PS 51-20
V 1.5 2.0 R9-87 U432 0.75 LB WG 0.75 U121
CABIN LAMP RY 34 54-32 ONE TOUCH DECEL SIG ARM IN PS 51-21
BOr 0.75 R5-2 LY 0.75 U122
ENG. START 35 NEGATIVE 1(N1) PS 51-22
W 2.0 N5-36 U419 YL 0.75 U127
START KEY_ACC BR 36 53-14 RAM LOCK SW(ON) ARM OUT PS 51-27
B 1.5 U420 N4-162 1.0 OR GrR 0.75 U128
CABIN_GND 37 53-16 SAFETY LEVER SWITCH NEGATIVE 2(N2) PS 51-28
·ELECTRICAL CIRCUIT (1/3)
V 1.5 U320 Or 0.75 U129
f31
BUCKET OUT PS
F19
CABIN LAMP RY 38 53-17 PWT SW(TRAVEL) 51-29
G 1.0 N5-39 U319 0.75 GW
START KEY_ACC BR 39 53-19 HOUR METER(+) WORKING BRAKE PS 51-30
WOr 1.0 R35-861 N4-162 U320 0.75 BW U1323
CAN 2
CAN 1
START KEY_IG 40 53-20 SEAT BELT
GrY 0.75 N5-41 U432 U1322
RX232(2)-TX 41 53-22 TRAVEL LEVER SW(NEUTRAL)
OrG 0.75 N5-42 U421 U1321
RX232(2)-RX 42 53-23 CREEP SW
P 0.75 N5-43 U319 Gr 1.0 U1325
PROGRAM DUMP 43 SENSOR POWER(10V) 51-32
BrW 0.75 N5-45 U206
CAM POWER 45 PUMP CONFLUX SOL.
YG 0.75 N5-46 P 0.75 U209
CAM0 LIN 46 31 TRAVEL BUZZER 52-09
Br 0.75 N5-47
CAM0 LVDS POS 47 51-04 GND(Pulse in) PUMP FLOW SYNC SOL. 52-04
Or 0.75 N5-48 GB 0.75 U205
CAM0 LVDS NEG 48 51-05 FAN Speed (Hyd) TRAVEL SPEED SOL 52-05
BL 0.75 N5-49 YG 0.75 U207 CD-52
CAM0 GND 49 51-06 GND(Pulse in) ARM REGEN SOL 52-07 U106 U106 0.8 Y
1
GROUP 2 HYDRAULIC CIRCUIT
GrW 1.5 R85-5 VB 0.75 U208 m

FAN
BEACON LAMP 50 51-07 Engine speed ATT BREAKER SOL 52-08 U105 U105 0.8 L rp
GW 0.75 U319 WG 0.75 U214 2
HOUR METER SIG 51 51-11 Spare (Resistor) 2 WAY SELECT SOL 52-14 U1E
OrW 0.75 U216 CN-154
GREASE RESET 52 51-12 Spare (Resistor) ATT CONFLUX SOL. 52-16 U4341 U4341 0.8 V
Or 0.75 N5-53 2
AIR COMP RY 53 51-13 Pump eppr (Pf) PS CREEP SOL. 52-17 U406 U406 0.8 G
SPEED FAN
LB 0.75 N5-54 GB 0.75 U218 1

AIR COMP RY 54 51-18 NC SWING PS 52-18
LOr 0.75 N9391 GrB 0.75 U219
DPF REGEN 55 51-23 Coolant Temp. WORKING PS 52-19
V 0.75 N9362
COOLING
DPF COM 56 51-27 Arm Out PS

VOr 0.75 N9387
DPF INHIBIT 57 51-29 Bucket Out PS REV. PILOT PS 52-20
GREASE LAMP 58 51-34 Sensor 5V(2) OPT PILOT PS 52-21
WOr 1.5 f04 LOr 0.75 U222
ROOM LAMP 24V 59 MAIN PUMP(P1) PS 52-22
Y 0.75 N5-15 U206 0.75 Gr GOr 0.75 U223
WIPER DRIVE 15 52-06 SAFETY SOL BOOM UP PILOT PS 52-23
Or 0.75 N5-17
CAN 2
CAN 1
WASHER SIG. 17 52-12 NC
L 0.75 N5-20 WBr 0.75 U225
WIPER INT. 20 52-14 Spare(Fan Reverse) BOOM CYL. ROD PS 52-25
P 1.0 U119
FUEL LEVEL 33 52-33 Accelerator Sig TRANSMISSION OIL PS 52-26
B 1.5 Lg 0.75 U227
CONT._GND 44 TRAVEL PS 52-27 0.75 Gr
CD-86
ROr 0.75 R13-871 G 0.75 U228 U1325
ILLUMINATION 60 53-02 Fan Reverse State OVERLOAD PS 52-28 A SUPPLY
U127 U127 0.75 YL
OUT
ARM
53-03 Preheat Relay BRAKE OIL PS 52-29 B SIG

U1312 0.75 Br
RH CONSOLE CN-8 53-15 Reverse SW(auto) C RETURN
1.0 WG 0.75 U231
GND-HAPTIC 1 53-16 Travel Alarm SW BOOM DOWN PS 52-31 CD-87
V 0.75 U109-2 U109-2 OrW 0.75 U232 U1325 0.75 Gr
CAN 2_HI 2 53-18 Battery relay(+) ATT PILOT PS 52-32 A SUPPLY
G 0.75 U108-2 U108-2 U129 U129 0.75 Or
OUT
CAN 2_LO 3 53-20 Reverse Fan SW(on) ATT EPPR1 2SE PS 52-34 B SIG
B 0.75 U1312 0.75 Br
CAN_SHIELD 4 53-24 NC C RETURN
NC 5 53-25 Governor motor(+) CD-85
RG 1.0 f091 LBr 0.75 U305 U1325 1.0 U1325 0.75 Gr
HAPTIC_BATT 6 53-26 Governor motor(-) BOOM FLOATING ROD-TK SOL 53-05 A SUPPLY
WR 1.0 f161 GrL 0.75 U306 U231 U231 0.75 WG
HAPTIC_IG 7 BOOM FLOATING HEAD-TK SOL 53-06 B SIG
Gr 0.75 N16-3 LY 0.75 U308 U1312 1.0 U1312 0.75 Br
BUCKET BOOM
DOWN
5V-DIAL_ECM 8 54-05 Boom Prior eppr(-) BOOM DOWN CUTOFF SOL 53-08 C RETURN
GW 0.75 N16-2 YL 0.75 U309
SIG-DIAL_ECM 9 54-06 Cool Fan eppr(-) ATT SAFETY SOL 53-09 CD-35
BL 0.75 N16-1 GB 0.75 U310 U1323 1.0 U1323 0.75 Gr
IN
GND-DIAL_ECMC 10 54-07 Straight eppr(-) POWER BOOST SOL 53-10 A SUPPLY

U315 U315 0.75 GW
54-11 Start Sig(SCANIA) RAM LOCK SOL. 53-12 B SIG
GW 0.75 U315 U1311 1.0 U1311 0.75 Br
RH CONSOLE CN-7 54-12 Water level sw BUCKET IN 53-15 C RETURN
BUCKET
WG 1.5 f29
CIGAR 24V 2 54-16 Engine oil PS CD-24
ROr 1.5 f27 U1323 0.75 Gr
CAN 2
CAN 1
AIR SEAT 24V 9 A SUPPLY
BrG 1.5 f301 U218 U218 0.75 GB
SWITCH POWER 8 B SIG
YW 0.75 N7-12 LW 0.75 U401 U1311 0.75 Br
SWING
SWITCH, STRAIGHT 12 PUMP SHIFT EPPR(-) 54-01 C RETURN

ROr 0.75 R13-872 WBr 0.75 U402
ILLUMINATION 1 P1 REGULATOR EPPR(-) 54-02 CD-32
Br 0.75 N7-04 Or 0.75 U403 U1323 0.75 Gr
LOW WIPER SW_PF 4 P2 REGULATOR EPPR(-) 54-03 A SUPPLY
UP
BrOr 0.75 N7-05 LB 0.75 U404 U223 U223 0.75 GOr

LOW WIPER SW_LOW 5 BOOM PRIORITY EPPR- 54-04 B SIG
BW 0.75 N7-06 0.75 U1311 0.75 Br
BOOM
GrG U406
LOW WIPER _WASHER 6 Cooling Fan eppr(-) 54-06 C RETURN
GrG 0.75 U409
AUTOGREASE SW 7 ATT RELIEF SET EPPR1(-) 54-09 CD-90
BY 0.75 U410 U1323 0.75 Gr
AUTOGREASE SW 11 ATT RELIEF EPPR2(-) 54-10 A SUPPLY
YG 0.75 U321 U4171 U121 U121 0.75 WG
ARM
SWING FINE SIG B SIG

IN PS
13
LY 0.75 N7-15 N9391 BL 1.0 U417 U1311 0.75 Br
SWING LOCK SIG. 15 ATT RELIEF EPPR(+) 54-17 C RETURN
B 1.5 N9362
A1
CIGAR GND 3 CRUISE EPPR(+) 54-25 CN-419

B 1.5 N9387 Br 0.75 U426 G5
SW& AIR SEAT GND 14 P2 REGULATOR EPPR(+) 54-26 1
GrL 0.75 U427
NC 10 P1 REGULATOR EPPR(+) 54-27 2
RW 0.75 U428
PUMP SHIFT EPPR(+) 54-28 CN-14 CN-420
U4341 1.5 B
A2
RH CONSOLE CN-6 4 1
GrY 0.75 N5-41 VB 0.75 U434 N7-15 1.5
RX232(2)-TX 1 BOOM PRIORITY EPPR+ 54-34 3 2
B 1.0 U206
JOYSTIC & SW GND 7 CN-421
BrB 0.75 R85-5
A3
MCU_RETURN 2 1
WL 0.75 U420 N5-36
BOOM FLOAT DOWN 3 2
Or 1.5 f281 R9-87
CAN 2
CAN 1
POWER_SWITCH 4 CN-370
OrG 0.75 N5-42 YG 0.75 U321 U321 U321 0.75 YG
RX232(2)-RX 5 SWING FINE SELEC SW 53-21 1 1
PARK PARK PARK FINE
RL 0.75 U419 f29 f31 0.75 BrR

BREAKER 6 2 2
CONT.
SWING SWING SWING SWING
P 0.75 R2-1 f301 Br 1.0 U131 U1312

HORN RY 8 GND(SENSOR_10V) 51-31
f30 U1311
NC 9
f282 U1E
NC 10
f281
NC 11
R35-861
NC 12 0.75
P N5-43 R35-86
PROGRAM DUMP 13
LB 0.75 F12C
f31
F19
PVG_5V 14 14 9
WL 0.75
PVG_GND 15
Gr 0.75 N3-10 R13-871 U422 0.75 OrW Br 1.0 U433
ROTATE RH, 2-WAY 16 54-22 A/C BLOWER STATE GROUND(EPPR) 54-33
R13-872 U115 0.75 WY
1.5 B
51-15 ALT VOLTAGE

B 1.0 U102
LH CONSOLE CN-4 GND_MAIN 51-02
LB 0.75 N3-7 R2-1 B 1.0
PVG_5V 1 GND_MAIN 51-10
WL 0.75 N3-8
PVG_GND 2 53-01 Urea level full warn.
OrW 0.75 N3-9 U215 0.75 WG BrB 1.0 U125
ROTATE LH 3 52-15 ANTI RESTART RY GND(FOR SENSOR_5V) 51-25
WOr 1.0 R35-86
EM'CY STOP SW 4
BrL 0.75 U421 N4-16
MCU_POWER MAX 5
1.0 BrB
LB 0.75 U432 f16 U213 0.75 V

MCU_DECEL 7 52-13 FUEL WARMER RY
GrW 0.75 N241 f161 RW 1.0 F13
CAN 2
CAN 1
QUICK COUPLER SW 9 KEY IG 24V 51-26
V 0.75 N4-10 f09
QUICK COUPLER SW 10 53-04 WORKING CUTOFF RELAY
BW 0.75 U320 f091 R 1.0
SEAT BELT 11 53-13 TWO-WAY PEDAL SOL BATT POWER_24V 51-01
f15
NC 12 53-11 PARKING RELAY
OrW 1.0 F12C f20
EM'CY STOP SW 13
BrG 1.0 f30 f08
SWITCH POWER 15 CD-10A
AIR
Or 1.0 N4-16 f32 0.75

SAFETY SOL 16 51-33 POWER_5V OUT Pa
BrB 0.75 N4-161 OrB 1.0 U413
MCU_SIG.GND 6 51-07 FAN CLUTCH PWM AIR CLEANER CLOGGING SW 54-13
BrB 0.75 f04
CLEANER SW
N4-162
MCU_SIG.GND 8 51-03 FAN SPEED INPUT+ CD-2
B 1.0 1.0 U125 R5-2 0.75
SAFETY SW GND 14 1
P 1.0 U119
51-24 GND(Sensor 5V) FUEL LEVEL SENDOR 51-19 2
FUEL
N5-39 0.75
CD-1
1 CD-7
F11 0.75 OrR LgB 1.0 U116 U1323 0.75 Gr
54-18 EPPR POWER 24V HYD TEMP SENDOR 51-16 2 A SUPPLY
LEVEL HYD
(A)
N5-53 U219 U219 0.75 GrB

TEMP
f02
F13
B SIG
N5-54 F13 1.0 RW U1311 0.75 Br
WORK
C RETURN
f02 1.5 R
U321 U321 YG U1323 0.75 Gr
CD-6
A SUPPLY
(A)
U125 U125 BrB U227 U227 0.75 Lg

B SIG
U119 U119 P U1311 0.75 Br
C RETURN
CN-249 add CN-366
N5-22 0.75 Y U410 U410 0.75 BY
CAN 2
CAN 1
1 LVDS POS CN-260 1

TRAVEL ATT
N5-12 N5-13 0.75 BL 0.75 U4171 U4171 0.75 Or

+
2 GND 1 2
SIREN
N5-13 N5-23 0.75 L 0.75

-
3 LVDS NEG 2 add CN-365

N5-22 N5-12 0.75 RL U409 U409 0.75 GrG
SPEAKER
CAMERA
4 POWER 6.5V CN-261 1

N5-23 U417 U417 0.75 BL
ATT
REAR VIEW
5 NC 4 SPK(-) 2
ADJUST SIGNAL
EPPR2 EPPR1
RELIEF RELIEF
6 3 SPK(+)
OPTION
G8 1.0 B
CN-9 2 GND
f17 1.0 RG
2 CLU VOUT GND 1 ACC
SIREN AMP
0.75 Y
3 CLU VOUT POS
0.75 L
AAVM
4 CLU VOUT NEG

U108 0.75 G
6 CAN 2 LO
U109 0.75 V
5 CAN 2 HI
N5-45 N5-45 0.75 BrW
7 CAM POWER CN-262A
N5-46 N5-46 0.75 YG
8 CAM0 LIN CS-61 1
N5-47 N5-47 0.75 Br
N5-24
N7-12
N4-10
9 CAM0 VIN POS 2 2

N5-48 N5-48 0.75 Or
FLOAT
10 CAM0 VIN NEG 1 CN-262

TRAVEL
CN-262B
SWITCH
N5-49 N5-49 0.75 BL G 0.75 B

11 CAM0 GND 2 1
STRAIGHT
1.0 B 0.75 L
CN-61 N7-12 0.75 YW
12 GND 4 CONTROL 1 2
1.0 RG 0.75 G
CAN 2
CAN 1
1 IG POWER 3 SWITCH PANEL

N7-04 1.5 B
2 1 M
N7-05 1.5 R
1 2
FUEL
N7-06
PUMP
FILLER
N16-3 CN-62
N16-2 1
CN-81
-
N16-1 f17 2 U209 U209

BZ
AUTO
CN-3A 1
1.0 GrW
+
N5-19 f18 f28 0.75 WR

GREASE
5 KEY IG DO-23 2
U108 0.75 G
TRAVEL
2 CAN 2 LO 1 CN-70
N4-161 U109 0.75 V U205 U205 0.75 GB
1 CAN 2 HI 2 1
N3-7 0.75 B f28 0.75 GrW
3 2
HIGH
GND CN-18 CN-408

N3-8 0.75 B 0.75 B
6 GND 1 1 add CN-242
N3-9 N4-161 1.0 N7-06 0.75 BW U402 U402 0.75 WBr
4 SAFTY 2 2 1
M
SPEED P1
WASHER P/P
N3-10 N3-7 0.75 LB U427 U427 0.75 GrL

7 5V POWER CN-407 2
N3-8 0.75 WL N7-04 2.0
5V GND
PVG EXT. HARNESS
8 1 2 E add CN-243
N3-9 0.75 OrW 0.75 B 1 Pf U403 U403 0.75 Or
9 ROTATE LH 2 1
P2
N3-10 0.75 Gr N7-05 3 B U426 U426 0.75 Br

10 ROTATE RH 4 2
SOL. REG. REG.
(M2) EPPR EPPR
0.75 ROr
1.0
11 NC 3 CD-70
12 NC A SUPPLY
N1
U122 U122 0.75 LY

CN-01
4 Lo 1 B SIG
M
LOW WIPER MOTOR
PRESS
C RETURN
CAN 2
CAN 1
2.0 U1323 0.75 Gr

CD-71
4 A SUPPLY
N2
B
CN-11 U128 U128 0.75 GrR
1 GND 2 B SIG
U422 U422 0.75 OrW U1311 0.75 Br
PRESS
2 BLOWER SIG 6 C RETURN

U115 f25 2.0
3 AC 24V CD-43
R7-86
AIR-CON
4 NC 8 A SUPPLY
P2
f07 2.0 Y U114 U114 0.75 YR

5 CONT. B+ 3 B SIG
1.0 GR
PRESS
6 AC COMP C RETURN
U108 Y
7 CAN_L0(2) CD-42
N7-04 U109 L
8 CAN_HI(2) A SUPPLY
P1
N7-05 U222 U222 0.75 LOr

PUMP HARNESS
CN-29 5 B SIG
N7-06 1.0 L
PRESS
CN-16/A 2 Pa C RETURN
N16-1 0.75 B N29-1
4-3
1 1 CD-44
N16-2 0.75 W
R/DRYER
2 A SUPPLY
P3
U206 N16-3 0.75 Gr U113 U113 0.75 WOr

3 CN-25 CL-5 7 B SIG
f04 0.75 BW 1.0 B
PRESS
4 2 1 C RETURN
f08 1.0 G
5 1 2 add CN-75
F12C U401 U401 0.75 LW
6 CN-20 CL-6 9 1
f15 1.0 B U428 U428 0.75 RW
HORN
MAIN
2 1 10 2
PUMP
f20 R2-5 1.0 G

DO-7 1 2
f27 N5-19 0.75 V
CAN 2
CAN 1
1 CN-12 CL-5
f281 0.75 ROr R4-87 2.0 RG
2 1 1
f29 2.0 B
CN-22 2 2
f30 0.75 V
1 CL-6 CN-135
f32 0.75 ROr U207 U207 0.75 YG
WASHER P/P
2 1 1
M
f28 0.75 WR
ARM
WORK LAMP
CL-4 2 2
N4-16 R13-87 1.5 R
1 CN-88
R2-1 N5-15 1.5 B U310 U310 0.75 GB
RH
2 1
R5-2 N5-17 f28 0.75 WR
CL-3 2
R9-87 N5-20 1.5 R
f33
f07
f25
REGEN BOOST
1
f201
POWER
LH
1.5 B
R7-86
2
R13-871
R35-86 1.5 R
CL-24
N5-24
N4-10
f28
f31
F19
1 CN-68
R85-5 1.5 B R48-4 0.75 Or
SOL
2 1
f26 0.75 GB
LAMP LAMP LAMP
HEAD HEAD HEAD
CN-96 2
N5-36 R46-87 2.0 Br
1 add CN-133
N5-39 2.0 B U404 U404 0.75 LB
2 1
REAR FUEL
ITY
N5-53 U434 U434 0.75 VB

3 2
HEATER
BOOM
N5-54
CAN 2
CAN 1
N4-10 0.75 V
CN-140
1
f17 N5-24 0.75 GrW
2
SAFETY PRIOR_ QUICK
f18
COUPLER
CN-376
f14 0.75 WBr
1 IG 24V
R4-85 0.75 W
4 WORK LIGHT
U215 R9-85 0.75 G
5 CABIN LIGHT
U213 R13-85 0.75 Br
13 HEAD LIGHT CN-369
SOL
R85-1 0.75 GR U308 U308 0.75 LY

15 BEACON 1
BOOM
DOWN
f201 F19 0.75 V

2 NC 2
CUTOFF
f25
16 NC CN-13 CN-367
f07 U306 U306 0.75 GrL
14 NC 2 1
R7-86 F19 1.5 V
SOL
17 NC 1 2
f33 N5-15 0.75 Y
RDU_MEMBRANE CONT.
3 WIPER CN-368
N5-17 0.75 Or U305 U305 0.75 LBr
11 WASHER 3 1
DOWN UP
N5-20 0.75 L
SOL
12 INT WIPER 2
U108 0.75 G
BOOM BOOM
18 CAN 2_LO
U109 0.75 V
10 CAN 2_HI
FLOATINGFLOATING
0.75 B
26 GND
0.75 B
27 GND CD-124
U1321 U1321 0.75 Gr
CAN 1
9 NC 4 A SUPPLY
U225 U225 0.75 WBr
5 B SIG
U1312 0.75 Br
1.0
6 C RETURN
R29-87
ROD PS
U1323 0.75 Gr
CD-31
BOOM CYL.
A SUPPLY
U228 U228 0.75 G
B SIG
f31 U1311 0.75 Br
B+
LOAD
f26
OVER
F19
C RETURN
MCU R f02 1.5 f28
R48-4
2 30A
ROOM LAMP/RADIO B+ WOr f04 1.5
4 10A
AIR CON / HEATER Y f07 2.0 F19

7 20A
WIPER RBr f08 1.0 R48-4
8 10A
CLUSTER B+ GY f09 1.0 CAN 1 CAN1
9 10A
f26
B+
MCU CONT. RW F13 1.0

13 20A
EPPR OrR F11 1.5
11 20A
RDU IG WBr f14 1.0 N5-39
14 10A
RADIO IG LR f15 1.0
15 10A
CLUSTER IG Gr f16 1.0
16 10A
AAVM / SIREN RG f17 1.0
17 10A
PROPORTIONAL YL f18 1.0
18 10A
F07
SOLENOID V F19 1.5 F13 5.0 B
CN-245
19 10A ISO MINI 2
PTC
f201 F11 5.0 W

30 1
1.2B
1.2G
1.2B
WIPER GrW f20 1.0 87a 87 85

1.2G
POWER
IG(POWER RY)
20 10A 86
f261
87 CN-263
SAFETY SOL VW f26 1.5 1.5 W
1
2
26 10A 85 2
DO-3
SEAT HEAT ROr f27 1.5 30 86 1.5 L f03

27 20A 87a 1
G5 0.75
CR-1
POWER
CR-13 ISO MINI CN-258

SOLENOIDE Or f28 1.0 f21 1.5 VW 5.0 W R51-5 1.0
BATT RY
28 20A 30 1
AIR COMP.
CIGAR WG f29 1.5 R13-871 0.75 GL 87a 87 85 N95-1 R50-5 2.0

29 20A 86 CD-16
R13-87 1.5 LY N60-1 0.75 BG
f14
f33
87 C RETURN
R2-5
BREAKER BrR f31 1.0 R13-85 0.75 Br N9335 0.75 WR

R85-1
R9-85
R4-87
R44-85
R13-85
R46-87
R13-87
R14-87
31 15A 85 B SIG
R14-871
CONVERTER V f32 1.5 0.75 V

HEAD LAMP
30 86
SENSOR
32 10A 87a CN-95 8W A SUPPLY

FRONT/REAR
8.0 W
1
90A
FUEL FILLER PUMP Y f33 1.5 8.0 W

33 20A 2 CN-380
8W 2.0 0.75 Br
"B" TERM.
4 POWER
0.75 B
TO:STARTER
CN-60 5R 3 RETURN
5.0 R N2-10 0.75 G
f30
f25
1 2 CAN HIGH
f261
R2-1
R5-2
R2-5
U215
U213
60A
F12C
U206
N60-2 N2-11 0.75 V

R4-87
R7-86
R4-85
R85-5
R85-1
R9-85
R9-87
N5-36
N5-54
N5-53
R48-4
N4-16
WATER LEVEL SENSOR
60R
R35-86
R46-87
2 1 CAN LOW
5R
2.0
TANK LEVEL
CIRCUIT BREAKER
G5
W N95-2 8.0 8.0 N95-2

12V X 2
R S74-2 5.0 S74-2 5.0 R

CS-74
L
2 CL-40
L
S
BATTERY
HEAD LAMP VW f21 2.0 5.0 R 0.75 Gr

21 20A 1 1
DEF
RY N9307 0.75 GB
CS-74B 2
60B
f06 2.0 Gr
2
HORN RY f24 1.0 N5-36 2.0 W
S
MASTER SW
24 10A 1 CN-381
WORK LAMP RL F34 2.0 N5-53 1.0 Br
DEF
N9340
LINE
34 30A 1
CABIN LAMP R F36 2.0 N5-54 1.0 B
36 30A 2
FUEL HEATER L f22 2.0
22 30A CN-382
AC / HEATER L 1.5 f25 1.0 N9339 1.0 Br
25 20A 1
DEF
OPTION, SWITCH BrG 1.5 f30 1.5 1.0 B

LINE
30 20A 2
CN-383
IG(BATTERY RY)
ECM W f01 3.0 N9338 2.0 1.0 Br

1 30A 1
ECM Or F12 1.0 1.0 B
12 5A 2
DEF
LINE
OrW F12C 1.0

G9
LAMP HEATER3 HEATER2 HEATER1
DEF MODULE Gr f03 1.5

3 15A
LINE HEATER LgR f05 2.0
5 15A
DEF&SCR WY f10 2.0
10 10A AT-5A
START, AIR-HEAT Lg f23 1.0 N2-02 1.0 Or
23 20A 1 DEF PUMP MOTOR SPEED SIG
N2-01 1.0 RBr
2 DEF PUMP MOTOR RELAY
N9306 1.0 BrY
3 DEF PUMP MOTOR SPEED CONTOL SIG
START KEY Gr 2.0 f06 1.0 RB
SCR&DEF
N9354
6 30A 4 DEF PUMP MOTOR
3.0 B
2.0
CAN1
SUPPLY MODULE
G7 0.75
f01
F12
R5-5
U115
R7-87
R36-5
U201
U202
N9376
N9375
N9383
N9303
N9338
N9379
N9391
N9362
N9387
TO: HARNESS ENGINE

CN-100
ISO MINI CR-35 CR-9 ISO MINI CN-2 CN-173

Gr f06 2.0 2.0 F36 2.0 R BY
30 30 AIR HEAT RY 15
0.75
85 87 87a WOr R35-86 1.0 0.75 R 87a 87 85 A A

86 86 NC 14 B
RW R35-87 R9-87 2.0 V WY 0.75
N9349
87 87 ALT LEVEL 13 C
B 0.75 R9-85 0.75 G OrW 1.5 B
RESISTOR
85 85 AC COMP 12
86 30 30 86 V 0.75 N2-11 AT9A
87a 87a CAN_LO 11
CABIN LAMP
G 0.75 N2-10 1 24V

POWER RELAY
MICRO CR-85 MICRO CAN_HI 10

R85-1 0.75 GR B 0.75 2 CAN_HI
1 1 CAN SH 9
1 5 4 1.5 f30 1.5 BrG 4 5 1 B 1.5 3 CAN_LO
2 2 START RY GND 8
0.75 BrG LY 0.75 4 RETURN
3 3 START RY 7
TO CN-5 56
TO CN-5 57
TO CN-5 55
YG 0.75 N2-06
BEACON
4 4 RETURN 6
2 3 R85-5 1.5 GrW 3 2 LW 0.75 N2-05 AT2A
5 5 AIR TEMP 5 1 24V
LOr 0.75 N2-04
CR-48 MICRO POWER SUPPLY 4 2
U206 0.75 Gr VW 0.75 N2-03 CAN_LO
1 AIR PRESS 3 3
f261 1.0 VW 4 5 1 Or 1.0 N2-02 CAN_HI
2 CC8C 2 4 RETURN
EXHAUST GAS TEMP SENSOR OUTLET NOX
N4-16 0.75 Or RBr 1.0 N2-01

3 CC8C 1
G6
SAFETY
R48-4 0.75 OrW

f23
f03
f05
f10
4 AT1E
R5-2
U215
5 3 2 CN-93 1 24V
00 00 2 CAN_LO
MICRO CR-51 MICRO
BR 0.75 LW 0.75 N9367 3 CAN_HI
1 1 REMOTE ACCEL SE 67
INLET NOX
1 5 4 Gr 0.75 4 5 1 LgY 1.0 DOC. 4 RETURN

2 2 HS_RETURN 76
Gr 1.0 2.0 WB 0.75 SCR
2.0
3 3 AIR HEATER RY 75
0.75
OrW 0.75 SIDE AT11A

4 4 STARTER LOCKOUT SIG 83 1 RETURN
2 3 RBr 1.0 R51-5 3 2 G 0.75 N9313 CN-430
5 5 WATER IN FUEL 13 2 DIFF. PRESS S/S
f03 RB 0.75 N9342 N9342 0.75 RB N1
MICRO CR-50 DEF OUTLET GAS P/S SIG 42 1 3 OUTLET PRESS S/S
B 0.75 G5 2.0 Br N2
CAC OUT TEMP 24
DPF PRESS SENSOR
1 2 4 24V
1 5 4 GrB 1.0 F36 V 0.75 0.75 N9362 N9341 0.75 YR N3
2 DEF LEVEL SENSOR RETURN 62 3
WY 2.0 f30 YR 0.75 N9341 2.0 B N4
3 DEF OUTLET GAS P/S SIG 41 4
GY 0.75 0.75 N9353
4 DEF DOSING V/V Lo 53 AT-6A
2 3 Br 2.0 R50-5 G 0.75 N9377 0.75 GY N5
5 DEF DOSING V/V Hi 77 5 1 DEF DOSING V/V_LO
0.75 YR N6
ISO MINI CR-52 CR-4 ISO MINI 00 00 6 2 DEF DOSING V/V_HI
LgR 2.0 N9379 F34 2.0 F34 2.0 RL Br 0.75 0.75 B N7
30 30 DEF LINE HEAT RY- 3 7 3 NC
85 87 87a 0.75 2.0 f22 0.75 RL 87a 87 85 Br 1.0 N9340 N9377 0.75 G N8
86 86 DEF LINE HEAT3 40 8 4 NC
Br 2.0 N9338 f25 R4-87 2.0 RG Br 1.0 N9339 N9308 0.75 V N9
87 87 DEF LINE HEAT2 39 9 5 SENSOR SUPPLY
Br 0.75 N9303 f24 R4-85 0.75 W Br 1.0 N9338 N9353 0.75 GY N10
20K9-92200-012
85 85 DEF LINE HEAT1 38 10 6 NC

86 30 30 86 GrG 0.75 N9382 N9332 0.75 BG N11
87a 87a DEF TANK HEAT V/V 82 11 7 SENSOR RETURN
WORK LAMP
RBr 0.75 N9357 N9316 1.0 BrY N12

MICRO CR-39 CR-46 ISO MINI HS RETURN 57 12 8 DEF DOSING PRESSURE SIG
LgY 1.0 N9376 2.0 f22 2.0 YR RW 0.75 N9363
1 30 ACCEL 2 _ SIG. 63
1 5 4 OrW 0.75 N9383 0.75 87a 87 85 BrY 1.0 N9316
DEF
2 86 DEF INJ. PRESS SENSOR 16

WG 0.75 R46-87 2.0 Br Or 1.0 N9381
3 87 A/T POWER RY 81 CN-16B
U213 V BrR 1.0 N9306 0.75 BG
DOSING
MODULE
DEF MODULE NOx SENSOR LINE HEATER STARTER
4 85 DEF P/P TEMP 6 1

LOCKOUT
2 3 BrG 0.75 30 86 RB 1.0 N9354 N9363 0.75 RW 2.5k

5 87a DEF P/P RETURN 54 2
N9381 BR 0.75 0.75 V
MICRO CR-5 CR-7 ISO MINI DEF PUMP MOTOR RY 79 3
BrG R5-1 f25 1.0 L BG 1.0 N9332 N9362 0.75 V 2.5k
1 30 OEM SENSOR RTN 32 4
1 5 4 LY 0.75 R7-86 1.0 L 87a 87 85 WR 0.75 N9335 M9367 0.75 LW
2 86 ENG. COOLANT LEVEL 35 5
Lg 0.75 f23 R7-87 1.0 OrW V 1.0 N9308
3 87 OEM SENSOR SUPPLY 8 6
0.75 B GB 0.75 N9307
4 85 POWER ON INDICATOR LAMP 7
FUEL HEATER AC COMP.
2 3 LY 1.0 R5-5 30 86 VOr 0.75

5 87a DPF INHIBIT 87
LOr 0.75
MICRO CR-36 CR-2 MICRO DPF REGEN 91
LgY 0.75 R2-1 0.75 P Or 0.75 F12
1 1 KEY SWITCH"ON" 5
1 5 4 WB 0.75 N9375 1.0 f24 1.0 RY 4 5 1 Y 0.75 U201
2 2 CAN 1_Lo 46
YR 0.75 f23 0.75 RY L 0.75 U202
HORN
3 3 CAN 1_Hi 22 CN-384

B 0.75 N9357 0.75 RBr
4 4 BATTERY(-) 52 2
ANTI-RESTART PRE-HEAT
V/V
2 3 BY 0.75 R36-5 R2-5 1.0 G 3 2 B 0.75 N9382 0.75 GrG

5 5 BATTERY(-) 51 1
B 0.75 3.0
BATTERY(-) 50
B 0.75
3.0
COOLANT
BATTERY(-) 49 CD-45
B 0.75 0.75 V
BATTERY(-) 73 2
W 0.75 3.0 f01 0.75 G
WIF
N9313
BATTERY(+) 28 1
W 0.75
BATTERY(+) 27 CN-174
W 0.75 L 0.75 U202
BATTERY(+) 26 A A CD-10
W 0.75 Y 0.75 U201 N2-06 1.0 YG
BATTERY(+) 25 B 1 RETURN
W 0.75 N2-05 1.0 LW
BATTERY(+) 1 C 2 AIR TEMP
3W 120ohm
B
TEMP
1.0 LOr
RESISTOR
N2-04 3 SUPPLY POWER

N2-33 1.0 VW
4 AIR PRESS
SENSOR,PRS
20K9-92200-012
CS-67
10
9 10
9
56B 0.8ROr
DC/DC CONVERTER 8
25A 0.8B
12V SOCKET HOUR METER 7 6
RMS 5
24V
6 4
25B 0.8ROr
12V 12V
1 FUEL LEVEL
5 3
h
70 1.0Y 2 CS-33
6 DOOR SW
4
CN-48
4 CAN1 LO
GND
1
3 CAN1 HI
24V
5 5
CN-138
3
CN-139
24 0.8ROr
CN-125B
5 KEY
4 4
3
2
1
NC
2 NC
8 NC
2
1
2
7 8
3
2
1
CN-21 56A 0.8ROr 3 3
1 0.8Br 15
7
WIPER CUT 2 2
0.8YL
3 1 QUICK COUPLING SW
0.8B
0.8Y
0.8G 16
1.2Or
1.2BW
R 10
22A 1.2B
1.2Or
1 1
1.2Or
2
5 3
Gr 12
CN-113
HARNESS LH,CONSOLE
4A EM'CY STOP SW
86
93
CS-53
R
85
79
60
4
9
25 0.8B
60
22
20
4 G 8 1
5 56 0.8Or CN-4
L 9 2 CN-247 NO. DESTINATION
6 M 2 6 0.8Gr 1 1 0.8Gr
2A B
5V
A 1 1 MCU_5V
BUZZER 0.8Or 2 2 0.8Or
Or
PROPOR- RETURN
B 2 2 MCU_RETURN
LH
WIPER MOTOR CN-56B CN-24 TIONAL
SIG 0.8LOr 3 3 0.8LOr
59 0.8B C 3 3 MCU_DIAL SIG
11
1
RW CAM 6.5V CS-1 2
0.8G 2 15 0.8Br
8 0.8L WR 1.2Gr 11 0.8V 3 4 4 EM'CY STOP SW
2 CAM GND 1 0.8Y 4 4 0.8Y
7 0.8Y B CAM DIFF H CN-10 NO. DESTINATION power 1 5 5 MCU_POWER MAX
3 B 0.8B 5 5 0.8B
CN-141 CN-157 0.8V WL CL-1 SPEAKER RH 1 1 NC
max
2 6 6 MCU_SIG.GND
G 8 4 CAM DIFF L 1.2Gr 11 11 1.2Gr CS-29 0.8Grw 6 6 0.8Grw
1 7 7 MCU_DECEL
FEED BACK 1
1 ANTENA POWER 5
W
CAM 1
DOOR S.W 3 2 2 DOOR SW R 0.8B 7 7 0.8B
MOTOR DRIVE SIG 2
W CN-17 L 2
0.8Y 1 1 0.8Y
3 3 FUSE
decel
2 8 8 MCU_SIG.GND
L 9 6 CAM 2 1.2B 6B 2 0.8G CS-19 8 0.8L
MOTOR DRIVE- 3 1 L 1 4 4 CASSETTE_RH- 9 9 Q/COUPLER SOL +
10 1 69 7 CAM 3 2 L 9 0.8V
R W 0.8GR 3 0.8V
MOTOR DRIVE+ 4 2 L CN-23 ROOM LAMP 5 5 CASSETTE_RH+ 10 0.8Gr
10 10 Q/COUPLER SOL -
B 2 2 B 1.2B 73 8 CAM SHIELD 0.8Y 4 4 0.8Y
GND 5 3 2 6 6 CASSETTE_LH- 11 11 MCU_SEAT BELT
70 1 Gr
GrW 3 3 GrW 0.8RY CLUSTER 0.8L 5 5 0.8L 12 NC
VCC 6 4 1 7 7 CASSETTE_LH+ 12
R 4 4 R 0.8R 14 CN-56A 6 2.0B 16 0.8G
CONTINUE 24V 7 5 10 0.75BW 8 8 GND CS-4 13 13 EM'CY STOP SW
V 5 5 V 0.8V 15 RW SPEAKER LHCL-7 7 2.0B B C 1.0B 12 12 1.0B
WASHER P/P 8 1 BATT.24V A 14 14 GND
6 9 0.75VBr WR 9 9 GND 13
L 6 6 L 0.8L 71 2 1.2BrW 8 8 1.2BrW 0.8RW
WASHER SIG. 9 7 IG 24V B 15 15 IG24V_FUSE
59 0.75B B 10 10 BEACON SW 0.8G 14 14 0.8G
Br 7 7 Br 0.8YOr 72 3 GND M 1.2B 6A 9 2.0V C
INT. SIG 10 8 11 11 CABIN LIGHT RY A 16 16 SAFETY SOL
11 8 0.75L Y
Or 4 CAN1_HI 10 2.0V
WIPER CUT SW 11 12 12 CABIN LIGHT RY SAFETY SW
7 0.75Y
5
Gr
CAN1_LO
BEACON LAMP
N.C 12 6 0.75V WL CL-8 CL-10 CL-9 CS-67
FEED BACK 13
Gr 12
5 0.75G
6
W
CAN2_HI
2.0V 9 2V 10A 10 2.0V HARNESS CABIN 10
WIPER MOTOR CONT. WIPER MOTOR HARNESS 7
L
CAN2_LO 2
2B 6
2
2B 7A 7 2B
2
10 9
9
8 RS-232 RX 1 1 1 0.8L 8A
L 8
CS-99 90
9 RS-232 TX CABIN LIGHT 6 7
1.0B 12A
0.75Y L
10 AUX LEFT 5
10 91 0.75L L 4 6
10 9 11 AUX RIGHT 1.0B 12B
9 92 0.75B L 3 5
12 AUX GND 2 0.8V 9
8 1 4
6 7 CLUSTER 3
5 0.8YR 37 CN-5 0.8RW 13
4 6 8 7 2
0.8Or 32A 1 1 NC 0.8L 8
3 5 1
2 2 2 NC
1 4 QUICK COUPLER
3 3 NC
3
0.8L 39 4 4 NC
8 7 2 5 0.75G
1
0.8W 40 5 5 CAN2_LO CS-250
6 0.75V
6 6 CAN2_HI
7 0.75Y 2 2
AIR-COMP SW 7 7 CAN1_LO
8 0.75L 1 1
8 8 CAN1_HI
59 0.75B SEAT BELT SW
9 9 CLUSTER_GND
9 0.75VBr
10 10 CLUSTER_IG 24V
10 0.75BW
11 11 CLUSTER_BATT.24V
11 0.75R
12 12 CAM POWER
12 0.75BW
CS-100 13 13 CAM GND
13 0.75W
14 14 CASSETTE RADIO IG
10 69 0.75GR
10 9 15 15 WIPER MOTOR DRIVE SIG
9 70 0.75RY
16 16 WIPER MOTOR IG24V
8 71 0.75L
17 17 WASHER SIG.
6 7 14 0.75R
5 18 18 WIPER MOTOR BATT24V
4 6 15 0.75V
19 19 WASHER P/P
3 5 72 0.75YBr
2 20 20 INT. SIG
1 4 73 1BR
0.8VW 1 21 21 WIPER MOTOR_GND
3 88 0.75RW
0.8R 2 22 22 LVDS POS
8 7 2 89 0.75LB
0.8LW 3 23 23 LVDS NEG HAPTIC
1 65 0.75ROr
24 24 Q/COUPLER SOL+
DPF SW 74 1B
25 25 CAN_SH
GND_EME'CY
CAN_SHIELD
20 1Or
POWER BAT
SIG_EME'CY
5V_EME'CY
26 26 DC/DC CONVERTER_24V
POWER IG
20 1Or
27
CAN_LO
27 Q/COUPLER SOL -
CAN_HI
22 1BW
28 28 DC/DC CONVERTER_GND
GND
GND
N.C
N.C
23 2B
29 29 CABIN_GND
24 1ROr
30 30 POWER_FUSE CN-363
12
11
10
25 1B
3
6
2
8
5
4
1
9
31 31 GND
32 32 NC
0.8BrW
0.8ROr
86 1P
0.8BW
33 33 FUEL LEVEL
0.8G
0.8B
0.8V
0.8B
0.8L
28 2V 28 2VW
SH
34 34 CABIN LAMP RY CN-156
CN-427 29 1BR 1.25B 38E
35 35 ENG. START SIG. 2
0.8W 33 30
15A
1W 1.25VW 33
17
18
24
IG 24V 1
22
16
15
19
20
36 36 START KEY 24V 1
0.8R 23 23B 1B
GND 2 37 37 CABIN_GND
0.8B 6C 28A 1VW AIR SEAT
CAN (HIGH) 3 38 38 CABIN LAMP RY
0.8.G 5C 32 0.75YBr
CAN (LOW) 4 39 39 START KEY_BR
33 1G
40 40 START KEY_IG
READER 87 0.75GrY
41 41 RX232(2)-TX
88 0.75OrG CS-79
CN-125A 42 42 RS232(2)-RX
10
1.2W 30B 89 0.75P
BATTERY POWER 1 43 43 PROGRAM DUMP 10 9
85 1B 9
1.2G 33A 44 44 CONT._GND 0.8BOr 29
KEY "IG" 2 34 0.75R 8
CAN (HIGH) 3
0.8V 6A 45 45 CAM0 POWER 0.8B 38C CN-8 NO. DESTINATION
35 0.75Br 6 7 15 0.8B
RX232(1)-TX 46 46 CAM0 LIN 5 1 1 GND
4 36 0.75L 4 6 16 0.8V
GND (SERIAL) 5 47 47 CAM0 LVDS POS 0.8BW 30 2 2 CAN_HI
87 37 0.75Y 3 5 17 0.8G
RX232(2)-TX 6 48 48 CAM0 LVDS NEG 2 0.8BOr 29 3 3 CAN_LO
38 0.75B 1 4 18 SH
88 49 49 CAM0 GND 0.8Br 28 4 4 CAN_SHIELD
RX232(2)-RX 7 39 3
0.8B 74 1BrW
CAN (SHIELD) 50 50 BEACON LAMP 1.2Or 32F 5 5 NC
8 79 0.75YL 8 7 2 19 0.8BrW
RX232(1)-RX 9 51 51 HOUR METER SIG 0.8BOr 29A 6 6 POWER_BATT
89 1 20 0.8ROr
PROGRAM DUMP 10 52 52 NC 7 7 POWER_IG
0.8G 81 0.75Y LOW WIPER SW
5A 53 53 AIR COMP RY 8 8 5V_ECM
CAN (LOW) 11 40
0.8B 85B 0.75L 9
MAIN GND 54 54 AIR COMP RY 9 SIG_ECM
12 41 0.75Gr
55 55 DPF SW_REGEN 10 10 GND_ECM
RMS 42 0.75YW CS-108
56 56 DPF SW_COM
44 0.75RW 10
57 57 DPF SW_INHIBIT 10 9
9
58 58 NC 0.8Or 31A CIGAR LIGHTER
45 0.75Y 8
59 59 ROOM LAMP 24V 0.8Or 32E
46 0.75GW 6 7 1.2ROr 25
60 60 ILLUMINATION 5
4 6 1.2Gr 26
3
2
5 1.2B 27
HARNESS RH,CONSOLE
1 4
CN-10 CL-2
CS-2A 3
0.8Or
1 NC 1 30 1.2W 31
2
H0 I
1.2Gr 93 1 8 7
2 DOOR SW 2 32 0.8YOr
0.75Y 45A 2 1 CN-7 NO. DESTINATION
0, I
3 ROOM LAMP 24V 3 47 1.2R 25 1.2ROr
0.75G 51 3 4 1 1 ILLUMINATION
AUTO GREASE SW
H
4 SPEAKER RH- 4 26 1.2Gr
0.75V 53 4 1 2 2 CIGARLIGHT IG24V
BR ACC
5 SPEAKER RH+ 5 2 27 1.2B
0.75Y 3 3 CIGARLIGHT_GND
B
52 5 3
6 SPEAKER LH- 6 29 1.2BOr 28 0.8Br
0.75L 55 6 CS-107 4 4 WIPER_Pf
7 SPEAKER LH+ 7 29 0.8BOr
2B 24 2B 10 5 5 SWITCH_Lo
ST C
23 5
8 GND 8 6 10 9 30 0.8BW
1B 23A 9 6 6 SWITCH_WASHER TANK
9 GND 9 0.8YW 36A 31 1.2Or
1BrW 39 START KEY SW 8 7 7 AUTO GREESE RESET
10 BEACON LAMP 10 0.8B 38 32 1.2Or
2VW 28 28 2V 6 7 8 8 SWITCH POWER
11 CABIN LIGHT 11 5 33 1.2VW
1VW 28B 6C 0.75V CAN_H 4 6 9 9 AIR SHEAT POWER
12 CABIN LIGHT 12 A 34 0.8V
5C 0.75G CAN_L 3 5 10 10 NC
B 2
HARNESS CABIN CN-27A
85G 0.75B
C GND 1 4
36 0.8YW
11 11
12
AUTO GREESE LAMP
TRAVEL ST_SOL
3 12
0.75W 13 CS-2B 0.8Or 32 37 0.8YR
ACC 1 2 13 13 FINE SWING SIG
0.75B 85E 8 7 0.8YW 36 38 1.2B
ILL- 2 CN-125 CN-125 1
39
14 14 GND
30A 1W 0.8W
NC 3 1 1 15 15 SWING LOCK SIG.
SPK FRT RH- 4
0.75G 51 47 1R R 77 STRAIGHT TRAVEL SW
0.75Y 52 2 2
SPK FRT LH- 5 85C 0.75B
3 3
TEL MUTE 6 33 1G R 77
4 4 CS-52
ANT 12V 7
BACK UP+ 8
0.75Y 45A GPS CONN. 10
10 9
0.75GW 46 9
ILL+ 9 0.8Y 35
8
NC 10 0.8B 38
0.75V 53 CN-402 6 7
SPK FRT RH+ 11 36 0.75L 5
1 LVDS POS 4 6
REMOCON+ 12 38 0.75B
2 GND 3 5
REMOCON GND 13 37 0.75Y 2
0.75L 55 3 LVDS NEG 1 4
SPK FRT LH+ 14 34 0.75R 0.8Y 35
4 POWER 24V 3
NC 15 0.8Or 32B
0.75B 85D 5 NC 2
GND 16 35 0.75Br 8 7
6 ADJUST SIGNAL 1
CN-27B
USB 5V
FRONT VIEW CAMERA 2PCS & DOZER SW
1
USB D- 2
USB D+ 3 CS-83
USB_GND 4 10
10 9
N.C 5 HARNESS RH SIDE 9
0.8YW 36A
0.75Y 90 8
AUX L 6 0.8B
0.75L 91 38
AUX R 7 6 7
0.75B 5
92 4 6
AUX GND 8 0.8Or 32B
3 5
CASSETTE RADIO 2
4
1
3
0.8B 32
8 7 2
0.8YW 36
1
THERMISTOR INTAKE ACT`R TEMP ACT`R MODE ACT`R
FINE SWING SW
4 2 7
3 1 M 3 M
M 7 7 CS-83
5 10
10 9
CONTROL BOX(A) 9
2
1
5
6
7
5
6
7
1
2
3
4
5
6
7
1
2
3
4
1
2
3
4
0.8W 39A
7B 8
GND 1 0.8B 38
6 6
20E
7
20B
20A
2
23
INLET (PBR) 5
3B
20
3A
15
14
11
10
12
13
6
4
3
5
4
6
5
TEMP (PBR) 3 0.8Or 32C

4 3 5
MODE(PBR)
REF(+5V)
4
5
3 HARNESS AIR-CON 1
2
4
0.8W 39
CN-11 NO. 3
NC 6 DESTINATION
7
1A 7
8 7 2 CN-126A
BATTERY(+) 1 1 AC GND
20F 19 1 NC 1
SENSOR GND 8 2 2 BLOWER ON SIG. 0.8GrY 1
15 8 RX232(2)-RX 2
INLET ACT`R(REC) 9 3 3 IG 24V SWING LOCK SW 0.8OrG 15
14 RX232(2)-TX 3
INLET ACT`R(FRE) 10 4 4 NC 0.8P 16
13 1 PROGRAM DUMP 4
TEMP ACT`R(COOL) 11 5 5 AC CONTROLLER B+
12 18
TEMP ACT`R(WARM) 12
17
6 6 COMP(DPS) RMS SERVICE TOOL
11
MODE ACT`R(FRONT) 13 7 7 CAN LOW CS-111
10 16
MODE ACT`R(FRONT-DEF) 14 8 8 CAN HI
10
NC 15 10 9
8A 9
IGN.24V 16
8
CONTROL BOX(B) 6 7
5
20 22 4 6
SENSOR GND 1 0
>
20C 3 5
NC 2 0 2
19 1 4
BLOWER ON SIG 3 INCAR SENSOR
18 3 CN-6 NO. DESTINATION
A/C THERMO (+) 4 1 0.8GrY
2 1 1 RX232(2)-TX
NC 5 8 7 2 0.8R
17 1 2 2 MCU_GND
CAN LOW 6 21 3 0.8LW
16 0 BOOM FLOATING SW 3 3 BOOM FLOAT DOWN SIG
>
CAN HI 7 20D 4 0.8G

0 4 4 IGN_24V
NC 8 0.8G 4 15 0.8OrG
1 5 5 RX232(2)-RX
NC 9 AMBIENT SENSOR BREAK B 0.8BW 5 5 0.8B/W
7C 2 6 6 BREAKER
GND 10 CS-26 0.8B 6 6 0.8B
1 7 7 GND
NC 11 HORN R 0.8Grw 7 7 0.8Grw
26 2 8 8 HORN RY
FET(G) 12 CS-5 0.8L 8 8 0.8L
25A 9 9 NC
FET(D) 13 2 L 0.8L 9 9 0.8L
24A 10 10 NC
BLOWER MOTOR(+) 14 0.8Gr 10 10 0.8Gr
11 11 NC
NC 15 1 Gr 0.8Gr 11 11 0.8Gr
23 12 12 NC
EVAP SENSOR(5V) 16 16 0.8P
CN-246 0.8GrR 12
13 13 PROGRAM DUMP
NC 17 5V 12 0.8GrR
A 14 14 MCU_5V
17A
16A
19A
22
7A
24
25
26
25
0.8W 13
24
INCAR SENSOR(5V) 18 13 0.8W

8
7
RH
PROPOR-
21
RETURN
B 15 15 MCU_SUPPLY GND
WITH APTC
TIONAL 0.8BY 0.8BY

AMB SENSOR(5V) 19 SIG 14 14
C 16 16 MCU_DIAL SIG
3
2
4
CAN CONNECT
2
1
NC 20
CS-26A
2
4
M
FET 2
0.8BW 5A
BLOWER
1
3
BLOWER 0.8G 4A
RELAY 1
MOTOR
BREAKER
20k8-95100-001
4-4
1 1.0 VW
C12
1 AIR PRESS
2 1.0 LOr
2 POWER SUPPLY
3 1.0 LW
3 AIR TEMP
4 1.0 YG
4 RETURN CN-3
1
ECM J1 2
3
4
5
6
CN-2 7
1.0 RBr 13
1.5 OrW
CN-28 8
1 DEF MOTOR RY 1 10
2 1
1.0 Or 14 9
2 LAMP_UREA 2 6B 1.5 B
1.0 VW 1 1
3 AIR PRESS 3 10
1.0 LOr 2 11
4 POWER SUPPLY 4
1.0 LW 3 AC COMP 12
5 AIR TEMP 5
6 RETURN 6
1.0 YG 4 CR-23 CN-45
7 START RY 7
1.0 LY
1.5 B
5
6
5
6A
1.0 LY
1.0 B
2
M M
8 GND 8 1
9 CAN SH 9
B+
134A
1.0 G
204
202
205
206
203
7
207
G44
208
18D
18C
209
18E
210
71A
72A
10 CAN_HI START RY. FROM BATT.RY
71B
72B
10
201
1.0 V 8
11 CAN_LO 11
1.5 OrW 10
STARTER
0.8YW
0.8LOr
0.8LW
0.8YW
12 AC COMP RY
0.8LW
0.8Or
0.8Or
0.8Or
0.8Gr
12
0.8Br
0.8G
0.8Y
0.8G
0.8B
0.8V
0.8L
0.8B
0.8L
0.8B
1.5 WY 11
13 ALT LEVEL 13 6 1.0 B 15 R
RS-1 13 1.25R
CN-74
14 NC 14
2 B+
CN-306
CN-305
1.0 BY
CN-307A
CN-307
12
11A 1.25 WY
C
15 PRE-HEAT RY
B
1
4
3
A
8
5
4
1
6
5
4
1
15
2
12
11
PWMOUT/DOUT/PVGOUT 10
3
12
11
10
3W/300
1 G
~
G46
G45
207
208
PWMOUT/DOUT/PVGOUT
PWMOUT/DOUT/PVGOUT
PWMOUT/DOUT/PVGOUT
PWMOUT/DOUT/PVGOUT
PWMOUT/DOUT/PVGOUT
PWMOUT/DOUT/PVGOUT
PWMOUT/DOUT/PVGOUT
11 1.25 WY 3
L
U
5Vdc sensor power+

