Lep 87637609NA - S.S. CX210B & CX240B (ENG) PDF

REPAIR MANUAL REPAIR MANUAL
SCHEMATIC SET SCHEMATIC SET

CRAWLER EXCAVATOR CRAWLER EXCAVATOR
CX210B CX210B
CX240B CX240B
87637609 NA 87637609 NA
1. Trim along dashed line. 1. Trim along dashed line.
2. Slide into pocket on Binder Spine. 2. Slide into pocket on Binder Spine.
TYPE 1-4 TYPE 1-4
REPAIR MANUAL REPAIR MANUAL

SCHEMATIC SET SCHEMATIC SET
CRAWLER EXCAVATOR CRAWLER EXCAVATOR
CX210B CX210B
CX240B CX240B
87637609 NA 87637609 NA
1. Trim along dashed line. 1. Trim along dashed line.
2. Slide into pocket on Binder Spine. 2. Slide into pocket on Binder Spine.
TYPE 1-4 TYPE 1-4
REPAIR MANUAL
SCHEMATIC SET
CRAWLER EXCAVATOR
CX210B
CX240B
87637609 NA
CNH AMERICA LLC North American English

700 STATE STREET Part Number 87637609 NA
RACINE, WI 53404 U.S.A. Printed in U.S.A. • Bur
Issued 03-2007
CRAWLER EXCAVATOR
CX210B-CX240B
SCHEMATIC SET
LEP 87637609B
TABLE OF CONTENTS
SECTION SECTION No. REFERENCE No.
Safety, General Information and Standard Torque Data .............................................. 1001 7-27691NA
General Specifications and Special Torque Settings ................................................... 1002 SC210B1002-0NA
Elecrical and Engine Functions & Service Support ..................................................... 4001 SC210B4001-1NA
Elecrical Equipment and Electrical Circuit Diagrams ................................................... 4020 SC210B4020-0NA
Specifications, Troubleshooting, Checks and Hydraulic Pressure Settings ................. 8001 SC210B8001-1NA
Hydraulic Functions...................................................................................................... 8020 SC210B8020-0NA
Hydraulic Component Functions .................................................................................. 8030 SC210B8030-0NA
Air Conditioner Functions and Troubleshooting ........................................................... 9006 SC210B9006-0NA
Large Size Hydraulic Schematics CX210B ............................................................... Pocket 87598354A
Large Size Hydraulic Schematics CX240B ............................................................... Pocket 87600992A
Large Size Electrical Schematics.............................................................................. Pocket 87598360A
NOTE: CNH Company reserves the right to make changes in the specification and design of the machine without prior notice
and without incurring any obligation to modify units previously sold.
The description of the models shown in this manual has been made in accordance with the technical specifications known as of
the date of design of this document.
Copyright © 2007 CNH America LLC.

CNH AMERICA LLC. All rights reserved.
700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Lep SC210BTOC-1NA Issued March, 2007
Lep SC210BTOC-1NA Issued 03-07
1001
Section
1001
SAFETY, GENERAL INFORMATION

AND TORQUE SPECIFICATIONS

All rights reverved.
Printed in U.S.A.
CNH Lep 7-27691NA Issued February, 2006
1001-2
TABLE OF CONTENTS
GENERAL INFORMATION ....................................................................................................................................... 3
SAFETY..................................................................................................................................................................... 4
STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS............................................................................... 6
WARNING : This symbol is used in this manual to indicate important safety messages. Whenever you see
! this symbol, carefully read the message that follows, as there is a risk of serious injury.
Lep 7-27691NA Issued 02-06

1001-3
GENERAL INFORMATION
Cleanning Gears
Clean all metal parts except bearings, in a suitable Check all gears for wear and damage. Replace gears
cleaning solvent or by steam cleaning. Do not use that have wear or damage.
caustic soda for steam cleaning. After cleaning, dry
and put oil on all parts. Clean oil passages with Oil seals, O-rings and gaskets
compressed air. Clean bearings in a suitable cleaning
Always install new oil seals, O-rings and gaskets. Put
solvent, dry the bearings completely and put oil on
petroleum jelly on seals and O-rings.
the bearings.
Inspection Shafts
Check all shafts that have wear or damage. Check
Check all parts when the parts are disassembled.
the bearing and oil seal surfaces of the shafts for
Replace all parts that have wear or damage. Small
damage.
scoring or grooves can be removed with a hone or
crocus cloth. Complete a visual inspection for Service parts
indications of wear, pitting and the replacement of
parts necessary to prevent early failures. Always install genuine Case service parts. When
ordering refer to the Parts Catalog for the correct part
Bearings number of the genuine Case replacement items.
Failures due to the use of other than genuine Case
Check bearings for easy action. If bearings have a
replacement parts are not covered by warranty.
loose fit or rough action replace the bearing. Wash
bearings with a suitable cleaning solvent and permit Lubrication
to air dry. DO NOT DRY BEARINGS WITH
COMPRESSED AIR. Only use the oils and lubricants specified in the
Operator’s or Service Manuals. Failures due to the
Needle bearings use of non-specified oils and lubricants are not
covered by warranty.
Before you press needle bearings in a bore always
remove any metal protrusions in the bore or edge of
the bore. Before you press bearings into position put
petroleum jelly on the inside and outside diameter of
the bearings.

1001-4
SAFETY
This symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED. The message that follows the
! symbol contains important information about safety. Carefully
read the message. Make sure you fully understand the
causes of possible injury or death.
To prevent injury always follow the Warning, Caution

and Danger notes in this section and throughout the
manual. WARNING: Before starting engine, study
Operator’s Manual safety messages. Read
Put the warning tag shown below on the key for the all safety signs on machine. Clear the area of
keyswitch when servicing or repairing the machine. other persons. Learn and practice safe use
One warning tag is supplied with each machine. of controls before operating.
Additional tags Part Number 331-4614 are available
from your service parts supplier
! It is your responsibility to understand and
f o l l o w m a n u f a c tu r e r s i n s tr u c t i o n s o n
. machine operation, service and to observe
pertinent laws and regulations. Operator’s
WARNING: Read the operator’s manual to and Service Manuals may be obtained from
your Case dealer.
! familiarize yourself with the correct control
functions.
WARNING: If you wear clothing that is too

WARNING: Operate the machine and loose or do not use the correct safety
equipment controls from the seat position equipment for your job, you can be injured.
! only. Any other method could result in Always wear clothing that will not catch on
serious injury. ! objects. Extra safety equipment that can be
required includes hard hat, safety shoes, ear
protection, eye or face protection, heavy
WARNING: This is a one man machine, no gloves and reflector clothing.
! riders allowed.
WARNING: When working in the area of the

! fan belt with the engine running, avoid loose
clothing if possible, and use extreme caution.
WARNING: When doing checks and tests

on the equipment hydraulics, follow the
! procedures as they are written. DO NOT
change the procedure.
WARNING: When putting the hydraulic

cylinders on this machine through the
! necessary cycles to check operation or to
remove air from a circuit, make sure all
people are out of the way.

1001-5
WARNING: Use insulated gloves or mittens WARNING: When servicing or repairing the
! when working with hot parts. machine, keep the shop floor and operator’s
compartment and steps free of oil, water,
! grease, tools, etc. Use an oil absorbing
WARNING: Lower all attachments to the material and/or shop cloths as required. Use
ground or use stands to safely support the safe practices at all times.
! attachments before you do any maintenance
or service.
WARNING: Some components of this
machine are very heavy. Use suitable lifting
WARNING: Pin sized and smaller streams ! equipment or additional help as instructed in
of hydraulic oil under pressure can penetrate this Service Manual.
the skin and result in serious infection. If
hydraulic oil under pressure does penetrate
the skin, seek medical treatment
WARNING: Engine exhaust fumes can
immediately. Maintain all hoses and tubes in
! good condition. Make sure all connections
cause death. If it is necessary to start the
engine in a closed place, remove the exhaust
are tight. Make a replacement of any tube or
hose that is damaged or thought to be
! fumes from the area with an exhaust pipe
extension. Open the doors and get outside
damaged. DO NOT use your hand to check
air into the area.
for leaks, use a piece of cardboard or wood.
WARNING: When the battery electrolyte is

WARNING: When removing hardened pins frozen, the battery can explode if (1), you try
such as a pivot pin, or a hardened shaft, use to charge the battery, or (2), you try to jump
start and run the engine. To prevent the
! a soft head (brass or bronze) hammer or use
a driver made from brass or bronze and a
! battery electrolyte from freezing, try to keep
steel head hammer. the battery at full charge. If you do not follow
these instructions, you or others in the area
can be injured.
WARNING: When using a hammer to
remove and install pivot pins or separate
parts using compressed air or using a
! grinder, wear eye protection that completely
encloses the eyes (approved goggles or
other approved eye protectors).
WARNING: Use suitable floor (service)

jacks or chain hoist to raise wheels or tracks
! off the floor. Always block machine in place
with suitable safety stands.

1001-6
STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS

Tightening of cap screws, nuts
Tighten alternately so that tightening torque can be applied evenly. The numbers in the figure below indicate the
order of tightening.
JS00481A
Cap screws which have had Loctite used (white residue remains after removal) should be cleaned with loght oil or
suitable cleaning solvent and dried. Apply 2-3 drops of Loctite to the thread portion of the cap screw and then
tighten.
Torque table
Tighten cap screws and nuts according to the table below if there are no other special instructions.
Cap Screw Name Size (Size) M6 M8 M10 M12 M14 M16 M18 M20
[mm] 10 13 17 19 22 24 27 30
Spanner
[in.] 0.39 0.51 0.67 0.75 0.87 0.95 1.06 1.18
Hexagon
Screw [Nm] 6.9 19.6 39.2 58.8 98.1 156.9 196.1 294.2
Tightening
torque
[lb-ft] 5.1 14.5 28.9 43.4 72.3 115.7 144.6 217
[mm] 5 6 8 10 12 14 14 17
Hexagon Spanner
[in.] 0.20 0.24 0.32 0.39 0.47 0.55 0.55 0.67
Socket
Head Cap [Nm] 8.8 21.6 42.1 78.5 117.7 176.5 245.2 343.2
Screw Tightening
torque
[lb-ft] 6.5 15.9 31.1 57.9 86.9 130.2 181 253.2

1002
Section
1002
SPECIFICATIONS
AND SPECIAL TORQUE SETTINGS
Copyright © 2007 CNH France S.A.

Printed in France
CNH Lep SC210B1002-0NA February 2007
1002-2
TABLE OF CONTENTS
WARNING: This symbol is used in this manual to indicate important safety messages. Whenever you see this
! symbol, carefully read the message which follows. Your safety depends on it.
TYPE, SERIAL NUMBER

AND YEAR OF MANUFACTURE OF THE MACHINE..................................................................................................... 3
Machine ....................................................................................................................................................................... 3
Engine .......................................................................................................................................................................... 3
Serial numbers of the components .............................................................................................................................. 3
FLUIDS AND LUBRICANTS ............................................................................................................................................ 4

Hydraulic fluid .............................................................................................................................................................. 4
Transmission component oil ........................................................................................................................................ 4
Grease ......................................................................................................................................................................... 4
Engine Oil .................................................................................................................................................................... 5
Fuel .............................................................................................................................................................................. 6
Anti-freeze/Anti-corrosion............................................................................................................................................. 7
Environment ................................................................................................................................................................. 7
Plastic and resin parts.................................................................................................................................................. 7
SPECIFICATIONS ........................................................................................................................................................... 8
Main data ..................................................................................................................................................................... 8
Performance ................................................................................................................................................................ 8
Complete machine dimensions .................................................................................................................................... 8
Main body dimensions ............................................................................................................................................... 10
Engine ........................................................................................................................................................................ 11
Cooling system .......................................................................................................................................................... 11
Capacity of coolant and lubricants ............................................................................................................................. 11
Hydraulic oil filter........................................................................................................................................................ 12
Fuel filter .................................................................................................................................................................... 12
Operating devices ...................................................................................................................................................... 12
Hydraulic system........................................................................................................................................................ 13
Swing unit .................................................................................................................................................................. 16
Travel lower body....................................................................................................................................................... 17
Work Unit ................................................................................................................................................................... 18
Digging force (ISO 6015) ........................................................................................................................................... 23
COMPONENT WEIGHT................................................................................................................................................. 24
Major component weight ............................................................................................................................................ 24
Other component weight ............................................................................................................................................ 26
SPECIAL TORQUE SETTINGS..................................................................................................................................... 28
MACHINE OVERALL DIMENSIONS ............................................................................................................................. 32
Lep SC210B1002-0NA Issued 02-07

1002-3
TYPE, SERIAL NUMBER
AND YEAR OF MANUFACTURE OF THE MACHINE
For all part orders, request for information or assistance, always specify the type and the serial number of the machine
to your Case dealer.
Fill in the following lines with the required information: Type, serial number, year of manufacture of the machine and the
serial numbers of the hydraulic and mechanical components.
Machine
CRIL05J002E00
Type.............................................................................................................................................................................
Serial number..............................................................................................................................................................
Year of manufacture ....................................................................................................................................................
Engine
Make and type.............................................................................................................................................................
Serial number..............................................................................................................................................................
Serial numbers of the components

Hydraulic pump ...........................................................................................................................................................
Swing reduction gear ..................................................................................................................................................
Travel reduction gears .................................................................................................................................................
Control valve ...............................................................................................................................................................

1002-4
FLUIDS AND LUBRICANTS
Lubricants must have the correct properties for each application.
WARNING: The conditions of use for individual fluids and lubricants must be respected.
!
Hydraulic fluid
CASE/AKCELA hydraulic fluid is specially designed for high pressure applications and for the CASE hydraulic system.
The type of fluid to be used depends on the ambient temperature.
Temperate climates: -20°C to +40°C (-4° to 104° F)
CASE/AKCELA: HYDRAULIC EXCAVATOR FLUID (MS 1230. ISO VG 46. DIN 51524 PART 2 HV)
Hot climates: 0°C to +50°C (32° to 122° F)
CASE/AKCELA: AW HYDRAULIC FLUID 68 HV (MS 1216. ISO VG 68. DIN 51524 PART 3 CATEGORY HVLP)
Cold climates: -25°C to +20°C (-13° to 68° F)
CASE/AKCELA: AW HYDRAULIC FLUID 32 (MS 1216. ISO VG 32. DIN 51524 PART 2)
Biodegradable fluid: -30°C to +40°C (-22° to 104° F)
This yellow-colored fluid is miscible with standard fluid. If used to change standard fluid, it is advised to drain the circuit
completely before refilling with this fluid.
CASE/AKCELA: HYDRAULIC EXCAVATOR FLUID BIO (MS 1230. ISO VG 46. DIN 51524 PART 2 HV)
Transmission component oil

Extreme pressure oil used for enclosed transmission components.
CASE/AKCELA: GEAR 135H EP (SAE 80W-90. API GL 5. MIL-L-2105 D. MS 1316. ZF TE-ML 05A)
Grease
CASE/AKCELA: MOLY GREASE 251H EP-M (251H EP-M. NLGI 2)
"Extreme Pressure" multipurpose grease with lithium soap and molybdenum disulphide.
CASE/AKCELA: MULTIPURPOSE GREASE 251H EP (251H EP. NLGI 2)
"Extreme Pressure" multipurpose grease with lithium soap and calcium.
CASE/AKCELA: PREMIUM GREASE EP2 (NLGI 2)
"Extreme Pressure" multipurpose grease with lithium soap.
Hydraulic breakers
CASE/AKCELA: MULTIPURPOSE GREASE 251H EP (NLGI 2).

1002-5
Engine Oil
THE CASE/AKCELA No. 1 engine oil is recommended
for your engine. This oil ensures proper lubrication of
your engine for all operating conditions.
If the CASE/AKCELA Multigrade "No. 1 ENGINE OIL"
cannot be obtained, use the oil corresponding to one of
the following categories: ACEA E7. API CI-4.
CP02N001
Oil viscosity / Oil range
1
2
2
3
3
CT02M001
1) With mineral base

(2) With semi-synthetic base
(3) With synthetic base

1002-6
Fuel
Use fuel which is to ASTM (American Society for Testing and Materials) D975 standard.
Use grade No. 2-D fuel. The use of other types of fuel can result in a loss of power of the engine and may cause high
fuel consumption.
In cold weather (below -7°C (19.4°F)), it is provisionally approved to use a mixture of fuels No. 1-D and No. 2-D. Consult
your fuel supplier or your CASE Dealer.
If the temperature falls below the fuel cloud point (point at which wax begins to form) the wax crystals will cause power
loss or will prevent the engine from starting.
Required conditions for diesel fuel
The diesel fuel used must:
- be free from dust particles, even minute ones.
- have the proper viscosity.
- have a high cetane number.
- present great fluidity at low temperatures.
- have low sulphur content.
- have very little residual carbon.
Diesel fuel recommendation
- JIS (Japanese Industrial Standard) : No. 2
- DIN (Deutsche Industrie Normen) : DIN 51601
- SAE (Society of Automotive Engineers) Based on SAE-J-313C: No. 2-D
- BS (British Standard) Based on BS/2869-1970: Class A-1
IMPORTANT : Using any other fuel will reduce the operating performance of the engine.
Using fuels other than those recommended can damage the fuel injection pump, the injector and other parts of the fuel
supply system and the engine. CASE disowns any responsibility concerning this kind of damage, which is not
covered by the guarantee. To avoid any damage to the engine fuel supply system, you are recommended to take the
following safety messages into account:
Some fuel suppliers mix used engine oil with diesel fuel. Certain manufacturers of large engines allow them to do this.
However, for your engine, do not use diesel fuel contaminated by engine oil. In addition to damaging the engine, this fuel
can actually adversely affect the correct purification of exhaust gases. Before using any diesel fuel, ask the supplier if
this fuel has been mixed with engine oil.
IMPORTANT : For a proper use of fuel additives consult your supplier or your CASE Dealer. Do not inject fuel oil or
gasoline, both fuels can damage the engine.
IMPORTANT : In cold weather, fill the fuel tank at the end of the day's work, in order to prevent the formation of conden-
sation.
Fuel storage
Long storage can lead to the accumulation of impurities and condensation in the fuel. Engine trouble can often be
traced to the presence of water in the fuel.
The storage tank must be placed outside and the temperature of the fuel should be kept as low as possible. Drain off
water and impurities regularly.

1002-7
Anti-freeze/Anti-corrosion
Use anti-freeze in all seasons to protect the cooling system from corrosion and all risk of freezing.
CASE/AKCELA: PREMIUM ANTI-FREEZE (MS 1710)
For areas where the temperature goes down to -38°C (-36.4°F), mix 50/50 with water.
IMPORTANT : Do not mix products of a different origin or brand. The same product must be used when topping up the
system.
Environment
Before carrying out any maintenance operation on this machine and before disposing of used fluids or lubricants,
always think of the environment. Never throw oil or fluid on the ground and never place it in leaking receptacles.
Contact your local ecological recycling centre or your CASE Dealer to obtain information on the correct method of dis-
posing of these lubricants.
Plastic and resin parts

When cleaning plastic parts, the console, the instrument panel, the indicators etc... avoid using petrol, kerosene, paint
solvents etc... Use only water, soap and a soft cloth.
The use of petrol, kerosene, paint solvents etc... causes discoloration, cracks or deformation of these parts.

1002-8
SPECIFICATIONS
Main data
Model name
CX210B (LC, NLC and LR type) and CX240B (LC and LR type) Hydraulic Excavator
Operating weight
CX210B (LC type) .........................................................................................................................21200 kg (46738 lbs)
CX210B (NLC type) ......................................................................................................................21350 kg (47069 lbs)
CX210B (LR type) .........................................................................................................................22300 kg (49163 lbs)
CX240B (LC type) .........................................................................................................................24500 kg (54014 lbs)
CX240B (LR type) .........................................................................................................................28000 kg (61730 lbs)
Engine output
CX210B......................................................................................................................................... 117.3 kW / 1800 rpm
CX240B......................................................................................................................................... 132.1 kW / 2000 rpm
Performance
Swing speed
CX210B........................................................................................................................................................11.5 Tr/min.
CX240B........................................................................................................................................................10.7 Tr/min.
Travel speed
CX210B....................................................................................................................... Low Speed 3.4 km/h (2.11 mph)
CX240B....................................................................................................................... Low Speed 3.5 km/h (2.17 mph)
CX210B...................................................................................................................... High Speed 5.6 km/h (3.48 mph)
CX240B...................................................................................................................... High Speed 5.5 km/h (3.42 mph)
Maximum drawbar pull
CX210B.....................................................................................................................................189.2 kN (42533.85 lbf)
CX240B..........................................................................................................................................201 kN (45186.6 lbf)
Grade ability ....................................................................................................................................................... 70% (35°)
Ground pressure
CX210B (LC, NLC type)................................................................................43 kPa (600 mm (23.62 in) grouser shoe)
CX210B (LC type) .........................................................................................37 kPa (700 mm (27.56 in) grouser shoe)
CX210B (LC and LR type) ............................................................................36 kPa (800 mm (31.50 in) grouser shoe)
CX210B (NLC type) ......................................................................................53 kPa (500 mm (19.68 in) grouser shoe)
CX240B (LR type) .........................................................................................42 kPa (800 mm (31.50 in) grouser shoe)
Complete machine dimensions

Arm (dipper)
CX210B (LC type) 2940 mm 2400 mm
(115.75 in) (94.49 in)
4955 mm 4955 mm
Lenght (without attachment)
(195.08 in) (195.08 in)
9400 mm 9480 mm
Lenght (with attachment)
(370.08 in) (373.23 in)
2970 mm 3190 mm
Height (with attachment)
(116.93 in) (125.59 in)
Arm (dipper)
CX210B (NLC type) 2940 mm 2400 mm
(115.75 in) (94.49 in)
5055 mm 5055 mm
(199.01 in) (199.01 in)
9500 mm 9590 mm
(374.01 in) (377.5 in)
2990 mm 3200 mm
(117.72 in) (125.98 in)

1002-9
Arm (dipper)
CX210B (LR type) 6400 mm
(251.97 in)
4950 mm
(194.88 in)
12470 mm
(490.94 in)
3000 mm
(118.11 in)
Arm (dipper)
CX240B (LC type) 3000 mm 2500 mm 3520 mm
(118.11 in) (98.42 in) (138.58 in)
5270 mm 5270 mm 5270 mm
(207.48 in) (207.48 in) (207.48 in)
9930 mm 9980 mm 9910 mm
(390.94 in) (392.91 in) (390.16 in)
3150 mm 3310 mm 3310 mm
(124.02 in) (130.31 in) (130.31 in)
Arm (dipper)
(314.96 in)
5265 mm
(207.28 in)
14380 mm
(566.14 in)
3130 mm
(123.23 in)

1002-10
Main body dimensions
Main body width ..............................................................................................................See machine overall dimensions
Upper side swing body width
CX210B (LC, LR type), CX240B ................................................................................................... 2770 mm (109.05 in)
CX210B (NLC type) ........................................................................................................................... 2540 mm (100 in)
Cab width ............................................................................................................................................ 1000 mm (39.37 in)
Main body height
CX210B (LC, LR type) .................................................................................................................. 2960 mm (116.54 in)
CX210B (NLC type) ...................................................................................................................... 2990 mm (117.72 in)
CX240B......................................................................................................................................... 3020 mm (118.90 in)
Engine displacement
CX210B (NLC type) ...................................................................................................................... 2830 mm (111.42 in)
CX240B......................................................................................................................................... 2950 mm (116.14 in)
Swing body tail distance
CX210B (NLC type) ...................................................................................................................... 2825 mm (111.22 in)
CX240B......................................................................................................................................... 2940 mm (115.75 in)
Swing body rear section bottom height
CX210B (LC, LR type) .................................................................................................................... 1040 mm (40.94 in)
CX210B (NLC type) ........................................................................................................................ 1070 mm (42.13 in)
CX240B........................................................................................................................................... 1100 mm (43.31 in)
Distance between tumblers
CX210B (LC type) ......................................................................................................................... 3370 mm (132.68 in)
CX210B (NLC, LR type)................................................................................................................ 3660 mm (144.09 in)
CX240B......................................................................................................................................... 3840 mm (151.18 in)
Overall track length
CX210B (LC type) ......................................................................................................................... 4180 mm (164.57 in)
CX210B (NLC, LR type)................................................................................................................ 4460 mm (175.59 in)
CX240B......................................................................................................................................... 4650 mm (183.07 in)
Width of track shoe
CX210B (LC type) ...............600 mm (23.62 in) (Optional: 700 mm (27.56 in), 800 mm (31.50 in), 900 mm (35.43 in))
CX210B (NLC type) .......................................................................... 500 mm (19.68 in) (Optional: 600 mm (23.62 in))
CX210B (LR type) ............................................................................................................................. 800 mm (31.50 in)
CX240B (LC type) ...............600 mm (23.62 in) (Optional: 700 mm (27.56 in), 800 mm (31.50 in), 900 mm (35.43 in))
CX240B (LR type) ............................................................................................................................. 800 mm (31.50 in)
Minimum ground clearance (To bottom of lower frame)
CX210B, CX240B ............................................................................................................................. 460 mm (18.11 in)
CX230B............................................................................................................................................. 450 mm (17.72 in)

1002-11
Engine
Name.......................................................................................................................................................... ISUZU, 4HK1X
Type: ........................................................4-cycle, water-cooled, overhead camshaft, vertical in-line, direct injection type
............................................................................................................................... (electronic control), with turbocharger.
No. of cylinders - bore x stroke.......................................................................... 4 - Ø115 mm x 125 mm (Ø4.53 x 4.92 in)
Displacement ....................................................................................................................................... 5.193 L (1.372 gal)
Compression ratio ........................................................................................................................................................17.5
Rated output
CX210B ...................................................................................................................................... 117.3 kW / 1800 min-1
CX240B ...................................................................................................................................... 132.1 kW / 2000 min-1
Maximum torque
CX210B .................................................................................................................. 628 N.m (463.19 lb-ft) / 1500 min-1
CX240B .................................................................................................................. 636 N.m (469.09 lb-ft) / 1500 min-1
Engine dimensions (LxWxH).................................................................. 1020.4x829x1011.8 mm (40.17x32.64x39.83 in)
Oil pan.......................................................................................................................................All direction 35°, inclinable
Oil pan capacity............................................... Maximum: 20.5 L (5.42 gal) Minimum: 13 L (3.43 gal) (excluding oil filter)
Direction of rotation .............................................................................................................. Clockwise (as seen from fan)
Starter, reduction type........................................................................................................................................24 V, 5 kW
Alternator, AC type ............................................................................................................................................. 24 V, 50 A
Battery..................................................................................................................................................2 x 12V, 92 Ah/5 Hr
Cooling system
Fan type ..........................................Ø 650 mm (25.59 in), suction type - 7 blades, plastic with belt mouth-type fan guide
Pulley ratio ................................................................................................................................................ 0.85 (reduction)
Radiator
Fin type ...................................................................................................................................................................wavy
Fin pitch ............................................................................................................................................. 2.0 mm (0.078 in)
Oil cooler
Fin type ...................................................................................................................................................................wavy
Fin pitch ........................................................................................................................................... 1.75 mm (0.069 in)
Inter-cooler
Fin type ...............................................................................................................................................triangular straight
Fin pitch ........................................................................................................................................... 1.75 mm (0.069 in)
Fuel cooler
Fin type ...................................................................................................................................................................wavy
Fin pitch ............................................................................................................................................. 2.0 mm (0.078 in)
Coolant capacity.....................................................................................................................14 L (3.70 gal) (engine only)
Capacity of coolant and lubricants

Coolant
CX210B ............................................................................................................................................... 25.6 L (6.76 gal)
CX240B ............................................................................................................................................... 25.2 L (6.66 gal)
Fuel ....................................................................................................................................................... 410 L (108.31 gal)
Lubricant for engine ................................................................................................................................... 23.1 L (6.1 gal)
Lubricant for travel reduction gear (per side) ............................................................................................. 5.0 L (1.32 gal)
Lubricant for swing reduction gear (per side)
CX210B ................................................................................................................................................. 5.0 L (1.32 gal)
CX240B ................................................................................................................................................. 9.7 L (2.56 gal)
Hydraulic oil
CX210B .............................................................................................................................................. 240 L (63.40 gal)
CX240B .............................................................................................................................................. 250 L (66.04 gal)
Capacity of hydraulic oil tank .................................................................................................................. 147 L (38.83 gal)

1002-12
Hydraulic oil filter
Suction filter (inside tank)
CX210B.............................................................................................................................................................. 150 µm
CX240B.............................................................................................................................................................. 155 µm
Return filter (inside tank) ............................................................................................................................................ 6 µm
Pilot line filter (inside housing).................................................................................................................................... 8 µm
Fuel filter
Main filter.................................................................................................................................................................... 4 µm
Pre-filter.................................................................................................................................................................... 10 µm
Operating devices
Operator's seat
Location: left side
Structure: Adjustable forward and back and up and down, reclining mechanism, with seat suspension.
Cab
Sealed steel type, all reinforced glass.
Levers and pedals
For travel use: Lever and pedal type (hydraulic pilot type) (x2)
For operating machine use: Lever type (hydraulic pilot type) (x2)
Instruments and switches
Work mode select switch: 3 modes (SP / super power, H / heavy duty, A / automatic)
Travel mode select switch: Low-speed / high-speed switch type
One-touch idle: Knob switch type
Engine emergency stop: Switch type
Monitor device
Machine status display (full-dot liquid crystal)
Work mode selection status: SP / H / A
Instruments (full-dot liquid crystal, except for hour meter)
Fuel gauge: bar graph indicator
Engine coolant temperature gauge: bar graph indicator
Hydraulic oil temperature gauge: bar graph indicator
Hour meter: digital type
Machine Status and Warning Alarms (full-dot liquid crystal and warning tone) *Items have a warning alarm
Over heat* Battery charge* Faulty electrical system*
Refill fuel* Engine oil pressure* Refill coolant*
Engine preheat Auto warm-up Air cleaner clogged
Anti-theft device triggered Faulty engine system Engine emergency stop
Lighting
Working light Tank: 24V, 70W (x1)
Boom: 24V, 70W (x1)
Cab: 24V, 70W (x2)
Interior light 24V, 10W (x1)
Horn: electric horn (x2)

Other
Wiper with intermittent function, Window washer, Air conditioner, Rear view mirrors (left and right), DC converter,
Clock

1002-13
Hydraulic system
Hydraulic pump drive system, directly coupled to the engine (no transmission)
Main pump
Manufacturer .............................................................................................................................................. Kawasaki
Pump type ..............................................................................................double variable displacement piston pump
Displacement volume .................................................................................................118.5 cm3 (7.23 cu in) x 2 /rev
Rated operating pressure .......................................................................................................... 34.3 MPa (4975 psi)
Maximum operating pressure .................................................................................................... 36.8 MPa (5337 psi)
Input revolution speed
CX210B................................................................................................................................................1800 min-1
CX240B................................................................................................................................................2000 min-1
Maximum discharge flow
CX210B................................................................................................. 211 L/min (55.74 gpm) x 2 at 1800 min-1
CX240B................................................................................................. 234 L/min (61.82 gpm) x 2 at 2000 min-1
Pilot pump
Pump type ...............................................................................................................................................Gear pump
Displacement volume .............................................................................................................10 cm3 (0.61 cu in)/rev
Operating pressure...................................................................................................................... 3.92 MPa (568 psi)
Maximum flow
CX210B.........................................................................................................18 L/min (4.75 gpm) (at 1800 min-1)
CX240B.........................................................................................................20 L/min (5.28 gpm) (at 2000 min-1)
Control method
Hydraulic simultaneous constant output control.
Maximum flow adjustment control through external commands (negative control).
Setting horsepower adjustment control through external command current.
Control Valve
Model; 4-spool section: integrated (1) or 5-spool section: integrated (1)
Operation method: hydraulic pilot method: travel, swing and operating machine
Maximum flow
CX210B .........................................................................................................213 L/min (52.27 gpm) (at 1800 min-1)
CX240B .........................................................................................................237 L/min (62.61 gpm) (at 2000 min-1)
Main relief set pressure ...........................................standard; 34.3 MPa (4975 psi), power boost 36.8 MPa (5337 psi)
Overload set pressure
CX210B (LR type)
.................................................................................................................................. bucket; 25.0 MPa (3626 psi)
.................................................................................................................................. arm in; 23.0 MPa (3336 psi)
CX240B (LR type)
.................................................................................................................................. bucket; 29.4 MPa (4264 psi)
............................................................................................................................... arm in; 21.1.0 MPa (3060 psi)
All
................................................................................................................ when boom down; 29.4 MPa (4264 psi)
.................................................................................................................................... other: 38.7 MPa (5613 psi)
Foot relief set pressure ............................................................................................................... 2.55 MPa (369.85 psi)
Functions
Straight travel circuit
Boom up / arm 2 pumps internal flow
Boom and arm load holding circuit
Boom-down regenerative circuit
Bucket-close regenerative circuit
Arm-in forced regenerative circuit
Swing priority variable orifice (for arm operation)
2 pumps flow
Variable foot relief

1002-14
Hydraulic Cylinders
Boom cylinder (x2)
CX210B
Cylinder bore .........................................................................................................................Ø120 mm (Ø4.72 in)
Rod diametre ...........................................................................................................................Ø85 mm (Ø3.35 in)
Maximum retracted lenghth .................................................................................................... 1753 mm (69.02 in)
Stroke ..................................................................................................................................... 1255 mm (49.41 in)
CX240B
Stroke ..................................................................................................................................... 1335 mm (52.56 in)
Arm (dipper) cylinder
CX210B (LC, NLC type)
Rod diametre .........................................................................................................................Ø100 mm (Ø3.94 in)
Stroke ..................................................................................................................................... 1460 mm (57.48 in)
CX210B (LR type)
Stroke ..................................................................................................................................... 1627 mm (64.05 in)
CX240B (LC type)
Stroke ..................................................................................................................................... 1660 mm (65.35 in)
CX240B (LR type)
Stroke ..................................................................................................................................... 1737 mm (68.39 in)
Bucket cylinder
CX210B (LC, NLC type)
Stroke ..................................................................................................................................... 1010 mm (39.76 in)
CX240B (LC type)
Stroke ..................................................................................................................................... 1070 mm (42.13 in)
CX210B (LR type), CX240B (LR type)
Cylinder bore ...........................................................................................................................Ø95 mm (Ø3.74 in)
Stroke ....................................................................................................................................... 881 mm (34.68 in)

1002-15
Rotating Joint
Operating pressure
High pressure passage (ABCD) ............................................................................................... 34.3 MPa (4975 psi)
Drain port (E).............................................................................................................................. 0.5 MPa (72.52 psi)
Pilot port (F)................................................................................................................................... 3.9 MPa (566 psi)
Flow
High pressure passage (ABCD) ............................................................................................ 234 L/min (61.82 gpm)
Drain port (E)............................................................................................................................. 10 L/min (2.64 gpm)
Pilot port (F)............................................................................................................................... 21 L/min (5.55 gpm)
Port A; forward right ................................................................................................................................................G3/4
Port B; forward left ..................................................................................................................................................G3/4
Port C; backward right ............................................................................................................................................G3/4
Port D; backward left...............................................................................................................................................G3/4
Port E; drain port ....................................................................................................................................................G1/2
Port F; pilot port .....................................................................................................................................................G1/4
Solenoid Valve
Maximum flow .......................................................................... P -> B: 25 L/min (6.60 gpm) Other: 5 L/min (1.32 gpm)
Rated pressure ............................................................................................................................. 4.5 MPa (652.67 psi)
Port size
P, T, B port ..........................................................................................................................................................G3/8
C1, C2, C3, C4, C5 port .....................................................................................................................................G1/4
Solenoid specifications
Operating voltage ................................................................................................................................ DC 20 to 32 V
Power consumption .................................................................................................................................. 17 W max.
Hand control valve
Manufacturer................................................................................................................................................... Kawasaki
Operating pressure .......................................................................................................................... 3.92 MPa (569 psi)
Secondary pressure, primary short type .......................................................... 0.64 to 2.45 MPa (92.82 to 355.34 psi)
Operating angle
Ports 1, 3 .............................................................................................................................................................. 19°
Ports 2, 4 .............................................................................................................................................................. 25°
Port 1, 3 Port 2, 4
4.0 4.0
Secondary pressure (MPa)
3.0 3.0
2.0 2.0
1.0 1.0
0 0
2 4 6 7 2 4 6 8 9.4
Push rod stroke (mm) Push rod stroke (mm)
0 5 10 15 19 0 5 10 15 20 25
Operating angle (deg.) Operating angle (deg.)
RST-03-01-001B

1002-16
Foot control valve
Manufacturer ................................................................................................................................................... Kawasaki
Operating pressure .......................................................................................................................... 3.92 MPa (569 psi)
Secondary pressure, primary short type........................................................... 0.64 to 2.45 MPa (92.82 to 355.34 psi)
Operating angle...................................................................................................................................................... 12.4°
3.9

3.0
2.0
1.0
0
2 4 5.5
Push rod stroke (mm)
0 5 10 12.4
Operating angle (deg.)
RST-03-01-001D
Swing unit
Swing circle ...........................................................................................................Swing bearing type (with internal gear)
Swing parking brake ................................................................................ Mechanical lock (operational lever linkage type)
Swing hydraulic motor .......................................................................Fixed displacement piston motor with parking brake
Displacement
CX210B ............................................................................................................................... 151 cm3 (9.21 cu in)/rev
CX240B ............................................................................................................................ 148.5 cm3 (9.06 cu in)/rev
Operating pressure
CX210B (LC, NLC type) ............................................................................................................ 29.4 MPa (4264 psi)
CX210B (LR type)...................................................................................................................... 24.0 MPa (3481 psi)
CX240B (LC type)...................................................................................................................... 28.9 MPa (4192 psi)
CX240B (LR type)...................................................................................................................... 27.0 MPa (3916 psi)
Operating flow
CX210B .............................................................................................................................. 210.6 L/min (55.63 gpm)
CX240B ................................................................................................................................. 214 L/min (56.53 gpm)
Mechanical brake torque
CX210B .........................................................................................................................821.5 Nm (605.91 lb-ft) min.
CX240B ............................................................................................................................846 Nm (623.98 lb-ft) min.
Brake off pressure
CX210B ........................................................................................................................... 3.2 MPa (464.12 psi) max.
CX240B ........................................................................................................................... 2.9 MPa (420.61 psi) max.
Relief valve set pressure
CX210B ..................................................................................................................................... 29.4 MPa (4264 psi)
CX240B ..................................................................................................................................... 28.9 MPa (4192 psi)
Reduction gear ....................................................................................................... Planetary gear 2-stage reduction gear
Reduction ratio
CX210B .......................................................................................................................................................... 16.757
CX240B ............................................................................................................................................................ 21.75

1002-17
Travel lower body
Travel hydraulic motor (x2) ......... Variable displacement piston motor, automatic 2-speed switch-over with parking brake
Displacement
CX210B .........................................................................................................168.9/100.3 cm3 (10.31/6.12 cu in)/rev
CX240B .........................................................................................................181.3/112.6 cm3 (11.06/6.87 cu in)/rev
Operating pressure ........................................................................................................................ 34.3 MPa (4975 psi)
Operating flow
CX210B .............................................................................................................................. 210.6 L/min (55.63 gpm)
CX240B ................................................................................................................................. 234 L/min (61.81 gpm)
Brake torque .............................................................................20.9 KNm (15415 Ib-ft) min. (including reduction gear)
Relief valve set pressure........................................................................................................... 35.3 MPa (5119.83 psi)
Automatic 2-speed switch-over pressure .................................................................................. 25.5 MPa (3698.46 psi)
Reduction gear....................................................................................................... Planetary gear 2-stage reduction gear
Reduction ratio.....................................................................................................................................................43.246
Travel brake .................................................................................................................................................. Hydraulic lock
Parking brake ................................................................................................... Mechanical lock (travel lever linkage type)
Track shoe
Model ........................................................................................................................Assembly type triple grouser shoe
Number of shoes (per side)
CX210B, .................................................................................................................................................................49
CX240B, .................................................................................................................................................................51
Shoe width
Standard
CX210B (LC type), CX240B (LC type)..................................................................................... 600 mm (23.62 in)
CX210B (NLC type) ................................................................................................................. 500 mm (19.68 in)
CX210B (LR type), CX240B (LR type)..................................................................................... 800 mm (31.50 in)
Optional
CX210B (LC type), CX240B (LC type)....................... 700 mm (27.56 in), 800 mm (31.50 in), 900 mm (35.43 in)
CX210B (NLC type) ................................................................................................................. 600 mm (23.62 in)
Grouser height ...................................................................................................................................... 26 mm (1.02 in)
Link pitch............................................................................................................................................. 190 mm (7.48 in)
Roller
Number of upper rollers (per side)................................................................................................................................2
Number of lower rollers (per side)
CX210B ....................................................................................................................................................................8
CX240B ....................................................................................................................................................................9
Track belt tension adjuster ...............................................................................Grease cylinder type (with cushion spring)
Mounting length of spring ................................................................................................................. 556 mm (21.89 in)

1002-18
Work Unit
Model..................................................................................................................................................Backhoe attachment
Components / dimensions / working dimensions
Standard boom
CX210B (LC type)
Standard arm Short arm
2940 mm 2400 mm
Arm (dipper) length
(115.75 in) (94.49 in)
5700 mm
Boom length (Standard boom spec.)
224.41 in
1450 mm
Bucket radius
57.09 in
Bucket wrist angle 177°
9900 mm 9420 mm
Maximum digging radius
389.76 in 370.87 in
9730 mm 9240 mm
Maximum digging radius at ground line
383.07 in 363.78 in
6650 mm 6110 mm
Maximum digging depth
261.81 in 240.55 in
5960 mm 5500 mm
Maximum vertical straight wall digging depth
234.64 in 216.53 in
9610 mm 9410 mm
Maximum digging height
378.35 in 370.47 in
6810 mm 6590 mm
Maximum dump height
268.11 in 259.45 in
3600 mm 3600 mm
Minimum swing radius at front
141.73 in 141.73 in
7640 mm 7690 mm
Height for minimum swing radius at front
300.79 in 302.76 in

1002-19
Standard boom
CX210B (NLC type)
Standard arm Short arm
2940 mm 2400 mm
Arm (dipper) length
(115.75 in) (94.49 in)
5700 mm
224.41 in
1450 mm
Bucket radius
57.09 in
9900 mm 9420 mm
389.76 in 370.87 in
9730 mm 9230 mm
383.07 in 363.38 in
6620 mm 6080 mm
260.63 in 239.37 in
5930 mm 5470 mm
233.46 in 215.35 in
9640 mm 9440 mm
379.53 in 371.65 in
6840 mm 6620 mm
Maximum dump height
269.29 in 260.63 in
3600 mm 3600 mm
141.73 in 141.73 in
7670 mm 7740 mm
301.97 in 304.72 in

1002-20
Standard boom
CX210B (LR type)
S-long arm
6400 mm
Arm (dipper) length
(251.97 in)
8700 mm
342.52 in
1200 mm
Bucket radius
47.24 in
15600 mm
614.17 in
15490 mm
609.84 in
12010 mm
472.83 in
10290 mm
405.12 in
12970 mm
510.63 in
10730 mm
Maximum dump height
422.44 in
5190 mm
204.33 in
10390 mm
409.05 in

1002-21
Standard boom
CX240B (LC type)
Standard arm Short arm Long arm
3000 mm 2500 mm 3520 mm
Arm (dipper) length
(118.11 in) (98.42 in) (138.58 in)
5850 mm
Boom length (Articulated boom spec.)
230.31 in
1570 mm
Bucket radius
61.81 in
10280 mm 9820 mm 10790 mm
404.72 in 386.61 in 424.80 in
10100 mm 9630 mm 10620 mm
397.64 in 379.13 in 418.11 in
6900 mm 6400 mm 7420 mm
271.65 in 251.97 in 292.13 in
6140 mm 5700 mm 6680 mm
241.73 in 224.41 in 262.99 in
9760 mm 9560 mm 10070 mm
384.25 in 376.38 in 396.46 in
6760 mm 6550 mm 7060 mm
Maximum dump height
266.14 in 257.87 in 277.95 in
3950 mm 3980 mm 3950 mm
155.51 in 156.69 in 155.51 in
7750 mm 7820 mm 7740 mm
305.12 in 307.87 in 304.72 in

1002-22
Standard boom
CX240B (LR type)
S-long arm
8000 mm
Arm (dipper) length
(314.96 in)
10300 mm
405.51 in
1200 mm
Bucket radius
47.24 in
18320 mm
721.26 in
18220 mm
717.26 in
14560 mm
573.23 in
12130 mm
477.56 in
13950 mm
549.21 in
11780 mm
Maximum dump height
463.78 in
6220 mm
244.88 in
11810 mm
464.96 in

1002-23
Digging force (ISO 6015)
Arm (dipper)
CX210B (LC, NLC type) 2940 mm 2400 mm
(115.75 in) (94.49 in)
103 kN 123 kN
Arm (dipper) digging force (standard)
(23155.3 lbf) (27651.5 lbf)
110 kN 132 kN
Arm (dipper) digging force (power up)
(24729 lbf) (29674.8 lbf)
142 kN 142 kN
Bucket digging force (standard)
(31922.9 lbf) (31922.9 lbf)
152 kN 152 kN
Bucket digging force (power up)
(34171 lbf) (34171 lbf)
Arm (dipper)
(251.97 in)
46 kN
Arm (dipper) digging force
(10341.2 lbf)
65 kN
Bucket digging force
(14612.6 lbf)
Arm (dipper)
CX240B (LC type) 3000 mm 2500 mm 3520 mm
(118.11 in) (98.42 in) (138.58 in)
120 kN 141 kN 107 kN
Arm (dipper) digging force (standard)
(26977.1 lbf) (31698.1 lbf) (24054.6 lbf)
129 kN 151 KN 115 kN
Arm (dipper) digging force (power up)
(29000.3 lbf) (33946.1 lbf) (25853 lbf)
162 kN 162 kN 162 kN
Bucket digging force (standard)
(36419 lbf) (36419 lbf) (36419 lbf)
174 kN 174 kN 174 kN
Bucket digging force (power up)
(39116.8 lbf) (39116.8 lbf) (39116.8 lbf)
Arm (dipper)
(314.96 in)
44 kN
Arm (dipper) digging force
(9891.6 lbf)
77 kN
Bucket digging force
(17310.3 lbf)

1002-24
COMPONENT WEIGHT
Major component weight
B
A
F H
G
RST-11-01-001A
Weight information is approximate
A) Operating weight
CX210B (LC type).....................................................................................................................21200 kg (46738 lbs)
CX210B (NLC type) ..................................................................................................................21350 kg (47069 lbs)
CX210B (LR type).....................................................................................................................22300 kg (49163 lbs)
CX240B (LC type).....................................................................................................................24500 kg (54013 lbs)
CX240B (LR type).....................................................................................................................28000 kg (61730 lbs)
B) Upper mechanism (including counterweight and turntable bearing)
CX210B (LC type).......................................................................................................................9630 kg (21231 lbs)
CX210B (NLC type) ..................................................................................................................10420 kg (22972 lbs)
CX210B (LR type).....................................................................................................................10700 kg (23589 lbs)
CX240B (LC type).....................................................................................................................11280 kg (24868 lbs)
CX240B (LR type)......................................................................................................................13600kg (29983 lbs)
C) Counterweight
CX210B (LC type).........................................................................................................................4120 kg (9083 lbs)
CX210B (NLC type) ....................................................................................................................4560 kg (10053 lbs)
CX210B (LR type).......................................................................................................................5120 kg (11288 lbs)
CX240B (LC type).......................................................................................................................5270 kg (11618 lbs)
CX240B (LR type).......................................................................................................................7520 kg (16579 lbs)
D) Lower mechanism (with standard grouser shoe)
CX210B (LC type).......................................................................................................................7460 kg (16446 lbs)
CX210B (NLC type) ....................................................................................................................6880 kg (15168 lbs)
CX210B (LR type).......................................................................................................................7200 kg (15873 lbs)
CX240B (LC type).......................................................................................................................8250 kg (18188 lbs)
CX240B (LR type).......................................................................................................................8830 kg (19467 lbs)

1002-25
E) Main Unit Weight
CX210B (LC type) .................................................................................................................... 17090 kg (37677 lbs)
CX210B (NLC type).................................................................................................................. 17300 kg (38140 lbs)
CX210B (LR type) .................................................................................................................... 17900 kg (39463 lbs)
CX240B (LC type) .................................................................................................................... 19530 kg (43056 lbs)
CX240B (LR type) .................................................................................................................... 22430 kg (49450 lbs)
F) Attachments
CX210B (LC, NLC type) ............................................................................................................... 4050 kg (8929 lbs)
CX210B (LR type) ........................................................................................................................ 4400 kg (9700 lbs)
CX240B (LC type) ...................................................................................................................... 4860 kg (10714 lbs)
CX240B (LR type) ...................................................................................................................... 5570 kg (12280 lbs)
G) Boom (including cylinders)
CX210B (LR type) ........................................................................................................................ 2780 kg (6129 lbs)
CX240B (LC type) ........................................................................................................................ 2750 kg (6063 lbs)
CX240B (LR type) ........................................................................................................................ 3680 kg (8113 lbs)
H) Arm (dipper) (including cylinders and linkage)
CX210B (LR type) ........................................................................................................................ 1290 kg (2844 lbs)
CX240B (LC type) ........................................................................................................................ 1300 kg (2866 lbs)
CX240B (LR type) ........................................................................................................................ 1550 kg (3417 lbs)

1002-26
Other component weight
Engine ..................................................................................................................................................531 kg (1170.6 lbs)
Air cleaner .................................................................................................................................................7.6 kg (16.8 lbs)
Hydraulic pump
CX210B (LC, LR type), CX240B ........................................................................................................144 kg (317.5 lbs)
CX210B (NLC type) ...........................................................................................................................165 kg (363.8 lbs)
Attachment control valve ........................................................................................................................203 kg (447.5 lbs)
Swing motor and reduction gear assembly
CX210B..............................................................................................................................................241 kg (531.3 lbs)
CX240B..............................................................................................................................................297 kg (654.8 lbs)
Travel motor and reduction gear assembly.............................................................................................328 kg (723.1 lbs)
Rotary joint .................................................................................................................................................31 kg (68.3 lbs)
Solenoid valve bank ..................................................................................................................................6.7 kg (14.8 lbs)
Cushion valve ..........................................................................................................................................12.5 kg (27.6 lbs)
Hand control valve.......................................................................................................................................1.9 kg (4.2 lbs)
Foot control valve ......................................................................................................................................7.8 kg (17.2 lbs)
Standard boom
CX210B (LC, NLC type).................................................................................................................1543 kg (3401.7 lbs)
CX210B (LR type) ..........................................................................................................................1820 kg (4012.4 lbs)
CX240B (LC type) ..........................................................................................................................1846 kg (4069.7 lbs)
CX240B (LR type) ..........................................................................................................................2532 kg (5582.1 lbs)
Standard arm (dipper)
CX210B (LC, NLC type)...................................................................................................................697 kg (1536.6 lbs)
CX240B (LC type) ............................................................................................................................792 kg (1746.1 lbs)
Short arm (dipper)
CX210B (LC, NLC type)...................................................................................................................670 kg (1477.1 lbs)
CX240B (LC type) ............................................................................................................................680 kg (1499.1 lbs)
Long arm (dipper)
CX240B (LC type) ............................................................................................................................893 kg (1968.7 lbs)
S-Long arm (dipper)
CX210B (LR type) ..........................................................................................................................1050 kg (2314.9 lbs)
CX240B (LR type) ..........................................................................................................................1320 kg (2910.1 lbs)
Boom cylinder (one)
CX210B..............................................................................................................................................164 kg (361.6 lbs)
CX240B..............................................................................................................................................204 kg (449.7 lbs)
Arm (dipper) cylinder
CX210B (LC, NLC type).....................................................................................................................263 kg (579.8 lbs)
CX210B (LR type) ..............................................................................................................................317 kg (698.9 lbs)
CX240B (LC type) ..............................................................................................................................324 kg (714.3 lbs)
CX240B (LR type) ..............................................................................................................................359 kg (791.5 lbs)
Bucket cylinder
CX210B (LC, NLC type).....................................................................................................................150 kg (330.7 lbs)
CX210B (LR type), CX240B (LR type).................................................................................................91 kg (200.6 lbs)
CX240B (LC type) ..............................................................................................................................190 kg (418.9 lbs)
Fuel tank.................................................................................................................................................160 kg (352.7 lbs)
Hydraulic oil tank ....................................................................................................................................152 kg (335.1 lbs)
Turntable bearing
CX210B..............................................................................................................................................263 kg (579.8 lbs)
CX240B..............................................................................................................................................404 kg (890.7 lbs)

1002-27
Muffler .....................................................................................................................................................15.9 kg (35.1 lbs)
Radiator total weight
CX210B .............................................................................................................................................134 kg (295.4 lbs)
CX240B .............................................................................................................................................142 kg (313.1 lbs)
Oil cooler
CX210B...................................................................................................................................... 27.5 kg (60.6 lbs)
CX240B......................................................................................................................................... 30 kg (66.1 lbs)
Radiator
CX210B...................................................................................................................................... 15.6 kg (34.4 lbs)
CX240B...................................................................................................................................... 15.2 kg (33.5 lbs)
Air cooler
CX210B........................................................................................................................................... 7 kg (15.4 lbs)
CX240B........................................................................................................................................... 8 kg (17.6 lbs)
Fuel cooler........................................................................................................................................ 1.2 kg (2.65 lbs)
Idler wheel................................................................................................................................................87 kg (191.8 lbs)
Upper roller ................................................................................................................................................ 17 kg (37.5 lbs)
Lower roller
CX210B ....................................................................................................................................................34 kg (75 lbs)
CX240B ................................................................................................................................................. 36 kg (79.4 lbs)
Recoil spring assembly
CX210B .............................................................................................................................................155 kg (341.7 lbs)
CX240B .............................................................................................................................................160 kg (352.7 lbs)
Recoil spring ........................................................................................................................................ 67.6 kg (149 lbs)
Grease cylinder assembly
CX210B ............................................................................................................................................. 30.4 kg (67 lbs)
CX240B ............................................................................................................................................. 35.4 kg (78 lbs)
Threaded rod ...................................................................................................................................... 29.7 kg (65.5 lbs)
Yoke .................................................................................................................................................... 25.6 kg (56.4 lbs)
Track chains (per side)
500 mm (19.68 in)
CX210B (NLC type)...................................................................................................................... 1203 kg (2653 lbs)
600 mm (23.62 in)
CX210B (LC, NLC type) ............................................................................................................ 1340 kg (2954.2 lbs)
CX240B ..................................................................................................................................... 1480 kg (3262.8 lbs)
700 mm (27.56 in)
CX210B (LC type) ........................................................................................................................ 1564 kg (3448 lbs)
CX240B (LC type) ..................................................................................................................... 1630 kg (3593.5 lbs)
800 mm (31.5 in)
CX210B (LC, LR type)............................................................................................................... 1710 kg (3769.9 lbs)
CX240B ..................................................................................................................................... 1780 kg (3924.2 lbs)
900 mm (35.43 in)
CX210B (LC type) ..................................................................................................................... 1658 kg (3655.3 lbs)
CX240B (LC type) ..................................................................................................................... 1924 kg (4241.7 lbs)

1002-28
SPECIAL TORQUE SETTINGS
No. Component Screw Wrench (mm) Torque setting
1* Travel motor and reduction gear assembly M16 24 267-312 Nm (197-230 lb-ft)
2* Drive sprocket M16 24 267-312 Nm (197-230 lb-ft)
3* Idler wheel M16 24 267-312 Nm (197-230 lb-ft)
4* Upper roller M20 30 521-608 Nm (385-448 lb-ft)
5* Lower roller M18 27 371-432 Nm (274-318 lb-ft)
6* Track guard M18 27 400-462 Nm (295-341 lb-ft)
7 Shoe bolt M20 30 755-853 Nm (557-629 lb-ft)
8 Counterweight M33 50 1862-2058 Nm (1374-1517 lb-ft)
9 Turntable bearing (lower frame) (CX210B (LC type)) M20 30 468-545 Nm (346-402 lb-ft)
9 Turntable bearing (lower frame) (CX240B) M24 36 784-914 Nm (579-674 lb-ft)
10 Turntable (swing frame) (CX210B (LC type)) M20 30 468-545 Nm (346-402 lb-ft)
10 Turntable (swing frame) (CX240B) M24 36 784-914 Nm (579-674 lb-ft)
11 * Swing unit (CX210B (LC type)) M20 30 539-630 Nm (398-464 lb-ft)
11 * Swing unit (CX240B) M24 36 784-914 Nm (579-674 lb-ft)
12 * Engine (engine mount) M16 24 265-314 Nm (196-231 lb-ft)
M10 17 64-74 Nm (47.20-54.58 lb-ft)
13 * Engine bracket
M16 24 206-247 Nm (152-182 lb-ft)
14 Radiator M16 24 147-177 Nm (109-130 lb-ft)
M10 64-74 Nm (47.20-54.58 lb-ft)
15 * Hydraulic pump 17
M20 367-496 Nm (271-365 lb-ft)
16 * Hydraulic reservoir M16 24 232-276 Nm (172-203 lb-ft)
17 * Fuel reservoir M16 24 232-276 Nm (172-203 lb-ft)
18 Control valve M16 24 267-312 Nm (197-230 lb-ft)
19 * 88-107 Nm (65-78 lb-ft)
Hydraulic swivel M12 19
20 109-127 Nm (81-93 lb-ft)
21 Cab M16 24 245-294 Nm (181-216 lb-ft)
22 Battery M10 17 20-29 Nm (14.75-21.39 lb-ft)
NOTE: Use Loctite 262 or an equivalent on retaining screws of those components marked with an asterisk (*).

1002-29
16 15
18
11
12, 13
17 8
14
22
7
19, 20 1, 2
9
5
6
21
4
3
4
7
3 5 8
RI08001-002

1002-30
11
9 10
14
13 12
15
15 16
RI08001-001

1002-31
18
18
17
19
20
22
RST-09-08-001E

1002-32
MACHINE OVERALL DIMENSIONS
NOTE: Numbers are subject to change without notice due to design change or other reasons.
The figures give values that include the shoe lug height (26 mm (1.02 in))
CX210B (LC type)

Standard boom, Standard arm (2940 mm (115.75 in))
Standard boom, Short arm (2400 mm (94.49 in))
RB03001-008

1002-33
CX210B (NLC type)
Standard boom, Standard arm (2940 mm (115.75 in))
RB03005-001
Standard boom, Short arm (2400 mm (94.49 in))
RB03005-003
CX210B (LR type)

S-long arm (6400 mm (251.97 in))
12470 2770
9750 2720 1430 1340
2960
3000
2940
460
1040
920
3660
26
26
600
4460 2390
2990
RB03004-003

1002-34
CX240B (LC type)
Standard arm (3000 mm (118.11 in))
9930
6990 2940 2770
340
3150
3020
3000
460
11
26
26
600
3840 2590
4650
3190
RB03001-009
Short arm (2500 mm (98.42 in))
9980
7040 2940 2770
340
3310
3020
3000
460
1
26
26
600
3840 2590
4650
3190
RB03001-010
Long arm (3520 mm (138.58 in))
9910
6970 2940 2770
1430 1340
3310
3020
3000
460
1100
26
26
600
3840 2590
3190
4650
RB03001-011

1002-35
CX240B (LR type)
S-long arm (8000 mm (314.96 in))
RB03004-002

1002-36
NOTES
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Section
4001
ELECTRICAL AND ENGINE FUNCTIONS,

&
SERVICE SUPPORT
4001

All rights reserved.
Printed in USA.
4001-2
TABLE OF CONTENTS
ELECTRIC CIRCUITS OPERATION EXPLANATION .................................................................................................. 5

Explanation of Electrical Functions ..................................................................................................................... 5
Engine Speed Control ............................................................................................................................................ 7
Throttle Control .................................................................................................................................................... 7
Idling Control (auto / one-touch) ......................................................................................................................... 11
Idling Start .......................................................................................................................................................... 12
Idle Up ................................................................................................................................................................ 13
Auto Warm Up .................................................................................................................................................... 13
Engine Start / Stop Control ................................................................................................................................. 15
Engine Start / Stop Judgment ............................................................................................................................ 15
Power-Cut Delay ................................................................................................................................................ 16
Engine Emergency Stop .................................................................................................................................... 17
Neutral Start ....................................................................................................................................................... 18
Pump Control ....................................................................................................................................................... 19
Work Mode Control ............................................................................................................................................ 19
Pump Added Horsepower Control ..................................................................................................................... 20
Pump Horsepower Cut Control .......................................................................................................................... 21
Power Save Control ........................................................................................................................................... 21
Swing ..................................................................................................................................................................... 24
Swing Brake ....................................................................................................................................................... 24
Free Swing (North America Only) ...................................................................................................................... 25
Swing Lock (for maintenance) ............................................................................................................................ 26
Swing Relief Cut ................................................................................................................................................. 27
Travel ..................................................................................................................................................................... 29
Travel Speed Switchover ................................................................................................................................... 29
Travel Alarm (North America only) ..................................................................................................................... 30
Valve Control ........................................................................................................................................................ 32
Lever Lock .......................................................................................................................................................... 32
Solenoid Sticking Prevention ............................................................................................................................. 33
Pressure Boost Control ...................................................................................................................................... 34
Monitor Control .................................................................................................................................................... 36
Bar Graph (coolant temperature gauge, oil temperature gauge, fuel gauge) .................................................... 36
Accessories .......................................................................................................................................................... 42
Horn ................................................................................................................................................................... 42
Working Light ..................................................................................................................................................... 43
Wiper & Washer ................................................................................................................................................. 44
Room Lamp ........................................................................................................................................................ 46
Radio Mute ......................................................................................................................................................... 48
Others .................................................................................................................................................................... 49
Anti-Theft ............................................................................................................................................................ 49
Battery Save Function ........................................................................................................................................ 50
Alternator Power Generation Detection ............................................................................................................. 51
Overload Alarm (Europe only) ............................................................................................................................ 52
Options .................................................................................................................................................................. 54
Option Line Control ............................................................................................................................................ 54
Option Line Control ............................................................................................................................................ 57
Feed Pump Automatic Stop ............................................................................................................................... 59
Return Filter Clogging Detected ......................................................................................................................... 62
Beacon (Europe Only) ........................................................................................................................................ 63
ENGINE SUMMARY .................................................................................................................................................... 65
Engine System Diagram .................................................................................................................................... 65
Fuel System Diagram ......................................................................................................................................... 66
Detailed Part ...................................................................................................................................................... 69

4001-3
Engine Control Summary ....................................................................................................................................74
EXPLANATION OF ENGINE FUNCTION ....................................................................................................................75
Engine Function Explanation table .....................................................................................................................75
EGR (Exhaust Gas Recirculation) ......................................................................................................................77
Relationship between ECM and sensor actuators ..............................................................................................78
Cautions for Maintenance ...................................................................................................................................79
Explanation of Engine Control ............................................................................................................................81
Engine Start/Stop Judgment ...............................................................................................................................84
SERVICE SUPPORT ....................................................................................................................................................85
Screen Operations ................................................................................................................................................85
Screen Display List ...............................................................................................................................................87
CHK (status display) Screen List ........................................................................................................................87
MAIN ...............................................................................................................................................................87
MNT ................................................................................................................................................................90
H / W-A ...........................................................................................................................................................92
H / W-B ...........................................................................................................................................................95
H / W-M ...........................................................................................................................................................98
DIAG (trouble diagnosis) Screen ........................................................................................................................99
Screen ............................................................................................................................................................99
Operation ......................................................................................................................................................100
Reset ............................................................................................................................................................100
HR (usage log) Screen List ...............................................................................................................................101
MAIN .............................................................................................................................................................101
ENG ..............................................................................................................................................................103
CFG (setting change) Screen ...........................................................................................................................106
Operation ......................................................................................................................................................106
Screen ..........................................................................................................................................................107
CAL (troubleshooting support) Screen ..............................................................................................................109
Operation ......................................................................................................................................................109
Screen ..........................................................................................................................................................109
Check the Monitor Switch (Self-diagnosis function) ..........................................................................................111
Screen ..........................................................................................................................................................111
Configuration ................................................................................................................................................111
Differences from CHK screen [CHK | H/W-M | 1] .........................................................................................112
Option Flow Setting ...........................................................................................................................................113
Screen ..........................................................................................................................................................113
Flow setting ...................................................................................................................................................113
Anti-theft Setting ...............................................................................................................................................115
Anti-theft setting and password registration ..................................................................................................115
Anti-theft function operation ..........................................................................................................................116
Model Setting ....................................................................................................................................................117
Engine Screen Information ...............................................................................................................................119
Purpose ........................................................................................................................................................119
How to go to this screen ...............................................................................................................................119
Engine start restriction ..................................................................................................................................119
Screen ..........................................................................................................................................................119
Monitor operation method .............................................................................................................................120
Engine Information (Q resistance, QR code, engine serial number) Copying Method .................................121
Rewriting Injector QR Codes ........................................................................................................................122
When Replacing Computer A at the Same Time ..........................................................................................123
Engine Information Obtained Timing ............................................................................................................123
Redoing Engine Information Obtained ..........................................................................................................123
Trouble Display .............................................................................................................................................123
Screen Display Details .......................................................................................................................................124
Message Display List ........................................................................................................................................124
Trouble Display ...................................................................................................................................................126
Diagnostic Trouble Code Display ......................................................................................................................126
Main Unit Diagnostic Trouble Code List ............................................................................................................127

4001-4
Diagnostic Trouble Code (Monitor Display) ..................................................................................................... 133
Sensor Trouble Operation Table ...................................................................................................................... 138
EPF (engine protection feature) ....................................................................................................................... 140
CNH-EST DIAGNOSTIC TOOL
The EST (Electronic Service Tool) system allows diagnoses on machines and engines by detecting the operating
parameters of electronic control components (control units, sensors etc.). It is also capable of reading fault codes. To
help with troubleshooting the failure mode.

4001-5
ELECTRIC CIRCUITS OPERATION EXPLANATION
Explanation of Electrical Functions
No. Item Control Contents

1 Throttle Control The engine speed, work mode, and boosted pressure state
are switched by the throttle volume.
2 Idling Control With auto / one-touch switchover function
Engine
3 Idling Start Runs the engine at low idle speed when it starts up.
1 Speed
Control 4 Idle Up In order to prevent the engine from stalling, during operation,
raises the low idle speed to the auto idle speed.
5 Auto Warm Up If the coolant temperature is low, warm-up operation is
executed automatically when the engine starts
1 Engine Start / Stop Judgment based on engine speed from ECM
Judgment
Engine Start 2 Power-Cut Delay When key ON OFF, 4-second delay; when engine running
2 / Stop OFF, 7-second delay
Control 3 Engine Emergency When the emergency stop switch is pressed, the ECM
Stop recognizes this and stops the engine.
4 Neutral Start Control Engine start load (cell not turning) when lever locked
1 Work Mode Control Linked with the throttle, the SP / H / A mode is switched over
and the pump horsepower is controlled.
2 Pump Added The pump horsepower milli-amp is raised when there is a high
Horsepower Control load or sharp load.
Pump 3 Pump Horsepower Cut The pump horsepower milli-amp is reduced by the transient
3
Control Control load control, engine stall prevention control, and PID control
conditions.
4 Power Save Control The negative control relief pressure for non-operation is varied
and the negative control pressure is lowered to reduce the
pump load.
1 Swing Brake When the upper and swing are not operated, the swing brake
is operated automatically and during travelling too
2 Swing Free Swing Swing option for North America
(option)
4 Swing
3 Swing Lock There is a swing lock function (for servicing) with monitor
operations.
4 Swing Relief Cut When a swing starts, the flow is reduced with the front side
proportional valve and the excess oil is eliminated.
1 Travel Speed Travel speed low-speed / high-speed switchover
5 Travel Switchover
2 Travel Alarm Buzzer sounded (for 10 seconds) during travel
1 Lever Lock Operation is not possible unless the gate lever is raised.
2 Solenoid Sticking When key ON, solenoid switched ON / OFF for 0.25 second.
Valve Prevention
6
Control 3 Pressure Boost Control The computer automatically raises the pressure from 34.3
MPa (433 bar / 4975 psi) => 36.8 MPa (368 bar / 5338 psi)
when necessary.
1 Monitor Function Output port control method change, lift crane and option
Monitor screen added to display screens, etc.
7
Control 2 Monitor Bar Graph Bar graph display of coolant temperature, oil temperature, and
fuel level on monitor

4001-6
No. Item Control Contents

1 Horn Switching between one or two horns with horn volume select
switch
2 Working Light Right housing and boom light illumination (option setting for
two lights at top of cab)
8 Accessories 3 Wiper & Washer Wiper with rise-up used (intermittent, continuous, washer)
4 Room Lamp The room lamp lights up when the door is opened and lights
up for exactly 30 seconds from when the door is opened with
the key OFF.
5 Radio Mute Mute switch setting on the knob
1 Anti-Theft Anti-theft set with password input to monitor
2 Battery Save Function When the key is ON, no output to travel switchover, boost,
power save, bucket lock, option switchover and free swing
9 Others solenoid valve.
3 Alternator Power Alternator L terminal voltage judged with 10 V comparator
Generation Detection
4 Overload Alarm Only mounted on machines for Europe
1 Option Line Control Switchover crusher / breaker with just rocker switch in cab
2 Option Line Control There are five flow settings each for the breaker and crusher,
for a total of 10 settings.
3 DC-DC Converter Convert 24 V into 12 V
4 Feed Pump Automatic Feed pump automatic stop. Full tank detected by fuel level
10 Options
Stop sensor and the pump stopped automatically
5 Return Filter Clogging Alarm issued when return filter clogged (only for breaker
Detected specifications)
6 Beacon Control Standard for Europe.
(rotating light)
11 Engine Commun rail control

4001-7
Engine Speed Control
1. Throttle Control
1) Throttle display
a) Configuration
Throttle display data
Throttle display
Target engine speed
1 Monitor 3 Engine
2 Computer A 4 Throttle volume
b) Summary
The throttle volume voltage signal is first input to Computer A. Computer A converts the voltage signal to a
target speed and sends it to the ECM with CAN communications.
At the same time, Computer A sends the throttle display data to the monitor.
2) Throttle volume position detection
a) Configuration
1 Throttle volume
2 Computer A
3 Potentiometer

4001-8
b) Structure
The detent and notches provide a click feel (15 notches; Notch 1 is the "SP mode" position).
Hysteresis about 2.5°
(Right turn)
When the detent
Small notch: 4 to 15 Large notch: 1 to 3 reaches the N- position,
it is judged to beat
Notch N.
(Left turn)
When the detent
reaches the N+ position,
it is judged to be at
Notch N.
Left turn Right turn Notch number (1 to 15)
Notch N
Detent
detent position detection:
Hysteresis is used to
absorb error.
c) Characteristic
Hysteresis
Detent position (notch number)
(AUTO)

4001-9
d) Potentiometer characteristic
Voltage (V)
Angle (deg)
Throttle operation range
Trouble Normal Trouble
Potentiometer operation range
e) Throttle volume degree of opening calculation

The throttle volume degree of opening (%) that can be checked on the CHK screen is calculated with the
standard below.
100% => When the detent is in the 1+ position
0% => When the detent is in the 15- position
Therefore, even if the detent is in the 1 position (SP), this does not necessarily mean that the degree of
opening is 100%.
In the same way, even if the detent is in the 0 position, the degree of opening is not necessarily 0%.

4001-10
f) Table
For the angle, voltage, and degree of opening for each detent position, see the following table.
Degree of
Detent Angle [degree] Voltage [V]
opening [%]
1+ 131.2 4.86 100.0
1 128.7 4.77 98.0
1- 126.2 4.67 96.1
2+ 109.6 4.06 83.0
2 107.1 3.97 81.1
2- 104.6 3.87 79.1
3+ 95.2 3.53 71.7
3 92.7 3.43 69.8
3- 90.2 3.34 67.8
4+ 88.0 3.26 66.1
4 85.5 3.17 64.1
4- 83.0 3.07 62.2
5+ 80.8 2.99 60.4
5 78.3 2.90 58.5
5- 75.8 2.81 56.5
6+ 73.6 2.73 54.8
6 71.1 2.63 52.8
6- 68.6 2.54 50.9
7+ 66.4 2.46 49.1
7 63.9 2.37 47.2
7- 61.4 2.27 45.2
8+ 59.2 2.19 43.5
8 56.7 2.10 41.5
8- 54.2 2.01 39.6
9+ 52.0 1.93 37.8
9 49.5 1.83 35.9
9- 47.0 1.74 33.9
10+ 44.8 1.66 32.2
10 42.3 1.57 30.2
10- 39.8 1.47 28.3
11+ 37.6 1.39 26.5
11 35.1 1.30 24.6
11- 32.6 1.21 22.6
12+ 30.4 1.13 20.9
12 27.9 1.03 18.9
12- 25.4 0.94 17.0
13+ 23.2 0.86 15.2
13 20.7 0.77 13.3
13- 18.2 0.67 11.3
14+ 16.0 0.59 9.6
14 13.5 0.50 7.6
14- 11.0 0.41 5.7
15+ 8.8 0.33 3.9
15 6.3 0.23 2.0
15- 3.8 0.14 0.0

4001-11
2. Idling Control (auto / one-touch)
1 Monitor display 5 One-touch idle switch 9 Pressure sensor (travel)

2 Computer A 6 Throttle volume 10 Pressure sensor (arm-in)
3 Engine 7 Pressure sensor (upper) ECM Engine Control Module
4 Coolant temperature sensor 8 Pressure sensor (swing)
Operation explanation:
a) Auto / one-touch switchover function
The operator can switch between one-touch and auto by pressing the auto idle switch on the monitor in the
figure below.
When auto idle is ON, the LED at the side of the switch lights up.
b) Auto idle control (A)

1. When auto idle is set, if the lever is left continuously unoperated for 5 seconds, the engine speed
automatically becomes the auto idle speed (1200 min-1).
This five-second setting for auto idle operation is the default value. This setting can be changed to from
1 to 30 seconds with service support operations.
2. When the lever is operated, the engine speed is automatically returned to the engine speed set for the
throttle volume.
3. Even with auto idle set, it is possible to move to auto idle or return from auto idle by pressing the knob
switch (one-touch idle switch) on the right operation lever.
c) One-touch idle control
When auto idle is not set, regardless of lever operation, it is possible to move to auto idle or return from
auto idle by pressing the knob switch (one-touch idle switch) on the right operation lever.
The idling speed for one-touch idle control is 1000 min-1 on CX160B to CX240B and 900 min-1 on CX290B.

4001-12
d) Idling speed
1. Auto idling speed => 1200 min-1
2. One-touch idling speed => 1000 min-1 on CX160B to CX240B and 900 min-1 on CX290B.
3. Low idling speed => 1000 min-1 on CX160B to CX240B and 900 min-1 on CX290B.
The speeds above are the default values. They can be set to from 900 to 1600 min-1 with service support
operation (See Screen Operation in Service Support). However, the settings are based on the following
conditions.
Low idle speed = One-touch idle speed ≤ Auto-idle speed
(The one-touch idle speed and auto-idle speed settings can be changed).
3. Idling Start
a) When the engine starts, the engine speed becomes the low idle speed regardless of the throttle position.
b) When the low idle speed is changed, the engine speed is controlled at this new speed.
c) During an idling start, the idling icon (A) is displayed at the top left of the monitor.
No message is displayed
.
d) An idling start is ended in the following cases and control becomes normal.
1. When the one-touch idle switch is pressed
2. When the throttle volume is operated
3. When the operation lever is operated (upper, travel, swing, arm-in pressure sensor ON)
e) Back-up operation
1. Sensor trouble
If trouble occurs in a sensor (upper, travel, swing, arm-in), the idling start is ended.
2. Throttle volume trouble
Even if the throttle volume is operated, the idling start is not ended. Also, even if the idling start is ended
with some other method, the throttle cannot be adjusted.
3. One-touch idle switch trouble
Even if the switch is pressed, the idling start is not ended.

4001-13
4. Idle Up
A function that when the engine speed is less than the idling speed, causes lever operation to automatically
raise the engine speed to the auto idling speed (Idle speed engine stall prevention function).
Operation conditions:
a) Control only when the engine speed is lower than the auto idling speed
b) The idle up speed is the same as the auto idling speed (Factory setting 1200 min-1).
c) This control does not operate when the idling speed is higher than the auto idling speed. Also, when auto idling
is operated, normally the auto idling function operates.
d) Even with one-touch idling operating, this control operates to raise the idling speed.
e) A lever is judged to have been operated when any pressure sensor (upper, travel, swing, arm-in) comes ON.
f) If trouble occurs in any of the above pressure sensors, idle up control is not executed.
Auto idle (down)
Idle up Throttle volume operation
Idle up speed
(auto-idle speed)
Engine speed 5 seconds
Pressure sensor SIG

(operation lever)
5. Auto Warm Up
If the coolant temperature is low when the engine starts up, warm-up operation is executed, automatically raising the
engine speed in steps.
a) Auto warm up is used if the coolant temperature is lower than 50 °C (122°F) when the engine starts.
b) If the coolant temperature is 50 °C (122°F) or higher, auto warm up is not used and an "idling start" is executed.
c) Operation
The engine speed is raised in steps from the low idle speed until 1800 rpm as below.
When the low idle speed is changed, the engine speed starts from the newly set speed.
The warm up time is the same, 14 minutes.
When the coolant temperature reaches 50 °C (122°F), the engine speed falls immediately to low idle
(Idling start).
Low idle
Low idle
900 or 1000min-1
5 minutes 3 minutes 3 minutes 3 minutes

4001-14
d) Monitor display
During auto warm up, the “Auto warm up icon” (A) is displayed at the top left of the monitor.
e) In the cases below, auto warm up is ended and operation shifts to "idling start".
1. When the coolant temperature reaches 50 °C (122°F)
2. When the one-touch idle switch is pressed
3. When the entire auto warm up process ends (after 14 minutes)
f) In the cases below, auto warm up is ended and operation shifts to the engine speed for the throttle position.
1. When the lever is operated (as detected by a pressure sensor)
2. When the throttle volume is operated
g) Back-up operation
1. Sensor trouble
If trouble occurs in a sensor (upper, travel, swing, arm-in, coolant temperature sensor), auto warm up is
not operated. Also, even trouble occurs in a sensor partway through a warm up, the warm up is ended
and operation shifts to normal control.
2. One-touch idle switch trouble
Even if the switch is pressed, auto warm up is not ended.
3. Throttle volume trouble
Even if the throttle volume is operated, the auto warm up is not ended

4001-15
Engine Start / Stop Control
1. Engine Start / Stop Judgment
a) Configuration
Speed
ECM
1 Computer A
2 Cam sensor
3 Crank sensor
b) Summary
Engine start and stop is judged based on the engine speed sent from the ECM with CAN communications.
c) Judgment value
Start 500 min-1, Stop 200 min-1
Start
Stop
200 min-1 500 min-1

4001-16
2. Power-Cut Delay
a) Configuration (fuses etc. omitted)
1 Computer A 5 Load A
2 Key switch 6 Power supply
3 Battery relay 7 Key switch signal
4 Battery 8 Battery relay hold
b) Summary
After the key is switched OFF, after the battery relay is held for a certain period, the power supply is cut off.
c) Purpose
1. This secures time after the key is switched OFF for data to be written in the EEPROM in the ECM and
Computer A.
2. This waits until the engine completely stops to avoid load dumping.
d) Operation
1. When the key is ON, the battery relay is held by the battery relay hold output (OUT1) from the ECM and
the key switch.
2. After the key is switched OFF, the battery relay is only held by the ECM.
3. After it detects the key going OFF through the key switch signal input (IN1), the ECM starts the count
down.
4. After a certain time has passed, the ECM stops output to the battery relay and the battery relay goes
OFF.
At the same time, the power supply to electrical parts, including the ECM and computer is cut (Except
the backup power supply).
5. The time from the key being switched OFF until the power supply goes OFF (the delay time) depends on
whether or not the engine was started.
• After the key is switched ON, if the key is switched OFF without the engine being started = about 4
seconds.
• If the key is switched OFF after the engine was started = about 7 seconds.

4001-17
3. Engine Emergency Stop

Function for stopping the engine in an emergency
When the emergency stop switch on top of the left console is pressed, the engine is stopped regardless of the
key switch position.
1 Monitor display 3 Engine

2 Computer A 4 Emergency stop switch
a) Circuit
1. When the emergency stop switch is pressed, a 24 V signal enters the ECM input port.
2. When the 1) signal enters, the ECM controls the injector, suction control valve, and EGR valve to stop
the engine.
3. The emergency stop switch signal enters computer A too and computer A sends the engine stop
command to the ECM with CAN communications.
4. At the same time, computer A sends the emergency stop and buzzer instructions to the monitor with
serial communications.
b) Display, alarm
1. When the emergency stop switch is switched ON, the "ENGINE STOP" message is displayed on the
monitor.
2. Even if there is another message, the "ENGINE STOP" message is displayed with priority for five
seconds after the switch is switched ON.
3. At the same time as 1), the buzzer in the monitor buzzes intermittently at 1 Hz.
4. If any kind of trouble is detected during the 1 Hz intermittent buzzing of 3), after the 5-second continuous
buzzing, which is the trouble alarm, the buzzing returns to the 1 Hz intermittent buzzing.
5. Even if the buzzing continues after the switch ON/OFF message display (for 5 seconds), the message
display is not extended.
6. The above message display and buzzer operate whether the engine is running or stopped.
c) An emergency stop takes priority over any other control and stops the engine.
• The engine stops even during lifting magnet suction, during elevator cab rising, and fan reverse
operation (large machine only).
d) When an emergency stop is made, it is not recorded in the trouble log.
e) The engine can be cranked with the emergency stop switch ON, but the engine will not start.

4001-18
4. Neutral Start
a) Purpose and summary
The engine will not start with the gate lever lifted (It will not crank).
This prevents accidental operation if the operation lever is accidentally bumped into when the engine is
started.
b) Configuration
Gate lever
Down (OFF)
Up (ON)
1 Key switch 5 Starter cut relay

2 Gate lock limit switch 6 Lever lock solenoid
3 Starter motor 7 Battery relay
4 Safety relay
c) Operation
When the gate lever is raised (and the limit switch comes ON), the starter cut relay is excited, the excitation
to the safety relay is cut off, and the engine does not crank. At this time, nothing in particular is displayed
on the monitor.

4001-19
Pump Control
1. Work Mode Control
a) Purpose:
Work mode control enables the operator to select the work mode to match the work contents, for example
emphasizing speed, emphasizing fuel economy, etc.
At the same time, the engine speed is adjusted (throttle adjustment).
Work mode display
Work mode display
Target engine speed
ECM
1 Monitor 6 Boost solenoid

2 Computer A 7 P1 pressure sensor
3 Engine 8 P2 pressure sensor
4 Throttle volume 9 N1 pressure sensor
5 Pump horsepower control proportional valve 10 N2 pressure sensor
b) Operation:
1. Manual switchover (main mode)
The operator can select one of the following work modes by turning the throttle volume.
For the correspondence between the throttle volume detents and the work modes, see the attached
table.
Mode Aim Display Monitor buzzer

The buzzer buzzes twice when
(1) SP mode Speed emphasis
this is selected.
Balances speed and The buzzer buzzes once when

(2) H mode
fuel economy this is selected.
Fuel economy
(3) A mode No buzzing
emphasis
2. Automatic switchover (submode)

Each of the main modes that can be selected manually has two sub-modes (high and low).
These sub-modes are switched automatically based on the sensor input values.
For the high and low milli-amp, refer to the explanation of the 2. Pump Added Horsepower Control in
next page.

4001-20
2. Pump Added Horsepower Control
a) Purpose:
To prevent drop in the engine speed when the lever is operated sharply, when there is high load, when
travelling, etc.
Control milli-amp
Volume position
1 2 3 4 to 8 9 to 15
Models (detent position)
Work mode SP H AUTO
Engine speed (min-1) 2000 1900 1800 1799 to 1300 1299 to 1000
Pump type Max High
CX160B
horsepower Max Low
milli-amp (mA) Min
Pump type Max High 600 600 600 314 50
CX210B
horsepower Max Low 586 570 570 314 50
milli-amp (mA) Min 314 314 314 314 50
CX240B
milli-amp (mA) Min 290 290 290 290 50
CX290B
milli-amp (mA) Min 314 314 314 405 50
Boosted pressure Automatic Automatic Normal
b) Operation:
1. Reduces the amount of speed drop under high load (SP-H mode)
Operation conditions => For high load
When the P1 + P2 pressure becomes high voltage, the milli-amp to the pump horsepower control
proportional valve Imax is changed Low => High to increase the pump flow.
2. Reduces the amount of speed drop under high load when digging with the arm-in (SP-H mode)
When the arm-in operation is detected by the arm-in pilot pressure sensor, high load is detected faster
than for other operations.
3. Rise speed up for sharp lever operation
Operation conditions => For sharp lever operation
When sharp lever operation is detected by the N1 or N2 negative control pressure sensor, the milli-amp
to the pump horsepower control proportional valve Imax is changed Low => High to increase the pump
flow.
4. For travel operation
For travel operation, the pump milli-amp is fixed to 600 mA.
However, if the engine speed is 1300 min-1 or less, the pump milli-amp is fixed to 50 mA (Prevention of
engine stalling is given priority).