Sensor power GND-
C
B
A
0.8G
0.8B
0.8B
0.8L
Power ground(+)
Power ground(-)
Power supply(+)
Power supply(+)
AIN/CAN Shield
DIN/AIN/FreqIN
DIN/AIN/FreqIN
DIN/AIN/FreqIN
DIN/AIN/FreqIN
DIN/AIN/FreqIN
SERVICE TOOL
ALT.
CN-309
CN-310
CR-24
2
1
1
15R
CAN(+)
CAN(-)
12 1.0 BY
CN-80
DIN
DIN
15R
G47
206
210
209
EPPR EPPR CONNECTOR 2(C2_BLACK) CONNECTOR 1(C1_GREY)
GLOW PLUG RY GLOW PLUG V/V-A1 V/V-A2
0.8G
0.8G
0.8Y
0.8B
CC8C
CN-307
7 1.0 G PROPORTIONAL VALVE & LEVER
2
4
3
1
1 CAN_HI
8 1.0 V
2 CAN_LO
13 1.0RBr
SIGNAL VOLT(Udc)
3
SIGNAL VOLT(Us)
ECM DEF MOTOR RY.MONITOR
14 1.0 Or
4 ATER. DEF PUMP MOTOR SPEED SIG
ENGINE SIDE CROSS
ERROR
OVER CONN.
GND
P/P VALVE
ENGINE HARNESS (PVG 32)
WEB CONTROLLER
0.5 R
TERMINAL 30 (B+) 1
DAT 2
0.5 Gr
GND 3
0.5BW 302 (a2)
DIAGNOSIS 4
- 5
CN-267A AAVM
PREHEATER HARNESS (TIMER+WEB)
CAM3 LVDS NEG

CAM3 LVDS POS
CAM1 LVDS NEG
CAM2 LVDS NEG

CAM2 LVDS POS
CAM0 LVDS NEG
CAM0 LVDS POS
CAM1 LVDS POS

CLU VOUT NEG
CLU VOUT POS
CAM3 POWER
CAM1 POWER
CAM0 POWER
CAM2 POWER
RS232_GND
CAM3 GND
CAM2 GND
CAM1 GND
CAM0 GND
RS232_RX
RS232_TX
CAM3 LIN
CAM1 LIN
CAM0 LIN
CAM2 LIN
CN-246B
CAN Lo
IGN 24V
CAN Hi
IGN 24V
4
3
2
1
GND
GND
CN-401
EASYSTART TIMER
60
74
75
20
22
57
78
21
56
23
24
26
27
28
29
30
46
47
48
49
50
76
86
77
87
58
79
59
71
80
72
0.5 R 303 (a4)
TERMINAL 30 (B+) 1
TERMINAL 58 (LIGHT SIG) 2
0.75Br
S2 B2 0.5 Gr G90C (a5, GND)
- - A A TERMINAL 31 (GND) 3
M 0.75W 0.5BW 302 (a2)
+ + B B DIAGNOSIS 4
DAT 5
WATER PUMP S+ 6
0.5Y 308
ADR 7
ADR 8
CN-405
Temp. Sensor(-) 9 8 0.85Y
1 LVDS POS
Temp. Sensor(+) 10 7E 0.85B
0.5BL 1 2 GND
7A 0.85BrW
0.5Br 2 CN-267 8 0.85R
3 LVDS NEG
4 POWER 24V
FLAME SENSOR 5 NC
1
2
8 0.85Gr
0.5BL 3 CS-74A 6 ADJUST SIGNAL
0.5BL 4 RIGHT VIEW CAMERA
SERVICE TOOL
6.0R
6.0R
FROM MASTER SW
CN-404
TEMPERATURE SENSOR 310 2.5R 0.8YW 71B 8 0.85Y
LVDS POS
0.5R 5
POWER CN-246B A A
0.8LW 72B 7E 0.85B
1
4
3
2
1
B B 2 GND
0.5R 6 0.8B 201 7A 0.85BrW
310
161
149
3 LVDS NEG
CN-301 C C
4
3
2
1
1 0.5BL CN-246A 8 0.85R

4 POWER 24V
OVERHEATING SENSOR 2 0.5Br
1 FLAME SENSOR CN-406
5 NC
2 SENSOR GROUND CS-74A
1
2
3 0.5BL 8 0.85Gr
6 ADJUST SIGNAL
3 TEMPERATURE SENSOR
4 0.5BL
5 0.5R
4 TEMPERATURE SENSOR FUSE BOX LEFT VIEW CAMERA
5 OVERHEATING SENSOR CN-403
6 0.5R
6 OVERHEATING SENDOR CN-261 8 0.85Y
1 LVDS POS
310A 1.0R 5A TIMER CONT. (B+) 1.0R 303 0.85B
7E
7 N/S 2 GND
310A 1.0R
7A 0.85BrW
8 N/S 3 LVDS NEG
1.5W 7 7 1.5W 310 2.5R 15A HEATER CONT. (B+) 2.5R 300 0.85R
9 GLOW PLUG(+) 8
4 POWER 24V
1.5Br 8 9 0.75Br
10 0.75W
10 WATER PUMP(-) CN-260 5 NC
WATER PUMP(+) 8 0.85Gr
11 ADJUST SIGNAL
GLOW PLUG 8 1.5Br
6
12 GLOW PLUG(-) CN-269
+ P1
0.75BK 11 11 0.75BK
13 BURNER ENGINE(+) 1
1.0B G90B (GND) REAR VIEW CAMERA
12 0.75Br 1.0G 301
M P2 14 BURNER ENGINE(-) 2
0.75Br 12
- P3
B7
CONTROLLER DOSING PUMP
BURNER ENGINE
B1(S1) 2.5R 300
Terminal 30 (B+) 1
2.5B G90A
Terminal 31 (GND) 2
Plus signal-Battery Sig. 3 CN-9
1.0G 301 1
No. CONN. No. Connector Name Part Number Supply Dosing pump 4
0.5BW 302 (4) 2
Diagnosis (HELJED) 5
CN-265 CONTROLLER 3A0973734 VW 3
N/S 6
0.5Y 308 4
Heter On 7
CN-267 EASYSTART TIMER 15-97-5101 Molex 5
N/S 8
6
CN-269 DOSING PUMP 282189-1 TE (Tyco)
CN-265 7
4.0B
BLOCK HEATER & CONTROLLER SUPPLIER PARTS 9

G90
10
11
12
ENGINE BLOCK HEATER
PREHEATER HARNESS (ONLY TIMER)
20K9-95300-00
4-5
MEMORANDUM
4-6
1. POWER CIRCUIT
The negative terminal of battery is grounded to the machine chassis directly.
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 [CR-1] Circuit breaker [CN-60] Master switch [CS-74]
Fuse box [No.1] Engine ECM [CN-93 (1, 25, 26, 27, 28)]
Fuse box [No.2] United MCU [CN-51 (01)]
Fuse box [No.3] DEF module [CR-51 (3)]
Urea purging lamp [CL-40 (1)]
Fuse box [No.4] l/conn [CN-5 (59)] l/conn [CN-10 (3)] Room lamp [CL-1 (2)]
Door switch [CS-1]
l/conn [CN-10 (2)] RMS [CN-125B (6)]
Radio & USB player [CN-27A (8)]
Fuse box [No.5] Line heater [CR-52 (30, 86)
Fuse box [No.6] Master switch [CS-74B] l/conn [CN-5 (36)] Start switch [CS-2A (1)]
RMS [CN-125A (1)]
GPS connection [CN-125 (1)]
Power relay [CR-35 (30)]
Fuse box [No.7] l/conn [CN-11 (5)] AC & Heater controller box A (7)
Blower relay (4)
Fuse box [No.8] I/conn [CN-5 (18)] I/conn [CN-17 (5)] Wiper motor controller [CN-141 (7)]
Wiper motor [CN-21 (4)]
Fuse box [No.9] I/conn [CN-5 (11)] Cluster [CN -56A (1)]
Hour meter [CN-48 (1)]
I/conn [CN-8 (6)] Jog dial module [CN-363 (2)]
Fuse box [No.10] NOx sensor [CR-50 (3)]
Fuse box [No.11] United MCU [CN-54 (18)]
※ 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
STOP OFF
③ - GND (battery relay) 20~25V
④ - GND (circuit breaker) 20~25V
※ GND : Ground
4-7
POWER CIRCUIT
300A4EL05
4-8
2. STARTING CIRCUIT
1) OPERATING FLOW
Battery (+) terminal Battery relay [CR-1] Circuit breaker [CN-60] Master switch [CS-74]
Fuse box [No.6] Master switch [CS-74B] I/conn [CN-5 (36)] Start switch [CS-2A (1)]
Power relay [CR-35 (30)]
(1) When start key switch is in ON position
Start switch ON [CS-2A (2)] I/conn [CN-5 (39)]
Battery relay [CR-1] Battery relay operating (all power is supplied with the electric component)
Start switch ON [CS-2A (3)] GPS conn [CN-125 (2) → (4)
I/conn [CN-5 (40)] Power relay [CR-35 (86) → (87)]
Fuse box [IG (power relay)]
l/conn [CN-4 (4)]
Emergency engine stop sw [CS-33 (2)→(1)]
l/conn [CN-4 (13)] Fuse box [No. 12]
Engine ECM [CN-93 (5)]
Reader [CN-427 (1)]
RMS [CN-125A (2)]
(2) When start key switch is in START position

Start switch START [CS-2A (6)] I/conn [CN-5 (35)] Anti-restart relay [CR-5 (2) → (5)]
l/conn [CN-2 (7)] Start relay [CR-23 (2)] Starter motor operating
2) CHECK POINT

① - GND (battery)
② - GND (start switch)
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)
4-9
STARTING CIRCUIT
300A4EL06
4-10
3. CHARGING CIRCUIT
When the starter is activated and the engine is started, the operator releases the start 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 "L" terminal I/conn [CN-2 (13)] United MCU alternator voltage [CN-51 (15)]
Cluster charging warning lamp (Via CAN interface)
(2) Charging flow

Alternator "B+" terminal Starter [CN-45 (B+)] Battery relay (CR-1)
Battery (+) terminal
Circuit breaker [CN-60] Master switch [CS-74] Fuse box [B+]
Circuit breaker [CN-95] Fuse box [IG, battery] Power relay [CR-35 (30)→(87)]
Fuse box [IG, power]
2) CHECK POINT

① - GND (battery voltage)
② - GND (battery relay)
OPERATING ON ③ - GND (alternator B+ terminal) 20~25V
④ - GND (alternator L terminal)
⑤ - GND (United MCU)
※ GND : Ground
4-11
CHARGING CIRCUIT
300A4EL07
4-12
4. HEAD AND WORK LIGHT CIRCUIT
1) OPERATING FLOW
Fuse box (No.21) Head light relay [CR-13 (30, 86)]
Fuse box (No.34) Work light relay [CR-4 (30, 86)]
Fuse box (No.14) RDU membrane controller [CR-376 (1)]
(1) Head light switch ON

Head light switch ON [CN-376 (13)] Head light relay [CR-13 (85) → (87)]
Head light ON [CL-3 (1), CL-4 (1), CL-24 (1)]
l/conn [CN-7 (1)] Cigar lighter [CL-2]
l/conn [CN-5 (60)] Radio & USB player illumination ON [CN-27A (9)]
(2) Work light switch ON

Work light switch ON [CN-376 (4)] Work light relay [CR-4 (85) → (87)]
l/conn [CN-12 (1)] Work light ON [CL-5 (1), CL-6 (1)
2) CHECK POINT
① - GND (fuse box)
② - GND (switch power output)
③ - GND (head light relay)
④ - GND (head light)
STOP ON 20~25V
⑤ - GND (fuse box)
⑥ - GND (switch power input)
⑦ - GND (work light relay)
⑧ - GND (work light)
※ GND : Ground
4-13
HEAD AND WORK LIGHT CIRCUIT
300A4EL08
4-14
5. BEACON LAMP AND CAB LIGHT CIRCUIT
1) OPERATING FLOW
Fuse box (No.30) Beacon lamp relay [CR-85 (2, 3)]
Fuse box (No.36) Cab light relay [CR-9 (30, 86)]
Fuse box (No.14) RDU membrane controller [CN-376 (1)]
(1) Beacon lamp switch ON
Beacon lamp switch ON [CN-376 (15)] Beacon lamp relay [CR-85 (1)→ (5)]
I/conn [CN-5 (50)] I/conn [CN-10 (10)] Beacon lamp ON [CL-7]
(2) Cab light switch ON
Cab light switch ON [CN-376 (5)] Cab lamp relay [CR-9 (85) → (87)]
I/conn [CN-5 (34, 38)] I/conn [CN-10 (11)] Cab light ON [CL-8 (2)]
I/conn [CN-10 (12)] Cab light ON [CL-9 (2), CL-10 (2)]
2) CHECK POINT
② - GND (beacon lamp relay)
③ - GND (switch power output)
④ - GND (beacon lamp)
STOP ON 20~25V
⑤ - GND (fuse box)
⑥ - GND (cabin light relay)
⑦ - GND (switch power input)
⑧ - GND (cab light)
※ GND : Ground
4-15
BEACON LAMP AND CAB LIGHT CIRCUIT
300A4EL09
4-16
6. WIPER AND WASHER CIRCUIT
1) OPERATING FLOW
(1) Key switch ON
Fuse box (No.14) RDU membrance controller [CN-376 (1)]
Fuse box (No.8) I/conn [CN-5 (18)] I/conn [CN-17 (5)] Wiper motor controller [CN-141 (7)]
Wiper motor [CN-21 (4)]
Fuse box (No.20) I/conn [CN-5 (16)] l/conn [CN-17 (4)] Wiper motor controller [CN-141 (6)]
Low wiper motor [CN-407 (3)]
Washer pump [CN-22 (2)]
(2) Wiper switch ON (Intermittent)
Wiper switch ON [CN-376 (12)] I/conn [CN-5 (20)] I/conn [CN-17 (8)]
Wiper motor controller [CN-141 (10)→(3)] Wiper motor [CN-21 (6)] intermittently operating
(3) Wiper switch ON (continual)
Wiper switch ON [CN-376 (3)] I/conn[CN-5 (15)] I/conn[CN-17 (2)]
Wiper motor controller [CN-141 (2) → (4)] Wiper motor [CN-21 (2)] Continual operating
(4) Washer switch ON
Washer switch ON [CN-376 (11)] I/conn [CN-5 (17)] I/conn [CN-17 (7)]
Wiper motor controller [CN-141 (9) → (8)] I/conn [CN-17 (6)] I/conn [CN-5 (19)]
Washer pump [CN-22 (1)] Washer operating
Wiper switch ON [CN-376 (3)] I/conn[CN-5 (15)] I/conn[CN-17 (2)]
Wiper motor controller [CN-141 (2) → (4)] Wiper motor [CN-21 (2)] Continual operating
(5) Auto parking (when switch OFF)
Switch OFF [CN-376 (3,12)] Wiper motor parking position by wiper motor controller
2) OPERATING FLOW (LOW WIPER)

(1) Key switch ON
Fuse box (No. 30) I/conn [CN-7 (8)] Low wiper switch [CS-79 (1, 5)]
(2) Wiper switch ON (1st)
wiper switch ON [CS-79 (1 → 2)] I/conn [CN-7 (5)] wiper motor [CN-407 (4)] Wiper operating
(3) Wiper switch ON (2nd)
wiper switch ON [CS-79 (5 → 4)] I/conn [CN-7 (6)] I/conn [NC-18 (2)] washer pump [CN-407 (2)]
Washer operating
3) CHECK POINT
② - GND (switch power input)
20~25V
③ - GND (wiper power input)
④ - GND (switch power output)
STOP ON
⑤ - GND (switch power output)
0 ~ 5V
⑥ - GND (wiper switch power input)
⑦ - GND (wiper power output) 24V
⑧ - GND (wiper motor) 0 or 24V
※ GND : Ground
4-17
WIPER AND WASHER CIRCUIT
300A4EL10
4-18
CONTROLLER CIRCUIT
300A4EL11
4-19
Monitoring CIRCUIT
IG(POWER RY) IG(BATTERY RY)
B+
ROOM LAMP/RADIO B+
FUEL FILLER PUMP

AIR CON / HEATER
START, AIR-HEAT
OPTION, SWITCH
PROPORTIONAL
HEAD LAMP
FUEL HEATER
AAVM / SIREN
DEF MODULE
LINE HEATER
CONVERTER
AC / HEATER
SAFETY SOL
CLUSTER B+
WORK LAMP
CABIN LAMP
CLUSTER IG
MCU CONT.
START KEY
SEAT HEAT
SOLENOID
SOLENOID
BREAKER
DEF&SCR
RADIO IG
ECM
RDU IG
WIPER
WIPER
CIGAR
HORN
MCU
EPPR
ECM
20A 21
10A 24
30A 34
30A 36
30A 22
20A 25
20A 30
5A 12
10A 10
20A 23
20A 13
20A 11
10A 14
10A 15
10A 16
10A 17
10A 18
10A 19
10A 20
10A 26
20A 27
20A 28
20A 29
15A 31
10A 32
20A 33
2
4
7
8
9
30A 1
30A 6
15A 3
15A 5
30A
10A
20A
10A
10A
1.0Or
3.0W
CN-174
0.75L
A A
0.75Y
B
C B
RESISTOR
CN-93
0.75W
1 BATTERY(+)
0.75W
25 BATTERY(+)
0.75W
26 BATTERY(+)
0.75W
27 BATTERY(+)
0.75W
28 BATTERY(+)
73 BATTERY(-)
CN-249
0.75Y 49 BATTERY(-)
LVDS POS 1
0.75BL 50 BATTERY(-)
GND 2
0.75L 51 BATTERY(-)
LVDS NEG 3 52 BATTERY(-)
0.75RL 0.75L
POWER 6.5V 4 22 CAN 1_ Hi
0.75Y
NC 5 46 CAN 1_Lo
0.75Or
ADJUST SIGNAL 6 5 KEY SWITCH"ON"
91 DPF REGEN
REAR VIEW CAMERA
CN-5 87 DPF INHIBIT
7 POWER ON INDICATOR LAMP
1 1.0V
CN-16B 8 OEM SENSOR SUPPLY
2 1
0.75BG 1.0BG
32 OEM SENSOR RTN
2.5k 0.75RW
3 2 35 ENG. COOLANT LEVEL
0.75V
4 3 79 DEF P/P MOTOR RY
2.5k 0.75V
5 4
0.75LW
54 DEF P/P RETURN
CN-56B 11 5 6 DEF P/P TEMP
RW 0.8B 0.75R 0.75RL 6 81 A/T POWER RY
CAM 6.5V 1 12
WR 0.8L 0.75BW 0.75BL 16 DEF INJ. PRESS SENSOR
CAM GND 2 13 0.75RW
B 0.8Y 63 ACCEL 2 SIG.
CAM DIFF H 3
0.8V
14 CN-9 57 HS RETURN
WL
CAM DIFF L 4 20 1 82 DEF TANK HEAT V/V
W
CAM 1 5 21 2 38 DEF LINE HEAT1
L 0.75RW 0.75Y
CAM 2 6 22 3 39 DEF LINE HEAT2
L 0.75LB 0.75L
40 DEF LINE HEAT3
CAM 3 7 23 4
L 3 DEF LINE HEAT RY-
CAM SHIELD 8 24 5
00 00
CLUSTER 6 41 DEF OUTLET GAS P/S SIG
7 53 DEF DOSING V/V LO
8 77 DEF DOSING V/V HI
0.75V
9 62 DEF LEVEL SENSOR RETURN
24 CAC OUT TEMP SIG
10
42 DEF OUTLET GAS P/S SIG
11
13 WATER IN FUEL
12 83 STARTER LOCKOUT SIG
CD-10A
0.75BrB 75 AIR HEATER RY
Pa 1.0OrB 76 HS RETURN
0.75LW
67 REMOTE ACCEL SW
AIR CLEANER SW
CN-401
74 IGN 24V
CD-2 75 IGN 24V
0.75BrB
1
1.0P
2 19 CLU VOUT GND
FUEL LEVEL 20 CLU VOUT POS
CLU VOUT NEG
CD-1 21
0.75BrB 22 RS232_RX
C 1
1.0LgB
2
AAVM
HYD TEMP
1.0OrB
1.0LgB
1.0BrB
0.75Y
0.75L
1.0P
1.0B
CN-51, 52, 53 & 54
51-25
51-19
52-02
54-13
52-01
51-16
51-02
AIR CLEANER CLOGGING SW
HYD. OIL TEMP SENDOR
FUEL LEVEL SENDOR

GND(for sensor 5V)
GND_MAIN
CAN #1 Lo
CAN #1 Hi
UNITED MCU
300A4EL12
4-20
CD-10A
Pa
SW
AIR
1
2
2
1
CLEANER
CN-140
QUICK COUPLER
AIR COMP RY
CN-263
CD-2
1 CS-99
2
FUEL
1
LEVEL
7 8
2
CD-1
10
3
CN-4
C 1
2 4 1
2
5 3
HYD TEMP
6 4
5
7 6
8
9
9 10
10
AIR-COMP SW
CS-67
10
9 10
9
CN-51, 52, 53 & 54 8
7 6
5
6 4
SENSOR POWER(10V) 51-32 5 3
2
4
ELECTRIC CIRCUIT FOR HYDRAULIC (1/2)
1
GND(for sensor 5V) 51-25 3
2 8
7
1
QUICK COUPLING SW
CN-113
GND_MAIN 51-02
1
2
GND (SENSOR 10V) 51-31
BUZZER
6
9
8
7
10
12
55
54
53
52
31
30
29
28
27
26
25
24
23
11
CN-5
MCU
30A 2
ROOM LAMP/RADIO B+
10A 4
AIR CON / HEATER

20A 7
WIPER
AIR CLEANER CLOGGING SW 54-13 10A 8
CLUSTER B+
10A 9
B+
MCU CONT.
20A 13
EPPR
20A 11
RDU IG
10A 14
RADIO IG
10A 15
CLUSTER IG
10A 16
AAVM / SIREN
10A 17
PROPORTIONAL
10A 18
SOLENOID
10A 19
WIPER
UNITED MCU
10A 20
SAFETY SOL
IG(POWER RY)
10A 26
SEAT HEAT
20A 27
ARM REGEN SOL 52-07
POWER BOOST SOL 53-10 1.0Or
1.5 SOLENOID
20A 28
CIGAR
20A 29
4-21
BREAKER
15A 31
CONVERTER
10A 32
P2 REGULATOR EPPR+ 54-26
54-03 FUEL FILLER PUMP
P2 REGULATOR EPPR- 20A 33
PUMP EPPR+ 54-28

PUMP EPPR- 54-01
P2 PRESS SENSOR 51-14

HEAD LAMP
20A 21
BUCKET IN PS 53-15
HORN
10A 24
WORK LAMP
BOOM DOWN PS 52-31 30A 34
CABIN LAMP
30A 36
N2 PRESS SENSOR 51-28 FUEL HEATER
30A 22
GROUND(EPPR) 54-33 AC / HEATER
20A 25
BOOM UP PS OPTION, SWITCH
52-23 20A 30
TRAVEL SPEED SOL 52-05
ECM
30A 1
ARM OUT PS 51-27 ECM
5A 12
IG(BATTERY RY)
BUCKET OUT PS 51-29
DEF MODULE
HYD. OIL TEMP SENDOR 51-16 15A 3
LINE HEATER
15A 5
DEF&SCR
10A 10
FUEL LEVEL SENDOR 51-19 START, AIR-HEAT
20A 23
ARM IN PS 51-21
START KEY
P1 PRESS SENSOR 30A 6
52-22
TRAVEL BUZZER 52-09*

PUMP EPPR Pf PS 51-13
N1 PRESS SENSOR 51-22
BOOM PRIORITY EPPR+ 54-34
BOOM PRIORITY EPPR- 54-04
SWING PS 52-18
WORKING PS 52-19
TRAVEL PS 52-27
P1 REGULATOR EPPR+ 54-27
P1 REGULATOR EPPR- 54-02
CD-6
SUPPLY A
SIG B
RETURN C
TRAVEL
CD-7
SUPPLY A
SIG B
WORK
RETURN C
CD-35
SUPPLY A
SIG B
5
3
4
1
9
8
7
6
2
10
RETURN C
BUCKET IN
CN-01
CD-24
SUPPLY A
SIG B
SWING
RETURN C
CD-85
SUPPLY A
SIG B
BOOM
DOWN
RETURN C
CD-32
SUPPLY A
SIG B
UP
BOOM
RETURN C
2
1
2
1
1
2
1
1
1
1
2
2
2
2
B
A
B
A
B
A
B
A
B
A
B
A
B
A
C
C
C
C
C
C
C
1
2
CD-90
CD-71
CD-87
CD-44
CD-86
CN-75
CD-42
CD-43
CD-70
A
CN-88
CN-70
CN-81
SUPPLY
CN-243
CN-242
CN-135
CN-133
SIG
SIG
SIG
SIG
SIG
SIG
SIG
IN
SIG B
ARM
SUPPLY
SUPPLY
SUPPLY
SUPPLY
SUPPLY
SUPPLY
SUPPLY
C
TRAVEL BZ
RETURN
RETURN
RETURN
RETURN
RETURN
RETURN
RETURN
RETURN
P2 REG P1 REG MAIN

ARM REGEN
POWER MAX
TRAVEL-HIGH
BKT OUT ARM OUT EPPR EPPR PUMP P3 P1 P2 N2 N1

BOOM PRIORITY
PRESS PRESS PRESS PRESS PRESS PRESS PRESS

330A4EL13
4
4
4
6
6
6
1
10
1
10
1
10
3
3
3
8
8
8
LH RH
max
B
2
Decel
2
PRO-
HORN
BREAK
Power
PRO-
3
CS-5
PORTIONAL
PORTIONAL
CS-26
C
CS-29
CS-19
4
7
7
7
9
9
9
L
B
L
5V
R
B
5V
2
5
2
5
2
5
Gr
Gr
SIG
SIG
RETURN
RETURN
10
10
10
4
8
4
8
4
8
1
2
3
7
3
7
3
7
9
9
9
1
2
5
6
1
2
5
6
1
2
5
6
5
4
3
2
1
A
B
C
2
2
2
1
1
1
1
1
2
2
B
A
B
A
C
SAFETY SW
CS-26A
CS-111
SAFETY SOL
CS-4
CS-83
CN-247
BREAKER
CN-68
CR-48
BOOM FLOATING
CS-83
CN-246
SWING LOCK
FINE SWING
SAFETY RELAY
4
6
1
10
7 8
9
2
5
10
4
8
3
7
9
1
2
5
6
CS-107
5
4
1
9
8
7
6
3
16
15
14
13
12
11
10
STRAIGHT TRAVEL
CN-4
1
2
CN-262
3
3
6
6
4
1
4
1
9
8
7
5
9
8
7
5
2
2
16
15
14
13
12
11
10
15
14
13
12
11
10
CN-6
CN-7
1
2
2
1
CD-31
SUPPLY A MCU
30A 2
CN-262B
CN-262A
SIG B ROOM LAMP/RADIO B+

10A 4
LOAD
OVER
STRAIGHT TRAVEL SOL
RETURN C
AIR CON / HEATER
20A 7
WIPER
ELECTRIC CIRCUIT FOR HYDRAULIC (2/2)
10A 8
CN-51, 52, 53 & 54 CLUSTER B+
10A 9
B+
MCU CONT.
SAFETY SOLENOID 52-06 20A 13
EPPR
20A 11
SENSOR POWER(10V) 51-32 RDU IG
10A 14
GND(SENSOR 5V) 51-25 RADIO IG
10A 15
BOOM CYL. ROD PS 52-25 CLUSTER IG
10A 16
AAVM / SIREN
10A 17
1.0YL PROPORTIONAL
ATT CONFLUX SOL. 52-16 10A 18
ATT SAFETY SOL 53-09
ATT BREAKER SOL 52-08 1.5V SOLENOID
10A 19
MAIN GND 51-02 WIPER

10A 20
IG(POWER RY)
1.5VW SAFETY SOL

GND(SENSOR 10V) 51-31 10A 26
SEAT HEAT
ATT PILOT PS 52-32 20A 27
SOLENOID
20A 28
CIGAR
20A 29
SWING FINE SELEC SW 53-21
1.0BrR BREAKER
15A 31
BREAKER OPER SIG CONVERTER
54-19 10A 32
BOOM UP FLOAT SOL 53-05
FUEL FILLER PUMP
20A 33
OVERLOAD PS
UNITED MCU
52-28
SAFETY LEVER SW 53-16
CAN #2 Lo 51-08
CAN #2 Hi 51-09
HEAD LAMP
20A 21
BOOM DOWN FLOAT SW 54-20 HORN

10A 24
BOOM DOWN FLOAT SOL 53-06 WORK LAMP
30A 34
CABIN LAMP
30A 36
FUEL HEATER
ATT RELIEF EPPR2+ 54-17 30A 22
AC / HEATER
ATT RELIEF EPPR2- 54-10 20A 25
OPTION, SWITCH
20A 30
BM DOWN CUTOFF SOL 53-08 ECM

IG(BATTERY RY)
30A 1
ECM
5A 12
2WAY SELECT SOL 52-14

DEF MODULE
15A 3
4-22
LINE HEATER
ATT RELIEF EPPR1- 54-09 15A 5
DEF&SCR
10A 10
START, AIR-HEAT
20A 23
CN-366
START KEY
1 30A 6
ATT
2
EPPR2
RELIEF
CN-365
1
ATT
5
3
4
1
9
8
7
6
2
12
11
10
EPPR1
CN-3
RELIEF
CN-369
1
SOL
2
BOOM
DOWN
CUTOFF
CN-368 CN-307
1
UP
ERROR 4
SOL
2 GND 3
BOOM
SIGNAL VOLT(Udc) 2
FLOATING
SIGNAL VOLT(Us) 1
(PVG 32)
CN-367
P/P VALVE
1 CN-13
SOL
BOOM 2 1
DOWN
CN-310
2 2
FLOATING 3
CD-124
EPPR
1
SUPPLY A 4
VALVE-A2
SIG B 5
RETURN C 6
ROD PS
CN-309
2
BOOM CYL.
1
EPPR
CD-69 CN-15
VALVE-A1
SUPPLY A 1 CN-306
SIG B 2 Power ground(+) 12
ATT. PS
RETURN C 3 Power supply(+) 11

4 PWMOUT/DOUT/PVGOUT 10
CN-149 5 PWMOUT/DOUT/PVGOUT 9
1 6 PWMOUT/DOUT/PVGOUT 8
SOL
ATT.
(A1/1B)
8 PWMOUT/DOUT/PVGOUT 6
CN-237
(A3)
ATT.
PWMOUT/DOUT/PVGOUT 3
CN-150
DIN/AIN/FreqIN 2
CONNECTOR 2(C2_BLACK)
1
(A1)
DIN/AIN/FreqIN 1
2
2WAY
PROPORTIONAL VALVE & LEVER
SAFETY CONFLUX SEL SOL
CN-305
CN-66 DIN/AIN/FreqIN 12
1
DIN/AIN/FreqIN 11
(A2)
SOL
2 DIN/AIN/FreqIN 10
Sensor power GND- 9
CN-370 CN-14
5Vdc sensor power+ 8
1 1
DIN 7
FINE
2 2
BREAKER SWING
DIN 6
3
AIN/CAN Shield 5
CN-419 4
CAN(-) 4
CONT SOL A1
1
CAN(+) 3
2
SWING
Power supply(+) 2
CONNECTOR 1(C1_GREY)
Power ground(-) 1
CN-420
A2
1 CN-307
2 C
SWING
B
PARKING PARKING
CN-421 A
A3
1
2
SERVICE TOOL
SWING
PARKING
330A4EL14
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
※ Check contact
Glow plug relay
24V 200A Normal : 0.942Ω
(for terminal 1-GND)
CR-24
5
4
1
6
2
3
※ Check contact
B-BR : 24V 1A
B
OFF : ∞Ω(for each terminal)

0, I
1
Start key B-ACC : 24V 10A

ON : 0Ω(for terminal 1-3 and 1-2)
H0 I B-ST : 24V 40A
START : 0Ω(for terminal 1-6)
4
3
2
6
5
STC BR ACC H
CS-2A
CS-2
A SUPPLY
B SIG
C RETURN ※ Check contact
Pressure 8~30V
sensor CD-6 CD-7 CD-16 CD-24 CD-31
CD-7 Normal : 0.1Ω
CD-32 CD-35 CD-42 CD-43 CD-44
CD-69 CD-70 CD-71 CD-85 CD-86
CD-87 CD-90 CD-124
A A
B 3W ※ Check resistance
Resistor
C B A-B : 120Ω
CN-173
CN-173 CN-174
4-23
Glow plug 24V 200A ※ Check resistance

0.25~0.12Ω
CN-80
C 1 ※ Check resistance
Temperature 50˚C : 804Ω
-
sensor 2 80˚C : 310Ω
(hydraulic)
CD-8 100˚C : 180Ω
CD-1
※ Check contact
Air cleaner Pa High level : ∞Ω
pressure switch (N.O TYPE)
Low level : 0Ω
CD-10A
※ Check resistance
Full : 50Ω 6/12 : 350Ω
2 11/12 : 100Ω 5/12 : 400Ω
10/12 : 150Ω 4/12 : 450Ω
Fuel sender - 9/12 : 200Ω 3/12 : 500Ω
1 8/12 : 250Ω 2/12 : 550Ω
CD-2 7/12 : 300Ω 1/12 : 600Ω
Empty warning : 700Ω
3 4 4
Relay 3 Normal : About 200Ω

(air con blower) 2 24V 20A (for terminal 1-3)
1
0Ω
1 2
(for terminal 2-4)
CR-46
1
4 5 1 ※ Check resistance
2
3 Normal : About 160 Ω
Relay 4
24V 16A (for terminal 1-2)
5 3 2
0Ω(for terminal 3-4)
CR-2 CR-2 CR-5
CR-5 CR-36CR-36
CR-39
CR-45 CR-62 ∞Ω(for terminal 3-5)
CR-48 CR-50 CR-51 CR-85
4-24
30
86
87a 87 85
87 Normal : About 160 Ω
Relay 85 24V 16A (for terminal 85-86)
87a 30 86
0Ω(for terminal 30-87a)
CR-4 CR-4
CR-7 CR-7
CR-9CR-9
CR-13 ∞Ω(for terminal 30-87)
CR-13 CR-35 CR-46
CR-35 CR-46 CR-52
1
2 ※ Check resistance
Solenoid valve CN-66CN-66
CN-68 CN-70
CN-68 CN-88
CN-70 24V 1A Normal : 15~25Ω
CN-88
CN-135 CN-135
CN-140 CN-140
CN-149 CN-150
CN-149 CN-236 CN-237 (for terminal 1-2)
CN-237 CN-262A CN-262B
CN-367 CN-368 CN-369 CN-370
CN-419 CN-420 CN-421
EPPR valve 700mA Normal : 15~25Ω
CN-75
CN-75 CN-133
CN-133CN-242
CN-238
(for terminal 1-2)
CN-239CN-243
CN-154 CN-240CN-309
CN-241
CN-242
CN-310 CN-365 CN-366
1
Speaker 2 20W
Normal : A fewΩ
CN-23(LH) CN-260
CN-24(RH)
※ Check contact
6
5
2
1
9
3
8
4
10
Normal
5
2
9
Switch ON : ∞ Ω(for terminal 2-3, 5-6)

24V 1.5A 0 Ω(for terminal 2-1, 5-4)
(locking type)
OFF : 0 Ω(for terminal 2-3, 5-6)
8
6
1
10
3
4
CS-52 CS-67 CS-73 CS-83 ∞ Ω(for terminal 2-1, 5-4)

CS-99 CS-107 CS-108 CS-111
※ Check disconnection
3 Normal : 1.0Ω
Room lamp 2 ON : 0Ω(For terminal 1-2)
24V 10W ∞Ω(For terminal 1-3)
1 OFF : ∞Ω(For terminal 1-2)
CL-1 0Ω(For terminal 1-3)
4-25
2
Head lamp,
24V 65W ※ Check disconnection
Work lamp, 1 (H3 Type) Normal : 1.2Ω
Cab lamp
CL-4CL-4
CL-3 CL-5
CL-5CL-6
CL-6
CL-8 CL-9
CL-8 CL-9 CL-10 CL-24
M 21V 70W ※ Check disconnection

Beacon lamp
(H1 Type) Normal : A fewΩ
CL
-
CL-7
4
3
2 1 M
24V 10A ※ Check resistance
Fuel filler pump 1 2
35ℓ /min Normal : 1.0Ω
CN-61
3 ※ Check operation
2 h Supply power(24V) to terminal
Hour meter 1
16~32V No.1 and connect terminal No.2
and ground
CN-48
1 ※ Check operation
DC22~28V Supply power(24V) to each
Horn 2
2A terminal and connect ground.
CN-20 CN-25
※ Check contact
B C A
Normal : 0Ω(for terminal A-B)
B 24V 15A
Safety switch ∞Ω(for terminal A-C)
(N.C TYPE)
A C Operating : ∞Ω(for terminal A-B)
CS-4 0Ω(for terminal A-C)
4-26
Wiper cut ※ Check contact

24V
switch
(N.O TYPE) Normal : 0Ω(one pin to ground)
CS-53
※ Check contact
Receiver dryer 24V 2.5A
Normal : ∞Ω
CN-29
10
11
12
13
14
15
16
1
2
3
4
5
6
7
9
8
※ Check voltage
Radio &
REMOCON GND
24V 2A 20~25V
SPK FRT RH+
SPK FRT LH+

SPK FRT RH-
SPK FRT LH-
REMOCON+
USB player
BACK UP+
TEL MUTE
ANT 12V
(for terminal 1-3, 3-8)

GND
GND
ACC
ILL+
ILL-
NC
NC
CN-27A
CN-27
M 2
24V 3.8A ※ Check contact
Washer pump
1 Normal : 10.7Ω(for terminal 1-2)
CN-22 CN-408
3 1
2
5 3
4 ※ Check disconnection
Wiper motor 4
24V 2A
5
Normal : 7Ω(for terminal 2-6)
6 M 2 6
CN-21
3 12V 12V
※ Check voltage
DC/DC 2 24V 12V 3A
24V
24V (for terminal 1-2)
Converter 1 GND
12V (for terminal 1-3)
CN-138
4-27
※ Check coil resistance

Normal : About 1MΩ
Cigar lighter 24V 5A 1.4W ※ Check contact
Normal : ∞Ω
Operating time : 5~15sec
CL
-
CL-2
B+
G
L
3~ ※ Check contact
Denso
Alternator U
Normal : 0Ω (for terminal B+-L)
24V 95A
Normal : 24~27.5V
CN-74
M
M ※ Check contact
Denso
Starter
24V 7.8kW Normal : 0.1Ω
B+
CN-45
※ Check contact
Travel alarm 24V 0.5A Normal : 5.2Ω
CN-81
1
Aircon ※ Check contact
24V 79W
compressor Normal : 13.4Ω
CN-28
※ Check contact
Start relay 24V 300A
Normal : 0.94Ω(for terminal 1-2)
CR-23
4-28
1 M ※ Check resistance
Blower motor 24V 9.5A
2 Normal : 2.5Ω(for terminal 1-2)
2 1˚C OFF
Thermistor Normal : 0Ω(for terminal 1-2),
4˚C ON
(switch) 1 the atmosphere temp :
Over 4˚C
Door switch 24V 2W
Normal : About 5MΩ
CS-1
CS-1
Switch
(power max,
one touch
24V 6A
decel, horn, 2 Normal : ∞Ω
breaker)
CS-5 CS-19
CS-26 CS-29
2
60A (CN-60) Normal : 0Ω
Circuit breaker 1 90A (CN-95) (connect ring terminal and check
CN-60 CN-95
CS-60 CS-95 resist between terminal 1 and 2)
L
S
L S ※ Check disconnection
Master switch 6-36V
Normal : 0.1Ω
1
1
2
CS-74, CS-74B
4-29
Quick clamp 1 24V 200mA

buzzer 2 107±4dB
CN-113
1
Socket 12V 10A
2
CN-139
6
5
2
1
7
3
9
8
4
10
※ Check contact
9
Normal
Switch 24V 8A
ON : 0Ω(for terminal 2-1, 2-3)
OFF : ∞Ω(for terminal 2-1, 2-3)
10
3
6
4
CS-100
Fuel heater -
B
A
CN-96
1
DEF/AdBlue®
-
line heater 2
CN-381 CN-382 CN-383
2
WIF sensor -
1
CD-45
4-30
1 POWER 24V
DEF/AdBlue® 2 CAN LO
3 CAN HI -
sensor
4 RETURN
AT1E AT2A AT9A
Temperature 2
>
sensor -
(A/C) 1
DEF/AdBlue® 1
fill up warning 2 -
lamp (LED)
CL-40
5V
A
RETURN
Proportional B
SIG -
valve sensor C
CN-246 CN-247
Normal
6
5
2
1
10
3
9
8
ON
9
Switch 24V 8A 1st step : 0Ω(for terminal 1-2)

2nd step : 0Ω(for terminal 1-2, 4-5)
10
3
4
OFF
CS-79
0Ω(for terminal 2-3, 5-6)
1 AIR PRESS
2 POWER SUPPLY
Sensor 3 AIR TEMP -
4 RETURN
C12
4-31
1 RETURN
2 AIR TEMP
Pressure temp
3 SUPPLY POWER -
sensor 4 AIR PRESS
CD-10
2
Coolant valve -
1
CN-384
1 RETURN
DPF pressure 2 DIFF. PRESS S/S
-
sensor 3 OUTLET PRESS S/S
4 24V
AT11A
1 DEF PUMP MOTOR SPEED SIG

SCR and DEF 2 DEF PUMP MOTOR RELAY
-
supply module 3 DEF PUMP MOTOR SPEED CONTOL SIG
4 DEF PUMP MOTOR
AT-5A
4 POWER
Tank level 3 RETURN
2 CAN HIGH -
sensor
1 CAN LOW
CN-380
4 SPK(-)
3 SPK(+)
Siren AMP 2 GND -
1 ACC
CN-261
4-32
2
3W/300 ※ Check resistance
Resistor 1 3W
Normal : 300Ω
RS-1
2
Float switch 1 -
CS-61
1 2 E
2 1 Pf
4 3 B
3
Low wiper
-
motor 4 Lo
M
CN-407
1 LVDS POS
2 GND
Camera 3 LVDS NEG
(front, rear, 4 POWER 6.5V -
5 NC
side) 6 ADJUST SIGNAL
CN-249 CN-402 CN-403

CN-404 CN-405
1
2.5k
2
3
2.5k
4
Resistor
5
-
6
CN-16B
2 2
Seat belt sw -
1 1
CS-250
4-33
NC 1
RMS service RX232(2)-RX 2
RX232(2)-TX -
tool PROGRAM DUMP
3
4
CS-126A
2
Breaker switch 1 -
CS-26A
CAN_H
A
CAN_L
B
Start button GND -
C
CS-2B
1 1
R 77
2 2
GPS connector 3
4 4
3
R 77 -
CN-125
IG 24V 1
GND 2
CAN (HIGH) 3
Reader CAN (LOW) 4 -
CN-427
ERROR 4
GND 3
Proportional SIGNAL VOLT(Udc) 2
-
valve SIGNAL VOLT(Us) 1
CN-307
4-34
1
Dosing pump
2
-
CN-269
1 CAN_HI
Engine side 2 CAN_LO
cross over 3 ECM DEF MOTOR RY.MONITOR -

connector 4 ATER. DEF PUMP MOTOR SPEED SIG
CC8C
TERMINAL 30 (B+) 1
TERMINAL 58 (LIGHT SIG) 2
TERMINAL 31 (GND) 3
DIAGNOSIS 4
DAT 5
Easystart timer S+ 6 -
ADR 7
ADR 8
Temp. Sensor(-) 9
Temp. Sensor(+) 10
CN-267
1
m
rp
Fan speed 2 -
CD-52
4-35
GROUP 4 CONNECTORS
1. CONNECTOR DESTINATION
Connector No. of Connector part No.
Type Destination
number pin Female Male
CN-1 AMP 12 I/conn (Frame harness-Pump PS harness) S816-010002 S816-110002
CN-2 AMP 15 I/conn (Frame harness-Engine harness) 2-85262-1 368301-1
CN-3A TYCO 12 I/conn (Frame harness-Pro vlv harness) 174661-2 368537-1
CN-4 AMP 16 I/conn (Console harness LH-Frame harness) 368047-1 368050-1
CN-5 DEUTSCH 60 I/conn (Side harness RH-Frame harness) DRB16-60SAE-L018 DRB12-60PAE-L018
CN-6 AMP 16 I/conn (Console harness RH-Frame harness) 368047-1 368050-1
CN-7 AMP 15 I/conn (Console harness RH-Frame harness) 2-85262-1 368301-1
CN-8 AMP 10 I/conn (Console harness RH-Frame harness) S816-010002 174657-2
CN-9 DEUTSCH 12 I/conn (Frame harness-AAVM harness) DT06-12SA-P021 DT04-12PA-P021
CN-10 DEUTSCH 12 I/conn (Cab harness-Side harness RH) DT06-12S-EP06 DT04-12PA-P021
CN-11 DEUTSCH 8 I/conn (Frame harness-Aircon harness) DT06-8S-EP06 -
CN-12 DEUTSCH 2 I/conn (Frame harness-Boom wire harness) DT06-2S-EP06 DT04-2P-E005
CN-13 AMP 6 I/conn (Frame harness-Boom floating) 174262-2 174264-2
CN-14 AMP 4 I/conn (Frame harness-Swing parking & fine control) 174257-2 174259-2
CN-15 AMP 10 I/conn (Frame harness-Breaker sol) 174655-2 174657-2
CN-16 TYCO 6 Emergency engine start & speed control S816-006002 S816-106002
CN-16B - 6 Resistor S816-006002 21NB-10710
CN-17 AMP 8 I/conn (Side harness RH-Wiper harness) S816-008002 S816-108002
CN-18 TYCO 2 I/conn (Frame harness-Washer pump) 174352-2 174354-2
CN-20 DEUTSCH 2 Horn DT06-2S-EP06 -
CN-21 AMP 6 Wiper motor S810-006202 -
CN-22 KET 2 Washer pump MG640605 -
CN-23 KET 2 Speaker-LH MG610070 -
CN-24 KET 2 Speaker-RH MG610070 -
CN-25 DEUTSCH 2 Horn DT06-2S-EP06 -
CN-27A KUM 16 Radio & USB player PK145-16017 -
CN-27B AMP 8 Radio & USB player - 174984-2
CN-28 KET 2 Aircon compressor MG610320 -
CN-29 KET 2 Receiver dryer MG640795 -
CN-36 - - Fuse & relay box 21Q7-10910 24L1-05100
CN-45 RING-TERM - Starter motor B+ S820-108000 -
CN-48 KET 1 Hour meter 2-520193-2 -
CN-51 TE 34 United MCU 2-1437285-3 3-6437285-0
CN-52 TE 34 United MCU 4-1437290-1 6473427-1
CN-53 TE 26 United MCU 1473416-1 6473427-1
CN-54 TE 34 United MCU 4-1437290-0 6437288-1
4-36
Type Destination
CN-56A AMP 12 Cluster - 174663-2
CN-56B AMP 8 Cluster - 174984-2
CN-60 YAZAKI 2 Circuit breaker - 7222-4220-30
CN-61 DEUTSCH 2 Fuel filler pump DT06-4S-EP06 -
CN-61 DEUTSCH 2 Auto grease connector DT06-2S-EP06 DT04-2P-E005
CN-66 DEUTSCH 2 Breaker solenoid DT06-2S-EP06 -
CN-68 DEUTSCH 2 Safety solenoid DT06-2S-EP06 -
CN-70 DEUTSCH 2 Travel high solenoid DT06-2S-EP06 -
CN-74 RING-TERM 1 Alternator "l" terminal S820-105000 -
CN-74 RING-TERM 1 Alternator "B+" terminal S820-108000 -
CN-75 AMP 2 Pump EPPR 174352-2 -
CN-81 DEUTSCH 2 Travel buzzer solenoid DT06-2S-EP06 -
CN-88 DEUTSCH 2 Power max solenoid DT06-2S-EP06 -
CN-93 DELPHI 96 ECM 13964577 -
CN-95 YAZAKI 2 Circuit breaker - 7222-4220-30
CN-96 AMP 4 Fuel heater 2-967325-3 2-967402-1
CN-100 KET 1 ECM ground MG640944-5 -
CN-113 KET 2 Buzzer MG651205-5 -
CN-125 Econoseal J 4 GPS connector S816-004002 S816-104002
CN-125A DEUTSCH 12 RMS DT06-12S-P021 DT04-12PA-P021
CN-125B DEUTSCH 8 RMS DT06-8S DT04-8P
CN-126 AMP 10 Service tool 174655-2 -
CN-126A DEUTSCH 4 RMS Service tool DT06-4S DT04-4P
CN-133 DEUTSCH 2 Boom priority solenoid DT06-2S-EP06 -
CN-138 FASTEN 3 DC/DC Converter S810-003202 -
CN-139 FASTEN 2 12V socket 172434-2 -
CN-140 DEUTSCH 2 Quick clamp solenoid DT06-2S-EP06 DT04-2P-E005
CN-141 AMP 13 Wiper motor controller 172498-1 -
CN-149 DEUTSCH 2 Attach safety solenoid DT06-2S-EP06 -
CN-150 DEUTSCH 2 2 way select solenoid DT06-2S-EP06 -
CN-154 DEUTSCH 2 Cooling fan DT06-2S-EP06 -
CN-156 DEUTSCH 2 Seat heat DT06-2S DT04-2P
CN-157 AMP 1 Antena power S822-014002 -
CN-173 DEUTSCH 3 Resistor DT06-3S-EP06 DT04-3P-EP10
CN-174 DEUTSCH 3 Resistor DT06-3S-EP06 DT04-3P-E005
CN-237 DEUTSCH 2 Attach conflux solenoid DT06-2S-EP06 -
CN-242 DEUTSCH 2 P1 regulator EPPR (A1) DT06-2S-EP06 -
CN-243 DEUTSCH 2 P2 regulator EPPR (A2) DT06-2S-EP06 -
CN-245 KET 2 PTC power MG620558 -
4-37
Type Destination
CN-246 DEUTSCH 3 Proportional valve-RH DT06-3S DT04-3P
CN-246A/B DEUTSCH 4 I/conn (Engine block heater harness -Timer harness) DT06-4S-EP06 DT04-4P-EP06
CN-247 DEUTSCH 3 Proportional valve-LH DT06-3S DT04-3P
CN-249 DEUTSCH 6 Rear view camera DT06-6S-EP06 DT04-6P-E005
CN-258 KET 1 Air compressor power MG640944-5 MG650943-5
CN-260 AMP 2 Siren lamp 174352-2 174354-2
CN-260 MTA 2 Engine block heater fuse box 03 01315 -
CN-261 MTA 2 Engine block heater fuse box 03 01305 -
CN-261 - 4 Siren AMP - -
CN-262 DEUTSCH 2 I/conn (Frame harness - Straight travel solenoid harness) DT06-2S-EP06 DT04-2P-E005
CN-262A DEUTSCH 2 Travel solenoid 1 DT06-2S-EP06 -
CN-262B DEUTSCH 2 Travel solenoid 2 DT06-2S-EP06 -
CN-263 DEUTSCH 2 Air compressor relay DT06-2S-EP06 DT04-2P-E005
CN-265 VW 8 Engine block heater controller 3A0973734 -
CN-267 MOLEX 10 Easy start timer 15-97-5101 -
CN-269 TE 2 Dosing pump 282189-1 -
CN-305 DEUTSCH 12 Proportional-Connector-1 DTM06-12SA -
CN-306 DEUTSCH 12 Proportional-Connector-2 DTM06-12SB -
CN-307 DEUTSCH 3 Proportional-Service tool DT06-3S-EP06 DT06-3P-E005
CN-308 AMP 4 Proportional-PVG32 2-967059-1 -
CN-309 DEUTSCH 2 Proportional-EPPR valve A2 DT06-2S-EP06 -
CN-310 DEUTSCH 2 Proportional-EPPR valve A1 DT06-2S-EP06 -
CN-363 AMP 12 Jog dial module 174045-2 -
CN-365 DEUTSCH 2 Attach relief EPPR valve1 DT06-2S-EP06 DT04-2P-E005
CN-366 DEUTSCH 2 Attach relief EPPR valve2 DT06-2S-EP06 DT04-2P-E005
CN-367 KET/DEUTSCH 2 Boom down floating solenoid 85202-1 DT04-2P-E005
CN-368 DEUTSCH 2 Boom up floating solenoid DT06-2S-EP06 DT04-2P-E005
CN-369 DEUTSCH 2 Boom down cut off solenoid DT06-2S-EP06 DT04-2P-E005
CN-370 DEUTSCH 2 Swing fine control solenoid DT06-2S-EP06 DT04-2P-E005
CN-376 TYCO 23 Membrane controller 7706087-2 -
CN-380 DEUTSCH 4 DEF/AdBlue® tank level sensor DT06-4S-EP06 -
CN-381 DEUTSCH 2 DEF line heater 1 DT06-2S-EP06 -
CN-384 TYCO 2 Coolant valve - 1-967325-3
CN-401 TE 35 AAVM controller 776164-1 -
CN-402 DEUTSCH 6 Front view camera DT06-6S-P021 DT04-6P-P021
CN-403 DEUTSCH 6 Rear view camera DT06-6S-EP06 DT04-6P-P021
CN-404 DEUTSCH 6 LH view camera DT06-6S-EP06 DT04-6P-EP14
4-38
Type Destination
CN-405 DEUTSCH 6 RH view camera DT06-6S-EP06 DT04-6P-EP14
CN-406 DEUTSCH 3 Service tool DT06-3S-EP06 DT04-3P-E005
CN-407 DEUTSCH 4 Low wiper motor DT06-4S-EP06 DT04-4P-E005
CN-408 KET 4 Washer tank MG640605 -
CN-419 DEUTSCH 2 Swing parking-A1 DT06-2S-EP06 -
CN-427 MOLEX 4 Reader-RMS 039012040 026013096
CN-430 TYCO/AMP 12 I/conn (Frame harness-Aftertreatment harness) 174661-2 S816-112002
AT1E TYCO 4 Inlet Nox sensor 2-1418390-1 -
AT2A TYCO 4 Outlet Nox sensor 1-1418390-1 -
AT-5A TYCO 4 SCR supply module 2-1703639-1 -
AT-6A TYCO 8 DEF/AdBlue® dosing module 1-141-8479-1 -
AT9A TYCO 4 SCR temp sensor 4-1418390-1 -
AT11A FRAMATOME 4 Diff perssure sensor F715600 -
CC8C DEUTSCH 4 Engine side cross over connector DT06-4S-EP06 -
C-12 FCI 4 Air cleaner (ECM J1) - 54200419
·Relay
CR-1 RING-TERM - Battery relay ST710289-2 -
CR-2 - 5 Horn relay - -
CR-4 - 5 Working lamp relay - -
CR-5 - 5 Anti restart relay - -
CR-7 - 5 Aircon compressor relay - -
CR-9 - 5 Cabin lamp relay - -
CR-13 - 5 Head lamp relay - -
CR-23 KET 2 Start relay S814-002001 S814-102001
CR-24 RING TERM 1 Preheat relay S822-014000 -
CR-35 - 5 Power relay - -
CR-36 - 5 Preheat relay - -
CR-39 - 5 Starter lock out relay - -
CR-46 - 5 Fuel warmer relay - -
CR-48 - 5 Safety relay - -
CR-50 - 5 NOX sensor relay - -
CR-51 - 5 DEF/AdBlue® module relay - -
CR-52 - 5 Line heater relay - -
CR-85 - 5 Beacon lamp relay - -
·Switch
CS-1 SHUR 1 Door switch S822-014002 S822-114002
CS-2A WP 6 Start switch S814-006100 -
4-39
Type Destination
CS-2B DEUTSCH 3 Start button DT06-3S-EP06 DT04-3P-E005
CS-2C KET 3 Button start MG651032 -
CS-2D KET 3 Button start key - MG641035
CS-4 DEUTSCH 3 Safety switch DT06-3S -
CS-5 DEUTSCH 2 Horn switch - DT04-2P
CS-19 DEUTSCH 2 One touch decel switch - DT04-2P
CS-26 DEUTSCH 2 Breaker switch DT06-2S -
CS-26A AMP 2 Breaker pedal switch S816-002002 S816-102002
CS-29 DEUTSCH 2 Power max switch DT06-2S -
CS-33 AMP 6 Emergency engine stop switch S816-006002 S816-106002
CS-52 CARLING 10 2 Piece switch VC2-01 -
CS-53 AMP 1 Wiper cut switch S822-014002 -
CS-61 AMP 2 Floating switch 174352-2 -
CS-67 CARLING 10 Quick clamp switch VC2-01 -
CS-73 CARLING 10 Swing lock switch VC2-01 -
CS-73A CARLING 10 Swing fine switch VC2-01 -
CS-74 DEUTSCH 2 Master switch DT06-2S-EP06 -
CS-74B DEUTSCH 2 Master switch DT06-2S-EP06 -
CS-79 CARLING 10 Lower wiper switch VC2-01 -
CS-83 CARLING 10 Swing lock switch VC2-01 -
CS-99 CARLING 10 Air compressor switch VC2-01 -
CS-100 CARLING 10 Exhaust system cleaning switch VC2-01 -
CS-107 CARLING 10 Travel straight switch VC2-01 -
CS-108 CARLING 10 Auto grease switch VC2-01 -
CS-111 CARLING 10 Boom floating switch VC2-01 -
CS-250 DEUTSCH 2 Seat switch DT06-2S -
·Light
CL-1 KET 3 Room lamp MG651032 -
S822-014002 S822-114002
CL-2 AMP 1 Cigar lighter
S822-014002 -
CL-3 DEUTSCH 2 Head lamp-LH DT06-2S-EP06 DT04-2P
CL-4 DEUTSCH 2 Head lamp-RH DT06-2S-EP06 DT04-2P
CL-5 DEUTSCH 2 Work lamp-LH DT06-2S-EP06 DT04-2P
CL-6 DEUTSCH 2 Work lamp-RH DT06-2S-EP06 DT04-2P
CL-7 SHUR 1 Beacon lamp S822-014002 S822-114002
CL-8 DEUTSCH 2 Cab lighter-LH DT06-2S-EP06 DT04-2P
CL-9 DEUTSCH 2 Cab lighter-RH DT06-2S-EP06 DT04-2P
CL-10 DEUTSCH 2 Cab lighter - RH DT06-2S-EP06 DT04-2P
CL-24 DEUTSCH 2 Head lamp-rear DT06-2S-EP06 DT04-2P-E005
4-40
Type Destination
CL-36 DEUTSCH 2 Work lamp - LH DT06-2S-EP06 -
CL-37 DEUTSCH 2 Work lamp - RH DT06-2S-EP06 -
CL-40 DEUTSCH 2 DEF/AdBlue® lamp DT06-2S-EP06 -
Sensor, sendor
CD-1 AMP 2 Hydraulic oil temp sender 85202-1 -
CD-2 DEUTSCH 2 Fuel sender DT06-2S-EP06 -
CD-6 DEUTSCH 3 Travel pressure switch DT06-3S-EP06 -
CD-7 DEUTSCH 3 Working pressure switch DT06-3S-EP06 -
CD-10 SUMITOMO 4 Pressure & temperature sensor 6098-0144 -
CD-10A AMP 2 Air cleaner switch 85202-1 -
CD-16 AMP 3 Water level sensor 1211 0293 -
CD-24 DEUTSCH 3 Swing pressure sensor DT06-3S-EP06 -
CD-31 DEUTSCH 3 Overload pressure sensor DT06-3S-EP06 DT04-3P-E005
CD-32 DEUTSCH 3 Boom up pressure sensor DT06-3S-EP06 -
CD-35 DEUTSCH 3 Bucket in pressure sensor DT06-3S-EP06 -
CD-42 DEUTSCH 3 Pump pressure 1 DT06-3S-EP06 -
CD-45 AMP 2 WIF sensor DT06-2S-EP06 -
CD-52 AMP 2 Fan speed 174352-2 -
CD-69 DEUTSCH 3 Attach pressure sensor DT06-3S-EP06 -
CD-70 DEUTSCH 3 N1 pressure sensor DT06-3S-EP06 -
CD-71 DEUTSCH 3 N2 pressure sensor DT06-3S-EP06 -
CD-85 DEUTSCH 3 Boom down pressure sensor DT06-3S-EP06 -
CD-86 DEUTSCH 3 Arm out pressure sensor DT06-3S-EP06 -
CD-87 DEUTSCH 3 Bucket out pressure sensor DT06-3S-EP06 -
CD-90 DEUTSCH 3 Arm in pressure sensor DT06-3S-EP06 -
CD-124 DEUTSCH 3 Boom cylinder rod pressure snensor DT06-3S-EP06 -
4-41
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 - 42
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
1 21
1 11
21
1 11 1 21
S811-021002 S811-121002
4 - 43
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 - 44
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 - 45
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 - 46
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 - 47
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 - 48
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 - 49
8) AMP 040 MULTILOCK CONNECTOR
No. of
pin
12 1 6
7 12
174045-2
9) AMP 070 MULTILOCK CONNECTOR