4001-21
3. Pump Horsepower Cut Control

a) Purpose:
The pump milli-amp is controlled in order to prevent black smoke under overload and engine speed drop and
in order to improve energy saving.
The control methods are the following three.
1. Overload reduction control
2. Engine stalling prevention control
3. PID control
ECM
1 Computer A 5 P2 pressure sensor

2 Pump 6 N1 pressure sensor
3 Engine 7 N2 pressure sensor
4 P1 pressure sensor 8 Pump horsepower control proportional valve
b) Overload reduction control

When the engine is under overload, the milli-amp to the pump horsepower proportional valve first drops to
50mA.
After that, the milli-amp is gradually raised while watching the difference between the actual engine speed
and the target engine speed.
Overload reduction control is executed in all work modes.
• The engine is judged to be overloaded when the following conditions are met.
1. Sharp lever operation
When there is sharp lever operation, this is judged from the upper pressure sensor state.
2. Operation for high loads and sharp loads
Judged from the P1 or P2 pump pressure sensor and from the pump main pressure boost state.
c) Engine stalling prevention control
When the target engine speed is 1300 min-1 or less, the milli-amp is 50 mA.
d) PID control
When the engine actual speed falls 30 min -1 or more below the target engine speed, the milli-amp is
gradually lowered to I Min.
When the difference of the actual engine speed from the target engine speed falls below 30 min-1 the milli-
amp rises to the I Max High for the each mode.
Backup control
If trouble occurs in a pressure sensor (P1, P2, upper), the overload restriction control is not carried out.
If trouble occurs in the pump horsepower control proportional valve, the output from the computer stops.
4. Power Save Control

a) Purpose:
When no lever is operated, the pump load is reduced with the control below to reduce fuel consumption.

4001-22
The control methods are the following two.
1. The negative control relief pressure is varied and the negative control pressure is lowered to reduce the
pump load.
2. The pump discharge amount is set to the minimum flow.
1 Computer A 6 Travel pressure sensor

2 Control valve 7 Negative control foot relief valve
3 Power save solenoid 8 Pump 1
4 Upper pressure sensor 9 Pump 2
5 Swing pressure sensor 10 P1 flow control proportional valve

4001-23
b) Operation explanation:
1. Normal operation
If more than one second passes with all the sensor signals to the computer OFF (upper, travel, and
swing pressure), the computer judges that no lever is being operated and outputs to the P1 flow control
proportional valve and the power save solenoid valve.
1. P1 pump discharge reduced
a)The P1 flow volume proportional valve milli-amp is increased from 50 mA to 740 mA.
b)The P1 pump swash plate is switched to the minimum tilt revolution and the discharge amount is set
to its minimum.
2. P2 pump discharge reduced
a)When the power save solenoid valve is switched, the pilot source pressure is fed to the P2 pump
negative control port via the solenoid valve.
b)The P2 pump swash plate is switched to the minimum tilt revolution and the discharge amount is set
to its minimum.
3. Negative control pressure reduction
a)When the power save solenoid valve is switched, the negative control foot relief valve spring
chamber is linked with the tank line and the negative control foot relief valve setting pressure drops
from 3 MPa (30 bar / 435 psi) to 1 MPa (10 bar / 145 psi).
b)By reducing the negative control relief pressure, the pressure within the circuit is reduced, and the
horsepower used by the pump is reduced. This saves energy.
2. Operation when the engine is stopped with the key ON.
Even if no lever is operated, when the engine stops, the battery save function works and there is no
output to the P1 flow control proportional valve or the power save solenoid.
3. Operation for trouble
If an abnormality occurs on either the input side (upper, swing, travel pressure sensors) or the output
side (P1 flow control proportional valve, power save solenoid valve), the system treats this as operation
being underway and control is fixed to the following.
milli-amp to the P1 flow volume valve => 50 mA, the power save solenoid valve is always OFF.
Caution: During a trouble, even if the abnormality is ended, trouble mode does not end until the key is
switched OFF.
1 second 1 second
Flow proportional
valve
Power save
solenoid
Pressure sensor
(upper)
Pressure sensor
(travel)
Pressure sensor
(swing)

4001-24
Swing
1. Swing Brake
a) Configuration
For North
America
1 Horn volume select switch 8 Swing brake solenoid

2 Computer A 9 Accumulator
3 Engine 10 Swing Motor
4 Working light switch 11 Swing Brake
5 Auto idle switch 12 Free swing solenoid
6 Upper pressure sensor 13 Free swing switch (momentary)
7 Swing pressure sensor

4001-25
b) Braking function during upper operation
When the upper pressure sensor is ON, the brake goes OFF, one second after upper pressure sensor goes
OFF, the brake comes ON.
c) Braking control through swing operation
When the swing pressure sensor is ON, the swing brake goes OFF (Swing brake solenoid = OFF).
Five seconds after the swing pressure goes OFF, the swing brake comes ON (Swing brake solenoid = ON).
d) Swing lock with key OFF
When the key is OFF (during power-cut delay), the swing brake comes ON unconditionally
.
Power-cut delay
b) c) b), c) d)
1 second 5 seconds 5 seconds

1 second
Swing brake
solenoid
Upper pressure
sensor
Swing pressure
sensor
Swing brake
solenoid
Key switch
2. Free Swing (North America Only)

a) Free swing switchover
When the free swing switch is pressed, the free swing mode is switched ON <=> OFF. When the
(momentary) key is OFF, always start with free swing OFF (Previous data reset).
b) Free swing control
When free swing is ON, the free swing solenoid is ON and the swing brake solenoid is OFF.
c) Mode display
When free swing is ON, the icon in the figure below is displayed on the monitor.
d) Battery save
While the engine is stopped with the key ON, if free swing is switched ON, the icon is displayed, but the
free swing solenoid valve does not come ON. It does come ON after the engine starts.
Free swing

4001-26
3. Swing Lock (for maintenance)

This is used for measuring the swing relief pressure and other maintenance tasks.
a) Swing lock switching
In order to prevent accidental operation under certain special circumstances, sometimes the swing brake
need to be left ON all the time. "Swing lock" At this time, the swing lock can be switched ON / OFF by
holding down the "horn volume select switch", the "working light switch", and the "auto idle switch" at the
same time for 3 seconds.
When turning the key to ON, always start with the swing lock OFF (Previous data reset).
b) Swing lock control
When the swing lock is ON, even if the upper or the swing is operated, the swing brake keep working. Be
particularly careful about swing operation because the swing brake plate is dragged.
(The swing pilot pressure is not shut off. This is no more than a simple swing lock).
c) Competition with free swing
If the swing lock is used, even if free swing is ON, the swing brake solenoid comes ON and the free swing
solenoid goes OFF (Swing lock priority).
d) Mode display
When free swing is ON, the icon in the figure below is displayed on the monitor.
Swing lock
e) Time chart (free swing & swing lock)

Power-cut Power-cut
delay delay
Swing brake
solenoid
Free swing
solenoid
Engine state
Key swing
Free swing
Swing lock
3-b) 3-c) 2-a) 3-a)

2-d) Previous Previous
data reset data reset
f) Trouble mode
If trouble occurs in an input (upper / swing pressure sensor), communications (CAN), or output (swing
brake solenoid / free swing solenoid), the system goes into trouble mode. In trouble mode, the swing brake
solenoid is OFF and the free swing solenoid is OFF. Even if the trouble is recovered from, this does not
recover the system from trouble mode.

4001-27
4. Swing Relief Cut
Purpose:
When swing single operation is running, the pump flow is reduced, and the excess oil ejected from the swing
motor relief valve is eliminated.
1 Computer A 8 Boom (2) 15 Travel (right)

2 Throttle volume 9 Swing 16 P1 pressure sensor
3 Travel pressure sensor 10 Option 1 17 P2 pressure sensor
4 Option 1 pressure switch 11 Travel (left) 18 Regulator
5 N1 pressure sensor 12 Arm (2) 19 P1 flow control proportional valve
6 N2 pressure sensor 13 Boom (1)
7 Arm (1) 14 Bucket
a) Operation conditions for swing relief cut control
The swing relief cut control provides relief when the pressure is boosted for the start of the swing due to
sharp swing operation and the drained off excess oil is held to the lowest amount possible. The purpose is
to provide an energy saving effect.
Control is executed when all the conditions below are satisfied.
1. Sharp swing operation => When the swing lever is operated, this is judged from the swing pilot pressure
sensor pressure rise.
2. Within 1 second after start of swing
3. Travel non-operation => Travel pressure sensor OFF
4. No attachments other than boom down are operating.
• That no attachment is operating is judged from the N2 negative control pressure and P1 pressure
sensor.
5. Option line non-operation => Option pressure sensor OFF

4001-28
b) Control contents
For the swing relief cut operation, after the milli-amp to the P1 flow control proportional valve is increased
and the P1 flow is reduced, while checking the P1 pump discharge pressure, the system gradually reduces
the output milli-amp to the P1 flow control valve and raises the P1 pump flow to the constant swing speed.
• Swing relief cut control flow
Judged as swing single operation + sharp operation => Swing relief cut operation => Increased milli-amp
to P1 flow control proportional valve.
=> P1 pump flow reduced => Milli-amp gradually decreased while watching swing pressure fall status =>
P1 pump flow increased
NOTE: P1 flow control proportional valve: milli-amp (high) => P1 pump flow (low); milli-amp (low) => P1
pump flow (high)
c) Swing relief cut end conditions
1. When swing operation is stopped
2. Travel ON
3. Boom up, arm out / in, bucket open / closed
4. Boom down sharp operation
5. Boom down pressure boost

4001-29
Travel
1. Travel Speed Switchover
The travel motor tilt revolution angle is changed by switching the travel speed between low speed and high
speed with the switch.
However, in high-speed mode, if the drive force becomes high due to the functioning of the travel motor itself,
the tilt revolution angle is automatically switched to low speed.
After that, when the drive force becomes low, the slope automatically returns to high speed.
Switch data
Engine actual speed
1 Computer A 4 Travel motor

2 Engine 5 Travel high-speed solenoid
3 Travel high-speed select switch 6 Key switch
a) Operation
1. When the key is ON, the speed becomes low speed. The previous travel mode is reset.
(If the service support operation is changed, it is possible to hold the previous data).
2. Each time the travel high-speed switch is pressed, the speed is switched between low speed and high
speed. During high speed, the LED at the top left of the switch lights up.
3. While the engine is stopped with the key ON, if the high speed travel switch is pressed, the solenoid
does not operate. The LED lights up.
(To prevent the battery being run down).
4. In high-speed mode, the tilt revolution angle is automatically switched between low speed and high
speed by the travel motor drive force.
However, the electrical control remains at high speed, the high-speed LED remains lit, and the solenoid
remains ON.

4001-30
b) Trouble mode
If an abnormality occurs in communications (CAN) or computer solenoid output, the speed is fixed to low
speed (The travel high-speed solenoid comes OFF).
Key switch
Engine
Travel high-speed
switch
LED
Travel high-speed
solenoid
High speed
Travel motor
Low speed
Drive voltage rise
Drive voltage fall
2. Travel Alarm (North America only)

a) Configuration
Travel alarm
Intermittent buzzing control is handled by

the travel alarm itself. In other words, while
the travel alarm is ON, computer A buzzes
the buzzer intermittently as it wants.
For North
America:
Standard
1 Computer A Travel alarm mode select switch (alternator)

3
2 Travel pressure sensor
b) Travel alarm (automatic stop)

When the travel pressure sensor comes ON due to travel operation, the travel alarm starts 1 Hz intermittent
buzzing. This buzzing automatically stops after 10 seconds.
c) Travel alarm (continuous buzzing)
When the travel alarm mode select switch is switched ON, the buzzer buzzes continuously during travel
(Function for North America only).
d) Signals when key is ON
After the key is switched ON, the travel alarm sounds for 0.4 second as a signal.

4001-31
e) Time chart
0.4 seconds 10 seconds

10 seconds 10 seconds
ON
Travel alarm
OFF
Travel pressure ON
sensor
OFF
ON
Key switch
OFF
Travel alarm ON
mode select
switch OFF
d) b) c) Mode switchover
during travel
f) Trouble mode
If trouble occurs in the travel pressure sensor, the machine goes into trouble mode and the travel alarm is
always OFF.

4001-32
Valve Control
1. Lever Lock
Gate lever
Down (OFF)
UP (ON)
1 Gate lock limit switch 3 Lever lock solenoid

2 Starter cut relay 4 Battery relay
When the battery relay is excited by the key being switched ON, the power enters the lever lock limit
switch. When the gate lever is raised, the lever lock switch (limit switch) comes ON and the lever lock
solenoid is operated (For details on neutral start control, see Neutral Start in Explanation of Functions and
Operations).

4001-33
2. Solenoid Sticking Prevention

a) Target solenoid
• Travel high-speed switchover solenoid
• Boost solenoid
• Option switchover solenoid
• Fan reverse solenoid (only for models with hydraulic drive fan)
• Free swing solenoid
• Bucket lock solenoid (only lift crane application machines)
Because the swing brake, power save solenoid, and electromagnetic proportional solenoid go ON and
OFF frequently in regular work, they are not subject to control.
b) Operation
When key ON, switched ON / OFF for 0.25 second.
After that, control is normal control. Control ends before the engine starts, so the machine does not operate
accidentally.
ON
Key switch
OFF
ON Normal control
Solenoid
OFF
0.25 second0.25 second

4001-34
3. Pressure Boost Control

a) Configuration
Message and icon
Engine load rate
1 Computer A 6 2nd option line pressure switch 11 P2 pressure sensor

2 Engine 7 Control valve 12 Pump 1
3 Upper pressure sensor 8 Main relief valve 13 Pump 2
4 Travel pressure sensor 9 Boost solenoid 14 Regulator
5 Option line pressure switch 10 P1 pressure sensor
b) During upper operation (upper pressure sensor = ON), the next time the high-load conditions are met, the boost
solenoid valve on the 5 stack solenoid valve comes ON, and the main relief valve pressure rises from 34.3 MPa
(343 bar / 4975 psi) to 36.8 MPa (369 bar / 5337 psi).
Conditions:
When the engine load ratio rises and the P1 or P2 pump pressure is boosted.
c) Auto power boost (ended by time restriction)
When the work mode is SP or H, the boost continues a maximum of 8 seconds, then is automatically ended
(boost solenoid = OFF). When the work mode is A, this time restriction is eliminated and the pressure boost
is always available.
d) Auto power boost (ended by operation stop)
Even before the time limit for auto power boost, if the upper pressure sensor goes OFF, the boost is ended.
e) Boost prohibition
During travel (travel pressure sensor = ON) or the breaker is in use (option line pressure switch = ON
and breaker mode), the boost is not used (Actuator protection).

4001-35
f) Auto power boost setting
Auto pressure boost can be switched ON / OFF and boost for breaker operation enabled / disabled with
service support operation.
g) During boosting, icon is displayed on the monitor
.
Icon
h) Time chart (when work mode = SP or H)

Less than 8 seconds
0.1 second 8 seconds 0.1 second 0.1 second 0.1 second
Boost solenoid
High-load conditions
Upper pressure
sensor
Message and icon
Travel pressure sensor

OR / AND
Option pressure sensor
c) d) e) b)
i) Trouble mode
If trouble occurs in an input (upper pressure sensor / travel pressure sensor), output (boost solenoid) or
communications (CAN), the system goes into trouble mode. In trouble mode, the boost solenoid is fixed to
OFF.
• Even if trouble occurs in UART communications, the system does not go into trouble mode.
• Trouble in the (2nd) option line pressure switch cannot be detected.
j) Recovery from trouble mode
Even if the trouble is recovered from, trouble mode continues.

4001-36
Monitor Control
1. Bar Graph (coolant temperature gauge, oil temperature gauge, fuel gauge)
1) Coolant temperature gauge
a) Configuration
Display data
Coolant
temperature
data
. 8-level bar graph type
. Displayed on monitor LCD
. The left is the gauche level 3 display state.
Gauge
level
1 Coolant temperature gauge 3 Computer A

2 Monitor 4 Coolant temperature sensor
b) Operation summary
The ECM reads the coolant temperature from the coolant temperature sensor installed on the engine and
send to computer A through CAN communication. After computer A receives the coolant temperature, it
judges the gauge level, and sends the display data to the monitor with UART communications.

4001-37
c) Gauge coolant temperature
The gauge level is judged based on the figure below.
Gauge level
Temperature
d) Preventing flickering
When the temperature moves up or down near the gauge level fluctuation threshold (for example 51 °C
[124°F]), the gauge goes on and off repeatedly causing flickering. In order to prevent that, the gauge level
is judged using the temperature (judgment coolant temperature) after the following processing.
• Judgment coolant temperature = Average of the coolant temperatures obtained the past 32 times
• Coolant temperature obtained period = 1 second
• Bar graph update period = 32 seconds (updates when the 32nd coolant temperature obtained)
e) Trouble mode
If trouble occurs in the coolant temperature sensor or CAN bus, the bar graph itself is not displayed.
1. If there is a short, the bar graph display is immediately ended.
2. For a disconnection, the display goes off 3 minutes after the engine starts.
If trouble occurs in UART communications (computer => monitor), the display is fixed at the last state sent.
When the trouble is recovered from, the display returns to normal.
For a disconnection, when the key is switched OFF more than three minutes after the engine starts, then
ON again, the display is recovered.
Trouble
Recovery
Non-display state
(oil temperature sensor
breakdown) or CAN bus
• Coolant temperature obtained during trouble:

If a meaningless coolant temperature were obtained and the processing in d) carried out, display upon
recovery would be strange. In order to prevent this, the coolant temperature is not obtained during a
coolant temperature sensor or CAN bus trouble.
f) Message display
When the gauge level reaches 8, "OVERHEAT" is displayed on the monitor and the buzzer buzzes.

4001-38
2) Oil temperature gauge

a) Configuration
<= Return
Display data
=> suction (to pump)
. 8-Level bar graph type
. display on monitor LCD
.The left is the gauge level 3 display state.
Gauge level
1 Oil temperature gauge 4 Hydraulic oil tank

2 Monitor 5 Oil temperature sensor
3 Computer A
Computer A reads the oil temperature from the oil temperature sensor installed in the hydraulic oil tank
outlet pipe and judges the gauge level. The gauge level is sent to the monitor with UART communications.

4001-39
c) Gauge and oil temperature
The gauge level is judged based on the figure below.
Gauge level
Oil temperature
d) Preventing flickering
When the temperature moves up or down near the gauge level fluctuation threshold (for example 25 °C
[77°F]), the gauge goes on and off repeatedly causing flickering. In order to prevent that, the gauge level is
judged using the temperature (judgment oil temperature) after the following processing.
• Judgment oil temperature = Average of the oil temperatures obtained the past 32 times
• Oil temperature obtained period = 1 second
• Bar graph update period = 32 seconds (updates when the 32nd oil temperature obtained)
e) Trouble mode
If trouble occurs in the oil temperature sensor, the bar graph itself is not displayed (Only for trouble due to
short).
If trouble occurs in UART communications (send: computer -> monitor), the display is fixed at the last state
sent.
Trouble
Recovery
Non-display state
(oil temperature sensor
breakdown)
• Oil temperature obtained during trouble.

If a meaningless oil temperature were obtained and the processing in d) carried out, display upon
recovery would be strange. In order to prevent this, the oil temperature is not obtained during an oil
temperature sensor trouble.
f) Message display
When the gauge level reaches 8, "OVERHEAT" is displayed on the monitor and the buzzer buzzes.

4001-40
3) Fuel gauge
a) Configuration
Full
Empty
Amount allowing
one more hour of
work
. 8-level bar graph type
. Displayed on monitor LCD
. The left is the gauge level 3 display state.
1 Monitor 3 Fuel tank

2 Computer A 4 Fuel sensor
Computer A reads the fuel level from the fuel sensor installed in the fuel tank and judges the gauge level.
The gauge level is sent to the monitor with UART communications.

4001-41
c) Relationship between gauge level and lever angle
Gauge level
7 88.3
6 81.0
5 71.9
4 62.0
3 48.0
2 27.3
7.4
1
Lever angle (%)
0 50 100
The figures in parentheses ( ) are the fuel sensor lever angles.

Gauge level and fuel level [L] Reserve
Rated 8 7 6 5 4 3 2 1 [L]
Model
[L] (100% (88.3% (81% (71.9% (62% (48% (27.3% (7.4%
(0.0%)
to) to) to) to) to) to) to) to)
CX160B
CX210B,
410 407.5 358.4 331.5 295.9 255.0 196.5 196.5 116.3 37.9
CX240B
CX290B 450 447.5 393.5 364.4 325.0 280.1 210.0 127.7 60.4 41.6
d) Message display
When the gauge level reaches 1, "LOW FUEL" is displayed on the monitor and the buzzer buzzes (See
"Message Display List").
e) Preventing flickering
When the fuel surface in the tank shakes and the fuel sensor lever angle moves up or down near the gauge
level fluctuation threshold (for example 7%), the gauge goes on and off repeatedly causing flickering.
In order to prevent that, the gauge level is judged using the lever angle (judgment lever angle) after the
following processing.
• Judgment lever angle = Average of the lever angles obtained the past 32 times
• Lever angle acquisition period = 1 second
• Bar graph update period = 32 seconds (updates when the 32nd lever angle obtained)
f) Trouble mode
If trouble occurs in the fuel sensor, the bar graph itself is not displayed.
If trouble occurs in UART communications, the display is fixed at the last state sent.
(Send: Computer A => Monitor)
g) Lever angle obtained during trouble
If lever angle were obtained and the processing in e) carried out, display upon recovery would not be
normal.
In order to prevent this, the lever angle is not obtained during a fuel sensor trouble.

4001-42
Accessories
1. Horn
Basic operation
a) When the horn switch is pressed, the horn is driven via a relay.
b) When the volume select switch is switched ON, the LED indicator lights up and only the left horn sounds (Horn
volume down).
The volume select switch state is retained even when the key is switched OFF (The previous data is held).
c) Communications with computer
When this switch is pressed, the signal is first sent to the computer and processed.
Then, the drive command is sent to the monitor and the monitor drives the right horn (R) relay.
d) Trouble mode
If there is an error in UART communications, the monitor goes into trouble mode.
In trouble mode, the monitor carries out the operation in b) on its own without receiving commands from the
computer.
However, the previous data is not held (The monitor always starts up with normal volume).
When the error is recovered from, trouble mode ends too and the monitor returns to normal mode
z
Switch signal Drive

command
1 Monitor panel 6 Horn (L) relay

2 Horn volume select switch 7 Horn (R) relay
3 Horn switch 8 Horn (R)
4 Computer A 9 Horn (L)
5 Key switch

4001-43
2. Working Light
Basic operation
a) When turning the key to ON, always start with the working light OFF (Previous data reset).
b) Each time the working light switch is pressed, the working light is switched between ON and OFF (Momentary).
When this light is ON, the LED indicator lights up.
c) Communications with computer
When the working light switch is pressed, the signal is first sent to the computer and processed.
Then, the light command is sent to the monitor and the monitor drives the relay.
d) Trouble mode
If there is an abnormality occurs in UART communications, the monitor goes into trouble mode.
In trouble mode, the monitor carries out the operation in b) on its own rather than commands from the
computer.
When the communications error is recovered from, trouble mode is exited and the monitor returns to
normal mode.
See
«Air Conditioner»
Switch Light
signal command
For expansion
1 Monitor panel 6 Working light relay (cab)

2 Working light switch (with LED indicator) 7 Working light (boom)
3 Computer A 8 Working light (tool etc.)
4 Key switch 9 Working light (cab top)
5 Working light relay (upper)

4001-44
3. Wiper & Washer

a) Configuration
LED
WIPER (INT)
OPEN
WIPER (CNT)
OPEN
WASHER
Switch signal Drive command
1 Monitor panel 6 Computer A

2 Washer switch 7 Key switch
3 Wiper switch (with LED indicator) 8 Wiper motor
4 Monitor 9 Washer motor
5 Front window limit SW
b) Wiper basic operation

When the wiper switch is pressed, it switches to the next state in the order: intermittent operation =>
continuous operation => OFF => intermittent. In intermittent operation, the I LED is lit and in continuous
operation, the II LED lights up (When the wipers are OFF, both are OFF). When turning the key ON, always
start from OFF (Previous data reset).
c) Washer basic operation
While the washer is pressed, the washer operates.
d) Wipers linked with washer
While the washer switch is pressed, after 0.5 second, the washer starts to operate linked with the wipers.
When the washer switch is released, the washer stops, and after two wipes, the wipers stop too.
1. Auto rise up
Even during wiper operation, if the key is turned OFF, the wipers are automatically stopped and
retracted.
2. Overload prevention
If the blades are locked, the monitor output is stopped.

4001-45
e) Front window open detection
If the front window is opened while the wipers or washer are operating, it is stopped.
The operations of b) and c) are not carried out while the front window is open.
f) Wiper computer duty
The wiper computer is responsible for b) - d). e) is provided by the monitor / computer detecting the front
window being opened and the output to the wiper computer being switched OFF.
g) Computer A duty
Computer A receives switch signals from the monitor through UART communications (wiper switch, washer
switch, front window limit switch).
This signal is processed by computer A and the three ports that control the wiper computer (WIPER (INT),
WIPER (CNT), and WASHER) are controlled as in the following time chart.
h) Time chart
0.5 second Double wipe

0.5 second
Double wipe
Wiper operation
mode
Operation Wiper LED
Washer
WIPER (INT)
Connection
to wiper WIPER (CNT)
controller
WASHER
Wiper switch
Input Washer switch
Front window
limit switch
2) 2)
1. During washer operation, wiper operations are handled automatically by the wiper controler even if there
is no output to WIPER (INT) or WIPER (CNT).
2. Wiper stop by front window open detection
3. Washer-linked wiper stop by front window open detection
i) Trouble mode
If there is an error in UART communications, the monitor cannot receive drive commands from computer A.
At this time, the monitor goes into trouble mode and executes the same control as for on its own as in h).
When the UART communications error is recovered from, the monitor recovers from trouble mode and
follows the drive commands from computer A.

4001-46
4. Room Lamp
a) Configuration
OPEN
CLOSE
DOOR
See «Air
Conditioner»
1 Key switch 4 Room lamp

2 Clock unit 5 Door limit switch
3 Room lamp relay
• The clock unit is not connected with computer A or B and controls the room lamp relay on its own.
• For the (B) connection destination, see "Air Conditioner".
• The clock unit is connected to the backup power supply and continues to operate even if the key is
switched OFF.
b) Door link
When the room lamp switch is set to the DOOR position, the lamp lights when the door is open and goes
out when the door is closed.
c) Auto lamp off
In b), in order to prevent the battery from being run down, the room lamp goes out 30 seconds after the
door is opened. However, this function only works when the key switch is OFF. If it is ACC or ON, auto lamp
off does not work (Because even if the room lamp relay is OFF, power is supplied from ACC).
The only purpose of this auto lamp off function is to prevent the battery from being run down if the door is
left open with the key OFF.

4001-47
d) Time chart
The time chart shows how the function in c) works. The room lamp switch is set to DOOR.
30 seconds
30 seconds 30 seconds 30 seconds 30 seconds
Room lamp
Room lamp
relay
Door limit
switch
Key switch
1. Door linked room lamp

2. Even after the door is closed, the room lamp relay is ON for 30 seconds.
3. 30 seconds is counted from the last time the door was closed.
4. After 30 seconds, the lamp goes off automatically.
5. Auto lamp off does not work if the key switch is ON or ACC.
6. When the key is switched OFF, the lamp goes out (After power-cut delay).
e) Trouble mode
Since the clock unit does not have a trouble detection function for either input (IN1) or output (OUT1), it
does not go into trouble mode.
f) Time chart
This shows the operation when the room lamp switch is ON.
30 30 30
seconds seconds seconds
Room lamp
Room lamp relay
Door limit switch

ON = OPEN
OFF = CLOSED
Key switch
1. If the key is OFF, the lamp goes out automatically after 30 seconds
2. The door is open, so it does not go out.
3. Power-cut delay

4001-48
5. Radio Mute
a) Configuration
1 Mute switch (knob) 5 Speaker (R) relay

2 Clock unit 6 Speaker (L)
3 Radio 7 Speaker (R)
4 Speaker (L) relay
b) Summary and purpose

The radio volume can be switched ON / OFF with one-touch by switching the speaker (L, R) signal lines on
and off with a relay.
c) Operation
Each time the mute switch on the knob is pressed, the radio volume is switched between ON <=> OFF
(Momentary).
When the key is switched ON, the radio always starts with mute off (normal radio volume, previous data
reset).
d) Battery save
In order to prevent the battery from being run down, when the key is at ACC (accessory), the radio is
always set to mute off (normal radio volume).
ON
Mute
OFF
Speaker (L / R) ON
relay
OFF
ON
Mute switch
OFF
ON
Key switch ACC
OFF
Momentary Previous data Battery save Previous data

reset reset

4001-49
Others
1. Anti-Theft
a) Anti-theft setting and password registration and cleaning.
For details, see the «service support operation procedure».
b) Anti-theft control
If the anti-theft password does not match (anti-theft is not ended), the machine operation is controlled.
1 Computer A 5 Travel pressure sensor

2 Engine 6 Upper pressure sensor
3 P1 pressure sensor 7 Swing brake solenoid
4 P2 pressure sensor 8 Travel alarm
1. If the engine is started without ending the anti-theft, the machine is controlled as follows:
1. The engine speed is fixed at low idle.
2. The swing brake cannot be released (Solenoid operation is not possible).
3. The travel alarm buzzes continuously.
2. In the state in 1., if any of the following operations is executed, the engine is forced to stop.
1. Upper or travel operation (Detected by the corresponding sensor)
2. The P1 or P2 pressure rises to 5 MPa (50 bar / 725 psi) or higher.
3. The engine load is 50% or higher for two seconds cumulative.
4. The upper, travel, P1, or P2 pressure sensor is removed.
3. Even in the state in 1., the anti-theft control can be ended by inputting the correct password.

4001-50
2. Battery Save Function

a) Summary and purpose
In order to prevent the battery from being run down when the key is ON and the engine is stopped, solenoid
and proportional valve output is suppressed.
b) Operation
See the table below.
Control targets Operation when the engine is stopped with the key ON.
Travel high-speed Fixed to OFF (low-speed) whether the travel speed select switch ON or OFF
switchover solenoid However, the LED at the side of the switch is linked with the switch.
Power save solenoid Fixed to OFF (power save OFF)
Fixed to OFF (free swing OFF) whether the free swing switch ON or OFF
Free swing solenoid
However, the free swing icon on the monitor is linked with the switch.
Fixed to OFF (crusher side) whether the breaker / crusher mode switch ON or
Option return line
OFF
switchover solenoid
However, the attachment icon on the monitor is linked with the switch.
Fixed to OFF (no boost) regardless of the work mode (throttle volume position)
Boost solenoid
However, the status icon on the monitor is linked with the throttle
0 mA, so the standby milli-amp for detecting disconnections of 50 mA does not
Pump horsepower
flow
proportional valve
Disconnections are only detected after the engine has started
Pump flow Same as above
proportional valve

4001-51
3. Alternator Power Generation Detection

a) Configuration (fuses etc. omitted)
10 V Comparator
To load
B: Charge
L: Running signal
R: Initial excitation
E: GND
1 Computer A 3 Battery relay

2 Key switch 4 Alternator
b) Separated from battery voltage

When the battery relay is closed, by looking not at the B terminal, where the battery voltage is applied, but
rather to the independent L terminal, defects in the alternator alone are detected (The battery voltage is
monitored by the ECM (IN2)).
c) Operation
Alternator L terminal output voltage judged with 10V comparator
ON when L terminal voltage ≥ 10 V
OFF when L terminal voltage < 10 V. * The threshold value of 10 V has a tolerance of ±1 V.
d) Power generation defect judgment
If the 10V comparator input is OFF even though the engine is running, it is judged that there is a power
generation defect. For details on the judgment conditions, see the "Main Unit Diagnostic Trouble Code
List".

4001-52
4. Overload Alarm (Europe only)

a) Configuration
Buzzer, message
1 Overload alarm switch (alternate) 4 Boom cylinder bottom pressure sensor

2 Monitor panel 5 Boom
3 Computer A 6 Boom cylinder
b) Alarm judgment
When the overload alarm switch is ON, the overload alarm is switched ON / OFF according to the following
conditions.
ON: (Boom cylinder bottom pressure ≥ set pressure) for 1 continuous second
OFF: (Boom cylinder bottom pressure ≤ set pressure - 2 MPa (- 20 bar / - 290 psi)) continuous for 1 second
• For the set pressure for each model, see "Overload set pressure".
• The set pressure can be changed with CFG (see the "Service Support" chapter).
c) Operation when alarm judgment ON
The "OVER LOAD" message is displayed on the monitor and the buzzer buzzes intermittently.
This message is handled as an "alert". For details, see "Message Display List".
d) Ending the alarm
To end an alarm that has been issued, either switch the overload alarm switch OFF or operate the
attachment in such a way that the judgment in b) goes OFF.
Note that there is no buzzer stop switch.
e) Trouble mode
If trouble occurs in the boom cylinder bottom pressure sensor, this function goes into trouble mode and the
alarm judgment is fixed to OFF.
Even if the trouble is recovered from, trouble mode continues until the key is switched OFF.
f) Trouble judgment
The boom cylinder bottom pressure sensor trouble judgment is made after the overload alarm switch has
come ON once.

4001-53
g) Time chart
1 second 1 second 1 second 1 second 1 second
ON
Message
OFF
ON
Monitor buzzer
OFF
ON
Alarm judgment
OFF
Boom cylinder Set pressure

bottom pressure
Set pressure
- 2 MPa
Overload alarm ON
switch
OFF

4001-54
Options
1. Option Line Control
a) Configuration [Multi purpose circuit with 2nd option line]
Crusher
Rotation
Center OR
bypass
cut
OPTION 1
(Pedal type)
The hydraulic pressure

source is different.
The ground
treatment is
different.
(Knob switch type)
1 Monitor panel 10 Shut-off valve

2 Breaker mode switch 11 2 pumps flow solenoid valve
3 Option select switch 12 Option switchover solenoid valve
4 Crusher mode switch 13 1st option pedal
5 2 pumps flow switch 14 1st option pressure switch
6 2nd option control valve 15 1st option switch (L)
7 4th pump 16 1st option switch (R)
8 Control valve 17 Computer A
9 3-direction valve

4001-55
Option select switch switchover (breaker mode <=> crusher mode)
Operation:
When the option select switch is set to the breaker mode switch side, the option switchover solenoid valve
is operated and the shut-off valve is switched to the 3-direction valve. When the switch is switched to
crusher mode, the option switchover solenoid valve goes OFF.
Option 2
(Pedal type
1 2nd option pedal

2 2nd option switch (L)
3 2nd option switch (R)
2 pumps flow select switch (1 pump <=> 2pumps)

Operation:
When the 2 pumps flow switch is switched ON, the solenoid valve for 2 pumps flow to 2 pumps flow.
Difference between pedal type and knob switch type
For the pedal type, solenoid valve for 2 pumps flow hydraulic pressure source is the secondary pressure
via the option 1 pedal shuttle, but for the knob switch type, the solenoid for the 2 pumps flow pressure
source comes directly from the gear pump.
Therefore, when the 2 pumps flow switch is switched ON, operation becomes always 2 pumps flow.
In order to prevent this, whereas for the pedal type the ground treatment for the 2 pumps flow switch is to
ground directly, with the knob switch type, it is set so that the switch is not grounded unless one or the
other of the option switches is ON.
• Be careful. The shuttle valve is built into the option 1 pedal remote control valve.

4001-56
Mode select switch
When the breaker mode switch / crusher mode switch is pressed, the option line mode changes as follows.
Breaker 1 Breaker 2 Breaker 5

mode mode mode
Breaker 1
mode
Normal dig Normal dig
Crusher 1
mode
Crusher 1 Crusher 2 Crusher 5
mode mode mode
• The factory setting is that only breaker 1 mode and crusher 1 mode can be selected.
• With settings on the service screen, the number of modes can be increased to five each for the breaker
and for the crusher, for a total of 10.
b) For a), the following icons are displayed according to the mode.
Breaker mode Crusher mode Normal dig mode
None

4001-57
2. Option Line Control

a) Configuration [Multipurpose circuit with 2nd option line (pedal type)]
There are two operation methods: the pedal type and the knob switch
type. With either type, when the pedal or knob switch is operated the
switch input port (IN3, IN4 = «option select and operating method» IN4,
IN5) is the same. (In other words, there is no need to be aware of the
difference in operating method).
The explanation below uses the pedal method.
1 Computer A 12 Swing pressure sensor

2 N2 pressure sensor 13 Travel pressure sensor
3 Arm (1) 14 Option pedal
4 Boom (2) 15 Option pressure switch
5 Swing 16 2nd option pedal
6 Option 1 17 2nd option pressure switch
7 Travel (left) 18 Boost solenoid
8 Arm (2) 19 P1 pump
9 Boom (1) 20 P2 pump
10 Bucket 21 P1 flow control proportional valve
11 Travel (right)

4001-58
b) Option line operation control
The table below shows the control for operation of the single option and compound operation.
Option line mode Breaker Crusher Option 2

1st option pressure 1st option pressure 2nd option pressure
switch => ON switch => ON switch => ON
Operation
(IN3 is ground) (IN3 is ground) (IN4 is ground)
Single Compound Single Compound Single Compound
Boost cut Yes Yes No
Flow restriction Yes Yes No No function (4th pump)
Engine speed /
Pump horsepower According to the command for the work mode selected with the throttle
milli-amp
• The flow is not cut for compound crusher operation (To secure speed for compound operation).
• Since the breaker often works while the machine is jacked up with the boom (compound operation), the
flow is cut even for compound work (The same as the engine reduction for the current breaker).
• The pressure boost is cut when Option 1 and Option 2 are operated at the same time (Boost cut
priority).
• The engine speed and pump horsepower milli-amp are according to the work mode currently selected
with the throttle (cannot be forced to change to another mode only for breaker/crusher).
c) Option 1 single operation judgment conditions
When all the conditions below are satisfied, it is judged that this is single operation.
Conditions:
1st option pressure switch => ON Swing pressure sensor => OFF
Travel pressure sensor => OFF N2 pressure sensor ≥ 2.4 MPa (24 bar / 348 psi)
d) Flow cut
The maximum flow for option line operation is restricted to the flow for the option line mode selected with
"Option line selection and 2 pumps flow".
Also, be careful about the fact that since the flow set for the option line is the flow for SP mode, when used
in H/A mode, the flow is slightly less than the display.
e) Trouble mode
If a trouble occurs in input (swing pressure sensor, travel pressure sensor, N2 pressure sensor) or output
(boost solenoid, flow proportional valve), the machine goes into trouble mode and
• Output command to boost solenoid = fixed to OFF
• Output command to flow proportional valve = fixed to OFF
Trouble mode continues until the key is switched OFF.

4001-59
3. Feed Pump Automatic Stop
a) Configuration
Full
100%
Empty
0%
The accessory switch is fixed ON.
Manual
(momentary)
Automatic
(alternate)
When ON, auto feed is disabled.

When OFF, auto feed is enabled.
Actual speed
1 Computer A 6 Oil feed pump

2 Feed switch 7 Feed stop relay
3 Fuel sensor 8 Full tank detection buzzer
4 Fuel tank 9 Engine
5 Oil feed start relay
Feed pump main unit accessory (original) switch. this must be fixed ON beforehand in order to use this
function.

4001-60
b) Operating method
1. With the engine stopped and the key ON, if the feed switch is flipped down to the Auto side, the fuel feed
starts.
2. When the tank is full, the fuel feed stops automatically and the buzzer buzzes to announce that.
3. Returning the feed switch to the center stops the buzzer.
4. To feed more fuel
Press the feed switch manual side. The fuel is fed while the switch is pressed.
c) Computer control targets
Input = Fuel sensor (0 to 100%), engine state (running / stopped)
Output = Feed stop relay
d) System state (when relay OFF)
When the feed switch is set to the Auto side, the start relay comes ON and the pump operates.
e) System state (when relay ON)
When the feed switch is set to the Auto side, the start relay goes OFF, and the pump does not operate.
Also, the buzzer buzzes.
f) Feed stop relay control (while engine running and key ON)
Always ON (no feed).
g) Feed stop relay control (while engine stopped and key ON)
When (fuel level < 94% continuously for 3 seconds), OFF (auto feed enabled)
When (fuel level ≥ 94% continuously for 3 seconds), ON (auto feed disabled).

4001-61
h) Time chart
g)
[2] f)
3 seconds 3 seconds
Full tank detection

buzzer
Feed pump
Feed relay
3 seconds
Feed stop
relay
Feed switch
3 seconds
Fuel level
Engine states
Key switch
1. Even if the level falls below 94%, no fuel can be fed as the engine is running.
2. Stopped, so fuel can be fed.
3. Fuel feed is not possible unless the key is switched ON.
4. If the engine is started during fuel feeding, the fuel feed stops.
5. When the operator forgets and leaves the switch switched to the Auto side, the pump operates during
the power-cut delay (When fuel level under 98%).
6. Power-cut delay.
i) Trouble mode
If trouble occurs in an input (fuel sensor), output (feed stop relay) or communication (CAN), the system
goes into trouble mode and the feed stop relay is fixed to OFF. Be careful. In trouble mode, even if the feed
switch is set to Auto, the fuel feed is not stopped.

4001-62
4. Return Filter Clogging Detected

a) Configuration
Return oil
OFF for a clog

ON for normal
1 Computer A
2 Return filter clog pressure switch
3 Hydraulic oil tank
4 Return filter
b) Return filter clog pressure switch specifications

ON: 0.1 MPa OFF: 0.08 MPa
(1 bar / 14.50 psi) (0.8 bar / 11.60psi)
ON
OFF 0.08 MPa 0.1 MPa

(0.8 bar / 11.60 psi) (1bar / 14.50 psi)
c) Detection cancellation when breaker used

When the breaker is used, the return oil pressure pulse is intense, so clog detection is not attempted.
d) Detection cancellation when oil temperature low
When the oil temperature is less than 30°C (86°F), its viscosity rises and filter pressure damage increases,
so clog detection is not attempted.