No. of
pin
1 6
14
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 - 50
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 - 51
13) KET SDL CONNECTOR
No. of
pin
14
7
6
14
MG610406
4 - 52
14) DEUTSCH DT CONNECTORS
DT 06 - 3S - ★★★★
Modifications (see below)

Number of contacts (P : Pin, S : Socket)
06 : Receptacle, 04 : Plug
Deutsch connectors
※ 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
2 1 1 2
2
DT06-2S DT04-2P
1 2 2 1
3 3
DT06-3S DT04-3P
1 4 4 1
2 3 3 2
DT06-4S DT04-4P
4 - 53
No. of
pin
1 6 6 1
3 4 4 3
DT06-6S DT04-6P
5 4 4 5
1 8
8 1
DT06-8S DT04-8P
7 6
6 7
12
12 1 1 12
DT06-12S DT04-12P
4 - 54
15) MOLEX 2CKTS CONNECTOR
No. of
pin
1 2
35215-0200
35215-0200
16) ITT SWF CONNECTOR

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

No. of
pin
1
1
NMWP01F-B
4 - 55
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 - 56
No. of
pin
S816-006002 S816-106002
S816-008002 S816-108002
10
S816-010002 S816-110002
12
S816-012002 S816-112002
4 - 57
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 - 58
21) DEUTSCH MCU CONNECTOR
No. of
Receptacle connector (Female) Plug connector (Male)
pin
5
1 6
11 1
10
2
3
11 4
5
21
40 21 31
32
6
7
8
9
33 10
34
35
31 36
37
20
30
20
38
35 39
40
36
30
40
DRC26-40SA/B
22) DEUTSCH SERVICE TOOL CONNECTOR

No. of
pin
C
D
E
A
9
F
B
G
H J
HD10-9-96P
23) AMP fuel warmer connector

No. of
pin
3 2
2-967325-3
4 - 59
24) DEUTSCH Engine ECM CONNECTOR
No. of
pin
1 5
6
11
1
10
2
11 3
4
21 5
21 31
6
50 31 41
42
7
8
9
10 20
43
44
41 45
20
46
47
30
40
30
48
45 49
50
46
50 40
DRC26-50S-04
25) DEUTSCH Intermediate CONNECTOR

No. of
pin
1
13 12
25 24
31
30
60 37
36
49
48
60
DRB16-60SAE-L018
4 - 60
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 System ----------------------------------------------------------------------- 5-9
Group 7 Engine Overheat Prevention System -------------------------------------------------------------- 5-10
Group 8 Variable Power Control System ----------------------------------------------------------------------- 5-11
Group 9 Attachment Flow Control System -------------------------------------------------------------------- 5-12
Group 10 Boom Floating Control System------------------------------------------------------------------------- 5-13
Group 11 Intelligent Power Control System---------------------------------------------------------------------- 5-14
Group 12 Anti-Restart System ------------------------------------------------------------------------------------------ 5-16
Group 13 Self-Diagnostic System ------------------------------------------------------------------------------------- 5-17
Group 14 Engine Control System ------------------------------------------------------------------------------------- 5-62
Group 15 EPPR Valve -------------------------------------------------------------------------------------------------------- 5-63
Group 16 Monitoring System --------------------------------------------------------------------------------------------- 5-68
Group 17 Fuel Warmer System ----------------------------------------------------------------------------------------- 5-108
GROUP 1 OUTLINE
The ADVANCED CAPO (Computer Aided Power Optimization) system controls engine and pump
mutual power at an optimum and less fuel consuming state for the selected work by mode selection,
auto-deceleration, power boost function, etc. It monitors machine conditions, for instance, engine
speed, coolant temperature, hydraulic oil temperature, and hydraulic oil pressure, etc.
It consists of a MCU, a cluster, an ECM, EPPR valves, and other components. The MCU 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.
Power mode selection (P, S, E)

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

ADVANCED
CAPO
SYSTEM
Variable power control system
Attachment flow control system
Boom floating control system
Intelligent power control system
Anti-restart system
MCU & cluster protection
Self-diagnostic system Open-short diagnosis & error code display
Machine error & ECM fault code display
Machine condition monitoring
Machine monitoring system
Electric signal monitoring
One touch deceleration system
5-1
SYSTEM DIAGRAM
Attachment pilot Work Travel

Work tool pressure pressure pressure
PS PS PS
MCV
Arm 1 Arm 2
SOLENOID VALVE EPPR VALVE
Option Bucket
Attachment Boom floating
pressure(opt) Boom 2 Boom 1 cartridge valve
Travel speed Attachment Swing Travel(LH) Boom priority

conflux(opt) EPPR
Power boost Attachment Travel(RH) Attachment

safety(opt) flow EPPR
A1 pump
pressure
Overload switch
pressure
sensor PS
PS A2 pump
pressure switch
PS
Boom cylinder
Engine Negacon 1
pressure
PS
PS
Negacon 2
ECM pressure
Main pump Pilot pump
EPPR PS Pump power
pressure shift EPPR
CAN #1
Signal
Pressure signal
Pressure signal
Drive signal
Drive signal MCU
Pressure signal
Switch signal
Power boost Pressure signal CAN #2 CN-16A CN-16
button
One touch Horn button Normal
decel button
CN-16B
Option Emergency
button
LH control RH control
lever lever
Jog dial module
SL SR AO AI BI BO BU BD
CAN #1 & #2
Terminal
block
PS PS PS PS PS PS PS
Swing Arm Arm Bkt Bkt Boom Boom Camera

ps out in in out up down
ps ps ps ps ps ps
Cluster
380A5MS01
5-2
GROUP 2 MODE SELECTION SYSTEM
1. POWER MODE SELECTION SYSTEM
Main control valve
Engine
ECM
Pump power
shift EPPR
CAN #1
Cluster
MCU Drive signal
Jog dial module

Power mode
pilot lamp
Emergency
CN-16B
Power mode switch signal CN-16A CN-16
CAN #1 & #2 CAN #2 Normal
300A5MS02
Mode selection system (micro computer based electro-hydraulic pump and engine mutual control
system) optimizes the engine and pump performance.
The combination of 3 power modes (P, S, E) and acceleration mode (10 set) of haptic controller
makes it possible to use the engine and pump power more effectively corresponding to the work
conditions from a heavy and great power requesting work to a light and precise work.
Engine rpm Power shift by EPPR valve
Power Standard Option Standard Option
Application
mode
Current Pressure Current Pressure
Unload Load Unload Load
(mA) (kgf/cm2) (mA) (kgf/cm2)
P Heavy duty power 1700±50 1700±50 1600±50 1600±50 290±30 8 (~3)±3 190±30 3 (~3)±3
S Standard power 1600±50 1600±50 1500±50 1500±50 330±30 10 (~5)±3 250±30 5 (~5)±3
E Economy operation 1500±50 1500±50 1400±50 1400±50 400±30 15 (~10)±3 400±30 15 (~10)±3
AUTO Engine
1000±100 - 1000±100 - 700±30 38±3 700±30 38±3
DECEL deceleration
One touch Engine quick
900±100 - 900±100 - 700±30 38±3 700±30 38±3
decel deceleration
KEY Key switch
900±100 - 900±100 - 700±30 38±3 700±30 38±3
START start position
※ Power shift (Standard/Option) can be changed by "Service menu" in "Management" on the cluster.
※ (~*) : Load
5-3
2. WORK MODE SELECTION SYSTEM
Work mode consists of the general operation (bucket) and the optional attachment (breaker,
crusher).
Attachment pilot
pressure sensor
PS Main control valve
Work tool
Arm 1 Arm 2
SOLENOID VALVE
Option Bucket
Breaker
Boom 2 Boom 1
Attachment
Swing Travel(LH) conflux
Attachment
Travel(RH) safety
Engine
ECM
Pump power
shift EPPR
CAN #1
Cluster
Drive signal
MCU Drive signal
Pressure signal
Jog dial module
Work mode
pilot lamp
Emergency
CN-16B
Work mode switch signal CN-16A CN-16
380A5MS03
1) General WORK MODE (bucket)

This mode is used to general digging work.
2) ATT WORK MODE (breaker, crusher)
It controls the pump flow and system pressure according to the operation of breaker or crusher.
General mode Work tool
Description
Bucket Breaker Crusher
Attachment safety solenoid OFF - ON
Attachment conflux solenoid OFF ON/OFF ON/OFF
Attachment flow EPPR current 100 mA 100~700 mA 100~700 mA
Breaker solenoid★ OFF ON -
★ When breaker operating button is pushed.
5-4
3. USER MODE SELECTION SYSTEM
Main control valve
Engine
ECM
Pump power
shift EPPR
CAN #1
Cluster
Drive signal
MCU
Jog dial module
User mode
pilot lamp
Emergency
CN-16B
User mode switch signal CN-16A CN-16
300A5MS04
1) High idle rpm, auto idle rpm and EPPR pressure can be adjusted and memorized in the U-mode.
2) LCD segment vs parameter setting
Step Engine speed Idle speed Power shift
( ) (rpm) (rpm) (bar)
1 1300 750 0
2 1400 800 3
3 1500 850 6
4 1600 900 9
5 1700 950 12
6 1800 1000 (auto decel) 16
7 1850 1050 20
8 1900 1100 26
9 1950 1150 32
10 2000 1200 38
5-5
GROUP 3 AUTOMATIC DECELERATION SYSTEM
Work Travel
pressure pressure
PS PS
Main control valve

Engine
ECM
Pilot pump
Main pump
CAN #1
Cluster
MCU
Pressure signal
Jog dial module

Auto idle
pilot lamp
Emergency
CN-16B
Auto idle switch signal CN-16A CN-16
300A5MS05
1. WHEN AUTO IDLE PILOT LAMP ON

When all of the work equipment control levers including swing and travel levers are at neutral for 4
seconds, MCU sends throttle command to ECM to reduce the engine speed to 1000 rpm. If the
control levers are at neutral for 1 minute, MCU reduces the engine speed to 900 rpm. 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 idle pilot lamp is turned off by pressing the switch or any control lever is operated, the
reduced engine speed rises upto the speed before deceleration in a second.
Engine rpm
Multimodal dial
set rpm
Auto idle 1000 rpm

rpm
4 sec
Low idle 900 rpm
rpm
60 sec 1sec
Lever Lever Time

neutral operation
330A5MS05
2. WHEN AUTO idle pilot LAMP OFF

The engine speed can be set as desired using the multimodal dial switch, and even if the control
levers are neutral, the engine speed is not reduced.
※ Auto idle function can be activated when multimodal dial position is over 4.
5-6
GROUP 4 POWER BOOST SYSTEM
Main control valve
Arm 1 Arm 2
Option Bucket
Boom 2 Boom 1
Swing Travel(LH)
Travel(RH)
Main relief
valve
PS
pressure
switch PS
pressure
switch
Power boost
solenoid valve
Engine
ECM
Power boost Pump power
button shift EPPR
CAN #1
LH control
lever Signal
Drive signal
Power max button signal
Pressure signal
MCU
Jog dial module
Emergency
CN-16B
Power mode sw signal CN-16A CN-16
Power max
pilot lamp CAN #1 & #2 CAN #2 Normal
Cluster
380A5MS06
· When the power boost switch on the left control lever knob is pushed ON, the power mode is set P
mode and maximum digging power is increased by 10 %.
· When 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.
Description Condition Function
- Power mode : P
- Multimodal dial power : 9
Power boost switch : ON
Activated - Power boost solenoid : ON
Multimodal dial : over 8
- Power boost pilot lmap : ON
- Operating time : max 8 seconds
- Pre-set power mode
Canceled Power boost switch : OFF - Power boost solenoid : OFF
- Power boost pilot lamp : OFF
※ When the auto power boost is set to Enable and power mode is set to P mode on the cluster, the
digging power is automatically increased as working conditions by the MCU. It is operated max 8
seconds.
5-7
GROUP 5 TRAVEL SPEED CONTROL SYSTEM
Main control valve Travel motor
Arm 1 Arm 2
Option Bucket
Boom 2 Boom 1 Regulator
Swing Travel(LH)
Travel(RH)
Travel speed
solenoid valve
Engine

Cluster
Drive signal
MCU
Travel speed
pilot lamp
Travel speed switch signal

CAN #1 & #2
380A5MS07
Travel speed can be switched manually by pressing the travel speed switch on the cluster.
Travel speed Lamp
Speed Operation
solenoid valve on cluster
Low OFF Turtle Low speed, high driving torque in the travel motor
High ON Rabbit High speed, low driving torque in the travel motor
※ Default : Turtle (Low)
5-8
GROUP 6 AUTOMATIC WARMING UP SYSTEM
300A5MS08
1. The MCU receives the engine coolant temperature from the ECM, and if the coolant temperature is
below 30˚C, it increases the engine speed from key start rpm to 1200 rpm. At this time the mode
does not change. If the coolant temperature sensor has fault, the hydraulic oil temperature signal is
substituted.
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 power mode set during the warming up function, the MCU
cancels the automatic warming up function.
3. LOGIC TABLE
- Coolant temperature : - Power mode : Default (E mode)
Actuated below 30˚C (after engine run) - Warming up time : 10 minutes (max)
- Warming up pilot lamp : ON
- Coolant temperature : Above 30˚C - Power mode : set mode
- Warming up time : Above 10 minutes - Warming up pilot lamp : OFF
- Changed power mode set by operator
Canceled - RCV lever or pedal operating
- Auto idle cancel
※ If any of the above conditions is
applicable, the automatic warming up
function is canceled
5-9
GROUP 7 ENGINE OVERHEAT PREVENTION system
300A5MS09
1. If the engine coolant temperature is overheated over 103˚C or the hydraulic oil temperature is
overheated over 100˚C, the warning lamp is ON and the pump input torque or the engine speed is
reduced as below logic table.
2. LOGIC TABLE
- Coolant temperature : - Warning lamp : ON , buzzer : OFF
Above 103˚C - Pump input torque is reduced.
Activated
- Hydraulic oil temperature : - Warning lamp & buzzer : ON
First step Above 100˚C - Pump input torque is reduced.
warning - Coolant temperature :
Less than 100˚C - Return to pre-set the pump absorption
Canceled
- Hydraulic oil temperature : torque.
Less than 95˚C
- Emergency warning lamp pops up on the
- Coolant temperature : Above 107˚C
Activated center of LCD and the buzzer sounds.
- Hydraulic oil temperature : Above 105˚C
- Engine speed is reduced after 10 seconds.
Second step
warning - Coolant temperature :
- Return to pre-set the engine speed.
Less than 103˚C
Canceled - Hold pump absorption torque on the first
- Hydraulic oil temperature :
step warning.
Less than 100˚C
5-10
GROUP 8 Variable power control SYSTEM
Travel
pressure
PS
Main control valve
Engine
ECM
Pump power
shift EPPR
CAN #1
Signal
Switch signal
Pressure signal MCU
RH control Pressure signal
LH control
lever lever
CAN #2 CN-16A CN-16
Normal
CAN #1 & #2
CN-16B
SL SR AO AI BI BO BU BD Emergency
Terminal
block
Power mode switch signal Jog dial module
Swing Arm Arm Bkt Bkt Boom Boom
ps ps ps ps ps ps
Power mode
Cluster
330A5MS10
· The variable power control system controls the engine and pump mutual power according to RCV
lever stroke and pump load.
It makes fuel saving and smooth control at precise work.
Description Working condition

Power mode P, S, E
Work mode General (bucket)
Pressure sensor Normal
※ The variable power control function can be activated when the power mode is set to all power
mode.
5-11
GROUP 9 Attachment flow control system
Attachment pilot
pressure sensor
Main control valve
PS
Work tool
Arm 1 Arm 2
SOLENOID VALVE
Option Bucket
Breaker
Boom 2 Boom 1
Attachment
conflux
Swing Travel(LH)
Attachment
Travel(RH) safety
Engine
ECM
Attachment
Cluster flow EPPR
CAN #1
Drive signal
Drive signal
MCU
Pressure signal
Jog dial module
Emergency
CN-16B
Work mode switch signal CN-16A CN-16
380A5MS11
· The system is used to control the pump delivery flow according to set of the work tool on the
cluster by the attachment flow EPPR valve.
Work tool
Description
Breaker Crusher
Flow level 100 ~ 220 lpm 100 ~ 520 lpm
Attach safety solenoid - ON
Attach conflux solenoid ON/OFF ON/OFF
Breaker solenoid★ ON -
※ Refer to the page 5-79 for the attachment kinds and max flow.
★ When breaker operating button is pushed.
5-12
GROUP 10 BOOM FLOATING control system
Boom cylinder
Rod pressure
PS
Head pressure
PS
Head to tank Rod to tank

solenoid solenoid
Boom down pilot

cutoff solenoid
Boom 1 spool
Main control valve
LH control RH control
lever lever
Breaker
button Main pump Pilot pump
Signal
SL SR AO AI BI BO BU BD Signal
Signal
Shuttle Pressure signal

block Pressure signal MCU
PS PS PS PS PS PS PS Switch signal Boom floating signal
Pressure signal
Boom Boom
up down
pressure pressure 330A5MS17
· Boom floating automatically controls boom cylinder along the ground by operating arm cylinder
only.
Description
Condition Function
Work mode★1 Floating mode
Rod to tank solenoid : ON
Boom up
Floating mode sw : ON Head to tank solenoid : OFF
floating★2
Boom down cutoff solenoid : OFF
General mode Floating mode sw : ON
Rod to tank solenoid : ON
Boom up/down Breaker button : Pressed
Head to tank solenoid : ON
floating★2 Boom down pilot pressure＞25 bar
Boom down cutoff solenoid : ON
Boom up pilot pressure＜5 bar
Floating mode sw : ON
Rod to tank solenoid : OFF
Boom down Breaker button : Pressed
Breaker mode Head to tank solenoid : ON
floating Boom down pilot pressure＞25 bar
Boom down cutoff solenoid : ON
Boom up pilot pressure＜5 bar
Rod to tank solenoid : OFF
During operation of boom floating
Temporarily canceled Head to tank solenoid : OFF
Boost sw : Pressed
Boom down cutoff solenoid : OFF
★1
Boom floating is not activated when work mode is crusher mode.
★2
These functions are activated just in case the excavator is not in jack up status.
5-13
GROUP 11 Intelligent Power control system
Travel
pressure
Main control valve PS
Arm 1 Arm 2
Option Bucket
Boom 2 Boom 1
Swing Travel(LH)
Travel(RH)
Attach flow
EPPR 1
Engine
ECM
Power boost Pump power
button shift EPPR
CAN #1
One touch Horn button

decel button
Option
button
LH control RH control Signal

lever lever
Pressure signal
MCU
SL SR AO AI BI BO BU BD
Switch signal Pressure signal
Shuttle Pressure signal
block
Swing Arm Arm Bkt Bkt Boom Boom

ps ps ps ps ps ps 380A5MS18
1. When the requirement of pump flow rate is low, IPC mode controls pump flow rate to improve fuel
efficiency.
Condition★1 Function
IPC mode : ON★2

Boom up
Arm in Limitation of pump flow rate : Activated
Not travel motion
Not swing motion
None of upper condition Limitation of pump flow rate : Canceled
★1
AND condition
★2
IPC mode ON/OFF is selected at "Mode setup > IPC mode". See next page.
5-14
2. IPC mode selection
IPC mode ON/OFF and the levels of flow rate limit can be selected at "Mode setup > IPC mode"
Q(cc/rev)
Balance
IPC modemode
1
Efficiency
IPC mode mode
2
300A3CD52 Pi(bar)
290F3CD311
IPC mode Description
Balance mode (default) IPC mode ON, limit level 1

Efficiency mode IPC mode ON, limit level 2
Speed mode IPC mode off
5-15
GROUP 12 ANTI-RESTART SYSTEM
140L5MS12
1. ANTI-RESTART FUNCTION
After a few seconds from the engine starts to run, MCU turns off the start safety relay to protect the
starter from inadvertent restarting.
5-16
GROUP 13 SELF-DIAGNOSTIC SYSTEM
1. OUTLINE
When any abnormality occurs in the ADVANCED CAPO system caused by electric parts malfunction
and by open or short circuit, the MCU diagnoses the problem and sends the error codes to the
cluster and also stores them in the memory.
2. Monitoring
1) Active fault
300A3CD65
300A3CD66 300A3CD67
· The active faults of the MCU, engine ECM or air conditioner can be checked by this menu.
2) Logged fault
300A3CD68
300A3CD69 300A3CD70
· The logged faults of the MCU, engine ECM or air conditioner can be checked by this menu.
3) Delete logged fault
300A3CD71
300A3CD72 300A3CD73
· The logged faults of the MCU, engine ECM or air conditioner can be deleted by this menu.
5-17
3. machine ERROR CODES TABLE
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
3 10 seconds continuous, Hydraulic Oil Temp. Measurement Voltage > 3.8V ●
4 10 seconds continuous, Hydraulic Oil Temp. Measurement Voltage < 0.3V ●
(Results / Symptoms)
101 1. Monitor – Hydraulic oil temperature display failure
2. Control Function – Fan revolutions control failure
(Checking list)
1. CD-1 (#2) - CN-51 (#16) Checking Open/Short
2. CD-1 (#1) - CN-51 (#25) Checking Open/Short
10 seconds continuous, Working Press. Sensor
0 ●
Measurement Voltage > 5.2V
10 seconds continuous, 0.3V≤ Working Press. Sensor Measurement
1 ●
Voltage < 0.8V
10 seconds continuous, Working Press. Sensor
4 ●
Measurement Voltage < 0.3V
105
1. Monitor – Working Press. display failure
2. Control Function – Auto Idle operation failure, Engine variable horse power control operation
failure
(Checking list)
1. CD-7 (#B) – CN-52 (#19) Checking Open/Short
2. CD-7 (#A) – CN-51 (#32) Checking Open/Short
3. CD-7 (#C) – CN-51 (#31) Checking Open/Short
10 seconds continuous, Travel Oil Press. Sensor
0 ●
10 seconds continuous, 0.3V ≤ Travel Oil Press. Sensor Measurement
1 ●
Voltage < 0.8V
10 seconds continuous, Travel Oil Press. Sensor
4 ●
108
1. Monitor – Travel Oil Press. display failure
2. Control Function – Auto Idle operation failure, Engine variable horse power control operation
failure, IPC operation failure, Driving alarm operation failure
(Checking list)
※ Some error codes are not applied to this machine.

G : General C : Crawler Type W : Wheel Type
5-18
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
10 seconds continuous, Main Pump 1 (P1) Press. Sensor Measurement
0 ●
Voltage > 5.2V
10 seconds continuous, 0.3V ≤ Main Pump 1 (P1) Press. Sensor
1 ●
4 ●
Voltage < 0.3V
120
1. Monitor – Main Pump 1 (P1) Press. display failure
2. Control Function – Automatic voltage increase operation failure, Overload at compensation control
failure
(Checking list)
0 ●
Voltage > 5.2V
10 seconds continuous, 0.3V≤ Main Pump 2 (P2) Press. Sensor
1 ●
4 ●
Voltage < 0.3V
121
1. Monitor – Main Pump 2 (P2) Press. display failure
2. Control Function – Automatic voltage increase operation failure, Overload at compensation control
failure
(Checking list)
(when you had conditions mounting pressure sensor)
1 10 seconds continuous, 0.3V ≤ Overload Press. Sensor Measurement ●
Voltage < 0.8V
4 10 seconds continuous, Overload Press. Sensor ●
122 (Results / Symptoms)
1. Monitor – Overload Press. display failure
2. Control Function – Overload warning alarm failure
(Checking list)

5-19
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
10 seconds continuous, Negative 1 Press. Sensor
0 ●
10 seconds continuous, 0.3V≤ Negative 1 Press. Sensor Measurement
1 ●
Voltage < 0.8V
4 ●
1. Monitor – Negative 1 Press. display failure
2. Control Function – IPC operation failure, Option attachment flow control operation failure
(Checking list)
0 ●
10 seconds continuous, 0.3V≤ Negative 2 Press. Sensor Measurement
1 ●
Voltage < 0.8V
4 ●
1. Monitor – Negative 2 Press. display failure
2. Control Function – Option attachment flow control operation failure
(Checking list)
10 seconds continuous, Boom Up Pilot Press. Sensor
0 ●
10 seconds continuous, 0.3V≤ Boom Up Pilot Press. Sensor Measurement
1 ●
Voltage < 0.8V
4 10 seconds continuous, Boom Up Pilot Press. Sensor Measurement < 0.3V ●
127 1. Monitor – Boom Up Pilot Press. display failure
2. Control Function – Engine/Pump variable horse power control operation failure, IPC operation
failure, Boom first operation failure
(Checking list)
3. CD-32 (#C) – CN-5 1(#31) Checking Open/Short

5-20
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
0 10 seconds continuous, Boom Down Pilot Press. Sensor Measurement ●
Voltage > 5.2V
1 10 seconds continuous, 0.3V≤ Boom Down Pilot Press. Sensor ●
4 10 seconds continuous, Boom Down Pilot Press. Sensor Measurement ●
128 Voltage < 0.3V
1. Monitor – Boom Down Pilot Press. display failure
2. Control Function – Boom floating operation failure
(Checking list)
10 seconds continuous, Arm In Pilot Press. Sensor
0 ●
10 seconds continuous, 0.3V≤ Arm In Pilot Press. Sensor Measurement
1 ●
Voltage < 0.8V
10 seconds continuous, Arm In Pilot Press. Sensor
4 ●
1. Monitor – Arm In Pilot Press. display failure
2. Control Function – IPC operation failure
(Checking list)
10 seconds continuous,
0 ●
Bucket In Pilot Press. Sensor Measurement Voltage > 5.2V
1 0.3V≤ Bucket In Pilot Press. Sensor ●
4 ●
Bucket In Pilot Press. Sensor Measurement Voltage < 0.3V
133
1. Monitor – Bucket In Pilot Press. display failure
2. Control Function – Engine variable horse power control operation failure
(Checking list)
5-21
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
10 seconds continuous, Swing Pilot Press. Sensor
0 ●
10 seconds continuous, 0.3V≤ Swing Pilot Press. Sensor Measurement
1 ●
Voltage < 0.8V
10 seconds continuous, Swing Pilot Press. Sensor
4 ●
1. Monitor – Swing Pilot Press. display failure
2. Control Function – IPC operation, Boom first operation failure
(Checking list)
Monitor – Select Attachment(breaker / crusher)
0 10 seconds continuous, Attachment Pilot Press. Sensor Measurement ●
Voltage > 5.2V
1 10 seconds continuous, 0.3V≤ Attachment Pilot Press. Sensor ●
4 10 seconds continuous, Attachment Pilot Press. Sensor Measurement ●
138 Voltage < 0.3V
1. Monitor – Attachment Pilot Press. display failure
(Checking list)
10 seconds continuous, 0.3V≤ Option Pilot Press. Sensor Measurement
1 ●
Voltage < 0.8V
10 seconds continuous, Option Pilot Press. Sensor
4 ●
139
1. Monitor – Option Pilot Press. display failure
(N.A)
2. Control Function – Auto Idle operation failure
(Checking list)

5-22
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
(Detection)
(When Pump EPPR Current is more than 10 mA)
10 seconds continuous, Pump EPPR drive current < 0 mA
5 ●
(Cancellation)
(When Pump EPPR Current is more than 10 mA)
3 seconds continuous, Pump EPPR drive current ≥10 mA
(Detection)
10 seconds continuous, Pump EPPR drive current > 1.0A
140 6 ●
(Cancellation)
3 seconds continuous, Pump EPPR drive current ≤ 1.0 A
1. Control Function – Pump horse power setting specification difference
(Fuel efficiency/speed specification failure)
(Checking list)
1. CN-75 (#2) – CN-54 (#28) Checking Open/Short
(Model Parameter) mounting Boom Priority EPPR
(Detection)
(When Boom Priority EPPR Current is more than 10 mA)
5 10 seconds continuous, Boom Priority EPPR drive current < 0 mA ●
(Cancellation)
(When Boom Priority EPPR Current is more than 10 mA)
3 seconds continuous, Boom Priority EPPR drive current ≥ 10 mA
(Detection)
141
10 seconds continuous, Boom Priority EPPR drive current > 1.0 A
6 ●
(Cancellation)
3 seconds continuous, Boom Priority EPPR drive current ≤ 1.0 A
1. Control Function – Boom first control operation failure
(Checking list)

5-23
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
(Detection)
(When Travel EPPR Current is more than 10 mA)
10 seconds continuous, Travel EPPR drive current = 0 mA
5 ●
(Cancellation)
(When Travel EPPR Current is more than 100 mA)
3 seconds continuous, Travel EPPR drive current ≥ 10 mA
(Detection)
143
10 seconds continuous, Travel EPPR drive current > 1.0 A
(N.A) 6 ●
(Cancellation)
3 seconds continuous, Travel EPPR drive current ≤ 1.0 A
1. Control Function – cruise control operation failure
(Checking list)
(Model Parameter) mounting Remote Cooling Fan EPPR
(Detection)
(When Remote Cooling Fan EPPR Current is more than 10 mA)
5 10 seconds continuous, Remote Cooling Fan EPPR drive current = 0 mA ●
(Cancellation)
(When Remote Cooling Fan EPPR Current is more than 10 mA)
3 seconds continuous, Remote Cooling Fan EPPR drive current ≥ 10 mA
(Detection)
145
10 seconds continuous, Remote Cooling Fan EPPR drive current > 1.0 A
6 ●
(Cancellation)
3 seconds continuous, Remote Cooling Fan EPPR drive current ≤ 1.0 A
1. Control Function – Remote fan control operation failure
(Checking list)

5-24
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
(Detection)
(When Working Cutoff Relay is Off)
10 seconds continuous, Working Cutoff Relay drive unit Measurement
Voltage ≤ 3.0V
4 ●
(Cancellation)
(When Working Cutoff Relay is Off)
3 seconds continuous, Working Cutoff Relay drive unit Measurement
Voltage > 3.0V
(Detection)
164 (When Working Cutoff Relay is On)
(N.A) 10 seconds continuous, Working Cutoff Relay drive current > 6.5 A
6 ●
(Cancellation)
(When Working Cutoff Relay is On)
3 seconds continuous, Working Cutoff Relay drive current ≤ 6.5 A
1. Control Function – (Wheel Excavator) In driving mode, attachment hydraulic pilot pressure cut off
failure
(Checking list)
1. CR-47 (#85) – CN-54 (#9) Checking Open/Short
2. CR-47 (#30, #86) – Fuse box (#28) Checking Open/Short
(Detection)
(When Power Max Solenoid is Off)
10 seconds continuous, Power Max Solenoid drive unit Measurement
Voltage ≤ 3.0V
4 ●
(Cancellation)
(When Power Max Solenoid is Off)
3 seconds continuous, Power Max Solenoid drive unit
(Detection)
166 (When Power Max Solenoid is On)
5 seconds continuous, Power Max Solenoid drive current > 4.5 A
6 ●
(Cancellation)
(When Power Max Solenoid is On)
3 seconds continuous, Power Max Solenoid drive current ≤ 4.5 A
1. Control Function – Voltage increase operation failure
(Checking list)
2. CN-88 (#2) – Fuse box (#28) Checking Open/Short

5-25
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
(Detection)
(When Travel Speed Solenoid is Off)
10 seconds continuous, Travel Speed Solenoid drive unit Measurement
Voltage ≤ 3.0V
●
(Cancellation)
Voltage > 3.0V
4 (When Parking mode is not)
(Detection)
Voltage ≤ 3.0V ●
(Cancellation)
167
Voltage > 3.0V
(Detection)
(When Travel Speed Solenoid is On)
10 seconds continuous, Travel Speed Solenoid drive current > 4.5 A
6 ●
(Cancellation)
(When Travel Speed Solenoid is On)
3 seconds continuous, Travel Speed Solenoid drive current ≤ 4.5 A
1. Control Function – driving in 1/2 transmission operation failure
(Checking list)
1. CN-70 (#1) – CN-52(#05) Checking Open/Short

5-26
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
Monitor – Selecting attachment(breaker / crusher)
(Detection)
(When Attachment Conflux Solenoid is Off)
10 seconds continuous, Attachment Conflux Solenoid drive unit
4 Measurement Voltage ≤ 3.0V ●
(Cancellation)
(When Attachment Conflux Solenoid is Off)
3 seconds continuous, Attachment Conflux Solenoid drive unit Measurement
Voltage > 3.0V
(Detection)
169 (When Attachment Conflux Solenoid is On)
10 seconds continuous, Attachment Conflux Solenoid drive Current > 6.5 A
6 ●
(Cancellation)
(When Attachment Conflux Solenoid is On)
3 seconds continuous, Attachment Conflux Solenoid drive Current ≤ 6.5 A
(Results / symptoms)
1. Control Function – Option attachment flow control – Joining operation failure
(Eco breaker mode, crusher mode)
(Checking list)
(Model Parameter) mounting Arm Regenerating Solenoid
(Detection)
(When Arm Regeneration Solenoid is Off)
10 seconds continuous, Arm Regeneration Solenoid drive unit Measurement
4 Voltage ≤ 3.0V ●
(Cancellation)
(When Arm Regeneration Solenoid is Off)
3 seconds continuous, Arm Regeneration Solenoid drive unit Measurement
Voltage > 3.0V
(Detection)
170
(When Arm Regeneration Solenoid is On)
10 seconds continuous, Arm Regeneration Solenoid drive current > 4.5 A
6 ●
(Cancellation)
(When Arm Regeneration Solenoid is On)
3 seconds continuous, Arm Regeneration Solenoid drive current ≤ 4.5 A
(Results / symptoms)
1. Control Function – Arm regeneration operation failure
(Checking list)

5-27
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
Monitor – Selecting attachment(crusher)
(Detection)
(When Attachment Safety Solenoid is Off)
10 seconds continuous, Attachment Safety Solenoid drive unit Measurement
(Cancellation)
(When Attachment Safety Solenoid is Off)
Voltage > 3.0V
(Detection)
171 (When Attachment Safety Solenoid is On)
10 seconds continuous, Attachment Safety Solenoid drive current > 6.5 A
6 ●
(Cancellation)
(When Attachment Safety Solenoid is On)
3 seconds continuous, Attachment Safety Solenoid drive current ≤ 6.5 A
1. Control Function – Option attachment flow control – Option spool pilot pressure cut off failure
(crusher mode)
(Checking list)
(Detection)
(When Breaker Operating Solenoid is Off)
(Cancellation)
(When Breaker Operating Solenoid is Off)
Voltage > 3.0V
(Detection)
179
(When Breaker Operating Solenoid is On)
10 seconds continuous, Attachment Safety Solenoid drive current > 6.5 A
6 ●
(Cancellation)
(When Breaker Operating Solenoid is On)
3 seconds continuous, Attachment Safety Solenoid drive current ≤ 6.5 A
1. Control Function – Option attachment flow control – Breaker operation failure (breaker mode)
(Checking list)

5-28
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
(Model Parameter) mounting Reverse Cooling Fan Solenoid
(Detection)
(When Reverse Cooling Fan Solenoid is Off)
10 seconds continuous, Reverse Cooling Fan Solenoid drive unit
(Cancellation)
(When Reverse Cooling Fan Solenoid is Off)
3 seconds continuous, Reverse Cooling Fan Solenoid drive unit
181
(N.A)
(Detection)
(When Reverse Cooling Fan Solenoid is On)
10 seconds continuous, Reverse Cooling Fan Solenoid drive current > 4.5 A
6 ●
(Cancellation)
(When Reverse Cooling Fan Solenoid is On)
3 seconds continuous, Reverse Cooling Fan Solenoid drive current ≤ 4.5 A
1. Control Function – Cooling Fan reverse control operation failure (not applicable)
(Detection)
(When Pump P1 regulator EPPR current is equal or more than 300 mA)
10 seconds continuous, Pump P1 regulator EPPR drive current < 100 mA
5 ●
(Cancellation)
3 seconds continuous, Pump P1 regulator EPPR drive current ≥ 100 mA
(Detection)
188 10 seconds continuous, Pump P1 regulator EPPR drive current > 1.0 A
6 ●
(Cancellation)
3 seconds continuous, Pump P1 regulator EPPR drive current ≤ 1.0 A
1. Control Function – IPC operation failure, Option attachment flow control operation failure
(Checking list)

5-29
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
(Detection)
10 seconds continuous, Pump P2 regulator EPPR drive current < 100 mA
5 ●
(Cancellation)
3 seconds continuous, Pump P2 regulator EPPR drive current ≥ 100 mA
(Detection)
189 10 seconds continuous, Attachment Flow EPPR 2 drive current > 1.0 A
6 ●
(Cancellation)
3 seconds continuous, Attachment Flow EPPR 2 drive current ≤ 1.0 A
(Checking list)
HW145
0 10 seconds continuous,
Attachment flow control EPPR 1 press. Sensor Measurement Voltage > 5.2V
HW145
1 10 seconds continuous,
0.3V≤ Attachment flow control EPPR 1 press. Sensor Measurement Voltage < 0.8V
HW145
196 4 10 seconds continuous,
(N.A) Attachment flow control EPPR 1 press. Sensor Measurement Voltage < 0.3V
1. Control Function – Driving second pump joining function operation failure
(Checking list)
0 10 seconds continuous, Pump EPPR Press. Sensor Measurement Voltage > 5.2V ●
10 seconds continuous, 0.3V≤ Pump EPPR Press. Sensor Measurement
1 ●
Voltage < 0.8V
4 10 seconds continuous, Pump EPPR Press. Sensor Measurement Voltage < 0.3V ●
1. Monitor – Pump EPPR Press. display failure
200
2. Control Function – Pump input horse power control failure, Overload at compensation control
operation failure (Fuel efficiency/speed performance failure)
(Checking list)
5-30
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
(Mounting pressure sensor)
0 10 seconds continuous, Boom Cylinder Rod Press. Sensor Measurement ●
Voltage > 5.2V
1 10 seconds continuous, 0.3V≤ Boom Cylinder Rod Press. Sensor ●
4 10 seconds continuous, Boom Cylinder Rod Press. Sensor Measurement ●
205 Voltage < 0.3V
1. Monitor – Boom Cylinder Rod Press. display failure
2. Control Function – Boom floating control operation failure
(Checking list)
Mounting pressure sensor (HCESPN128 or HCESPN 205)
(Detection)
(When Boom Up Floating Solenoid is Off)
10 seconds continuous, Boom Up Floating Solenoid drive unit Measurement
(Cancellation)
(When Boom Up Floating Solenoid is Off)
3 seconds continuous, Boom Up Floating Solenoid drive unit Measurement
Voltage > 3.0V
(Detection)
218
(When Boom Up Floating Solenoid is On)
10 seconds continuous, Boom Up Floating Solenoid drive current > 6.5 A
6 ●
(Cancellation)
(When Boom Up Floating Solenoid is On)
3 seconds continuous, Boom Up Floating Solenoid drive current ≤ 6.5 A
(Checking list)
5-31
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
Mounting pressure sensor (HCESPN 128 or 205)
(Detection)
(When Boom Down Pilot Pressure Cutoff Solenoid is Off)
Boom Down Pilot Pressure Cutoff Solenoid drive unit
(Cancellation)
(When Boom Down Pilot Pressure Cutoff Solenoid is Off)
Boom Down Pilot Pressure Cutoff Solenoid drive unit
(Detection)
220
(When Boom Down Pilot Pressure Cutoff Solenoid is On)
10 seconds continuous, Boom Down Pilot Pressure Cutoff Solenoid drive
current > 6.5 A
6 ●
(Cancellation)
(When Boom Down Pilot Pressure Cutoff Solenoid is On)
3 seconds continuous, Boom Down Pilot Pressure Cutoff Solenoid drive
current ≤ 6.5 A
(Checking list)
(Detection)
(When ATT Relief Setting EPPR 1 Current is equal or more than 10 mA)
5 10 seconds continuous, ATT Relief Setting EPPR 1 drive current = 0 mA ●
(Cancellation)
ATT Relief Setting EPPR 1 Current is equal or more than 10 mA)
3 seconds continuous, ATT Relief Setting EPPR 1 drive current ≥ 10 mA
(Detection)
221
10 seconds continuous, ATT Relief Setting EPPR 1 drive current > 1.0 A
6 ●
(Cancellation)
3 seconds continuous, ATT Relief Setting EPPR 1 drive current ≤ 1.0 A
1. Control Function – Option attachment flow control – P1 relief pressure setting failure
(Checking list)

5-32
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
Monitor – Selecting attachment(crusher)
(Detection)
5 10 seconds continuous, ATT Relief Setting EPPR 2 drive current = 0 mA ●
(Cancellation)
3 seconds continuous, ATT Relief Setting EPPR 2 drive current ≥ 10mA
(Detection)
222
10 seconds continuous, ATT Relief Setting EPPR 2 drive current > 1.0 A
6 ●
(Cancellation)
3 seconds continuous, ATT Relief Setting EPPR 2 drive current ≤ 1.0 A
1. Control Function – Option attachment flow control – P2 relief pressure setting failure
(Checking list)
3 10 seconds continuous, Fuel Level Measurement Voltage > 3.8V ●
4 10 seconds continuous, Fuel Level Measurement Voltage < 0.3V ●
301 1. Monitor – Fuel remaining display failure
(Checking list)
1. CD-2 (#2) – CN-51 (#19) Checking Open/Short
2. CD-2 (#1) – CN-51 (#25) Checking Open/Short
(Model Parameter) mounting Fuel Warmer Relay
(Detection)
(When Fuel Warmer Relay is Off)
10 seconds continuous, Fuel Warmer Relay drive unit
(Cancellation)
(When Fuel Warmer Relay is Off)
3 seconds continuous, Fuel Warmer Relay drive unit
(Detection)
325
(When Fuel Warmer Relay is On)
10 seconds continuous, Fuel Warmer Relay drive current > 4.5 A
6 ●
(Cancellation)
(When Fuel Warmer Relay is On)
3 seconds continuous, Fuel Warmer Relay drive current ≤ 4.5 A
1. Control Function – Fuel warmer operation failure
(Checking list)
2. CR-46 (#86) – Fuse box (#22) Checking Open/Short

5-33
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
10 seconds continuous, Transmission Oil Press. Sensor Measurement
0 ●
Voltage > 5.2V
10 seconds continuous, 0.3V≤ Transmission Oil Press. Sensor
1 ●
10 seconds continuous, Transmission Oil Press. Sensor Measurement
4 ●
501 Voltage < 0.3V
(N.A) (Results / Symptoms)
1. Monitor – Transmission Oil Press. display failure, Transmission Oil low pressure warning failure
(Checking list)
10 seconds continuous, Brake Oil Press. Sensor
0 ●
10 seconds continuous, 0.3V≤ Brake Oil Press. Sensor Measurement
1 ●
Voltage < 0.8V
10 seconds continuous, Brake Oil Press. Sensor
4 ●
503 Measurement Voltage < 0.3V
1. Monitor – Brake Oil Press. display failure, Brake Oil low pressure warning failure
(Checking list)
10 seconds continuous, Working Brake Press. Sensor Measurement
0 ●
Voltage > 5.2V
10 seconds continuous, 0.3V≤ Working Brake Press. Sensor Measurement
1 ●
Voltage < 0.8V
10 seconds continuous, Working Brake Press. Sensor Measurement
4 ●
505 Voltage < 0.3V
1. Monitor – Working Brake Oil Press. display failure, Working Brake Oil low pressure warning failure
(Checking list)

5-34
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
(Detection)
(When Parking Relay is Off)
10 seconds continuous, Parking Relay drive unit
Measurement Voltage ≤ 3.0V
4 ●
(Cancellation)
(When Parking Relay is Off)
3 seconds continuous, Parking Relay drive unit
(Detection)
514
(When Parking Relay is On)
(N.A)
10 seconds continuous, Parking Relay drive current > 6.5 A
6 ●
(Cancellation)
(When Parking Relay is On)
3 seconds continuous, Parking Relay drive current ≤ 6.5 A
1. Control Function – Parking Relay operation failure
(Checking list)
(Detection)
(When Traveling Cutoff Relay is Off)
10 seconds continuous, Traveling Cutoff Relay drive unit Measurement
Voltage ≤ 3.0V
4 ●
(Cancellation)
(When Traveling Cutoff Relay is Off)
3 seconds continuous, Traveling Cutoff Relay drive unit Measurement
Voltage > 3.0V
(Detection)
517
(When Traveling Cutoff Relay is On)
(N.A)
10 seconds continuous, Traveling Cutoff Relay drive current > 6.5 A
6 ●
(Cancellation)
(When Traveling Cutoff Relay is On)
3 seconds continuous, Traveling Cutoff Relay drive current ≤ 6.5 A
1. Control Function – Traveling Cutoff Relay operation failure
(Checking list)
5-35
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
(Detection)
(When Ram Lock Solenoid is Off)
10 seconds continuous, Ram Lock Solenoid drive unit Measurement
Voltage ≤ 3.0V
4 ●
(Cancellation)
(When Ram Lock Solenoid is Off)
3 seconds continuous, Ram Lock Solenoid drive unit
(Detection)
525
(When Ram Lock Solenoid is On)
(N.A)
10 seconds continuous, Ram Lock Solenoid drive current > 6.5 A
6 ●
(Cancellation)
(When Ram Lock Solenoid is On)
3 seconds continuous, Ram Lock Solenoid drive current ≤ 6.5 A
1. Control Function – Ram lock control operation failure
(Checking list)
(Detection)
(When Creep Solenoid is Off)
10 seconds continuous, Creep Solenoid drive unit
4 ●
(Cancellation)
(When Creep Solenoid is Off)
3 seconds continuous, Creep Solenoid drive unit
(Detection)
527
(When Creep Solenoid is On)
(N.A)
10 seconds continuous, Creep Solenoid drive current > 6.5 A
6 ●
(Cancellation)
(When Creep Solenoid is On)
3 seconds continuous, Creep Solenoid drive current ≤ 6.5 A
1. Control Function – Creep mode operation failure
(Checking list)

5-36
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
10 seconds continuous, Travel Forward Press. Sensor Measurement
0 ●
Voltage > 5.2V
10 seconds continuous, 0.3V≤ Travel Forward Press. Sensor Measurement
1 ●
Voltage < 0.8V
10 seconds continuous, Travel Forward Press. Sensor Measurement
4 ●
Voltage < 0.3V
530
(N.A)
1. Monitor – Travel Forward Press. display failure
2. Control Function – Driving interoperability power control operation failure
(Checking list)
10 seconds continuous, 0.3V≤ Travel Reverse Press. Sensor Measurement
1 ●
Voltage < 0.8V
10 seconds continuous, Travel Reverse Press. Sensor Measurement
4 ●
Voltage < 0.3V
531
1. Monitor – Travel Reverse Press. display failure
(N.A)
2. Control Function – Driving interoperability power control operation failure
(Checking list)
0 10 seconds continuous, Battery input Voltage > 35V ●
1 10 seconds continuous, Battery input Voltage < 18V ●

1. Control Function – Startup impossibility
(Checking list)
1. CS-74A (#1) – CN-74 (B+) Checking Open/Short
(When Engine is equal or more than 400 rpm) 10 seconds continuous,
1 Alternator Node I Measurement Voltage < 18V ●
(In case 12v goods, Alternator Node I Measurement Voltage < 9V)
1. Control Function – Battery charging circuit failure
(Checking list)
1. CS-74A (#1) – CN-74 (B+) Checking Open/Short

5-37
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
(Model Parameter) Mounting Acc. Dial
3 ●
10 seconds continuous, Acc. Dial Measurement Voltage > 5.2V
(Model Parameter) Mounting Acc. Dial
4 ●
10 seconds continuous, Acc. Dial Measurement Voltage < 0.3V
714
(N.A)
1. Monitor – Acc. Dial Voltage display failure
2. Control Function – Engine rpm control failure
(Checking list)
(Detection)
(When Travel Alarm (Buzzer) Sound is Off)
10 seconds continuous, Travel Alarm (Buzzer) Sound Relay drive unit
4 ●
(Cancellation)
(When Travel Alarm (Buzzer) Sound Relay is Off)
3 seconds continuous, Travel Alarm (Buzzer) Sound Relay drive unit
(Detection)
(When Travel Alarm (Buzzer) Sound is On)
722 10 seconds continuous, Travel Alarm (Buzzer) Sound Relay drive
current > 4.5 A
6 ●
(Cancellation)
(When Travel Alarm (Buzzer) Sound is On)
3 seconds continuous, Travel Alarm (Buzzer) Sound Relay drive
current ≤ 4.5 A
1. Control Function – Driving alarm operation failure
(Checking list)
(When mounting the A/C Controller)
2 ●
60 seconds continuous, A/C Controller Communication Data Error
831 1. Control Function – A/C Controller operation failure
(Checking list)
2 60 seconds continuous, Cluster Communication Data Error ●
1. Control Function – Cluster operation failure
840
(Checking list)
1. CN-56A (#5) – CN-52 (#01) Checking Open/Short

5-38
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
2 10 seconds continuous, ECM Communication Data Error ●
1. Control Function – ECM operation failure
841
(Checking list)
(When mounting the Jog dial module)
2 ●
60 seconds continuous, Jog dial module Communication Data Error
848 1. Control Function – Jog dial module operation failure
(Checking list)
(When mounting the RMCU)
2 ●
60 seconds continuous, RMCU communication Data Error
(Resuluts / Symptoms)
850 1. Control Function – RMCU operation failure
(Checking list)
(When mounting the AAVM)
2 ●
60 seconds continuous, AAVM communication Data Error
866 1. Control Function – AAVM operation failure
(Checking list)
2 60 seconds continuous, RDU communication Data Error ●
1. Control Function – RDU operation failure
867
(Checking list)
5-39
DTC Application
Diagnostic Criteria
HCESPN FMI G C W
2 60 seconds continuous, Switch Controller communication Data Error ●
1. Control Function – Switch Controller operation failure
868
(Checking list)
(When mounting the BKCU)
2 ●
60 seconds continuous, BKCU communication Data Error
869 1. Control Function – BKCU operation failure
(Checking list)
1. CS-2B (#A) – CN-51 (#08) Checking Open/Short
2. CS-2B (#B) – CN-51 (#09) Checking Open/Short
5-40
4. ENGINE FAULT CODE
Fault code
J1939 SPN Item Description
J1939 FMI
111 Engine control module critical internal failure Bad intelligent device or component
629
12
122 Intake manifold 1 pressure sensor circuit Voltage above normal, or shorted to high source
102
3
123 Intake manifold 1 pressure sensor circuit Voltage below normal, or shorted to low source
102
4
133 Remote accelerator pedal or lever position sensor Voltage above normal, or shorted to high source
974 1 circuit
3
134 Remote accelerator pedal or lever position sensor Voltage below normal, or shorted to low source
974 1 circuit
4
135 Engine oil rifle pressure 1 sensor circuit Voltage above normal, or shorted to high source
100
3
141 Engine oil rifle pressure 1 sensor circuit Voltage below normal, or shorted to low source
100
4
143 Engine oil rifle pressure Data valid but below normal operating range -
100 moderately severe level
18
144 Engine coolant temperature 1 sensor circuit Voltage above normal, or shorted to high source
110
3
145 Engine coolant temperature 1 sensor circuit Voltage below normal, or shorted to low source
110
4
146 Engine coolant temperature Data valid but above normal operating range -
16
147 Accelerator pedal or lever position 1 sensor Data valid but below normal operating range
91 circuit frequency
1
148 Accelerator pedal or lever position sensor 1 Data valid but above normal operational range -
91 most severe level
0
151 Engine coolant temperature Data valid but above normal operational range -
0
153 Intake manifold 1 temperature sensor circuit Voltage above normal, or shorted to high source
105
3
154 Intake manifold 1 temperature sensor circuit Voltage below normal, or shorted to low source
105
4
※ Some fault codes are not applied to this machine.
5-41
Fault code
J1939 FMI
187 Sensor supply 2 circuit Voltage below normal, or shorted to low source
3510
4
197 Coolant level Data valid but below normal operating range -
18
227 Sensor supply 2 circuit Voltage above normal, or shorted to high source
3510
3
234 Engine crankshaft speed/position Data valid but above normal operational range -
0
235 Coolant level Data valid but below normal operational range -
1
237 External speed command input Data erratic, intermittent or incorrect
644 (Multiple unit synchronization)
2
3511
4
3511
3
241 Wheel-based vehicle speed Data erratic, intermittent or incorrect
84
2
242 Wheel-based vehicle speed sensor circuit Abnormal rate of change
84 tampering has been detected
10
271 Engine fuel pump pressurizing assembly 1 circuit Voltage below normal, or shorted to low source
1347
4
272 Engine fuel pump pressurizing assembly 1 circuit Voltage above normal, or shorted to high source
1347
3
285 SAE J1939 multiplexing pgn timeout error Abnormal update rate
639
9
286 SAE J1939 multiplexing configuration error Out of calibration
639
13
288 SAE J1939 multiplexing remote accelerator pedal Received network data in error
974 or lever position sensor system
19
293 Auxiliary temperature sensor input 1 circuit Voltage above normal, or shorted to high source
441
3
5-42
Fault code
J1939 FMI
294 Auxiliary temperature sensor input 1 circuit Voltage below normal, or shorted to low source
441
4
297 Auxiliary pressure sensor input 2 circuit Voltage above normal, or shorted to high source
1388
3
298 Auxiliary pressure sensor input 2 circuit Voltage below normal, or shorted to low source
1388
4
322 Injector solenoid driver cylinder 1 circuit Current below normal or open circuit
651
5
655
5
653
5
656
5
652
5
654
5
334 Engine coolant temperature Data erratic, intermittent or incorrect
110
2
343 Engine control module warning internal hardware Bad intelligent device or component
629 failure
12
349 Transmission output shaft speed Data valid but above normal operating range -
16
351 Injector power supply Bad intelligent device or component
3597
12
3509
4
3509
3
415 Engine oil rifle pressure Data valid but below normal operational range -
1
5-43
Fault code
J1939 FMI
418 Water in fuel indicator Data valid but above normal operating range -
97 least severe level
15
428 Water in fuel indicator sensor circuit Voltage above normal, or shorted to high source
97
3
429 Water in fuel indicator sensor circuit Voltage below normal, or shorted to low source
97
4
431 Accelerator pedal or lever idle validation switch Data erratic, intermittent or incorrect
558
2
432 Accelerator pedal or lever idle validation switch Out of calibration
558 circuit
13
435 Engine oil rifle pressure Data erratic, intermittent or incorrect
100
2
451 Injector metering rail 1 pressure sensor circuit Voltage above normal, or shorted to high source
157
3
452 Injector metering rail 1 pressure sensor circuit Voltage below normal, or shorted to low source
157
4
483 Injector metering rail 2 pressure sensor circuit Voltage above normal, or shorted to high source
1349
3
484 Injector metering rail 2 pressure sensor circuit Voltage below normal, or shorted to low source
1349
4
488 Intake manifold 1 temperature Data valid but above normal operating range -
16
489 Transmission output shaft speed Data valid but below normal operating range -
18
497 Multiple unit synchronization switch Data erratic, intermittent or incorrect
1377
2
3514
3
3514
4
527 Auxiliary input/output 2 circuit Voltage above normal, or shorted to high source
702
3
5-44
Fault code
J1939 FMI
529 Auxiliary input/output 3 circuit Voltage above normal, or shorted to high source
703
3
553 Injector metering rail 1 pressure Data valid but above normal operating range -
16
556 Crankcase pressure Data valid but above normal operational range -
0
559 Injector metering rail 1 pressure Data valid but below normal operating range -
18
584 Starter relay driver circuit Voltage above normal, or shorted to high source
677
3
585 Starter relay driver circuit Voltage below normal, or shorted to low source
677
4
599 Auxiliary commanded dual output shutdown Special instructions
640
14
611 Engine shut down hot Condition exists
1383
31
649 Engine oil change interval Condition exists
1378
31
689 Engine crankshaft speed/position Data erratic, intermittent or incorrect
190
2
691 Turbocharger 1 compressor intake temperature Voltage above normal, or shorted to high source
1172 circuit
3
692 Turbocharger 1 compressor intake temperature Voltage below normal, or shorted to low source
1172 circuit
4
693 Turbocharger 1 compressor intake temperature Data erratic, intermittent or incorrect
1172
7
731 Engine speed / position camshaft and crankshaft Mechanical system not responding or out of
723 misalignment adjustment
7
741 Turbocharger 1 compressor intake pressure Voltage above normal, or shorted to high source
1176 circuit
3
742 Turbocharger 1 compressor intake pressure Voltage below normal, or shorted to low source
1176 circuit
4
5-45
Fault code
J1939 FMI
743 Turbocharger 1 compressor intake pressure Data erratic, intermittent or incorrect
1176
2
769 Brake switch circuit Voltage above normal, or shorted to high source
597
3
771 Brake switch circuit Voltage below normal, or shorted to low source
597
4
778 Engine camshaft speed / position sensor Data erratic, intermittent or incorrect
723
2
1117 Power supply lost with ignition on Data erratic, intermittent or incorrect
3597
2
1239 Accelerator pedal or lever position sensor 2 Voltage above normal, or shorted to high source
2623 circuit
3
1241 Accelerator pedal or lever position sensor 2 Voltage below normal, or shorted to low source
2623 circuit
4
1242 Accelerator pedal or lever position sensor 1 Data erratic, intermittent or incorrect
91
2
1358 Accelerator pedal or lever position sensor 1 Voltage above normal, or shorted to high source
91 circuit
3
1359 Accelerator pedal or lever position sensor 1 Voltage below normal, or shorted to low source
91 circuit
4
1515 SAE J1939 multiplexed accelerator pedal or lever Received network data in error
91 sensor system
19
1539 Auxiliary pressure sensor input 1 circuit Voltage above normal, or shorted to high source
1387
3
1621 Auxiliary pressure sensor input 1 circuit Voltage below normal, or shorted to low source
1387
4
1668 Aftertreatment 1 diesel exhaust fluid tank level Voltage below normal, or shorted to low source
1761 sensor circuit
4
1669 Aftertreatment 1 diesel exhaust fluid tank level Voltage above normal, or shorted to high source
1761 sensor circuit
3
1673 Aftertreatment 1 diesel exhaust fluid tank level Data valid but below normal operational range
1761 -most severe level
1
5-46
Fault code
J1939 FMI
1677 Aftertreatment 1 diesel exhaust fluid tank Voltage below normal, or shorted to low source
3031 temperature sensor
4
1678 Aftertreatment 1 diesel exhaust fluid tank Voltage above normal, or shorted to high source
3
1679 Aftertreatment 1 diesel exhaust fluid tank Data erratic, intermittent or incorrect
3031 temperature
2
1682 Aftertreatment 1 diesel exhaust fluid dosing unit Condition exists
3362 input lines
31
1685 Aftertreatment diesel exhaust fluid quality sensor Voltage below normal, or shorted to low source
3364 circuit
4
1686 Aftertreatment diesel exhaust fluid quality sensor Voltage above normal, or shorted to high source
3364 circuit
3
1695 Sensor supply 5 Voltage above normal, or shorted to high source
3513
3
1696 Sensor supply 5 Voltage below normal, or shorted to low source
3513
4
1713 Aftertreatment 1 diesel exhaust fluid tank heater Data valid but above normal operating range -
16
1714 Aftertreatment diesel exhaust fluid quality Out of calibration
3364
13
1715 Aftertreatment diesel exhaust fluid quality Root cause not known
3364
11
1843 Crankcase pressure circuit Voltage above normal, or shorted to high source
101
3
1844 Crankcase pressure circuit Voltage below normal, or shorted to low source
101
4
1852 Water in fuel indicator Data valid but above normal operating range -
16
1879 Aftertreatment diesel particulate filter differential Voltage above normal
3251 pressure sensor circuit
3
1881 Aftertreatment diesel particulate filter differential Voltage below normal
4
5-47
Fault code
J1939 FMI
1883 Aftertreatment diesel particulate filter differential Data erratic, intermittent or incorrect
3251 pressure sensor
2
1885 Aftertreatment 1 intake NOx sensor circuit Voltage below normal, or shorted to low source
3216
4
1887 Aftertreatment 1 outlet NOx sensor circuit Voltage below normal, or shorted to low source
3226
4
1921 Aftertreatment diesel particulate filter differential Data valid but above normal operating range
3251 pressure
16
3251 pressure
0
1993 Aftertreatment 1 diesel particulate filter missing Condition exists
4795
31
3512
3
3512
4
2311 Electronic fuel injection control valve circuit Condition exists
633
31
2321 Engine crankshaft speed/position Data erratic, intermittent or incorrect
190
2
2322 Engine camshaft speed / position sensor Data erratic, intermittent or incorrect
723
2
2346 Turbocharger turbine Intake temperature Data valid but above normal operating range -
2789 least severe
15
2373 Exhaust gas pressure sensor 1 circuit Voltage above normal, or shorted to high source
1209
3
2374 Exhaust gas pressure sensor 1 circuit Voltage below normal, or shorted to low source
1209
4
2448 Coolant level Data valid but below normal operating range -
17
2554 Exhaust gas pressure 1 Data erratic, intermittent or incorrect
1209
2
5-48
Fault code
J1939 FMI
2557 Auxiliary PWM driver 1 circuit Voltage above normal, or shorted to high source
697
3
2558 AuxiliaryPWM driver 1 circuit Voltage below normal, or shorted to low source
697
4
2571 Engine charge air cooler outlet temperature Voltage above normal, or shorted to high source
2630
3
2572 Engine charge air cooler outlet temperature Voltage below normal, or shorted to low source
2630
4
2638 Aftertreatment 1 diesel oxidation catalyst Data valid but below normal operating range -
5298 conversion efficiency moderately severe level
17
3251 pressure
15
2771 Aftertreatment 1 outlet NOx sensor Abnormal update rate
3226
9
2778 Aftertreatment fuel rate Data valid but above normal operating range -
16
2973 Intake manifold 1 pressure Data erratic, intermittent or incorrect
102
2
3133 Aftertreatment 1 diesel particulate filter outlet Voltage above normal, or shorted to high source
3
3134 Aftertreatment 1 diesel particulate filter outlet Voltage below normal, or shorted to low source
4
3135 Aftertreatment 1 diesel particulate filter outlet Data erratic, intermittent or incorrect
3610 pressure
2
3139 Engine air shutoff circuit Voltage above normal, or shorted to high source
3667
3
3141 Engine air shutoff circuit Voltage below normal, or shorted to low source
3667
4
3142 Aftertreatment 1 SCR intake temperature sensor Voltage above normal, or shorted to high source
4360 circuit
3
3144 Aftertreatment 1 SCR intake temperature sensor Data erratic, intermittent or incorrect
4360
2
5-49
Fault code
J1939 FMI
3146 Aftertreatment 1 SCR outlet temperature sensor Voltage above normal, or shorted to high source
4363 circuit
3
3147 Aftertreatment 1 SCR outlet temperature sensor Voltage below normal, or shorted to low source
4363 circuit
4
3148 Aftertreatment 1 SCR outlet temperature sensor Data erratic, intermittent or incorrect
4363
2
3151 Aftertreatment 1 SCR catalyst system missing Condition exists
4974
31
3165 Aftertreatment 1 SCR outlet temperature Data valid but above normal operational range -
4363 most severe
0
3232 Aftertreatment 1 intake NOx sensor Abnormal update rate
3216
9
3235 Aftertreatment 1 SCR outlet temperature Data valid but above normal operating range -
16
3251 Aftertreatment 1 diesel oxidation catalyst intake Data valid but above normal operating range
4765 temperature
16
3253 Aftertreatment 1 diesel particulate filter intake Data valid but above normal operating range
3242 temperature
16
3255 Aftertreatment 1 diesel particulate filter outlet Data valid but above normal operating range
3246 temperature
16
3311 Aftertreatment 1 diesel particulate filter intake Data valid but above normal operation
3242 temperature
0
3312 Aftertreatment 1 diesel particulate filter outlet Data valid but above normal operation
3246 temperature
0
3313 Aftertreatment 1 diesel oxidation catalyst intake Voltage below normal, or shorted to low source
4765 temperature sensor circuit
4
3314 Aftertreatment 1 diesel oxidation catalyst intake Voltage above normal, or shorted to high source
3
3315 Aftertreatment 1 diesel oxidation catalyst intake Data erratic, intermittent or incorrect
4765 temperature
2
3316 Aftertreatment 1 diesel particulate filter intake Voltage below normal, or shorted to low source
4
5-50
Fault code
J1939 FMI
3317 Aftertreatment 1 diesel particulate filter intake Voltage above normal, or shorted to high source
3
3318 Aftertreatment 1 diesel particulate filter intake Data erratic, intermittent or incorrect
3242 temperature
2
3319 Aftertreatment 1 diesel particulate filter outlet Voltage above normal, or shorted to high source
3
3321 Aftertreatment 1 diesel particulate filter outlet Voltage below normal, or shorted to low source
4
3322 Aftertreatment 1 diesel particulate filter outlet Data erratic, intermittent or incorrect
3246 temperature
2
3326 SAE J1939 multiplexed accelerator pedal or lever Abnormal update rate
91 sensor system
9
3341 Engine air filter differential pressure - data valid Moderately severe level
107 but above normal operating range
16
3375 Aftertreatment diesel particulate filter Condition exists
5397 regeneration too frequent
31
3376 Aftertreatment diesel particulate filter incomplete Condition exists
5319 regeneration
31
5125
3
5125
4
3497 Aftertreatment 1 diesel exhaust fluid tank level Data valid but below normal operating range -
17
3498 Aftertreatment 1 diesel exhaust fluid tank level Data valid but below normal operating range -
18
3527 Accelerator pedal or lever idle validation switch Received network data in error
558
19
3528 Accelerator pedal or lever idle validation switch Abnormal update rate
558
9
3545 Aftertreatment 1 outlet NOx sensor Abnormal rate of change
3226
31
5-51
Fault code
J1939 FMI
3547 Aftertreatment diesel exhaust fluid tank empty Condition exists
4096
31
3558 Aftertreatment 1 diesel exhaust fluid dosing unit Voltage above normal, or shorted to high source
3361
3
3559 Aftertreatment 1 diesel exhaust fluid dosing unit Voltage below normal, or shorted to low source
3361
4
3565 Aftertreatment 1 diesel exhaust fluid dosing valve Voltage above normal or shorted to high source
5394 1 circuit
3
3567 Aftertreatment diesel exhaust fluid dosing valve Current below normal or open circuit
5394
5
3568 Aftertreatment diesel exhaust fluid dosing valve Mechanical system not responding or out of
5394 adjustment
7
3571 Aftertreatment 1 diesel exhaust fluid pressure Voltage above normal, or shorted to high source
4334 sensor
3
3572 Aftertreatment 1 diesel exhaust fluid pressure Voltage below normal, or shorted to low source
4334 sensor
4
3574 Aftertreatment 1 diesel exhaust fluid pressure Data valid but below normal operating range
4334 sensor
18
3575 Aftertreatment 1 diesel exhaust fluid pressure Data valid but above normal operating range
4334 sensor
16
3583 Aftertreatment 1 outlet nox sensor heater Abnormal rate of change
5031
10
3596 Aftertreatment 1 diesel exhaust fluid pressure Data erratic, intermittent or incorrect
4334 sensor
2
3641 Transmission output retarder Abnormal update rate
748
9
3649 Aftertreatment 1 intake NOx sensor heater Abnormal rate of change
5024
10
3681 Aftertreatment 1 outlet NOx sensor power supply Data erratic, intermittent or incorrect
3228
2
3682 Aftertreatment 1 intake NOx sensor power supply Data erratic, intermittent or incorrect
3218
2
5-52
Fault code
J1939 FMI
3697 Engine control module calibration memory Bad intelligent device or component
630
12
3712 Aftertreatment SCR operator inducement Data valid but above normal operational range -
0
3714 Engine protection torque derate Condition exists
1569
31
3725 Aftertreatment 1 intake NOx sensor Abnormal rate of change
3216
10
3727 High pressure common rail fuel pressure relief Mechanical system not responding or out of
5571 valve adjustment
7
3737 Engine starter mode overcrank protection Condition exists
1675
31
3741 High pressure common rail fuel pressure relief Data valid but above normal operational range
5571 valve
0
3748 Aftertreatment 1 intake NOx sensor Data not rational - drifted high
3216
20
3765 Auxiliary temperature sensor input 2 circuit Voltage above normal, or shorted to high source
442
3
3766 Auxiliary temperature sensor input 2 circuit Voltage below normal, or shorted to low source
442
4
3838 Estimated engine parasitic losses - percent Abnormal update rate
2978 torque
9
3841 Cruise control enable switch Data erratic, intermittent or incorrect
596
2
3843 Cruise control disable command Abnormal update rate
5603
9
3845 Cruise control disable command Condition exists
5603
31
3866 Aftertreatment diesel exhaust fluid quality Data valid but below normal operational range -
1
3868 Aftertreatment diesel exhaust fluid quality Abnormal update rate
3364
9
5-53
Fault code
J1939 FMI
3878 Aftertreatment diesel exhaust fluid quality Data erratic, intermittent or incorrect
3364
2
4151 Aftertreatment diesel particulate filter temperature Abnormal update rate
5742 sensor module
9
4152 Aftertreatment selective catalytic reduction Abnormal update rate
5743 temperature sensor module
9
4158 Aftertreatment diesel particulate filter temperature Bad intelligent device or component
5742 sensor module
12
4159 Aftertreatment selective catalytic reduction Bad intelligent device or component
12
4161 Aftertreatment diesel particulate filter temperature Voltage above normal, or shorted to high source
5742 sensor module
3
4162 Aftertreatment diesel particulate filter temperature Voltage below normal, or shorted to low source
5742 sensor module
4
4163 Aftertreatment diesel particulate filter temperature Data valid but above normal operating range
5742 sensor module
16
4164 Aftertreatment selective catalytic reduction Voltage above normal, or shorted to high source
3
4165 Aftertreatment selective catalytic reduction Voltage below normal, or shorted to low source
4
4166 Aftertreatment selective catalytic reduction Data valid but above normal
16
4259 Aftertreatment diesel particulate filter temperature Root cause not known
5742 sensor module
11
4261 Aftertreatment selective catalytic reduction Root cause not known
11
4277 Aftertreatment diesel exhaust fluid quality Abnormal rate of change
3364
10
4284 Desired engine fueling state Abnormal update rate
5793
9
4452 Aftertreatment 1 outlet NOx sensor closed loop Condition exists
3226 operation
7
5-54
Fault code
J1939 FMI
4484 Engine air shutoff Mechanical system not responding or out of
3667 Adjustment
7
4526 Brake pedal position Data erratic, intermittent or incorrect
521
2
4572 Aftertreatment 1 diesel exhaust fluid tank Abnormal update rate
3031 temperature
9
4584 Aftertreatment diesel particulate filter system Special instructions
3936
14
4585 Aftertreatment 1 SCR catalyst system Special instructions
4792
14
4677 SAE J1939 multiplexing pgn timeout error Abnormal update rate
1761
9
4724 Auxiliary input/output 2 circuit Current below normal or open circuit
702
5
4725 Auxiliary input/output 2 circuit Current above normal or grounded circuit
702
6
4731 Aftertreatment 1 diesel exhaust fluid tank Out of calibration
13
4734 Auxiliary input/output 1 Special instructions
701
14
4737 Aftertreatment 1 diesel exhaust fluid tank Root cause not known
3031 temperature
11
4739 Aftertreatment 1 diesel exhaust fluid tank level Root cause not known
1761 sensor
11
4747 Aftertreatment intake oxygen sensor Data not rational - drifted high
3217
20
4748 Aftertreatment intake oxygen sensor Data not rational - drifted low
3217
21
4749 Aftertreatment outlet oxygen Data not rational - drifted high
3227
20
4751 Aftertreatment outlet oxygen Data not rational - drifted low
3227
21
5-55
Fault code
J1939 FMI
4768 Aftertreatment 1 diesel exhaust fluid property Root cause not known
3521
11
4769 Aftertreatment 1 diesel exhaust fluid tank level Abnormal rate of change
1761 sensor
10
4842 Aftertreatment diesel exhaust fluid quality Data valid but above normal operating range -
3364 Least severe level
15
4863 Aftertreatment diesel exhaust fluid tank low level -
5245 indicator
31
4953 Alternator 1 status Voltage above normal, or shorted to high source
3353
3
4954 Alternator 1 status Voltage below normal, or shorted to low source
3353
4
5248 Tachograph output shaft speed Out of calibration
1623
13
5271 Engine exhaust back pressure regulator Voltage above normal, or shorted to high source
649 control circuit
3
5272 Engine exhaust back pressure regulator control Voltage below normal, or shorted to low source
649 circuit
4
5273 Engine exhaust back pressure regulator control Current below normal or open circuit
649 circuit
5
5274 Engine exhaust back pressure regulator position Data erratic, intermittent or incorrect
5625
2
5275 Engine exhaust back pressure regulator position Voltage above normal, or shorted to high source
5625 sensor circuit
3
5276 Engine exhaust back pressure regulator position Voltage below normal, or shorted to low source
5625 sensor circuit
4
5292 Excessive time since last engine air shutoff Condition exists
520809 maintenance test
31
5316 Turbocharger turbine intake temperature Data valid but above normal operating range -
9
5383 Aftertreatment 1 diesel particulate filter ash load Data valid but above normal operating range -
3720 percent least severe level
15
5-56
Fault code
J1939 FMI
5576 Engine air filter differential pressure Data valid but above normal operating range -
15
5632 SCR system cleaning inhibited due to inhibit Condition exists
6918 switch
31
5652 Exhaust pressure 1 Data valid but above normal operating range -
15
5653 SCR operator inducement override switch Abnormal update rate
6881
9
5654 SCR operator inducement override switch Out of calibration
6881
13
5655 Aftertreatment 1 scr conversion efficiency Condition exists
4364
31
5689 Aftertreatment 1 outlet nox sensor Root cause not known
3226
11
5715 Aftertreatment 1 diesel particulate filter differential Abnormal rate of change
3521 pressure
10
5716 Aftertreatment 1 diesel particulate filter outlet Abnormal rate of change
3610 pressure
10
5864 Aftertreatment 1 diesel exhaust fluid pump Voltage above normal or shorted to high source
4375 command circuit
3
5865 Aftertreatment 1 diesel exhaust fluid pump Voltage below normal or shorted to low source
4375 command circuit
4
5866 Aftertreatment diesel exhaust fluid dosing unit Voltage above normal or shorted to high source
520953 relay feedback
3
5867 Aftertreatment diesel exhaust fluid dosing unit Voltage below normal or shorted to low source.
520953 relay feedback
4
5868 Aftertreatment 1 scr feedback control status Mechanical system not responding or out of
4339 adjustment
7
5935 Aftertreatment 1 diesel exhaust fluid pressure Mechanical system not responding or out of
4334 adjustment
7
5936 Aftertreatment 1 diesel exhaust fluid pressure Data valid but above normal operating range -
15
5-57
Fault code
J1939 FMI
5938 Aftertreatment 1 diesel particulate filter conditions Special instructions
3750 not met for active regeneration
14
Machine constrained operation Abnormal update rate. No communication or an
5939
Invalid data transfer rate has been detected on
520968
the J1939 data link between the ECM and the
9
machine
5941 Machine constrained operation Received network data in error. The received
520968 J1939 datalink message was not valid.
19
6256 Battery 1 voltage Data valid but below normal operating range -
15
6257 Battery 1 voltage Data valid but below normal operating range -
17
6258 Electric lift pump for engine fuel supply circuit Voltage above normal, or shorted to high source
1075
3
6259 Electric lift pump for engine fuel supply circuit Voltage below normal, or shorted to low source
1075
4
6263 Fan control circuit Voltage above normal, or shorted to high source
647
3
6418 Engine brake actuator driver 1 circuit Voltage above normal, or shorted to high source
1072
3
6419 Engine brake actuator driver 1 circuit Voltage below normal, or shorted to low source
1072
4
6421 Engine brake actuator driver output 2 circuit Voltage above normal, or shorted to high source
1073
3
6422 Engine brake actuator driver output 2 circuit Voltage below normal, or shorted to low source
1073
4
6264 Fan control circuit Voltage below normal, or shorted to low source
647
4
6456 Engine fan clutch 2 control circuit Voltage above normal, or shorted to high source
5484
3
6457 Engine fan clutch 2 control circuit Voltage below normal, or shorted to low source
5484
4
6467 Fan speed Data valid but above normal operational range -
15
5-58
Fault code
J1939 FMI
6468 Fan speed Data valid but below normal operational range -
17
6471 Fan blade pitch position sensor circuit Voltage above normal, or shorted to high source
6799
3
6472 Fan blade pitch position sensor circuit Voltage below normal, or shorted to low source
6799
4
6475 Aftertreatment 1 diesel exhaust fluid tank heater Mechanical system not responding or out of
3363 adjustment
7
6476 Aftertreatment 1 diesel exhaust fluid tank heater Data valid but below normal operating range -
18
6477 Aftertreatment diesel exhaust fluid line heater Voltage above normal, or shorted to high source
5491 relay
3
6478 Aftertreatment diesel exhaust fluid line heater Voltage below normal, or shorted to low source
5491 relay
4
6479 Aftertreatment 1 diesel exhaust fluid tank heater Voltage above normal, or shorted to high source
3363
3
6481 Aftertreatment 1 diesel exhaust fluid tank heater Voltage below normal, or shorted to low source
3363
4
6511 Maintain ECM power lamp Voltage above normal, or shorted to high source
6655
3
6512 Maintain ECM power lamp Voltage below normal, or shorted to low source
6655
4
6522 Coolant level sensor 1 circuit Voltage above normal, or shorted to high source
111
3
6523 Coolant level sensor 1 circuit Voltage below normal, or shorted to low source
111
4
6526 Aftertreatment 1 diesel exhaust fluid tank level Out of calibration
1761 sensor
13
6531 Aftertreatment 1 diesel exhaust fluid line heater 1 Voltage above normal, or shorted to high source
4340 circuit
3
6532 Aftertreatment 1 diesel exhaust fluid line heater 1 Voltage below normal, or shorted to low source
4340 circuit
4
5-59
Fault code
J1939 FMI
6533 Aftertreatment 1 diesel exhaust fluid line heater 2 Voltage above normal, or shorted to high source
4342 circuit
3
6534 Aftertreatment 1 diesel exhaust fluid line heater 2 Voltage below normal, or shorted to low source
4342 circuit
4
6535 Aftertreatment diesel exhaust fluid line heater 3 Voltage above normal, or shorted to high source
4344 circuit
3
6536 Aftertreatment diesel exhaust fluid line heater 3 Voltage below normal, or shorted to low source
4344 circuit
4
6556 Engine intake air heater 1 circuit Voltage above normal, or shorted to high source
729
3
6557 Engine intake air heater 1 circuit Voltage below normal, or shorted to low source
729
4
6563 Auxiliary intermediate (PTO) speed switch Data erratic, intermittent or incorrect
976 validation
2
6568 Aftertreatment regeneration inhibit switch Data erratic, intermittent or incorrect
3695
2
6583 Auxiliary temperature sensor input 1 Special instructions
441
14
6584 Auxiliary pressure sensor input 2 Special instructions
1388
14
6595 Engine speed Root cause not known
190
11
6596 Diesel particulate filter active regeneration Condition exists
3713 inhibited due to system timeout
31
6599 Engine cranks slowly Condition exists
521002
31
6611 Engine starter motor relay control circuit Voltage above normal or shorted to high source
6385
3
6612 Engine starter motor relay control circuit Voltage below normal or shorted to low source
6385
4
6613 SCR monitoring system malfunction Special instructions
5842
14
5-60
Fault code
J1939 FMI
6618 Parking brake switch Data erratic, intermittent, or incorrect
70
2
6619 Aftertreatment 1 diesel exhaust fluid temperature Abnormal rate of change
3515 2
10
6654 Engine exhaust back pressure regulator Mechanical system not responding or out of
5626 adjustment
7
6726 Aftertreatment 1 diesel oxidation catalyst missing Condition exists
4796
31
6752 Aftertreatment diesel exhaust fluid quality Data valid but below normal operating range -
18
6771 Aftertreatment system assembly Special instructions
521032
14
6938 Desired engine fueling state Abnormal update rate
5793
9
6939 Engine start request Abnormal update rate
7745
9
7133 Engine start request Out of calibration
7745
13
7134 Engine start consent Out of calibration
7746
13
7135 Engine turbocharger speed Data valid but above normal operating range -
15
7285 Engine protection torque derate Special instructions
1569
14
7393 Engine start request Abnormal update rate
7745
9
7453 Aftertreatment 1 diesel particulate filter intake Data valid but above normal operating range -
3242 temperature least severe level
15
7454 Aftertreatment 1 diesel particulate filter outlet Data valid but above normal operating range -
3246 temperature least severe level
15
5-61
GROUP 14 ENGINE CONTROL SYSTEM
1. MCU and Engine ECM (Electronic Control Module)
ECM(Engine control module)
LED
2
1
1 United MCU
4
-5
N
C
3
-5
N
C
2 Bolt
2
-5
N
C
1
-5
N
C
380A5MS13
2. MCU ASSEMBLY
1) To match the pump absorption torque with the engine torque, MCU varies EPPR valve output
pressure, which control pump discharge amount whenever feedbacked engine speed drops under
the reference rpm of each mode set.
2) Three LED lamps on the MCU display as below.
LED lamp Trouble Service

G is turned ON Normal -
G and R are turned ON Trouble on MCU · Change the MCU
G and Y are turned ON Trouble on serial · Check if serial communication
communication line lines between MCU and cluster are disconnected
Three LED are turned OFF Trouble on MCU power · Check if the input power wire (24 V, GND) of MCU
is disconnected
· Check the fuse
G : green, R : red, Y : yellow
5-62
GROUP 15 EPPR VALVE
1. Pump EPPR valve

1) Composition
EPPR (Electro Proportional Pressure Reducing) valve consists of electro magnet and spool valve
installed at main pump.
(1) Electro magnet valve
Receive electric current from MCU 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 main pump flow.
When the electro magnet valve is activated, pilot pressure enters into flow regulator of main pump.
(3) Pressure and electric current value for each mode
Pressure Electric current Engine rpm
Mode
kgf/cm
2 psi (mA) (at accel dial 10)
P 8±3 114 ± 42.7 290 ± 30 1700 ± 50

Standard S 10 ± 3 142 ± 42.7 330 ± 30 1600 ± 50
E 15 ± 3 213 ± 42.7 400 ± 30 1500 ± 50
P 3±3 42.7 ± 42.7 190 ± 30 1600 ± 50
Option S 5±3 71.1 ± 42.7 250 ± 30 1500 ± 50
E 15 ± 3 213 ± 42.7 400 ± 30 1400 ± 50
2) HOW TO SWITCH THE POWER SHIFT (STANDARD ↔ OPTION) ON THE CLUSTER

You can switch the EPPR valve pressure set by selecting the power shift (standard ↔ option).
- Management
·Service menu
300A3CD105
300A3CD106 300A3CD107
· Power shift (standard/option) : Power shift pressure can be set by option menu.
5-63
3) OPERATING PRINCIPLE (pump EPPR valve)
(1) Structure
6 7
2 3 4 5
5-22(1)
1 Sleeve 4 O-ring 6 Solenoid valve

2 Spring 5 O-ring 7 Connector
3 Spool
A
P Pilot oil supply line (pilot pressure)
P
T Return to tank
T
A Secondary pressure to flow regulator at main pump
(2) Neutral
Pressure line is blocked and A oil returns
to tank.
P A
P T
T
A
(3) Operating
Secondary pressure enters into A.
P A
T
P T
A
5-22(2)
5-64
4) EPPR VALVE CHECK PROCEDURE Spec : 100~700 mA
(1) Check electric current value at EPPR valve
① Disconnect connector CN-75 from Adapter(P/no.:21Q6-50410)
EPPR valve. CN-75

Multimeter
② Insert the adapter to CN-75 and install
multimeter as figure.
③ Start engine.
EPPR valve
④ Set S-mode and cancel auto decel
mode.
⑤ Position the accel dial at 10.
Main pump
⑥ If rpm display show approx 1600±50
rpm check electric current at bucket
circuit relief position. 330L5MS21
⑦ Check electric current at bucket circuit

relief position.
(2) Check pressure at EPPR valve Spec : 2~25 kgf/cm2 (30~350 psi)
① Remove plug and connect pressure
gauge as figure.
·Gauge capacity : 0 to 50 kgf/cm2 Pressure adjusting
(0 to 725 psi) Pilot pressure
screw locknut
CN-75
supply line
② Start engine.
③ Set S-mode and cancel auto decel
mode.
④ Position the accel dial at 10. EPPR valve
⑤ If tachometer show approx 1600±50
rpm check pressure at relief position of Main pump
bucket circuit by operating bucket control
lever.
⑥ If pressure is not correct, adjust it. 330L5MS22
⑦ After adjust, test the machine.
5-65
2. Boom priority EPPR valve
1) Composition
The boom priority EPPR valve is built in a manifold and mainly consisting of valve body and coil.
This EPPR valve installed under the solenoid valve.
2) Control
The boom priority EPPR valve has to be controlled by a specific electronic amplifier card, which is
supplying the coil with a current 580 mA at 30Ω and 24 V.
3) Operating principle
(1) Structure
1 5 4 6
P T
2 Control spool 3
21095MS14
P : Pilot supply line

P
A T : Return to tank
T
A : Secondary pressure to flow MCV
1 O-ring 3 Valve body 5 Connector

2 Support ring 4 Coil 6 Cover cap
(2) Operation
In de-energized mode the inlet port (P) is closed and the outlet port (A) is connected to tank port
(T).
In energized mode the solenoid armature presses onto the control spool with a force
corresponding to the amount of current. This will set a reduced pressure at port A. The setting is
proportional to the amount of current applied.
(3) Maximum pressure relief
If a pressure from outside is applied on port A the valve may directly switch to tank port (T) and
protect the system before overload.
5-66
2) EPPR VALVE CHECK PROCEDURE Spec : 400~600 mA
(combined boom up and swing operation)
(1) Check electric current value at EPPR
valve Solenoid valve
① Disconnect connector CN-133 from

EPPR valve.
multimeter as figure. A1
A
A5 2
③ Start engine.
④ Set s-mode and cancel auto decel
mode.
⑤ If rpm display approx 1600±50 rpm Boom priority
disconnect one wire harness from EPPR EPPR valve
valve.
CN-133
⑥ Check electric current in case of
combined boom up and swing operation.
Adapter
Multimeter (P/no.:21Q6-50410)
380A5MS15
(2) Check pressure at EPPR valve Spec : 12~37 kgf/cm2 (170~530 psi)
① Remove hose from A5 port and connect (combined boom up and swing operation)
pressure gauge as figure. Pressure
·Gauge capacity : 0 to 50 kgf/cm2 gauge
(0 to 725 psi)
② Start engine.
Solenoid valve
③ Set s-mode and cancel auto decel
mode.
④ If rpm display approx 1600±50 rpm
check pressure (In case of combined
A1
boom up and swing operation). A

A5 2
⑤ If pressure is not correct, adjust it.

⑥ After adjust, test the machine.
Boom priority
EPPR valve
380A5MS20
5-67
GROUP 16 MONITORING SYSTEM
1. OUTLINE
Monitoring system consists of the monitor part and switch part.
The monitor part gives warnings when any abnormality occurs in the machine and informs the
condition of the machine.
Various select switches are built into the monitor panel, which act as the control portion of the machine
control system.
2. CLUSTER
1) MONITOR PANEL
Time display
Warning lamps
(see page 5-74)
Gauge(see page 5-71)
Main menu(see page 5-88)
Tripmeter
(see page 5-102)
Pilot lamps
(see page 5-81)
Switches
(see page 5-84)
330A5CD20
※ The warning lamp pops up and/or blinks and the buzzer sounds when the machine has a
problem.
The warning lamp blinks until the problem is cleared. Refer to page 5-74 for details.
※ This cluster is adjustable. Forward
· Vertical (forward/backward) : each 15°
· Horizontal (left only) : 8°
Left
Backward
290F3CD47
5-68
2) CLUSTER CHECK PROCEDURE
(1) Start key : ON
① Check monitor
a. Buzzer sounding for 4 seconds with HYUNDAI logo on cluster.
※ If the ESL mode is set to the enable, enter the password to start engine.
② After initialization of cluster, the operating screen is displayed on the LCD.
Also, self diagnostic function is carried out.
a. Engine rpm display : 0 rpm
b. Engine coolant temperature gauge : White range
c. Hydraulic oil temperature gauge : White range
d. Fuel level gauge : White range
③ Indicating lamp state
a. Power mode pilot lamp : E mode or U mode
b. Work mode pilot lamp : General operation mode (bucket)
c. Travel speed pilot lamp : Low (turtle)
(2) Start of engine

① Check machine condition
a. RPM display indicates at present rpm
b. Gauge and warning lamp : indicate at present condition.
※ When normal condition : All warning lamp OFF
c. Work mode selection : General work
d. Power mode selection : E mode or U mode
e. Travel speed pilot lamp : Low (turtle)
② When warming up operation
a. Warming up pilot lamp : ON
b. After engine started, engine speed increases to1200 rpm.
※ Others same as above.
③ When abnormal condition
a. The warning lamp lights up and the buzzer sounds.
b. If BUZZER STOP switch is pressed, buzzer sound is canceled but the lamp warning lights up
until normal condition.
※ The pop-up warning lamp moves to the original position and blink when the buzzer stop switch is
pushed. Also the buzzer stops.
5-69
3. CLUSTER CONNECTOR
1) CN-56A
No. Name Signal
1 Battery 24V 20~32V
2 Power IG (24V) 20~32V CN-56B
3 GND - CN-56A
4 CAN 1 (H) 0~5V

5 CAN 1 (L) 0~5V
6 CAN 2 (H) 20~32V
7 CAN 2 (L) 20~32V
8 RS-232 (RX) ±15V Cluster 1 6
9 RS-232 (TX) ±15V
10 Aux left 0~5V
11 Aux right 0~5V
12 Aux gnd -
7 12
CN-56A
2) CN-56B
1 4
No. Name Signal
1 CAM 6.5V 6.3~6.7V
2 CAM GND -
3 CAM DIFF (H) 0~5V
4 CAM DIFF (L) 0~5V 5 8
CN-56B
5 CAM 1 NTSC signal
6 CAM 2 NTSC signal
7 CAM 3 NTSC signal
8 CAM shield - 300L5MS14
NTSC : National Television System Committee
5-70
4) Gauge
(1) Operation screen
When you first turn starting switch ON, the operation screen will appear.
1
2
4
7
5 3
6
8
300A3CD21
1 RPM / speed gauge 5 DEF/AdBlue® level gauge

2 Engine coolant temperature gauge 6 Tripmeter display
3 Hydraulic oil temperature gauge 7 Eco guage
4 Fuel level gauge 8 Accel dial gauge
(2) RPM / speed gauge

① This display the engine speed.
300A3CD22
(3) Engine coolant temperature gauge

① This gauge indicates the temperature of coolant.
·White range : 40-107˚C (104-225˚F)
·Red range : Above 107˚C (225˚F)
② If the indicator is in the red range or lamp pops up and the
buzzer sounds turn OFF the engine and check the engine
cooling system.
※ If the gauge indicates the red range or lamp blinks in
290F3CD53
red even though the machine is on the normal condition,
check the electric device as that can be caused by the poor
connection of electricity or sensor.
5-71
(4) Hydraulic oil temperature gauge
① This gauge indicates the temperature of hydraulic oil.
·White range : 40-105˚C(104-221˚F)
·Red range : Above 105˚C(221˚F)
② If the indicator is in the red range or lamp pops up and the
buzzer sounds reduce the load on the system. If the gauge
stays in the red range, stop the machine and check the cause
290F3CD54
of the problem.
(5) Fuel level gauge

① This gauge indicates the amount of fuel in the fuel tank.
② Fill the fuel when the red range, or lamp pops up and the
buzzer sounds.
290F3CD55
(6) DEF/AdBlue® level gauge

① This gauge indicates the amount of liquid in the DEF/AdBlue®
tank.
② Fill the DEF/AdBlue® when the red range, or lamp pops
up and the buzzer sounds.
③ Do not pour DEF/AdBlue® overfull.
※ Refer to page 5-79.
290F3CD57
(7) Tripmeter display

① This displays the engine the tripmeter.
※ Refer to page 5-102 for details.
290F3CD56
5-72
(8) Eco gauge
① This gauge indicates the fuel consumption rate and machine
load status. so that operators can be careful with fuel econo-
my.
② The fuel consumption rate or machine load is higher, the
number of segment is increased.
③ The color of Eco gauge indicates operation status.
·White : Idle operation
290F3CD58
·Green : Economy operation
·Yellow : Non-economy operation at a medium level.
·Red : Non-economy operation at a high level.
(9) Accel dial gauge

① This gauge indicates the level of accel dial.
290F3CD59
5-73
5) Warning lamps
Check engine warning lamp Battery charging warning lamp
Engine oil pressure warning lamp Air cleaner warning lamp
Coolant level warning lamp Overload warning lamp
Emergency warning lamp
Engine stop warning lamp Water in fuel warning lamp
Fuel level warning lamp Engine coolant

temperature warning lamp
DEF/AdBlue R
level warning lamp Hydraulic oil temperature
warning lamp
HEsT warning lamp
Exhaust system cleaning

inhibit warning lamp
seat belt reminder warning lamp Exhaust system cleaning warning lamp
Fail in sCR system warning lamp
300A3CD23A
※ Warning lamps and buzzer

Warnings When error happened Lamps and buzzer
All warning lamps Warning lamp pops up on · The pop-up warning lamp moves to the original position and
except below the center of the LCD and blinks, and the buzzer stops when ;
the buzzer sounds - the buzzer stop switch is pushed
- the knob of the jog dial module is pushed
- the lamp of the LCD is touched
Warning lamp pops up on · The pop-up warning lamp moves to the original position and
the center of the LCD and light ON or blinks, and the buzzer stops when ;
the buzzer sounds - the buzzer stop switch is pushed
- the knob of the jog dial module is pushed
- the lamp of the LCD is touched
※ Refer to page 5-79 for details.
the center of the LCD and lights ON, and the buzzer stops when 2 seconds elapsed.
the buzzer sounds
the center of the LCD and blinks, and the buzzer stops when 2 seconds elapsed.
the buzzer sounds
Warning lamp pops up on ※ Refer to page 5-75 for details.
the center of the LCD and
the buzzer sounds
Warning lamp lights ON ※ Refer to page 5-79 for details.
and the buzzer sounds
※ Refer to page 5-85 for the buzzer stop switch and page 3-64 for the jog dial module.
5-74
(1) Engine coolant temperature warning lamp
① Engine coolant temperature warning is indicated two steps.
- 103˚C over : The lamp pops up and the buzzer sounds.
② The pop-up , lamps move to the original position and blinks
290F3CD61
when the buzzer stop switch is pushed. And the buzzer
stops and , lamps keep blink.
③ Check the cooling system when the lamps keep blink.
(2) Hydraulic oil temperature warning lamp

① Hydraulic oil temperature warning is indicated two steps.
② The pop-up , lamps move to the original position and blinks
when the buzzer stop switch is pushed. And the buzzer
290F3CD62
stops and , lamps keep blink.
③ Check the hydraulic oil level and hydraulic oil cooling system.
(3) Fuel level warning lamp

① This warning lamp pops up and the buzzer sounds when the
level of fuel is below 61ℓ(16.1 U.S. gal).
② Fill the fuel immediately when the lamp blinks.
290F3CD63
(4) Emergency warning lamp

① This warning lamp pops up and the buzzer sounds when each
of the below warnings is happened.
- Engine coolant overheating (over 107˚C)
- Hydraulic oil overheating (over 105˚C)
290F3CD64
- MCU input voltage abnormal
- Cluster communication data error
- Engine ECM communication data error
※ The pop-up warning lamp moves to the original position and
blinks when the buzzer stop switch is pushed. And the
buzzer stops.
② When this warning lamp blinks, machine must be checked and
serviced immediately.
5-75
(5) Engine oil pressure warning lamp
engine oil pressure is low.
② If the lamp lights ON, shut OFF the engine immediately.
Check oil level.
290F3CD65
(6) Check engine warning lamp

communication between MCU and engine ECM on the engine
is abnormal, or if the cluster received specific fault code from
engine ECM.
290F3CD66
② Check the communication line between them.
If the communication line is OK, then check the fault codes on
the cluster.
(7) Battery charging warning lamp

battery charging voltage is low.
② Check the battery charging circuit when this lamp blinks.
290F3CD67
(8) Air cleaner warning lamp

filter of air cleaner is clogged.
② Check the filter and clean or replace it.
290F3CD68
(9) Overload warning lamp (opt)

① When the machine is overload, the overload warning lamp
pops up and the buzzer sounds during the overload switch is
ON. (if equipped)
② Reduce the machine load.
290F3CD69
5-76
(10) Engine stop warning lamp
① This warning lamp pops up and the buzzer sounds when 30
minutes elapsed with empty condition of the DEF/AdBlue®
tank, stop the engine immediately and check the DEF/
AdBlue® tank.
290F3CD252
② Fill the DEF/AdBlue® immediately in the DEF/AdBlue® tank.
③ This lamp pops up and the buzzer sounds when the stationary
SCR system cleaning is not performed.
※ Please contact your Hyundai service center or local dealer.
※ "Engine shutdown" cluster message up when the exhaust
gas temperature reaches above 800℃.
(11) Exhaust system cleaning warning lamp

① This warning lamp lights ON or blinks when the exhaust sys-
tem cleaning is needed as table below.
290F3CD70
Warning lamp
Exhaust Check engine Stop engine
Description
Off Off Off · Automatic exhaust system cleaning

· The status of a manual (stationary) exhaust system cleaning
Blink Off Off when the exhaust system cleaning switch has been activated.
· The aftertreatment exhaust system needs to be cleaned immedi-
· ately.
※ Engine power will be reduced automatically if action is not taken.
On On Off
The exhaust system cleaning can be accomplished by :
- Changing to more challenging duty cycle.
- Performing a manual exhaust system cleaning.
· These lamps will be ON when a stationary (manual) exhaust
system cleaning is not performed.
On On On
· Stop the engine immediatary.
· Please contact your Hyundai service center or local dealer.
(12) Exhaust system cleaning inhibit warning lamp

① This warning lamp indicates, when illuminated, the exhaust
system cleaning switch is pushed inhibit position, therefore
automatic and manual exhaust system cleaning can not occur.
※ Refer to the page 3-41 for the exhaust system cleaning
switch.
2609A3CD20
5-77
※ Manual exhaust system cleaning
※ Manual exhaust system cleaning applies if the machine is

in a fireproof area.
※ To stop a manual exhaust system cleaning before it has
completed, set to the exhaust system cleaning switch to
the inhibit position or turn OFF the engine.
① Stop and park the machine.
safety button
1
2
② Pull the safety button and push the switch to position ② to
initiate the manual exhaust system cleaning.
※ Refer to the operator's manual page 3-41 for the exhaust sys-
tem cleaning switch operation.
※ The engine speed may increase to 950~1050 rpm and exhaust
system cleaning begins and it will take approximately 20~30
minutes.
Exhuast warning HEsT warning

③ The exhaust system cleaning warning lamp will blink and
lamp blink lamp ON HEST warning lamp will light ON during the exhaust system
cleaning is operating.
④ The exhaust system cleaning and/or HEST warning lamp will

Exhuast warning HEsT warning
light OFF when the exhaust system cleaning is completed.
lamp OFF lamp ON OFF
290F3CD73A
(13) HEST (High exhaust system temperature) warning lamp

① This warning lamp indicates, when illuminated, that exhaust
temperatures are high due to exhaust system cleaning.
② The lamp will also illuminate during a manual exhaust system
cleaning.
③ When this lamp is illuminated, be sure the exhaust pipe outlet
2609A3CD21 is not directed at any surface or material that can melt, burn, or
explode.
When this lamp is illuminated, the exhaust gas temperature
could reach 800˚C [1500˚F], which is hot enough to ignite or
melt common materials, and to burn people.
※ The lamp does not signify the need for any kind of equipment
or engine service; It merely alerts the equipment operator to
high exhaust temperatures. It will be common for the lamp to
illuminate on and off during normal equipment operation as the
engine completes exhaust system cleaning.
5-78
(14) DEF/AdBlue® level warning lamp
① This warning lamp indicates when ON or blinking, that the
DEF/AdBlue® level is low as table below.
※ It is recommended that the DEF/AdBlue® tank be filled
completely full of the DEF/AdBlue® in order to correct any
fault conditions.
290F3CD257
Warning lamp
Fail in SCR DEF/AdBlue®
Check engine Stop engine
system level
Description
· The DEF/AdBlue® level has fallen below the