4001-63
e) Solution for machines with no breaker setting
Machines with no breaker setting from c) (= machines with no return filter clog pressure switch)
Even with these machines, filter clogs would be detected. In order to prevent this, a special connector is
set that is always shorted.
Always-shorted special
connector
1 Computer A
f) Disconnection detection
When the key is ON, if IN1 was OFF before the engine was star ted, the situation is judged to be a
disconnection abnormality.
5. Beacon (Europe Only)

a) Configuration
Up to here is the
common harness
1 Beacon switch (alternate)

2 Computer A
3 Beacon
b) Operation
The beacon is driven via the beacon relay linked with the beacon switch.
This function is not mediated by the computer.

4001-64
This page has been left blank intentionally

4001-65
ENGINE SUMMARY
1. Engine System Diagram
Flow of air and combustion gas

Flow of fuel
1
Flow of coolant
5
6 7
8 12 13
2 3 4 9
10
11
In
14
15 16 17
1. Air cleaner
2. Fuel cooler
3. Inter cooler
4. Radiator
5. Turbo
6. Compressor side
7. Turbine side
8. Engine
9. Injector
10. Common rail
11. Supply pump
12. EGR cooler
13. Muffler
14. Fuel main filter
15. Fuel tank
16. Fuel prefilter
17. Charge fuel pump

4001-66
2. Fuel System Diagram
1) System schematic diagram (4JJ1)
8
2 9
11
1
5 6
13 3
4 ECM
12 7 10
TSJJ0102
1. Common rail
2. Fuel filter
3. Injector
4. Fuel tank
5. Pre-filter
6. Supply pump
7. CKP sensor
8. Common rail pressure sensor
9. Pressure limiter
10. Each sensor
11. Electromagnetic pump
12. CMP sensor
13. Fuel cooler

4001-67
2) System schematic diagram (4HK1)
8
9
11 2 1
10
5
14 3
4 ECM
13
12 7 TSHK0037
1. Common rail
2. Fuel filter
3. Injector
4. Fuel tank
5. Pre-filter
6. Supply pump
7. CKP sensor
9. Pressure limiter
10. Each sensor
12. CMP sensor
13. Each sensor
14. Fuel cooler

4001-68
3) System schematic diagram (6HK1)
8
2 9
11 1
10
6
5
14
3
4 ECM
12 13
7 TSHK0038
1. Common rail
2. Fuel filter
3. Injector
4. Fuel tank
5. Pre-filter
6. Supply pump
7. CKP sensor
9. Pressure limiter
10. Each sensor
12. CMP sensor
13. Each sensor
14. Fuel cooler

4001-69
3. Detailed Part
1) ECM (Engine Control Module)
Roles of the ECM

1. The ECM constantly monitors information sent from the various sensors and controls the power train
systems.
2. The ECM executes system function diagnosis, detects problems in system operation, issues trouble
alarms to warn the operator and stores the diagnostic trouble code into memory.
The diagnostic trouble code identifies the area in which the problem occurred and supports repair work
by the service engineer.
3. The ECM puts out 5 V and other voltages to supply power to the various sensors and switches.
The ECM controls output circuits by controlling ground or power supply circuits via one device or
another.
2) Supply Pump
(6HK1 drawing)
1
BF01003-004
1. Fuel Temperature sensor 3. Feed Pump

2. SCV (Suction Control Valve)
Supply pump
The supply pump uses the force of the engine rotation to raise the fuel pressure and send fuel to the
common rail. The SCV, fuel temperature sensor, and feed pump are installed on the supply pump.
SCV (suction control valve)
The SCV is installed on the supply pump and controls the sending of fuel to the common rail (discharge
volume). The ECM controls the electrified time to the SCV and controls the fuel discharge volume.

4001-70
3) Common Rail
(6HK1 drawing)
1. Flow damper (Only orifice on 4JJ1 engine) 3. Pressure limiter

2. Common rail 4. Common rail pressure sensor
Common rail
The common rail receives the fuel from the supply pump, holds the common rail (fuel) pressure, and
distributes the fuel to each cylinder. The common rail pressure sensor, flow damper, and pressure limiter
are installed on the common rail.
Flow damper (4HK1 & 6HK1)
The flow dampers are installed on the discharge port of each injector of the common rail. They suppress
pressure pulses in the common rail and prevent excess fuel injection from the injectors.
When a flow damper operates, the fuel supply to the injector stops.
Common rail pressure sensor
This sensor sends the pressure inside the common rail to the ECM as a voltage signal. From the signal
sent, the ECM calculates the actual common rail pressure (fuel pressure) and uses this for fuel injection
control.
Pressure limiter
If the pressure in the common rail becomes abnormally high pressure, the pressure limiter relieves the
pressure by returning excess fuel to the tank.
4) Injector
The injectors are installed on the cylinder head sections. They are controlled from the ECM and inject
fuel. The injector drive voltage is boosted (to 118 V) inside the ECM and applied to the injectors. By
controlling the injector electrified time, the ECM controls the fuel injection, injection timing, etc.

4001-71
5) Engine coolant temperature sensor
The engine coolant temperature sensor is installed on the engine block. The resistance of its thermistor
varies with the temperature.
The resistance is low when the engine coolant temperature is high and high when the coolant temperature
is low. From the ECM voltage variation, the ECM calculates the engine coolant temperature and uses this
for fuel injection control etc.
6) Engine oil pressure sensor
(6HK1 drawing)
The engine oil pressure sensor is installed near the cylinder block starter motor. It detects the engine
oil pressure, converts this pressure into an electrical signal, and sends that signal to the ECM.
7) Cam position sensor (CMP sensor)
(6HK1 drawing)
This sensor sends a signal to the ECM when the engine camshaft cam section passes this sensor.
The ECM identifies the cylinders through this sensor input, determines the crank angle, and uses this
information to control the fuel injection and to calculate the engine speed.
Also, it provides a back-up function in case of trouble in the CKP sensor. However, if there is trouble in the
CMP sensor system, there is no change in the behavior while the engine runs, but after it stops, the engine
cannot start.

4001-72
8) Crank position sensor (CKP sensor)
(6HK1 drawing)
This sensor sends a signal to the ECM when the projection section of the engine flywheel passes this
sensor.
The ECM identifies the cylinders through this sensor input, determines the crank angle, and uses this
information to control the fuel injection and to calculate the engine speed.
In case of trouble in the CKP sensor, the CMP sensor provides a back-up function.
9) Atmospheric pressure sensor
The atmospheric pressure sensor is installed in the cab. The ECM converts the atmospheric pressure into an
electric signal and calculates the atmospheric pressure from this voltage signal and corrects the fuel injection
quantity according to the atmospheric pressure.
10)Suction air temperature sensor
The suction air temperature sensor is installed midway through the suction air duct. It detects the suction
air temperature in order to optimize the fuel injection quantity.
11)Boost pressure sensor
The boost pressure sensor uses a pressure hose between the boost pressure sensor and intake pipe to detect
the boost (suction air pressure), converts this pressure into an electrical signal, and sends that signal to the
ECM.

4001-73
12)Boost temperature sensor
(6HK1 drawing)
The boost temperature sensor is installed on the upstream side of the EGR valve on the intake manifold.
This sensor is the thermistor type. The internal resistance of the sensor changes with the temperature.
13)Charge Fuel Pump
Converting the fuel filter and pre-filter to remote operation increased the distance from the fuel tank to the
feed pump.
Therefore, this pump was added to assist in drawing the fuel from the tank and to make it easy to bleed out
air during maintenance.
This pump always operates when the key switch is ON.
14)Lead Valve (check valve) (4HK1 & 6HK1)
The lead valve is installed between the EGR valve outlet and the inlet manifold. It suppresses EGR gas
back flow and allows the EGR gas to only flow in one direction.
15)EGR Valve
The operation of the EGR valve (lift amount) is controlled by signals from the ECM.

4001-74
4. Engine Control Summary

Electronic control fuel injection system (common rail type)
This is a system in which the engine speed, engine load, and other information (signals from many sensors)
are acquired from the engine control module (ECM) and based on that information, the ECM sends electrical
signals to the supply pump, injectors, etc. to appropriately control the fuel injection quantity and timing for
each cylinder.
Injection quantity control
To provide the optimum injection quantity, the ECM controls the injectors based mainly on the engine speed
and the instructed speed from computer A and controls the fuel injection quantity.
Injection pressure control
The injection pressure is controlled by controlling the fuel pressure in the common rail. The appropriate
pressure in the common rail is calculated from the engine speed and fuel injection quantity and by controlling
the supply pump, the appropriate quantity of fuel is discharged and the pressure sent to the common rail is
controlled.
Injection timing control
Instead of a timer function, the injectors are controlled primarily by calculating the appropriate fuel injection
timing from the engine speed, injection quantity, etc.
Injection ratio control
In order to improve the combustion in the cylinder, at first only a small amount of fuel is injected (pre-
injection), the fuel is ignited, then once the fuel has ignited, a second injection (main injection) is carried out.
This injection timing and quantity control is effected by controlling the injectors.

4001-75
EXPLANATION OF ENGINE FUNCTION
1. Engine Function Explanation table
Name Function
Receives the high-pressure fuel sent under pressure from the supply pump, holds the
Common rail
fuel pressure, and distributes the fuel to each injector.
Pressure limiter Operates to allow pressure within the common rail to escape if the pressure in the
(common rail common rail becomes abnormally high.
component part)
Flow damper Installed on the discharge port of each injector. Suppress pressure pulses in the
(common rail common rail and prevent fuel supply to the injectors when there is pipe damage.
component part)
Common rail pressure Detects the pressure inside the common rail, converts it to a voltage, and sends that
sensor (common rail voltage to the ECM.
component part)
Injector Controlled by the ECM and injects the fuel.
Raise the fuel pressure and send it under pressure to the common rail by using the
Supply pump
force of the engine rotation.
SCV (suction control Controls the fuel pressure (discharge quantity) sent to the common rail.
valve) (supply pump The ECM controls the time during which power is on to the SCV to increase or decrease
component part) the amount of fuel discharged.
Fuel temperature Detects the fuel temperature and sends it to the ECM.
sensor (supply pump Used for supply pump control etc.
component part)
EGR (Exhaust Gas Recirculates part of the exhaust gas in the intake manifold and mixes the EGR gas with
Recirculation) the suction air to reduce the combustion temperature and reduce NOx.
EGR valve The EGR valve operation (open and close) timing and the lift amount are controlled by
signals from the ECM. (The valve lift amount is detected by the EGR position sensor)
(EGR position sensor)
EGR cooler Cools the high-temperature EGR gas by using the engine coolant.
Lead valve Increases the amount of EGR by suppressing back flow of the EGR gas and letting it
(4HK1 & 6HK1) flow only in one direction.
ECM Constantly monitors the information from each sensor and controls the engine system.
(engine control
module)
QOS Determines the glow time according to the engine coolant temperature, operates the
glow relay, and makes starting at low temperatures easy and also reduces white smoke
(quick on start system) and noise immediately after the engine starts.
Sends a signal to the ECM when the projection section of the engine flywheel passes
CKP sensor this sensor.
(crank position The ECM identifies the cylinders through this sensor input, determines the crank angle,
sensor) and uses this information to control the fuel injection and to calculate the engine speed.
In case of trouble in the CKP sensor, the CMP sensor provides a back-up function.
Detects the engine oil pressure and sends it to the ECM.
Oil pressure sensor
Used for oil pressure drop alarms etc.
Engine coolant Detects the engine coolant temperature and sends it to the ECM.
temperature sensor Used for fuel injection control, QOS control, etc.
Sends a signal to the ECM when the engine camshaft cam section passes this sensor.
The ECM identifies the cylinders through this sensor input, determines the crank angle,
CMP sensor and uses this information to control the fuel injection and to calculate the engine speed.
(cam position sensor) Also provides a back-up function in case of trouble in the CKP sensor.
However, if there is trouble in the CMP sensor system, there is no change in the
behavior while the engine turns, but after it stops, restarting is difficult.
Atmospheric pressure Detects the atmospheric pressure and sends it to the ECM. The injection quantity is
sensor corrected according to the atmospheric pressure.

4001-76
Name Function
Suction air Detects the suction air temperature and sends it to the ECM. Optimizes the fuel
temperature sensor injection quantity.
Detects the boost (suction air pressure) inside the intake pipe and sends it to the ECM.
Boost pressure sensor
Used to control fuel injection with the boost pressure.
Boost temperature Detects the boost temperature and sends it to the ECM. Used for fuel injection control
sensor etc.

4001-77
2. EGR (Exhaust Gas Recirculation)

A B
9
10
1
2
C
3
4
D
5 6
1. EGR valve 8. Boost temperature sensor

2. EGR position sensor 9. EGR cooler
3. Engine speed 10. Lead valve (4HK1 & 6HK1 only)
4. Engine coolant temperature sensor A. Coolant out
5. Engine load B. Coolant in
6. Intake air temperature sensor C. Exhaust gas
7. Boost pressure sensor D. Suction air
EGR system is an abbreviation of «Exhaust Gas Recirculation» system. The EGR system recirculates part of
exhaust gas into intake manifold and mixes inactive gases with the suction air to reduce the combustion
temperature and suppress the generation of nitrogen oxides (NOx). The EGR quantity is controlled by the
operation (opening and closing) of the EGR valve installed between exhaust manifold and the intake
manifold.
The ERG quantity is determined from the engine speed and engine load ratio (fuel injection quantity) and the
EGR amount is controlled. A cooling system (EGR cooler) is installed in the EGR gas path to cool the high-
temperature EGR gas with this EGR cooler. This cooled EGR gas is mixed with new air intake to make the
combustion temperature lower than with normal EGR, which contributes to the reduction of NOx. (Cooled
EGR)
Furthermore, a lead valve is used in the EGR system to suppress EGR gas back flow and allow the EGR gas
to only flow in one direction.

4001-78
3. Relationship between ECM and sensor actuators
Engine Control Module

Sensor Actuator
Trottle signal
Engine speed Injection quantity control

Injection timing control
Cylinder
identification signal
Correction signal
Injection pressure control
1. Throttle volume (Computer A)

2. Crank shaft position sensor
3. Camshaft position sensor
4. Other sensors
5. Injector
7. Supply pump
8. EGR valve

4001-79
4. Cautions for Maintenance

Cautions concerning fuel used
With common rail engines, the supply pump and injector are lubricated by the fuel running through them.
Therefore, if any fuel other than diesel is used, this leads to engine trouble, so use of non-specified fuel is
strictly prohibited.
Please be aware that troubles resulting from the use of non-specified fuel are not covered by the warranty.
Specified fuel
See section 1002 about detail of CASE approval fuel.
The parts of the fuel system (injector internal part etc.) and the holes and gaps that form the fuel path are
made with extremely high precision
Therefore, they are extremely sensitive to foreign matter. Foreign matter in the fuel path can damage it, so
use great care to keep out foreign matter.
1. Clean and care for the fuel line and its surroundings before starting other maintenance.
2. Those working on the fuel line must have hands clean of dirt and dust. Wearing gloves while working is
strictly prohibited.
3. After removing fuel hoses and fuel pipes, always seal the hoses and pipes by covering the open sections
with plastic bags or the like.
4. When replacing parts, do not open the packing for the new parts until it is time to install them.
5. Do not reuse any gaskets or O-rings. Replace them with new ones.
Do not reuse fuel system high pressure fuel lines or injector pipes. If they are removed, replace them
with new parts.
Do not replace a pressure limiter, fuel temperature sensor or flow damper alone. If there is any
problem, replace the common rail assembly and all the fuel pipes.
(6HK1 drawing)

4001-80
The SCV pump alone cannot be replaced because the fuel temperature sensor is installed on the
pump main unit. Always replace the supply pump assembly.
(6HK1 drawing)
1. Injector pipes 4. Fuel temperature sensor

2. Flow damper (Orifice only on 4JJ1) 5. Pressure limiter
If there is engine trouble, it is strictly prohibited to judge individual cylinders as OK or NG by starting

up the engine and loosening the injection pipes (Never do this. The high-pressure fuel sprays out
dangerously.)
(6HK1 drawing)
1) Loosening when engine starts strictly prohibited.
Be careful. High voltage of 118 V or higher is applied to the injectors. Disconnect the battery cable
ground before replacing injectors.

4001-81
Explanation of Engine Control
1) Fuel Injection Quantity Correction
The ECM calculates the basic injection quantity from the throttle volume boost sensor, CKP sensor, CMP
sensor, and other signals.
According to the common rail pressure, engine coolant temperature, and other conditions at this time, the
ECM controls the SCV and controls the injector electrified time to attain optimum injection timing and correct
the injection quantity.
2) Starting Q Correction
The engine starting Q correction is terminated at the idling speed +α min -1 (+ α depends on the coolant
temperature.).
Also, below the system recognition engine speed (30 min-1), the ECM cannot recognize engine rotation, so
starting Q correction and engine starting become impossible.
• Minimum engine starting speed is 60 min-1
3) Preheat Control (QOS quick on start)
The ECM determines the glow timing (pre-glow, glow, and after-glow) according to the engine coolant
temperature and control the glow relay.
The QOS system makes starting at low temperatures easier and reduces white smoke and noise immediately
after starting.
When the key is switched ON, the ECM detects the coolant temperature with the signal from the engine
coolant sensor and varies the glow time to always obtain the optimum starting conditions.
Also, the after-glow function makes it possible to stabilize the idling rotation immediately after starting.
Also, if there is trouble in the engine coolant temperature sensor system, control assumes a fixed coolant
temperature of -20°C (-4°F) for engine starting and 80°C (176°F) for running.
Also, EGR control stops. (Thermostat valve opening temperature 82°C (200°F))
4) Atmospheric Pressure Correction (high altitude correction)
The ECM calculates the current altitude from the atmospheric pressure sensor signals.
The ECM controls the SCV and controls the injector electrified time to attain optimum fuel flow according to
the altitude and other conditions at the time.
Also, if there is sensor trouble, control assumes a fixed atmospheric pressure of 80 kPa (equivalent to an
altitude of 2000 m) and stops EGR control too.
Barometrical press. - Fuel ratio (@ 1800 min-1)
Fuel
limitation
ratio (%)
Barometrical (kPa)

4001-82
5) Control for Overheating

When the engine overheats, in order to protect the engine, if the engine coolant temperature exceeds 100°C
(212°F), fuel flow restriction is started.
If the temperature rises further, the fuel flow is further restricted.
If engine coolant temperature rises to 120°C (248°F), the engine is stopped.
The protection function is started 1 minute after the engine starts (In order to detect a stable coolant
temperature).
Setting Judgment time Engine control Recovery condition

100°C ECM: Reduced fuel injection quantity -
-
(212°F) CX controller: Normal
8th on coolant 7th or lower on coolant
105°C
temperature temperature gradation
(221°F)
gradation
110°C ECM: Reduced fuel injection quantity
5 seconds
(230°F) CX controller: Idling
120°C ECM: Reduced fuel injection quantity Key switched ON after engine
5 seconds
(248°F) CX controller: Engine stopped stopped
• The protection function does not work if any of the error codes below occurs.
0117 (Coolant temperature sensor abnormally low voltage)
0118 (Coolant temperature sensor abnormally high voltage)
2104 (Faulty CAN bus)
2106 (Faulty CAN time-out)
0090 (CAN communication error)
100°C
(212°F) Fuel restriction start
100%
Fuel
Flow 110°C Control of idling rotation
(230°F)
0%
105°C 120°C
(221°F) (248°F)
Overheat alarm Engine stop

4001-83
6) Control for Boost Temperature Rise

If the boost temperature exceeds 80°C (176°F), fuel flow restriction is started.
If temperature rises to 90°C (194°F), the engine is stopped.
The protection function is star ted 1 minute after the engine star ts. (In order to detect a stable boost
temperature)
Judgment Engine control Recovery condition

Setting
time
80°C ECM: Normal State of 70°C (°158F) or less
5 seconds
(°176F) CX controller: Idling control continues for 30s
90°C ECM: Normal Key switched ON after engine
5 seconds
(°194F) CX controller: Engine stop control stopped
1112 (Boost temperature sensor abnormally low voltage)
1113 (Boost temperature sensor abnormally high voltage)
7) Control for Engine Oil Pressure Drop
If the engine oil pressure drops, the engine is stopped to prevent engine damage.
The protection function is started 30s after the engine starts. (In order to detect a stable engine oil pressure)
Judgment Engine control Recovery condition

Setting
time
ECM: Normal Key switched ON after engine
40 kPa 5 seconds
CX controller: Engine stop control stopped
0522 (Oil pressure sensor abnormally low voltage)
0523 (Oil pressure sensor abnormally high voltage)
1633 (Faulty 5 V power supply 3 voltage/sensor power supply)
8) Start Control (coolant temperature monitoring)
When the coolant temperature is 0°C (°32F) or lower, the ECM controls the fuel amount depending on the
coolant temperature, for stable engine starting.

4001-84
9) Long Cranking Control

For the purpose of reducing black smoke when starting the engine and as backup in case adequate starting Q
(fuel injection) is not obtained, for example due to injector wear, after the stipulated time after the start of
cranking, the starting Q is raised the stipulated amount to improve startability.
Pattern with normal Pattern in with cranking time is at least 1 second

cranking time
Key switch
1 second
Idling cranking
Engine Speed
Starting Q
ST-Q. Standard starting Q NL-Q. Q for no load

UP-Q. Starting Q after increase
10)Starting Control for Reduced Number of Cylinders
When the fact that there is a stopped injector is detected with trouble diagnosis (when an error code is
detected), for the purpose of emergency escape, the fuel injection quantity is corrected to secure engine
startability.
The injection quantity for the troubled injector is allocated to the normal injectors. (The total injection
quantity is made the same.)
• The injector correction factors are as follows.
Number of effective cylinders 6 5 4 3 2 1 0

Correction factor 1.0 1.2 1.5 2.0 1.0 1.0 1.0
CAUTION: No control if there is trouble in injectors for 5 or more cylinders. No control if an injector
has a mechanical trouble.
11)Normal Stop (key switch OFF operation)
1. The key switch is set OFF.
2. When the ECM recognizes that the key is OFF, [3.] to [5.] are carried out at the same time.
3. Injector injection quantity calculation stop
4. Suction control valve (SCV) full close instruction
5. EGR valve full close instruction, EGR valve initial correction
6. When the operations in [3.] to [5.] end, the trouble log etc. are written to the EEPROM in the ECM.
7. The main relay is switched OFF and the power feed to the ECM is switched OFF.
5. Engine Start/Stop Judgment

Engine start and stop is judged based on the engine speed sent from the ECM with CAN communications.

4001-85
SERVICE SUPPORT
Screen Operations
1) Screen Shift
Key ON
(Anti-theft protection ON)

(Authentication OK)
(Anti-theft protection OFF)
(Model selection not completed)
(Model selection completed) (Authentication OK)
All reset One-touch

idle switch
No error pressed 5 times
10 seconds
3 seconds elapse
Breaker or crusher switch
3 seconds Flow reset
10 seconds
1 second 3 seconds
3 seconds Main Unit

(Service)
1 second
(Engine Service)
DIAG reset
10 seconds
or HR reset
10 seconds
CFG reset
10 seconds
Exit this mode by

switching OFF the
key
Screen on which the engine S/N,

Q adjustment, and QR can be
viewed

4001-86
a) Operation for shifting to service support screen
1. If both the travel high-speed switch and the horn volume select switch on the switch panel are held down
for 3 seconds, the display switches to the service support screen.
2. If both the high-speed travel switch and the horn volume select switch on the switch panel are held down
again for 1 second, the display returns to the normal screen.
Normal screen Service support screen
Hold down for 024.6

3 seconds 1800 013.7
0350 02.56
Hold down for 0120 00.93
1 second
b) Service support screen switching operation
B C
1 2 3
D
C HK MA I N 1 P1 000.0 MPa
Eng 0000 min-1 P2 000.0 MPa
Power 0000 mA N1 00.00 MPa
Flow 0000 mA N2 00.00 MPa
A
A Mode select switch 1 Mode (switching with high speed travel switch A)
B Section select switch 2 Section (switching with horn volume select switch B)
C Page (-) 3 Page (switching: forward with light switch D and back with washer
D Page (+) switch C)
[Mode] [Section] [Page]

CHK MAIN (1 - 10)
MNT (1 - 3)
H/W-A (1 - 8)
H/W-B (1 - 8)
H/W-M (1)
DIAG ALL (1 - 16)
HR MAIN (1 - 14)
ENG (1 - 12)
CFG MAIN (1 - 3)
CAL MAIN (1)

RE07003-002

4001-87
Screen Display List
1. CHK (status display) Screen List
In CHK mode, in addition to the machine status (milli-amp, oil pressures, temperatures, etc.), it is possible to
check sensor and switch input/output states, as well as the angle, load ratio and work radius, etc. at the
applied machine (liftcrane application machine, lifting magnet machine).
Section
Select switch
Page (-)
Page (+)
1 Section 2 Page
NOTE: From the CHK mode screen, if the wiper switch and the light switch are held down for 3 seconds,
the display shifts to the model selection screen.
A) MAIN
1) Engine and pump
Eng : Engine speed
CHK MA I N 1 P1 000.0 MPa Power : Actual milli-amp for horsepower control
proportional valve
Eng 0000 min -1 P2 000.0 MPa
Flow : Actual milli-amp for flow control proportional
Power 0000 mA N1 00.00 MPa valve
Flow 0000 N2 00.00 P1 : Pump1 Discharge pressure
mA MPa
P2 : Pump2 Discharge pressure
N1 : Pump1 Negative control pressure
2) Temperature and pressure

Coolnt : Radiator coolant temperature
CHK MA I N 2 Baro 0000 h Pa HydOil : Hydraulic oil temperature
Coolnt 0000 EngOil 0000 FuelT : Fuel temperature
˚C k Pa
Baro : Barometric pressure
HydOil 0000 ˚C BstT 0000 ˚C EngOil : Engine oil pressure
FuelT 0000 ˚C Air 0000 ˚C BstT : Boost temperature
Air : Suction air temperature
3) Load and boost

Eng : Engine speed
CHK MA I N 3 P1 000.0 MPa Load : Load ratio
Power : Actual milli-amp for horsepower control
Eng 0000 min-1 P2 000.0 MPa proportional valve
Load 0000 % BstT 0000 ˚C P1 : Pump 1 Discharge pressure
P2 : Pump 2 Discharge pressure
Power 0000 mA BstP 0000 kPa
BstT : Boost temperature
BstP : Boost pressure

4001-88
4) Load and milli-amp for horsepower control proportional valve
Eng : Engine speed
CHK MAIN 4 P1 000.0 MPa Load : Load ratio
Eng 0000 min -1 P2 000.0 MPa Power : Actual milli-amp for horsepower control
proportional valve
Load 0000 % N1 00.00 MPa P1 : Pump 1 Discharge pressure
Power 0000 mA N2 00.00 MPa P2 : Pump 2 Discharge pressure
N1 : Pump 1 Negative control pressure
5) Target and actual milli-amp for horsepower control proportional valve

Eng : Engine speed
CHK MAIN 5 -4- Load : Load ratio
Power : Actual milli-amp for horsepower control
Eng 0000 min-1 tEng 0000 min -1
proportional valve
Load 0000 % ThVol 0000 % -4- : *
Power 0000 tPower 0000 tEng : Target engine speed
mA mA
ThVol : Throtle volume degree of opening
tPower : Target milli-amp for horsepower control
proportional valve
6) Target and actual milli-amp for flow control proportional valve

Eng : Engine speed
CHK MAIN 6 P1 000.0 MPa Power : Actual milli-amp for horsepower control
Eng 0000 min -1 N1 00.00 MPa proportional valve
Flow : Actual milli-amp for flow control proportional
Power 0000 mA Swg 00.00 MPa valve
Flow 0000 mA tFlow 0000 mA P1 : Pump 1 Discharge pressure
Swg : Swing pilot pressure
tFlow : Target milli-amp for flow control proportional
valve
7) Target and actual milli-amp for hydraulic fan proportional valve

Eng : Engine speed
CH K MAIN 7 HydOil 0000 ˚C Coolnt : Radiator coolant temperature
Fan : Actual milli-amp for hydraulic fan proportional
Eng 0000 min-1 FuelT 0000 ˚C valve
Coolnt 0000 ˚C BstT 000 ˚C HydOil : Hydraulic oil temperature
0000 tFan 000 FuelT : Fuel temperature
Fan mA mA
BstT : Boost temperature
tFan : Target milli-amp for hydraulic fan proportional
valve
8) Pilot pressure
CHK MAI N 8 Upr 00.00 MPa P2 : Pump2 Discharge pressure
Cyl(B) : Boom bottom pressure
P1 000.0 MPa Swg 00.00 MPa
Upr : Upper pilot pressure
P2 000.0 MPa Trv 00.00 MPa Swg : Swing pilot pressure
Cyl(B) 000.0 MPa AmCls 00.00 MPa Trv : Travel pilot pressure
AmCls : Arm-in pilot pressure

4001-89
9) Hydraulic circuits; Input/ouput and pressure

CHK MA I N 9 P1 000.0 MPa P2 : Pump2 Discharge pressure
In P2 000.0 N1 : Pump1 Negative control pressure
MPa
Out1 N1 00.00 MPa
Out2 N2 00.00 MPa
Hydraulic circuit input /output state ( = OFF, = ON )
In Out1 Out2
1 5 9
2 6 10
3 7 11
4 8 12
1 Pressure sensor; Arm in 7 Solenoid; Boost
2 Pressure sensor; Travel 8 Solenoid; Swing brake
3 Pressure sensor; Swing 9 Relay; Travel alarm
4 Pressure sensor; Upper 10 Solenoid; Fan reverse (large machine only)
5 Solenoid; Free swing / beacon 11 Solenoid; Option line switchover
6 Solenoid; Travel high-speed switchover 12 Solenoid; Power save
10)Electrical circuits; Input/ouput

Eng : Engine speed
CHK MA I N 10 Eng 0000 -1 Coolnt : Radiator coolant temperature
min
Batt : Battery voltage
In Coolnt 0000 ˚c
FuelLv : Fuel sensor
Out1 Batt 0000 V
Out2 FuelLv 0000 %
Electrical circuit input /output state ( = OFF, = ON )
In Out1 Out2
*
1
*
4
*7
2 5 8
3 6 9
1 Switch; Anti-theft protection 6 Glow signal

2 Battery charge 7 Engine stop due to trouble
3 Switch; Key 8 Low idle restriction due to trouble
4 A/C coolant temprerature transmission 9 Restriction on milli-amp for horsepower control
5 Relay; Feed pump automatic stop proportional valve due to trouble

4001-90
B) MNT
1) Computer S Information
CHK MNT 1 4 0140 1 4400 2

1 4400 5 4132 2 0035
3
2 0035 6 31 3 3 4783
3 4783 7 0530 4 0140

4
5 4132
7 0530 1 6 31 3
5 7
* The longitude and latitude are displayed when the continuous GPS 6 8
position measurement time is 5 minutes or longer.
CHK MNT 2 4 0052 1 0605
1 0605 5 0130 2 2803 9

2 2803 6 0130 3 1432
3 1432 7 0122 4 0052 10
* UTC (universal time coordinate) is the global standard time.

5 0130 11
* Displayed after the completion of GPS position measurement. 6 0130
* For 3D position measurement, the altitude can be measured. 12
* GCC is a land station. 130 is the GCC for Japan (122 is South Korea). 7 0122
1 GPS continuous position measurement time (for example, 5 minutes 30 second of continuous position
measurement)
2 Computer S part number bottom 4 digit display (example, KHR14400)
3 Latitude: inside the O, 0 = North hemisphere, 1 = Southern hemisphere (example, 35 degrees 47.83 minutes)
4 Longitude: inside the O, 0 = Longitude east, 1 = Longitude west (example, 140 degrees 41.32 minutes
longitude east)
5 GPS position measurement status
0 = GPS not yet operating
1 = GPS measuring
2 = 2D measurement status
3 = 3D measurement status
6 Satellite communication status
0 = No satellite supplement
1 = Satellite supplement
2 = Q1200 communication abnormal
7 Default setting send status
0 = Default setting send wait
1 = Send inhibit wait
2 = ACK send wait
3 = Default setting send complete
8 Blank
9 UTC (Universal Time Coordinate) (example: May 28, 2006, 03:14:32)
10 Altitude (Example: 52 m)
11 Send GCC number
12 Supplementary GCC number

4001-91
CHK MN T 3 4 0000 1 0324 3

1 0324 5 0000 2 0020
4 5
2 0020 6 0001
3 0255 7 0001 3 0255 6
4 0000 7
6 0001 1 5 0000 8
7 0001 2
Event send setting
The default state is fuel volume warning, anti-theft operation warning event send inhibited.
These can be changed to enabled with signals from the web server. When this signal is received, No. 4 becomes the
display below.
Fuel volume Anti-theft operation warning Anti-theft operation warning

Nr. 4 warning (without position information) (with position information)
0028 Inhibited Inhibited Inhibited
0156 Enabled Inhibited Inhibited
0220 Enabled Enabled Inhibited
0188 Enabled Inhibited Enabled
0092 Inhibited Enabled Inhibited
0060 Inhibited Inhibited Enabled
1 Engine start enable setting

0 = Inhibited, 1 = Enabled
2 Send destination count
* The send destination is the server, so it is fixed at 1.
3 Time until next sending (example: 3 hours 24 minutes more until the next sending)
4 Send wait message count (example: 2)
5 Q1200 status
0 = Waiting
1 = Sending
4 = Receiving
5 = Receiving complete
6 Send distribution setting (not set)
7 Event send setting
8 Send inhibition setting (not set)

4001-92
C) H / W-A
1) Digital input / output
CHK H / W -A 1 DI1
DO1 DI2
DO2 DI3
DO3 DI4
Input /output state ( = OFF, = ON )
DO1 DO2 DO3

1 5
2 6
*
3 7
*
4 8
*9
DI1 DI2
10 14
11 15
12 16
13 17
DI3 DI4
* 20
*
18
21
22
19
*
1 Solenoid; Power save 12 Switch; Anti-theft
2 Solenoid; Boost 13 Switch; One-touch idle
3 Solenoid; Travel high-speed switchover 14 Switch; Travel alarm / overload
4 Solenoid; Swing brake 15 Switch; Free Swing (North America)
5 Buzzer; Travel alarm 16 Switch; Pressure (2nd option)
6 Solenoid; Option line switchover 17 Switch; Pressure (Option)
7 Solenoid; Free swing (North America) 18 Switch; Fan reverse (large machine only)
8 Solenoid Fan reverse (large machine only 19 Switch; Clog (Return filter)
9 Relay; Feed pump 20 Alternator
10 Switch; Clog (Air cleaner) 21 Switch; Engine emergency stop
11 Switch; Level Coolant 22 Switch; Key

4001-93
2) Digital output / output monitor
CHK H / W -A 2 -4-
DO1 DOM1
DO2 DOM2
DO3 DOM3
DO1 DO2 DO3

1 5
2 6
*
3 7
*
4 8
*
9
-4- DOM1
* 1
* 2
* 3
* 4
DOM2 DOM3
5 *
6
7
*
8
*
9
1 Solenoid; Power save 6 Solenoid; Option line switchover
2 Solenoid; Boost 7 Solenoid; Free swing ( North America)
3 Solenoid; Travel high-speed switchover 8 Solenoid; Fan reverse (large machine only)
4 Solenoid; Swing brake 9 Relay; Feed pump
5 Buzzer; Travel Alarm (North America)
3) Potentio-meter voltage
Pot1 : Sensor pressure P1
CHK H / W -A 3 Pot4 0000 V Pot2 : Sensor pressure P2
Pot3 : Sensor pressure N1
Pot1 0000 V Pot5 0000 V
Pot4 : Sensor pressure N2
Pot2 0000 V Pot6 0000 V Pot5 : Sensor pressure Swing
Pot3 0000 V Pot7 0000 V Pot6 : Sensor pressure Upper
Pot7 : Sensor pressure Travel
4) Potentio-meter and sensor voltage (Resistance)

Pot8 : Sensor pressure Arm in
CHK H / W -A 4 Sn1 0000 V Pot9 : Sensor throttle
Pot10 : Sensor pressure Overload
Pot8 0000 V Sn2 0000 V
Sn1 : Sensor temperature Hydraulic oil
Pot9 0000 V Sn1 0000 Ω Sn2 : Sensor level Fuel
Pot10 0000 V Sn2 0000 Ω Sn1 : Sensor temperature Hydraulic oil
Sn2 : Sensor level Fuel

4001-94
5) PWM data
PWM# : PWM channel number
CHK H / W -A 5 duty 0000 % actcur : Actual milli-amp for horsepower control
proportional valve
PWM# 1 freq 0000 Hz tgtcur : Target milli-amp for horsepower control
actcur 0000 mA volt 0000 V proportional valve
____ duty : Duty
tgtcur 0000 mA ovc
freq : Frequency
volt : Voltage
ovc : Overcurrent detection status
(+: Overcurrent, - Normal)
6) PWM data
CHK H / W -A 6 duty 0000 % actcur : A c t u a l m i l l i - a m p fo r h y d r a u l i c fa n
proportional valve
PWM# 2 freq 0000 Hz tgtcur : Ta r g e t m i l l i - a m p fo r hy d r a u l i c fa n
actcur 0000 mA volt 0000 V proportional valve
____ duty : Duty
tgtcur 0000 mA ovc
freq : Frequency
volt : Voltage
7) PWM data
CHK H / W -A 7 duty 0000 % actcur : Actual milli-amp for flow control proportional
valve
PWM# 3 freq 0000 Hz tgtcur : Target milli-amp for flow control proportional
actcur 0000 mA volt 0000 V valve
____ duty : Duty
tgtcur 0000 mA ovc
freq : Frequency
volt : Voltage
8) Frequency and communication

FreqIn : Frequency input
CHK H / W -A 8 RS232 CAN : CAN reception state
Hz UART : UART reception state
FreqIn 0000 -5-
RS232 : RS232C communication state
CAN -6- -5- : *
UART -7- -6- : *
-7- : *
Input /output state ( = Receiving)
CAN
1
2
3
1 Computer S reception state
2 Computer B reception state
3 ECM reception state

4001-95
D) H / W-B
1) Computer B digital input / output
CHK H /W -B 1 DI1
DO1 DI2
DO2 DI3
DO3 DI4

DO1 DO2 DO3
*
1
* *
2
* *
3
* *
* *
DI1 DI2 DI3
4 *
5
*
6
* *
7
*
8
*
*
IDI4
*
*
*
*
1 Solenoid; lever lock 6 Switch; Interference (Temporary release)
2 Rotating light and bucket lock 7 Switch; Lifting magnet mode
3 Buzzer; Crane 8 Switch; Interference (Shut-off release)
4 Switch; Crane Mode
5 Switch; Crane (Display switching)

4001-96
2) Digital output / output monitor
C HK H /W -B 2 -4-
DO1 DOM1
DO2 DOM2
DO3 DOM3

DO1 DO2 DO3
1
* * *
2
* *
3
* *
* *
-4- DOM1 DOM2
* *1 *
* 2
*
* 3
*
* *
DOM3
*
*
*
*
1 Solenoid; Lever lock
2 Rotating light and bucket lock
3 Buzzer; Crane
3) Potentio-meter voltage
Pot1 : Sensor; Angle boom
CHK H /W -B 3 Pot4 0000 V Pot2 : Sensor; Angle arm
Pot3 : Sensor; Angle offset
Pot1 0000 V Pot5 0000 V
Pot4 : Sensor; Pressure bottom
Pot2 0000 V Pot6 0000 V Pot5 : Sensor; Pressure rod
Pot3 0000 V Pot7 0000 V Pot6 : *
Pot7 : *
4) Potentio-meter and sensor voltage (resistance)

Pot8 : *
CHK H /W -B 4 Sn1 0000 V Pot9 : *
Pot10 : *
Pot8 0000 V Sn2 0000 V
Sn1 : *
Pot9 0000 V Sn1 0000 Ω Sn2 : *
Pot10 0000 V Sn2 0000 Ω Sn1 : *
Sn2 : *

4001-97
5) PWM data
CHK H /W -B 5 duty 0000 % actcur : Actual milli-amp for boom propor tional
valve
PWM# 0000 mA freq 0000 Hz tgtcur : Target milli-amp for boom propor tional
____ duty : Duty
tgtcur 0000 mA ovc
freq : Frequency
volt : Voltage
6) PWM data
CHK H /W -B 6 duty 0000 % actcur : Actual milli-amp for offset proportional
valve
PWM# 0000 mA freq 0000 Hz tgtcur : Target milli-amp for offset proportional
____ duty : Duty
tgtcur 0000 mA ovc
freq : Frequency
volt : Voltage
7) PWM data
CHK H /W -B 7 duty 0000 % actcur : Actual milli-amp for arm proportional valve
tgtcur : Target milli-amp for arm proportional valve
PWM# 0000 mA freq 0000 Hz
duty : Duty
actcur 0000 mA volt 0000 V freq : Frequency
____ volt : Voltage
tgtcur 0000 mA ovc
8) Frequency and communication

FreqIn : Frequency input
CHK H / W -B 8 RS232 CAN : CAN reception state
Hz UART : UART communication state
FreqIn 0000 -5-
RS232 : RS232C communication state
CAN -6- -5- : *
UART -7- -6- : *
-7- : *
Input /output state ( = Receiving)
CAN
1
2
3
1 Computer S reception state
2 Computer B reception state
3 ECM reception state

4001-98
E) H / W-M
1) Monitor
C HK H /W -M 1 DI1
DO1 DI2
DO2 DI3
DO3 DI4

DO1 DO2 DO3
1 * *
2 * *
3 * *
4 5 *
DI1 DI2
6 10
7 11
8 12
9 13
DI3 IDI4
*
14 *
15 *
16 *
*
1 Working light 9 Switch; Horn volume select
2 Motor Washer 10 Switch; Breaker select
3 Wiper CNT 11 Switch; Limit Front window
4 Wiper INT 12 Switch; Wiper
5 Relay; horn volume switchover 13 Switch; Washer
6 Switch; Working light 14 Switch; Reserve
7 Switch ; Travel high-speed select 15 Switch; 2 pumps flow
8 Switch; Auto idle select 16 Switch; Crusher select

4001-99
2. DIAG (trouble diagnosis) Screen

1. In diagnosis mode, you can check from the contents for the trouble currently occurring to a log
of trouble that has occurred in the past.
1 Status occurence count 4 Diagnostic trouble code

2 Initial occurence time 5 Cursor movement
3 Final occurence time
• In "DTC-1" through "DTC-4", the data is displayed in order from the most recently occurring trouble
code.
• The cursor is moved with the wiper switch and auto idle switch.
(The cursor moves between "DTC-1" and "DTC-4").
* There is no "section" in diagnosis mode.
• The information for the trouble code for the location under the cursor is displayed in the order "ST/OC",
"1st", "Last".
• The mark displayed at the left most of "ST/OC" shows whether or not the trouble is currently
occurring.
• The black circle means the trouble is currently occurring.
• The clear circle means the trouble is not occurring now, but has occurred in the past.
• "1st" indicates the time at which this trouble occurred the first time and "last" indicates the time at which
this trouble occurred the last time.
2. For details on "diagnostic trouble codes" that can be read in diagnosis mode and their contents, see the
"Main Unit Diagnostic Trouble Code List"
A) Screen
(C)
D I AG MAI N 1 DTC1 7002 4
1 St/Oc 005 DTC2 0238

2 1st 0010 hr DTC3 ----
3 Last 0901 hr DTC4 ----
1. Displays the status at the cursor(C) and the occurrence count.