On On Off Off
initial warning level (10%).
· The DEF/AdBlue® level has fallen below the
initial derate level (2.5%).
On On On Off
· The engine power will be limited automati-
cally.
· This is happened when 30 minutes elapsed
with empty conditions (0%) of the DEF/
AdBlue® tank.
· The engine will enter the final derate level
On Blink On On which may include low idle lock or engine
shutdown with restart limitations.
· In order to remove the final derate, the DEF/
AdBlue® tank must be filled to above 10
persent gauge reading.
(15) Water in fuel warning lamp

① This warning lamp lights ON and the buzzer sounds when the
water separator is full of water or malfunctioning.
※ When this lamp lights ON, stop the machine and spill water
out of the separator.
300A3CD24
5-79
(16) Seat belt reminder warning lamp
① When operator don’t fasten the seat belt, the seat belt remind-
er warning lamp pops up and the buzzer sounds.
② Fasten the seat belt.
300A3CD25
(17) Coolant level warning lamp

① This warning lamp indicates lack of coolant.
② Check and refill coolant.
760F3CD58
(18) Fail in SCR system warning lamp

① This warning lamp indicates there are faults related to SCR
system.
② The lamp lights ON when each of the below warnings is hap-
pened.
300A3CD15
a. Low DEF/AdBlue® level
b. Poor quality of DEF/AdBlue®
c. Tempering or malfunction in the aftertreatment system
③ Once the lamp lights ON, the engine will derate shortly.
※ Please contact your Hyundai service center or local dealer.
5-80
6) Pilot lamps
300A3CD26
(1) Mode pilot lamps

No Mode Pilot lamp Selected mode
Heavy duty power work mode
1 Power mode Standard power mode
Economy power mode
2 User mode User preferable power mode
General operation - IPC speed mode
General operation - IPC balance mode
3 Work tool mode General operation - IPC efficiency mode
Breaker operation mode
Crusher operation mode
Low speed traveling

4 Travel mode
High speed traveling
5 Auto idle mode Auto idle
(2) Power max pilot lamp

① The lamp will be ON when pushing power max switch on the
LH RCV lever.
② The power max function is operated maximum 8 seconds.
※ Refer to the operator's manual page 3-43 for power max
function.
300A3CD32
5-81
(3) Preheat pilot lamp
① Turning the start key switch ON position starts preheating in
cold weather.
② Start the engine after this lamp is OFF.
290F3CD79
(4) Warming up pilot lamp

① This lamp is turned ON when the coolant temperature is below
30˚C (86˚F ).
② The automatic warming up is cancelled when the engine cool-
ant temperature is above 30˚C, or when 10 minutes have
passed since starting the engine.
290F3CD80
(5) Decel pilot lamp

① Operating one touch decel switch on the RCV lever makes the
lamp ON.
② Also, the lamp will be ON and engine speed will be lowered
automatically to save fuel consumption when all levers and
pedals are at neutral position, and the auto idle function is
300A3CD33 selected.
※ One touch decel is not available when the auto idle pilot
lamp is turned ON.
※ Refer to the operator's manual page 3-44
(6) Fuel warmer pilot lamp

① This lamp is turned ON when the coolant temperature is below
10˚C (50˚F ) or the hydraulic oil temperature 20˚C (68˚F ).
② The automatic fuel warming is cancelled when the engine
coolant temperature is above 60˚C, and the hydraulic oil tem-
perature is above 45˚C since the start switch was ON position.
300A3CD34
(7) Maintenance pilot lamp

① This lamp will be ON when the consuming parts are needed to
change or replace. It means that the change or replacement
interval of the consuming parts remains below 30 hours.
② Check the message in maintenance information of main menu.
Also, this lamp lights ON for 3 minutes when the start switch is
300A3CD35 ON position.
※ Refer to the page 5-95.
5-82
(8) Entertainment pilot lamp
① This lamp is on when audio or video files are playing.
290F3CD84
(9) Smart key pilot lamp (opt)

① This lamp is on when the engine is started by the start button.
② This lamp is red when the a authentication fails, green when
succeeds.
300A3CD36
(10) Auto safety lock pilot lamp

① Auto safety lock system prevents unintended operation of the
machine in order to improve safety.
② Only if safety lever is locked, engine is started.
③ If operator unlock safety lever when RCV lever is pressed,
machine is not controlled by RCV lever.
300A3CD37
300A3CD38
5-83
7) SWITCHES
Aircon quick Entertainment

touch switch quick touch switch
Main menu quick

touch switch
Work mode
pilot lamp Travel speed pilot lamp
Power/user mode Auto idle pilot lamp
pilot lamp
user mode switch Travel speed switch
Power mode switch Auto idle/Buzzer stop switch
Work mode switch Escape(previous or parent menu)
Rear camera(option)
Work light switch
Cab light switch Overload switch(option)
Head light switch Travel alarm switch
Intermittent wiper switch Beacon switch(option)
Washer switch Wiper switch
300A3CD39
※ When some of the switches are selected, the pilot lamps are displayed on the LCD. Refer to
the page 5-81 for details.
(1) Power mode switch

① This switch is to select the machine power mode and selected
power mode pilot lamp is displayed on the pilot lamp position.
·P : Heavy duty power work.
·S : Standard power work.
·E : Economy power work.
290F3CD76
② The pilot lamp changes E → S → P → E in order.
(2) Work mode switch

① This switch is to select the machine work mode, which shifts
from general operation mode to optional attachment operation
mode.
· : General operation mode
· : Breaker operation mode (if equipped)
290F3CD88
· : Crusher operation mode (if equipped)
·Not installed : Breaker or crusher is not installed.
※ Refer to the operator's manual page 2-7 for details.
5-84
(3) User mode switch
① This switch is used to memorize the current machine operating
status in the MCU and activate the memorized user mode.
·Memory : Push more than 2 seconds.
·Action : Push within 2 seconds.
·Cancel : Push this switch once more within 2 seconds.
290F3CD89
② Refer to the page 5-89 for another set of user mode.
(4) Travel speed switch

① This switch is used to select the travel speed alternatively.
· : Low speed
· : High speed
※ Do not change the setting of the travel speed switch.
290F3CD91
Machine stability may be adversely affected.
Personal injury can result from sudden changes in machine
stability.
(5) Auto idle/ buzzer stop switch

① This switch is used to activate or cancel the auto idle function.
·Pilot lamp ON : Auto idle function is activated.
·Pilot lamp OFF : Auto idle function is cancelled.
② The buzzer sounds when the machine has a problem.
In this case, push this switch and buzzer stops, but the warn-
290F3CD90
ing lamp blinks until the problem is cleared.
(6) Escape/Camera switch

① This switch is used to return to the previous menu or parent
menu.
② In the operation screen, pushing this switch will display the
view of the camera on the machine (if equipped).
Please refer to page 5-102 for the camera.
290F3CD92
③ If the camera is not installed, this switch is used only ESC
function.
(7) Work light switch

① This switch is used to operate the work light.
② The pilot lamp is turned ON when operating the switch.
290F3CD93
5-85
(8) Head light switch
① This switch is used to operate the head light.
290F3CD94
(9) Intermittent wiper switch

① This switch is used to wipe operates intermittently.
290F3CD95
(10) wiper switch

① This switch is used to operate the window wiper.
② Note that the wiper will self-park when switched off.
③ The pilot lamp is turned ON when operating the switch.
※ If the wiper does not operate with the switch in ON position,
turn the switch OFF immediately. Check the cause.
290F3CD96 If the switch remains ON, motor failure can result.
(11) washer switch

① The washer liquid is sprayed and the wiper is operated only
while pressing this switch.
290F3CD100
(12) Cab light switch

① This switch turns ON the cab light on the cab.
290F3CD99
5-86
(13) Beacon switch
① This switch turns ON the rotary light on the cab.
290F3CD97
(14) Overload switch

① When this switch turned ON, buzzer makes sound and over-
load warning lamp comes ON in case that the machine is
overload.
② When it turned OFF, buzzer stops and warning lamp goes out.
Overloading the machine could impact the machines stabil-
290F3CD98 ity which could result in tipover hazard. A tipover hazard
could result in serious injury or death. Always activate the
overload warning device before you handle or lift objects.
(15) Travel alarm switch
① This switch is to activate travel alarm function surrounding
when the machine travels to forward and backward.
② On pressing this switch, the alarm operates only when the
machine is traveling.
③ The pilot lamp is turned ON when operating the switch.
290F3CD101
(16) Air conditioner quick touch switch

① This switch used to select air conditioner control mode.
290F3CD216
(17) Main menu quick touch switch

① This switch is to activate the main menu in the cluster.
290F3CD217
(18) Entertainment quick touch switch

① This switch is to activate the entertainment control menu in the
cluster.
290F3CD218
5-87
8) Main menu
※ You can select or set the menu by the jog dial module or touch screen.
On the operation screen, tap Menu to access the main menu screen.
On the sub menu screen, you can tap the menu bar to access functions or applications.
· Operation screen
Main menu screen sub menu screen
Tap
+
Press
300A3CD40
※ Please refer to the jog dial module, operator's manual page 3-65 for selection and change of
menu and input value.
(1) Structure
No Main menu Sub menu Description
Work tool Breaker, Crusher, Not installed
U mode power User mode only
Boom/Arm speed Boom speed, Arm speed
Auto power boost Enable, Disable
1
IPC mode Speed mode, Balance mode, Efficiency mode
Mode Auto engine shutdown (option) One time, Always, Disable
Initial mode Key on initial mode, Accel initial mode / step
290F3CD103 Emergency mode Switch function
Active fault MCU, Engine ECM
Logged fault MCU, Engine ECM
2 Delete logged fault All logged fault delete, Initialization canceled
Monitoring Machine information, Switch status, Output status,
Monitoring
290F3CD104
Fuel rate information General record, Hourly, Daily, Mode record

Maintenance information Replacement, Change interval oils and filters
Machine security ESL mode setting, Password change
Machine information Model, MCU, Monitor, jog dial module, switch controller,
RMCU, Relay drive unit, FATC, AAVM (opt)
3
Contact A/S phone number, A/S phone number change
Service menu Power shift, Operating hour, Breaker mode pump
Management acting, EPPR current level, Overload pressure
Clinometer Clinometer setting
290F3CD105
Update Cluster, ETC device
Display item Engine speed, Tripmeter A, Tripmeter B, Tripmeter C

Clock Clock
Brightness Manual, Auto
4
Unit setup Temperature, Pressure, Flow, Distance, Date format
Display Language selection Korean, English, Chinese, ETC
290F3CD106
Screen type A type, B type
Entertainment Play Video, Audio, Smart terminal.

Tripmeter 3 kinds (A, B, C)
5 Camera Number of active, Display order, AAVM (opt)
Utilities
290F3CD107
5-88
(2) Mode setup
① Work tool
300A3CD41
300A3CD42 300A3CD43
A B
· Select on installed optional attachment

- A : It can set the user's attachment.
It is available in setting #1~#10.
- B : Max flow - Set the maximum flow for the attachment.
Relief pressure - Set the relief pressure.
② U mode power
Step Engine Idle speed Power

speed shift
( ) (rpm) (rpm) (bar)
1 1300 750 0
2 1400 800 3
3 1500 850 6
300A3CD44 4 1600 900 9
300A3CD45 5 1700 950 12
· Engine high idle rpm, auto idle rpm and pump torque 6 1800 1000 (auto decel) 16
(power shift) can be modulated and memorized sepa- 7 1850 1150 20
rately in U-mode. 8 1900 1100 26
· U-mode can be activated by user mode switch. 9 1950 1150 32
10 2000 1200 38
※One touch decel & low idle : 900 rpm
③ Boom/Arm speed
300A3CD46
300A3CD47 300A3CD48
· Boom speed
- Boom priority function can be activated or cancelled
Enable - Boom up speed is automatically adjusted as working conditions by the MCU.
Disable - Normal operation
· Arm speed
- Arm regeneration function can be activated or cancelled.
Enable - Arm in speed is up.
Disable - Normal operation.
5-89
④ Auto power boost
300A3CD49
300A3CD50
· The power boost function can be activated or cancelled.

Enable - The digging power is automatically increased as working conditions by the MCU.
It is operated max 8 seconds.
Disable - Not operated.
⑤ IPC mode
300A3CD51 300A3CD52 300A3CD53
300A3CD54 300A3CD55
300A3CD56 300A3CD57
· The IPC mode can be selected by this menu.

- Speed mode
- Balance mode (default)
- Efficiency mode
· This mode is applied only general operation mode of the work tool mode.
※ Please update the cluster programs if this mode is not displayed in the mode setup menu. Refer
to the page 5-98.
5-90
⑥ Automatic engine shutdown (option)
300A3CD58
300A3CD59 300A3CD60
· The automatic engine shutdown function can be set by this menu.

- One time
- Always
- Disable
- Wait time setting : Max 40 minutes, min 2 minutes
⑦ Initial mode
300A3CD61
300A3CD62
· Key on initial mode

- Selected the power mode is activated when the engine is started.
· Key on initial work mode
- Not installed
- Last setting
- Work mode
· Accel initial mode
- Last setting value
- User setting value
· Accel initial step
- 0~9 step
⑧ Emergency mode
300A3CD63
300A3CD64
· This mode can be use when the switches are abnormal on the cluster.
· The cluster switches will be selected by touched each icon.
5-91
(3) Monitoring
① Active fault
300A3CD65
300A3CD66 300A3CD67
· The active faults of the MCU, engine ECM or air conditioner can be checked by this menu.
② Logged fault
300A3CD68
300A3CD69 300A3CD70
· The logged faults of the MCU, engine ECM or air conditioner can be checked by this menu.
③ Delete logged fault
300A3CD71
300A3CD72 300A3CD73
· The logged faults of the MCU, engine ECM or air conditioner can be deleted by this menu.
④ Monitoring
300A3CD74
300A3CD75 300A3CD76
· The machine status such as the engine rpm, oil temperature, voltage and pressure etc. can
be checked by this menu (Analog input).
· The switch status or output status can be confirmed by this menu (Digital input & Digital
output).
· The activated switch or output pilot lamps are light ON.
5-92
(4) Management
① ECO report
This reports the machine’s inefficient operation status in order to improve operator’s improper
working habit.
High idle
300A3CD77
300A3CD78
Idle
·Show each usage ratio of high idle, idle and relief
operation when monitor is turned ON.
·Show the usage ratio’s daily record for 7 days and ac-
cumulated record from the first operation.
300A3CD79
Relief operation
300A3CD80
5-93
② Fuel rate information
300A3CD81
300A3CD82
A
·General record (A)
- Average fuel rate (left) (from "Reset" to now)
Fuel consumption devided by engine run time
(service meter time).
- A days fuel used (right)
Fuel consumption from 24:00 (or "Reset" time) to 300A3CD83
now (MCU real time).

B
·Hourly record (B)
- Hourly fuel rates for past 12 hours (service meter
time).
- No record during key-off time.
- One step shift to the right for every one hour.
- Automatic deletion for 12 hours earlier data.
300A3CD84
- All hourly records deletion by "Reset".
C
·Daily record (C)
- Daily fuel consumption for past seven days (MCU
real time).
- No record during key-off time.
- One step shift to the right at 24:00 for every day.
- Automatic deletion for 7 days earlier data.
300A3CD85
- All daily records deletion by "Reset".
D
·Mode record (D)
- Average fuel rate for each power mode/accel dial (at
least 7) from "Reset" to now.
- No record during idle.
- All mode records deletion by "Reset".
300A3CD86
5-94
③ Maintenance information
300A3CD87
300A3CD88 300A3CD89
· Alarm lamp ( ) is ON when oil or filter needs to be changed or replaced.

· Replacement : The elapsed time will be reset to zero (0).
· Change interval : The change or replace interval can be changed in the unit of 50 hours.
· Change or relpace interval
No Item Interval
1 Engine oil 1000
2 Final gear oil 1000
3 Swing gear oil 1000
4 Hydraulic oil 5000
5 Pilot line filter 1000
6 Drain filter 1000
7 Hydraulic oil return filter 1000
8 Engine oil filter 1000
9 Fuel filter 1000
10 Pre-filter 1000
11 Hydraulic tank breather 1000
12 Air cleaner (inner & outer) 2000
13 Radiator coolant 2000
14 Swing gear pinion grease 1000
15 DEF/AdBlue® supply module filter 4500
16 DEF/AdBlue® tank filter 2000
5-95
④ Machine security
300A3CD90
300A3CD91 300A3CD92
· ESL mode setting

- ESL : Engine Starting Limit
- ESL mode is desingned to be a theft deterrent or will pre-
vent the unauthorized operation of the machine.
- If the ESL mode was selected Enable, the password will
be required when the start switch is turned ON.
- Machine security 300A3CD93
Disable : Not used ESL function
Enable (always) : The password is required whenever the
operator starts engine.
- Interval : The password is required when the operator
starts engine first. But the operator can restart
the engine within the interval time without input-
ting the password.
The interval time can be set maximum 4 hours. 300A3CD94
※Default password : 00000＋
※Password length : (5~10 digit)＋
- Smart key (option) : Smart key is registered when equipped with optional smart key. If smart
key is not inside of the cabin, authentication process fails and the pass-
word entering is needed.
· Password change
- The password is 5~10 digits.
300A3CD95
300A3CD96 300A3CD91
Enter the current password
300A3CD98 300A3CD99
Enter the new password again Enter the new password
5-96
⑤ Machine Information
300A3CD100
300A3CD101
· This can confirm the identification of the model information (ECU), MCU, monitor, jog dial
module, switch controller, RMCU, relay driver unit, FATC (air conditioner controller), AAVM
(opt).
⑥ Contact (A/S phone number)
300A3CD102
300A3CD103 300A3CD104
Enter the new A/S phone number
⑦ Service menu
300A3CD105
300A3CD106 300A3CD107
· Power shift (standard/option) : Power shift pressure can be set by option menu.
· Operating hours : Operating hours since the machine line out can be checked by this menu.
· Breaker mode pump acting (1 pump/2 pump)
· EPPR current level (attach flow EPPR 1 & 2, boom priority EPPR, attach relief pressure EPPR
1& 2)
· Overload pressure : 100 ~ 350 bar
⑧ Clinometer
300A3CD108
300A3CD109
· When the machine is on the flatland, if tap the "initialization", the values of X, Y reset "0".
· You can confirm tilt of machine in cluster's operating screen.
5-97
⑨ Update (cluster & ETC devices)
300A3CD110
300A3CD111 300A3CD112
380F3CD06 300A3CD114
· ETC devices and cluster can be updated through CAN 2 network.

· Insert USB memory stick which includes program files, start download.
⑩ OME (owner menu editing)

The owner of machine can restrict operators access the set of functions.
300A3CD115
300A3CD116 300A3CD117
· Owner can set the status of the function.

- Enable
- Disable
· the menu, owner can set the list of the function to
In
lock or unlock it.
· Owner password (default password : 11111)
- Owner can manage and change the password. 300A3CD118
- Necessary to input the password to access the set

of function.
5-98
(5) Display
① Display item
300A3CD119
300A3CD120 300A3CD121
· The center display type of the LCD can be selected by this menu.
· The engine speed or each of the tripmeter (A,B,C) is displayed on the center display.
② Clock
300A3CD122
300A3CD123
· The first line's three spots "**/**/****" represent Month/Day/Year each.

· The second line shows the current time. (0:00~23:59)
③ Brightness
300A3CD124
300A3CD125 300A3CD126
300A3CD127 300A3CD128
300A3CD129
· If "Auto" is chosen, brightness for day and night can be differently set up. Also by using the
bar in lower side, users can define which time interval belongs to day and night.
(in bar figure, white area represents night time while orange shows day time)
5-99
④ Unit
300A3CD130
300A3CD131 300A3CD132
· Temperature : ˚C ↔ ˚F
· Pressure : bar ↔ MPa ↔ kgf/cm2
· Volume :ℓ↔ gal
· Flow : lpm ↔ gpm
· Distance : km ↔ mile
· Date format : yy/mm/dd ↔ mm/dd/yy ↔ dd-mm-yy
⑤ Language
300A3CD133
300A3CD134
· User can select preferable language and all displays are changed the selected language.
5-100
(6) Utilities
① Entertainment
300A3CD135
A 300A3CD136 300A3CD139
B 300A3CD137 300A3CD140
C 300A3CD138 300A3CD141
300A3CD142
- Video (A) : This menu operates the video play function.

mp4, mkv, avi files and so on.
- Audio (B) : This menu operates the play music.
mp3, mp4 files and so on.
- Smart terminal (C) : The menu features a smartphone and operates the miracast.
5-101
② Tripmeter
300A3CD143
300A3CD144
· Maximum 3 kinds of tripmeters can be used at the same time.

· Each tripmeter can be turned on by choosing "Start" while it also can be turned off by
choosing "Stop".
· If the tripmeter icon is activated in the operation screen, it can be controlled directly there.
③ Camera setting
· If the rear camera is not installed on the machine, set disable.
· If the rear camera installed on the machine, set enable.
300A3CD145
300A3CD146 300A3CD147
· In the operation screen, rear camera screen show up when ESC/CAM button is pushed.
300A3CD97
290F3CD221
5-102
④ AAVM (All Around View Monitoring, option)
· The AAVM buttons of the cluster consist of EsC/CAM and AuTO IDlE/Buzzer stop.
Buzzer stop switch
Escape switch
300A3CD149
- Escape button
· It will enter into the AAVM mode from the beginning screen if the AAVM is installed.
· While in the AAVM mode, select the EsC button to return to the beginning screen.
300A3CD97
The beginning screen

AAVM mode 290F3CD222
- Buzzer stop button

· In AAVM mode, it detects surrounding pedestrians or objects and the warning buzzer sounds.
· user can turn OFF the warning sound by pressing buzzer stop button.
· When the worker or pedestrian go to the blue line
(radius 5 m), an external danger area of equipping
on the cluster screen, the warning buzzer sounds
and it displays the blue rectangular box for the rec-
ognition of the worker and pedestrian.
At this time, the operator should stop work imme-
diately, and stop the buzzer by pressing the buzzer
stop button. And then, please work after you check
290F3CD246 whether the danger factors are solved.
· When the worker or pedestrian go inside of red line

(radius 3 m), an internal danger area of equipping
on the cluster screen, the warning buzzer sounds
and it displays the red rectangular box for the
recognition of the worker and pedestrian.
At this time, the operator should stop work imme-
diately, and stop the buzzer by pressing the buzzer
stop button. And then, please work after you check
290F3CD247
whether the danger factors are solved.
※ In AAVM mode, a touch screen of the lCD is available only. The multimodal dial of the jog
dial module is not available.
5-103
9) Air conditioner and heater
Full auto air conditioner and heater system automatically keeps the optimum condition in accor-
dance with operator's temperature configuration sensing ambient and cabin inside temperature.
· Location of air flow ducts
B
B
B
B
D
C
Cluster : or
Jog dial module :
setting temperature
Power switch Temperature switch
Air conditioner switch Fersh air/air recirculation switch
Auto switch Air mode switch
Fan speed Fan speed switch

220A3CD21
※ Jog dial module : Refer to the operator's manual page 3-65.
5-104
(1) Power switch
① This switch makes the system ON/OFF.
Just before the power OFF, set values are stored.
② Default setting values
Function Air conditioner In/outlet LCD Temperature Mode
Previous sw Previous sw
290F3CD251 Value off Inlet off
off off
(2) Air conditioner switch

① This switch turns the compressor ON/OFF.
※ Air conditioner operates to remove vapor and drains water
through a drain hose. Water can be sprayed into the cab in
case that the drain cock at the ending point of drain hose
has a problem.
290F3CD203 In this case, exchange the drain cock.
(3) Auto switch

① Auto air conditiner and heater system automatically keeps the
optimum condition in accordance with operator's temperature
configuration sensing ambient and cabin inside temperature.
290F3CD223
(4) Setting temperature

① Display the temperature setting out.
290F3CD224
(5) Temperature switch

① Setting temperature indication
· Lo (17˚C), 17.5~31.5˚C, Hi (32˚C)
② Max cool and max warm beeps 5 times.
③ The max cool or the max warm position operates as following
table.
290F3CD225
Temperature Compressor Fan speed In/outlet Mode
Max cool on Hi (8 step) Recirculation Face
Max warm off Hi (7 step) Fresh Def/Foot
④ Temperature unit can be changed between celsius (˚C) and
fahrenheit (˚F)
a. Default status (˚C)
b. Push Up/Down temperature switch simultaneously more than
5 second displayed temperature unit change (˚C → ˚F)
5-105
(6) Fan speed switch
① Fan speed is controlled automatically by setted temperature.
② This switch controls fan speed manually.
· There are 8 up/down steps to control fan speed.
· The maximum step or the minimum step beeps 5 times.
290F3CD226
(7) Fan speed

① Steps 1 through 8 to display the amount of wind.
290F3CD227
(8) Fresh air/air recirculation switch

① It is possible to change the air-inlet method.
a. Fresh air ( )
Inhaling air from the outside.
b. Air recirculation ( )
It recycles the heated or cooled air to increase the energy
290F3CD228 efficiency.
※ Change air occasionally when using recirculation for a
long time.
※ Check out the fresh air filter and the recirculation filter
periodically to keep a good efficiency.
(9) Air mode switch

① Operating this switch, it beeps and displays symbol of each
mode in order. (Face → Face/Rear → Face/Rear/Foot → Foot
→ Def/Foot)
Face Face/Rear Face/Rear/Foot Foot Def/Foot
Mode
switch
290F3CD229
A ● ● ●
B ● ●
Outlet
C ● ● ●
D ●
② When defroster mode operating, fresh air/air recircu-

lation switch turns to FRESH AIR mode and air conditioner
switch turns ON.
5-106
(10) Self diagnosis function
① Diagnostic methods : Diagnostic information window, select
② Diagnostic indication (Displays fault)
Fault code Description Fail safe function

F01 Ambient temperature sensor open
20˚C alternate value control
F02 Ambient temperature sensor short
F03 Cab inside temperature sensor open
F04 Cab inside temperature sensor short
F05 Evaporate temperature sensor open
F06 Evaporate temperature sensor short
F07 Null -
F08 Null -
F09 Mode 1 actuator open/short The alternate value is face
F10 Mode 1 actuator drive circuit malfunction If not, the alternate value is Def/Foot
F11 Intake actuator open/short The alternate value is air recirculation
F12 Intake actuator drive circuit malfunction The alternate fresh air
F13 Temperature actuator open/short If opening amount is 0 %, the alternate value is 0 %
F14 Temperature actuator drive circuit malfunction If not, the alternate value is 100 %
F15 Null -
F16 Null -
5-107
GROUP 17 Fuel warmer system
1. Specification
1) Operating voltage : 24±4 V
2) Power : 350±50 W
3) Current : 15 A
2. Operation Filter head &

fuel warmer
1) T h e c u r r e n t o f f u e l w a r m e r s y s t e m i s
automatically controlled without thermostat
according to fuel temperature.
2) At the first state, the 15 A current flows to the fuel
warmer and engine may be started in 1~2
Prefilter
minutes.
3) If the fuel starts to flow, ceramic-disk in the fuel
warmer heater senses the fuel temperature to
reduce the current as low as 1.5 A.
So, fuel is protected from overheating by this
mechanism. 300L5MS15
3. Electric circuit
B+ iG(POweR Ry) iG(BatteRy Ry)
2.0Rw
POweR Ry
87a 87 85
30 86
ROOm lamP/RaDiO B+
FUel FilleR PUmP

aiR cOn / HeateR
staRt, aiR-Heat
OPtiOn, switcH
cR-35
PROPORtiOnal
HeaD lamP
87a
FUel HeateR
30
86
85
aaVm / siRen
87
DeF mODUle
line HeateR
ac / HeateR
cOnVeRteR
saFety sOl
clUsteR B+
wORK lamP
caBin lamP
clUsteR iG
mcU cOnt.
staRt Key
seat Heat
sOlenOiD
sOlenOiD
BReaKeR
DeF&scR
RaDiO iG
ecm
1.0wOr
RDU iG
2.0Rw
wiPeR
wiPeR
ciGaR
HORn
0.75B
2.0Gr
mcU
ePPR
ecm
20a 21
10a 10
20a 23
10a 24
30a 34
30a 36
30a 22
5a 12
20a 25
20a 30
20a 13
20a 11
10a 14
10a 15
10a 16
10a 18
10a 17
10a 19
10a 20
10a 26
20a 27
20a 28
20a 29
15a 31
10a 32
20a 33
2
4
7
8
9
30a 1
15a 3
15a 5
30a 6
30a
10a
20a
10a
10a
5.0R
1.0Rw
3.0w
1.5R
2.0Gr 8.0w cn-263

2
1
cn-96 2.0l cn-258

1.0wB
2.0w
1.0lg
2.0 Br 5w
1
masteR sw
1 1
2.0 B 2.0Gr
HeateR
2 2 aiR cOmP
cs-74B
FUel
3
5.0R
POweR
4 1
5.0R
s
l
2
l
cR-46
30
2.0yR cn-93 cs-74
0.75w cn-245
85 87 87a 0.75yR
86 1 BatteRy(+) 5B
2.0Br 0.75w 90a cn-95 2
87 25 BatteRy(+) 8w 5w
V 0.75w 2 1
85 26 BatteRy(+) 8w
86 30 87a 0.75w 1 Ptc POweR
27 BatteRy(+)
FUel HeateR Ry 0.75w ciRcUit BReaKeR
28 BatteRy(+)
0.75B 5R
73 BatteRy(-)
2
0.75B 5R
1
49 BatteRy(-)
0.75B
50 BatteRy(-)
60a cn-60
0.75B
1.0wOr
51 BatteRy(-)
2.0w
0.75B
0.75wB
52 BatteRy(-) cR-1
cn-5
75 aiR HRateR Relay 60R 60B

34
35
36
37
38
39
40
41
42
43
57
58
59
60
3
1
4
5
6
7
2
0.75Or
05 Key switcH "On"
1.0G
1.0w
BatteRy
cn-125 ecm Batt Ry (12VX2)
1.0w cn-100
1 1 3B 3B
0.8w
2 2
1.0Rw
0.75V
3 3
1.0R
1.0G R
4 4 cn-45
1.2w
1.2G
GPs cOnn. cn-2 m

cn-427
cn-51, 52, 53 & 54
m
1.2w
52-13
51-26
51-01
4
2
4
3
1
cn-125a
5
cR-36
cs-2a
1
2
6 B+
1
5
4
1
6
2
3
11
BatteRy POweR
0.75wB 4 5 1
Batt POweR _24V
staRteR
FUel waRmeR Ry
2 12
B
0, i 0.75yR
3 13
1
can (HiGH)
cR-24
can (lOw)
Key iG 24V
4 14 15R
Key "iG"
1.0By 1.0By
0.75By
iG 24V
5 3 2 15 cn-80
GnD
i 0 H 15R
4
3
2
6
5
c st acc BR H
PRe-Heat Ry
ReaDeR Rms staRt Key sw UniteD mcU GlOw PlUG Ry GlOw PlUG
330A5MS16
5-108
Group 1 Before Troubleshooting -------------------------------------------------------------------------------------- 6-1

Group 2 Hydraulic and Mechanical System ------------------------------------------------------------------- 6-4
Group 3 Electrical System ----------------------------------------------------------------------------------------------- 6-25
Group 4 Mechatronics System ---------------------------------------------------------------------------------------- 6-44
Group 5 Air con & Heater System ----------------------------------------------------------------------------------- 6-74
GROUP 1 BEFORE TROUBLESHOOTING
1. INTRODUCTION
When a trouble is occurred in the machine, this section will help a service man to repair to maintain
the machine with easy.
The trouble of machine is parted Hydraulic & Mechanical system, Electrical system, Mechatronics
system and Air con & Heater system. (fault codes displayed on monitor display) At each system
part, a service man can check the machine according to the troubleshooting process diagram.
※ Before carring out troubleshooting procedure, check monitoring menu in the cluster.
Hydraulic &
GROUP 2
Mechanical part
Electrical part GROUP 3
Troubles occur
Mechatronics
part GROUP 4
Air con & Heater

part GROUP 5
HCESPN 3digit See page

+ FMI 1 or 2 digit 5-18
Fault codes (machine)
displayed on
monitor display
3 or 4 digit See page
(engine) 5-22
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
13031SH03
repaired 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
such as low battery voltage, loose connections INSPECTION
and blown out fuses will result in malfunction of

the controllers causing total operational failures (210-7) 6-2(3)
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.
(210-7) 6-3(1)
STEP 5. Perform troubleshooting

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

Before reaching a conclusion, check the most
suspectible causes again. Try to trace what
the real cause of the trouble is.
Make a plan of the appropriate repairing

procedure to avoid consequential malfunctions.
(210-7) 6-3(3)
6-3
GROUP 2 HYDRAULIC AND MECHANICAL SYSTEM
1. INTRODUCTION
1) MACHINE IN GENERAL
(1) If even a minor fault is left intact and operation is continued, a fatal failure may be caused,
entailing a large sum of expenses and long hours of restoration.
Therefore when even a small trouble occurs, do not rely on your intuition and experience, but look
for the cause based on the troubleshooting principle and perform maintenance and adjustment to
prevent major failure from occurring. Keep in mind that a fault results from a combination of
different causes.
(2) The following lists up commonly occurring faults and possible causes with this machine. For the
troubleshooting of the engine, refer to the coming troubleshooting and repair.
(3) When carrying out troubleshooting, do not hurry to disassemble the components.
It will become impossible to find the cause of the problem.
(4) Ask user or operator the following.
① Was there any strange thing about machine before failure occurred?
② Under what conditions did the failure occur?
③ Have any repairs been carried out before the failure?
(5) Check before troubleshooting.
① Check oil and fuel level.
② Check for any external leakage of oil from components.
③ Check for loose or damage of wiring and connections.
2) Machine status monitoring on the cluster
(1) The machine status such as the engine rpm, oil temperature, voltage and pressure etc. can be
checked by this menu.
Note 7
Note 3
Note 5 Note 4
Note 6 Note 2
Note 1
Analog
Analog 11 Analog
Analog22 300L6HS01
(2) Specification
No. Description Specification
Note 1 Work pilot pressure 40 +20 bar
Note 2 Swing pilot pressure 0~40 bar
Note 3 Boom up pilot pressure 0~40 bar
Note 4 Arm/bucket pilot pressure 0~40 bar
Note 5 Pump 1 regulator pressure 0~50 bar
Note 6 Pump 2 regulator pressure 0~50 bar
Note 7 Pump 1 pressure 350 bar
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 YES
Negative Clean air
setscrew is slack. pressure in pump breather or tank
Check if hydraulic tank
air breather or tank suction strainer
NO
strainer is clogged.
ⓐ
NO
YES Replenish speified

oil to the standard
level.
Is hydraulic oil level

ⓐ in hydaulic oil tank YES Water or air is Refer to the
is low?
included in oil. remedy of 3.1)
Is hydraulic oil
NO cloudy? YES Replace hydraulic
oil to be specified.
Has not hydraulic

NO oil passed specified
replacement
hours?
NO
Return filter is not Flush with
replaced at hydraulic oil and
proper intervals. replace return
filter.
6-5
2) ENGINE STARTS BUT MACHINE DOES NOT OPERATE AT ALL
Cause Remedy
Is safety Sol YES
ⓐ
valve operating
properly?
Safety Sol valve Disassemble

NO
is faulty. and repair.
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 Abnormal noise

pump and pump YES comes out of YES
connections pump Coupling element See item 1).
YES
make abnormal connection is broken or worn. at page 6-5
noise?
Is pilot pump
pressure within ⓑ
NO standard level?
See Note 1
YES
Clean pilot
Is pilot piping piping interior or
YES clogged or is oil
repair piping.
leakage present
on pilot piping?
RCV and safety Disassemble
NO
solenoid valve is and repair.
ⓑ faulty.
YES
Pilot relief valve in Repair or
gear pump is replace.
Is gear pump
faulty.
NO delivering oil?
Gear pump is Disassemble

NO
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
Oil cooler clogged. Clean oil cooler.
Bypass check Replace
Is oil cooler clogged
and is bypass check valve is defective.
YES valve always open? YES ⓐ
Is fan belt
NO tension proper?
Adjust belt
NO tension or
replace belt.
Is not the set
pressure of main YES Readjust set
relief, port relief pressure.
ⓐ and travel relief
Is main relief
valve lower than
valve used very YES Reduce load.
the standard NO often?
level?
6-7
3) CAVITATION OCCURS WITH PUMP
Cause Remedy
NO Replenish
specified oil to
the standard
Is hydraulic oil level.
volume proper? YES
Replace oil with
one of proper
Is not viscosity viscosity.
of hydraulic oil
YES YES
too high? Clean suction
Is not suction strainer.
NO strainer clogged? Is not air intruding
from pump Check for air
NO intrusion in
suction line?
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
Does safety YES
ⓐ specified oil to the
YES solenoid valve
standard level.
operation
Is gear pump pilot normal? Safety solenoid Repair or replace.
NO
pressure within valve faulty or not
YES standard level?
Is oil in hydraulic operated.
YES tank within
See Note 1 Gear pump faulty. Repair or replace.
standard level? NO
YES
Are broken pieces Pump connection Disassemble and
of coupling present coupling is broken. repair.
ⓐ when dust plug
under engine fly Is main relief NO
Are attachment wheel is removed? NO valve faulty? Hydraulic pump is Disassemble and
and travel out of order. repair.
motions
impossible at all? NO
Does swing Swing control valve Disassemble and
YES
control valve spool is stuck. repair.
Is MCV swing spool move?
YES pilot pressure YES
ⓑ
within standard See Note 5
level?
ⓒ
Is RH travel See Note 2 NO
NO function normal?
Does not symptom
change when A1 YES
and A2 pump Hydraulic pump is Disassemble and
NO
discharge hoses broken. repair.
are exchanged?
YES
Swing parking Disassemble and
brake release valve repair.
Is swing parking is broken.
ⓑ brake 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 in Disassemble and
NO Is gear pump gear pump is faulty. repair or replace.
delivering oil?
Gear pump is out of Disassemble and
NO
Is gear pump pilot order. repair.
ⓒ pressure within
standard level? YES
Is there oil Clean pilot piping
See Note 1 interior or repair
leakage from
YES pilot piping or is it piping.
clogged? RCV is broken. Disassemble and
NO
repair.
6-9
2) SWING SPEED IS LOW
Cause Remedy
YES
Swing port relief Disassemble and
YES Does swing spool valve is faulty. repair or replace.
move?
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
See Note 2 Is pilot piping
Single direction clogged or is it piping.
NO leaking oil?

Is the trouble in RCV or shuttle Disassemble
one direction or NO
valve is faulty. and repair.
in both direction? YES
ⓐ
YES Does swing spool
Both directions move?
YES Is MCV pilot Swing spool is Disassemble
pressure within NO
Is Arm speed See Note 5 stuck. and repair.
standard level?
within standard ⓑ
value? See Note 2 NO
ⓒ
NO
Is swing motor's NO
ⓐ drain rate within Swing motor is Disassemble
standard value? broken. and repair.
Check that pilot
YES piping is clogged NO
or oil is leaking RCV or shuttle Disassemble
from it? valve is faulty. and repair.
Clogged or oil leak. Clean pilot piping

Is gear pump pilot interior or repair
ⓑ pressure within piping.
standard level?
Pilot relief valve
YES
See Note 1 in gear pump is Disassemble and
Is gear pump defective. repair or replace.
NO delivering oil?
NO
broken. and repair.
NO
Main relief valve Main relief valve
faulty. pressure resetting
or repair.
Is main relief Does the symptom YES Hydraulic pump
ⓒ Disassemble
valve setting change when A1
YES is broken. and repair.
pressure normal? and A2 pump
discharge hoses
See Note 7
are exchanged? NO Shuttle valve is Repair or replace.
Is MCV pilot faulty.
YES pressure within
standard level? YES
Is gear pump Pilot relief valve Repair or replace.
See Note 2 output pressure is faulty.
NO within standard
level? Gear pump is Repair or replace.
NO
See Note 1 faulty.
6-10
3) SWING MOTION IS IMPOSSIBLE IN ONE DIRECTION
Cause Remedy
Does symptom YES
change when LH Swing port relief Disassemble
YES and RH port valve is faulty. and repair.
relief valves of
swing motor are
exchanged? NO Shuttle valve is Disassemble
YES Does swing control faulty. and repair.
valve spool move?
Is MCV pilot Swing control valve Disassemble

NO
pressure same spool is stuck. and repair.
for LH and RH?
NO
See Note 2
Check if pilot RCV is faulty. Disassemble
piping is clogged and repair.
NO or does have oil
leakage. Clogged or oil
YES leak.
Clean pilot piping
interior or repair
piping.
4) MACHINE SWINGS BUT DOES NOT STOP
Cause Remedy
YES
Pilot relief valve is Disassemble
faulty. and repair or
YES Is MCV pilot YES Is gear pump pilot
pressure within pressure within replace.
standard value? standard level?
See Note 2 See Note 1 Gear pump is Disassemble
NO
broken. and repair.
YES Does swing spool
move?
RCV is faulty. Disassemble
NO
and repair.
Is swing control
valve's return
spring normal? Swing spool is Disassemble
NO
stuck. and repair.
Return spring is Disassemble

NO
faulty. and 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 spool Brake spring is Disassemble
NO
normal? faulty. and replace.
Return spring of Disassemble

NO
swing control and replace.
valve is faulty.
YES
Is drain rate of Swing port relief Disassemble
YES swing motor valve is faulty. and repair or
within standard replace.
Is swing relief value? Swing motor is Disassemble
pressure within NO
ⓐ broken. and repair.
standard level?
SPEC : 300±10kgf/cm2 Adjust swing
NO
relief valve
pressure or
replace swing
relief valve.
6-12
6) LARGE SHOCK OCCURS WHEN STOP SWINGING
Cause Remedy
YES
Swing motor is Disassemble
broken. and repair.
YES Is time delay

valve is normal?
Is swing RCV
output pressure
at neutral and in
swing operation Time delay valve Disassemble
NO
within standard is faulty. and repair or
level? replace.
Malfunction of Disassemble
NO
swing RCV and repair.
7) LARGE SOUND OCCURS WHEN STOP SWINGING
Cause Remedy
YES
Seal of suction Disassemble
valve is faulty. and repair.
Is there a
YES leakage on
suction check
valve?
Is relief valve
setting pressure Internal defect of Disassemble
NO
nomal? swing motor. and repair.
Malfunction of Adjust swing

NO
relief valve. relief valve
pressure or
replace swing
relief valve.
6-13
5. TRAVEL SYSTEM
1) TRAVEL DOES NOT FUNCTION AT ALL ON ONE SIDE
Cause Remedy
YES
Does ⓐ
YES counterbalance
spool move lightly
by hand? Counter spool is
Is travel brake Disassemble
NO
YES valve pressure stuck. and repair or
within standard replace.
level? Does the symptom
change when
relief valves in YES
Relief valve built Disassemble
NO travel motor are
Has travel spool exchanged? in travel motor is and repair.
YES
changed over faulty.
positively?
YES Control system is Disassemble
defective. inspect and
Does travel spool
repair.
NO move?
NO
Travel spool is Disassemble
stuck. and repair.
Is bucket or arm
operation YES Travel reduction Disassemble
possible? Do not metallic
unit is faulty. and repair.
particles come
ⓐ out of drain port
in travel
reduction unit? Travel motor is Disassemble
NO
out of order. and repair.
Does the symptom
NO
change when A1 YES
and A2 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.
6-14
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.
YES
and RH travel 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
YES Has travel spool travel motors are
changed over exchanged? ⓐ
positively? NO
YES
Control system is Disassemble,
faulty . inspect and
Does spool move? repair.
Is the lower NO
speed (bucket or
arm) within See Note 5, 6 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 A1
NO travel relief valves YES and A2 pump YES
Hydraulic pump is Disassemble
are exchanged? discharge hoses
Is external pilot are exchanged? broken. and repair.
pressure within
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
travel motor is parking brake is and clean pilot
Is drain rate of removed? not released piping.
ⓐ travel motor within
standard level? properly.
Travel motor is Disassemble

NO
faulty. and repair.
6-15
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
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? defective. and repair.
value?
SPEC : 15.7 kgf/cm2
Brake valve is Disassemble

NO
faulty. and repair or
replace.
4) LH AND RH TRAVEL MOTIONS ARE IMPOSSIBLE
YES
Cause Remedy
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
disabled is
Is bucket or arm
operation extremely seldom
possible? statistically.
OK
Disassemble both faulty. and repair.
OK travel relief valves
Remove dust and inspect for
plug under engine any fault.
OK flywheel and Travel relief valve Disassemble
check that there is Faulty is faulty. and repair or
no coupling
replace.
element particles.
Check oil volume Particles present. Coupling at pump
in hydraulic oil connection is Disassemble
NO tank. broken. and repair.
Short Replenish
hydraulic oil.
6-16
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 NO
pressure within faulty. and repair.
standard level?
Is travel relief
valve pressure Travel brake valve Disassemble
NO
within standard 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,
draw out piston Parking brake Disassemble
ⓐ NO
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.
6-17
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 straight spool

normal?
Straight spool is Repair or

Is pilot pressure NO
for travel straight faulty. replace.
spool within
standard level? YES
Remove dirt on
signal orifice.
Is signal orifice
YES Is pilot relief NO
NO clogged? Pilot relief valve is Disassemble
valve normal?
defective. and repair or
Is gear pump
replace.
NO delivering oil?

NO
broken. and repair.
6-18
6. ATTACHMENT SYSTEM
1) BOOM OR ARM ACTION IS IMPOSSIBLE AT ALL
Cause Remedy
YES
Does the Port relief valve is Disassemble
YES symptom change faulty. and repair or
when port relief replace.
valve is replaced
with other valve? NO ⓐ
YES Is MCV pilot
pressure within
standard level?
Inspect if pilot
See Note 3, 4 piping is clogged OK
RCV is faulty. Disassemble
NO or oil is leaking
YES Are other from the piping. and repair.
attachments
operatable?
YES
Is gear pump
pilot pressure YES Is gear pump faulty. and repair or
NO within standard delivering oil? replace.
level? Gear pump is Disassemble
See Note 1 NO
broken. and repair.
Are LH/RH travel
operations OK
possible? Hydraulic pump is Disassemble
Disassemble broken. and repair.
NO main relief valve
Remove dust plug and check if it is
under engine not irregular.
OK flywheel and
Main relief valveDisassemble
Faulty
check if coupling is defective. and repair or
element particles replace.
Inspect oil are not present. Coupling at pump Disassemble
Particles present
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?
MCV spool is Disassemble
See Note 5, 6 NO
stuck. and repair.
6-19
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? up and at arm Does spool of flow Replace
extrusion? summation check spring.
NO valve move lightly
Are LH/RH travel by hand? Flow summation Disassemble
NO
NO speeds within check valve is and repair.
standard levels?
stuck.
YES
Are both LH/RH faulty. and repair.
travel speeds YES ⓒ
NO
low? Is MCV pilot
pressure within
NO
standard? ⓓ
NO
See Note 3, 4
OK
Does the Port relief valve is Disassemble
YES
symptom change faulty. and repair or
when port relief
replace.
valve is replaced
Does control with other valve? Cylinder is faulty. Disassemble
YES NO
valve spool and repair.
move ?
See Note 7 MCV spool is Disassemble
Is MCV pilot NO
ⓐ pressure within stuck. and repair.
standard level?
YES
Is not MCV pilot Clean pilot
See Note 3, 4
pressure piping piping interior or
clogged or is not
NO repair piping.
there oil
leakage? RCV is defective. Disassemble
NO
and repair.
YES
Is pilot pressure NO faulty. and repair or
Is gear pump
ⓑ within standard replace.
delivering oil?
level?
NO
See Note 1 broken. and repair.
AIs engine NO
ⓒ revolution within Adjust engine
standard level? revolution.
YES
Clean orifice in
control valve.
Is not orifice in
ⓓ main control YES
valve clogged? Clean pilot
Is pilot piping
clogged or is oil piping interior or
NO leaking from the repair piping.
piping? Is RCV normal? RCV is faulty. Disassemble
NO NO
and repair.
6-20
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
relief valve is replace.
YES
replaced with ⓐ
normal value? 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.
inspect load between control
YES
check valve in
MCV and check valve casing and
for any fault. spool is poor.
Is cylinder Contact surface Disassemble
internal leakage Abnormal
ⓐ between poppet and repair.
within standard
level? and seat is poor.
Cylinder is faulty. Disassemble

NO
and repair.
6-21
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
standard level? faulty. repair or replace.
See Note 7
Main relief valve Adjust pressure,
NO
is defective. repair or replace.
5) ONLY BUCKET OPERATION IS TOTALLY IMPOSSIBLE
Cause Remedy
NO
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
with other valve? Does control broken. and repair.
valve spool
Is MCV pilot YES move?
YES
pressure within MCV spool is Disassemble
standard level? See Note 5 NO
stuck. and repair.
See Note 4
Is LH travel RCV is faulty. Disassemble

NO
possible? 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?
6-22
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.
7) TIME LAG OF MACHINE WORKING IS LARGE.
Cause Remedy
YES
Refer to 2)
Is overload relief
valve for each
spool working
properly?
Overload relief Disassemble and

NO
valve is faulty. repair.
6-23
※ 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.
300L6TS01
2. Disconnect hose (A) from rod side of boom

cylinder and drain oil from cylinders and
hose. (put cups on piping and hose ends) A
(210-7) 6-20(2)
3. Raise bucket OFF the ground by retracting

the arm cylinder rod.
If oil leaks from piping side and boom
cylinder rod is retracted there is an internal
leak in the cylinder.
If no oil leaks from piping side and boom
cylinder rod is retracted, there is an internal
leak in the control valve.
300L6TS02
6-24
GROUP 3 ELECTRICAL SYSTEM
1. WHEN STARTING SWITCH IS TURNED ON, CLUSTER 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. 9, 16.
·After checking, insert the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
Defective cluster Replace
Check voltage YES
between Disconnection in Repair or replace
CN-56A (2) wiring harness or (after clean)
and (3)
Check voltage poor contact
Starting switch : ON between CN-5
Voltage : 20~32V between
NO (9) and (10)
CN-5-CN-56A
Starting switch : ON
Voltage : 20~32V Disconnection in Repair or replace
NO
wiring harness or (after clean)
poor contact
between CN-5 (9)
-GND or fuse No.
9, 16
Check voltage
YES 20~32V
NO 0V
CLUSTER
FUSE
BATT 24V 1 11
No.9
IG 24V 2 10
FUSE
GND 3 9
No.16
CN-56A CN-5
300L6ES101
6-25
2. COMMUNICATION ERROR FLASHES ON THE CLUSTER (HCESPN 840, FMI 2)
·Before carrying out below procedure, check all the related connectors are properly inserted.
Cause Remedy
YES
Check voltage
YES between
CN-56A (6, 7)
and (3) Disconnection in Repair or replace
NO wiring harness or (after clean)
Check voltage Voltage : 2V poor contact
between between CN-56A
CN-5 (5) and (6) (6, 7)-CN-5 (5, 6)
Voltage : 2V Defective united Replace
NO MCU Repair or replace
Disconnection in (after clean)
wiring harness or
poor contact
between CN-5 (5,
6)- CN-51 (08, 09)
Check voltage
YES 2V
NO 0V
CLUSTER
GND 3 9 UNITED MCU
CAN 2 HIGH 6 6 09 CAN 2 HIGH
CAN 2 LOW 7 5 08 CAN 2 LOW
CN-51
CN-56A CN-5
140L6ES102
6-26
3. BATTERY CHARGING WARNING LAMP LIGHTS UP (Starting switch : ON)
Cause Remedy
YES
Defective united Replace
YES Check voltage MCU
between CN-51
(15) and chassis Disconnection in Repair or replace
NO
Check voltage wiring harness or (after clean)
YES Voltage : 20~32V
poor contact
between CN-2
(13) and chassis between CN-51
(15)-CN-2 (13)
Voltage : 20~32V
Check voltage Disconnection in Repair or replace
between alternator poor contact
terminal "L" and between CN-2 (13)
chassis alternator terminal
Engine : Running "L"
Voltage : 20~32V
Defective alternator Replace

NO
Check voltage
YES 20~32V
NO 0V
ALTERNATOR
UNITED MCU B+
G
L 3~
ALT VOLTAGE 15 13
U
CN-74
CN-51 CN-2
220F6ES103
6-27
4. WHEN COOLANT OVERHEAT WARNING LAMP LIGHTS UP (engine is started)
Cause Remedy
YES
Check use HRDT Check or replace
Check resistance
YES between engine
ECM connector
(34)-(83)
Spec : 180Ω~160 kΩ Disconnection in Repair or replace
NO
Check resistance poor contact
between temp between temp
sensor (A)-(B)
sensor-engine
Starting switch : OFF ECM connector
Spec : 180Ω~160 kΩ
See table
Defective coolant Replace

NO
temp sensor
Check Table
Temperature (˚C ) 0 25 50 80 95
Resistance (kΩ) 30~37 9.3~10.7 3.2~3.8 1.0~1.3 0.7~0.8
SERVICE TOOL Engine ECM

CAN Lo F 6 01 ENGINE COOLANT
CN-93 TEMPERATURE SENSOR
CAN Hi E 5 02
22 CAN Hi 34 A
RS232 TX C 3 11
46 CAN Lo 83 B C
RS232 RX B 2 03
Engine ECM
P DUMP A 1 30 connector
CN-126 CN-52
300L6ES104
6-28
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-10A Short circuit in Repair or replace
Starting switch : ON wiring harness (After clean)
Engine : Start Check resistance
between CD-10A-
between CN-54
NO CN-54 (13)
(13) and chassis
Starting switch : OFF
Disconnect CN-54
NO
MCU
Check resistance
YES MAX 1Ω
NO MIN 1MΩ
UNITED MCU CN-51 AIR CLEANER SWITCH
GND (FOR SENSOR 5V) 25

Pa
AIR CLEANER CLOGGING SW 13
CD-10A
CN-54
140L6ES106
6-29
6. WHEN ENGINE OIL PRESSURE WARNING LAMP LIGHTS UP (engine is started)
Cause Remedy
NO
Defective circuit, Contact Cummins.
sensor or ECM.
NO Fault code 143

active?
Fault code 386 Voltage above Refer to engine
YES
active? normal or shorted fault code 143
to high source
Voltage above Refer to engine
YES
normal or shorted fault code 386
to high source
Signal Return
Engine ECM
ENGINE OIL
CN-93 PRESSURE SENSOR
22 CAN Hi 63 3
54 2
46 CAN Lo
SERVICE TOOL 76 1
CAN Lo F 6 01 Engine ECM

connector
CAN Hi E 5 02 +5V supply
RS232 TX C 3 11
RS232 RX B 2 03
P DUMP A 1 30
CN-126 CN-52
220A6ES107
6-30
7. WHEN HYDRAULIC OIL TEMPERATURE WARNING LAMP LIGHTS UP (engine is started)
Cause Remedy
YES
High temperature Check hydraulic
Resistance system
YES between CD-1
(1, 2) is in range
of 164~151Ω?
Does display go Starting switch : ON Defective temp Replace
Disconnect CD-1 NO
off when sensor
disconnect
CD-1? YES
Short circuit Repair or replace
Starting switch : ON between temp
Engine : Start
Resistance
between CN-51 sensor and united
NO (16) and CN-51 MCU
(25) is 0~1Ω?
Starting switch : OFF Defective united Replace
Disconnect CN-51 NO
MCU
Check Table
Temperature (˚C ) ~ -30 ~ -10 ~0 ~ 40 ~ 70 ~ 80 ~ 90 ~ 100 105~
22.22 8.16 5.18 1.06 0.39 0.322 0.243 0.185 0.164
Resistance (kΩ)
~31.78 ~10.74 ~ 6.6 ~1.28 ~0.476 ~0.298 ~0.219 ~0.167 ~0.151
UNITED MCU HYDRAULIC OIL

TEMPERATURE SENDER
HYD TEMP SENDER 16 2 C

GND (FOR SENSOR 5V) 25 1
CD-1
CN-51
140L6ES108
6-31
8. WHE RE GAUGE DOES NOT OPERATE
Cause Remedy
YES
Check use HRDT Check or replace
Check resistance
YES between engine
ECM connector
(34)-(83)
Spec : 180Ω~160 kΩ Disconnection in Repair or replace
NO
between temp between temp
sensor (A)-(B)
sensor-engine
Starting switch : OFF ECM connector
Spec : 180Ω~160 kΩ
See table
Defective coolant Replace

NO
temp sensor
Check Table
Temperature (˚C ) 0 25 50 80 95
Resistance (kΩ) 30~37 9.3~10.7 3.2~3.8 1.0~1.3 0.7~0.8
SERVICE TOOL Engine ECM

CAN Lo F 6 01 ENGINE COOLANT
CN-93 TEMPERATURE SENSOR
CAN Hi E 5 02
22 CAN Hi 34 A
RS232 TX C 3 11
46 CAN Lo 83 B C
RS232 RX B 2 03
Engine ECM
P DUMP A 1 30 connector
CN-126 CN-52
220A6ES104
6-32
9. WHEN FUEL GAUGE DOES NOT OPERATE (HCESPN 301, FMI 3 or 4)
Cause Remedy
YES
Check resistance MCU or cluster
YES between CN-51
(25) and CN-51
(19)
Starting switch : OFF Disconnection in Repair or replace
Check resistance Disconnect CN-51 NO
between fuel Spec : 50~600Ω wiring harness or
sender (1) and poor contact
(2) between fuel
Starting switch : OFF sender-united
Spec : 50~600Ω
See table
MCU
Defective fuel Replace

NO
sender
Check Table
Range Resistance (Ω) Range Resistance (Ω)
Full 50 5/12 400
11/12 100 4/12 450
10/12 150 3/12 500
9/12 200 2/12 550
8/12 250 1/12 600
7/12 300 Empty warning 700
6/12 350 - -
UNITED MCU
FUEL LEVEL SENDER
FUEL LEVEL SENSOR 19 2
GND (FOR SENSOR 5V) 25 1
CD-2
CN-51
140L6ES110
6-33
10. WHEN SAFETY SOLENOID DOES NOT OPERATE
short of fuse No. 26.
Cause Remedy
YES
Hydraulic system Check hydraulic
YES Check operation malfunction system
of solenoid
Defective solenoid Replace
NO
Safety lever : ON-OFF
YES
Disconnect in Repair or replace
poor contact
Check voltage
between CN-68 between
(1) - (2) Check resistance CN-4-CN-68 or
YES between CN-4 defective safety
Starting switch : ON relay
Voltage : 20~30V
(16) and chassis
Safety state YES
Starting switch : OFF Disconnect in Repair or replace
Safety state
Spec : 0Ω wiring harness or (after clean)
Check voltage Disconnect CN-4 Check resistance poor contact
between CN-68 between CS-4 between
NO NO
(2) and chassis (A)-(C) CN-4-CS-4
Safety lever : OFF Starting switch : OFF
Starting switch : ON Safety switch : ON-0Ω Defective safety Replace
NO
Voltage : 20~30V OFF-∞ switch
NO
Disconnection in Repair or replace
wiring harness
between CN-68
(2)-fuse No. 26
FUSE
No.26
SAFETY SWITCH
B C A 14 SAFETY SOLENOID
B 15 2
A C 16 1
CS-4 SAFETY RY CN-68
CN-4 1
4 5 1
2
UNITED MCU 3
SAFETY SOL 06 4
5 3 2
CN-52
CR-48
220A6ES109
6-34
11. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE (HCESPN 167, FMI 4 or 6)
Cause Remedy
YES
wiring harness or
YES
between CN-70 between CN-70-
(1) and (2) CN-52
Starting switch : OFF Defective solenoid Replace
Spec : 30Ω NO
YES Check fault code Disconnect CN-70
167 active?
YES
Defective hydraulic Check hydraulic
system system
Check voltage
Check if travel between CN-70
speed lamps( , NO (1) and (2)
) change when
pressing the travel Starting switch : ON Disconnection in Repair or replace
Spec : 20~30 V NO
speed switch on wiring harness or
Disconnect CN-70
the cluster poor contact
between CN-70-
fuse No. 28
Y R G YES
Check united
MCU
NO
Y R G
NO
MCU
Y R G
FUSE
No.28
UNITED MCU HIGH SPEED

TRAVEL SOLENOID
TRAVEL SPEED SOL 05 1
CN-70
CN-52
140L6ES107
6-35
12. TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP SOUNDING
Cause Remedy
YES
The fuse is blown Replace the fuse
Check the fuse YES

for travel alarm The travel alarm Check the united
inside fuse box signal of united MCU program
* Prepare with
whether fuse is Check the starting switch MCU is defective
blown or not signal of MCU's OFF, then turn YES
pin for back start engine and The travel buzzer Replace the
buzzer whether carry out is defective travel buzzer
ground signal troubleshooting :
NO (DO) generate
Between CN-81
or not when (2) - chassis * Prepare with
machine travel ground : 20-30 starting switch
mode. voltage . OFF, then carry
Between CN-81 out trouble-
(1) - chassis shooting without
NO ground : Max 1 Ω turning starting
(resistance) switch ON :
Is the above 1. Disconnection
value normal? in wiring or
defective contact
** Note : in connector
Since voltage between CN-81
value , connector (2) inline In case of the Replace
number and pin NO connector-end NO value of connector
number varies connector : Max resistance, Connect the wire
with each model, 1 Ω (resistance) disconnection in
should refer to 2. Short circuit
wiring or defective
the electric circuit with ground
of each model. circuit between contact in
CN-81 (2) inline connector or short
connector-end circuit with ground
connector - circuit
chassis ground :
Min 1MΩ
(resistance)
FUSE FUSE
No.11 No.28
UNITED MCU
EPPR POWER 24V 18

GROUND(EPPR) 33
CN-81
CN-54
2
TRAVEL BUZZER 09 1
CN-52 TRAVEL BUZZER
220A6ES150
6-36
13. HORN DOES NOT SOUND
Cause Remedy
YES
The fuse is blown Replace the fuse
YES
The relay is broken Replace the relay
* Prepare with
starting switch
Check the fuse OFF, then turn
for horn inside YES
starting switch The horn is Replace the horn
fuse box whether ON and carry out
fuse is blown or defective
troubleshooting :
not Between CN-20
(1) or CN-25 (1) -
After replacing chassis ground
the relay for (with horn switch
NO horn, check the turned ON) :
horn operate 20-30 voltage
* Prepare with
starting switch
OFF, then carry
out
troubleshooting
* Prepare with
without turning
starting switch
starting switch
OFF, then carry
ON :
out trouble-
NO Between CN-20
shooting without
(2) or CN-25 (2)-
turning starting
chassis ground :
switch ON :
Max 1 Ω
1. Disconnection
(resistance)
in wiring or
Is the above
defective contact
value normal?
in connector
** Note :
between CN-20
Since voltage
(1) or CN-25 (1) -
value , connector
inline connector- NO In case of the Replace
number and pin NO value of connector.
end connector :
number varies
Max 1 Ω resistance, Connect the wire
with each model,
(resistance) disconnection in
should refer to
2. Short circuit wiring or defective
the wiring
with ground contact in
diagram of each
circuit between connector or short
model.
CN-20 (1) or circuit with ground
<CN-20 (1)/
CN-25 (1) - inline
CN-25 (1) : Horn circuit
connector-end
connector (+)
connector -
terminal CN-20
chassis ground :
(2) /CN-25 (2) :
Min 1M Ω
Horn connector
(resistance)
(-) terminal>
HORN SW
1 7 CR-2
2 8 1
4 5 1
CS-5 2
CN-6
3
4
FUSE 5 3 2
HORN RY
No.24
CN-25
1
2
HORN
1
2
CN-20
220A6ES151
6-37
14. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE (HCESPN 167, FMI 4 or 6)
Cause Remedy
YES
wiring harness or
YES
between CN-70 between CN-70-
(1) and (2) CN-52
Starting switch : OFF Defective solenoid Replace
Spec : 30Ω NO
YES Check fault code Disconnect CN-70
167 active?
YES
Defective hydraulic Check hydraulic
system system
Check voltage
Check if travel between CN-70
speed lamps( , NO (1) and (2)
) change when
pressing the travel Starting switch : ON Disconnection in Repair or replace
Spec : 20~30 V NO
speed switch on wiring harness or
Disconnect CN-70
the cluster poor contact
between CN-70-
Y R G
fuse No. 28
YES
Check united Defective cluster Replace
MCU
NO Y R G

NO
Starting switch : ON MCU
Y R G
FUSE
No.28
UNITED MCU TRAVEL SOLENOID
TRAVEL SPEED SOL 05 1
CN-70
CN-52
220A6ES03
6-38
15. WHEN ENGINE DOES NOT START ( lights up condition)
CN-125
2
CS-2A
short of fuse No. 1, 6, 12, 13, 23.
H0 I
CN-5 1
35
·After checking, insert the disconnected connectors again immediately unless otherwise specified. 2
0, I
40 3 4
H
39 4 1
BR ACC
B
2
Cause Remedy 36 5 3
6
YES
Defective ECM or Replace
ST C
5
Check voltage 6
YES YES CN-93 (5) and battery START KEY SW
chassis CR-35
Disconnection in Repair or replace No.1
NO wiring harness or 30
87a 87 85
Key switch : ON 86
Spec : 20~30V poor contact 87

No.6
between CR-35 85
30 86
(86) -CN-93 (5) 87a
POWER RY
Check operation YES
start motor Check voltage Defective magnet Replace
YES between starter of start motor
Starting switch : START magnet coil and No.12 2.0W
chassis Defective start relay Replace 1
MASTER SW
S
2.0Gr
NO 2
Starting switch : START No.13 CS-74B
Check operation Spec : 20~30V YES 5.0R
YES Check voltage ⓐ 1
5.0R
of start relay
S
L
2
between CN-2
L
NO
CR-23 (7) and chassis Disconnection in Repair or replace CS-74
NO
Starting switch : START wiring harness or
Starting switch : START IG (BATT RELAY)
poor contact
Check operation Spec : 20~30V between CN-2 (7) No.23
of anti-restart -CR-5 (5)
NO relay CR-5
YES
Check voltage Defective anti- Replace CN-93
between CR-5 restart relay BATTERY(+) 26

NO KEY SWITCH "ON" 5 90A CN-95
(1, 2)
NO
ⓑ STARTER LOCKOUT SIG 83 2
1
Starting switch : Start HS RETURN 76
Spec : 20~30V REMOTE ACCEL SW 67 2
ECM 1
60A CN-60 BATTERY
YES CN-51
Check voltage Defective start relay Replace KEY IG 24V 26 CIRCUIT BREAKER
ⓐ between CR-23 United MCU
ANTI-RESTART RY 15
and chassis Disconnection in Repair or replace CR-1
NO CN-52
wiring harness or
Starting switch : Start poor contact CR-39
1
Spec : 20~30V
between CN-2 (7) 1 5 4
2
-CR-5 (5) BATT RY
3
4 DO-3
2 3 5 2
YES STARTER LOCKOUT
1
Disconnection in Repair or replace DIODE
wiring harness or CR-5
Check voltage poor contact 1
ⓑ between CR-5 between CN-52
1 5 4
2
(2) and chassis (15)-CR-5 (1) 3 CN-2 CR-23 START MOTOR
4
M
Starting switch : Start NO Disconnection in Repair or replace 2 3 5 7 2 M
Spec : 20~30V wiring harness or ANTI-RESTART RY 8 1
poor contact START RY B+

between CS-2A CN-45
(6)- CR-5 (2)
220F6ES114
6-39
16. WHEN STARTING SWITCH ON DOES NOT OPERATE
CN-125
2
·Before carrying out below procedure, check all the related connectors are properly inserted, master CS-2A
H0 I
switch ON and check open circuit of circuit breaker (CN-60). CN-5 1
35 2
0, I
·After checking, insert the disconnected connectors again immediately unless otherwise specified. 40 3 4
H
39 4 1
BR ACC
B
2
36 5 3
ST C
5
6
Cause Remedy START KEY SW
YES
Disconnection in Repair or replace CR-35
No.1
wiring harness or (after clean) 30
87a 87 85
86
poor contact
YES Check voltage
87
between DO-3 (2)- No.6
between DO-3 CR-1 or defective
85
30 86
87a
(2) and chassis battery relay POWER RY
Voltage : 20~30V
YES Check voltage NO wiring harness or (after clean)
between CS-2A No.12
poor contact 2.0W
(2) and chassis 1
MASTER SW
S
between CS-2A (2)- 2
2.0Gr
Voltage : 20~30V CN-5(39)- DO-3 (2) No.13 CS-74B

5.0R
Starting switch : ON 1
5.0R
S
L
Defective start Replace 2
L
NO
YES Check voltage switch CS-74
between CS-2A
(1) and chassis YES
Disconnection in Replace IG (BATT RELAY)
wiring harness or
Voltage : 20~30V No.23
poor contact
between CS-2A
Check voltage
(1)-CN-5 (36)
between CN-5
NO CN-93
Check voltage (36) and chassis YES
Disconnection in Charge or replace BATTERY(+) 26
and specific wiring harness or (after clean)
gravity of battery Voltage : 20~30V Check voltage KEY SWITCH "ON" 5 90A CN-95
poor contact 2
between STARTER LOCKOUT SIG 83
Specific gravity : MIN 1.28 between CS-74B 1
Voltage : MIN 24V NO CS-74B (1) and (1) -CN-5 (36)
HS RETURN 76
chassis REMOTE ACCEL SW 67 2
ECM 1
Voltage : 20~30V ⓐ 60A CN-60 BATTERY
NO CN-51
KEY IG 24V 26 CIRCUIT BREAKER
United MCU
Battery capacity Charge or replace ANTI-RESTART RY 15
CR-1
NO too low (after clean) CN-52
CR-39
1
1 5 4
YES 2
Defective master Replace BATT RY
Check voltage 3
DO-3
ⓐ switch 4
between CS-74 2 3 5 2
(2)- chassis 1
NO
Disconnection in Charge or replace STARTER LOCKOUT
DIODE
Voltage : 20~30V wiring harness or (after clean) CR-5
poor contact 1
1 5 4
between CS-74 (2) 2
-CR-1 3 CN-2 CR-23 START MOTOR

4
2 3 7 M
5 2 M
ANTI-RESTART RY 8 1
START RY B+
CN-45 220F6ES115
6-40
17. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE
·Before carrying out below procedure, check all the related connectors are properly inserted and the fuse
No. 8, 14 and 20 is not blown out. CN-21
3 1
2
5 3
Cause Remedy 4
4 CN-22
NO 5 CN-5
Defective wiper Replace 2 M
6 M 2 6
cut switch
1
NO
Short circuit in Repair or replace WIPER MOTOR WASHER PUMP
Check operation wiring harness or (after clean)
wiper cut switch DO-5
poor contact CN-141
2
between CN-141 FEED BACK 1
Front sliding door
Check valtage (11)- CS-53 MOTOR DRIVE SIG 2 CN-17
1
open-close
between CN-141 YES MOTOR DRIVE- 3 1 15
YES (11) and chassis Defective RDU Replace FUSE
MOTOR DRIVE+ 4 2
membrane 16
NO Check voltage GND 5 3 No.20
Front sliding door-close between CN-376 controller 17
Voltage : 4~5V VCC 6 4 FUSE
Check operation (1) and chassis
of RDU 1)Recheck fuse Replace CONTINUE 24V 7 5 18
Starting switch : ON NO No.14 WASHER P/P 8 6 19 No.8
YES membrane Vottage : 20~30V
controller LED 2)Disconnection in Repair or replace WASHER SIG. 9 7
20
ON. wiring harness or (after clean) INT. SIG 10 8
ⓐ poor contact 21
YES WIPER CUT SW 11
Starting switch : ON between
Push wiper switch button N.C 12
CN-376(1)-Fuse
No.14 FEED BACK 13
Check voltage between NO WIPER MOTOR CONTROLLER

CN-376 (12) and Defective RDU Replace CS-53
chassis membrane
Intermittent
controller
NO
Check voltage CN-376 1) Recheck fuse Replace
ⓐ No.8
(11) and chassis WIPER CUT SW
2) Disconnection Repair or replace FUSE
Washing Check operation in wiring harness (after clean)
of wiper motor or poor contact No.14
Check voltage CN-376 and controller
(3) and chassis between
check voltage CN-141(7)-Fuse,
Sarting switch : ON YES CN-141 (7) and
CN-21(4)-Fuse
Voltage : 0~1V chassis, CN-21
(4) and chassis NO
1) Recheck fuse Replace
Starting switch : OFF No.20
Voltage : 20~30V Check voltage 2) Disconnection Repair or replace
CN-376
CN-141 (6) and CN-141(6)-Fuse (after clean)
10
11
12
13
14
15
16
17
18
19
26
27
YES chassis
1
2
3
4
5
6
7
8
9
No.20
Starting switch : ON ⓑ
Check continuity YES
Voltage : 20~30V
BEACON LAMP SW
NO
between Disconnection in Repair or replace
WORK LIGHT
CABIN LIGHT
CN-141 (2)-CN-376 (3), wiring harness or (after clean)
HEAD LIGHT
INT WIPER
CAN 2_LO
WASHER
CAN 2_HI
CN-141 (9)-CN-376 (11), poor contact
WIPER
IG 24V
CN-141 (10)-CN-376 (12),
GND
GND
NC
NC
NC
NC
ⓑ
NC
NC
NC
NC
NC
NO
CN-141 (5)-Chassis , Check wiper Defective wiper Replace
CN-141 (1)-CN-21 (5), motor resistance motor RDU MEMBRANE CONTROLLER
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
Resistance : 3~4Ω
220A6ES116
6-41
18. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP
short of fuse No.14 & 21.
FUSE
Cause Remedy
YES No.21
Defective bulb Replace
Check voltage FUSE
YES between CL-4 (1),
CR-13
CL-3 (1), CL-24 No.14
30 30 86
(1) and chassis Disconnection in Repair or replace 86
NO
Voltage : 20~30V wiring harness or (after clean) 87
poor contact 85
Check voltage between CR-13 87a
87a 87 85
YES
between CR-13 (87)-CL-4 (1), HEAD LAMP RY
(87) and chassis CR-13 (87)-CL-3
(1) or CR-13 (87)- CL-4
Starting switch : ON CL-24 (1)
Head lamp switch : ON 2
Voltage : 20~30V YES 1
Defective RDU Replace
CN-376
Check voltage membrane HEAD LAMP-RH
Check voltage
10
11
12
13
14
15
16
17
18
19
26
27
1
2
3
4
5
6
7
8
9
between CR-13 controller
between CN-376 CL-24
(30) and chassis, NO
CR-13 (86) and (13) and chassis
2
chassis
BEACON LAMP SW
Disconnection in Repair or replace 1
Starting switch : ON NO wiring harness or (after clean)
WORK LIGHT
Head lamp switch : ON
CABIN LIGHT
HEAD LIGHT
Voltage : 20~30V HEAD LAMP-REAR
INT WIPER
poor contact
CAN 2_LO
Voltage : 20~30V
WASHER
CAN 2_HI
WIPER
between CN-376
IG 24V
CL-3
GND
GND
NC
NC
NC
NC
NC
NC
NC
NC
NC
(13)-CR-13 (85)
RDU MEMBRANE CONTROLLER 2
1
NO
Disconnection in Repair or replace HEAD LAMP-LH
poor contact
between CR-13
(30) and chassis
or CR-13 (86) -
chassis
Recheck fuse Replace

No. 21
220A6ES117
6-42
19. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP
short of fuse No.14 & 34.
Cause Remedy FUSE

YES
Defective bulb Replace No.34
YES
Check voltage
between CL-5 (1)
and chassis
CR-4
Disconnection in Repair or replace FUSE
30 30 86
poor contact No.14 86
between CR-4 87
YES Check voltage
between CR-4 (87)-CL-5 (1) 85
87a 87 85
87a
(87) and chassis
WORK LAMP RY
Starting switch : ON CL-5
Work lamp switch : ON CN-12
Voltage : 20~30V YES
Defective RDU Replace 1 1
Check voltage membrane 2 2
between CR-4 Check voltage controller
(30) and chassis, between CN-376 WORK LAMP
NO
CR-4 (86) (4) and chassis
chassis 1
Starting switch : ON Disconnection in Repair or replace
Work lamp switch : ON NO wiring harness or (after clean) 2
Voltage : 20~30V
Voltage : 20~30V poor contact
between CR-4 CL-6
CN-376
10
11
12
13
14
15
16
17
18
19
26
27
(85)-CN-376 (4)
1
2
3
4
5
6
7
8
9
CL-5
1
BEACON LAMP SW
NO 2
WORK LIGHT
CABIN LIGHT
HEAD LIGHT
poor contact
INT WIPER
WORK LAMP
CAN 2_LO
WASHER
CAN 2_HI
between CR-4
WIPER
IG 24V
GND
GND
(30) and chassis
NC
NC
NC
NC
NC
NC
NC
NC
NC
1
or CR-4 (86) and
RDU MEMBRANE CONTROLLER 2
chassis
CL-6
Recheck fuse Replace
No.34
220A6ES118
6-43
4. MECHATRONICS SYSTEM
1. ALL ACTUATORS SPEED ARE SLOW

※ Boom, Arm, Bucket, Swing and travel speed are slow, but engine speed is good.
※ Spec : P-mode 1700 ± 50 rpm S -mode 1600 ± 50 rpm E-mode 1500 ± 50 rpm
※ Before carrying out below procedure, check all the related connectors are properly inserted and
fault code on the cluster.
1) INSPECTION PROCEDURE
Cause Remedy
YES
Defective
YES Check pressure hydraulic system
at EPPR valve
NO Check electric Defective Replace
current at EPPR SPEC : 2~25 kgf/cm2
NO
EPPR valve
valve See TEST 3
SPEC : 100~700 mA
See TEST 2
Check if HCESPN NO
MCU
140 active fault
display on the LCD YES
Short circuit or Check & repair
poor connection wire harness or
between CN-54 between CN-54
Check resistance
YES at EPPR valve -CN-75 -CN-75
SPEC : 15~25Ω(20。C) Defective EPPR Replace

See TEST 1 NO
valve
Wiring diagram
UNITED MCU
FUSE
EPPR POWER 24V 18
No.11
PUMP SHIFT EPPR (+) 28
MAIN PUMP
PUMP SHIFT EPPR (-) 01 EPPR VALVE
9 1
GROUND(EPPR) 33
10 2
CN-54 CN-1 CN-75
300A6MS01
6-44
2) TEST PROCEDURE SPEC : 15~25Ω(20˚C)
(1) Test 1 : Check resistance at connector
CN-75
CN-75.
① Starting switch OFF. Multimeter
② Disconnect connector CN-75 from EPPR
valve at main hydraulic pump.
③ Check resistance between 2 lines as
figure.
EPPR valve
Main pump
330L6MS02
(2) Test 2 : Check electric current at EPPR Spec : 100~700 mA

valve.
① Disconnect connector CN-75 from EPPR Adapter(P/no.:21Q6-50410)
valve.
CN-75
Multimeter
③ Start engine.
④ Set S-mode and cancel auto decel
mode. EPPR valve
⑤ Position the multimodal dial at 10.
⑥ If tachometer show approx 1600±50 rpm
disconnect one wire harness from EPPR
Main pump
valve.
relief position. 330L5MS21
(3) Test 3 : Check pressure at EPPR valve. Spec : 2~25 kgf/cm2 (30~350 psi)
gauge as figure. Pressure adjusting
screw locknut
·Gauge capacity : 0 to 50 kgf/cm2 Pilot pressure
CN-75
supply line
(0 to 725 psi)
② Start engine.
mode.
④ Position the multimodal dial at 10. EPPR valve
⑤ If tachometer show approx 1600±50 rpm
check pressure at relief position of bucket
Main pump
circuit by operating bucket control lever.
⑥ If pressure is not correct, adjust it.
⑦ After adjust, test the machine. 330L5MS22
6-45
2. ENGINE STALL
※ Before carrying out below procedure, check all the related connectors are properly inserted.
Cause Remedy
YES
Not enough Check engine
engine power fault
YES Check pressure Contact cummins
at EPPR valve
SPEC:2~25 kgf/cm2 Defective EPPR Replace

See TEST 5 NO
Check electric valve
current at EPPR
valve
YES
Short circuit or Check and repair
SPEC : 100~700 mA poor connection wire harness
See TEST 4
Check resistance between
between CN-54-CN-75
NO at EPPR valve
SPEC : 15~25Ω(20˚C)
See TEST 1
NO
Defective EPPR Replace
valve
Wiring diagram
UNITED MCU
FUSE
EPPR POWER 24V 18
No.11
PUMP SHIFT EPPR (+) 28
MAIN PUMP
PUMP SHIFT EPPR (-) 01 EPPR VALVE
9 1
GROUND(EPPR) 33
10 2
CN-54 CN-1 CN-75
300A6MS01
6-46
2) TEST PROCEDURE Spec : 100~700 mA
(1) Test 4 : Check electric current at EPPR
valve. Adapter(P/no.:21Q6-50410)
① Disconnect connector CN-75 from EPPR
CN-75
valve. Multimeter
③ Start engine.
④ Set S-mode and cancel auto decel EPPR valve
mode.
⑤ Position the multimodal dial at 10.
⑥ If rpm show approx 1600±50 rpm discon-
Main pump
nect one wire harness from EPPR valve.
relief position.
330L5MS21
(2) Test 5 : Check pressure at EPPR valve. SPEC : 2~25 kgf/cm2 (30~350 psi)
gauge as figure.
·Gauge capacity : 0 to 50 kgf/cm2
Pressure adjusting
(0 to 725 psi) Pilot pressure
screw locknut
CN-75
② Start engine. supply line
mode.
④ Position the multimodal dial at 10.
⑤ If rpm show approx 1600±50 rpm check
EPPR valve
pressure at relief position of bucket
circuit by operating bucket control lever.
⑥ If pressure is not correct, adjust it. Main pump
⑦ After adjust, test the machine.
330L5MS22
6-47
3. MALFUNCTION OF CLUSTER OR MODE SELECTION SYSTEM
Y R G
Cause Remedy
YES
No power supply to Check fuse No.2
See if all lamps Y R G the united MCU
YES off in the united
MCU case YES
Y R G United MCU failure Replace
Y R G Y R G
See if HCESPN
Y R G
840 active fault NO
display on the LCD
Y R G
NO Y R G
ⓐ
NO
OK Y R G
Check connection Cluster failure Replace
between CN-51
ⓐ (09) - CN-56A (6)
or CN-51(08) -
CN-56A (7) No connection Check and repair
NO
KEY OFF
Wiring diagram
BATT.24V
IG 24V UNITED MCU
GND
CAN1 HI
CAN1 LO
CAN2 HI 6 6 09 CAN 2 HIGH
CAN2 LO 7 5 08 CAN 2 LOW
RS-232 RX
RS-232 TX CN-56A CN-5 01 BATT POWER_24V
AUX LEFT
CN-51
AUX RIGHT
AUX GND FUSE
CLUSTER No.2
220F6MS102
6-48
4. AUTO DECEL SYSTEM DOES NOT WORK (N.A)
· Fault code : HCESPN 105, FMI 0~4 (work pressure sensor)
HCESPN 108, FMI 0~4 (travel oil pressure sensor)
Cause Remedy
YES
MCU
YES
Check voltage Defective travel Replace
NO between CD-104 pressure sensor
(or 105) (A) and
(C) Short circuit or poor Replace or repair
Check voltage NO
connection
between CN-52 Spec : 24±2V
Starting switch ON between CN-51
(27)-GND and (32)-CD-104 (or
CN-52 (19)-GND
105) (A) and / or
Spec : 1~5V CN-51 (31)-CD-
Actuator operating 104 (or 105) (C)
See TEST 7, 8 (fault code 108
YES
displayed)
Replace
Check voltage Defective work
between CD-7(A) pressure sensor
NO and (C)
Replace or repair
NO
Short circuit or poor
Spec : 24±2V
Starting switch ON connection
between CN-51
(32)-CD-7 (A) and /
or CN-51 (31)-
CD-7 (C) (fault code
105 displayed)
Wiring diagram
CN-51
CD-6
SENSOR POWER(10V) 32 A SUPPLY
B SIG
GND(SENSOR_10V) 31 C RETURN
TRAVEL PRESSURE SENSOR
UNITED MCU
TRAVEL PS 27 CD-7
A SUPPLY
WORKING PS 19 B SIG
C RETURN
CN-52 WORK PRESSURE SENSOR
300A6MS03
6-49
2) TEST PROCEDURE (N.A) SPEC : Actuator operating : 1~5 V
(1) Test 7 : Check voltage at CN-52 (27) and
ground.
① Prepare 1 piece of thin sharp pin, steel or MCU
copper. PIN
② Insert prepared pin to rear side of CN-51 CN-52 CN-53 CN-54
connectors : One pin to (27) of CN-52.

③ Starting switch ON.
④ Check voltage as figure.
ground.
① Prepare 1 piece of thin sharp pin, steel or 9 8 7 6 5 4 3 2 1
copper 17 10 CN-52
② Insert prepared pin to rear side of 25
27
18
Female
connectors : One pin to (19) of CN-52. 34 33 32 31 30 29 28 27 26
③ Starting key ON. Ground

Multimeter
9 8 7 6 5 4 3 2 1
17
19
10 CN-52
25 18
Female
34 33 32 31 30 29 28 27 26
Ground
Multimeter
140L6MS104
6-50
5. Malfunction of pump 1 pressure sensor
· Fault code : HCESPN 120, FMI 0~4
Cause Remedy
YES
MCU
YES
Short circuit or Replace or repair
poor connection
YES Check voltage between CN-51
between CN-1
(31)-CN-1 (5)
Check voltage (5)-GND
between CN-51
Spec : 1~5V Detective P1 Replace or repair
(22) - GND Actuator operating NO
Check voltage pressure sensor
Spec : 1~5V YES between CD-42 Short circuit or Replace or repair
Actuator operating (A)-(C) poor connection
See TEST 9
between CN-1
Spec : 24±2V
Starting switch ON (5)-CD-42 (B)
Check voltage
between CN-1 Short circuit or Replace or repair
NO (4)-(6) NO
poor connection
between CD-42
Spec : 24±2V
Starting switch ON
(A)-CN-1 (4) or
CD-42 (C)-CN-1
(6)

NO
poor connection
between CN-1
(4)-CN-51 (32) or
CN-1 (6)-CN-52
(31)
Wiring diagram
UNITED MCU
CD-42
SENSOR POWER(10V) 32 4 A SUPPLY
5 B SIG
GND(SENSOR_10V) 31 6 C RETURN
CN-51 P1 PUMP DELIVERY
MAIN PUMP (P1) PS 22
CN-52
220A6MS105
6-51
2) TEST PROCEDURE SPEC : Actuator operating : 1~5 V
ground.
① Prepare 1 piece of thin sharp pin, steel or
copper.
② Insert prepared pin to rear side of MCU
connectors : One pin to (22) of CN-52. PIN
③ Starting switch ON. CN-51 CN-52 CN-53 CN-54
9 8 7 6 5 4 3 2 1
17 10 CN-52
25
22
18
Female
34 33 32 31 30 29 28 27 26
Ground
Multimeter
220A6MS106
6-52
Cause Remedy
YES
MCU
YES
poor connection
YES Check voltage between CN-51
between CN-1
(3)-GND (14)-CN-1 (3)
Check voltage
between CN-51
Spec : 1~5V Detective P2 Replace or repair
Spec : 1~5V YES between CD-43 Short circuit or Replace or repair
See TEST 10
between CN-1
Spec : 24±2V
Check voltage
NO (4)-(6) NO
poor connection
between CD-43
Spec : 24±2V
Starting switch ON
(A)-CN-1 (4) or
CD-43 (C)-CN-1
(8)

NO
poor connection
between CN-1
(4)-CN-51 (32) or
CN-1 (6)-CN-51
(31)
Wiring diagram
UNITED MCU
CD-43
MAIN PUMP (P2) PS 14 3 B SIG
GND(SENSOR_10V) 31 6 C RETURN
CN-51 P2 PUMP DELIVERY
220A6MS107
6-53
ground.
copper.
MCU
② Insert prepared pin to rear side of
PIN
CN-51 CN-52 CN-53 CN-54
9 8 7 6 5 4 3 2 1
17
14
10 CN-51
25 18
Female
34 33 32 31 30 29 28 27 26
Ground
Multimeter
220A6MS108
6-54
Cause Remedy
YES
MCU
YES
poor connection
YES Check voltage between CN-51-
between
CN-1 (7)-GND (13)-CN-1 (7)
Check voltage Spec : 1~5V Detective P3 Replace or repair
between CN-51 Actuator operating NO
(13) - GND YES between Short circuit or Replace or repair
Spec : 1~5V CD-44 (A)-(C) poor connection
Actuator operating between CN-1
See TEST 11 Spec : 24±2V
Check voltage Short circuit or Replace or repair

NO
between poor connection
NO CN-1 (4)-(6) between
CD-44 (A)-CN-1
Spec : 24±2V
Starting switch ON
(4) or CD-44
(C)-CN-1 (6)

NO poor connection
between CN-1
(4)-CN-51 (32) or
CN-1 (6) - CN-51
(31)
Wiring diagram
CN-51 CN-51
CD-44CD-44
32
SENSOR POWER(10V) 32 4 4 A A
SUPPLYSUPPLY
13
PUMP EPPR Pf PS 13 7 7 B SIG
B SIG
GND(SENSOR_10V)
31 31 6 6 C RETURN
C RETURN
PUMP PUMP
3 PRESSURE SENSOR
3 PRESSURE SENSOR
UNITED UNITED
MCU MCU CN-1 CN-1
300A6MS09
6-55
(1) Test 11 : Check voltage at CN-51 (13)
and ground.
copper.
9 8 7 6 5 4 3 2 1
17
13
10 CN-51
25 18 Female
34 33 32 31 30 29 28 27 26
Ground
Multimeter
140L6MS110
6-56
8. Malfunction of Negative 1 pressure sensor
Cause Remedy
YES
MCU
YES
poor connection
between CN-1
(22)-CN-1 (1)
(1)-GND
Check voltage
between CN-51 Spec : 1~5V Detective N1 Replace or repair
Actuator operating NO
(22) - GND Check voltage pressure sensor
YES between CD-70 Short circuit or Replace or repair
Spec : 1~5V
See TEST 12 between CN-1
Spec : 24±2V

NO
between CN-1 poor connection
NO (4)-(6) between CD-70
(A)-CN-1 (4) or
Spec : 24±2V CD-70 (C)-CN-1
Starting switch ON
(6)

NO poor connection
between CN-1
(4)-CN-51 (32) or
CN-1 (6) - CN-51
(31)
Wiring diagram
UNITED MCU
CD-70
NEGATIVE 1 (N1) PS 28 1 B SIG
GND (SENSOR_10V) 31 6 C RETURN
NEGATIVE 1 PRESSURE SENSOR
CN-51 CN-1
330A6MS111
6-57
and ground.
copper.
9 8 7 6 5 4 3 2 1
17
22
10 CN-51
25 18
Female
34 33 32 31 30 29 28 27 26
Ground
Multimeter
140L6MS112
6-58
9. Malfunction of Negative 2 pressure sensor
Cause Remedy
YES
MCU
YES
poor connection
between CN-1
(28)-CN-1 (2)
(2)-GND
Check voltage
between CN-51 Spec : 1~5V Detective N2 Replace or repair
YES between CD-71 Short circuit or Replace or repair
Spec : 1~5V
See TEST 13 between CN-1
Spec : 24±2V

NO
between CN-1 poor connection
NO (4)-(6) between CD-71
(A)-CN-1 (4) or
Spec : 24±2V
Starting switch ON
CD-71 (C)-CN-1
(6)

NO poor connection
between CN-1
(4)-CN-51 (32) or
CN-1 (6) - CN-51
Wiring diagram (31)
CN-51
CD-71
NEGATIVE 2 (N2) PS 28 2 B SIG
GND (SENSOR_10V) 31 6 C RETURN
NEGATIVE 2 PRESSURE SENSOR
UNITED MCU CN-1
220A6MS113
6-59
and ground.
copper.
PIN
9 8 7 6 5 4 3 2 1
17 10 CN-51
25
28
18
Female
34 33 32 31 30 29 28 27 26
Ground
Multimeter
140L6MS114
6-60
10. Malfunction of Swing pressure sensor
Cause Remedy
YES
MCU
Check voltage YES

between CN-52 Detective swing Replace or repair
(18) - GND pressure sensor
Spec : 1~5V Short circuit or Replace or repair
Actuator operating Check voltage poor connection
See TEST 14 between CD-24 between CN-52
NO (A)-(C) (18)-CD-24 (B)
Spec : 24±2V
Starting switch ON
NO
poor connection
between CD-24
(A)-CN-51 (32) or
CD-24 (C)-CN-51
(31)
Wiring diagram
SWING PILOLT
UNITED MCU
PRESSURE SENSOR
B SIG
CN-51 CD-24
SWING PILOT PRESSURE 18
CN-52
220A6MS114
6-61
ground.
copper.
9 8 7 6 5 4 3 2 1
17 10 CN-52
25 18 18 Female
34 33 32 31 30 29 28 27 26
Ground
Multimeter
220A6MS116
6-62
11. Malfunction of ARM OUT pressure sensor
Cause Remedy
YES
MCU
Check voltage YES

between CN-51 Detective arm in/ Replace or repair
(27) - GND out & bucket in
Spec : pressure sensor
Actuator operating: 1~5V Check voltage Short circuit or Replace or repair
See TEST 15 between CD-86 poor connection
NO (A)-(C) between CN-51
(27)-CD-86 (B)
Spec : 24±2V
Starting switch ON
NO
poor connection
between CD-86
(A)-CN-51 (32) or
CD-86 (C)-CN-
51 (31)
Wiring diagram
UNITED MCU
ARM OUT PILOLT
PRESSURE SENSOR
ARM OUT PILOT PRESSURE 27 B SIG
GND (SENSOR_10V) 31 C RETURN
CD-86
CN-51
220A6MS117
6-63
and ground.
copper.
MCU
② Insert prepared pin to rear side of
PIN
CN-51 CN-52 CN-53 CN-54
9 8 7 6 5 4 3 2 1
17 10 CN-51
25 18
Female
27
34 33 32 31 30 29 28 27 26
Ground
Multimeter
220A6MS118
6-64
12 . Malfunction of BOOM up pressure sensor
Cause Remedy
YES
MCU
Check voltage YES

between CN-52 Detective boom up Replace or repair
NO (A)-(B) (23)-CD-32 (B)
Spec : 24±2V
Starting switch ON
NO
poor connection
between CD-32
(A)-CN-51 (32) or
CD-32 (C)-CN-
51 (31)
Wiring diagram
BOOM UP PILOLT
UNITED MCU
PRESSURE SENSOR
B SIG
CN-51 CD-32
BOOM UP PILOT PRESSURE 23
CN-52
220A6MS119
6-65
and ground.
copper.
9 8 7 6 5 4 3 2 1
17 10 CN-52
25
23
18
Female
34 33 32 31 30 29 28 27 26
Ground
Multimeter
220A6MS120
6-66
13. Malfunction of BOOM DOWN pressure sensor
Cause Remedy
YES
MCU
Check voltage YES

between CN-52 Detective boom up Replace or repair
NO (A)-(B) (31)-CD-85 (B)
Spec : 24±2V
Starting switch ON
NO
poor connection
between CD-85
(A)-CN-51 (32) or
CD-85 (C)-CN-
51 (31)
Wiring diagram
BOOM DOWN PILOLT

UNITED MCU PRESSURE SENSOR
B SIG
CN-51 CD-85
BOOM DOWN PILOT PRESSURE 31
CN-52
220A6MS121
6-67
and ground.
copper.
9 8 7 6 5 4 3 2 1
17 10 CN-52
25 18
Female
31
34 33 32 31 30 29 28 27 26
Ground
Multimeter
220A6MS122
6-68
14. MALFUNCTION OF POWER MAX
· Fault code : HCESPN 166, FMI 4 or 6
Cause Remedy
YES
Short circuit or poor Repair or replace
connection between
YES Check resistance CN-88 (1)-CN-53
between CN-88 (10)
(1)-(2)
Defective power Repair or replace
YES Check resistance SPEC: 15-35Ω
NO
between CN-54 See TEST 19 max. solenoid valve
(21)-GND Check hydraulic
system
Is voltage between SPEC Repair or replace
CN-88(2)-GND Power max button Short circuit or poor
pressed ON : 0Ω NO
normal? connection between
pressed OFF : ∞ Ω
CN-54 (21)-CS-29
SPEC (1)
Starting swich
ON : 24±1V Repair or replace
OFF : 0V Short circuit or poor
See TEST 18 NO
connection between
CN-88 (2)-
Fuse No. 28
Wiring diagram
UNITED MCU
CN-88
POWER BOOST SOL 10 1
2
CN-53
POWER MAX SOLENOID
POWER BOOST SW 21 5
FUSE
6
No.28
CN-54 CN-4
CS-29
1
GND(FOR SENSOR_5V) 25
2
CN-51 POWER MAX SWITCH
220A6MS21
6-69
2) TEST PROCEDURE SPEC : Starting switch ON : 24±1V
Starting switch OFF : 0V
(1) Test 18: C
heck voltage between connector
CN-88 (2) - GND.
① Disconnect connector CN-88 from power
max solenoid valve.
② Start switch ON. Power max switch
③ Check voltage as figure.
LH RCV-lever
CN-88
Power max
solenoid valve
2 1
1 2
Ground
Multimeter
140L6MS123
(2) Test 19: Check resistance of the solenoid SPEC : 15~35Ω

valve between CN-88 (1)-(2).
① Starting switch OFF.
② Disconnect connector CN-88 from power Power max switch
max solenoid valve.
③ Check resistance as figure.
LH RCV-lever
CN-88
Power max 2 1
solenoid valve
1 2
Multimeter 140L6MS124
6-70
15. MALFUNCTION OF boom priority eppr valve
Cause Remedy
YES
Short circuit or poor Repair or
connection between replace
CN-54 (04)-CN-133
Check resistance (1) or CN-54 (34)-
between CN-133 CN-133 (2)
(1)-(2)
SPEC : 20~30V Defective EPPR Repair or
NO
Starting switch ON valve replace
Wiring diagram
BOOM PRIORITY
UNITED MCU EPPR VALVE
BOOM PRIORITY EPPR(-) 04 1

BOOM PRIORITY EPPR(+) 34 2
CN-54 CN-133
330A6MS123
6-71
16. MALFUNCTION OF ARM regeneration solenoid
Cause Remedy
YES
MCU
YES Check voltage
YES
(07)-GND
poor connection
Check resistance between CN-52
SPEC : 24±2V
Starting switch ON between arm
Check voltage NO (07)-CN-135 (1)
See TEST 20 regen solenoid
between CN-135
(2) - GND SPEC : 15~35Ω Defective Replace
NO
SPEC : 20~30V solenoid valve
Starting switch ON
Open circuit Replace or repair

NO
between CN-135
(2)-Fuse No. 28
Wiring diagram
UNITED MCU
CN-135
ARM REGEN SOL 07 1
2
ARM REGENERATION SOLENOID
FUSE
No.28
CN-52
220A6MS27
6-72
2) TEST PROCEDURE SPEC : Starting switch : 24±2 V
and ground.
copper.
9 8 7 6 5 4 3 2 1
07
CN-52
17 10 Female
25 18
34 33 32 31 30 29 28 27 26
Ground
Multimeter
140L6MS128
6-73
GROUP 5 AIR CONDITIONER & HEATER SYSTEM
1. AIR CONDITIONER DOES NOT OPERATE
Cause Remedy
NO Check air con YES
fuse. Is there Fuse is blown Replace
problem?
NO
When the air con Fan does not operate Refer to 1)
switch is pushed.
Does air con YES Weak air flow Refer to 2)
lamp light up?
Abnormal operation Refer to 3)
Check the air
flow of fan motor. NO Refer to 4)
YES Is there roblem?
(weak flow or no
Check the
flow) NO
compressor. Refer to 5)
NO Does it operate?
Check the
compressor.
YES
Does it operate?
YES Refer to 6)
1) FAN DOES NOT OPERATE

Cause Check Remedy
Fuse is blown or * Fuse

Replace
abnormal relay operation * Does relay normally operate?
Harness short or Check any harness short or

Repair shortage
poor contact abnormal contact of connnector
Supply 24V to 2 lead wire from motor

Fan motor failure Replace
and check the operation
Resistor is broken Check current flow of resistor with tester Replace
Push fan switch by turn and check

Fan switch failure Replace
the operation
6-74
2) WEAK AIR FLOW FROM FAN MOTOR
Cause Check Remedy
Clogged evaporator or
Check if evaporator is contaminated Clean
obstacles around air inlet
Leakage of air flow Check HVAC case assembly Adjust
Duct sensor failure Check if evaporator is frozen Replace
3) ABNORMAL OPERATION OF FAN MOTOR

Cause Check Remedy
4 step only operate Replace resistor

Abnormal operation of
1 or 2 step does not operate Replace control
each step of control
3 or 4 step does not operate Replace relay
4) COMPRESSOR DOES NOT ROTATE OR HARDLY ROTATE

Cause Check Remedy
Loose belt Belt shaking is severe Adjust tension
Failure of compressor
Belt slip Repair or Replace
itself
Low voltage of battery Slip when rotate Charge battery
Replace magnetic
Fieldcoil short Slip when rotate
clutch
Replace magnetic
Oily clutch face Contamination around clutch
clutch, clean
Magnetic clutch does not operate or

Fieldcoil is broken Replace compressor
"∞" resistance
Leakage of refrigerant or Replace compressor

Check if wet with oil
oil inside Charge refrigerant
6-75
5) COMPRESSOR OPERATE NORMALLY AND AIR FLOW IS NORMAL
Cause Check Remedy
When air con operate during 5~10 min

Repair leakage joint
Shortage of refrigerant small temperature difference between
Charge refrigerant
high and low pressure pipes.
*Magnetic clutch on/off rapidly Recharge refrigerant

Overcharge of refrigerant *High pressure over specification following
*Lukewarm air from nozzle specification
Shortage of refrigerant Make up refrigerant
Replace
Clogged receive dryer
receive dryer
Lower pressure than
Replace
normal condition at Clogged expansion valve
expansion valve
low side
Replace pipe or
Clogged or crushed pipe
clean
Failure of duct sensor Replace duct sensor
6) COMPRESSOR OPERATE NORMALLY AND AIR FLOW IS NORMAL

Cause Check Remedy
Failure of duct sensor

Replace duct sensor
Magnetic clutch off before air
Lower pressure than or adjust location
temperature sufficiently down
normal condition at
low side Defective compressor gasket
Repair compressor
When compressor off, high and low
or Replace
pressure balance immediatly
Failure of condensing
Clean the condenser
Contamination on condenser or
Repair fan
Higher pressure than insufficient air flow from fan
normal condition at
Overcharge of refrigerant Adjust refrigerant
high side
Vacuum and
Entrained air
recharge
Lower pressure than

normal condition at Shortage of refrigerant Make up refrigerant
high side
6-76
Group 1 Operational Performance Test ------------------------------------------------------------------------- 7-1

Group 2 Major Components -------------------------------------------------------------------------------------------- 7-21
Group 3 Track and Work Equipment ------------------------------------------------------------------------------ 7-36
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 Working
parts and reassembled at a customer's condition
site, it must be tested to confirm that the
operational performance of the machine
meets Hyundai spec.
2) OPERATIONAL PERFORMANCE OF A Maintenance
record
WORKING MACHINE
With the passage of time, the machine's
operational performance deteriorates, so
that the machine needs to be serviced
periodically to restore it to its original
performance level. Operating
Before servicing the machine, conduct
performance tests to check the extent of
deterioration, and to decide what kind of
service needs to be done(by referring to
the "Service Limits" in this manual).
3) OPERATIONAL PERFORMANCE OF A
REPAIRED MACHINE
After the machine is repaired or serviced, it
must be tested to confir m 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 perfor mance 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 20 m,
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
(210-7) 7-3
among coworkers. Once the test is
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 CLUSTER
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 Measure the engine RPM.
Engine RPM display
(3) Measurement Power mode switch
① Start the engine. The engine will run at Pilot lamp(P, S, E)
start idle speed. Measure engine speed
with a engine rpm display.
② Measure and record the engine speed at
each mode (P, S, E).
③ Select the P-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. 380A7MS01
(4) Evaluation
The measured speeds should meet the following specifications.
Unit : rpm
Model Engine speed Standard Remarks

Start idle 900±100
P mode 1700±50
S mode 1600±50
HX380A L
E mode 1500±50
Auto decel 1000±100
One touch decel 900±100
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 20 m 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 5 m on 0.3~0.5m
both ends for machine acceleration and
deceleration.
③ Hold the bucket 0.3 to 0.5 m above the
ground with the arm and bucket rolled in.
④ Keep the hydraulic oil temperature at
380A7MS02
50±5˚C.
(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.
· Power mode switch : P mode
③ Star t traveling the machine in the
acceleration zone with the travel levers 3~5m 20m 3~5m
at full stroke.
④ Measure the time required to travel 20 m.
⑤ After measuring the forward travel
speed, turn the upperstructure 180。
and measure the reverse travel speed. 380A7MS03
⑥ Repeat steps ④ and ⑤ three times in

each direction and calculate the average
values.
(4) Evaluation
The average measured time should meet the following specifications.
Unit : Seconds / 20 m
Model Travel speed Standard Maximum allowable Remarks
1 Speed 23.2±2.0 27.3
HX380A L
2 Speed 14.4±1.0 16.4
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. Mark
Keep the boom-arm angle between 90 to
110˚ as shown. Place blocks under
machine frame.
380A7MS04
50±5˚C.
(3) Measurement
① Select the following switch positions.
· Travel mode switch : 1 or 2 speed
· Auto idle 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 33±2.0 42.5
HX380A L
2 Speed 25.5±2.0 25.5
7-6
5) TRAVEL DEVIATION
(1) Measure the deviation by the tracks from
a 20 m straight line.
(2) Preparation
① Adjust the tension of both tracks to be
equal.
② Provide a flat, solid test yard 20 m in
length, with extra length of 3 to 5 m on 0.3~0.5m
both ends for machine acceleration and
deceleration.
③ Hold the bucket 0.3 to 0.5 m above the
ground with the arm and bucket rolled in.
380A7MS02
50±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 Star t traveling the machine in the 3~5 m extra length
acceleration zone with the travel levers at a
M
20
full stroke.
④ Measure the distance between a straight
20 m line and the track made by the 3~5 m extra length
machine. (Dimension a)
⑤ After measuring the tracking in forward
travel, turn the upperstructure 180。and
measure that in reverse travel. (210-7) 7-7(2)
⑥ Repeat steps ④ and ⑤ three times and

(4) Evaluation
Mistrack should be within the following specifications.
Unit : mm / 20 m
Model Standard Maximum allowable Remarks
HX380A L 200 below 250 -
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.
50±5˚C. 380A7MS05
(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 mode switch Standard Maximum allowable
HX380A L P mode 19.0±1.5 23.9
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
380A7MS05
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
360 swing
test the opposite direction. 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 Power mode switch Standard Maximum allowable Remarks

HX380A L P 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
(210-7) 7-10(1)
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
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 50 cm.
Record the dial gauge reading (h2).
③ Calculate bearing play (H) from this data
(h1 and h2) as follows.
H=h2-h1
(4) Evaluation 380A7MS06
The measured drift should be within the following specifications.