...7002 error now occuring / trouble has occured 5 times in the past.
St/Oc 005 Status
005 Occurence count
[Status]
• Displays whether the diagnostic trouble code under the cursor is current or from the past.
• For , the trouble is current or continuing.
• For , the status is normal or recovered.
(The trouble is not occurring now, but has occurred in the past).
[Occurrence count]
• The number of times that diagnostic trouble code under the cursor has occurred

4001-100
2. Displays the time at which the trouble under the cursor first occurred
1st 0010 ...Occurred first at 10 hours

hr
3. Displays the time at which the trouble under the cursor last occurred
Last 0901 ...Occurred last at 901 hours

hr
4. Diagnostic trouble code
The troubles are sorted with the last one to occur at the top of the list.
The diagnostic trouble code under the cursor is displayed in (1) - (3).
...7002 (faulty N1 pressure sensor)
DTC1 7002
...0238 (Boost pressure sensor abnormally high voltage)
DTC2 0238
DTC3 ---- For details on diagnostic triuble code, see the Main Unit Diagnostic Trouble Code
List.
DTC4 ----
Maximum display count
4 codes per page X 16 pages = 64 diagnostic trouble codes are displayed. From the 65th code onward, the
oldest code is erased. However, even though these codes are not displayed, the data is retained.
B) Operation
1) Cursor up/down:
Up operation ... wiper switch
1 Down operation ... auto idle switch
2) Page forward / back:
Forward operation ... light switch
Back operation ... washer switch
2
C) Reset
If the washer switch and the light switch are held down for 10 seconds, the trouble log is reset.

4001-101
3. HR (usage log) Screen List

In HR mode, operation times for mechanical parts, electrical parts, etc., operation counts for switches
and solenoids, as well as pressure distributions, etc. can be displayed.
Section
Select switch
Page (-)
Page (+)
1 Section 2 Page
A) MAIN
1) Main unit operating time
KeyOn : Computer A power supply ON time
HR MA I N 1 Upr 0000 hr EngOn : Alternator power generating time
Work : Machine operating time
KeyOn 0000 hr Swg 0000 hr (Upper ON or travel ON)
EngOn 0000 hr Trv 0000 hr Upr : Upper operating time
Work 0000 TrSolo 0000 Swg : Swing operating time
hr hr
Trv : Travel operating time
TrSolo : Travel single operation time
2) Electrical part operating time

WpInt : Wiper (intermittent) operating time
HR MA I N 2 WLight 0000 hr WpCnt : Wiper (continuous) operating time
Wsh : Washer operating time
WpInt 0000 hr HornLo 0000 hr
WLight : Working light ON time
WpCnt 0000 hr DrOpn 0000 hr HornLo : Horn volume low time
Wsh 0000 hr WinOpn 0000 hr DrOpn : *
WinOpn : Front window open time
3) Idle time
1 : Auto idle time
HR MA I N 3 4 0000 hr 2 : One-touch idle time
3 : Boosted pressure time
1 0000 hr 5 0000 hr
4 : Low-speed travel time
2 0000 hr 6 0000 hr 5 : High-speed travel time
3 0000 hr 7 0000 hr 6 : *
7 : *
4) Pressure switch operation count

1 : Upper pressure sensor (ON count X 1000)
HR MA I N 4 4 0000 times 2 : Swing pressure sensor (ON count X 1000)
3 : Travel pressure sensor (ON count X 1000)
1 0000 times 5 0000 times
4 : Arm-in pressure switch (ON count X 1000)
2 0000 times 6 0000 times 5 : 1st option pressure switch (ON count X 1000)
3 0000 times 7 0000 times 6 : 2nd option pressure switch (ON count X 1000)
7 : *

4001-102
5) Operation switch operation count
1 : Key ON count X 10
HR MAI N 5 4 0000 times 2 : Engine start count X 10
3 : Front window open count X 10
1 0000 times 5 0000 times
4 : *
2 0000 times 6 0000 times 5 : Boost solenoid ON count X 1000
3 0000 times 7 0000 times 6 : Swing brake solenoid ON count X 1000
7 : Power save solenoid ON count X 1000
6) Work mode
1 : Mode usage time SP-hi
HR MAI N 6 4 0000 hr 2 : Mode usage time SP-lo
3 : Mode usage time H-hi
1 0000 hr 5 0000 hr
4 : Mode usage time H-lo
2 0000 hr 6 0000 hr 5 : Mode usage time A1-hi
3 0000 hr 7 0000 hr 6 : Mode usage time A1-lo
7 : Mode usage time (other than above)
7) Breaker usage time

1 : Breaker 1 operation time
HR MAI N 7 4 0000 hr 2 : Breaker 2 operation time
1 0000 hr 5 0000 hr
2 0000 hr 6 0000 hr 5 : Breaker 5 operation time
3 0000 hr 7 0000 hr 6 : Breaker 1-5 operation time
7 : *
8) Crusher usage time

1 : Crusher 1 operation time
HR MAI N 8 4 0000 hr 2 : Crusher 2 operation time
1 0000 hr 5 0000 hr
2 0000 hr 6 0000 hr 5 : Crusher 5 operation time
3 0000 hr 7 0000 hr 6 : Crusher 1-5 operation time
7 : *
9) P1 pressure (P) distribution

1 : P < 10 MPa Time
HR MAI N 9 4 0000 hr 2 : 10 MPa ≤ P < 15 MPa Time
3 : 15 MPa ≤ P < 20 MPa Time
1 0000 hr 5 0000 hr
4 : 20 MPa ≤ P < 25 MPa Time
2 0000 hr 6 0000 hr 5 : 25 MPa ≤ P < 30 MPa Time
7 : 35 MPa ≤ P Time
10)P2 pressure (P) distribution

1 : P < 10 MPa Time
HR MAI N 10 4 0000 hr 2 : 10 MPa ≤ P < 15 MPa Time
3 : 15 MPa ≤ P < 20 MPa Time
1 0000 hr 5 0000 hr
4 : 20 MPa ≤ P < 25 MPa Time

4001-103
11)N1 pressure (P) distribution
1 : P < 1.0 MPa Time
HR MA I N 11 4 0000 hr 2 : 1.0 MPa ≤ P < 1.5 MPa Time
3 : 1.5 MPa ≤ P < 2.0 MPa Time
1 0000 hr 5 0000 hr
4 : 2.0 MPa ≤ P < 2.5 MPa Time
2 0000 hr 6 0000 hr 5 : 2.5 MPa ≤ P < 3.0 MPa Time
7 : 3.5 MPa ≤ P Time
12)N2 pressure (P) distribution

1 : P < 1.0 MPa Time
HR MA I N 12 4 0000 hr 2 : 1.0 MPa ≤ P < 1.5 MPa Time
3 : 1.5 MPa ≤ P < 2.0 MPa Time
1 0000 hr 5 0000 hr
4 : 2.0 MPa ≤ P < 2.5 MPa Time
7 : 3.5 MPa ≤ P Time
13)P1 + P2 pressure (P) distribution

1 : P < 20 MPa Time
HR MA I N 13 4 0000 2 : 20 MPa ≤ P < 30 MPa Time
hr
3 : 30 MPa ≤ P < 40 MPa Time
6 : 60 MPa ≤ P < 70 MPa Time
3 0000 hr 7 0000 hr
14)Oil temperature (T) distribution

1 : T< 45°C Time (bar graph 1st and 2nd gradation)
2 : 45°C ≤ T< 60°C Time (bar graph 3rd gradation)
HR MA I N 14 4 0000 hr
3 : 60°C ≤ T < 80°C Time (bar graph 4th gradation)
1 0000 hr 5 0000 hr 4 : 80°C ≤ T < 88°C Time (bar graph 5th gradation)
2 0000 hr 6 0000 hr 5 : 88 °C ≤ T < 95 °C Time (bar graph 6th gradation)
6 : 95 °C ≤ T < 98 °C Time (bar graph 7th gradation)
3 0000 hr 7 0000 hr
7 : 98 °C ≤ T Time (bar graph 8th gradation)
B) ENG
1) Oil temperature / coolant temperature / pressure maximum values
(Measured starting 10 minutes after engine started)
Coolnt : Radiator coolant temperature
HR EN G 1 Air 0000 ˚C HydOil : Hydraulic oil maximum temperature
FuelT : Fuel maximum temperature
Coolnt 0000 ˚C BstT 0000 ˚C Air : Suction air maximum temperature
HydOil 0000 ˚C BstP 0000 kPa BstT : Boost maximum temperature
BstP : Boost maximum pressure
FuelT 0000 ˚C EngOil 0000 kPa
EngOil : Engine oil minimum pressure

4001-104
2) Engine actual speed (S) distribution
1 : S < 1025 min-1 Time
HR ENG 2 4 0000 2 : 1025 min-1 ≤ S < 1225 min-1 Time
hr
3 : 1225 min-1 ≤ S < 1425 min-1 Time
1 0000 hr 5 0000 hr 4 : 1425 min-1 ≤ S < 1625 min-1 Time
2 0000 hr 6 0000 hr 5 : 1625 min-1 ≤ S < 1825 min-1 Time
6 : 1825 min-1 ≤ S < 2025 min-1 Time
3 0000 hr 7 0000 hr
7 : 2025 min-1 ≤ S Time
3) Coolant temperature (T) distribution

1 : T < 77 °C Time (bar graph 1st and 2nd gradation)
HR ENG 3 4 0000 hr 2 : 77 °C ≤ T < 82 °C Time (bar graph 3rd gradation)
2 0000 hr 6 0000 hr
7 : 105 °C ≤ T Time (bar graph 8th gradation)
4) Fuel temperature (T) distribution

1 : T < 40 °C Time
HR ENG 4 4 0000 hr 2 : 40 °C ≤ T < 50 °C Time
1 0000 hr 5 0000 hr 3 : 50 °C ≤ T < 60 °C Time
4 : 60 °C ≤ T < 70 °C Time
2 0000 hr 6 0000 hr 5 : 70 °C ≤ T < 80 °C Time
3 0000 hr 7 0000 hr 6 : 80 °C ≤ T < 90 °C Time
7 : 90 °C ≤ T Time
5) Suction air temperature (T) distribution

1 : T < -20 °C Time
HR ENG 5 4 0000 hr 2 : -20 °C ≤ T < 0 °C Time
1 0000 hr 5 0000 hr 3 : 0 °C ≤ T < 15 °C Time
4 : 15 °C ≤ T < 30 °C Time
2 0000 hr 6 0000 hr
5 : 30 °C ≤ T < 45 °C Time
3 0000 hr 7 0000 hr 6 : 45 °C ≤ T < 60 °C Time
7 : 60 °C ≤ T Time
6) Boost temperature (T) distribution

1 : T < 50 °C Time
HR ENG 6 4 0000 hr 2 : 50 °C ≤ T < 80 °C Time
1 0000 hr 5 0000 hr 3 : 80 °C ≤ T < 110 °C Time
4 : 110 °C ≤ T < 140 °C Time
2 0000 hr 6 0000 hr
5 : 140 °C ≤ T < 170 °C Time
3 0000 hr 7 0000 hr 6 : 170 °C ≤ T < 200 °C Time
7 : 200 °C ≤ T Time
7) Atmospheric pressure (P) distribution

1 : P < 600 hPa Time
HR ENG 7 4 0000 hr 2 : 600 hPa ≤ P < 690 hPa Time
1 0000 hr 5 0000 hr 3 : 600 hPa ≤ P < 780 hPa Time
4 : 780 hPa ≤ P < 870 hPa Time
2 0000 hr 6 0000 hr
5 : 870 hPa ≤ P < 960 hPa Time
3 0000 hr 7 0000 hr 6 : 960 hPa ≤ P < 1050 hPa Time
7 : 1050 hPa ≤ P Time

4001-105
8) Engine oil pressure (P) distribution
1 : P < 0 kPa Time
HR ENG 8 4 0000 hr 2 : 0 kPa ≤ P < 150 kPa Time
1 0000 hr 5 0000 hr 3 : 150 kPa ≤ P < 300 kPa Time
4 : 300 kPa ≤ P < 450 kPa Time
2 0000 hr 6 0000 hr
5 : 450 kPa ≤ P < 600 kPa Time
7 : 750 kPa ≤ P Time
9) Boost pressure (P) distribution

1 : P < 150 kPa Time
HR EN G 9 4 0000 hr 2 : 150 kPa ≤ P < 180 kPa Time
4 : 210 kPa ≤ P < 240 kPa Time
2 0000 hr 6 0000 hr
5 : 240 kPa ≤ P < 270 kPa Time
7 : 300 kPa ≤ P Time
10)Load ratio (R) distribution

1 : R < 30 % Time
HR EN G 10 4 0000 hr 2 : 30 % ≤ R < 40 % Time
1 0000 hr 5 0000 hr 3 : 40 % ≤ R < 50 % Time
4 : 50 % ≤ R < 60 % Time
2 0000 hr 6 0000 hr
5 : 60 % ≤ R < 70 % Time
3 0000 hr 7 0000 hr 6 : 70 % ≤ R < 80 % Time
7 : 80 % ≤ R Time
11)Load ratio (R) distribution for SP mode

1 : R < 30 % Time
HR EN G 11 4 0000 hr 2 : 30 % ≤ R < 40 % Time
1 0000 hr 5 0000 hr 3 : 40 % ≤ R < 50 % Time
4 : 50 % ≤ R < 60 % Time
2 0000 hr 6 0000 hr
5 : 60 % ≤ R < 70 % Time
3 0000 hr 7 0000 hr 6 : 70 % ≤ R < 80 % Time
7 : 80 % ≤ R Time
12)Load ratio (R) distribution for H mode

1 : R < 30 % Time
HR EN G 12 4 0000 hr 2 : 30 % ≤ R < 40 % Time
1 0000 hr 5 0000 hr 3 : 40 % ≤ R < 50 % Time
4 : 50 % ≤ R < 60 % Time
2 0000 hr 6 0000 hr
5 : 60 % ≤ R < 70 % Time
3 0000 hr 7 0000 hr 6 : 70 % ≤ R < 80 % Time
7 : 80 % ≤ R Time

4001-106
4. CFG (setting change) Screen

The item where the cursor is located flashes.
Can be changed
The cursor appears if the auto

idle switch is held down
• Hold down the auto idle switch for 1 second. The cursor is displayed and the value starts to flash.
• The flashing value can be changed with the washer switch /working light switch.
• When the travel high-speed switch is pressed, value is finalized and the change is reflected in the actual
machine.
• When the horn volume select switch is pressed, the change is cancelled
A) Operation
CFG MA I N 1 PrUp1 ++++

Cursor LowIdl 1000 min -1 PrUp2 ____
AtIdl1 0005 sec PwrAj 300 mA
AtIdl2 1200 min -1 -7-
1) View mode (screen switching operation)

1) Switching to edit mode
Hold down the auto idle switch for one second.
The mode switches to edit mode and the cursor is
displayed.
1
Forward operation => light switch
Back operation => washer switch
2
2) Edit mode (setting change operation)
1) Cursor up / down:
Up operation => wiper switch
4 Down operation => auto idle switch
1 2) Numeric value increase / decrease:
Increase value => light switch
3 Decrease value => washer switch
3) Enter: Enters the set contents.
4) Cancel: Cancels the set contents.
When (3) and (4) is executed, this exits edit mode
2 and shifts the mode to view mode (the cursor
disappears).
3) Reset
If the washer switch and the light switch are held down for 10 seconds, the setting contents are reset and all
settings return to their default values.

4001-107
B) Screen
1) MAIN 1
CFG M A IN 1 PrUp1 ++++

LowIdl 1000 min -1 PrUp2 ----
AtIdl1 0005 sec PwrAj 300 mA
AtIdl2 1200 -1 -7-
min
Item name Explanation Setting range Default value

LowIdl Low idling speed Min speed to Auto-idle speed 1000
AtIdl1 Auto idling shift time 1 to 30 5
AtIdl2 Auto idling speed Low idling speed to 1500 1200
PrUp1 Auto pressure boost yes / no + : YES, - : NO +
PrUp2 Auto pressure boost for option line usage yes / no + : YES, - : NO -
PwrAj Transient load minimum mili-amp 50 to 400 300
-7-
NOTE: PwrAj is the previous high altitude mode.
2) MAIN 2
CFG M A IN 2 CoolDn
TrSpd ____ EPF ++++
TrAlm1 ++++ Unit 0000

TrAlm2 0010 sec -7-

TrSpd Travel speed previous data held yes / no + : YES, - : NO -
TrAlm1 Travel alarm buzzing yes / no + : YES, - : NO +
TrAlm2 Travel alarm automatic stop time 1 to 30 10
CoolDn
EPF EPF (Engine Protection Feature) yes / no + : YES, - : NO +
Unit Display unit 0: MPa, 0
1: PSI,
2: kgf/cm2
-7-
* Display unit contents … MPa = (MPa,°C), PSI = (psi, °F), kgf/cm2 = (kgf/cm2, °C)

4001-108
3) MAIN 3
CFG MA I N 3 MntMsg ++++

Spd1 min -1 Cycle 0500 hr
Spd2 min -1 Remain 0500 hr
OvLd 0000 MPa -7- ++++

Spd1
Spd2
OvLd Pressure at which alarm starts
MntMsg "SERVICE DUE" display yes / no + : YES, - : NO +
Cycle "SERVICE DUE" display range 0 to 5000 500
Remain Time until next "SERVICE DUE" display 0 to 5000 500
-7- New harness yes / no + : YES, - : NO
* OvLd is an option for Europe.
-7- is battery charge and engine emergency stop port substitution.

4001-109
5. CAL (troubleshooting support) Screen
A) Operation
CAL MA I N 1 P1 000.0 MPa

Cursor tEng 0000 min -1 P2 000.0 MPa
tPower 0000 mA N1 00.00 MPa
tFlow 0000 mA N2 00.00 MPa
1) View mode (screen switching operation)

1) Switching to edit mode
Hold down the auto idle switch for one second.
The mode switches to edit mode and the cursor is
displayed.
1 Forward operation => light switch
Back operation => washer switch
2) Edit mode (setting change operation)

1) Cursor up / down:
Up operation => wiper switch
4 Down operation => auto idle switch
2) Numeric value increase / decrease:
1 Increase value => light switch
3 Decrease value => washer switch
3) Enter: Enters the set contents.
4) Cancel: Cancels the set contents.
Use the travel high-speed select switch or the
horn volume select switch to cancel. Exits edit
2 mode and shifts the mode to view mode (the
cursor disappears).
B) Screen
1) Engine pump override 1
CAL MA I N 1 P1 000.0 MPa

-1
tEng 0000 min P2 000.0 MPa
tPower 0000 mA N1 00.00 MPa
tFlow 0000 mA N2 00.00 MPa

tEng Target engine speed 500 to max speed Low idling
tPower Target milli-amp for horsepower control proportional valve 50 to 740 500
tFlow Target milli-amp for flow control proportional valve 50 to 740 500
P1 P1 pressure - -
P2 P2 pressure - -
N1 N1 pressure - -
N2 N2 pressure - -

4001-110
2) Engine pump override 2
CAL MAI N 2 P1+P2 0 0 0 . 0 MPa

-1
tEng 1000 min Eng 0000 min-1
tPower 0500 mA Power 0000 mA
tFlow 0500 mA Flow 0000 mA

tEng Target engine speed 500 to max speed Low idling
tPower Target milli-amp for horsepower control proportional valve 50 to 740 500
tFlow Target milli-amp for flow control proportional valve 50 to 740 500
P1+P2 P1+P2 pressure - -
Eng Actual engine speed - -
Power Actual milli-amp for horsepower control proportional valve - -
Flow Actual milli-amp for flow control proportional valve - -
3) Hydraulic pressure drive fan override
CAL MAI N 3 HydOil 0000 ˚C

-1
Eng 0000 min Fuel T 0000 ˚C
Coolnt 0000 ˚C Bst T 0000 ˚C
t Fan 0500 mA Fan 0000 mA

Eng Actual engine speed - -
Coolnt Coolant temperature - -
tFan Target milli-amp for hydraulic fan proportional valve fan current 50 to 740 500
HydOil Oil temperature - -
FuelT Fuel temperature - -
BstT Boost temperature - -
Fan Actual milli-amp for hydraulic fan proportional valve fan current - -

4001-111
6. Check the Monitor Switch (Self-diagnosis function)
A) Screen
After the key is switched ON, the "CASE" logo screen is displayed on the monitor.
At this time, the display can be switched to the monitor switch check screen by pressing the one-touch idle
switch five times.
The switch contents are as follows:

WIPER SW Wiper Switch
SW1 Front window limit switch WASHER SW Washer Switch
SW2 Breaker mode switch W. LAMP SW Working light switch
SW3 Crusher mode switch T. MODE SW Travel high-speed select switch
SW4 2 pumps flow switch A. IDLE SW Auto idle switch
SW5 Not Used HORN VOL. SW Horn volume select switch
B) Configuration
6 Wiper switch
1 Washer switch
Working light switch
Travel high-speed
select switch
EXT-SW1 Auto idle switch
2
Horn volume select
switch
EXT-SW2
3
EXT-SW3
4
EXT-SW4
5 No communications
with computer A
(Monitor alone)
Not used EXT-SW5

x
1 Switch panel 4 Breaker mode switch

2 2 pumps flow switch 5 Crusher mode switch
3 Front window limit switch 6 Monitor
4001-112
C) Differences from CHK screen [CHK | H/W-M | 1]
Monitor main unit input / output can also be checked on the CHK screen.
However, for the CHK screen, after the switch input is sent to computer A with communication, the switch input
is processed by computer A and the results are sent to the monitor as screen data and displayed.
On the monitor switch check screen, the switch input recognized by the monitor itself is displayed directly on
the screen (without involving communications or Computer A), so it is possible to diagnose purely the switches
themselves.

4001-113
7. Option Flow Setting
A) Screen
When three seconds have passed, the logo screen shifts to the user screen.
With the user screen being displayed, if either the "breaker" or "crusher" rocker switch on the right panel is held
down for 3 seconds, the "option flow setting screen" is displayed on the monitor.
Option line icon: Displays the option

line for which the flow is set (select for
the breaker 1/2/3/4/5 and crusher 1/2/
3/4/5).
D i s p l ay s t h e m a x i m u m f l o w fo r
1 pump.
D i s p l ay s t h e m a x i m u m f l o w fo r
2 pumps.
Pump discharge pressure (P1 pump
main pressure).
B) Flow setting
1. Press the breaker or crusher mode switch to select the mode to set the flow for.
Rocker switch
1
2 4
1 Flow increase 3 Crusher mode (1 to 5) switchover

2 Flow decrease 4 Breaker mode (1 to 5) switchover

4001-114
2. The flow setting for the selected mode is selected by pressing the wiper switch or auto idle select switch.
The flow setting can be set to 10 levels from Level 1 to Level 10.
CAUTION: The set flow is the flow value when SP mode is selected.
Be careful. If run with the engine speed reduced, the actual flow is not the flow displayed.
Unit CX160B CX210B CX240B CX290B

1 pump flow (flow Level 1) L / min 142 210 234 243
2 pumps flow (flow Level 1) L / min 284 420 468 486
3. There is no need to do anything to finalize the setting. End by leaving this screen or switching OFF the
key.
The factory settings for each mode are as follows.
There are no 4 or 5 settings for the breaker or crusher. Just a hyphen is displayed for these settings.
Mode Flow display Flow display

(CX210B & CX240B) (CX160B & CX290B)
Breaker circuit 1 / Crusher 1 Level 2 flow Level 3 flow
Breaker circuit 4 / Crusher 4 (Not used) (Not used)
Breaker circuit 5 / Crusher 5 (Not used) (Not used)

4001-115
8. Anti-theft Setting
A) Anti-theft setting and password registration

1) Enabling the anti-theft function
With the key OFF, connect the anti-theft knob terminal.
When the male and female knob terminals are connected on the cab main harness in the rear cover, the anti-
theft function is enabled.The factory setting is for these knob terminals to be disconnected.
Anti-theft setting knob
Connect VG (purple / green) and BG (black /
green)
2) Setting the password

When the knob terminals are connected, then the key switched ON, the following screen is displayed.
Enter any 4-digit number made up of the numbers 1 to 9.
(If all four digits are not input, "ERROR" is displayed).
Input by using the monitor switches as follows.
When the Enter button is pressed, the password is stored into memory and display returns to the normal
screen.
1 Enter 3 Numeric value increase / decrease

2 Cursor movement
3) Changing the password

If the password has been forgotten or it is desired to change the password, if the knob terminal in A)1) is
disconnected and the key switched ON, the password is cleared. To re-input the password, repeat the
procedure in b).

4001-116
B) Anti-theft function operation

1) Enabling the anti-theft function
1. If the key is switched twice in a row ON => OFF => ON => OFF with the engine stopped, the anti-theft
function is switched ON.
(All the key switching operations must be done within 2 seconds)
2. When the anti-theft comes ON, the monitor buzzes and the "key" icon is displayed.
(Once the anti-theft is switched ON, this icon is displayed while the power is OFF)
3. The next time the key is switched ON, the anti-theft operates and the password input screen is displayed.
Input the password made up of 4 digits 0 to 9.
Input by using the monitor switches below.
If an incorrect number is input, "ERROR" is displayed and the buzzer buzzes.
The key must be switched OFF, then ON again before the password can be re-input.
1 Enter 3 Numeric value increase / decrease

2 Cursor movement
2) Disabling the anti-theft function

1. If the engine is stopped by switching OFF the key, the anti-theft function does not operate.
2. To disable the anti-theft function, disconnect the anti-theft knob terminals VG (purple/green) and BG
(black/green). The registered password is canceled.

4001-117
9. Model Setting
If the model selection has not been completed, immediately after the key is switched ON, the "Model select screen"
is displayed
1 MACHINE : CX ???? - ?? CRANE : ?

TERRITORY : ? A. INTF : ?
LANGUAGE : ?? CONT. A ERR CONT. B ERR
4
SPEC. :? MONITOR ERR ECM ERR
ATT.No. :?
CONT.A : KHR 10020-00 CONT.B : KHR 14000-00
2 3
1 Cursor 3 Computer B; Part number

2 Computer A; Part number 4 Error display section
1. For the "CONT.A" item, the part number for computer A is automatically displayed.
2. In the same way, if computer B is connected (for the liftcrane application or interference prevention
application), the part number for computer B is automatically displayed for the "CONT. B" item.
3. Items that must be input are displayed with '?'.
MACHINE : Model CX160B, CX210B, CX240B,CX290B ...
TERRITORY : Destination 2 = CASE NA, 3= CASE EU
LANGUAGE : Language (0: Japanese, 1: English, 2: Thai, 3: Chaina, 4: German, 5: French,
6 : I ta l i a n , 7 : S p a n i s h , 8 : Po r t u g u e s e, 9 : D u t c h , 1 0 : D a n i s h ,
11: Norwegian, 12: Swedish, 13: Finnish, 14: Turkish, 15: Arabic,
16: Malay, 17: Indonesian, 18: Icon)
SPEC : Main unit specifications (input 0)
ATT.No. : Attachment specification (input 0)
CRANE : 0: No crane, 1: Crane
A.INTF : 0: No interference prevention function, 1: Interference prevention function - '1'
4. Input operating method

Input by using the monitor switches as follows.
When the model select screen is displayed on the monitor, the normal monitor switch functions do not
work.
1) Enter button
3 2) Numeric value change
3) Cursor movement
1
2
When the throttle volume position or all the input is complete, press " " (Enter button).
(The throttle volume must always be at the "H" mode position).
If the input is inappropriate (*), "CONT. A. ERR" is displayed.
* When there is still an item left with "?" displayed or the combination of model, destination, specification,
and the like is inappropriate.

4001-118
5. On the model setting screen, the ECM part number is automatically checked.
If the input model and the ECM part number do not correspond, “ECM ERR” is displayed.
6. Even after the model selection is complete, it is possible to change just the "LANGUAGE", "CRANE", or
"ATT. NO." setting without an all reset, which is discussed below.
7. All reset
• On the model select screen, if the wiper switch and light switch are held down for 10 seconds, the
data below is erased (All reset).
• Data input in model selection => All this data returns to "?".
• Trouble log
• Usage log
• Data changed with CFG

4001-119
10. Engine Screen Information
A) Purpose
It has been made possible to copy the engine information (Q adjustment, QR code, engine serial
number) stored in the ECM to the new ECM when the ECM and injector are replaced.
B) How to go to this screen

See the service support screen operation.
C) Engine start restriction

When this screen is displayed, the engine cannot be started.
D) Screen
The engine information held in computer A can be checked as follows.
The information inside the ECM is checked by changing the display mode with the method shown in "Replacing
computer A at the Same Time".
1. Pages 1 to 4: Injector cylinder 1 to 4 QR code (Pages 5 and 6 are not used and cannot be input).
1) Page
2) QR code 24 digits
3) Error code
4) Indicates the display mode.

Currently displays the information in
computer A
2. Page 7: Q resistance data

1) Q resistance data 3 digits
3. Page 8: Engine serial (number)

1) Engine serial number 6 digits
4. ECM Part Number

1) ECM part number

4001-120
E) Monitor operation method

1) View Mode.
Display mode (switching between information

in controller A / information in ECM)
page +/-
Each time this switch is pressed, the second
line of each page is switched as follows.
Hold down for one second to shift to Edit Mode

AA AA (Mode displaying information (only valid while QR code displayed and when in
in computer A) "AA AA" mode)
Be careful. Shifting to edit mode will not be done
EE EE (Mode displaying information when in "EE EE" mode
in ECM)
Hold down for three seconds to start copying the engine
information.
For details see "Engine Information Copying Method"
2) Edit Mode
Can only be shifted to during QR code display.
Cancel editing and exit edit mode Value increased
Cursor movement
Start the QR code writing and exit edit mode.
For details see "Rewriting Injector QR Codes" Value decreased

4001-121
F) Engine Information (Q resistance, QR code, engine serial number) Copying Method

If the ECM is replaced with a new one for any reason, the engine information is copied with the procedure
below
1. Connect the service ECM and check the following.
• The old ECM information must still be in computer A.
• The ECM must match the model (Check on the ECM parts nimber screen).
• No display for faulty computer A EEPROM or faulty EEPROM on ECM.
2. Go to the engine information screen, then hold down for 3 seconds. The buzzer buzzes and the copy
starts.
• The display may be any page (1 to 8) and either display mode (computer A or ECM).
When held for three seconds, the

buzzer buzzes.
During copying, the display is as below. During writing, the error code 99 is displayed.
Wait about 10 seconds.
When the copy ends normally, the error code 00 is displayed.
When the copy ends abnormally, error code displayed.
• Example: Starting copying from the Q resistance screen.
Error Code:
00: Normal.
01: Message interruption.
02: Message internal trouble.
03: Outside instruction value constant.
04: Engine running.
98: Faulty EEPROM
99: Writing
During rewriting, the mode display
section is "0".
3. When the copy ends normally, check that the information has been rewritten by switching the key switch
OFF => ON once.

4001-122
G) Rewriting Injector QR Codes

When an injector is replaced, input and write the QR codes with the following procedure.
1. Arrange for the replacement injector.
Input the part below from the character array written on the injector
QR Code
QR Code
Injector ASM
Input section 24 digits
Input the QR codes one at a time.

Engine information screen Pages 1 to 4 (4 cylinders engine) or Pages 1 to 6 (6 cylinders engine)
correspond to the injectors with those numbers (See the figure below.)
Engine rear
Engine front
1 2 3 4
Injector No.
Engine rear
Engine front
1 2 3 4 5 6
Injector No.
2. Hold down the idle switch for 1 second to shift the Edit mode.
Hold down for 1 second
3. Cursor is displayed.
ENG. INF 1
5A 52 70 1E 35 DD 21 57 00 1F 5A
BD AA AA 00 Cursor displayed

4001-123
4. Move the cursor with the washer and light switchs. Use the wiper and the auto idle switchs to raise and
lower the value and input the QR codes written on the injector.
Value increased / decreased
Cursor
movement
Error Code:
00: Normal.
ENG. INF 1 01: Message interruption.
5A 52 70 1E 35 DD 21 57 00 1F 5A 02: Message internal trouble.
BD AA AA 00 03: Outside instruction value constant.
04: Engine running.
98: Faulty EEPROM
99: Writing
Cursor only moves as
far as here
5. When the QR code input is complete, press .

The buzzer buzzes once and the writing starts.
The error code 99 (writing) is displayed. When the copy ends normally, the error code 00 is displayed.
When the writing ends abnormally, the buzzer buzzes twice and the error code is displayed. (To cancel
input, press the horn switch)
6. Switch OFF the key switch, then ON again and check that the QR codes have been written.
H) When Replacing Computer A at the Same Time

If the ECM and computer A have trouble at the same time and the engine information inside the ECM cannot
be used, restore the engine information with the procedure below.
1. Rather than a service ECM, arrange for an ECM with the engine information already written into it and
use that as the replacement.
• An ECM with the engine information already written into it means one into which the Q resistance
data has been written with EMPS.
2. Input the injector QR codes one at a time (with the procedure in the preceding item).
I) Engine Information Obtained Timing

The engine information is acquired only the first time the key is switched ON after assembly.
J) Redoing Engine Information Obtained

To re-aquire the engine information, on the engine information screen, hold down the washer switch and the
light switch for 10 seconds.
K) Trouble Display
If the engine information cannot be displayed correctly due to an ECM time-out, CAN communications trouble,
or faulty EEPROM, the display is all Fs.
• Display for faulty ECM EEPROM, CAN communications trouble, or ECM time-out
ENG. INF 1
FF FF FF FF FF FF FF FF FF FF FF
FF EE EE 00

4001-124
Screen Display Details
1. Message Display List
Display Message Display ON timing Display OFF timing
type
When the "engine oil pressure abnormally low" trouble
LOW OIL PRESS Warning occurs
When the "ECM mismatch" trouble occurs.

CHECK ENGINE Warning Also, when a diagnostic trouble code is sent from the ECM
When any of the troubles below occur

Pressure Sensors; (P1), (P2), (N1), (N2), (Overload),
(Bottom), (Rod), (Upper), (Swing), (Travel),(Arm in)”,
Sensor; Fuel level,
Temperature Sensors; (Oil),
Angle Sensors; (Boom), (Arm), (Offset), None Does not go off
Pressure switch; (Return filter clog), while the key is ON.
Solenoid; (Swing brake), (Travel high-speed), (Power
save), (Option return circuit),(Free swing) (Fan reverse),
ELEC. PROBLEM
Warning (Bucket lock) (Lever lock),
(*1)
Air conditioner signal output,
Relay; Feed pump automatic stop,
Buzzer; Liftcrane"
Rotating light,
Proportional valve; (Horsepower pump), (Pump flow),
(Fan reverse),(Boom) , (Offset), (Arm)”,
Communication (monitor), (ECM), (computer B),
(computer S),
CAN bus
When any of the troubles below occur When all the troubles
"Abnormally high coolant temperature 1", "Abnormally below are recovered
high oil temperature" from "Abnormally high
OVERHEAT Warning
coolant temperature 1"
"Abnormally high oil
temperature"
When the "Coolant level low" trouble occurs
LOW COOLANT Warning
When the "Abnormally low alternator voltage" trouble

BATTERY CHARGE Warning occurs
None Does not go off
CHECK HYD.OIL When the "Return filter clogged" trouble occurs while the key is ON.
Warning
FILTER
When the "Air cleaner clogged" trouble occurs
AIR FILTER Warning
When the "Abnormally high boost temperature 1" trouble When the "Abnormally
occurs high boost
BOOST TEMP.HIGH Warning
temperature 1" trouble
is recovered from
When the "Fuel level drop" trouble occurs When the "Fuel level
LOW FUEL Warning low" trouble is
recovered from
When the breaker mode is ON and 2nd speed merge is
SWITCH TO 1-PUMP Alert ON
When the engine emergency stop switch is ON When the conditions on
ENGINE STOP Alert the left are no longer
met
When the boom cylinder bottom pressure exceeds the set
OVER LOAD Alert pressure

4001-125
Display Message Display ON timing Display OFF timing

type
During one-touch idling or auto idling
ENGIN IDLING Icon
During auto power boost When the conditions on

POWER UP Icon
the left are no longer
When power ON to glow plug met
ENG. PRE HEAT Icon
During auto warm up

AUTO WARMUP Icon
When the key is ON and the hour meter has reached the After 1 minute after the
SERVICE DUE Status regulation time key was switched ON
(*1) Even if one of the following troubles occurs, "ELEC. PROBLEM" is not issued.
"BZ travel alarm", "Monitor thermistor", "Air conditioner coolant signal output"
Message type:
1. Status (Message only)
2. Alert (The intermittent alarm continues to sound at one-second intervals)
3. Warning (The continuous alarm sounds for just 5 seconds)
4. Icon (Only an icon is displayed).

4001-126
Trouble Display
1. Diagnostic Trouble Code Display
1) Purpose and summary
When a trouble occurs, the diagnostic trouble code (DTC) is displayed on the user screen.
This enables the operator to verbally communicate the trouble to the service engineer.
2) Screen
Displayed with the ! mark next to the work mode followed by a four-digit number.
If there is no trouble, nothing at all is displayed.
ELEC. PROBLEM
3) Trouble display
The "ELEC. PROBLEM" or "CHECK ENGINE" message is displayed.
When trouble occurs, the corresponding diagnostic trouble code is displayed. If the message makes clear
the trouble location, the location is not displayed elsewhere.
For details, see the "Main Unit Diagnostic Trouble Code List". All the diagnostic trouble codes sent from the
ECM are subject to display.
4) Displayed trouble status

Only current and ongoing troubles are displayed.Troubles that have been recovered from are not displayed.
5) Multiple trouble display

When multiple troubles occur, they are displayed in turn at intervals of five seconds.

4001-127
2. Main Unit Diagnostic Trouble Code List

1) Electrical troubles (input) [7000-7199]
Diagnostic Occurrence judgment Recovery judgment

trouble code
Trouble location Trouble mode Judgment timing Prerequisites
Dis-
DTC play Conditions Conditions
Ground short/
Sensor; disconnection Voltage ≤ 0.25 V
Pressure 7000 O Immediately after None 0.25 V < Voltage < 4.75 V
key switched ON
(P1) Power supply short Voltage ≥ 4.75 V
Ground short/
key switched ON
(P2) Power supply short Voltage ≥ 4.75 V
Ground short/
key switched ON
(N1) Power supply short Voltage ≥ 4.75 V
Ground short/
Immediately after
Pressure 7003 O key switched ON None 0.25 V < Voltage < 4.75 V
(N2) Power supply short Voltage ≥ 4.75 V
Ground short/
Immediately after EU selected as
Pressure 7004 O key switched ON destination 0.25 V < Voltage < 4.75 V
(Overload) Power supply short Voltage ≥ 4.75 V
Ground short/ Voltage ≤ 0.25 V
Sensor; disconnection Immediately after Liftcrane
Pressure 7005 O key switched ON selected 0.25 V < Voltage < 4.75 V
(Bottom) Power supply short Voltage > 4.75 V
Ground short/
Immediately after Liftcrane
Pressure 7006 O key switched ON selected 0.25 V < Voltage < 4.75 V
(Rod) Power supply short Voltage ≥ 4.75 V
Ground short/
disconnection Voltage ≤ 0.25 V
Sensor; Immediately after
Pressure (Upper) 7020 O key switched ON None 0.25 V < Voltage < 4.75 V
Power supply short Voltage ≥ 4.75 V
Ground short/
7021 O None 0.25 V < Voltage < 4.75 V
Pressure (Swing) key switched ON
Ground short/
7022 O None 0.25 V < Voltage < 4.75 V
Pressure (Travel) key switched ON
Ground short/
Immediately after
Pressure 7023 O None 0.25 V < Voltage < 4.75 V
key switched ON
(Arm in) Power supply short Voltage ≥ 4.75 V
Disconnection Resistance ≥ 100 Ω

Fuel level 7040 O key switched ON None 2Ω < Resistance < 100Ω
Short Resistance ≤ 2 Ω
Resistance ≥
3 minutes after
Sensor;
Disconnection
engine starts 67 200 Ω 111 Ω < Resistance <
Oil 7041 O None (Voltage ≥ 4.93 V ) 67 200 Ω
temperature
Immediately after Resistance ≤ 111 Ω (0.5 V < Voltage < 4.93 V)
Short
key switched ON (Voltage ≤ 0.5 V)
Monitor Disconnection
thermistor 7045 X Immediately after None Trouble bit received No trouble bit received from
key switched ON from monitor monitor
(*1) Short
Ground short/
disconnection
Liftcrane or Voltage ≤ 0.2 V
Sensor; Immediately after interference
7060 O 0.2 V < Voltage < 4.8 V
Angle (Boom) key switched ON prevention
Power supply short selected Voltage ≥ 4.8 V

4001-128
Diagnostic
trouble code Occurrence judgment Recovery judgment
Dis-
DTC Conditions Conditions
play
Ground short/
Sensor; disconnection
Immediately after interference
Angle 7061 O key switched ON prevention 0.2 V < Voltage < 4.8 V
(Arm) Power supply short selected Voltage ≥ 4.8 V
Ground short/
Sensor; disconnection
Immediately after interference
Angle 7062 O key switched ON prevention 0.2 V < Voltage < 4.8 V
(Offset) Power supply short selected Voltage ≥ 4.8 V
From immediately
Pressure switch after key switched Pressure switch =
return filter clog Disconnection 7063 O ON until engine None OFF Pressure switch = ON
starts
For items for which X is displayed, the “ELEC. PROBLEM” message is not displayed. Also, there is no DTC
display on the user screen.
However, the DTC is recorded on the service (DIAG) screen.

4001-129
2) Electrical troubles (output) [7200-7399]
Diagnostic
Occurrence judgment Recovery judgment
trouble code
DTC Dis- Conditions Conditions
play
Disconnection
Solenoid;
7200 O
Immediately after
None Output ≠ Output = Output monitor
Swing brake key switched ON Output monitor
Short
Solenoid; Disconnection
Travel 7201 O
Immediately after
high-speed key switched ON Output monitor
Short
Disconnection
Solenoid;
7202 O
Immediately after
Boost key switched ON Output monitor
Short
Disconnection
BZ travel alarm
7203 X
Immediately after
(*1) key switched ON Output monitor
Short
Disconnection
Solenoid; 7204 O Immediately after None Output ≠ Output = Output monitor
Power save key switched ON Output monitor
Short
Disconnection
REL feed pump
7205 O
Immediately after
stop key switched ON Output monitor
Short
Solenoid; Disconnection
Option return 7206 O Immediately after None Output ≠ Output = Output monitor
key switched ON Output monitor
circuit Short
Disconnection
Solenoid;
7207 O
Immediately after
Free swing key switched ON Output monitor
Short
Disconnection
Solenoid; 7208 O Immediately after None Output ≠ Output = Output monitor
Fan reverse key switched ON Output monitor
Short
Air conditioner Disconnection

coolant
7209 X
Immediately after
temperature key switched ON Output monitor
signal output (*1) Short
Disconnection
BZ liftcrane 7210 O
Immediately after
Short
REL Disconnection
rotating light and 7211 O
Immediately after
bucket lock Short
Disconnection
Solenoid;
7212 O
Immediately after
Gate lock key switched ON Output monitor
Short
Proportional Disconnection After engine starts Milli-amp ≤ 30 mA

valve;
Horsepower 7240 O None 30 mA < Milli-amp < 3 A
Immediately after
pump Short
key switched ON Milli-amp ≥ 3 A

valve; 7241 O None 30 mA < Milli-amp < 3 A
Immediately after
Pump flow Short

Immediately after
Fan Short

4001-130
Diagnostic
trouble code Occurrence judgment Recovery judgment
Dis-
DTC Conditions Conditions
play

Immediately after
Boom Short

Immediately after
Arm Short

Immediately after
Offset Short

4001-131
3) Mechanical troubles [7400-7599]
Diagnostic
Occurrence judgment Recovery judgment
trouble code
play
Coolant Coolant temperature Coolant temperature
Abnormally high temperature
7400 O
temperature 1 sensor = Normal ≥ 105°C (221°F) < 105°C (221°F)
CAN
Coolant Abnormally high 1 minute after communication Coolant temperature Coolant temperature
7402 O
temperature temperature 2 engine starts
= Normal ≥ 110°C (230°F) < 105°C (221°F)
ECM 5 V power
Abnormally high supply voltage = Coolant temperature Coolant temperature
7403 O
temperature 3 Normal ≥ 120°C (248°F) < 120°C (248°F)
Abnormally high 1 minute after Oil temperature Oil temperature Oil temperature
Oil temperature 7404 O
temperature engine starts sensor = Normal ≥ 95°C (203°F) < 95°C (203°F)
Boost
temperature
sensor =
Normal,
Abnormally high CAN Boost temperature Boost temperature
7405 O
Boost temperature 1 1 minute after communication ≥ 80°C (176°F) ≤ 70°C (158°F)
temperature engine starts = Normal,
ECM 5 V power
supply voltage =
Normal
Abnormally high Boost temperature Boost temperature
7406 O
temperature 2 ≥ 90°C (194°F) < 90°C (194°F)
Abnormally low 10s after engine Generated voltage
Alternator voltage 7420 O None Generated voltage > 10 V
voltage starts ≤ 10 V
Coolant level Drop 7421 O Immediately after None Level SW = ON Level SW = OFF
key switched ON
Oil pressure
sensor =
Normal,
CAN Pressure
Engine oil Abnormally low 30s after engine Pressure
7422 O communication
pressure pressure starts
= Normal, ≤ 40 kPa (5.8 PSI
> 40 40 kPa (5.8 PSI)
ECM 5 V power
supply voltage =
Normal
Air cleaner Clog 7423 O 10s after engine None Vacuum SW = ON Vacuum SW = OFF
starts
Return filter
Return filter Clog 7424 O 10s after engine pressure switch Pressure SW = OFF Pressure SW = ON
starts
= Normal

4001-132
4) Faulty communication [7600-7799]
Diagnostic Occurrence
Recovery judgment
trouble code judgment
play
Immediately after Bus off or error When the occurrence
CAN bus Faulty bus 7600 O key switched ON None passive conditions are not met
Packets not coming When the occurrence
Faulty reception
from monitor conditions are not met
Communication Immediately after Reception from
7601 O None
monitor Faulty key switched ON monitor When the occurrence
transmission Defective packet conditions are not met
received
Communication Time out 7602 O Immediately after None Messages not When the occurrence
ECM key switched ON coming from ECM conditions are not met
Liftcrane or
Communication Immediately after interference Messages not When the occurrence
Time out 7603 O coming from
computer B key switched ON prevention computer B conditions are not met
selected
Messages not
Communication Time out 7604 O Immediately after None coming from When the occurrence
computer S key switched ON conditions are not met
computer S
ECM Mismatch 7605 O

10 s after engine Model selection Model ≠ ECM None. No recovery
starts completed calibration No.
Previously stored
Previously stored
EEPROM Faulty data 7606 X
Immediately after
None checksum ≠ checksum =
key switched ON Current calculated Current calculated checksum
checksum

4001-133
3. Diagnostic Trouble Code (Monitor Display)
Patterns
for
Error Diagnostic trouble code
Trouble contents Main symtoms when trouble occurs Back-up function Conceivable cause recovery
Code display conditions
from
trouble
Fuel system clogged (element), pipe (hose), etc. blocked
Wiring defect (short) between ECM and common rail pressure sensor
Multi-injection stop
No pump pressure send Possibility of engine vibration, idle instability, drop Actual rail pressure of 15 MPa (150 bar/2175 PSI) or Injector defect
0087 Target common rail pressure upper limit 1
(fuel leak) of output power, black smoke, excess output lower for 3s or longer
(80 MPa (800 bar/11600 PSI))
Common rail pressure sensor defect
Supply pump defect
Pressure limiter defect
1st stage
Rail pressure exceeds 185 MPa for 5s or longer,
common rail pressure sensor voltage is 3.9 V or Fuel system pipe (hose), etc. blocked
Faulty common rail pressure Engine vibration, idle instability, drop of output higher Air in fuel system (check hose connection).
0088 Target common rail pressure upper limit 1
(1st stage, 2nd stage) power, rev-up defect 2nd stage
(80 MPa (800 bar/11600 PSI))
Common rail pressure sensor defect
First stage established, rail pressure exceeds 190 Supply pump defect
MPa for 5s or longer, common rail pressure sensor
voltage is 4 V or higher
Faulty common rail pressure Multi-injection stop Common rail pressure sensor defect
Engine vibration, idle instability, drop of output Actual rail pressure 40 MPa (400 bar/5801 PSI) or
(pump sending too much 0089 Target common rail pressure upper limit Supply pump defect 1
power, rev-up defect more above the target rail pressure for 5s or longer
pressure) (80 MPa (800 bar/11600 PSI)) ECM, SCV, common rail pressure sensor connector connection defect
When the SCV drive milli-amp exceeds the rated
SCV defect
SCV drive system milli-amp for 2s or longer Multi-injection stop
Wiring defect (disconnection, short, high resistance) between ECM and
disconnection, +B short, 0090 Black smoke and excess output When the difference between the target and actual Target common rail pressure upper limit 2
SCV
ground short milli-amp exceeds the rated milli-amp for 2s or (80 MPa (800 bar/11600 PSI))
ECM internal defect
longer
Faulty atmospheric EGR control stop
Black smoke at high altitudes, insufficient output at The atmospheric pressure sensor voltage is 0.5 V or atmospheric pressure sensor
pressure sensor 0107 Default value setting 80 kPa 2
low altitudes lower for 5s or longer. Atmospheric pressure sensor defect
(abnormally low voltage) (equivalent to 2500 m)
ECM internal defect
Faulty atmospheric EGR control stop
Black smoke at high altitudes, insufficient output at The atmospheric pressure sensor voltage is 3.8 V or atmospheric pressure sensor
pressure sensor 0108 Default value setting 80 kPa 2
low altitudes higher for 4s or longer. Atmospheric pressure sensor defect
(abnormally high voltage) (equivalent to 2500 m)
ECM internal defect
EGR control stop
Faulty suction air Wiring defect (short) between ECM and suction air temperature sensor
Possibility of white smoke when starting at low The suction air temperature sensor voltage is 0.1 V Default value setting
temperature sensor 0112 Suction air temperature sensor defect *2
temperatures or lower for 4s or longer. Starting: -10°C (14°F), Running: 25°C
(abnormally low voltage) ECM internal defect
(77°F)
EGR control stop Wiring defect (disconnection, short, high resistance) between ECM and
Faulty suction air
Possibility of white smoke when starting at low The suction air temperature sensor voltage is 4.95 V Default value setting suction air temperature sensor
temperature sensor 0113 *2
temperatures or higher for 4s or longer. Starting: -10°C (14°F), Running: 25°C Suction air temperature sensor defect
(abnormally high voltage) (77°F) ECM internal defect
EGR control stop
Faulty engine coolant Wiring defect (short) between ECM and engine coolant sensor
Poor starting at low temperatures, black smoke, The coolant temperature sensor voltage is 0.1 V or Default value setting
temperature sensor 0117 Engine coolant sensor defect *2
drop of output power lower for 4s or longer. Starting: -20°C (-4°F), Running: 80°C
(176°F)
Faulty engine coolant EGR control stop, default value setting
Increase in noise, white smoke at low The coolant temperature sensor voltage is 4.85 V or engine coolant sensor
temperature sensor 0118 Starting: -20°C (-4°F), Running: 80°C *2
temperatures, rough idling higher for 4s or longer. Engine coolant sensor defect
(abnormally high voltage) (176°F)
ECM internal defect
Faulty fuel temperature Default value setting Wiring defect (short) between ECM and fuel temperature sensor
The fuel temperature sensor voltage is 0.1 V or
sensor 0182 Nothing in particular Starting: -20°C (-4°F), Running: 70°C Fuel temperature sensor (supply pump) defect *2
lower for 4s or longer.
(abnormally low voltage) (158°F) ECM internal defect
Faulty fuel temperature Default value setting
The fuel temperature sensor voltage is 4.85 V or fuel temperature sensor
sensor 0183 Nothing in particular Starting: -20°C (-4°F), Running: 70°C *2
lower for 4s or longer. Fuel temperature sensor (supply pump) defect
(abnormally high voltage) (158°F)
ECM internal defect

4001-134
Patterns
for
from
trouble
Faulty common rail
The common rail pressure sensor voltage is 0.7 V or Default value setting 80 MPa (800 bar/ common rail
pressure sensor 0192 Engine rev-up defect, hunting 2
lower. 11600 PSI) Common rail pressure sensor defect (common rail)
Faulty common rail
Possibility of drop of output power and engine The common rail pressure sensor voltage is 4.5 V or Default value setting 80 MPa (800 bar/ common rail
pressure sensor 0193 2
stalling higher. 11600 PSI) Common rail pressure sensor defect (common rail)
(abnormally high voltage) ECM internal defect
No. 1 injector intermediate connector
No. 1 cylinder injector drive circuit disconnection/
No. 1 injector terminal looseness
Injection nozzle #1 drive High engine vibration, idle instability, drop of output short detected No. 1 cylinder injection stop
0201 Wiring defect (disconnection, high resistance) between No. 1 injector 1
system disconnection power, rev-up defect No. 1 cylinder injector monitor input EGR control stop
intermediate connector and No. 1 injector terminal
No signal for 2.4s or longer
No. 1 injector defect
ECM internal defect
ECM internal defect
ECM internal defect
ECM internal defect
ECM internal defect
ECM internal defect
Faulty engine main unit (common rail, supply pump, injector)
Injection quantity restriction It is necessary to check whether or not there is another diagnostic trouble
Overrun 0219 Drop of output power The engine speed isthe set speed of 2000 min-1 or When the speed drops, the restriction is code. 2
higher for 1 second or longer. ended. Mechanical engine trouble (turbo damaged, engine oil mixed in)
ECM internal defect
Faulty boost pressure
The boost pressure sensor voltage is 0.1 V or lower Default value setting 150 kPa (21.75 boost pressure sensor
sensor 0237 Nothing in particular 2
for 3s or longer. PSI) Boost pressure sensor defect

4001-135
Patterns
for
from
trouble
Faulty boost pressure
The boost pressure sensor voltage is 4.9 V or higher boost pressure sensor
sensor 0238 Black smoke Default value setting 150 kPa 2
for 3s or longer. Boost pressure sensor defect
Possibility of drop of output power, white smoke, Wiring defect (disconnection, short, high resistance) between ECM and
Faulty crank position (CKP) engine vibration When the CMP sensor is normal, CKP sensor
0335 There is a CMP signal, but not a CKP signal. 1
sensor (no signal) Possibility of engine stalling (when the CMP sensor cam standard control CKP sensor defect
is normal, restarting is possible). ECM internal defect
Possibility of drop of output power, white smoke, Wiring defect (short) between ECM and CKP sensor
Faulty crank position (CKP) engine vibration When the CMP sensor is normal, CKP sensor defect
0336 CKP signal pulses do not match 1
sensor (faulty signal) Possibility of engine stalling (when the CMP sensor cam standard control Flywheel ring gear tooth missing
is normal, restarting is possible). ECM internal defect
While engine turning: When the CKP CMP sensor
Faulty cam position (CMP) No fault during engine rotation, but when it is sensor is normal, crank standard CMP sensor defect
0340 There is a CKP signal, but not a CMP signal. 1
sensor (no signal) stopped once, it cannot be restarted. After engine stop: Restart is impossible Faulty cam gear
due to inability to discriminate cylinders Supply pump defect
ECM internal defect
Wiring defect (short) between ECM and CMP sensor
While engine turning: When the CKP
CMP sensor defect
Faulty cam position (CMP) No fault during engine rotation, but when it is When excess cam pulses detected or insufficient sensor is normal, crank standard
0341 Faulty camshaft gear 1
sensor (faulty signal) stopped once, it cannot be restarted. cam pulses detected After engine stop: Restart is impossible
Supply pump defect
due to inability to discriminate cylinders
ECM internal defect
Wiring defect (disconnection, short, high resistance) between fuse and
glow relay
The glow relay drive instruction signal and glow relay
Faulty glow relay 0380 Low-temperature starting defect monitor signal (line 339 in electrical circuit diagram) No backup 1
glow relay
are different.
Glow relay defect
ECM internal defect
Signal inputs from EGR position sensor U, V, and W EGR position sensor
Faulty EGR position sensor 0487 Nothing in particular EGR valve all-close command 2
all ON or all OFF for 3s or longer EGR valve (position sensor) defect
ECM internal defect
When the difference between the target valve lift and
EGR motor
Faulty EGR valve control 0488 Nothing in particular the actual position is larger than 20 % for 10s or EGR valve all-close command 2
EGR valve defect
longer
ECM internal defect
Wiring defect (short) between ECM and oil pressure sensor
Faulty oil pressure sensor The oil pressure sensor voltage is 0.1 V or lower for
0522 Nothing in particular No backup Oil pressure sensor defect 2
(abnormally low voltage) 4s or longer.
ECM internal defect
Faulty oil pressure sensor The oil pressure sensor voltage is 4.85 V or higher oil pressure sensor
0523 Nothing in particular No backup 2
(abnormally high voltage) for 4s or longer. Oil pressure sensor defect
ECM internal defect
Faulty ROM
Faulty ROM detected
(ECM internal component 0601 Engine stop No backup (engine stop) ECM internal defect 2
Reflash failure
part)
Faulty EEPROM
(ECM internal component 0603 Nothing in particular Faulty EEPROM detected No backup ECM internal defect 2
part)
The CPU monitoring IC detects faulty main CPUs for
Faulty CPU Multi-injection stop
100 ms after the key is switched ON.
(ECM internal component 0606 Drop of output power, starting not possible Injection quantity restriction ECM internal defect 2
The RUN-SUB pulse (signal between CPU and
part) The SUB-CPU stopped the CPU.
SUB-CPU) was unchanging for 20 ms or longer.
The RUN-SUB pulse (signal between CPU and
Faulty CPU monitoring IC 0606 Drop of output power Injection quantity restriction ECM internal defect 2
SUB-CPU) was unchanging for 20 ms or longer.

4001-136
Patterns
for
from
trouble
Engine vibration, idling instability, drop of output ECM terminal, ECM ground terminal defect (disconnection, high
When the ECU charge circuit bank 1 voltage is low Common 1 stop (No. 1, 4 cylinder stop)
Faulty charge circuit 1 0611 power resistance) 2
for 1.5s or longer EGR stop
Possibility of rev-up defect, engine stalling ECM internal defect
Engine vibration, idling instability, drop of output ECM terminal, ECM ground terminal defect (disconnection, high
When the ECU charge circuit bank 2 voltage is low Common 2 stop (No. 2, 3 cylinder stop)
Faulty charge circuit 2 0612 power resistance) 2
for 1.5s or longer EGR stop
Possibility of rev-up defect, engine stalling ECM internal defect
The ratio for the fuel flow command signal to the
SCV is 33 % or less. Fuel system clogged, pipe (hose) blocked
Charge fuel pump defect (discharge defect)
Differential pressure send amount is 2800 mm3/s or
Multi-injection stop Wiring defect (short) between ECM and common rail pressure sensor
No pump pressure send Engine vibration, idle instability, drop of output longer
1093 Target common rail pressure upper limit Injector defect 1
(second stage) power, rev-up defect, black smoke, engine stalling When any of the above occurs and the condition
(80 MPa (800 bar/11600 PSI)) Supply pump defect
below At 1200 min-1 or higher, actual rail pressure is Common rail pressure sensor defect (common rail)
30 MPa (300 bar/4351 PSI) or more below the target Pressure limiter defect (common rail)
rail pressure for 5s or longer
Fuel system pipe (hose), etc. blocked
Air in fuel system (Check hose connection).
When the pressure limiter is open or when the Pressure limiter defect
Pressure limiter open 1095 Drop of output power, hunting common rail pressure exceeds 200 MPa (2000 bar/ Injection quantity restriction Common rail pressure sensor defect 1
29008 PSI)for 1s or longer Wiring defect (short) between ECM and common rail pressure sensor
Supply pump defect
ECM internal defect
Faulty boost
The boost temperature sensor voltage is 0.1 V or boost temperature sensor
temperature sensor 1112 Nothing in particular No backup *2
lower for 4s or longer. Boost temperature sensor defect
Faulty boost
The boost temperature sensor voltage is 4.95 V or boost temperature sensor
temperature sensor 1113 Nothing in particular No backup *2
higher for 4s or longer. Boost temperature sensor defect
Wiring defect (short) between ECM and engine coolant sensor
Drop of output power
The coolant temperature is higher than Engine cooling system trouble (radiator clog or the like)
Overheat 1173 If the coolant temperature exceeds 108 °C during No backup 2
120°C (248°F) for 5s or longer. Engine coolant level too low
overheating, the fuel flow is restricted.
Engine coolant sensor defect
Common 1 stop No 1, 4 injector harness defect for 4JJ1 & 4HK1 (disconnection, short)
Engine vibration, idling instability, drop of output
Faulty injection nozzle Injector monitor inputs for all common 1 system (No. 1, 4 cylinder stop for 4JJ1 & 4HK1) No 1, 3, 5 injector harness defect for 6HK1 (disconnection, short)
1261 power 1
common 1 drive system Possibility of rev-up defect, engine stalling
No signal for 3s or longer (No. 1, 3, 5 cylinder stop for 6HK1) Injector defect
EGR stop ECM defect
Common 2 stop No 2, 3 injector harness defect for 4JJ1 & 4HK1 (disconnection, short)
Engine vibration, idling instability, drop of output
Faulty injection nozzle Injector monitor inputs for all common 2 system (No. 2, 3 cylinder stop for 4JJ1 & 4HK1) No 2, 4, 6 injector harness defect for 6HK1 (disconnection, short)
1262 power 1
common 2 drive system Possibility of rev-up defect, engine stalling
No signal for 3s or longer (No. 2, 4, 6 cylinder stop for 6HK1) Injector defect
EGR stop ECM internal defect
No change when error occurs
No fault during engine rotation, but when it is CMP sensor
CMP sensor out of phase 1345 No correct CMP sensor pulse in crank gap position (shift to crank sensor) 1
stopped once, it cannot be restarted. Camshaft gear installation defect
However, engine cannot be restarted.
Flywheel installation defect
Main relay input power supply voltage 1 V or lower main relay
for 2s or longer Wiring defect (disconnection, short, high resistance) with fusible link
Faulty main relay system 1625 Engine starting difficulty, power supply not cut off No backup 2
Even when the main relay coil OFF command is main relay
issued, the relay does not cut off within 5s Main relay defect
ECM internal defect
Analog sensor system default
processing (sensors operating with
default values, because conversion not
Faulty A/D conversion 1630 Drop of output power, black smoke Analog/digital conversion not possible possible) ECM internal defect 2
Target common rail pressure upper limit
(80 MPa (800 bar/11600 PSI))

4001-137
Patterns
for
from
trouble
Faulty 5 V power supply
EGR control stop Power supply circuit wiring defect (short) between ECM and atmospheric
2 voltage Black smoke at high altitudes, insufficient output at Key switch power supply voltage is 5.5 V or higher or
1632 Default value setting 80 kPa pressure sensor 2
(atmospheric pressure low altitudes 4.5 V or lower for 0.5s or longer.
(equivalent to 2500 m) ECM internal defect
sensor power supply)
Faulty 5 V power supply Power supply circuit wiring defect (short) between ECM and oil pressure
Key switch power supply voltage is 5.5 V or higher or
3 voltage 1633 Poor starting and black smoke at low temperatures Control using default values sensor 2
4.5 V or lower for 0.5s or longer.
(engine oil pressure sensor) ECM internal defect
Faulty 5 V power supply Power supply circuit wiring defect (short) between ECM and boost
Key switch power supply voltage is 5.5 V or higher or
4 voltage 1634 Black smoke Control using default values pressure sensor 2
4.5 V or lower for 0.5s or longer.
(boost pressure sensor) ECM internal defect
Faulty 5 V power supply

5 voltage Power supply circuit wiring defect (short) between ECM and common rail
Possibility of poor engine rev-up, drop of output Key switch power supply voltage is 5.5 V or higher or
(common rail pressure 1635 Control using default values pressure sensor 2
power, black smoke, engine stalling 4.5 V or lower for 0.5s or longer.
sensor, EGR position ECM internal defect
sensor)
Engine rotation that computer A sends with CAN computer A
Faulty CAN bus 2104 Engine speed down to 1500 min-1. stops for 1s or longer. Engine speed down to 1500 min-1. ECM internal defect
2
Computer A internal defect
Control from actual machine side stops working Wiring defect (disconnection, short, high resistance) between ECM and
because CAN communication become Engine rotation that computer A sends with CAN computer A
Faulty CAN time-out 2106
stops for 2s or longer. Engine speed down to 1500 min-1. ECM internal defect
2
impossible.The engine speed drops to 1500 min-1. Computer A internal defect
NOTE: Patterns for recovery from troubles:

There are the following two ways to recover from trouble.
Because the error code is cleared according to conditions, the following main switch operations are required.
• Type 1: When the key is switched ON, the engine is started and held for 10 seconds, then the key is switched OFF, the display is recovered to normal.
• Type 2: When the key is switched ON and held for 10 seconds, then the key is switched OFF, the display is recovered to normal.
However, for temperature sensors in the section marked *, after the key is switched ON, it is held for 3 to 10 minutes before it is switched OFF.

4001-138
4. Sensor Trouble Operation Table

• The table below shows the operations when there is trouble with a sensor (current, recovered from, ongoing).
• ‘*’ indicates that it is not related to (not affected by) that trouble.
Input Coolant
Upper pressure Arm-in pressure Swing pressure Travel pressure P1 pressure P2 pressure N1 pressure N2 pressure Oil temperature
temperature Fuel sensor
Output and function sensor sensor sensor sensor sensor sensor sensor sensor sensor
sensor
Trouble
0 MPa (Bar/PSI) 0 MPa (Bar/PSI) 0 MPa (Bar/PSI) 0 MPa (Bar/PSI) 0 MPa (Bar/PSI) 0 MPa (Bar/PSI) 0 MPa (Bar/PSI) 0 MPa (Bar/PSI) -40°C (-40°F) 214 °C (417°F) 0%
Backup value continuation
Recovery Input value Input value Input value Input value Input value Input value Input value Input value Input value Input value Input value
Backup value Backup value Backup value Backup value
Auto idle * * * * * * *
control (*1) control (*1) control (*1) control (*1)
Idling start * * * * * * *
Engine target control (*2) control (*2) control (*2) control (*2)
speed Backup value Backup value Backup value Backup value
Auto warm up * * * * * * *
Idle up * * * * * * *
Engine Anti-theft Fixed to ON (*22) * * Fixed to ON (*22) Fixed to ON (*22) Fixed to ON (*22) * * * * *
Stop command
Static horsepower
* * * * * * * * * * *
control
Dynamic Backup value Backup value Backup value
* * * * * * * *
horsepower control control (*5) control (*5) control (*5)
Milli-amp for pump
Travel horsepower Backup value
horsepower control * * * * * * * * * *
boost control (*6)
proportional valve
Arm-in boost Backup value
* * * * * * * * * *
horsepower control (*7)
Engine stall
* * * * * * * * * * *
prevention
Relief cut Fixed to 50 mA (*8) * Fixed to 50 mA (*8) Fixed to 50 mA (*8) Fixed to 50 mA (*8) Fixed to 50 mA (*8) Fixed to 50 mA (*8) Fixed to 50 mA (*8) * * *
Pump flow Speed limit Fixed to 50 mA (*9) * Fixed to 50 mA (*9) Fixed to 50 mA (*9) Fixed to 50 mA (*9) Fixed to 50 mA (*9) Fixed to 50 mA (*9) Fixed to 50 mA (*9) * * *
proportional valve
Fixed to 50 mA Fixed to 50 mA Fixed to 50 mA Fixed to 50 mA Fixed to 50 mA Fixed to 50 mA Fixed to 50 mA
Power save * * * *
(*10) (*10) (*10) (*10) (*10) (*10) (*10)
Power save Backup value Backup value Backup value
Power save * * * * * * * *
solenoid control (*10) control (*10) control (*10)
Backup value Backup value Backup value
Auto power boost * * Fixed to OFF (*13) * * * * *
control (*11) control (*12) control (*12)
Boost solenoid Always boosted * * * Fixed to OFF (*13) * * * * * * *
Boost cut * * * Fixed to OFF (*13) * * * * * * *
Auto brake Fixed to OFF (*14) * Fixed to OFF (*14) * * * * * * * *

Swing brake
Swing lock Fixed to ON (*15) * Fixed to ON (*15) * * * * * * * *
solenoid
Anti-theft Fixed to ON (*16) * Fixed to ON (*16) * * * * * * * *
Backup value
Travel alarm * * * * * * * * * *
control (*17)
Travel alarm Key ON alarm * * * * * * * * * * *
Anti-theft * * * * * * * * * * *
Coolant Coolant
* * * * * * * * * Not displayed (*18) *
temperature gauge temperature display
4001-139
Input Coolant
Upper pressure Arm-in pressure Swing pressure Travel pressure P1 pressure P2 pressure N1 pressure N2 pressure Oil temperature
temperature Fuel sensor
Output and function sensor sensor sensor sensor sensor sensor sensor sensor sensor
sensor
Trouble
0 MPa (Bar/PSI) 0 MPa (Bar/PSI) 0 MPa (Bar/PSI) 0 MPa (Bar/PSI) 0 MPa (Bar/PSI) 0 MPa (Bar/PSI) 0 MPa (Bar/PSI) 0 MPa (Bar/PSI) -40°C (-40°F) 214 °C (417°F) 0%
Backup value continuation
Recovery Input value Input value Input value Input value Input value Input value Input value Input value Input value Input value Input value
Oil temperature Oil temperature
* * * * * * * * Not displayed (*19) * *
gauge display
Fuel gauge Fuel level display * * * * * * * * * * Not displayed (*20)
Cold blast Backup value

Air Conditioner * * * * * * * * * *
prevention control (*21)
- Symptom -
(*1) Idle cannot be ended. Idles even during work.
(*2) Idle cannot be ended.
(*3) Auto warm up cannot be ended.
(*4) Idle speed cannot be raised.
(*5) Dynamic horsepower control (for overload) is not possible.
(*6) No horsepower boost even for travel.
(*7) No horsepower boost even for arm-in.
(*8) No swing relief cut (deterioration in fuel economy).
(*9) No swing speed limit (Excessive swing speed).
(*10) No power save (deterioration in fuel economy).
(*11) Auto power boost stops (Constant power boost for A mode is executed).
(*12) Auto power boost is not carried out for a pump load on only one side.
(*13) Boost is always OFF.
(*14) Swing brake is always OFF.
(*15) During a swing lock, held ON even if there is trouble.
(*16) During swinging with anti-theft prevention, held ON even if there is trouble.
(*17) Travel alarm stops (Key ON alarm sounds).
(*18) Coolant temperature gauge is not displayed (Goes out).
(*19) Oil temperature gauge is not displayed (Goes out).
(*20) Fuel level gauge is not displayed (Goes out).
(*21) Air flow max.
(*22) The engine cannot be started if the password has not been input.

4001-140
5. EPF (engine protection feature)

This feature controls the engine speed or stopping when the coolant temperature rises, the boost temperature rises, or the oil pressure drops.
Trouble state:
Recovered = State in which trouble recovered from during the key ON cycle
Ongoing = State in which the key was switched OFF, then ON again with the previous trouble underway (or continuing)
Degree of speed restriction Explanation

Trouble underway 0: None -
Coolant temperature over
Recovered 0: None -
105°C (221°F)
Ongoing 0: None -
Trouble underway 2: Low idle -
Coolant temperature over Recovered 0: None When the coolant temperature falls below 105°C (221°F), the system recovers and controls returns to normal.
110°C (230°F) Ongoing 2: Low idle When the key is switched ON again and the engine starts, for the time (2 minutes) until judgment starts, the engine speed is restricted to low
idle.After that, the status moves to trouble underway or recovered based on the judgment results.
Trouble underway 4: Stop (restart possible) Engine stop.The engine cannot be restarted until either the key is switched ON again or the coolant temperature recovers to the normal level.
Recovered 0: None When the coolant temperature falls below 120°C (248°F), the degree of restriction due to the coolant temperature being over 120°C (248°F)goes
Coolant temperature over to 0 (Normal control). However, if the degree of restriction due to the coolant temperature being over 110°C (230°F) is not 0, that degree of
120°C (248°F) restriction is applied.
Ongoing 2: Low idle When the key is switched ON again and the engine starts, for the time (1 minute) until judgment starts, the engine speed is restricted to low
Trouble underway 2: Low idle -
Boost temperature over Recovered 0: None When the boost temperature falls below 70°C (158°F), the system recovers and controls returns to normal.
80°C (176°F) Ongoing 2: Low idle When the key is switched ON again and the engine starts, for the time (1 minute) until judgment starts, the engine speed is restricted to low idle.
After that, the status moves to trouble underway or recovered based on the judgment results.
Trouble underway 4: Stop (restart possible) Engine stop.The engine cannot be restarted until either the key is switched ON again or the boost temperature recovers to the normal level.
Recovered 0: None When the boost temperature falls below 90°C (194°F), the degree of restriction due to the boost temperature being over 90°C (194°F) goes to 0
Boost temperature over (Normal control). However, if the degree of restriction due to the boost temperature being over 80°C (176°F) is not 0, that degree of restriction is
90°C (194°F) applied.
Ongoing 2: Low idle When the key is switched ON again and the engine starts, for the time (1 minute) until judgment starts, the engine speed is restricted to low
Trouble underway 4: Stop (restart possible) Engine stop. The engine cannot be restarted until the key is switched ON again. Recovery cannot be judged until the engine is restarted, so the
system does not move from trouble underway to be recovered.
Engine oil pressure drop Recovered 0: None The engine oil pressure recovers to less than 40 kPa (5.8 PSI) and controls returns to normal.
Ongoing 2: Low idle When the key is switched ON again and the engine starts, for the time (30 s) until judgment starts, the engine speed is restricted to low idle. After
that, the status moves to trouble underway or recovered based on the judgment.

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Section
4020
ELECTRICAL EQUIPEMENT
&
ELECTRIC CIRCUIT DIAGRAMS
4020

Printed in USA.
4020-2
TABLE OF CONTENTS
ELECTRICAL EQUIPEMENT LAYOUT DIAGRAM ....................................................................................................... 3

Overall View ............................................................................................................................................................. 3
Main Unit Right Side Layout Diagram (radiator compartment) ................................................................................. 6
Engine Section Layout Diagram ............................................................................................................................... 9
Main Unit Left Side Layout Diagram (pump compartment) .................................................................................... 12
Main Unit Center Section Layout Diagram ............................................................................................................. 15
Cab Layout Diagram 1 ........................................................................................................................................... 16
Controller A ........................................................................................................................................................ 17
Relay .................................................................................................................................................................. 17
ECM (engine control module) ............................................................................................................................ 17
Fuse box ............................................................................................................................................................ 17
Layout Around Operator Seat ................................................................................................................................ 18
Stand-Alone Parts Diagram ................................................................................................................................... 19
Connection Connector Pin Layout ......................................................................................................................... 35
Computer A ........................................................................................................................................................ 35
Monitor ............................................................................................................................................................... 36
ELECTRIC CIRCUIT DIAGRAM .................................................................................................................................. 38
List of components ................................................................................................................................................. 38
Sequence Circuit Diagram (CX160B) ..................................................................................................................... 39
Sequence Circuit Diagram (CX210B, CX240B) ..................................................................................................... 40
Sequence Circuit Diagram (CX290B) ..................................................................................................................... 41
BLOC DIAGRAM .................................................................................................................................................... 42
Computer A ........................................................................................................................................................ 42
Computer S ........................................................................................................................................................ 43
ECM (Engine Control Module) (CX160B) .......................................................................................................... 44
ECM (Engine Control Module) (CX210B, CX240B) ........................................................................................... 45
ECM (Engine Control Module) (CX290B) .......................................................................................................... 46
Monitor Display .................................................................................................................................................. 47
Air Conditioner ................................................................................................................................................... 48
Lever Lock .......................................................................................................................................................... 49
Horn ................................................................................................................................................................... 49
Working Light ..................................................................................................................................................... 50
Option ................................................................................................................................................................. 50
Others ................................................................................................................................................................ 51
Electrical Symbol List ......................................................................................................................................... 52
ELECTRICAL CONNECTOR WIRING DIAGRAM ....................................................................................................... 53
Main Frame ............................................................................................................................................................ 53
Main Frame CX160B .......................................................................................................................................... 53
Main Frame CX210B, CX240B .......................................................................................................................... 54
Main Frame CX290B .......................................................................................................................................... 55
Cab ......................................................................................................................................................................... 56
Cab main harness .............................................................................................................................................. 56
Cab sub harness ................................................................................................................................................ 57
In cab harness .................................................................................................................................................... 58
Engine Harness ...................................................................................................................................................... 59
CX160B .............................................................................................................................................................. 59
CX210B, CX240B .............................................................................................................................................. 60
CX290B .............................................................................................................................................................. 61
Console .................................................................................................................................................................. 62
Console Right harness ....................................................................................................................................... 62
Console Left harnes ........................................................................................................................................... 62

4020-3
ELECTRICAL EQUIPEMENT LAYOUT DIAGRAM
Overall View
a) CX160B
1 5
2 4
1 Main unit right side (radiator compartment)

2 Engine
3 Main unit left side (pump compartment)
4 Main unit center section
5 In cab

4020-4
b) CX210B, CX240B
1 5
2 4

2 Engine
5 In cab

4020-5
c) CX290B
1 5
2 4

2 Engine
5 In cab

4020-6
1. Main Unit Right Side Layout Diagram (radiator compartment)
a) CX160B
2 1 9
5 8
3
11
12
6 7
14
13
10
LE01002-002
1 Air cleaner sensor 6 Fuse: ECM 20A (F4) 11 Safety relay

2 Suction air temperature sensor 7 Fuse: controller 20A (F5) 12 Battery relay
3 Fusible link 65A (F1) 8 Fuse: GPS 15A (F6) 13 Receiver dryer sensor
4 Fusible link 50A (F2) 9 Swing pilot pressure sensor 14 Battery
5 Fuse: key 15A (F3) 10 Washer motor

4020-7
b) CX210B, CX240B
1
5 8
10
6
11 7
12
14
13


4020-8
c) CX290B
8 9
4
7 10
3
14
12
13
11
BE01003-00


4020-9
2. Engine Section Layout Diagram
a) CX160B
3
11 1
10 12
LE01002-003
1 Engine coolant temperature sensor 7 Starter motor

2 Boost pressure sensor 8 Engine coolant temperature sensor
3 Overheat switch 9 Suction control valve
4 Common rail pressure sensor 10 Fuel temperature sensor
5 EGR valve 11 Cam position sensor
6 Boost temperature sensor 12 Crank position sensor

4020-10
b) CX210B, CX240B
2
1
3
6
10
8
7
9
12
11


4020-11
c) CX290B
11
2 6
3
7
10
8
9 12


4020-12
3. Main Unit Left Side Layout Diagram (pump compartment)
a) CX160B
4
7
5 8
6 9
10 12
13
11
14
LE01002-004
1 Electromagnetic fuel pump 8 Power save

2 P1 pressure sensor 9 Lever lock
3 P2 pressure sensor 10 N1 pressure sensor
4 5-way solenoid valve 11 P1 flow control proportional valve
5 Boosted pressure 12 Horsepower control proportional valve
6 Travel speed 13 N2 pressure sensor
7 Swing lock 14 Oil temperature sensor

4020-13
b) CX210B, CX240B
7
5 8
6 9
10
11
12
13
14


4020-14
c) CX290B
2
1
4
3
7
5 8
6 9
10
13
11
12
14
BE01003-004


4020-15
4. Main Unit Center Section Layout Diagram
CX160B CX210B, CX240B, CX290B
1
3
2
1 Upper side pressure sensor

2 Arm-in pressure sensor
3 Travel pressure sensor

4020-16
5. Cab Layout Diagram 1
1 Air conditioner solar radiation sensor 7 Monitor display 13 Air conditioner control panel
2 Clock 8 12 V socket 14 Emergency stop switch
3 Cigar lighter 9 Wiper motor 15 Rocker switch
4 Knob 10 Radio 16 Gate lock limit switch
5 Wiper controller 11 Throttle volume
6 Rocker switches (4) 12 Key cylinder

4020-17
1 3
R1
R3
R2 R5
R4 R7
R6 R9
R8 R11
4 R10
F7
F8
F10
F9
F11
F12
F13
F14
F15
F16
F17
F18
F19
F20
F21
F22
F23
F24
F25
F26
1) Controller A
2) Relay
R1 Main relay R5 Horn relay L R9 Room lamp relay
R2 Glow relay R6 Horn relay R R10 Beacon relay
R3 Lamp relay R7 Speaker relay R R11 Starter cut relay
R4 Lamp relay (CAB) R8 Speaker relay L
3) ECM (engine control module)
4) Fuse box
F7 Memory, cab light, car radio (10 A) F17 Fuel filler pump (20 A)
F8 Engine pre-heating (30 A) F18 Clock (10 A)
F9 Optional (10 A) F19 Cigarette lighter, operator’s seat (15 A)
F10 Air conditioning, heater (5 A) F20 DC rectifier (10 A)
F11 Air conditioning condenser fan (15 A) F21 Rotating beacon / Travel Alarm (10 A)
F12 Air conditioning compressor (5 A) F22 Not used (15 A)
F13 Solenoid (10 A) F23 Fuel supply electric pump (10 A)
F14 Windshield wiper/washer (15 A) F24 Not used (15 A)
F15 Horn (10 A) F25 Hydraulic control cancellation (10 A)
F16 Cab light (15 A) F26 Working lights (15 A)

4020-18
6. Layout Around Operator Seat
7 5
3 2
10
1 Cup holder
2 Key switch
3 Rocker switch base
4 AM / FM radio
5 Tilt lever
6 Throttle volume
7 Ashtray
8 Air conditioner control panel
9 Gate lever
10 Emergency stop switch

4020-19
Stand-Alone Parts Diagram
Name No. Shape Circuit Remarks
Safety relay K8 Model: 24 V DC
Battery relay K7 For +24 V DC
Starter motor M1 CX210B model 5.0 kW-24 V
Alternator G2 CX210B model 50 A-24 V
Battery G1
Washer motor M4

4020-20

Fusible link (F1) F1 Model: 65A
Fusible link (F2) F2 Model: 50A
Fuse box (F3, F3 Model: 20A & 15A

F4, F5, F6)
F4
F5
F6
Throttle volume R3
Starter switch S1 Model: 24 V DC

4020-21

Fuel level sensor R5
Electromagnetic M20 Model: 24 V DC

pump
Reserve tank S55

limit switch
Vacuum sensor S71
Glow plug R1 I

4020-22

EGR motor M15 4JJ1
8
7
EGR position 6
5
sensor B53 4
3
2
1
4HK1-6HK1
5
6
7
8
1
2
3
4
Common rail B52

pressure sensor
Cam position B50

sensor
(4JJ1) VCC
OUT(PULSE)
GND
Cam angle B50

sensor
(4HK1-6HK1)
Crank position B49

sensor
(4JJ1) VCC
OUT(PULSE)
GND
Crank angle B49

sensor
(4HK1-6HK1)
Oil pressure B21

sensor

4020-23

Boost pressure B47
sensor
Boost B51
temperature
sensor
Fuel B3
temperature
sensor
Suction control Y35

valve
(4JJ1)
Suction control Y35

valve
(4HK1-6HK1)
Injector (4JJ1) (4HK1-6HK1)
Suction air B6
temperature
sensor

4020-24

Engine coolant B1
temperature
sensor
Atmospheric B48
pressure sensor
Computer A A1
Relay R Model:
24 V DC
DC-DC U1
converter
Alarm B82
(feed pump)
Feed pump M14

4020-25

Feed pump S61
switch
Lamp (right side E1 Model:

housing) 24 V 70 W
Lamp (boom) E2 Model:

24 V 70 W
Lamp (cab top) E3 Model:

24 V 70 W
Speakers
(R & L)
Monitor display P4

4020-26

Pressure B42 Model:
sensors B44 50.0 MPa
(P1) (P2)
Pressure Model:
sensors 5.0 MPa
(N1) (N2) B43
(swing) B40
(upper side) B22
(travel) (arm-in) B26
B27
B33
Pressure switch B28 Model:
(option) 0.49 MPa
(second option)
Pressure switch S61

(filter)
5-way solenoid Y2
valve
Y3
Y4
Y5
Y6

4020-27

2-way solenoid Y9
valve (knob
Y27
switch type)
2-way solenoid Y9
valve (pedal
Y27
type)
P1 flow control Y11

proportional
valve
Horsepower Y7
control
proportional
valve
Free swing S22 Nor th America

switch Only
CAB seat air X6

suspension
connector

4020-28

Free swing Y18 Nor th America
solenoid Only
(CX160/210/240B)(CN.134)
(CX290B)(CN.133)
Hydraulic oil B2
temperature
sensor
Clock P9
Knob right (with P3 Model:

one-touch with two switches
switch)
Knob right (with P3 Model:

one-touch with four switches
switch)
(short type)
Knob left (with P2 Model:

horn switch and with two switches
radio mute)

4020-29

Knob left (with P2 Model:
horn switch and with four switches
radio mute)
(short type)
Travel alarm H2 Basic frequency:

2560 Hz
Nor th Amecrica
only
Horn (low) B81 Basic frequency:

370 Hz
Horn (high) B81 Basic frequency:

415 Hz
Diode (washer M4
motor)
Lever lock limit S51

switch

4020-30

Radio connector X8
Lamp E4 Model: 24 V, 10 W
(room lamp)
Accessory X15 Model: 12 V DC

socket
Cigar lighter E51 Model: 24V
Air conditioner E52

unit

4020-31

Limit switch S54
(front window)
(door)
Wiper controller A4
Wiper motor M3
Solar radiation B61

sensor
Receiver drier S52

(switch)

4020-32

Air conditioner Y8
compressor
(magnetic
clutch)
Motor actuator M5
(air mix) (mode)
(recycle /
refresh)
Evaporator B5
sensor
Interior R4
temperature
sensor
Relay K17
(compressor)
(blower OFF)

4020-33

Blower motor M8
Blower amp A6
Air conditioner P6
switch panel
Option select S14

switch (breaker /
crusher)
Option select
switch (breaker)
Option select
switch (crusher)

4020-34

2nd speed S35
merge select
switch (2 pumps
flow)
Emergency stop S9
switch
Over load S13 Europe Only

warning
Travel alarm S28 Nor th America

switch Only
Beacon switch S6 Europe Only

4020-35
Connection Connector Pin Layout
1) Computer A
1PIN 12PIN
CN. C4
11PIN 22PIN
1PIN 7PIN
CN. C3
6PIN 12PIN
1PIN 9PIN
CN. C2
8PIN 16PIN
1PIN 14PIN
CN. C1
13PIN 26PIN

4020-36
2) Monitor
9PIN 20PIN
1PIN 10PIN

4020-37
This page is left blank intentionally

4020-38
ELECTRIC CIRCUIT DIAGRAM
List of components
(AS SHOWN ON THE FOLLOWING DIAGRAMS) K36 RELAY SPEAKER LEFT
A1 COMPUTER K37 RELAY SPEAKER RIGHT
A2 ENGINE CONTROLLER K38 RELAY HORN LEFT
A4 WIPER CONTROLLER K39 RELAY HORN RIGHT
A6 BLOWER CONTROLLER M1 STARTER MOTOR
A9 AIR CONDITIONER CONTROLLER M3 WIPER MOTOR
B1 COOLANT TEMPERATURE SENSOR M4 WASHER MOTOR
B2 HYDRAULIC OIL TEMPERATURE SENSOR M5 MOTOR (AIR CHANGING)
B3 FUEL TEMPERATURE SENSOR M6 AIR VENT DIRECTION CONTROL MOTOR
B5 EVAPORATOR SENSOR M7 MOTOR ACT (AIR-MIX)
B6 AIR INTAKE TEMPERATURE SENSOR M8 BLOWER MOTOR
B21 ENGINE OIL PRESSURE SWITCH M14 FUEL FEED PUMP MOTOR
B22 SWING PILOT PRESSURE SWITCH M15 EXHAUST GAS RECIRCULATION MOTOR
B23 BREAKER / CRUSHER PILOT PRESSURE SWITCH P1 INSTRUMENT PANEL
B26 UPPER PILOT PRESSURE SENSOR P5 HOURMETER
B27 TRAVEL PILOT PRESSURE SENSOR P6 AIR CONDITIONER CONTROL PANEL
B33 ARM CLOSE PRESS. SENSOR (CX210B TO CX290B) P9 CLOCK
B42 PUMP PRESSURE SENSOR (P1) R1 GLOW PLUG
B43 PRESSURE SENSOR (NEGA-CONT) R3 THROTTLE VOLUME
B44 PUMP PRESSURE SENSOR (P2) (BLUE BAND) R4 THERMISTOR INNER TEMPERATURE
B45 OVERLOAD INDICATOR PRESSURE SWITCH R5 FUEL SENSOR
B47 BOOST PRESSURE SENSOR S1 KEY SWITCH
B48 AMBIENT AIR (BAROMETRIC) PRESSURE SENSOR S9 ENGINE EMERGENCY STOP SWITCH
B49 CRANKSHAFT POSITION SENSOR S13 OVERLOAD SWITCH (EUROPE)
B50 CAMSHAFT POSITION SENSOR S14 BREAKER / CRUSHER SWITCH
B51 BOOST TEMPERATURE SENSOR S15 HORN SWITCH
B52 COMMON RAIL PRESSURE SENSOR S16 ONE TOUCH IDLE
B53 EXHAUST GAS RECIRCULATION VALVE POSITION S31 OPTION 1 SOLENOID VALVE SWITCH (NORTH AMERICA)
SENSOR S32 OPTION 1 SOLENOID VALVE SWITCH (NORTH AMERICA)
B61 SUNLOAD SENSOR S33 OPTION 2 SOLENOID VALVE SWITCH
E1 WORKING LIGHT (UPPERSTRUCTURE) S34 OPTION 2 SOLENOID VALVE SWITCH
E2 WORKING LIGHT (ATTACHMENT) S35 CRUSHER OPTION TWO FLOW SOLENOID VALVE
E3 WORKING LIGHT (CAB) SWITCH
E4 CAB LIGHT S51 HYDRAULIC FUNCTION CANCELLATION LEVER SWITCH
E51 CIGARETTE LIGHTER S52 AIR CONDITIONING COMPRESSOR CLUTCH SWITCH
F1 FUSE 65A; MAIN FUSE FOR F8 TO F26 S54 FRONT WINDOW LIMIT SWITCH
F2 FUSE 50A; MAIN FUSE FOR F1 S55 RESERVE TANK LOW SWITCH
F3 FUSE 15A; KEY SWITCH AND MAIN FUSE FOR F7 S61 REFUEL PUMP SWITCH
F4 FUSE 20A; MAIN RELAY AND ENGINE STOP S62 AIR CLEANER SENSOR
F5 FUSE 20A; COMPUTEUR CONTROL AND INSTRUMENT S69 RADIO MUTE SWITCH
PANEL S71 PRESSURE SWITCH FILTER INDICATOR (HAMMER)
F6 FUSE 15A; CONTROLLER S U1 DC-DC (24V-12V) CONVERTER
F7 FUSE 10A; MEMORY, CAB LIGHT, RADIO X2 ROTARY LIGHT CONNECTOR (EUROPE)
F8 FUSE 30A; ENGINE PRE-HEATING X4 ENGINE TEST POINT CONNECTOR
F9 FUSE 10A; OPTION LINE X5 CONTROLLER TEST POINT CONNECTOR
F10 FUSE 5A; AIR CONDITIONER HEATER UNIT X6 CAB SEATCOMPRESSOR MOTOR CONNECTOR
F11 FUSE 15A; AIR CONDITIONER BLOWER X8 RADIO CONNECTOR
F12 FUSE 5A; AIR CONDITIONER COMPRESSOR X9 ANTI-THEFT SYSTEM CONNETOR
F13 FUSE 10A; SOLENOID X15 ACCESSORY SOCKET
F14 FUSE 15A; WINDSHIELD WIPER / WASHER X23 CLEAR MEMORY 1
F15 FUSE 10A; HORN Y2 PILOT PRESSURE SOLENOID VALVE (BLUE BAND)
F16 FUSE 15A; LAMP (BOOM, HOUSE) Y3 SWING BRAKE SOLENOID VALVE (WHITE BAND)
F17 FUSE 20A; FUEL FILLER PUMP Y4 2 STAGE TRAVEL SOLENOID VALVE (RED BAND)
F18 FUSE 10A; CLOCK, BACK MONITOR Y5 POWER-UP SOLENOID VALVE (YELLOW BAND)
F19 FUSE 15A; CIGAR. LIGHTER, CAB SEAT Y6 POWER SAVE SOLENOID VALVE (GREEN BAND)
F20 FUSE 10A; DC /DC CONVERTER Y7 MAIN PUMP POWER PROPORTIONAL SOLENOID
F21 FUSE 10A; TRAVEL ALARM / BEACON Y8 AIR CONDITIONER MAGNET CLUTCH
F22 FUSE 15A; SPARE Y9 CRUSHER OPTION TWO FLOW SOLENOID VALVE
F23 FUSE 10A; FUEL SUPPLY PUMP Y11 MAIN PUMP FLOW PROPORTIONAL SOLENOID
F24 FUSE 15A; SPARE Y18 FREE SWING SOLENOID VALVE (NORTH AMERICA)
F25 FUSE 10A; LEVER LOCK (GATE) Y23 OPTION 1 SOLENOID VALVE (NORTH AMERICA)
F26 FUSE 15A; LAMP (CAB) Y24 OPTION 1 SOLENOID VALVE (NORTH AMERICA)
G1 BATTERY Y25 OPTION 2 SOLENOID VALVE (RED TAPE)
G2 ALTERNATOR Y26 OPTION 2 SOLENOID VALVE (BLUE BAND)
H1 AUDIBLE WARNING DEVICE Y27 HAMMER RETURN CIRCUIT SOLENOID VALVE
H2 TRAVEL ALARM (NORTH AMERICA) Y35 SUCTION CONTROL VALVE (SCV)
K2 RELAY-GLOW PLUG
K5 RELAY-ROTARY LIGHT (EUROPE)
K6 RELAY-AIR CONDITIONER CONDENSER FAN
K8 RELAY SAFETY
K10 RELAY-WORKING LIGHT (UPPERSTRUCTURE /
ATTACHMENT)
K11 RELAY-WORKING LIGHT (CAB)
K17 BLOWER OFF RELAY
K30 REFUEL PUMP RELAY
K31 REFUEL PUMP STOP RELAY
K33 MAIN RELAY
K34 RELAY STARTER CUT
K35 RELAY ROOM LAMP
4020-39
Sequence Circuit Diagram (CX160B)
R101
B G1 G2 ACC M ST
Cigar lighter
R103
R102
F19
YR210 B HEAT G1
OFF
YR212 B712 B711
To CAB. S1 ACC
F4
F3
YR211 YR211 SEAT
X6 M14 ON
E51
RW120
ST
RG125
Fuel pump
F23
LgR530
GrR009
WR290
PW230 B753 B700
M RW120 K34
RW121
PW231 B754
DC / DC converter LgR520
BR
B779
BR
B600
F7
F20
U1 WR521
OR220 R150 BG609
6 R157 R11
2 Safety relay
R002
F2 WR003
12 V output RY280 R11
CN45 3 GrR010
LR104 S
12 V output WR281 YR974 R7 YW970
K36 WR003
B
K8 B750 B700
R105
CN46 1 R(+) E
Radio BY971
WR282
R(-) BrR523
R
WR291
ACC X8 LR975 R8 LW972
F5
L(+) Y004
F1
B705 B700 BL973 C
5 R152 L(-)
(ACC)
Accessory socket 12V X15 Back-up
B710
W130
GND
R106
BW706 R001
CN47 4 B Starter
K37 CLOCK Y004
S motor M1 E
Y904 Y904
WR293 LG832 Left knob
S69
R8
Cab light 70 W P9 S / W (mute)
K11 WR292 R7
LG831 LG
4 L852 BG622
E3 R155 R
7
BG
BrR523
Cab light 70 W 2 5 Alternator
F26 R4 G
GrR185 GrR185 GR903 B R153 R9 YL829 YL 8
3 Br016
Y L
F18 LgR160 LgR
6
GrR186 R4 WR824 Boom light 70 W 1 G015
R G2 E
B797
Y900 B740 E2 Monitor R155 R155 R030 R030 B
K10 2
Breaker / crusher switch
GW Pulverizer
R3
House light 70 W 17 S14 OR853
LW180 Y900 L901 B741
E1 P1 LW
BG
E4
16
R9
R9
Breaker
OPT 2nd speed S / W Y BG
F16
LW180 LW181 WR823 WR Y BG S35 K35
Room lamp S51 Lever lock L / S Lever lock solenoid Y2
LR906
LR906
R3 9 15 BG
OFF VW170 OR850 B760
Front window L / S (1) LR DOOR VY
YG BG ON
6
F15 Horn S / W S54
LgW175 LgW176
R5
G851 B722
S15 20
BG VY480
K2 Glow plug
R1
(L) 14 G G
LgW175 R5 R107 F8 WR020
R2
L021 L021
LR907 LR907 B747 BrW BrW525 BrR524
H 7
K38 (R) H1
LR908 R6 YR909 B749 GrR Wiper controller
H 3 10
YR
LgW177
R6
LY830 LY
8
18 A4 Washer
19 LR F14 BrR190 2
WV841
M
B742
Computer A 1
K39 LR489
A1 1
W135
Wiper motor
CNC1-4 BG613 GrR
13 VW
M4
GW228 7
V809 YR
PL056 PL056 12 VR M
BO450 CNC2-12 4 8
CNC1-1 LR 11
PW055 PW055
CNC2-4 13 GW
LY430 5
R3 Throttle volume CNC1-25
6
GR M3
Y410 WL061
CNC2-7 CNC2-10
W060 BrR523
Auto / Manual CNC2-3
WR063 LgR531
S/W CNC3-12
F17 VR866 WR062
CNC3-11
GW215
L867 L868 YL820 CNC2-2
BW064
PB082
X4
R13 CNC4-17
LgR530
GrR337 46 DIAG S/W
L867 R13 WR917 ECM 52
PB082 PB083 BG691
W133 F25
S61 K31 R13
CNC4-22
W132
R112 VW170 Glow relay
BrR916
B B759 CNC4-11 R2 BrR339
10 A2 MEMORY CLEAR
X23
WR521
W131 BrY084 BG692
CNC4-12 LR336 32
M14 VR866 B758 CNC4-1
W130 K2 24
K30 R12
CNC1-8
BrR523
RG125 RG125
R1
WR330
2
Main relay
LgR531 YR332 BG608
R12
CNC1-7
Engine stop S / W WR331 5
21 R1 K33
GW215 LR915
M
B757 S9 RG126 LG340
47
40
YR333
L374
WR062
F22 98
BW064
WL061
BG694
W140 LG528
S52 G375 CMP B50
W060
BrW236 BrW236 BrW236 CN9-1 DIAGNOSTIC
CN9-2 B737 W373
VW817 CN9-12 Connector PL080 BL687 sensor
F21 CN9-3 BG634 38 100
LgR532
VY480
GW225 GW226 GW227 R10 VW858 CN9-13 11 4 7 12 2
BG635 P042
CN9-14 18 W307
H2 GW225 W840 PG045
CN9-11 CN9-6 BY069 X4 87
Common
A CNC4-18
K5 P044
CN9-10 CN9-7 Y065
8 EST
1 connector
PG043
37 82 L317 rail B52
F13 Free swing Travel alarm (B) B790 Magnetic clutch pressure
GR250 GR257 VY806 YL066 4 PB082 Dust S / W L318
CN9-8 3 1 90
Y18 CNC4-14 GL910
X2 R12 sensor
BG693
BG690
Swing brake SOL GW226
R10
To beacon
CN9-9
YR067
6
PL080
5 K6 BrR GW980 W981 Y8 B
101
G327
R251 VG800 C/R 7
Y3 CNC4-6 connector Connection to controller B B720 94 GB363 U EGR position
Travel 2nd speed SOL CNC2-6
P040 P040 P046
C
A X5 F12
LR205 R BrW556
93 GW364
V sensor B53
R252 LG801 R151 R12 CN29-18 GR365
B
Y4 CNC4-4
DEUTSCH EST connector (A) B721 P6
92 W
Boosted pressure PL081 PL080 A6 CN28-6
R253 YG802 PG041 PG041 PG047 E
Y5 CNC4-7 CNC2-14 D M8 Filter check 111 WR360 U
Power save P042 P042 Blower amp W557 CN29-21 A9 103 WB361 V M EGR M15
Y27 Y6
R254 BrG803
CNC4-3 PG043 PG043
F11
WR200
R13
Blower motor
LR RL
WG558 CN29-22 110 WL362
W valve motor
BrY551
M CN29-13
LG528 LG528 LB550 CN29-12 WB303
80
F9 LW260 LY807 B23 CNC1-20
F10
CNC4-15 Y313
OPT 2nd speed
VR547
R13
VW548 CN29-8 67 Oil pressure B21
BrY855 VY463 VR195 BY323 sensor
Y9 CNC1-3 CN28-14 79
(S31) Knob R Evaporator sensor RG316 BY Coolant B1
GL861 GL861 B714 B K17 B5 L560
84
temperature sensor
CN28-2
Y23 83 YG315 BY Fuel B3
(S32) Knob L Fuel sensor Temperature sensor temperature sensor
GW862 B713 CNC1-15 GL412 BG660
R5 R4 Sb559
CN28-1 95
RW304
Y24 BG620
Computer S CN28-5 91 L314 Boost B47
(S33) Knob R Air cleaner sensor pressure
B724
Solar radiation sensor GW324
YL863 LW471 F6 sensor
Y25 CNC1-16 BG661
S62 P048 RB145 R115
WY563
CN28-7
109
(S34) Knob L PG049

CNC7-8 CNC6-1 B61 WL564
CN28-8 74
GR312 RL Boost
B51
CNC7-16 CNC6-2
YG864 GR541
temperature sensor
B723
Y26 YL472
Filter indicator
BG663
CNC6-12
Motor actuator CN29-2 R370
CKP
GY464
CNC1-17
CNC1-5 S71 CNC6-13
LgR533 (air mix) M L371
G372
B49
CNC6-7 G555
107 sensor
BW689
CN29-17 108
One-touch IDL
Air conditioner RW368
CNC2-15
YL475 BG610
S16 M7 S/W
105
SCV
GW542
CN29-3 panel 113 RW369
(suction control Y35
Reserve tank L / S LY540 CN29-1 RG366
89 valve)
GrW470 GL553
CNC2-8 BG662
S55 BL549
CN29-15
97 RG367
CN29-11
Anti-theft protection setting knob
VG481 BG632
CNC2-16 X9 Motor actuator LY
(mode) YL552 CN29-14 W350 Injector #1
121
B L352
YR543 119
CN29-4
W400 Pump horsepower proportional valve M6 M

CNC1-11 Y554
YR940 CN29-16
CNC3-3 Injector #2
B42 P1 sensor Y420 CNC1-21
CNC3-6
BY941 Y7 BARO 118
P355
YW544 (atmospheric pressure)
P2 sensor L421 CN29-5
B44 CNC1-9 Pump flow proportional valve
LR545
sensor
Motor actuator CN29-6 W300
LR942 61
B43 N1 sensor Lg422
CNC1-22 CNC3-2
(recirculate) M
116
R351 Injector #3
Br423
BL943 Y11 LG562 B48 YL310
71 120
Y353
B43 N2 sensor CNC1-10 CNC3-5
M5 CN28-4
Swing B701 B701 G320
B22 P sensor G424 CNC1-23 CNC4-5
B702
60
Upper side CNC4-16 LW546 Injector #4

CN29-7
B26 P sensor
V425 CNC1-12
BG601 BG601 VY480
B6 G321 L311
72
117
G354
CNC4-2 CN28-9
Travel
B27 P sensor
YG426 CNC1-24 CNC4-13
BG602 LgR532
CN29-20 Suction air temperature
Over load Y904 sensor B770
GR428 CN28-13 1
B45 HBCV CNC1-26 CNC1-18
WG488 BG612
S13
sensor 3
B771
BW440 CNC1-14
OL822 OL822 B772
CNC4-19 CN28-11 4
Oil temperature sensor BG670
CN28-10 43
BW451 BrW411
B2 CNC1-2
62
BG671
BG672
81
Front window L / S (2)
S54 VG478 BG615
* Front window L / S (1) and (2) are the same switches.

4020-40
Sequence Circuit Diagram (CX210B, CX240B)
R101
B G1 G2 ACC M ST
Cigar lighter
R103
R102
F19
YR210 B HEAT G1
OFF
YR212 B712 B711 S1 ACC
F4
F3
To KAB. X6
YR211 YR211 M14 ON
E51 SEAT
RW120
ST
RG125
Fuel pump
F23
LgR530
GrR009
WR290
PW230 B753 B700
M RW120 K34
RW121
PW231 B754
LgR520 B779
DC / DC converter BR
BR
B600
F7
F20
U1 WR521
OR220 R150 BG609
6 R157 R11
2 Safety relay
R002
F2 WR003
CN45 3 GrR010
LR104 S
B750 B700
12 V output WR281 Radio YR974 R7 YW970 K36 WR003
B
K8
R105
CN46 1 R(+) E
BY971
WR282
R(-) BrR523
R
WR291 R8 LW972
ACC X8 LR975
F5
L(+) Y004
F1
B705 B700 BL973 C
5 R152 L(-)
(ACC)
B710
W130
GND
R106
BW706 R001
CN47 4 B Starter motor
CLOCK Y004
M1
K37 S E
Y904 Y904
WR293 R8
LG832 Left knob S69
K11 WR292 R7
LG831 LG
4 7
L852 BG622
E3 R155 R BG
BrR523
F26 R4 G
GrR185 GrR185 GR903 B R153 R9 YL829 YL 3 8 Br016
Y L
F18 LgR160 LgR
6
B797
GrR186 R4 WR824 Boom light 70 W 1 G015
R G2 E
Y900 B740
E2 Monitor R155 R155 R030 R030 B
K10 2
Pulverizer Breaker / crusher switch
House light 70 W GW
LW180
R3
Y900 L901 B741 P1
17 BG S14 E4
OR853
E1 16
LW
R9
R9
F16
Breaker
OPT 2nd speed S / W Room lamp
Y BG S51 Lever lock L / S Y2
LW180 LW181 WR823 WR BG
K35 Lever lock solenoid
Y
S35
LR906
LR906
R3 9 15 BG
OFF VW170 OR850 B760
YG BG ON
Horn S / W 6
F15 S54 VY480
LgW175 LgW176
R5
G851 B722
S15 20 BG K2 Glow plug
R1
(L) 14 G G
LgW175 R5 R107 F8 WR020
R2
L021 L021
LR907 LR907 B747 BrW BrW525 BrR524
H 7
K38 LR908
(R) H1 Wiper controller
R6 YR909 B749 GrR
H 3 10
YR Washer
LgW177
R6
LY830 LY
8
18 A4
19 LR F14 BrR190 2
WV841
M
B742
Computer A
K39 LR489
A1 1
W135 1
Wiper motor
CNC1-4 BG613 GrR
13 VW
M4
GW228 7
V809 YR
PL056 PL056 12 VR M
CNC2-12 4 8
BO450 LR
CNC1-1 PW055 PW055 11
CNC2-4 13 GW
Throttle LY430 5
R3 volume
CNC1-25
6
GR M3
Y410 WL061
CNC2-7 CNC2-10
W060 BrR523
WR063 LgR531
S/W CNC3-12
F17 VR866 WR062
GW215 CNC3-11 PB082
L867 L868 YL820 CNC2-2
BW064 X4
R13 CNC4-17
GrR337 DIAG S/W
LgR530
46 ECM PB082 PB083 BG691
L867 R13 WR917 52
W133 F25 Glow relay
S61 K31 R13
CNC4-22
W132
R112 VW170
BrR339
BrR916
B B759 CNC4-11 R2 10 A2 MEMORY CLEAR
WR521
BrY084 BG692
CNC4-12
W131
LR336
24
32 X23
M14 VR866 B758 CNC4-1
W130
K2
K30 R12
CNC1-8
BrR523
RG125 RG125
R1
WR330 2
Main relay
LgR531 YR332 BG608
R12
CNC1-7
21 R1 K33
GW215 LR915
M
B757
S9 RG126 LG340
47
40
YR333
107 L371
WR062
F22
BW064
WL061
BG694
W140 LG528
S52
W060
BrW236 BrW236 DIAGNOSTIC
BrW236
VW817
CN9-2 CN9-1
CN9-12
B737
Connector
106
G372
BW689
CKP B49
CN9-3 PL080 108 sensor
F21 BG634 38
LgR532
VY480
GW225 GW226 GW227 R10 VW858 CN9-13 11 4 7 12 2
BG635 P042 W373
CN9-14 99
GW225 W840 PG045 BY069 EST X4 18
L374 CMP
H2 A CNC4-18
K5 P044
CN9-11 CN9-6
Y065
8 connector (B) PG043
37
98
BL687 B50
Free swing Travel alarm
CN9-10 CN9-7 1
B790 100 sensor
F13 YL066 4 PB082 Dust S / W Magnetic clutch
GR250
Y18 GR257 VY806
CNC4-14 CN9-8 3 1 R12 Y8
BG693
GW226
R10 GL910 To X2 CN9-9
YR067
6
BG690
5
K6 BrR GW980 W981 B 87 W307
Swing brake SOL beacon PL080
R251 VG800 C/R 7 L317 Common rail
82
Y3 CNC4-6 connector Connection to controller B B720
L318
pressure B52
90 sensor
Travel 2nd speed SOL CNC2-6
P040 P040 P046
C
A X5 F12
LR205 R BrW556
R252 LG801 R151 R12 CN29-18 G327
Y4 CNC4-4 B 101
DEUTSCH B721 P6
R253
Boosted pressure
YG802 PG041 PG041 PG047
EST PL081 PL080 A6 CN28-6
94 GB363 U
Y5 connector (A) E Filter check EGR position
CNC4-7 CNC2-14 D
M8 W557
93 GW364
V
sensor B53
Blower amp GR365
Power save P042 P042
Blower motor WG558
CN29-21
A9 92 W
Y27 Y6 R254 BrG803
CNC4-3 PG043 PG043
F11
WR200
R13
LR RL BrY551
CN29-22
M CN29-13
WR360
LG528 LG528 LB550 CN29-12 111 U
F9 B23 CNC1-20
F10 WB361 M15
LW260 LY807
CNC4-15
103 V M EGR
VR547 VW548 WL362
OPT 2nd speed R13 CN29-8 110 W valve motor
BrY855 VY463 VR195
Y9 CNC1-3 CN28-14
80
WB303
(S31) Knob R Evaporator sensor
GL861 GL861 B714 B K17 B5 L560
CN28-2
67
Y313
Oil pressure B21
Y23 79
BY323 sensor
(S32) Knob L Fuel sensor Temperature sensor
GW862 B713 CNC1-15 GL412 BG660
R5 R4 Sb559
CN28-1 84
RG316 BY
Coolant B1
Y24 BG620 temperature sensor
Computer S CN28-5
(S33) Knob R Air cleaner sensor Solar radiation sensor
83 YG315 BY
Fuel temperature B3
YL863 B724 LW471 BG661 F6 WY563 sensor
Y25 CNC1-16 S62 P048 RB145 R115 CN28-7
95
RW304
(S34) Knob L PG049

CNC7-8
CNC7-16
CNC6-1
CNC6-2
B61 WL564
CN28-8
L314 Boost
YG864 B723 Filter indicator GR541
91
pressure B47
Y26 YL472 BG663
CNC6-12
Motor actuator CN29-2
109
GW324
sensor
GY464
CNC1-17
CNC1-5 S71 CNC6-13
LgR533 (air mix) M
GR312 RL
CNC6-7 Boost temperature
One-touch IDL
G555
CN29-17
74
sensor B51
CNC2-15
YL475 BG610
S16 M7 S/W
105
RW369 SCV (suction
Reserve tank L / S
GW542
LY540
CN29-3 panel 113
control valve) Y35
CN29-1 89 RG366
GrW470 BG662 GL553
CNC2-8 S55 BL549
CN29-15
97 RG367
Anti-theft protection CN29-11
setting knob
VG481 BG632
CNC2-16
X9 Motor actuator LY
(mode) YL552 CN29-14 W350 Injector #1
121
B L352
YR543 119
CN29-4
W400 Pump horsepower proportional valve M6 M

Y554
CNC1-11 CN29-16
YR940 Injector #2
CNC3-3
B42 P1 sensor Y420 CNC1-21
CNC3-6
BY941 Y7 BARO 118
P355
L421 CN29-5
B44 P2 sensor CNC1-9 Pump flow proportional valve sensor
LR545
Motor actuator CN29-6 W300
Lg422 LR942 61 R351 Injector #3
(recirculate) M
116
BL943 Y11 B48 YL310
71 Y353
B43 N2 sensor Br423 CNC1-10 CNC3-5 M5 LG562 CN28-4
120
Swing G424 B701 B701 G320

60
B22 P sensor CNC1-23 CNC4-5
B702 LW546 Injector #4
CNC4-16
Upper side V425 CN29-7 G321 L311
B26 P sensor CNC1-12
CNC4-2
BG601 BG601 VY480
CN28-9
B6 72
117
G354
B27 Travel YG426 CNC1-24 CNC4-13

BG602 LgR532 Suction air
CN29-20
P sensor Over load temperature
Y904 B770
Arm VG427 WG488 BG612 CN28-13 sensor 1
B33 P sensor
CNC1-13 CNC1-18 S13 B771
GR428 3
B45 HBCV CNC1-26
OL822 B772
sensor CNC4-19 OL822 CN28-11 4
BW440 CNC1-14 BG670
CN28-10 43
BG671
Oil temperature sensor 62
B2 BW451 BrW411 CNC1-2 S54 Front window L / S (2) 81
BG672
VG478 BG615

4020-41
Sequence Circuit Diagram (CX290B)
R101
B G1 G2 ACC M ST
Cigar lighter
R103
R102
F19 HEAT G1
YR210 B
OFF
YR212 B712 B711
S1 ACC
F4
F3
YR211 YR211 X6
To KAB. SEAT M14 ON
E51
RW120
ST
RG125
Fuel pump
F23
LgR530
GrR009
WR290
PW230 B753 B700
M RW120
K34
RW121
DC / DC converter PW231 B754
LgR520 B779
BR
BR
U1 B600
F7
WR521
F20 OR220 BG609
6 R157 R150 R11
2 Safety relay
R002
F2 WR003
CN45 3 GrR010
LR104 S
B750 B700
12 V output WR281 YR974 R7 YW970
K36 WR003
B K8
R105
CN46 1 R(+) E
Radio BY971
WR282
R(-) BrR523
R
WR291 R8 LW972
ACC X8 LR975
F5
L(+) Y004
F1
B705 B700 BL973 C
5 R152 L(-)
(ACC)
B710
W130
GND
R106
BW706 R001
CN47 4 B Starter motor
K37 CLOCK Y004
S M1 E
Y904 Y904
WR293 R8
LG832 Left knob S69
K11 WR292 R7
LG831 LG
4 7
L852 BG622
E3 R155 R BG
BrR523
F26 R4 G
GrR185 GrR185 GR903 B R153 R9 YL829 YL 8
3 Br016
Y L
F18 LgR160 LgR
6
B797
GrR186 R4 WR824 Boom light 70 W
Y900
1 G015
R G2 E
B740
E2 Monitor 2
R155 R155 R030 R030 B
K10 GW Pulverizer Breaker / crusher switch
House light 70 W
LW180
R3
Y900 L901 B741 P1
17 BG S14 E4
OR853
E1 16
LW
R9
R9
F16
LW180 LW181 WR823 WR
Breaker
OPT 2nd speed S / W Room lamp
Y BG S51 Lever lock L / S Lever lock solenoid Y2
Y BG
LR906
LR906
R3 9 15 S35 K35 OFF
BG
VW170 OR850 B760
YG BG ON
Horn S / W 6
F15 LgW175 LgW176 B722
S54 VY480
R5
G851
S15 20 BG
G G
K2 Glow plug
R1
(L) 14
F8 R2
LgW175 R5 LR907 LR907 B747 BrW BrW525 BrR524 R107 WR020 L021 L021
H 7
K38 LR908
(R) H1 Wiper controller
R6 YR909 B749 GrR
H 3 10
LgW177 YR Washer
R6
LY830 LY
8
18
LR F14
A4 WV841 B742
Computer A 19 BrR190 2 M
1
K39 LR489
CNC1-4
A1 1
W135
Wiper motor
GW228
BG613 GrR
13 VW
M4
YR 7
V809 PL056 PL056 12 VR
CNC2-12 4 8 M
BO450 LR
CNC1-1 PW055 PW055 11
CNC2-4 13 GW
Throttle LY430 5
R3 volume
CNC1-25
WL061
6
GR M3
Y410 CNC2-10
CNC2-7 BrR523
W060
WR063 LgR531
S/W CNC3-12
F17 VR866 WR062
CNC3-11
GW215
L867 L868 YL820 CNC2-2
BW064
PB082
X4
R13 CNC4-17
LgR530
GrR337 46 DIAG S/W
L867 R13 WR917 ECM 52
PB082 PB083 BG691
W133 F25 Glow relay
S61 K31 R13
CNC4-22
W132
R112 VW170
BrR339
BrR916
B B759 CNC4-11 R2 10 A2 MEMORY CLEAR
WR521
CNC4-12
W131
W130
LR336
24
32
BrY084 BG692
X23
M14 VR866
R12
B758 CNC4-1 K2
K30 CNC1-8
BrR523
LgR531
RG125 RG125
R1
WR330
2
Main relay
YR332 BG608
R12
CNC1-7
21 R1 K33
GW215 LR915 YR333
M
B757
S9 RG126 LG340
47
40
L374
WR062
F22 98
BW064
WL061
BG694
W140 LG528
DIAGNOSTIC S52 G375 CMP
W060
BrW236 BrW236 BrW236 CN9-1
CN9-2
VW817
CN9-3
CN9-12
B737 Connector
PL080 100
BL687
W373
sensor B50
F21 BG634 38
LgR532
VY480
GW225 GW226 GW227 R10 VW858 CN9-13 11 4 7 12 2
BG635 P042
CN9-14 W307
GW225 W840 PG045
CN9-11 CN9-6 BY069 X4 18 87
Common
H2 A CNC4-18
K5 P044
CN9-10 CN9-7 Y065
8 EST PG043
37 L317 rail
F13 Free swing Travel alarm YL066
1 connector (B) B790
4 PB082 Dust S / W Magnetic clutch
82
L318 pressure B52
GR250
Y18
GR257 VY806
CNC4-14 GL910 CN9-8 3 1 R12 Y8 90
sensor
BG693
BG690
Swing brake SOL GW226
R10 To X2 CN9-9
YR067
6 5
K6 BrR GW980 W981 B
G327
PL080 101
R251 VG800 beacon C/R 7
Y3 CNC4-6
P040 P040
connector Connection to controller B B720 94 GB363 U EGR position
Travel 2nd speed SOL P046 A F12 GW364
R252 LG801
CNC2-6 C X5 R151 LR205 R R12
BrW556
CN29-18
93
GR365
V sensor B53
Y4 CNC4-4
DEUTSCH
B 92 W
Boosted pressure EST connector (A)
A6
B721
CN28-6 P6
PG047 PL081 PL080
Y5
R253 YG802
CNC4-7 CNC2-14
PG041 PG041
D E M8 Filter check 111 WR360 U
Power save Blower amp W557
CN29-21 WB361 EGR M15
R254 BrG803
P042 P042
Blower motor WG558 A9 103 V M
valve motor
Y27 Y6 CNC4-3 PG043 PG043
F11
WR200
R13
LR RL BrY551
CN29-22 110 WL362
W
M CN29-13
LG528 LG528 LB550 CN29-12 WB303
80
F9 LW260 LY807 B23 CNC1-20
F10
CNC4-15 VR547 VW548 Y313 Oil pressure
OPT 2nd speed R13 CN29-8 67
sensor B21
BrY855 VY463 BY323
Y9 CNC1-3
VR195
CN28-14 79
(S31) Knob R Evaporator sensor 84

RG316 BY Coolant B1
GL861 GL861 B714 B
K17 B5 L560 temp. sensor
Y23 CN28-2
83 YG315 BY Fuel B3
(S32) Knob L Fuel sensor Temperature sensor temperature sensor
Y24 GW862 B713 CNC1-15 GL412 BG660
R5 R4 Sb559
CN28-1 95
RW304
BG620 Boost
(S33) Knob R Air cleaner sensor Computer S CN28-5 91 L314
pressure B47
Solar radiation sensor GW324 sensor
Y25 YL863 B724
CNC1-16 LW471 BG661
S62 P048 RB145
F6
R115
WY563
CN28-7
109
(S34) Knob L PG049

CNC7-8
CNC7-16
CNC6-1
B61 WL564
CN28-8 74
GR312 RL Boost
B51
CNC6-2 temp. sensor
Y26 YG864 B723 Filter indicator CNC6-12
Motor actuator
GR541
CN29-2 R370
YL472 BG663 G372
GY464
CNC1-17
CNC1-5 S71 CNC6-13
(air mix) L371 CKP
CNC6-7
LgR533 M
G555
107
BW689 sensor
B49
CN29-17 108
One-touch IDL
YL475 BG610 105
CNC2-15 S16 M7 S/W RW369 SCV (suction
Reserve tank L / S
GW542
LY540
CN29-3 panel 113
RG366 control valve) Y35
CN29-1 89
GrW470 BG662 GL553
CNC2-8 S55 BL549
CN29-15
97 RG367
CN29-11
Anti-theft protection setting knob 121 W350 Injector #1
VG481 BG632
CNC2-16 Motor actuator LY
X9 (mode) YL552 119
L352
CN29-14
B
YR543
CN29-4 Injector #2
WB356
114
W400
CNC1-11
Pump horsepower proportional valve M6 M
Y554
YR940 CN29-16
CNC3-3 Injector #3
Y420
B42 P1 sensor CNC1-21
CNC3-6
BY941 Y7 BARO 117
G354
L421 CN29-5
P2 sensor CNC1-9 Pump flow proportional valve sensor
B44 Motor actuator
LR545
CN29-6 W300 116 R351 Injector #4
Lg422 LR942 61
(recirculate) M YL310 115
WR357
Br423 CNC3-5
BL943 Y11 LG562 B48 71
B43 N2 sensor CNC1-10
M5 CN28-4
Injector #5
Swing G424 B701 B701 G320
60
B22 P sensor CNC1-23 CNC4-5
CNC4-16
B702 LW546
120
Y353
Upper side V425 CN29-7 G321 L311

B26 P sensor
CNC1-12
CNC4-2
BG601 BG601 VY480
CN28-9
B6 72
Injector #6
Travel YG426 BG602 LgR532 Suction air temperature P355
B27 P sensor
CNC1-24 CNC4-13
Over load CN29-20 sensor 118
Y904 B770
Arm VG427 WG488 BG612 CN28-13 1
CNC1-13
B33 P sensor
CNC1-18 S13 B771
GR428 3
B45 HBCV CNC1-26
OL822 OL822 4
B772
sensor CNC4-19 CN28-11
BW440 CNC1-14 BG670
CN28-10 43
BG671
Oil temperature sensor 62
BW451
B2 BrW411 CNC1-2
Front window L / S (2) 81
BG672
VG478 BG615
S54

4020-42
BLOC DIAGRAM
1) Computer A
Computer A
LR489
CNC1-4 BG613
GW228
V809
A1
Monitor
PL056 PL056
P1
BO450 CNC2-12 4
CNC1-1 PW055 PW055
CNC2-4 13
R3 Throttle volume
LY430
CNC1-25
Y410 WL061 WL061
CNC2-7 CNC2-10 12
W060 W060
Auto / Manual CNC2-3 7
WR063 EST
S/W CNC3-12 connector (B)
F17 VR866 WR062 WR062
GW215 CNC3-11 4
YL820 BW064 BW064 BG694
L867 L868 CNC2-2 11 2
R13 CNC4-17
L867 R13 WR917 Engine stop S / W F4

S61 CNC1-20
LG528 RG126 RG125 R103 R101
R13
BrR916 B759
B W133
CNC4-22
W132 S9
K31 CNC4-11
W131
G1
CNC4-12 F5 BR
W130 W130 LR104
CNC4-1
F21
H2 Safety relay
GW225
A CNC4-18
Travel alarm
CNC1-8
BrR523 BrR523
R
K8
F13 Free swing
GR250 GR257 VY806
Y18 CNC4-14
KEY S / W
Swing brake SOL S1
R251 VG800 Alternator
Y3 CNC4-6 Br016
L
Travel 2nd speed SOL
R252 LG801 CNC1-7
LgR531 G015
R G2
Y4 CNC4-4
Boosted pressure
R253
Y5 YG802
CNC4-7
Power save ECM
Y27 Y6 R254 BrG803
CNC4-3 CNC2-6
P040 P042
18
F9 A2
LW260 LY807
CNC4-15 PG041 PG043
CNC2-14 37
OPT 2nd speed
BrY855 VY463
CNC1-3
Y9
(S31) Knob R
GL861 GL861 B714 B
Y23
(S32) Knob L
GW862 B713 Fuel sensor
Y24 CNC1-15 GL412 BG660
R5
(S33) Knob R
Y25 YL863 B724 Air cleaner sensor
LW471 BG661
(S34) Knob L CNC1-16 S62
Y26 YG864 B723
GY464 Filter indicator
CNC1-17
CNC1-5
YL472 BG663 S71
One-touch IDL
YL475 BG610
CNC2-15 S16
Reserve tank L / S
GrW470 BG662
CNC2-8 S55
Anti-theft protection setting knob
VG481
CNC2-16 BG632
X9
W400 Pump horsepower proportional valve

CNC1-11
YR940
CNC3-3
B42 P1 sensor
Y420 CNC1-21
CNC3-6
BY941 Y7
L421 CNC1-9
B44 P2 sensor Pump flow proportional valve
Lg422 LR942
CNC3-2
B43 N1 sensor CNC1-22
BL943 X11
Br423 CNC1-10 CNC3-5
B43 N2 sensor
Swing G424 CNC1-23 CNC4-5
B701 B701
B22 P sensor CNC4-16
B702
Upper side V425 CNC1-12
B26 P sensor CNC4-2
BG601 BG601
Travel YG426 BG602
(B33) CX210B to B27 P sensor CNC1-24 CNC4-13
Over load
Arm
CX290B only B33
VG427 WG488 BG612
CNC1-13 CNC1-18
P sensor
B45 HBCV GR428
CNC1-26
sensor
BW440
S13
CNC1-14 Air conditioner S / W panel
Oil temperature sensor
BW451 BrW411 CNC4-19 OL822 OL822
CN28-11 P6
B2 CNC1-2