Unit : mm
Model Standard Maximum allowable Remarks

HX380A L 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
Boom cylinder
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. Arm cylinder
Lower the boom until the bucket is 0.5 m
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.
④ Keep the hydraulic oil temperature at Bucket cylinder
50±5˚C.
(3) Measurement
Roll out Roll in
② To measure cylinder cycle times.
- Boom cylinders. 0.5m
Measure the time it takes to raise the 380A7MS07
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
as possible.
7-11
- Bucket cylinders
Measure the time it takes to roll in the
bucket, and the time it takes to roll out
the bucket. To do so, position the bucket
at one stroke end, then move the control
as possible.
- Repeat each measurement 3 times and
(4) Evaluation
The average measured time should meet the following specifications.
Unit : Seconds
Model Function Standard Maximum allowable Remarks

Boom raise 3.9±0.4 4.8
Boom lower 2.5±0.4 3.6
Arm in 3.2±0.4 3.9
HX380A L
Arm out 3.1±0.3 3.4
Bucket load 2.8±0.4 3.6
Bucket dump 2.4±0.3 3.5
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 30 mm extended from the fully retracted
position.
③ Position the bucket cylinder with the rod
20 to 30 mm retracted from the fully
380A7MS08
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 15
HX380A L Arm cylinder 10 below 15
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 1.3 or below 1.7
Arm lever 1.3 or below 1.7
HX380A L Bucket lever 1.3 or below 1.7
Swing lever 1.3 or below 1.7
Travel lever 2.1 or 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 90±10 115
Arm lever 90±10 115
HX380A L Bucket lever 90±10 115
Swing lever 90±10 115
Travel lever 142±10 178
7-15
13) PILOT PRIMARY PRESSURE
(1) Preparation Main pump
50±5˚C.
(2) Measurement a2
a1
· Auto decel switch : OFF
② Slowly operate the boom control lever of Pressure sensor
boom up functions at full stroke over

relief and measure the primary pilot
pressure by the monitoring menu of the
cluster. Monitoring
(analog)
Cluster 330A7MS16
(3) Evaluation
The average measured pressure should meet the following specifications:
Unit : kgf / cm2

Model Engine speed Standard Allowable limits Remarks
HX380A L P mode 40 +20 -
7-16
14) FOR TRAVEL SPEED SELECTING PRESSURE:
(1) Preparation
② Loosen the cap and relieve the pressure
in the tank by pushing the top of the air
breather.
③ To measure the speed selecting pressure:
Install a connector and pressure gauge
④ assembly to turning joint P port as shown. P
Star t the engine and check for on D A
leakage from the adapter. C
⑤ Keep the hydraulic oil temperature at DR

50±5˚C.
(2) Measurement
· Power mode switch : P mode 380A7MS14
· 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 -
HX380A L
2 Speed 40±5 -
7-17
15) SWING PARKING BRAKE RELEASING PRESSURE
(1) Preparation
② Loosen the cap and relieve the pressure
in the tank by pushing the top of the air
breather.
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 Star t the engine and check for oil
leakage from the adapter.
⑥ Keep the hydraulic oil temperature at
50±5˚C.
(2) Measurement 380A7MS15

② Operate the swing function or arm roll in
function and measure the swing brake
c o n t r o l p r e s s u r e w i t h t h e b ra ke
disengaged. Release the control lever
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 40 31~49
HX380A L
Brake applied 0 -
7-18
16) MAIN PUMP DELIVERY PRESSURE
Main pump
(1) Preparation
50±5˚C.
(2) Measurement a2
a1

② Measure the main pump deliver y
Pressure sensor
pressure in the P mode (high idle).
Monitoring
(analog)
Cluster
330A7MS16
(3) Evaluation
The average measured pressure should meet the following specifications.
Unit : kgf / cm2
Model Engine speed Standard Allowable limits Remarks
HX380A L High idle 40±5 -
7-19
17) SYSTEM PRESSURE REGULATOR RELIEF SETTING
(1) Preparation
① Keep the hydraulic oil temperature at Main pump
50±5˚C.
(2) Measurement
① Select the following switch positions. a2
· Power mode switch : P mode a1
② Slowly operate each control lever of

boom, arm and bucket functions at full
stroke over relief and measure the Pressure sensor
pressure.
③ In the swing function, place bucket
against an immovable object and
measure the relief pressure. Monitoring
④ In the travel function, lock undercarriage (analog)
with an immovable object and measure
the relief pressure.
Cluster
330A7MS16
(3) Evaluation
Unit : kgf / cm2
Model Function to be tested Standard Port relief setting
Boom, Arm, Bucket 350 (380)±10 390±10
HX380 L Travel 360±10 -
Swing 300±10 -
( ) : Power boost
7-20
GROUP 2 MAJOR COMPONENT
1. MAIN PUMP
3 2 1
9 6 5 4 7 8 380A7MS21
Standard Recommended
Part name & inspection item replacement Counter measures
dimension value
Clearance
between piston(1) & Replace piston
d D 0.043 0.070 or cylinder.
cylinder bore(2)
(D-d)
Play between
piston(1) & shoe caulking
0-0.1 0.3
section(3)
(δ) Replace
assembly of
Thickness of shoe δ piston & shoe.
(t) t 5.4 5.0
Free height of cylinder

spring(4) Replace cylinder
47.9 47.1 spring.
(L)
L
Combined height of set

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

necessary to be corrected 3z
valve plate (sliding face)
(7,8), swash plate (shoe Lapping
plate area) (9), & Standard surface roughness
0.4z or lower
cylinder(2) (sliding face) (corrected value)
7-21
2. MAIN CONTROL VALVE
1) PART INSPECTION
Part name Inspection item Criteria & measure
Casing ·Existence of scratches, rust or corrosion. ·In case of damage in following section,
replace part.
- Sliding section of casing hole and spool,
especially land sections applied with held
pressure.
- Surface of spool and spring cover where
O-ring contacts.
- 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 ·Existence of scratch, gnawing, rusting or ·Replacement when its outside sliding
corrosion. section has scratch (especially on seal-
contacting section).
·O-ring seal sections at both ends. ·Replacement when its sliding section has
scratch.
·Insert spool into casing hole, rotate and ·Correction or replacement when O-ring is
reciprocate it. damaged or when spool does not move
smoothly.
Poppet ·Damage of spring ·In case spring has damage, replace it.
·Damage of poppet ·Correction or replacement when sealing is
incomplete.
·Insert poppet into casing and operate it. ·Normal when it can function lightly and
smoothly without sticking.
Spring and related ·Rusting, corrosion, deformation or breakage ·Replacement for significant damage.
parts of spring, spring seat, plug or cover.
Around seal for ·External oil leakage. ·Correction or replacement.

spool
·Rusting, corrosion or deformation of seal ·Correction or replacement.
plate.
Main relief valve, ·External rusting or damage. ·Replacement.

port relief valve,
·Contacting face of valve seat. ·Replacement in case of damage.
negative control
relief valve ·Contacting face of poppet. ·Replacement in case of damage.
·Abnormal spring. ·Replacement.
·O-rings, back up rings & seals ·Replacement in principle.
7-22
2) TROUBLESHOOTING
(1) General
① When any abnormal phenomenon is noticed, investigate whether it is a failure of the control
valve itself or a problem in the pump proper, third pump or the circuit. For this purpose, the pilot
pressure, pump discharge pressure, load pressure, etc. should be measured. Besides, when
disassembling and checking is carried out even partly, follow the above-mentioned
disassembling and assembling procedures.
② Since dust is very harmful to hydraulic components, pay full attention to dust prevention.
Even for partial disassembling, take measures for dust prevention.
③ Handle movable parts carefully. If damaged even slightly, correct the damage with an oil stone or
something.
④ Work carefully not to damage the gasket surfaces for O-rings. These damages are sure to cause
oil leakage.
(2) Control valve
Phenomenon Estimated cause Remedy

1.Machine does 1) Main relief valve malfunctions. 1) Measure pressure of main relief valve.
neither travel nor
·Existence of scratches, rust or corrosion. ·Disassemble valve and clean parts.
swing, functions
Replace assembly, if damaged severely.
at low speed
(insufficient force) ·Dirt is included between poppet and seat ·The same as above
or responds
·Clogging of main poppet restrictor ·The same as above
slowly.
·Sticking of main poppet ·Replace main relief valve
·Breakage or wear of spring ·Replace main relief valve
·Loosening of adjusting screw ·Make readjustment, and tighten the lock
nut to specified torque.
2. Cylinder falls 1) Excessive clearance between casing and 1) Replacement of spool
much by its weight spool
when spool is
2) Spool does not return to correct neutral 2) Measure secondary pilot pressure.
neutral.
position.
(Boom cylinder or ·Dirt is included between casing and spool. ·Disassemble valve and clean parts.
arm cylinder falls Replace assembly, if damaged severely.
much)
·Casing and spool are stuck together. ·Correct stuck section with oilstone, or
replace.
·Spring is broken or fatigued. ·Replace spring.
·Pilot line is clogged with dirt. ·Remove dirt.
3) Port relief valve malfunctions. 3) Measure pressure of port relief valve.
(See 1. 1) above.) (See 1. 1) above.)
4) Lock valve assy malfunctions 4) Replace lock valve assy.
(arm, boom).
5) Lock valve poppet malfunctions 5)
·Dirt is included between poppet and casing. ·Disassemble poppet and clean parts.
Replace poppet, if damaged severely.
·Poppet is stuck. ·Correct stuck section with oilstone, or
replace.
7-23
3. Simultaneous 1) Travel straight spool malfunctions. 1) Measurement of pilot secondary
operation of travel pressure.
and other
·Sticking of spool. ·Disassemble assembly and clean parts.
attachments causes
Replace spool, if damaged severely.
fluctuation without
traveling straight. ·Breakage or wear of spring. ·Replace spool.
·Excessive clearance between casing and ·Replace spool.
spool.
4. When lever is Load check valve malfunctions.
turned to cylinder
·Dirt is included between poppet and casing. ·Disassemble valve and clean parts.
hoisting, it falls at
Replace poppet, if damaged severely.
beginning.
·Poppet is stuck. ·Correct stuck section with oilstone, or
replace poppet.
5. Bucket, boom, 1) Main spool malfunctions. 1) Measure secondary pilot pressure.
and arm only
·Clearance between casing and spool is ·Replace spool.
do not work.
excessive.
Action is slow
(insufficient ·Dirt is included between casing and spool. ·Disassemble spool and clean parts.
force) or Replace spool, if damaged severely.
response is slow.
·Spool is stuck. ·Correct stuck section with oilstone, or
replace it.
·Return spring is broken or fatigued. ·Replace spring.
·Pilot line is clogged with dirt. ·Remove dirt.
2) Main relief valve malfunctions. 2) Measure pressure of main relief valve
3) Port relief valve malfunctions. 3) Measure pressure of port relief valve
6. Swing priority Arm1 logic control valve malfunctions. Replace Arm 1 logic control valve.
function does not
Arm1 logic poppet malfunctions. Replace Arm 1 logic poppet.
work.
7. Boom and arm Each confluence spool malfunctions. Measure secondary pilot pressure.
confluence does
·Spool is stuck. ·Correct stuck section with Oilstone, or
not function.
replace.
·Return spring is broken or fatiguen. ·Replace spring.
8. Boom hoisting Logic control valve malfunctions. Replacement of logic control valve assy.
operation is slow
Logic poppet malfunctions Replacement of logic poppet assy.
(insufficient force) or
response is slow,
during simultaneous
operation boom
hoisting and swing
operate.
7-24
9. Arm regeneration Arm regeneration cut valve malfunctions.
cut function does not
·Dirt is included between spool and sleeve. ·Disassemble valve and clean parts, or
work.
replace assembly if damaged severely.
·Sticking of spool. ·Correction of sticking portion with oil stone.
·Spring is broken or fatigued. ·Replacement of spring.
(3) Relief valve

1.Pressure does not 1) Main poppet or pilot poppet in relief valve is ·Check for foreign matter included in mating
rise at all. stuck or remains open , or dirt is included in sections of poppet.
valve seat.
·Check if parts slide freely.
·Clean all parts thoroughly.
2. Relief pressure Pilot poppet seat in relief valve is scored. ·Replace scored parts.
is not steady.
·Clean all parts thoroughly.
3. Relief pressure is 1) Wear due to dirt. 1) Replace scored parts.
not correct.
2) Locknut and adjusting screw are loose. 2) Adjust pressure.
4. Oil leakage 1) Seat is scored. 1) Replace scored or worn parts.
O-ring is worn. Check that all parts move smoothly, before
reassembling them.
2) Parts are stuck with dirt. 2) Check them for scratch, notch or foreign
matter, before reassembling them.
7-25
3. SWING DEVICE
1) WEARING PARTS
Inspection item replacement Counter measures
dimension value
Replace piston or
Clearance between piston and cylinder block bore 0.028 0.058
cylinder block
Replace assembly
Play between piston and shoe caulking section (δ) 0 0.3
of piston and shoe
Replace assembly
Thickness of shoe (t) 5.5 5.3
of piston and shoe
Replace set of
Combined height of retainer plate and spherical
6.5 6.0 retainer plate and
bushing (H-h)
sperical bushing
Thickness of friction plate 4.0 3.6 Replace
H
h
δ
t
2) SLIDING PARTS
Part name Standard roughness Allowable roughness Remark
0.8-Z (Ra=0.2)
Shoe 3-Z (Ra=0.8)
(LAPPING)
0.4-Z (Ra=0.1)
Shoe plate 3-Z (Ra=0.8)
(LAPPING)
1.6-Z (Ra=0.4)
Cylinder 12.5-Z (Ra=3.2)
(LAPPING)
0.8-Z (Ra=0.2)
Valve plate 6.3-Z (Ra=1.6)
(LAPPING)
7-26
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) WEARING PARTS (TYPE 1)
Part name & inspection item value for Remedy
dimension replacement
Clearance between piston &
0.052 mm 0.077 mm Replacement
cylinder bore (D-d)
Clearance caulked part

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

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

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

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

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

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

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

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

- -
Oil seal disassembly, in principle.
7-27
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
7-28
2) WEARING PARTS (TYPE 2)
Replace piston or
Clearance between piston and cylinder block bore 0.05 mm 0.065 mm
cylinder block
Replace assembly of
Play between piston and shoe caulking section (k) 0 0.3 mm
piston and shoe
Replace assembly of
Thickness of shoe (t) 5.5 mm 5.2 mm
piston and shoe
Replace set of set

Combined height of set plate and ball guide (H-h) 13.5 mm 13.3 mm
plate and ball guide
If the plate thickness is

below 5.8 mm, change
Thickness of set plate (t1) 6 mm 5.8 mm the set plate and ball
guide at the same
time
t k t1
h
t k t1 H
h
H
Shoe Ball guide Set plate
7-29
3) REDUCTION GEAR
Pitting area rate : Replacement pitting
Pitting or crack of gear -
10% or crack is found
Motor driving gear external Overpin

43.31 mm (Z=14)
spline 43.91 (Ø5)
Overpin
No. 1 sun gar internal spline 30.85 mm Replacement (Z=14)
30.25 (Ø5)
Displacement
No. 1 sun gear 41.92 mm Do. (Z=23)
Reduction ratio 42.22 (4teeth)
i = 70.145 Displacement
No. 1 planetary gear 43.68 mm Do. (Z=26)
43.98 (4teeth)
Overpin
No. 1 carrier internal spline 82.162 mm Do. (Z=23)
81.562 (Ø5)
Displacement
31.40 (3teeth)
Displacement
43.67 (4teeth)
Overpin
No. 2 carrier internal spline 112.84 mm Do. (Z=25)
112.24 (Ø10)
Displacement
54.92 (4teeth)
Displacement
54.93 (3teeth)
Overpin
Ring gear (3rd stages) 349.34 mm 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.
7-30
Replacement of abnormal
Radial clearance of needle bearing 0.01-0.04 mm 0.07 mm
parts as a set.
Replacement if such damage

Crack of spline contact part - - as crack, crevice of chipping is
found.
Dimension check and

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

seizure is found on sliding
Thrust ring (027) 8 mm thick 7.6 mm surface.
Replacement of scratch or
rust is found in sliding surface.
Floating seal - -
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 oil
Gear oil -
(API GL-5) without fail.
The above times are
measured with engine
hour meter.
7-31
5. RCV LEVER
Maintenance
Criteria Remark
check item
Leakage The valve is to be replaced when the leakage Conditions :

becomes more than 1000 cc/m at neutral handle Primary pressure : 40 kgf/cm2
position, or more than 2000 cc/m during operation. Oil viscosity : 23 cSt
Spool This is to be replaced when the sliding surface has The leakage at the left condition is
worn more than 10 μm, compared with the non- estimated to be nearly equal to the
sliding surface. above leakage.
Push rod
Ø7
1 mm
This is to be replaced when the top end has worn

more than 1 mm.
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.
2 mm 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.

7-32
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 : 40 kgf/cm2
drop. Oil viscosity : 23 cSt
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
1 mm
This is to be replaced when the top end has worn

more than 1 mm.
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.
2 mm 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.
7-33
7. TURNING JOINT
Part name Maintenance standards Remedy
Sliding surface with Plating worn or peeled due to seizure or contamination. Replace
sealing sections.
Sliding surface ·Worn abnormality or damaged more than 0.1 mm Replace

between body and (0.0039 in) in depth due to seizure contamination.
Body, stem other than
·Damaged more than 0.1 mm (0.0039 in) in depth. Smooth with oilstone.
Stem sealing section.
Sliding surface ·Worn more than 0.5 mm (0.02 in) or abnormality. Replace
with thrust plate.
·Worn less than 0.5 mm (0.02 in). Smooth
·Damage due to seizure or contamination remediable Smooth
within wear limit (0.5 mm) (0.02 in).
Sliding surface ·Worn more than 0.5 mm (0.02 in) or abnormality. Replace
with thrust plate.
Cover ·Worn less than 0.5 mm (0.02 in). Smooth
·Damage due to seizure or contamination remediable Replace
within wear limit (0.5 mm) (0.02 in).
·Extruded excessively from seal groove square ring. Replace
- Extrusion
Square ring
·Slipper ring 1.5 mm (0.059 in) narrower than seal Replace

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

(0.059 in)
7-34
8. CYLINDER
Part name Inspecting section Inspection item Remedy
Piston rod ·Neck of rod pin ·Presence of crack ·Replace
·Weld on rod hub ·Presence of crack ·Replace
·Stepped part to which piston is
·Presence of crack ·Replace
attached.
·Threads ·Presence of crack ·Recondition or replace
·Plating is not worn off to base ·Replace or replate
metal.
·Plated surface
·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. ·Replace
Cylinder tube ·Weld on bottom ·Presence of crack ·Replace
·Weld on head ·Presence of crack ·Replace
·Weld on hub ·Presence of crack ·Replace
·Tube interior ·Presence of faults ·Replace if oil leak is seen
·Bushing at mounting part ·Wear on inner surface ·Replace
Gland ·Replace if flaw is deeper
·Bushing ·Flaw on inner surface
than coating
7-35
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 clearance limit Replace
5 Shaft Hole
and bushin bushing
-0.25 +0.176
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
7-36
2) CARRIER ROLLER
4 3
5
21037MS02
Unit : mm

1 Outside diameter of flange
Ø200 -
Rebuild or
replace
3 Width of tread 51 56
4 Width of flange 20 -
5 Shaft Hole
and support bushing
0 +0.3 0.1
Ø57.15 -0.1 Ø57.15 +0.1 1.2
to 0.4
7-37
3) IDLER
8
1
2
7
3 5
4
21037MS03
Unit : mm
1 Outside diameter of protrusion
Ø646 -
Rebuild or
replace
3 Width of protrusion 102 -
4 Total width 203 -
5 Width of tread 50.5 57.5
6 Shaft Hole
and bushing bushing
Ø85 0 Ø85.35 +0.05 0.35 to 0.435 2.0
-0.035 0
Clearance between shaft 0 +0.09
7 Ø85 -0.035 Ø85 +0.036 0.036 to 0.125 1.2 Replace
and support
Side clearance of idler Standard clearance Clearance limit
8 Replace
(Both side) 0.25 to 1.2 2.0
7-38
4) track
2 1
5
3
21037MS04
Unit : mm
Standard size Repair limit Turn or
1 Link pitch
215.9 220.9 replace
2 Outside diameter of bushing Ø71 Ø60.4

Rebuild or
3 Height of grouser 36 21 replace
4 Height of link 129 115
5 Tightening torque Initial tightening torque : 140±14 kgf·m Retighten
7-39
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 120 116
- 1.5 replace
+2
Track frame 292 -1
296
2 Horizontal width of idler guide
Idler support 290 - 287
Installation Installation Installation
3 Recoil spring Free length Free length Replace
length load load
Ø254×740 595 24500 kg - 19600 kg
7-40
2. work equipment
A C D E f
B K J I H G
380A7MS31
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 〃
7-41
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 6 Travel Device ----------------------------------------------------------------------------------------------------- 8-74
Group 7 RCV Lever --------------------------------------------------------------------------------------------------------- 8-106
Group 8 Turning Joint ------------------------------------------------------------------------------------------------------ 8-120
Group 9 Boom, Arm and Bucket Cylinder --------------------------------------------------------------------- 8-125
Group 10 Undercarriage --------------------------------------------------------------------------------------------------- 8-147
Group 11 Work Equipment ----------------------------------------------------------------------------------------------- 8-159
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
kgf·m lbf·ft
1 Engine mounting bolt (engine-bracket) M12 × 1.75 11.5 ± 1.0 83.2 ± 7.2
3 Engine mounting bolt (bracket-frame) M24 × 3.0 90 ± 9.0 651 ± 65
4 Engine Radiator, oil cooler mounting bolt M16 × 2.0 29.7 ± 4.5 215 ± 32.5
5 Coupling mounting socket bolt M20 × 2.5 46.5 ±2.5 336 ±18.1
6 Fuel tank mounting bolt M20 × 2.5 57.8 ±5.8 418 ± 42.0
7 Main pump housing mounting bolt M10 × 1.5 6.5 ± 0.7 47.0 ± 5.1
8 Main pump mounting socket bolt M20 × 2.5 57.9 ± 8.7 419 ± 62.9
Hydraulic
9 Main control valve mounting nut M20 × 2.5 57.9 ± 8.7 419 ± 62.9
system
10 Hydraulic oil tank mounting bolt M20 × 2.5 57.9 ± 5.8 419 ± 42
11 Turning joint mounting bolt, nut M12 × 1.75 12.3 ± 1.3 89.0 ± 9.4
12 Swing motor mounting bolt M20 × 2.5 57.9 ± 8.7 419 ± 62.9
13 Swing bearing upper part mounting bolt M24 × 3.0 100 ± 10 723 ± 72.3
Power
14 train Swing bearing lower part mounting bolt M24 × 3.0 100 ± 10 723 ± 72.3
system
15 Travel motor mounting bolt M24 × 3.0 84 ± 8.0 608 ± 57.8
16 Sprocket mounting bolt M20 × 2.5 57.9 ± 6.0 419 ± 43.4
17 Carrier roller mounting bolt, nut M16 × 2.0 29.7 ± 3.0 215 ± 21.7
18 Track roller mounting bolt M20 × 2.5 57.9 ± 6.0 419 ± 43.4
Under
19 Track tension cylinder mounting bolt M16 × 2.0 29.7 ± 4.5 215 ± 32.5
carriage
20 Track shoe mounting bolt, nut M22 × 1.5 123 ± 6.0 890 ± 43.4
21 Track guard mounting bolt M20 × 2.5 57.9 ± 8.7 419 ± 62.9
22 Counterweight mounting bolt M36 × 3.0 337 ± 30 2440 ± 217
23 Cab mounting bolt M12 × 1.75 12.8 ± 3.0 92.6 ± 21.7
Others
24 Operator's seat mounting bolt M 8 × 1.25 4.05 ± 0.8 29.3 ± 5.8
25 Under cover mounting bolt M12 × 1.75 12.8 ± 3.0 92.6 ± 21.7
※ For tightening torque of engine and hydraulic components, see engine maintenance guide and
service manual.
8-4
2. TORQUE CHART
Use following table for unspecified torque.
1) BOLT AND NUT
(1) Coarse thread
8.8T 10.9T 12.9T
Bolt size
kgf·m lbf·ft kgf·m lbf·ft kgf·m lbf·ft
M 6 × 1.0 0.8 ~ 1.2 5.8 ~ 8.6 1.2 ~ 1.8 8.7 ~ 13.0 1.5 ~ 2.1 10.9 ~ 15.1
M 8 × 1.25 2.0 ~ 3.0 14.5 ~ 21.6 2.8 ~ 4.2 20.3 ~ 30.4 3.4 ~ 5.0 24.6 ~ 36.1
M10 × 1.5 4.0 ~ 6.0 29.0 ~ 43.3 5.6 ~ 8.4 40.5 ~ 60.8 6.8 ~ 10.0 49.2 ~ 72.3
M12 × 1.75 6.8 ~ 10.2 50.0 ~ 73.7 9.6 ~ 14.4 69.5 ~ 104 12.3 ~ 16.5 89.0 ~ 119
M14 × 2.0 10.9 ~ 16.3 78.9 ~ 117 16.3 ~ 21.9 118 ~ 158 19.5 ~ 26.3 141 ~ 190
M16 × 2.0 17.9 ~ 24.1 130 ~ 174 25.1 ~ 33.9 182 ~ 245 30.2 ~ 40.8 141 ~ 295
M18 × 2.5 24.8 ~ 33.4 180 ~ 241 34.8 ~ 47.0 252 ~ 340 41.8 ~ 56.4 302 ~ 407
M20 × 2.5 34.9 ~ 47.1 253 ~ 340 49.1 ~ 66.3 355 ~ 479 58.9 ~ 79.5 426 ~ 575
M22 × 2.5 46.8 ~ 63.2 339 ~ 457 65.8 ~ 88.8 476 ~ 642 78.9 ~ 106 570 ~ 766
M24 × 3.0 60.2 ~ 81.4 436 ~ 588 84.6 ~ 114 612 ~ 824 102 ~ 137 738 ~ 991
M30 × 3.5 120 ~161 868 ~ 1164 168 ~ 227 1216 ~ 1641 202 ~ 272 1461 ~ 1967
(2) Fine thread

8.8T 10.9T 12.9T
Bolt size
kgf·m lbf·ft kgf·m lbf·ft kgf·m lbf·ft
M 8 × 1.0 2.1 ~ 3.1 15.2 ~ 22.4 3.0 ~ 4.4 21.7 ~ 31.8 3.6 ~ 5.4 26.1 ~ 39.0
M10 × 1.25 4.2 ~ 6.2 30.4 ~ 44.9 5.9 ~ 8.7 42.7 ~ 62.9 7.0 ~ 10.4 50.1 ~ 75.2
M12 × 1.25 7.3 ~ 10.9 52.8 ~ 78.8 10.3 ~ 15.3 74.5 ~ 110 13.1 ~ 17.7 94.8 ~ 128
M14 × 1.5 12.4 ~ 16.6 89.7 ~ 120 17.4 ~ 23.4 126 ~ 169 20.8 ~ 28.0 151 ~ 202
M16 × 1.5 18.7 ~ 25.3 136 ~ 182 26.3 ~ 35.5 191 ~ 256 31.6 ~ 42.6 229 ~ 308
M18 × 1.5 27.1 ~ 36.5 196 ~ 264 38.0 ~ 51.4 275 ~ 371 45.7 ~ 61.7 331 ~ 446
M20 × 1.5 37.7 ~ 50.9 273 ~ 368 53.1 ~ 71.7 384 ~ 518 63.6 ~ 86.0 460 ~ 622
M22 × 1.5 51.2 ~ 69.2 370 ~ 500 72.0 ~ 97.2 521 ~ 703 86.4 ~ 116 625 ~ 839
M24 × 2.0 64.1 ~ 86.5 464 ~ 625 90.1 ~ 121 652 ~ 875 108 ~ 146 782 ~ 1056
M30 × 2.0 129 ~ 174 933 ~ 1258 181 ~ 245 1310 ~ 1772 217 ~ 294 1570 ~ 2126
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 : 210ᎌ
5
(55.5 U.S. gal) 2 3
(5) Remove socket bolts (5) and disconnect 4
pipes (1, 2).
(6) Disconnect pilot line hoses (6, 7, 8, 9, 10, 380A8MP01
11, 12).
(7) Remove socket bolts (4) and disconnect
7
pump suction tube (3).
※ When pump suction tube is disconnected,
the oil inside the piping will flow out, so
catch it in oil pan. 6
(8) Sling the pump assembly and remove the

pump mounting bolts.
9
· Weight : 190 kg (420 lb)
8
· Tightening torque : 57.9±8.7 kgf·m 380A8MP02
(419±62.9 lbf·ft)
※ Pull out the pump assembly from housing.
When removing the pump assembly,
check that all the hoses have been 11
10
disconnected.
12
380A8MP03
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
497 312 956 401
380A2MP02
04 Gear pump 261 Seal cover (F) 717 O-ring

111 Drive shaft (F) 271 Pump casing 719 O-ring
113 Drive shaft (R) 312 Valve block 724 Square ring
114 Spline coupling 313 Valve plate (R) 725 O-ring
123 Roller bearing 314 Valve plate (L) 728 O-ring
124 Needle bearing 401 Hexagon socket screw 732 O-ring
127 Bearing spacer 406 Hexagon socket screw 774 Oil seal
012 Cylinder block 466 VP Plug 789 Back up ring
151 Piston 468 VP Plug 792 Back up ring
152 Shoe 497 Plug 808 Hexagon head nut
153 Set plate 531 Tilting pin 824 Snap ring
156 Bushing 532 Servo piston 885 Pin
157 Cylinder spring 534 Stopper (L) 886 Spring pin
211 Shoe plate 535 Stopper (S) 901 Eye bolt
212 Swash plate 548 Feedback pin 953 Set screw
214 Bushing 702 O-ring 954 Adjust screw
251 Support plate 710 O-ring 956 Set screw

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
Allen wrench Hexagon socket PT plug PO plug Hexagon socket
B
head bolt (PT thread) (PF thread) head setscrew
4 M 5 BP-1/16 - M 8
5 M 6 BP1/ 8 - M10
B 6 M 8 BP-1/ 4 PO-1/4 M12, M14
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, VP plug
- Hexagon head bolt Hexagon head bolt
socket wrench, double (single) (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 8-10, 11.
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
36078MP11
shaft can be fitted easily.
(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)
412 876 874 656 735 413 497 438 413
755
A 858
897 B 614
612
615 Pi
613
A 875
B 611
438 722 724 725 436
VIEW C
641
P2
Pf
438
Pi1
801
924
B
730 643 708 644 645 646 728 Hydraulic circuit
SECTION B-B 380A2MP04

Pi Pilot port PF 1/4-15
438 Hexagon socket screw 725 O-ring Pf Power shift port -
497 Plug 728 O-ring P2 Companion delivery port -
611 Feed back lever 730 O-ring
614 Fulcrum plug 801 Nut
615 Adjust plug 858 Snap ring
643 Pilot piston 874 Pin
644 Spring seat (Q) 875 Pin
645 Adjust stem (Q) 876 Pin
646 Pilot spring 897 Pin
656 Block cover 924 Set screw
8-20
2) structure (2/2)
SECTION A-A 380A2MP05
601 Casing 630 Lock nut 734 O-ring

621 Compensator piston 631 Sleeve, pf 753 O-ring
622 Piston case 641 Pilot cover 756 O-ring
623 Compensator rod 651 Sleeve 763 O-ring
624 Spring seat (C) 652 Spool 802 Nut
625 Outer spring 653 Spring seat 814 Snap ring
626 Inner spring 654 Return spring 836 Stop ring
627 Adjust stem (C) 655 Set spring 887 Pin
628 Adjust screw (C) 732 O-ring 898 Pin
629 Cover (C) 733 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
Allen wrench Hexagon socket PT plug PO plug Hexagon socket
B
head bolt (PT thread) (PF thread) head setscrew
4 M 5 BP-1/16 - M 8
B 5 M 6 BP1/ 8 - M10
6 M 8 BP-1/ 4 PO-1/4 M12, M14
Double ring spanner,
socket wrench, double (single) VP plug
open end spanner - Hexagon head bolt Hexagon head nut
(PF thread)
B
6 M8 M8 -
Adjustable angle wrench Small size, Max 36 mm
Screw driver Minus type screw driver, Medium size, 2 sets
Hammer Plastic hammer, 1 set
Pliers For snap ring, TSR-160
Steel bar 4×100 mm
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), 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) A f t e r r e m o v i n g c o v e r ( C , 6 2 9 )
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, 4 mm 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) D r a w o u t p i s t o n c a s e ( 6 2 2 ) ,
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.
③ Therefore, wash parts well with cleaning
oil, let them dry with jet air and handle
them in clean place.
④ Always tighten bolts, plugs, etc. to their
specified torques.
⑤ Do not fail to coat sliding surfaces with
clean hydraulic oil before assembly.
Replace seals such as O-ring with new
ones as a rule.
(2) P u t c o m p e n s a t i n g r o d ( 6 2 3 ) i n t o
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 lever (2).
36078RE13
(8) Fit fulcrum plug (614) so that pin force-

fitted in fulcrum plug (614) can be put into
pin hole of lever (2).
Then fix 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), adjusting stem (C, 627),
lock nut (630), hexagon nut (802) and set
screw (924).
Then tighten them with hexagonal socket
head screws (438).
This completes assembly.
36078RE18
8-30
GROUP 4 MAIN CONTROL VALVE

1) REMOVAL
pressure in the hydraulic piping.

penetrate the skin causing serious
injury.
※ When pipes and hoses are disconnected,

Ac
the oil inside the piping will flow out, so Atr
catch it in oil pan.

Btr
Bc As
Ab Bs
(4) Remove bolts and disconnect pipes.

Aa
Ba
Bb
(5) Disconnect pilot line hoses. Mounting bolt

380A8MC01
(6) Disconnect pilot pipes.
(7) Sling the control valve assembly and
remove the control valve mounting bolts.
·Weight : 340 kg (750 lb) Dra
Pz
· Tightening torque : 57.9±8.7 kgf·m Dr1
Drb
PH
(419±62.9 lbf·ft) N2
PG
(8) Remove the control valve assembly. N1
Pns
When removing the control valve Px
assembly, check that all the piping have Rs1

Dr2
Dr3 Dr4
been disconnected.
380A8MC02
2) INSTALL
to removal. XAtr
XAtL
XBb1
(2) Bleed the air from below items. XBa1

PbL
PAcs
XBb2
① Cylinder (Boom, arm, bucket) XAc

XAs
XBa2
② Swing motor PaL
③ Travel motor
XBp2
Pna1
XBtr
※ See each item removal and install. XBc

XBtL
XAb1
XBs
XAb2
(3) Confirm the hydraulic oil level and XAa2

XAb2
XAa1
recheck the hydraulic oil leak or not.

380A8MC03
8-31
2. structure (1/4)
380A8MC10
103 Casing C 252 Lock valve 371 Spring

151 Plug 257 Arm relief valve assy 375 Spring
153 Plug 261 O-ring 515 Poppet
162 O-ring 271 Hexagon socket bolt 521 Spring
163 O-ring 273 Hexagon socket screw 551 Plug
167 O-ring 331 Seat 561 O-ring
169 O-ring 332 Spring seat 602 Relief valve assy
201 Spring cover 333 Spacer bolt 611 Nega-con relief valve assy
202 Spring cover 336 Spacer bolt 971 Hexagon socket screw
211 Plate 337 Stopper
8-32
structure (2/4)
380A8MC11
151 Plug 265 O-ring 333 Spacer bolt

167 O-ring 266 O-ring 334 Stopper
168 O-ring 267 O-ring 341 Plug
202 Spring cover 271 Hexagon socket screw 511 Poppet
203 Spool cover 272 Hexagon socket screw 513 Poppet
205 Spool cover 275 Hexagon socket screw 514 Poppet
213 Flange 276 Hexagon socket screw 521 Spring
214 Load check cover 277 Hexagon socket screw 522 Spring
215 Blank flange 302 Arm 1 spool kit 523 Spring
253 Logic control valve assy 306 Arm 2 spool kit 531 Spring seat
255 Logic control valve assy 310 Bypass spool kit 551 Plug
261 O-ring 311 Bypass spool kit 553 Plug
262 O-ring 323 Spring 561 O-ring
263 O-ring 324 Spring 602 Relief valve assy
264 Square ring 331 Seat 611 Nega-con relief valve assy
8-33
structure (3/4)
380A8MC12
102 Casing B 261 O-ring 375 Spring

153 Plug 263 O-ring 511 Poppet
161 O-ring 264 Square ring 513 Poppet
164 O-ring 271 Hexagon socket screw 521 Spring
165 O-ring 275 Hexagon socket screw 523 Spring
169 O-ring 303 Boom 1 spool kit 551 Plug
170 O-ring 304 Bucket spool kit 553 Plug
171 O-ring 307 Boom 2 spool kit 555 Plug
172 O-ring 309 Option spool kit 561 O-ring
201 Spring cover 332 Spring seat 563 O-ring
203 Spool cover 336 Spacer bolt 602 Relief valve assy
204 Spring cover 337 Stopper 605 Relief valve assy
213 Flange 342 Valve piston 991 Name plate
252 Lock valve 371 Spring 992 Rivet screw
8-34
structure (4/4)
380A8MC13
101 Casing A 203 Spool cover 372 Spring

151 Plug 253 Logic control valve assy 511 Poppet
152 Plug 255 Logic control valve assy 512 Poppet
153 Plug 261 O-ring 521 Spring
161 O-ring 263 O-ring 522 Spring
165 O-ring 271 Hexagon socket screw 541 Steel ball
166 O-ring 301 Travel spool kit 542 Spring seat
167 O-ring 305 Swing spool kit 543 Spring
169 O-ring 308 Travel spool kit 551 Plug
168 O-ring 332 Spring seat 552 Plug
170 O-ring 336 Spacer bolt 554 Plug
171 O-ring 337 Stopper 561 O-ring
172 O-ring 351 Orifice 562 O-ring
201 Spring cover 371 Spring 601 Relief valve assy
8-35
3. DISASSEMBLY AND ASSEMBLY
1) GENERAL PRECAUTIONS
(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 36, 46
Hexagon key wrench Each 1 piece 5, 6, 8, 10, 12, 14, 17
Loctite #262 1 piece -
Spanner Each 1 piece 32 (main relief valve, 601)
36 (port relief valve, 602, 605)
8-36
3) Disassembling
The figure in ( ) shown after the part name in the explanation sentence shows its number in
the construction figures.
(1) Place control valve on working bench.

※ Disassemble it in clean place and pay
attention not to damage flange face.
380A8MC26
(2) Disassembling of main spool (travel

(301), bucket (304), swing (305), option
(309), arm 2 (306), boom 2 (307))
① Loosen the hexagon the socket head
bolts (271), and remove the spring cover
(201 or 204) and the O-ring (261).
(hexagon key wrench 8 mm)
② Pull out spool, spring, spring seats (332),
stopper (337) and spacer bolt (336) in 380A8MC27
spool assembly condition from casing.

※ When pulling out spool assembly from
casing, pay attention not to damage
casing.
380A8MC28
8-37
③ Hold the spool in the mouthpiece-
attached vise applying a protection plate
(aluminum plate and the like) in between.
Remove spacer bolt (336) and
disassemble spring, stopper (337) and
spring seats (332).
Loosen plug (555) before removing
bucket spring cover (204) from casing B 380A8MC29
(102). Then, pull out piston (342).

(3) Disassembling of the boom1 spool

(303)
① Loosen the hexagon socket head bolts
(271) and remove the spring cover (201)
and O-ring (261).
② Pull out the boom1 spool (303), spring
(371), spring seat (332), stopper (337)
and spacer bolt (336) in the spool 380A8MC30
assembly condition from the casing B

(102).
※ When pulling out the spool assembly
from casing B (102), pay attention not to
damage the casing.
③ Hold the boom1 spool (303) in the
mouthpiece-attached vise applying a
protection plate (aluminum plate and the
like) in between. Remove the spacer bolt
(336) and disassemble spring (371),
stopper (337) and spring seats (332).
④ Do not disassemble the boom1 spool
(303) more than these conditions.
8-38
(4) Disassembling of the arm 1 spool (302)
① Loosen the hexagon socket head bolts
(271) and remove the spring cover (201)
and O-ring (261).
② Pull out the arm1 spool (302), spring
(371), spring seat (332), stopper (337)
and spacer bolt (336) in the spool
assembly condition from casing C (103). 380A8MC31

from casing C (103), pay attention not to
damage the casing.
③ Hold the arm1 spool (302) in the
like) in between. Remove spacer bolt
④ Do not disassemble the arm1 spool
(302) more than these conditions.
(6) Disassembling of the travel straight

spool (308)
① Loosen hexagon socket head bolts (271)
and remove the spring cover (201) and
O-ring (261).
② Remove travel the straight spool (308),
spring (372), spring seat (332), stopper
(337) and spacer bolt (336) in the spool 380A8MC32
assembly condition from the casing A

(101).
③ Hold the travel straight spool (308) in the
④ Do not disassemble the travel straight
spool (308) more than these conditions.
8-39
(6) Disassembling of the bypass cut spool
(310)
① Loosen hexagon socket head bolts (272)
and remove the spring cover (202) and
O-ring (262).
② Pull out the bypass cut spool (310),
spring (323, 324), spring seats (331),
stopper (334) and spacer bolt (333) in 380A8MC33
the spool assembly condition from

casing C (103).
from casing C (103), pay attention not to
damage the casing.
③ Hold the travel spool (310) in the

(333) and disassemble spring (323,
324), stopper (334) and spring seats
(331).
380A8MC34
(7) Disassembly of spool covers (203, 205)

Loosen hexagon socket head bolts (271),
and remove the spool cover (203, 205)
and O-ring (261, 263).
380A8MC35
(8) Removal of the main relief valve (601)

and the port relief valves (602, 605,606).
Remove the main relief valve (601) and
the port relief valve (602, 605,606) from
the casing.
Main relief valve (601) : spanner 32 mm

Port relief valve (602) : box wrench or
spanner 36 mm
380A8MC36
Port relief valve (605) : box wrench or
spanner 36 mm
Port relief valve (606) : spanner 36 mm
8-40
※ Do not disassemble the relief valves
more after.
380A8MC37
380A8MC38
(9) Removal of the lock valve selector

(252)
Loosen hexagon socket head bolts (252-
601) and remove the lock valve selector
(252) and O-ring (252-161).
Do not disassemble the lock valve select-
or (252) more than these conditions.
380A8MC40
252-601
252-161
380A8MC39
8-41
(10) Removal of the negative control relief
valve (611)
Remove the plug (551) from the casing C
(103). Pull out poppet (611-611), spring
(611-621) and damping rod (611-631).
380A8MC42
611-631 611-621 611-611
380A8MC41
(11) Removal of the arm regeneration cut

valve (257)
Remove the body (257-101), the spool
(257-103) and sleeve (257-102) from the
casing C (103).
(box key wrench 46 mm)
380A8MC43
257-101
257-103
Dr
257-102
T
AR
380A8MC44
8-42
(12) Disassembly of the logic control valve
(255), the swing logic valve assembly
(254) and the arm 1 logic valve assem-
bly (253)
① Loosen hexagon socket head bolts (255-
276) and remove the logic control valve
(255) and O-ring (255-264).
② Pull out the swing logic valve (254) and 380A8MC45
the arm 1 logic valve (253) in the

assembly condition from casing.
③ Do not disassemble the logic poppet and
the logic valve assy (253, 254) more
than these conditions.
380A8MC46
255-264 255-276
255-205
255-265
255-206
380A8MC47
8-43
(13) Disassembly of the check valve
① CT1, CT2, CP1, CP2, LCb, LCb2, CCb,
LCk, LCo, LCAT2
Remove the plug (551) and take out
poppet (511) and spring (521).
② CMR1, CMR2
poppet (512) and spring (522). 380A8MC48
380A8MC49
③ Hva, Hvb
④ CCk, CCo
⑤ Remove the plug (554) and take out 380A8MC50
steel ball (541), spring (543) and spring

seat (542).
(14) Disassembly of the flanges (213)
Loosen hexagon socket head bolts (275)
and remove the flange (213) and O-ring
(264).
8-44
(15) Disassembly of the plate (211)
Loosen hexagon socket head bolts (273)
and remove the plate (211) and O-ring
(162, 163).
(16) Disassembly of the orifices for signal line
Do not disassemble the plug (152) and
the orifice (351) unless required specifica-
lly.
(17) Disassembly of the casing:
① Except when required specially, do not
disassemble tie bolts of the casing A
(101) and C (103).
② Since the plugs not described in above
disassembling procedures are the blind 380A8MC51
plugs for sacrifice holes and blind plugs

for casing sanitation, do not disassemble
them as far as not required specially.
8-45
(18) 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.
① Control valve
a. Check whole surfaces of all parts for burrs, scratches, notches and other defects.
b. Confirm that seal groove faces of casing and covers are smooth and free of dust, dent, rust etc.
c. Correct dents and damages on check seat faces of casing and block, if any, by lapping.
※ Pay attention not to leave lapping agent in casing and block.
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.
② 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.
8-46
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
① Pay attention to keep seals free from defects in its forming and damages in its handling.
② Apply grease, hydraulic oil or so on to seals and seal-fitting sections for full lubrication.
③ Do not stretch seals so much to deform them permanently.
④ 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.
⑤ Tighten fitting bolts at all sections with torque wrench to their respective tightening torques
shown in "Maintenance standards".
(4) Assembly of check valve

① Assemble poppets (511, 512, 513, 515) and springs (521, 522, 523).
② Put O-rings (561, 562) onto the plugs (551, 552, 553).
③ Tighten the plugs (551, 552, 553) with their specified torques.
※ Use poppets, springs and plugs in following

groups.
Poppet Spring Plug Remark
511 521 551 511 in 10 positions
512 522 552 512 in 2 positions
513 523 553 513 in 2 positions
515 521 551 515 in 2 positions
Tightening torque
Tightening torque
Plug no. Hex wrench
kgf·m lbf·ft
551 17 mm 37.7~41.8 273~302
552 12 mm 23.5~26.5 170~192
553 17 mm 37.7~41.8 273~302
8-47
(5) Assembly of the plate (211)
Fit O-rings (162, 163) to the casing C (103), and tighten hexagon socket head bolts (273) with
specified torque.
(box wrench 14 mm)
·Tightening torque : 21.4~26.5 kgf·m (155~192 lbf·ft)
So turn the control valve that the plate face may be directed downward.
(6) Assembly of the flange (213)
Fit O-rings (264) to the flange (213), and tighten hexagon socket head bolts (275) with specified
torque.
(box wrench 12 mm)
(7) Assembly of the logic control valve (255) and the swing logic valve assembly (254)
① Assemble the swing logic valve ass’y (254) into the casing A (101).
② Fit the O-rings (255-264) to the plate (255-206). Fit the O-rings (255-265) to the cover (255-205),
and tighten the hexagon socket head bolts (255-276) with specified torque.
(box wrench 8 mm)
·Tightening torque : 5.3~6.3 kgf·m (38.4~45.7 lbf·ft)
(8) Assembly of the logic control valve (255) and the arm 1 logic valve assembly (253)
① Assemble the arm 1 logic valve ass’y (253) into the casing C (103).
② Fit the O-rings (255-264) to the plate (255-206). Fit the O-rings (255-265) to the cover (255-205),
and tighten the hexagon socket head bolts (255-276) with specified torque.
(box wrench 8mm)
(9) Assembly of the negative control relief valve (611)
Assemble poppet (611-611), spring (611-621) and damping rod (611-631) into the casing C
(103).
Put O-ring (561) onto the plug (511) and tighten the plug (511) with its specified torque.
(box wrench 17 mm)
(10) Assembly of the arm regeneration cut valve (257)
Assemble the sleeve (257-102), spool (257-103), and body (257-101) into the casing C (103).
Tighten it with specified torque.
(box wrench 46mm)
8-48
(11) Assembly of the lock valve selector (252)
Fit the O-rings (252-161) to the lock valve selector (252) and tighten the hexagon socket head
bolts (252-601) with specified torque.
(box wrench 5 mm)
(12) Assembling of the main relief valve (601) and the port relief valve (602, 605, 606)
Assemble the main relief valve (601) and the port relief valves (602, 605,606) to the casing and
tighten it with specified torque.
Tightening torque
Item Size
kgf·m lbf·ft
Main relief valve (601) Spanner 32 mm 12.2~14.3 88.2~103
Spanner 36 mm
Port relief valve (602, 605) 12.2~14.3 88.2~103
Box wrench 36 mm
Port relief valve (606) Spanner 36 mm 12.2~14.3 88.2~103
(13) Assembling of the travel straight spool (308) :

① Hold the middle of the travel straight spool (308) in the mouthpiece-attached vise applying a
protection plate (aluminum plate and the like) in between. Set spring seat (332), stopper (337)
and spring (372), and tighten spacer bolt (336) with specified torque.
※ Before tightening spacer bolt (336), apply loctite #262 to it.
(box wrench 8 mm)
Pay attention not to fasten the vise excessively to the shape of the travel straight spool (308) is
deformed.
② Insert the spool assemblies of Items ① above into the casing A (101).
※ Fit the spool assemblies into casing A (101) carefully and slowly.
Do not push them forcibly without fail.
(14) Assembling of the boom1 spool (303)
① Hold the middle of the boom1 spool (303) in the mouthpiece-attached vise applying a protection
plate (aluminum plate and the like) in between. Set spring seat (332), spring (371) and stopper
(337), and tighten spacer bolt (336) with specified torque.
※ Before tightening spacer bolt (336), apply Loctite #262 to them.
(box wrench 8 mm)
Pay attention not to fasten the vise excessively to the shape of the boom 1 spool (303) is
deformed.
② Insert the spool assemblies of Items ① above into the casing B (102).
※ Fit the spool assemblies into the casing B (102) carefully and slowly.
8-49
(15) Assembling of the arm 1 spool (302)
① Hold the middle of the arm 1 spool (302) in the mouthpiece-attached vise applying a protection
plate (aluminum plate and the like) in between. Set spring seats(332), spring (371) and stopper
(337), and tighten spacer bolt (336) with specified torque.
※ Before tightening spacer bolt (336), apply Loctite #262 to it.
(box wrench 8 mm)
Pay attention not to fasten the vise excessively to the shape of the arm1 spool (302) is
deformed.
② Insert the spool assemblies of Items ① above into the casing C (103).
※ Fit the spool assemblies into the casing C (103) carefully and slowly.
(16) Assembling of the main spool (travel (301), bucket (304), swing (305), option (309), arm 2 (306),
boom 2 (307))
① Hold the middle of each spool in the mouthpiece-attached vise applying a protection plate
(aluminum plate and the like) in between. Set spring seats (332), springs and stopper (337), and
tighten spacer bolt (336) with specified torque.
·Tightening torque 3.8~4.2 kgf·m (22.8~30.2 lbf·ft)
Pay attention not to fasten the vise excessively to the shape of spool is deformed.
② Insert spool assemblies of Items ① above into the casing A (101), B (102) and C (103).
※ Fit spool assemblies into the casing A (101), B (102) and C (103) carefully and slowly. Do not
push them forcibly without fail.
(17) Assembly of the bypass cut spool (310)
① Hold the middle of the bypass cut spool (310) in the mouthpiece-attached vise applying a
protection plate (aluminum plate and the like) in between. Set spring seats(331), spring (323,
324) and stopper (334), and tighten spacer bolt (333) with specified torque.
(box wrench 10 mm)
Pay attention not to fasten the vise excessively to the shape of the bypass cut spool (310) spool
is deformed.
② Insert the spool assemblies of Items ① above into the casing C (103).
※ Fit the spool assemblies into the casing C (103) carefully and slowly. Do not push them forcibly
without fail.
8-50
(18) Assembling of the covers
① Fit the spool covers (203, 205) to sides reverse to spring sides of spools, and tighten hexagon
socket head bolts (271) with specified torque.
(box wrench 8 mm)
※ Confirm that O-rings (261, 263) have been fitted to spool cover (203, 205).
② Bucket the spring cover (204):
Assemble piston (342) into the bucket spring cover (204). Put O-ring (563) onto the plug (555)
and tighten it with specified torque.
(box wrench 17 mm)
③ Fit the spring covers (201, 202, 204) to spring sides of spools, and tighten hexagon socket head
bolts (271, 272) with specified torque.
(271 : Hexagon key wrench 8mm, tightening torque 5.3~6.3 kgf·m (38.4~45.7 lbf·ft)
(272 : Hexagon key wrench 6mm, tightening torque 2.5~3.5 kgf·m (18.4~25.1 lbf·ft)
※ Confirm that O-rings (261) have been fitted to spring covers (201, 202, 204).
8-51
GROUP 5 SWING DEVICE
1. REMOVAL AND INSTALL OF MOTOR

1) REMOVAL

injury. 5 4
Dr

the oil inside the piping will flow out, so B
A

10
(4) Disconnect hoses (2, 3, 4, 5, 6, 7, 8, 9). 3
1
(5) Sling the swing motor assembly (1) and 2
remove the swing motor mounting bolts

(10). 380A8SM01
· Motor device weight : 95 kg (209 lb)
· Tightening torque : 97.8 ± 15 kgf·m
(707 ± 108 lbf·ft)
(6) Remove the swing motor assembly.
※ When removing the swing motor
6
assembly, check that all the piping have
been disconnected. Mu
PG
9 SH
2) INSTALL
(1) Carry out installation in the reverse order 7
SGr
to removal. 8
(2) Bleed the air from the swing motor.
① Remove the air vent plug.
380A8SM02
② Pour in hydraulic oil until it over flows
from the port.
③ Tighten plug lightly.
④ Start the engine, run at low idling, and
⑤ Tighten plug fully.
(3) Confirmed the hydraulic oil level and
check the hydraulic oil leak or not.
8-52
2. SWING MOTOR
1) STRUCTURE
1 7 11 12 13 23 25 24 18 20 37 19 21
22
6
5
2
36
31 38
28 39
3 4 8 9 10 14 15 16 17 29
380A8SM05
1 Casing 12 Cylinder spring 23 O-ring

2 Valve casing 13 Cylinder block 24 O-ring
3 Drive shaft 14 Friction plate 25 O-ring
4 Roller bearing 15 Separation plate 28 Socket bolt
5 Roller bearing 16 Brake piston 29 Socket bolt
6 Oil seal 17 Brake spring 30 Socket bolt
7 Shoe plate 18 Valve plate 31 VP plug assy
8 Retainer plate 19 Plunger 36 Snap ring
9 Shoe 20 Check spring 37 Relief valve
10 Piston 21 RO plug assy 38 Brake valve
11 Thrust ball 22 Pin 39 Reactionless valve
8-53
(1) Tools
Tool name Remark

Allen wrench 17 B
5
Socket for socket wrench, spanner 19
36
Plier (for stop ring) For shaft Ф 45 mm
Plier (for lock ring) For hole Ф 100 mm
For hole Ф 45 mm
Driver (-) type, 2EA
Steel rod 10x8x200 mm, 1EA
Hammer Plastic hammer, steel hammer, each 1EA
Torque wrench (adjust range) 1.0~4.5 kgf·m (7.2~32.5 lbf·ft)
4.0~18 kgf·m (28.9~130 lbf·ft)
12~48 kgf·m (86.8~347 lbf·ft)
Slide hammer bearing plier -
Brake piston subtract jig -

Torque Wrench size
Part name Item Size
kgf·m lbf·ft mm inch
Socket bolt 30 M6 1.2±0.2 8.7±1.4 5 0.20
Socket bolt 28, 29 M14 11.3±1.1 81.7±8.0 17 0.67
Relief valve 37 M33 18±1.0 130±7.2 19 0.75
Plug 31 PF 1/4 3.7±0.2 26.8±1.4 36 1.42
8-54
3) DISASSEMBLING
※ The disassembling procedures are as following.
※ Figure in ( ) shown after part name in explanation sentence shows number in construction
figure.
(1) Bind the circumference of the motor and lift up by crane.
Clean the motor with cleaning oil and dry it with compressed air.
(2) Drain the oil from the casing (1) through the drain port.
(3) Place the drive shaft (3) with the shaft

2
side with down ward and fix it on a work
table for easy disassembling. 30
(4) Put a fitting mark on the casing (1) and

valve casing (2) and loosen the socket
bolt (30) and remove the brake valve (38)
form the swing motor.
38 1
380A8SM06
(5) Loosen the relief valve (37) and take off it

from the valve casing (2).
37
380A8SM07
(6) Remove the RO plug (42) from the valve 2

39
casing (2) and pull out the reactionless 42
valve (39).
380A8SM08
8-55
(7) Loosen the RO plug (21) from the valve
casing (2) and pull out the spring (20) and
plunger (19).
21 20 19
2
380A8SM09
(8) Loosen the socket bolt (28, 29) and take

28
off the valve casing (2).
※ The valve casing (2) is separated from the
casing (1) automatically by the brake
spring (17) force when the socket bolt (28,
29) is loosened.
2
29
380A8SM10
(9) Pull out the brake spring (17) from the 17

brake piston (16). 16
380A8SM11
(10) The brake piston (16) from the casing (1)

16
by using a jig.
※ Pull the brake piston (16) straight up
when using the bolt hole of the brake pis-
ton (16).
380A8SM12
8-56
(11) Put the motor horizontally and pull out the 3
cylinder block (13) from the drive shaft
(3). And the piston assy (9, 10), retainer
7
(8), thrust ball (11) and shoe plate (7).
※ Take care not to damage sliding face of
the cylinder block (13), thrust ball (11)
and shoe (9) when pull out the cylinder
block (13).
380A8SM13
(12) Take off the friction plate (14) and separa- 15

tion plate (15) from the casing (1). 14
380A8SM14
(13) Separate drive shaft (3) from the casing

(1).
1 3
380A8SM15
(14) Pull the shoe plate (7) from the casing (1)
by tapping lightly the cylinderical roller
bearing (4) side with a plastic hammer.
7
380A8SM16
8-57
(15) Pull the roller bearing (4) from the casing
4
(1) by tapping lightly with a steel rod.
※ Take care not to damage the bearing by
tapping the inner race of the cylinderical
roller bearing evenly with a steel rod.
※ Do not reuse the dissembled bearing.
1
380A8SM17
※ Following works perform if necessary.

(16) Disassemble the oil seal (6) from the cas- 6 1
ing (1).
※ Disassemble the oil seal (6) by tapping
bottom side of the oil seal with a steel
rod.
380A8SM18
(17) Disassemble the O-ring (23, 25) from the

casing (1). 23 25
380A8SM19
(18) Disassemble the valve (18) from the

valve casing (2). 18
380A8SM20
8-58
(19) Disassemble the roller bearing (5) from
the valve casing (2) with a plastic ham- 5
mer.
380A8SM21
(20) This is the end of disassembling proce-

dures.
※ Check every part for any abnormals.
8-59
4) ASSEMBLY
(1) For reassembling reverse the disassembling procedures, paying attention to the following items.
① Do not fail to repair the parts damaged during disassembling, and 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 8-62-2.
(2) Place the casting (1) on a suitable place. 1
380A8SM22
(3) Assemble the oil seal (6) on the casting

(1). 6 1
380A8SM23
(4) Assemble the oil seal with a jig when

assembling it and take care not to dam-
age the lip of the oil seal (6).
Oil seal Casing
380A8SM24
8-60
(5) Using a jig, assemble the roller bearing
4
(4) on the casting (1) by tapping the roller
bearing (4) lightly.
※ Take care not to damage the bearing by
tapping the inner race of the cylinderical
roller bearing evenly with a steel rod.
380A8SM25
(6) Apply some grease to the back side of

the show plate (7) and assemble it on the
swash plate of the casing (1).
7
※ Take care not to mistake front and rear
side of the shoe plate (7).
380A8SM26
(7) Assemble the drive shaft (3) into the cas-

ing (1).
1 3
380A8SM27
(8) Insert the nine cylinder block springs (12)

into the cylinder block (13). 9,10
(9) Confirm the assembling of the springs
and put the thrust ball (11) on the springs. 8
(10) Assemble the retainer (8) and piston
11
assy (9, 10) after assembling thrust ball
12
(11).
13
380A8SM28
8-61
(11) Place the motor horizontally and assem- 13,9
ble the cylinder block (13), piston assy (9, 10,8
11,7
10), retainer (8), thrust ball (11) and shoe
plate (7) into the drive shaft (3).
※ Take care not to sliding face of the thrust
ball (11) and shoe (9). 1
380A8SM29
(12) Assemble the three friction plates (14) 15

and four separation plates into the casing 14
(1).
380A8SM30
(13) Apply some grease to the O-ring (23, 25) 23 25

and assemble them on the valve casing
2
(2).
380A8SM31
(14) Assemble the brake piston (16) into cas-

16
ing (1).
※ Assemble the brake piston (16) by tap-
ping lightly with a plastic hammer when
assembling it.
380A8SM32
8-62
(15) Put the twenty four brakes springs (17) 17
on the brake piston (16). 16
※ Take care not to slip down brake springs
(17) when assembling them.
380A8SM33
(16) Insert the pin (22) into the valve casing 22

22
(1) by using a jig.
22
380A8SM34
(17) Assemble the cylinderical roller bearing

(5) into the valve casing (2) by using a 5
plastic hammer. 5
※ Tap the bearing with a hammer lightly
when assembling them.
2
2
380A8SM35
(18) Apply some grease to the back side of

the valve plate (18) and align the hole of 18
18
the pin (22) and assemble it on the valve 24
casing (2). 22 24
22
And assemble the O-ring into the hole of
the O-ring.
2
2
380A8SM36
8-63
(19) Align the bolt hole of the valve casing (2)
and casing (1) and tightening the socket 28
bolt (28, 29) as specification torques.

※ Take care not to damage the bearing
when assembling it.
2
29
380A8SM37
(20) Assemble the spring (20) and RO plug

(21) into the valve casing (2) after seat
making the plunger (19) on the valve cas-
ing (2) two or three times.
21 20 19
2
380A8SM38
(21) Assemble the reactionless valve (39) into 1

the valve casing (2) and assemble the 42 39
RO plug (42) by using L-wrench.
380A8SM39
(22) Assemble the relief valve (37) into the

valve casing (2).
37
※ Apply some grease to O-ring of the relief
valve when assembling it. 2
※ Tighten with a specified torque when
tightening.
380A8SM40
8-64
(23) Assemble the brake valve (38) on the
casing (1) with the socket bolts (30).
※ Take care not to miss the O-ring of the 30
brake valve when assembling.
38 1
380A8SM41
(24) Clean the face of the motor to the reduc-

tion gear with cleaning oil and dry it by
compressed air.
380A8SM42
(25) This is the end of assembling proce-

dures.
8-65
3. REDUCTION GEAR
1) STRUCTURE
36,35 34 33 32 31 30 3 1 4 37 5 6 7 28 39
8 15 14 9 10
11 12 13 40
42
* *
27
41
26
46 2 47 37 45 38 29 17 25 24 21 19 18 20 22 23
49 48 16
380A2SM03
1 Casing 17 Carrier 1 33 Pinion gear

2 Drive shaft 18 Planetary gear 1 34 Lock plate
3 Taper roller bearing 19 Pin 1 35 Hexagon bolt
4 Spacer ring 20 Needle cage 36 Lock washer
5 Oil seal 21 Side plate 1 37 Plug
6 Taper roller bearing 22 Side plate 2 38 Plug
7 Carrier 2 assy 23 Stop ring 39 Socket bolt
8 Carrier 2 24 Spring pin 40 Cover
9 Planetary gear 2 25 Thrust ring 41 O-ring
10 Pin 2 assy 26 Sun gear 2 42 Hexagon socket bolt
11 Pin 2 27 Sun gear 1 43 Plug
12 Bushing 2 28 Ring gear 45 Air breather assy
13 Spring pin 29 Knock pin 46 Gauge pipe
14 Thrust washer 30 Cover plate 47 Gauge bar
15 Spring pin 31 Hexagon bolt 48 Air breather post
16 Carrier 1 assy 32 Spacer 49 Air breather cap
8-66
2) DISASSEMBLY
(1) Removal of cover
※ Loosen the socket bolt (39) with 16mm
hexagonal socket and remove the cover
(40).
(2) Removal of carrier 1 assembly assembly

Remove sun gear 1 (27) and thrust ring
(25), install eye bolt to tap hole (M10) and
remove carrier 1 assembly (16) itself.
3607A8SR03
(3) Removal of carrier 2 assembly

Remove sun gear 2 (26), install eye bolt
to tap (M10) of carrier 2 (8) and remove
carrier 2 assembly (7) itself.
3607A8SR04
(4) Disassembly of carrier 2 assembly

① Insert spring pin (15) into pin 2 (11) by
hammering.
※ Do not reuse spring pin after removal.
3607A8SR05
8-67
② Remove pin 2 (11), planetary gear 2 (9)
and thrust washer (14) from carrier 2 (8)
with hands.
3607A8SR06
(5) Removal of ring gear

Remove ring gear (28) 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 (32),
and loosen hex bolt (31) with a tool and
remove cover plate (30).
3607A8SR08
② Install hydraulic press at the end face of

shaft, and remove drive shaft (2), spacer
ring (4), and taper roller bearing (3) as
assembly.
※ Do not reuse oil seal after removal.
3607A8SR09
8-68
③ Remove taper roller bearing (6) from
gear casing (1).
3607A8SR10
④ Remove oil seal (5) from gear casing (1).
3607A8SR11
(7) Disassembly of shaft assembly

Insert motor side of shaft (2) into steel
tube (inner dia : Ø145 mm) and push the
end of output shaft side with hydraulic
press and then remove taper roller beari-
ng (3), and spacer ring (4) as assembly
from drive shaft (2).
3607A8SR12
8-69
3) ASSEMBLY
(1) Assembly of drive shaft assembly
① After heat taper roller bearing (3) up to
50˚C plus surrounding temperature and
assemble it to shaft with hydraulic press
and then assemble spacer ring (4) in
this order.
※ Pay attention to the assembling direction
of cover plate (30).
3607A8SR13
(2) Installation of oil seal

Remove oil from assembled face of oil
seal of gear casing (1) and oil seal (5).
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) Install 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 150 mm) below of
gear case (1) for seal protector contact
with work table.
3607A8SR15
8-70
(4) Install of taper roller bearing
Put gear casing under output shaft and
heat taper roller bearing (6) up to 50˚C
plus surrounding temperature and then
assemble it to the shaft (2).
3607A8SR16
(5) Assembly of ring gear

① Remove oil from mating faces between
gear casing (1) and ring gear (28), and
knock pin (29). Assemble collar of gear
casing and apply fluid packing (three
bond of grey color).
3607A8SR17
② Assemble ring gear (28).
36078SR18
(6) Assembly of carrier 2 assembly

① Assemble planetary gear 2 (9) to carrier
2 (8) with thrust washer (14) and insert
pin 2 (11).
※ Lubricate gear oil to inside of gear and
outside of shaft.
3607A8SR19
8-71
② Insert spring pin (15) by hammering.
※ Insert as the clearance between spring
pins toward planetary gear 2 (9).
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
(28). Rotate carrier assembly lightly so
that splines of drive shaft (2) are
engaged.
3607A8SR21
② Insert sun gear 2 (26) to planetary gear 2

(9).
3607A8SR22
(8) Assembly of sun gear 1, carrier 1

assembly
① Mount eye bolt into tap hole (M10) of
carrier 1 (17) and lift carrier assembly
and then insert carrier assembly being
engaged with internal teeth of ring gear
(28).
Rotate holder assembly lightly so that
sun gear 2 (26) is engaged with teeth of
carrier 1 (17). 3607A8SR23
8-72
② Insert sun gear 1 (27) to planetary gear 1
(18).
3607A8SR24
(9) Check rotation of sun gear 1 (27) by turni-

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

Remove oil from mating faces between
ring gear (28) and cover (40) and apply
fluid packing.
Assemble cover (40) and tighten socket
bolt (39) with 16 mm hexagonal socket.
Tightening torque : 28.5±3.0 kgf·m
(206±21.7lbf·ft)
36078SR27
This completes assembly
8-73
GROUP 6 TRAVEL DEVICE

1) REMOVAL
(1) Swing the work equipment 90° and lower

it completely to the ground.

injury.
(4) Remove the track shoe assembly.
For details, see removal of track shoe 2
assembly.
(5) Remove the cover. 1
(6) Remove the hoses.
※ Fit blind plugs to the disconnected hoses.
(7) Remove the bolts and the sprocket.
(8) Sling travel device assembly (1). 380A8TM01
(9) Remove the mounting bolts (2), then

remove the travel device assembly.
·Weight : 380 kg (840 lb)
·Tightening torque : 57.9 ± 8.7 kgf·m
(419 ± 62.9 lbf·ft)
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.
8-74
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
451
303
131
103
111
114
472
502 503 123 272 707 702 708 546 547
3809A2TM02
101 Drive shaft 272 Shaft casing 545 Orifice

102 Roller bearing 303 Valve casing 546 Orifice
103 Needle bearing 351 Reducing valve 547 O-ring
107 Snap ring 352 Cover 702 Brake piston
111 Cylinder block 435 Snap ring 703 Orifice
113 Spherical bushing 451 Pin 704 Orifice
114 Cylinder spring 461 Plug 705 Brake spring
121 Piston 472 O-ring 707 O-ring
122 Shoe 491 Oil seal 708 O-ring
123 Set plate 502 Piston 741 Separation plate
131 Valve plate 503 Shoe 742 Friction plate
201 Swash plate 504 Pivot ball
8-75
STRUCTURE (2/2)
402 366 364 564 022 361 365 362

571
572
531
533
509
464
SECTION E-E
485
E
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 570 O-ring
365 O-ring 533 Tilting spring 571 RO plug
366 Hex socket 541 Seat 572 O-ring
401 Hex socket 542 Stopper
8-76
(1) Tools
Tool name Remark
Allen wrench 2
2.5
4
B
6
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
8-77
3. TRAVEL REDUCTION GEAR
1) STRUCTURE
1 16 19 22 13 36 55 56 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
3809A2TRG01
1 Ring gear 20 Side plate 37 Snap ring

2 Housing 21 Needle cage 44 Snap ring
4 Side cover 22 Needle cage 45 Clip
5 Carrier 1 23 Needle cage 46 W clip
6 Carrier 2 24 Inner ring 47 Nutring
9 Sun gear 1 25 Floating bushing 51 Name plate
10 Sun gear 2 26 Thrust ring 52 Rivet
11 Sun gear 3 27 Thrust ring 53 Washer
12 Planetary gear 1 29 Socket bolt 54 Set screw
13 Planetary gear 2 30 Socket bolt 55 Nutring stopper
14 Planetary gear 3 32 RO plug 56 Hex socket bolt
16 Pin 2 33 Angular bearing 81 O-ring
17 Pin 3 34 Floating seal 82 O-ring
18 Side plate 35 Shim 83 O-ring
19 Side plate 36 Spring pin
8-78
(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
8-79
4. DISASSEMBLING
1) GENERAL PRECAUTIONS
(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
8-80
(6) Remove carrier 1 (5), together with
planetary gears 1 (12), sun gear 2 (10),
etc. fitted.
370078TM03
(7) D i s a s s e m bl i n g o f c a r r i e r 1 s u b -
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
8-81
(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) D i s a s s e m bl i n g o f c a r r i e r 2 s u b -
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
8-82
(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
8-83
(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
8-84
(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
8-85
③ Remove plug (564) from valve casing
(303). And then screw two M10×135
bolts on the holes of compelling 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 fr iction plate (742) and

separation plate (741) from cylinder
block (111).
※ In this case, motor should be located in
horizontally.
370078TM27
8-86
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
8-87
⑪ Take out oil seal (491) from shaft casing
(272).
※ Do not reuse the disassembling oil seal
(491).
370078TM32
(2) Disassembling 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),

counterbalance 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
8-88
④ Remove plug (569), stopper (542), steel
ball (543) and seat (541).
※ When no abnor mality 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 i s a s s e m b l i n g o f c y l i n d e r s u b -
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
8-89
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 8-74, 8-76.
(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.
370078TM39
※ Pay attention to not fitting snap ring the
other way around.
(2) A s s e mbl i n g o f val ve c a s in g s u b -

assembly
① Tighten plugs (461, 564) into valve
casing (303) with specified torque.
·Plug(461) : 0.9 kgf·m (6.5 lbf·ft)
·Plug(564) : 2.2 kgf·m (15.9 lbf·ft)
370078TM40
② Interference-fit pin (451).
370078TM41
8-90
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 : 3.7 kgf·m (26.8 lbf·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 : 10 kgf·m (72.3 lbf·ft)
※ Confirm that O-ring (365) has been
inserted in cover.
370078TM45
8-91
⑦ Assemble tilting spool (531), tilting spring
(533) and plug (571) in the order named.
·Tightening torque : 7.5 kgf·m (54.2
lbf·ft)
370078TM46
⑧ Assemble orifice (703) and tighten them

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

piston (702). And then screw two
M10×135 bolts on the holes for
compelling 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
8-92
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) : 0.9 kgf·m (6.5 lbf·ft)
·Plug (545, 546) : 0.7 kgf·m (5.1 lbf·ft)
370078TM51
370078TM51A
② Interference-fit oil seal (491) into shaft

casing (272) by special tool.
370078TM52
8-93
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
8-94
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
8-95
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 : 44 kgf·m (318 lbf·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) : 18 kgf·m (130 lbf·ft)
- Reducing valve (351) : 4.5 kgf·m (32.5
lbf·ft)
370078TM61
8-96
370078TM61A
⑫ Mount cover (352).
370078TM63
⑬ Disassemble two M10×135 bolts on the

holes for compelling brake release.
And then assemble plug (564).
lbf·ft)
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
8-97
(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
8-98
(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 : 60 kgf·m (434 lbf·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 : 1 kgf·m (7.2 lbf·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
8-99
(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 : 30 kgf·m (217 lbf·ft)
·Loctite specifications : #636
370078TM76
8-100
(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
8-101
(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
8-102
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).
370078TM86
(18) Measure height "A" from sun gear 1 end

face to ring gear (1) mating face with
straight edge and depth gage.
370078TM87
8-103
(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 1.5~2.0 mm.
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
8-104
(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(0.3 kgf/cm2) is inserted that in water during the 2 minutes, it should be not
happened air bubble.
·Gear oil : 5.5ℓ/ 1.5 U.S. gal (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 (3 kgf/cm2) is inserted opened port in water during the 2 minutes, it should
be not happened air bubble.
·Working fluid : 1.5 liter (0.33 U.S. gal)
8-105
GROUP 7 RCV LEVER

1) REMOVAL

(4) Loosen the socket bolt (1).
(5) Remove the cover of the console box. 1
(6) Disconnect pilot line hoses (3).

2
(7) Remove the pilot valve assembly (2).
※ When removing the pilot valve assembly,
check that all the hoses have been 3
disconnected.
2) INSTALL
to removal.
330A8RL01
8-106
1) STRUCTURE
1 Case
2 Bushing
3 Spool
4 Shim
5 Spring
6 Spring seat
7 Spring
8 Plug
9 Push rod
10 O-ring
11 Rod seal
20 12 Plate
13 Spacer
14 Boot
15 Joint assembly
21
16 Swash plate
22 17 Adjusting nut
17 18 Bushing
13 19 Plug
15
20 Handle assembly
21 Handle bar
23 22 Nut
16
23 Boot
9 24 Last guard filter
14 11 25 Connector
12 26 Connector
8
27 Connector
18
28 Connector
10
27~34 27 Connector
6 29 Connector
7 30 Connector
5
31 Small guide
4
32 Connector
2 3
33 Big guide
19
34 Connector
1
24
25
26
210S2RL06
8-107
(1) Tools
Tool name Remark
Allen wrench 6 B
22
Spanne
27
(+) Driver Length 150
(-) Driver Width 4~5

Torque
Part name Item Size
kgf·m lbf·ft
Joint 15 M14 3.8 27.5
Swash plate 16 M14 7.0 50.6±2.9
Adjusting nut 17 M14 7.0 50.6±2.9
Lock nut 22 M14 5.0±0.35 36.2±2.5
8-108
3) DISASSEMBLY
※ Procedures are based on the type L11.
(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 (23) from case (1)
and take it out upwards. 300E8RL01
※ For valve with switch, remove cord also

through hole of casing.
300E8RL02
(4) Loosen lock nut (22) and adjusting nut

(17) with spanners on them respectively,
and take out handle section as one body.
300E8RL03
(5) Remove the boot (14).
1408DA61
8-109
(6) Loosen adjusting nut (17) and swash
plate (16) with spanners on them
respectively, and remove them.
36078RL01
36078RL02
(7) Turn joint anticlockwise to loosen it,

utilizing jig (Special tool).
※ When return spring (7) is strong in force,
plate (12), plug (8) and push rod (9) will
come up on loosening joint.
Pay attention to this.
36078RL03
36078RL04
8-110
(8) Remove plate (12).
36078RL05
(9) When return spring (7) is weak in force,

plug (8) 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 (7) force.
36078RL06
Pay attention to this.
(10) Remove reducing valve subassembly

and return spring (7) out of casing.
※ Record relative position of reducing valve
subassembly and return springs.
36078RL07
(11) Separate spool (3), spring seat (6), spring

(5) and shim (4) individually.
※ Pay attention not to damage spool
surface.
※ Record original position of spring seat (6).
※ Until being assembled, they should be
handled as one subassembly group.
36078RL10
8-111
(12) Take push rod (9) out of plug (8).
36078RL11
(13) Remove O-ring (10) and seal (11) from

plug (8).
Use small minus screwdriver or so on to
remove this seal.
36078RL12
36078RL13
8-112
(14) Remove lock nut (22) and then boot (23).
36078RL14
2507ARL10
8-113
(15) 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.
(16) 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.
8-114
4) ASSEMBLY
(1) Put shim (4), springs (5) and spring seat
(6) onto spool (3) in this order.
36078RL16
(2) Assemble spring (7) into casing (1).

Assemble reducing valve subassembly
into casing.
※ Assemble them to their original positions.
36078RL18
(3) Assemble O-ring (10) onto plug (8).
36078RL19
(4) Assemble seal (11) to plug (8).

※ Assemble seal in such lip direction as
shown below.
36078RL20
8-115
(5) Assemble push rod (9) to plug (8).
※ Apply working oil on push-rod surface.
36078RL21
(6) Assemble plug subassembly to casing.

※ When return spring is weak in force,
subassembly stops due to resistance of
O-ring.
36078RL22
(7) When return spring is strong in force,

assemble 4 sets at the same time,
utilizing plate (12), and tighten joint (15)
temporarily.
36078RL23
(8) Fit plate (12).
(9) Tighten joint (15) with the specified torque

to casing, utilizing jig.
36078RL24
8-116
(10) Assemble swash plate (16) to joint (15).
※ Screw it to position that it contacts with 4
push rods evenly.
※ Do not screw it over.
36078RL25
(11) Assemble adjusting nut (17), apply

spanner to width across flat of plate (16)
to fix it, and tighten adjusting nut to the
specified torque.
※ During tightening, do not change position
of disk.
36078RL26
(12) Fit boot (14) to plate.
1408DA61
8-117
(13) Fit boot (23) and lock nut (22), and handle
subassembly is assembled completely.
2507ARL10
36078RL27
(14) Pull out cord and tube through adjusting

nut hole provided in direction 60。to
120。from casing hole.
1408DA66
(15) Assemble bushing (18) to plate and pass

cord and tube through it.
※ Provide margin necessary to operation.
300E8RL04
8-118
(16) Determine handle direction, tighten lock
nut (22) to specified torque to fix handle.
300E8RL05
(17) Apply grease to rotating section of joint

and contacting faces of disk and push
rod.
300E8RL06
(18) Assemble lower end of bellows to casing.

(19) Inject volatile rust-preventives through all
ports and then put blind plugs in ports.
300E8RL07
8-119
GROUP 8 TURNING JOINT

1) REMOVAL

injury.
B
(4) Disconnect all hoses. D A
(5) Sling the turning joint assembly (1) and C
remove the mounting bolt (2). 1

Weight : 55 kg (120 lb)
Tightening torque : 12.3±1.3 kgf · m
(89±9.4 lbf · ft)
220A8TJ01
(6) Remove the turning joint assembly.

※ When removing the turning joint, check
that all the hoses have been
disconnected.
2) INSTALL
to removal.
※ Take care of turning joint direction. 1
※ Assemble hoses to their or iginal
※ positions.
Confirm the hydraulic oil level and check
2
380A8TJ02
8-120
1) STRUCTURE
14 3
15 6
10
12 4
11 5
11
9
8
21098TJ01
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
8-121
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

10
(3) Remove retainer ring (12), spacer (4) and
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 shaft Wooden block
(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 11

(9), two wear ring (11) from hub (1).
7
11
9
21078DA12
8-122
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 wear ring (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).
4
(6) Fit shim (6) to shaft (2).
5
21078DA11
8-123
(7) Install cover (3) to body (1) and tighten
14
bolts (14).
15
Torque : 10~12.5 kgf · m
(72.3~90.4 lbf · ft) 3
21078DA10
8-124
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.
※ Escaping fluid under pressure can
Fit blind plugs in the hoses after
disconnecting them, to prevent dirt or dust
from entering.
① Set block between bucket cylinder and
arm.
29078CY001
② Remove bolt (2), nut (3) and pull out pin

(1).
※ Tie the rod with wire to prevent it from
coming out.
(419 ± 62.9 lbf·ft)
300A8DA02
③ Disconnect bucket cylinder hoses (4),

grease line hose (7) and put plugs (5) on
cylinder pipe.
300A8DA03
8-125
④ Sling bucket cylinder assembly (8) and
remove bolt (6) then pull out pin (5).
⑤ Remove bucket cylinder assembly (8).
(419 ± 62.9 lbf·ft)
300A8DA04
(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
8-126
2) ARM CYLINDER
(1) Removal
stop the engine.
Loosen the breather slowly to release 13031GE18

disconnecting them, to prevent dirt or Arm cylinder
dust from entering.
① Set block between arm cylinder and
boom.
Block
380A8CY01
② Disconnect grease line hose (9).

③ Remove bolt (2) and pull out pin (1).
coming out.
(419 ± 62.9 lbf·ft)
300A8CY02
④ Disconnect arm cylinder hoses (4) and

put plugs on cylinder pipe.
⑤ Disconnect greasing pipings (5). Plug
380A8CY03
8-127
⑥ Sling arm assembly (8) and remove bolt
(7) then pull out pin (6).
⑦ Remove arm cylinder assembly (8). 8
(419 ± 62.9 lbf·ft)
6
7
380A8CY04
(2) Install
to removal.
the pin hole.
※ Bleed the air from the arm cylinder.
※ Confirm the hydraulic oil level and check
8-128
3) BOOM CYLINDER
(1) Removal
stop the engine.
Loosen the breather slowly to release 13031GE18
disconnecting them, to prevent dirt or dust
from entering.
1
① Disconnect greasing hoses (1).
② Sling boom cylinder assembly.
380A8CY05
③ Remove bolt (4), pin stopper (5) and pull 4

out pin (2). 2
※ Tie the rod with wire to prevent it from 5
coming out.
·Tightening torque : 100 ± 15 kgf·m
(723 ± 109 lbf·ft) 4
380A8CY06
④ Lower the boom cylinder assembly (6)

on a stand.
380A8CY07
8-129
⑤ Disconnect boom cylinder hoses (7) and
put plugs on cylinder pipe.
380A8CY08
⑥ Remove bolt (9) and pull out pin (8).

⑦ Remove boom cylinder assembly (6).
(419 ± 62.9 lbf·ft)
6
8
9
380A8CY09
(2) Install
to removal.
the pin hole.
※ Bleed the air from the boom cylinder.
※ Conformed the hydraulic oil level and
check the hydraulic oil leak or not.
8-130
1) STRUCTURE
(1) Bucket cylinder (CHANGZHOU)
24,26 25,26
31QA-60112CGG
1 Tube assembly 12 Back up ring 23 Hexagon socket head bolt

2 Rod assembly 13 Cushion ring 24 Dimple bushing
3 Gland 14 Piston 25 Dimple bushing
4 DD2 bushing 15 Piston seal 26 Dust seal
5 Snap ring 16 Wear ring 27 Band assembly
6 Rod seal 17 Dust ring 28 Pipe assembly-R
7 Back up ring 18 O-ring 29 Pipe assembly-B
8 Buffer ring 19 Back up ring 30 O-ring
9 Dust wiper 20 Lock nut 31 Hexagon socket head bolt
10 Snap ring 21 Set screw
11 O-ring 22 O-ring
8-131
Bucket cylinder (SHPAC)
4,5 9 10 27 26 13 14 15 18 17 16 19,20 21 22
29,30 25 28 24,26,27 29,30
31QA-60112EGG
1 Tube assembly 11 O-ring 21 Lock nut

2 Rod assembly 12 Back up ring 22 Hexagon socket set screw
3 Gland 13 O-ring 23 Hexagon socket head bolt
4 Dust wiper 14 Cushion ring 24 Pipe assembly-B
5 Retaining ring 15 Piston 25 Pipe assembly-R
6 Rod seal 16 Piston seal 26 O-ring
7 Back up ring 17 Wear ring 27 Hexagon socket head bolt
8 Buffer ring 18 Dust ring 28 Band assembly
9 Dry bearing 19 O-ring 29 Dimple bushing
10 Retaining ring 20 Back up ring 30 Dust seal

8-132
Bucket cylinder (DY POWER)
11,12 9,10 8 6 26 7 39,10 36 5 15 13,14 1 3 16 17 21,22 20 19 18 17 24,25
35
33,34
4,45 37,38 41,42,43 31,32 2,44
31KA-60140
1 Tube assembly 15 O-ring 29 Spring washer

2 Pin bushing 16 Cushion ring 30 Hexagon bolt
3 Rod assembly 17 Piston 31 Pipe assembly-RD
4 Dimple bushing 18 Piston seal 32 O-ring
5 Rod cover 19 Wear ring 33 Spring washer
6 Rod bushing 20 Dust ring 34 Hexagon socket head bolt
7 Retaining ring 21 O-ring 35 Spacer
8 Buffer ring 22 Back up ring 37 Pipe assembly-BS
9 U-packing 23 Piston nut 41 Clamp
10 Back up ring 24 Steel ball 42 Spring washer
11 Wiper ring 25 Screw 43 Hexagon bolt
12 Retaining ring 26 Hexagon socket head bolt 44 Pin wiper
13 O-ring 27 Band assembly 45 Pin wiper
14 Back up ring 28 Band clamp
8-133
(2) Arm cylinder (CHANGZHOU)
24,26 25,26
31QA-60112CGG
1 Tube assembly 14 Piston 27 Coil spring

2 Rod assembly 15 Piston seal 28 O-ring
3 Gland 16 Wear ring 29 Plug
4 DD2 bushing 17 Dust ring 30 Band assembly (R)
5 Snap ring 18 O-ring 31 Band assembly (B)
6 Rod seal 19 Back up ring 32 Pipe assembly (R)
7 Back up ring 20 Lock nut 33 Pipe assembly (B)
8 Buffer ring 21 Set screw 34 O-ring
9 Dust wiper 22 O-ring 35 O-ring
10 Snap ring 23 Hexagon socket head bolt 36 Hexagon socket head bolt
11 O-ring 24 Dimple bushing 37 Hexagon socket head bolt
12 Back up ring 25 Dust seal
13 Cushion ring 26 Check valve
8-134
Arm cylinder (SHPAC)
4,5 6,7 8 9 28 10 31 30 3 13 11,12 1 2 14 15 18 17 16 19,20 21 22
Internal detail
25,26,27
37,38 29 33 32 37,38
31QA-50130EGG
1 Tube assembly 14 Cushion ring 27 Hexagon plug

2 Rod assembly 15 Piston 28 Hexagon socket head bolt
3 Gland 16 Piston seal 29 Pipe assembly-R
4 Dust wiper 17 Wear ring 30 O-ring
5 Retaining ring 18 Dust ring 31 Hexagon socket head bolt
6 Rod seal 19 O-ring 32 Band assembly-B
7 Back up ring 20 Back up ring 33 Band assembly-R
8 Buffer ring 21 Lock nut 34 U-bolt
9 Dry bearing 22 Hexagon socket set screw 35 Hexagon nut
10 Retaining ring 23 Cushion plunger 36 Spring washer
11 O-ring 24 Stop ring 37 Dimple bushing
12 Back up ring 25 Check valve 38 Dust seal
13 O-ring 26 Coil spring
8-135
(3) Boom cylinder (CHANGZHOU)
9,10 6,7 8 4,5 23 32 31 22 11,12 3 1 2 13 14 17 16 15 18,19 20 21
Internal detail
24,26 29 28 30 25,27
31QA-50111CGG
1 Tube assembly 12 Back up ring 23 Hexagon socket head bolt

2 Rod assembly 13 Cushion ring 24 Dimple bushing (R)
3 Gland 14 Piston 25 Dimple bushing (B)
4 DD2 bushing 15 Piston seal 26 Dust seal
5 Snap ring 16 Wear ring 27 Dust seal
6 Rod seal 17 Dust ring 28 Band assembly
7 Back up ring 18 O-ring 29 Pipe assembly (R)
8 Buffer ring 19 Back up ring 30 Pipe assembly (B)
9 Dust wiper 20 Lock nut 31 O-ring
10 Snap ring 21 Set screw 32 Hexagon socket head bolt
11 O-ring 22 O-ring
8-136
Boom cylinder (SHPAC)
4,5 6,7 8 9,10 23 27 26 13 11,12 3 1 2 14 15 18 17 16 19,20 21 22
29,30,31
33,35 25 28 24,26,27 32,34
31QA-50111EGG
1 Tube assembly 13 O-ring 25 Pipe assembly-R

2 Rod assembly 14 Cushion ring 26 O-ring
3 Gland 15 Piston 27 Hexagon socket head bolt
4 Dust wiper 16 Piston seal 28 Band assembly
5 Retaining ring 17 Wear ring 29 U-bolt
6 Rod seal 18 Dust ring 30 Hexagon nut
7 Back up ring 19 O-ring 31 Spring washer
8 Buffer ring 20 Back up ring 32 Dimple bushing
9 Dry bearing 22 Lock nut 33 Dimple bushing
10 Retaining ring 22 Hexagon socket set screw 34 Dust seal
11 O-ring 23 Hexagon socket head bolt 35 Dust seal
12 Back up ring 24 Pipe assembly-B
8-137
(1) Tools
Tools Remark
6
8 B
Allen wrench
10
12
14
17
7
Spanner
8
(-) Driver Small and large sizes

Torque
Part name Item Size
kgf·m lbf·ft
★1★3
23 M20 46.0±5.0 333±36.2
23★1★4 M20 52.2±5.2 378±37.6
26★2★5 M18 41.0±3.0 297±21.7
Bucket cylinder
31★3 M12 9.4±1.0 68.0±7.2
27★4 M12 11.3±1.1 81.7±8.0
40★5 M14 14.5±0.5 105±3.6
23★1★3 M22 63.0±6.0 456±45.6
Socket head bolt 23★1★4 M22 69.4±6.9 502±49.9
Boom cylinder
32★3 M12 9.4±1.0 68.0±7.2
27★4 M12 11.3±1.1 81.7±8.0
23★1★3 M22 63.0±6.0 456±43.4
28★1★4 M22 69.4±6.9 502±49.9
Arm cylinder
36★3 M12 9.4±1.0 68.0±7.2
31★4 M12 11.3±1.1 81.7±8.0
★1 : Apply loctite #243 on the thread of bolt.
★3 : CHANGZHOU
★4 : SHPAC
★5 : DY POWER
8-138
Torque
Part name Item Size
kgf·m lbf·ft
★3
20 - 100±10.0 723±72.3
Bucket cylinder 21★4 M82 100±10.0 723±72.3
23★5 M85 190±19.0 1374±137
Lock nut 20★3 - 150±15.0 1085±108
Boom cylinder
21★4 M80 150±15.0 1085±108
20★3 - 200±20.0 1447±145
Arm cylinder
21★4 M90 200±20.0 1447±145
14★3 - 150±15.0 1085±108
Bucket cylinder 15★4 M95 150±15.0 1085±108
17★5 M85 100±10.0 723±72.3
Piston 14★3 - 200±20.0 1447±145
Boom cylinder
15★4 M100 200±20.0 1447±145
14★3 - 200±20.0 1447±145
Arm cylinder
15★4 M110 200±20.0 1447±145
21★3 M10 5.4±0.5 39.1±3.6
Bucket cylinder 22★4 M10 2.5±0.3 18.1±2.2
25★5 M110 6.5 47.0
Set screw 21★3 M10 5.4±0.5 39.1±3.6
Boom cylinder
22★4 M10 2.5±0.3 18.1±2.2
21★3 M10 5.4±0.5 39.1±3.6
Arm cylinder
22★4 M10 2.5±0.3 18.1±2.
★3 : CHANGZHOU
★4 : SHPAC
★5 : DY POWER
8-139
3) DISASSEMBLY
(1) Remove cylinder head and piston rod
※ Procedures are based on the bucket
cylinder (CHANGZHOU type).
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 200

mm (7.1 in). Because the rod assembly
is rather heavy, finish extending it with air
pressure after the oil draining operation.
m
0m
20
21078DA30
③ Loosen and remove socket bolts (23) of

Hexagon
the gland in sequence. socket wrench 23
※ Cover the extracted rod assembly (2)
with rag to prevent it from being
Turn counter
accidentally damaged during operation.
clockwise
Cover here
with rag
2
300L8DA01
④ Draw out cylinder head and rod assembly

together from tube assembly (1). Lift
※ Since the rod assembly is heavy in this
case, lift the tip of the rod assembly (2)
with a crane or some means and draw it Full straight
sideways
out. However, when rod assembly (2)
has been drawn out to approximately
two thirds of its length, lift it in its center
Oil pan
to draw it completely.
21078DA32
8-140
Note that the plated surface of rod
assembly (2) is to be lifted. For this
reason, do not use a wire sling and
others that may damage it, but use a
strong cloth belt or a rope.
⑤ Place the removed rod assembly on a

wooden V-block that is set level. Piston assy
※ Cover a V-block with soft rag.
Wooden block
21078DA33
(2) Remove piston and cylinder head 13 14 18 19 20 21

① Remove set screw (21).
※ Since set screw (21) and lock nut (20) is
tightened to a high torque, use a
hydraulic and power wrench that utilizers
a hydraulic cylinder, to remove the set
screw (21) lock nut (20).
② Remove piston assembly (14), back up
ring (19), and O-ring (18).
2907A8CY02
③ Remove the cylinder head assembly

Plastic
from rod assembly (2). hammer
※ If it is too heavy to move, move it by
Lift with a crane
striking the flanged part of cylinder head
with a plastic hammer.
Pull straight
※ Pull it straight with cylinder head
assembly lifted with a crane.
Exercise care so as not to damage the
lip of rod bushing (4) and packing
21078DA35
(5,6,7,8,9,10) by the threads of rod
assembly (2).
8-141
(3) Disassemble the piston assembly 17 16 15 16 17
① Remove wear ring (16).
② Remove dust ring (17) and piston seal
(15).
※ Exercise care in this operation not to
damage the grooves.
2907A8CY03
(4) Disassemble cylinder head assembly

① Remove back up ring (12) and O-ring 10 9 6 7 8 4 5 22 12 11
(11) and O-ring (22).
② Remove snap ring (10), dust wiper (9).
③ Remove back up ring (7), rod seal (6)
and buffer ring (8).
※ Exercise care in this operation not to
damage the grooves.
※ Do not remove seal and ring, if does not
380A8DA36
damaged.
8-142
3) ASSEMBLY
(1) Assemble cylinder head assembly
※ Check for scratches or rough surfaces if
found smooth with an oil stone.
① Coat the inner face of gland (3) with
hydraulic oil.
21078DA37
② Coat dust wiper (9) with grease and fit Press here
dust wiper (9) to the bottom of the hole of (Straight down)
dust seal. Metal
At this time, press a pad metal to the 9
metal ring of dust seal.
③ Fit snap ring (10) to the stop face.
8-157(2)
④ Fit back up ring (7), rod seal (6) and

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

Push bar
Therefore, confirm it before fitting them.
※ Fitting rod seal (6) upside down may
damage its lip. Therefore check the
correct direction that is shown in fig.
21078DA38
8-143
⑤ Fit back up ring (12) to gland (3).
※ Put the backup ring in the warm water of 11
30~50˚C . 12
⑥ Fit O-ring (11) and O-ring (22) to gland 22
(3).
380A8DA39
(2) Assemble piston assembly

※ Check for scratches or rough surfaces.
If found smooth with an oil stone.
① Coat the outer face of piston (14) with
hydraulic oil.
8-158(2)
② Fit piston seal (15) to piston.

※ Put the piston seal in the warm water of 15
60~100˚C for more than 5 minutes.
※ After assembling the piston seal, press
its outer diameter to fit in.
2907A8CY04
③ Fit wear ring (16) and dust ring (17) to 17 16 15 16 17

piston (14).
14
2907A8CY05
8-144
(3) Install piston and cylinder head
① Fix the rod assembly to the work bench. Cylinder head assembly
② Apply hydraulic oil to the outer surface of Rod assembly
rod assembly (2), the inner surface of
piston and cylinder head.
③ Insert cylinder head assembly to rod
assembly.
21078DA40
④ Insert cushion ring (13) to rod assembly.

※ Note that cushion ring (13) has a 13
direction in which it should be fitted.
Insert
8-159(2)
⑤ Fit piston assembly to rod assembly. Piston assembly

·Tightening torque : 150±15.0 kgf·m
(1085±108 lbf·ft)
50078CY09
⑥ Fit lock nut (20) and tighten the screw 20 21

(21).
·Tightening torque :
Item 20 : 100±10.0 kgf·m (723±72.3 lbf·ft)
Item 21 : 5.4±0.5 kgf·m (39.1±3.6 lbf·ft)
50078CY10
8-145
(3) Overall assemble Fix with a bar
① Place a V-block on a rigid work bench.
Mount the tube assembly (1) on it and Lift
fix the assembly by passing a bar
through the clevis pin hole to lock the
assembly. Straight
② Insert the rod assembly in to the tube
assembly, while lifting and moving the
rod assembly with a crane. Appply liquid packing
21078DA41
※ Be careful not to damage piston seal by
thread of tube assembly.
③ Match the bolt holes in the cylinder head
flange to the tapped holes in the tube Turn clockwise
assembly and tighten socket bolts to a Apply loctite
specified torque.
※ Refer to the table of tightening torque.
Place rag
21078DA42
8-146
GROUP 10 UNDERCARRIAGE
1. TRACK LINK
1) REMOVAL
(1) Move track link until master pin is over
front idler in the position put wooden block
Master pin
as shown.
(2) Loosen tension of the track link.
※ If track tension is not relieved when the
grease valve is loosened, move the
machine backwards and forwards.
※ Unscrew the grease nipple after release
the tension by pushing the poppet only
when necessarily required.
Grease leaking hole is not existing. So,
Block
while unscrew the grease nipple, grease
is not leaking until the grease nipple is
completely coming out. If the tension is
not released in advance, the grease
nipple can be suddenly popped out by
pressurized grease.
(3) Push out master pin by using a suitable
300S8UC01
tool.
(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
8-161(2)
2) INSTALL
to removal.
Adjust the tension of the track link.
90 ~ 110
380A4OP09
8-147
2. UPPER ROLLER Frame
1) REMOVAL
Grease
(1) Loosen tension of the track link. valve
8-162(1)
(2) Jack up the track link height enough to

permit upper roller removal.
Jack Upper roller
220SA8UC02
(3) Loosen the lock nut (1). 1 Upper roller

(4) Open bracket (2) with a screwdriver, push
2
out from inside, and remove upper roller
assembly.
·Weight
General : 80 kg (176 lb)
·Tightening torque : 29.7±4.5 kgf·m
(215±32.5 lbf·ft)
220SA8UC03
2) INSTALL
to removal.
8-148
3. LOWER ROLLER Frame
1) REMOVAL
(1) Loosen tension of the track link. Grease
valve
8-163(1)
(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
380A4OP09
(3) Remove the mounting bolt (1) and draw

out the lower roller (2). 1 2
·Weight : 75.3 kg (166 lb)
(419±43.4 lbf·ft)
8-163(3)
2) INSTALL
(1) Carry out installation in the reverse order to
removal.
8-149
4. IDLER AND RECOIL SPRING
1) REMOVAL
(1) Remove the track link.
For detail, see removal of track link.
380A8UC10
(2) Sling the recoil spring (1) and pull out idler
and recoil spring assembly from track
frame, using a pry. 1
·Weight : 977 kg (2514 lb)
380A8UC11
(3) Remove the bolts (2), washers (3) and

separate idler from recoil spring.
(226±34.0 lbf·ft)
2
3
380A8UC12
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.
380A8UC13
8-150
3) DISASSEMBLY AND ASSEMBLY OF IDLER
(1) Structure
5
8
2
1
4 6
3
380A8UC20
1 Shell 4 O-ring 7 Spring pin

2 Bushing 5 Seal assembly 8 Plug
3 Shaft 6 Bracket
8-151
(2) Disassembly
① Remove plug and drain oil.
② Draw out the spring pin (7), using a
press.
7 380A8UC21
③ Pull out the shaft (2) with a press.

Press
④ Remove seal (5) from shell (1) and
bracket (6).
⑤ Remove O-ring (4) from shaft.
3
8-166(2)
⑥ Remove the bushing (2) from idler, using

a special tool.
※ Only remove bushing if replacement is
necessity.
2
8-166(3)
8-152
(3) Assembly
※ Before assembly, clean the parts.
※ Coat the sliding surfaces of all parts with 1 2 Press
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.
8-167(1)
② Coat O-ring (4) with grease thinly, and

install it to shaft (3).
③ Insert shaft (3) into bracket (6) and drive
4
in the spring pin (7).
3
300S8UC22
④ Install seal (5) to shell (1) and bracket

(6). 5
8-167(3)
⑤ Install shaft (3) to shell (1).

3 1
8-167(4)
8-153
⑥ Install bracket (6) attached with seal (5).
380A8UC23
⑦ Knock in the spring pin (7) with a

hammer. 6
7
1
380A8UC24
⑧ Lay bracket (6) on its side.

6
Supply engine oil to the specified level,
and tighten plug.
8-168(3)
8-154
4) DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING
(1) Structure
4 7 8 6 5 3 2 14 16 15 1 9 10 11 12
13
81QA-14015
1 Body 7 Bolt 13 Grease valve

2 Tie bar 8 Spring washer 14 Stopper tube
3 Spring 9 Rod packing 15 Spacer
4 Bracket 10 Back up ring 16 Spring pin
5 Lock nut 11 Dust seal
6 Lock plate 12 Adjust rod
8-155
(2) Disassembly
※ The illustrations are base on the type 1.
① Apply pressure on spring (3) with a 4
press. 7,8
※ The spring is under a large installed 6
load. This is dangerous, so be sure to
5
set properly.
3
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. 15
④ Lighten the press load slowly and
remove bracket (4), spring (3) and
spacer (15). 380A8UC31
⑤ Remove rod (12) from body (1).

⑥ Remove grease valve (13) from rod (12). 1 12
13
380A8UC32
⑦ Remove rod seal (9), back up ring (10)

and dust seal (11).
1 9 10 11
380A8UC33
8-156
(3) Assembly
① Install dust seal (11), back up ring (10) 1 12
and rod seal (9) to body (1).
※ When installing dust seal (11) and rod
seal (9), take full care so as not to
damage the lip.
13
380A8UC32
② Pour grease into body (1), then push in

rod (12) by hand. 1 12
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 : 13.0±1.0 kgf·m 13
(94±7.2 lbf·ft)
380A8UC34
④ Install spacer (15), spring (3) and bracket

(4) to body (1). Press
⑤ Apply pressure to spring (3) with a press
and tighten lock nut (5). 4
· Spring set load
24500 kg (54010 lb)
※ Apply sealant before assembling.
※ During the operation, pay attention 3
specially to prevent the press from
slipping out.
15
380A8UC35
8-157
⑥ Lighten the press load and confirm the
set length of spring (3). Press
·Set length : 610±1.5 mm
⑦ After the setting of spring (3), install lock
plate (6), spring washer (8) and bolt (7). 7,8
·Tightening torque : 13.3±2.7 kgf·m 6
(96.2±19.5 lbf·ft) 5
3
Set length
380A8UC36
8-158
GROUP 11 WORK EQUIPMENT
1. STRUCTURE
A
A
SECTION A SECTION B SECTION C
380A8WE01
8-159
1) BUCKET ASSEMBLY
(1) Removal
① Lower the work equipment completely to
ground with back of bucket facing down. A
B
8-174(1)
② Remove nut (1), bolt (2) and draw out

the pin (A). 2
·Tightening torque : 57.9±8.7 kgf·m A
1
(419±62.9 lbf·ft)
300L8WE01
③ Remove nut (3), bolt (4) and draw out 4

the pin (B).
3 B
(419±62.9 lbf·ft)
300L8WE02
(2) Install
to removal.
the pin hole.
※ Adjust the bucket clearance.
For detail, see operation manual.
300A8WE03
8-160
2) ARM ASSEMBLY
(1) Removal
※ Loosen the breather slowly to release
penetrated the skin causing serious
injury.
① Remove bucket assembly.
For details, see removal of bucket 8-175(1)
assembly.
② Disconnect bucket cylinder hose (1).
Fit blind plugs in the piping at the
chassis end securely to prevent oil
from spurting out when the engine is
started.
③ Sling arm cylinder assembly, remove
spring, pin stopper and pull out pin.
coming out.
④ For details, see removal of arm cylinder
300A8DA02
assembly.
Place a wooden block under the cylinder
and bring the cylinder down to it.
⑤ Remove bolt (2), plate (3) and pull out
the pin (4) then remove the arm
assembly. Crane
·Weight : 1450 kg (3197 lb)
·Tightening torque (2) : 57.9±8.7 kgf·m
(419±62.9 lbf·ft) 2, 3, 4
※ When lifting the arm assembly, always
lift the center of gravity.
8-175(3)
(2) Install
① Carry out installation in the reverse
order to removal.
When lifting the arm assembly, always
※ Bleed the air from the cylinder.
8-161
3) BOOM CYLINDER
(1) Removal
① Remove arm and bucket assembly.
For details, see removal of arm and
bucket assembly.
② Remove boom cylinder assembly from
boom.
For details, see removal of arm cylinder
assembly. 8-176(1)
③ Disconnect head lamp wiring.

④ Disconnect bucket cylinder hose (2)
and arm cylinder hose (1).
※ When the hose are disconnected, oil 2 1
may spurt out.
1 2
⑤ Sling boom assembly (3).
380A8DA45
⑥ Remove bolt (4), plate (5) and pull out

Crane
the pin (6) then remove boom assembly.
·Weight : 3150 kg (6944 lb)
※ When lifting the boom assembly always
(419±43.4 lbf·ft) 4, 5, 6
3
8-176(3)
(2) Install 4
① Carry out installation in the reverse order 5
6
to removal.
When lifting the arm assembly, always
※ Bleed the air from the cylinder.
380A8DA46
8-162

Hyundai HX380AL

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Hyundai HX380AL

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CONTENTS

Group 1 Safety Hints ------------------------------------------------------------------------------------------------------ 1-1

SECTION 2 STRUCTURE AND FUNCTION

Group 1 Pump Device ---------------------------------------------------------------------------------------------------- 2-1

SECTION 3 HYDRAULIC SYSTEM

Group 1 Hydraulic Circuit ----------------------------------------------------------------------------------------------- 3-1

SECTION 4 ELECTRICAL SYSTEM

Group 1 Component Location --------------------------------------------------------------------------------------- 4-1

SECTION 5 MECHATRONICS SYSTEM

Group 1 Outline --------------------------------------------------------------------------------------------------------------- 5-1

Group 1 Before Troubleshooting ------------------------------------------------------------------------------------ 6-1

SECTION 7 MAINTENANCE STANDARD

Group 1 Operational Performance Test ------------------------------------------------------------------------ 7-1

SECTION 8 DISASSEMBLY AND ASSEMBLY

Group 1 Precaution --------------------------------------------------------------------------------------------------------- 8-1

2. Convert 550 mm into inches.

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 1 kg = 2.2046 lb

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

-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

Be careful of slippery conditions on platforms,

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

heat goes beyond the immediate flame area.

PREVENT BATTERY EXPLOSIONS

USE TOOLS PROPERLY

Use only recommended replacement parts.

REPLACE SAFETY SIGNS

LIVE WITH SAFETY

Arm Arm cylinder Boom Boom cylinder Cab Handrail Counterweight

Bucket cylinder Connecting link Idler Carrier roller Sprocket

Side cutter Connecting rod Track roller Track Travel motor

1) HX380A L, MONO BOOM (1/2)

Boom 6.15 (20' 2") 6.50 (21' 4")

Lower chassis assembly 14,450 31,856 14,240 31,394

Front attachment assembly 8,450 18,629 8,450 18,629

7.5 m kg 7790 7790 7050 7050 7.80

9.0 m kg 5580 5580 7.43

7.5 m kg 7790 7790 7050 7050 7.80

7.5 m kg 7790 7100 7050 6610 7.80

9.0 m kg 5580 5580 7.43