4020-43
2) Computer S
Computer S
F6 15A RB145
CNC6-1
RB CNC6-2
CNC6-12 B
B
CNC6-13
LgR530 LgR533
M CNC6-7
CN54
GW070
CN54-2 CNC7-6
YR074
CN54-8 CNC7-4
GL071
CN54-3 CNC7-14
YL075
CN54-9 CNC7-13
Computer A
PG041
A1 CNC2-14
Computer B
PG047 PG049
CNCR2-14 CNC7-16
PG051
CNA0-23
Computer A
P040
A1 CNC2-6
Computer B
P044 PG049
CNCR2-6 CNC7-16
P042
CNA0-18

4020-44
3) ECM (Engine Control Module) (CX160B)
KEY S/W K2 ECM

S1 LgR530 LR336 A2 L374
M ST 24 98
G375
Glow relay W373 CMP sensor B50
BrR339 BL687
R2 10 100
R11
GrR009 GrR010 GrR337 46
87 W307
L317
Common rail
82
L318
pressure sensor B52
Main relay 90
YR332
K33 R1 21
101
G327
YR333 40
94 GB363 U
F4 93 GW364
V
EGR position sensor B53
R1
RG125 WR330 GR365
2 92 W
WR331 5
Engine stop S / W 111 WR360 U

S9 RG126 LG340
47 103 WB361 V M EGR valve motor M15
110 WL362
W
WB303
DIAGNOSTIC Connector 80
CN51 Y313
67 Oil pressure sensor B21
X4 79
BY323
BG691 DIAG S/W PB083 PB082
52 RG316 BY
84 Coolant temperature sensor B1
MEMORY CLEAR YG315 BY
X23
BG692 BrY084
32
83 Fuel temperature sensor B3
RW304
95
91 L314 Boost
pressure sensor B47
GW324
109
GR312 RL
74 Boost temperature sensor B51
Computer A R370
G372
107
L371 CKP sensor B49
A1 CNC2-6
P040 P042
18 108
BW689
PG041 PG043 RW368

CNC2-14 37 105
113 RW369 SCV (suction control valve) Y35
89 RG366
97 RG367
W350
Injector #1
121
L352
119
Injector #2
BARO 118
P355
(atmospheric pressure)
sensor
W300
61 Injector #3
R351
116
B48 YL310
71 Y353
120
G320
60
Injector #4
Suction air temperature G354
sensor 117
B6 G321 L311
72
B770
1
B771
3
B772
4
BG670
43
BG671
62
BG672
81

4020-45
4) ECM (Engine Control Module) (CX210B, CX240B)
KEY S/W K2 ECM A2

S1 M ST
LgR530 LR336 24 107 L371
Glow relay 106

G372 CKP sensor B49
BrR339 BW689
R2 10 108
R11
GrR009 GrR010 GrR337 99 W373
46
98
L374 CMP sensor B50
BL687
100
Main relay
YR332 87 W307
K33 R1 21
L317 Common rail
YR333 40 82
L318
pressure sensor B52
90
F4 R1
RG125 WR330 G327
2 101
WR331 5
94 GB363 U
Engine stop S / W 93 GW364
V
EGR position sensor B53
S9 RG126 LG340
47 92 GR365
W
111 WR360 U
DIAGNOSTIC Connector 103 WB361 V M EGR valve M15
X4 CN51
110 WL362 motor
W
BG691 DIAG S/W PB083 PB082 WB303

52 80
67
Y313 Oil pressure B21
MEMORY CLEAR BY323 sensor
BG692 BrY084 79
X23 32
84
RG316 BY Coolant temperature B1
sensor
83 YG315 BY Fuel temperature
sensor B3
RW304
95
91 L314 Boost
Computer A pressure sensor B47
GW324
109
GR312 RL
A1 P040 P042 74 Boost temperature sensor B51
CNC2-6 18
PG041 PG043 RW368
CNC2-14 37 105
SCV (suction
113 RW369
control valve) Y35
89 RG366
97 RG367
W350 Injector #1
121
L352
119
Injector #2
BARO 118
P355
sensor
W300
61
R351 Injector #3
116
B48 YL310
71 Y353
120
G320
60
Injector #4
Suction air temperature G354
sensor 117
B6 G321 L311
72
B770
1
B771
3
B772
4
BG670
43
BG671
62
BG672
81

4020-46
5) ECM (Engine Control Module) (CX290B)
KEY S/W K2 ECM

S1 LgR530 LR336 24 L374
ST M 98
G375
Glow relay A2 W373 CMP sensor B50
BrR339 BL687
R2 10 100
R11
GrR009 GrR010 GrR337 46
87 W307
Common rail
82 L317
pressure sensor B52
L318
Main relay 90
WR332
K33 R1 21
101
G327
WR333 40
94 GB363 U
GW364 EGR position sensor B53
F4 R1 93 V
RG125 WR330 GR365
2 92 W
WR331 5
Engine stop S / W 111 WR360 U

S9 RG126 LG340
47 103 WB361 V M EGR valve motor M15
110 WL362
W
WB303
DIAGNOSTIC Connector 80
CN51 67
Y313
Oil pressure sensor B21
X4 BY323
DIAG S/W 79
BG691 PB083 PB082
52 RG316 BY
84 Coolant temperature sensor B1
MEMORY CLEAR YG315 BY
X23 BG692 BrY084
32
83 Fuel temperature sensor B3
RW304
95
91 L314 Boost
pressure sensor B47
GW324
109
GR312 RL
74 Boost temperature sensor B51
Computer A R370
G372
L371 CKP sensor B49
107
A1 CNC2-6
P040 P042
18 108
BW689
PG041 PG043 RW368

CNC2-14 37 105
113 RW369 SCV (suction control valve) Y35
89 RG366
97 RG367
121 W350 Injector #1

L352
119
Injector #2
WB356
114
Injector #3
BARO 117
G354
sensor R351 Injector #4
W300 116
61
B48 YL310 115
WR357
71
Injector #5
G320
60 Y353
120
G321 L311
72
Injector #6
B6 Suction air temperature P355
sensor 118
B770
1
B771
3
B772
4
BG670
43
BG671
62
BG672
81

4020-47
6) Monitor Display
M4
A4 Wiper controller
Washer
F14 BrR190 2
WV841
M
B742
1
Wiper motor
GrR
13 VW
YR 7
12
8
VR M M3
LR 11
GW
5
GR
6
P1 Monitor Display S14

Breaker / crusher switch
19 WIPER INT OUT1
GW Pulverizer
18 WIPER CNT OUT2 IN3 CRUSH S / W 17 BG
LW
IN2 BREAKER S / W 16
3 WASHER OUT3 Breaker
S35 OPT 2nd speed
S/W
BG
Y
Computer A IN4 OPT 2ND SPEED 15
CNC2-4
PW055
13 MON TXD UART S54 Front window L / S
A1
PL056 YG BG
CNC2-12 4 MON RXD UART IN1 FRONT WINDOW 6
VG
F5 W130 W135
1 BATT BG
GND 20
F7 R155 Alternator
2 IGN
BrW525
HOUR 7 L
G2
CLOCK
G
P9 8 14 ILUMI
Cab light 70 W
K11 E3
Cab light 70 W
R4
GR903
F26 GrR185 WR824
R4 Boom light 70 W
F16 Y900 B740
LW180 WR823 WR E2
R3 9 OUT4
House light 70 W
R3 L901 B741
Y900
K10
F15 LgW175
R6
LY830
8 HORN VOL OUT5 E1
S15 Horn S / W
G851 G B722
K39 R5
(L)
R5 LR907 B747
H
K38 (R)
R6 YR909 B749
H
K39 H1

4020-48
7) Air Conditioner
K6 S52 Y8
Dust S / W Magnetic clutch
R12
BrR GW980 W981 B
B720
F12
LR205 R BrW556 BrW556
R12 CN29-18
B721
CN28-6 A9
A6 Filter check
K17 M8 W557
Blower amp CN29-21
Blower motor WG558
F11 R13 CN29-22
WR200 LR RL BrY551
M CN29-13
LB550 CN29-12
F10
VR547 VW548
R13 CN29-8
VR195
CN28-14
Evaporator sensor
L560
B6 CN28-2
Temperature sensor
Sb559
R4 CN28-1
BG620
CN28-5
Solar radiation
WY563
sensor B61 CN28-7
WL564
CN28-8
GR541 GR541
(air mix) M
G555 G555
CN29-17
M7
GW542 GW542
CN29-3
LY540 LY540 CN29-1
GL553 GL553 CN29-15
BL549 BL549
CN29-11
Motor actuator LY
Air conditioner
S/W
(mode) YL552 YL552 CN29-14 panel
B
YR543 YR543
CN29-4
M6 M Front window
Y554 Y554 L/S
CN29-16
BG615
CN28-10
YW544 YW544
CN29-5 S54
LR545 LR545
(recirculate) M
M5 LG562 LG562 CN28-4
S1
LW546 LW546
CN29-7
KEY S / W
LgR530 LgR532
B M CN29-20
Computer A
OL822
CNC4-19 CN28-11
K10 A1
R3 Y900 Y904
CN28-13
Room lamp
OFF
E4
R9 DOOR VY480
LR906 CN28-9
ON
K35
RE03003-006

4020-49
8) Lever Lock
Lever lock L / S Lever lock solenoid

F25 VW170 OR850 B760
S51 Y2
KEY S / W
S1 BG609 B600
B M ST R11
F3 RW120 R11 Safety relay
K34 GrR010 K7
S
BrR523 B750 B700

R E
Computer A
BrR523
CN1-8
A1 Alternator
Br016
L G2
G015
R
9) Horn
S15
K38
Horn S / W
F15 LgW175 LgW176 G851 G B722
R5
Horn
Horn (L)
LgW175 R5 LR907 LR907 B747
H H1
LR908
Horn (R)
R6 YR909 B749
H H1
K39 Monitor S / W
LgW177 LY830
R6 CN5-8 P1

4020-50
10) Working Light
Cab light 70 W
K11 E3
R4 Cab light 70 W
F26 GrR185 GR903
GrR185
E3
GrR186 R4 WR824
Monitor S / W
F16
LW180 LW181 WR823 E1
R3 CN5-9
R3
House light 70 W
LW180 Y900 L901 B741
E2
K10 Boom light 70 W
Y900 B740
E1
11) Option
Y27
F9 Breaker
LW260 LW260 LY807 LY807
B23 VY463
OPT(2SP)
LW261 BrY855 LG856 GL858
Y9
(LB856)
S31
OPT1 LEV R-R Knob (R)
LW262 GL861 GL861 B714
Y23
OPT1 LEV R-L

S32 Knob (L)
LW263 GW862 GW862 B713
Y24
S33 Knob (R)

OPT2 LEV L-R
LW264 YL863 YL863 B724
Y25
YL466
S34 Knob (L)

OPT2 LEV L-L
LW265 YG864 YG864 B723
Y26
YG467
GY464
A1

4020-51
12) Others
E51 Cigar lighter

F19
YR210 B
YR212 B712 B711

YR211 YR211 To CAB. SEAT X6
M14 Fuel pump

F23
PW230 B753 B700
M
PW231 B754
DC / DC converter
F20 OR220
U1
CN22-6
F7 R150 R157
CN22-2
12 V output RY280
CN45 CN22-3
12 V output WR281
CN46 CN22-1
WR282
B705 B700
CN22-5
Accessory socket 12V X15
BW706
CN47 CN22-4

4020-52
13) Electrical Symbol List
Symbol Name Symbol Name

Fuse Variable solenoid valve
Diode Resistor
LED Variable resistor
Toggle switch "a" contact Variable resistor
Push switch "a" contact Alarm
A
Limit switch "a" contact Buzzer
B
Limit switch "b" contact Horn
H
Relay coil Motor
R M
Relay contact "a" contact Solar radiation sensor
R
Relay contact "b" contact Speaker

R
Solenoid valve Lamp

4020-53
ELECTRICAL CONNECTOR WIRING DIAGRAM
Main Frame
1) Main Frame CX160B
FIX CONNECTOR(CN124F) 0.85 0.85 0.85 0.85 0.85
WHITE TAPE Lg
0.85 0.85 WITH RED TAPE. BW W BL LR
B PW
753 230 442 422 402 943 942

0.85 0.85 0.85 0.85
R R R R
0.85
CN136F(ELEC.FUEL PUMP) GR
CN117F(PRESSURE SENSOR:N1) CN114F(PROPORTIONAL S/V:FLOW)
B
CN143 0.85 0.85 0.85
749 BW Y W
254 253 252 251
754 231 0.85 0.85
448 428 408
FIX CONNECTOR GL BG
(CN137F) 0.85 0.85 440 420 400 250
B PW 412 660 0.85 0.85 0.85 GREEN TAPE
WITH RED TAPE. BW Gr W HORN(RIGHT) CN120F(PRESSURE SENSOR:UPPER)
0.85 0.85
CN137F(DIODE:ELEC.FUEL PUMP) YR CN126F(JOINT CONNECTOR) BrG R
CN142 CN115F(PRESSURE SENSOR:P1) WHITE TAPE
CN135F(FUEL LEVEL SENSOR) CN.124F(OVER LOAD HARNESS) 909 CN131F(POWER SAVE SOL.V)
0.85 0.85 0.85 803 254
BW V W
0.85 0.85
CN118F(PRESSURE SENSOR:N2) BrW BW
BLUE TAPE 445 425 405
B
CN141
747 0.85 0.85 0.85 411 451
YL BG BW Br W BLUE TAPE
472 663
0.85 0.85 0.85 0.85 0.85
HORN(LEFT) 443 423 403
CN121F(PRESSURE SENSOR:TRABEL) BW L W CN125F(OIL TEMP.SENSOR) B OR
1.25 1.25
757 215 B GW
CN127F(LOCK LEVER SOL.V)
CN134F(FILTER INDICATOR) LR 760 850
820 YL 907 CN140 0.85 0.85 0.85 441 421 401 FIX CONNECTOR(CN126F)
FIX CONNECTOR
BW YG W WITH RED TAPE.
(CN133F)
WITH RED TAPE.
FIX CONNECTOR CN155F(REFUEL PUMP HARNESS) 446 426 406 BLUE TAPE
VY GR (CN155F) CN116F(PRESSURE SENSOR:P2)
1.25 1.25 RED TAPE
WITH RED TAPE B Y
806 257
0.85 0.85
740 900 0.85 0.85 LG R
1.25
L 901 BY YR CN129F(2STAGE TRAVEL SOL.V)
CN133F(FREE SWING HARNESS) 801 252
1.25 741 941 940
B CN146F(BOOM LAMP HARNESS) WHITE TAPE
CN113F(PROPORTIONAL S/V:POWER)
CN144F(LAMP:HOUSE)
YELLOW TAPE
WHITE TAPE
0.85 0.85
YG R
CN130F(2STAGE RELIEF SOL.V)
802 253
WHITE TAPE LABEL WHITE TAPE

WHITE TAPE
CNB1F(CAB MAIN HARNESS:A) WHITE TAPE
106 CN149F(TRAVEL ALARM) 8
0.85 0.85
8R VG R
GW W CN128F(SWING BRAKE SOL.V)
CNG3(ALTERNATOR GND) 8B 797 8 800 251
0.85
225 840 FIX CONNECTOR 760 B
B GL CN150F(BEACON HARNESS)
(CN149F)
755 910 WITH RED TAPE. 4
CNG2(GND G2)
300 339 332 337 336 330
FIX CONNECTOR(CN150F)
084 082 080 043 042 340 320 310 WITH RED TAPE. RED TAPE 004 5Y
0.85 0.85 CN112(ALTERNATOR:E)
BG LW 8B 797 6
0.85 0.85 0.85 0.85 0.85 1.25
CN100(BATTERY RELAY B) 1.25 CN109(STARTER MOTOR:S)
W BrR YR GrR LR WR R 115 8
0.85 0.85 0.85 0.85
661 471 WHITE TAPE
PB PL PG P 1.25 CND13F(AIRCON COMPRESSOR)
BrY LG G YL 981 W
CNB6F(CAB MAIN HARNESS:F) CN139(AIR-CLEANER SENSOR) 1.25 1.25

Br G
(BATTERY RELAY IGN)
CN110F(ALTERNATOR:L,R) 016 015
0.85 0.85 0.85 CN102
BW G W 0.75 0.85 8R 105 8
OL G
0.85 CN105M(BATTERY RELAY GND) 0.75 0.75 0.75 0.75
444 424 404 311 321 779 B 370 688 371 372 R BW L G
806 803 802 801 0.75 0.75 0.75 0.75
304 316 686 374 RW RG BL L
943 942 941 940 901 900 230 CN101 1.25
104 8
LR 0.75 0.75 0.75 0.75
CNA7F(INTAKE AIR TEMP.) 307 323 313 303 W BY Y WB
CN119F(PRESSURE SENSOR:SWING)
6 0.75 0.75 0.75 0.75
314 312 327 317 L GR G L
0.85 0.85 0.85
VY BrG YG LG 373 375 324 0.75 0.75 0.75
W G GW
0.85 0.85 0.85 0.85 1.25 1.25 0.85 030 8R
BL LR BY YR L Y PW CN108M(SAFETY RELAY:C)
WHITE TAPE 004 5Y
(BATTERY RELAY COIL)
CNA2M(ENGINE HARNESS:A)
CNB4F(CAB MAIN HARNESS:D) CN111(ALTERNATOR:B)
CN104 1.25
521 4
WR
8 700 600
CNG1(GND G1) 351 350 1.25 1.25
2B 2BG 003 5WR CN107F(SAFETY RELAY:B) R W
0.75 0.75 0.75 0.75
354 353 355 352 G Y P L
426 425 424 423 422 421 420 400 CN103 0.85
LgR 520 4
980 472 412 411 428 440
CN148F(DIODE:WASHER) 1.25
5R 002 750 B CNA3F(ENGINE HARNESS:B)
0.85 0.85 0.85 0.85 0.85 0.85 0.85 0.85 0.85 0.85
YG V G Br Lg L Y W 5WR 003 010 523 GrR BrR
0.85 0.85 0.85 0.85 0.85 GrW BG
GW YL GL BrW Gr BW
470 662 CN138F(LLC RESERVE TANK)
743 842 RED TAPE BLUE TAPE YELLOW TAPE CN106F(SAFETY RELAY:S,R,E)
CNF2M(FUSIBLE LINK50A) 363 364 365 358 0.75 0.75 0.75 0.75
GB GW GR W
CNB5F(CAB MAIN HARNESS:E) B WV 0.75 0.75 0.75 0.75
360 361 362 359 WR WB WL G
0.85 1.25 CNA4F(ENGINE HARNESS:C)

GW W
800 250 850 010 523 521 520 120 980 981 CND12F(RECIEVER DRIER)
8R 105
633 910 820 471 470 841 909 907 840 225
8R 106 1.25 1.25 1.25 1.25
102 R 103 R 104 LR 115 R 0.75 0.75 0.75
366 368 315 RG RW YG
0.85 1.25 1.25 1.25
0.85 0.85 0.85 0.85 0.85 1.25 0.85 0.85 120 RW 125 RG 130 W 145 YR
VG GR OR GrR BrR WR LgR RW CNF1M(FUSIBLE LINK65A)
0.85 0.85 FIX CONNECTOR(CN148F)
BG GL YL LW GrW WV YR LR W GW WITH RED TAPE.
841 WV CNF3F(FUSE:KEY) CNF4F(FUSE:ECM) CNF5F(FUSE:CONT.) CNF6F(FUSE:GPS)
CN147F(WASHER MOTOR) CNA5F(ENGINE HARNESS:D)
742 B
CNB3F(CAB MAIN HARNESS:C)
ENG.COMPUTER C-2 ENG.COMPUTER C-1 CNA6M(ENGINE HARNESS:E)

1.25 1.25 1.25 021 3L
GW 3L W RG 215 021 130 125
1.25 1.25
2BG 2B B YR 600 700 703 145
CNB2F(CAB MAIN HARNESS:B)
DETAIL OF ENGINE COMPUTER
350 353 352 369 360 362 324 689 371 339 042 332 336 331 772
368 361 359 687 374 084 043 080 333 670
355 354 771
367 304 363 364 365 314 318 337 340 082 320 300 671
351 366 358 316 315 317 313 310 311 312 323 303 672 330 770
1.25 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.85 0.85 0.85 1.25 1.25
W Y L RW WR WL GW BW L BrR P YR LR WR B
0.75 0.75 0.75 0.75 0.75 0.85 0.85 0.85
RW WB G BL L BrY PG PL YR BG
0.75 0.75 1.25
P G B
0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.85 0.85 0.85 0.85 0.85
RG RW GB GW GR L L GrR LG PB G W BG
1.25 0.75 0.75 0.75 0.75 0.75 0.75 0.85 0.75 0.75 0.75 0.75 0.85 1.25 1.25
R RG W RG YG L Y YL OL GR BY WB BG WR B
CNA1F(ENGINE COMPUTER C-2) CNA0F(ENGINE COMPUTER C-1)

KLR10280-E01

4020-54
2) Main Frame CX210B, CX240B
COMPUTER COMPUTER
COMPUTER
KRR12930-E00
COMPUTER COMPUTER

4020-55
3) Main Frame CX290B
COMPUTER COMPUTER
KBR10740-E02

4020-56
Cab
1) Cab main harness

4020-57
2) Cab sub harness

4020-58
3) In cab harness
GPS UNIT A GPS UNIT B
1 151A 2 151B 3 151C 4 151D 5 166A 6 164A 7 152A 8 154A 9 210G 10 172A 11 169A 1 174A 2 175A 3 157A 4 161A 5 220A 6 159A 7 210J 8 155A
1.25R/B 1.25R/B 0.85R/B 0.85R/B 0.5 W/L 0.85 Br/R 0.85 Lg/R 0.5 B/Y 0.85B/G 0.85 L/G 0.85 Y 0.85 L/R 0.85Y/G 0.5 P/L 0.5 Y/R 0.5 B/L 0.5 G/W 0.5 B/G 0.5 P
12 200E 13 200F 14 200G 15 200H 16 167A 17 165A 18 153A 19 168A 20 210H 21 171A 22 170A 9 173A 10 176A 11 158A 12 177A 13 162A 14 160A 15 210K 16 156A
1.25 B 1.25 B 0.85 B 0.85 B 0.5 W/Y 0.85 Br/Y 0.5 G/R 0.5 V/Y 0.85B/G 0.85 L/Y 0.85 B/Y 0.85L/W 0.5 V/G 0.5 P/W 0.5 V/R 0.5 Y/L 0.5 G/L 0.5 B/G 0.5 P/G
ACCESSORY SOCKET (12V)

141A 140A
0.85B/W 0.85W/R
090
to CLOCK HARNESS MONITOR DISPLAY
5 111A 4 138A 3 137A 2 128B 1 120A 9 133A 8 132A 7 124A 6 119A 5 163A 4 130A 3 108A 2 128A 1 129A
OPT. LINE SELECT SW OPT. 2SPEED SW
0.85Y/R 0.5 L/G 0.5 Y/L 0.5 R 0.5 Lg/R 0.5 W/R 0.5 L/Y 0.85 Br/W 0.5 Y/G 0.5 V/W 0.5 P/L 0.5 Gr/R 1.25 R 1.25 W
8 1 126A 2 210B 3 125A 10 8 1 2 210C 3 127A 10
12 200B 11 110A 10 109A 9 135A 8 136A 7 123A 6 210E 20 210A 19 106A 18 107A 17 126A 16 125A 15 127A 14 135A 13 131A 12 11 10
0.5 G/W 0.5 B/G 0.5 L/W * 0.5 B/G 0.5 Y
0.85 B 0.5 W/Y 0.5 W/L 0.5 G 0.5 L 0.5 Y 0.85B/G 1.25B/G 0.5 L/R 0.5 Y/R 0.5 G/W 0.5 L/W 0.5 Y 0.5 G 0.5 P/W
7 4 5 6 9 7 4 5 139A 6 134A 9
0.5 L/G 0.5 Br/Y
WIPER CONTROLER
AMP : 172498-1 Front Rear
Blue tape Yellow tape
6 101A 5 100A 4 3 2 105A 1 104A CLIP * mark (7 locations)
0.5 G/R 0.5 G/W NC NC 0.5 W/V 0.85Br/R
13 108A 12 107A 11 106A 10 200D 9 8 103A 7 102A
0.5 Gr/R 0.5 Y/R 0.5 L/R 1.25 B NC 0.5 V/R 0.5 V/W
EARTH
200A
CN-A 1.25 B
WIPER MOTOR *
*
YAZAKI : 7323-2262
White marking
MAIN HARNESS A
3 101A 2 1 100A 1 128A 2 129A 3 120A 4 111A 5 104A 6 105A 7 137A 8 138A 9 112A 10 140A
* Yellow tape
0.5 G/R NC
*
0.5 G/W 1.25 R 1.25 W 0.5 Lg/R 0.85Y/R 0.85 Br/R 0.5 W/V 0.5 Y/L 0.5 L/G 0.5 L/R 0.85W/R
6 103A 5 200C 4 102A 11 124A 12 130A 13 131A 14 132A 15 133A 16 114A 17 115A 18 116A 19 117A 20 121A 21 210A 22 141A
0.5 Y/R 1.25 B 0.5 Y/W 0.85Br/W 0.5 P/L 0.5 P/W 0.5 L/Y 0.5 V/R 0.5 B/Y 0.5 Y/W 0.5 B/L 0.5 L/W 1.25G/R 1.25B/G 0.85B/W
CLIP
MAIN HARNESS C
1 163A 2 164A 3 165A 4 166A 5 167A 6 168A 7 169A 8 170A
0.5 V/W 0.85 Br/R 0.85 Br/Y 0.5 W/L 0.5 W/Y 0.5 V/W 0.85 Y 0.85 B/Y
Bl
MAIN BODY
ue
9 171A 10 172A 11 173A 12 174A 13 175A 14 176A 15 177A 16 17 18 200J HARNESS
ta
0.85 L/Y 0.85 L/G 0.85L/W 0.85 L/R 0.85Y/G 0.5 V/G 0.5 V/R NC NC 1.25 B
pe
Part number entry
The two ends must CLIP
be pasted on with tape.
MAIN HARNESS B
1 151A 2 152A 3 153A 4 154A 5 155A 6 156A 7 157A 8 158A 9 220A
1.25R/B 0.85Lg/R 0.5 G/R 0.5 B/W 0.5 P 0.5 P/G 0.5 P/L 0.5 P/W 0.5 B/L
10 159A 11 160A 12 161A 13 162A 14 136A 15 122A 16 118A 17 134A 18 139A 19 110A 20 109A
0.5 G/W 0.5 G/L 0.5 Y/R 0.5 Y/L 0.5 L 0.5 V/Y 0.5 V/G 0.5 Br/Y 0.5 L/G 0.5 W/Y 0.5 W/L
*
CLIP
210F 121A
0.5 B/G 1.25G/R
* TO HARNESS ROOF
118A 119A 200A
0.5 V/G 0.5 Y/G 1.25 B
113-D020-A
116A 114A
0.5 B/L 0.5 B/Y to SPEAKER
117A 115A
0.5 L/W 0.5 Y/W
122B 112A to HARNESS ROOM LAMP

0.5 V/Y 0.5 L/R
123A 210D
0.5 Y 0.5 B/G to HARNESS DOOR SW
122A
0.5 V/Y

4020-59
Engine Harness
1) CX160B
E411 E422 E423 E414
INJECTOR 1 INJECTOR 2 INJECTOR 3 INJECTOR 4
1 2 1 2 1 2 1 2
2 2 2 2 2 2 2 2
L W G R P R Y W
E112
SENSOR:CAM ANGLE(G)
1 2 3 1
0.5 0.5 0.5 5
T O/B Y B/W
GLOW PLUG(No.4)
H1
1 2
0.75 0.75
B/Y Y/G E75
3
0.75
R SENSOR:BOOST PRESS
SENSOR:WATER 1 2 3
1 2 3 4
0.75 0.75 0.75 0.75
0.75 0.75 0.75 L G/Y G/W G/B
E90 1 R/L L R/W 5 6 7 8
0.75 0.75 0.75 0.75 0.75
G L/W W/L W/B W/R
EGR VALVE
SWITCH:O/H
E163 E80
E164
SENSOR:MAT(BOOST TEMP)
1 2
0.75 0.75 1 2 3
E113 R/L B/R
0.5 0.5 0.5
Gr/B W/B V/W
SENSOR:COMMON RAIL
SENSOR:NE.CRANK
1 2 3
0.5 0.5 0.5 E98
L/W Br L
1 2
0.75 0.75
B/Y Y/G
SENSOR:FUEL TEMP
E93
1 2 3 4
0.5 0.5 0.75 0.5
W/B Gr/B B V/W
5 6 7 8
0.5 0.75 0.75 0.75
T B/W Y/G R/W
9 10 11 12 1
1 2 0.75 0.75 0.75 0.5
W/B L/Y B/Y L 5
0.75 0.75 B/W
R/W R/B 13 14 15 16
0.5 0.5 0.75 0.75
SCV Br L/W B/R L H22
17 18 19 20
0.75 0.5 0.5
E161 R/L O/B Y
SENSOR:OIL PRESSRE 1 2 3
0.75 0.75 0.75
E76 B/Y L/Y W/B H20
3 2 1
0.75 0.75 0.75
Y/G R/W R/B
4 3 2 1 6 5 4
2 2 0.75 0.75
W R G R
8 7 6 5
4 3 2 1
2
L G
2
P
2 2
Y 0.75 0.75 0.75 0.75 H6
L G/Y G/W G/B
12 11 10 9 8 7 6 5
0.75 0.75 0.75 0.75
L/W W/L W/B W/R
H12 H8

4020-60
2) CX210B, CX240B
SENSOR:BOOST PRESS
E80 E75
EGR VALVE 1 2 3
E113 0.75 0.75 0.75
R/L L R/W
SENSOR:COMMON RAIL 1
0.75
2
0.75
3
0.75
4
0.75
L G/Y G/W G/B
5 6 7 8
1 2 3
0.5 0.5 0.5 0.75 0.75 0.75 0.75
L/W Br L L/W W/L W/B W/R
H94
1 2 3 4 INJECTOR
1.25 1.25 1.25 1.25
W R R W
5 6 7 8
0.75 0.75 0.75 0.75
L L/R L/Y L/W
E163
SENSOR:MAT(BOOST TEMP)
1 2
0.75 0.75
R/L B/R
1 1 2 3
5 0.75 0.5 0.5
B/W B/W V/W Y
GLOW PLUG(No.1) SENSOR:CAM ANGLE(G)

E112
H1
E161
1 2
1 2
0.75 0.75 SCV 1 2
0.75 0.75 R/W R/B
B/Y R/B 0.5 0.5
1 Y V /W
3 0.75
0.75 G SENSOR:NE.CRANK
R
SENSOR:WATER SWITCH:O/H E93 E98

E90 E164 SENSOR:FUEL TEMP
1 2
0.75 0.75
B/Y Y/G
1 2 3
0.75 0.75 0.75
B/Y L/Y W/B
SENSOR:OIL PRESSRE
E76
1
5
B/W
H22
1 2 3 4
0.5 0.5 0.75 0.5
Y V/W B Y
5 6 7 8
0.5 0.75 0.75 0.75
V/W B/W R/B R/W
4 3 2 1 9 10 11 12
1.25 1.25 0.75 0.75 0.75 0.5
W R W/B L/Y B/Y L
3 2 1 4 3 2 1 8 7 6 5
0.75 0.75 0.75 0.75 0.75 0.75 13 14 15 16
Y/G R/W R/B G/Y G/W G/B 0.75 0.75 0.75 0.75
L L/R L/Y L/W 0.5 0.5 0.75 0.75
6 5 4 8 7 6 5 Br L/W B/R L
12 11 10 9
0.75 0.75 0.75 0.75 0.75 17 18 19 20
G R W/L W/B W/R 0.75
R/L
H6 H8 H12 H20

4020-61
3) CX290B
1 2 3 4
0.75 1.25 1.25
G/B R R
5 6 7 8
0.75 0.75
L/R L/Y
H95
INJECTOR 2(#4.5.6 )
H94
INJECTOR 1(#1.2.3 )
1 2 3 4
0.75 1.25 1.25
L W W
5 6 7 8
1
5 0.75 0.75
B/W L/W G/R 1 2 3 4
0.75 0.75 0.75 0.75
L G/Y G/W G/B
H1 5 6 7 8
0.75 0.75 0.75 0.75
GLOW PLUG L/W W/L W/B W/R
E80
1 2
EGR VALVE
0.75 0.75
B/Y R/B
3 1 2 3
0.75 0.75 0.75 0.75
R R/L L R/W E93
1 2
0.75 0.75 SENSOR:FUEL TEMP
E90 B/Y Y/G
E75
SENSOR:WATER 1 2
SENSOR:BOOST PRESS 0.75 0.75
R/L B/R
E163
E164 SENSOR:MAT(BOOST TEMP) 1 2

0.75 0.75
R/W R/B
SWITCH:O/H
1
0.75 E161
G
SCV
1 2 3
0.5 0.5 0.5
L/W Br L
1 2 3
0.75 0.5 0.5
E113 B/W V/W Y
SENSOR:COM(PC) E112
SENSOR:CAM ANGLE(G)
1 2
1 2 3 0.5 0.5
0.75 0.75 0.75
B/Y L/Y W/B
E76 Y V /W
E98
SENSOR:OIL PRESSRE
SENSOR:NE.CRANK
1 2 3 4
0.5 0.5 0.75 0.5
Y V/W B Y
5 6 7 8
0.5 0.75 0.75 0.75
V/W B/W R/B R/W
4 3 2 1 9 10 11 12
1.25 1.25 0.75 0.75 0.75 0.5
W R W/B L/Y B/Y L
3 2 1 4 3 2 1 8 7 6 5 13 14 15 16
0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.5 0.5 0.75 0.75
Y/G R/W R/B G/Y G/W G/B L L/R L/Y L/W Br L/W B/R L 1
6 5 4 8 7 6 5 12 11 10 9 17 18 19 20 5
0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 B/W
G R W/L W/B W/R G/R G/B R/L
H6 H8 H12 H20 H22

4020-62
Console
1) Console Right harness
2) Console Left harnes

8001
Section
8001
SPECIFICATIONS, TROUBLESHOOTING,
INSPECTIONS AND HYDRAULIC PRESSURE SETTING

Printed in USA.
CNH Lep SC210B8001-1NA March 2007
8001-2
TABLE OF CONTENTS
WARNING: This symbol is used in this manual to indicate important safety messages. Whenever you see
! this symbol, carefully read the message which follows. Your safety depends on it.
SPECIFICATIONS .................................................................................................................................................... 5
SPECIAL TOOLS ...................................................................................................................................................... 5

Tester .................................................................................................................................................................... 5
HYDRAULIC EQUIPMENT LAYOUT........................................................................................................................ 7

Overall view .......................................................................................................................................................... 7
Pump chamber...................................................................................................................................................... 8
Swing body center section .................................................................................................................................... 9
Housing left side ................................................................................................................................................. 10
Cab ..................................................................................................................................................................... 11
IDENTIFICATION OF HYDRAULIC COMPONENTS ............................................................................................. 12

Pump - CX210B (LC, LR type), CX240B ............................................................................................................ 12
Pump - CX210B (NLC type)................................................................................................................................ 13
Remote control valves (upper side, travel).......................................................................................................... 14
Control valve ....................................................................................................................................................... 15
5 Way solenoid valve .......................................................................................................................................... 18
2 Way solenoid valve .......................................................................................................................................... 19
Cushion valve ..................................................................................................................................................... 20
4 way multi-valve ................................................................................................................................................ 21
2 way multi-valve ................................................................................................................................................ 22
Direction valve / Shut-off valve............................................................................................................................ 23
Safety valve ........................................................................................................................................................ 24
Manifolds............................................................................................................................................................. 24
Swing motor - CX210B ....................................................................................................................................... 26
Swing motor - CX240B ....................................................................................................................................... 27
Travel motor ........................................................................................................................................................ 28
Center joint.......................................................................................................................................................... 29
PREPARATION BEFORE INSPECTION................................................................................................................ 30

Releasing pressure in the hydraulic system and Pressure measurement preparations ..................................... 30
Procedures for pressure measurement from the monitor display ....................................................................... 31
Procedures for measuring hydraulic oil temperature from the monitor display ................................................... 32
Pressure measuring port..................................................................................................................................... 33
Control valve ....................................................................................................................................................... 34

8001-3
PRESSURE MEASUREMENT ............................................................................................................................... 35
Main Pressure Measurement.............................................................................................................................. 35
Pressure gauge installation ............................................................................................................................ 35
Attachment pressure measurement ............................................................................................................... 36
Travel pressure measurement ....................................................................................................................... 37
Swing pressure measurement........................................................................................................................ 37
Swing lock switching ...................................................................................................................................... 37
Option line pressure measurement ................................................................................................................ 38
Pilot pressure measurement............................................................................................................................... 39
Negative pressure measurement........................................................................................................................ 40
PRESSURE ADJUSTMENT ................................................................................................................................... 41

Main pressure adjustment .................................................................................................................................. 41
Adjustment preparation work.......................................................................................................................... 41
Main relief pressure adjustment ..................................................................................................................... 42
Overload relief pressure adjustment .............................................................................................................. 43
Swing relief pressure adjustment (CX240B) .................................................................................................. 44
Pilot pressure adjustment ................................................................................................................................... 44
HYDRAULIC PUMP FLOW MEASUREMENT PROCEDURE................................................................................ 45

Work preparations .............................................................................................................................................. 45
Flow measurement ............................................................................................................................................. 47
Flow curve - CX210B (LC, LR type) ................................................................................................................... 48
Flow curve - CX210B (NLC type) ....................................................................................................................... 49
Flow curve - CX240B.......................................................................................................................................... 50
DRAIN VOLUME MEASUREMENT PROCEDURE................................................................................................ 51

Preparations ....................................................................................................................................................... 51
Measuring conditions ..................................................................................................................................... 51
Travel motor drain volume measurement ........................................................................................................... 51
Swing motor drain volume measurement ........................................................................................................... 53
AIR BLEED PROCEDURE ..................................................................................................................................... 54

Hydraulic pump................................................................................................................................................... 54
Travel motor........................................................................................................................................................ 55
Swing motor........................................................................................................................................................ 56
Safety valve ........................................................................................................................................................ 57
Boom cylinder safety valve............................................................................................................................. 57
Arm cylinder safety valve ............................................................................................................................... 57
LEVER PATTERN CHANGE PROCEDURE .......................................................................................................... 58

Items to prepare.................................................................................................................................................. 58
ISO type.............................................................................................................................................................. 58
Cushion valve port.......................................................................................................................................... 58
ISO type to Sumitomo type................................................................................................................................. 59
ISO type to Mitsubishi type ................................................................................................................................. 60
ISO type to Shinko type ...................................................................................................................................... 61

8001-4

8001-5
SPECIFICATIONS
See section 1002.
SPECIAL TOOLS
Tester
1 2
3
CS02K573 CD01B005
1. OEM 1652 DIGITAL PRESSURE GAUGE 3. FEMALE COUPLING JOINT E47894 (1)
PRESSURE TEST POINT 14X1.5 A3237549 (2)
MALE COUPLING JOINT WITH UNION (3) AND
PLUGS (4) CONTAINED IN THE SUITCASE CAS
40023A.
CS02K574
2. OEM 1653 DIGITAL PRESSURE TEMPERATURE
ANALYSER
CS99B532
4. SET OF UNIONS FOR PRESSURE TEST AND
HYDRAULIC FLOW CAS 40023A AND CAS
40035.

8001-6
CD99C002
5. SET OF HIGH PRESSURE HYDRAULIC HOSES
CAS 30036 (INCLUDING TWO HIGH PRESSURE
HOSES).
B785789R
6. CAS 10280 FLOW METER

8001-7
HYDRAULIC EQUIPMENT LAYOUT
Overall view
RST-04-01-001A
1 Left side housing

2 Swing body center section
3 Pump compartment
4 Hydraulic oil tank
5 Fuel tank

8001-8
Pump chamber
2
1
5
7
8 4
11
10
RST-04-01-001B
1 Hydraulic pump 7 P1 pressure sensor

2 Accumulator 8 Pilot pump
3 Pilot filter 9 N2 sensor
4 5 stack solenoid valve 10 Horsepower control electromagnetic proportional valve
5 N1 sensor 11 Hydraulic oil temperature sensor
6 P2 pressure sensor

8001-9
Swing body center section
RST-04-01-001C
1 Swing motor
2 Center joint
3 Control valve

8001-10
Housing left side
RST-04-01-001D
1 Cushion valve (with heat circuit) 4 4-way selector valve

2 Swing pilot pressure sensor 5 Oil cooler
3 4-way selector valve installation seating

8001-11
Cab
1 2
RST-04-01-001E
1 Travel remote control valve

2 Upper operation remote control valve

8001-12
IDENTIFICATION OF HYDRAULIC COMPONENTS
Pump - CX210B (LC, LR type), CX240B
A2 A1
Pi1
a7
a2 a1
a6 a5
P1 Pi2
a8
Dr
Psv
B3
P2
B1 a4
Pi1
P1
P2
Pi1
A3
Pi2
RST-04-06-001A
Port Description Location

A1, A2 Discharge port SAE6000psi 3/4
B1 Suction port SAE2500psi 2-1/2
Dr Drain port G 3/4-20
P1 Proportional valve primary pressure port G 1/4-13
P2 P2 port G 1/4-13
Psv Servo assist port G 1/4-15
Pi1, Pi2 Negative control port G 1/4-15
a1, a2, a4 Gauge port G 1/4-15
a5, a6 Gauge port G 3/8-17
a7, a8 Gauge port G 1/4-15
A3 Gear pump discharge port G 1/2-19
B3 Gear pump suction port G 3/4-20

8001-13
Pump - CX210B (NLC type)
a2
B4
Dr1 Pi2
B3
A1 a1
B1
Psv
A2
A4 a4 a8
Dr2 P2
Pi1
a7
A3
P1
RD06004-001

A1, A2 Discharge port SAE6000psi 3/4
B1 Suction port SAE2500psi 2-1/2
Dr1 Drain port G 3/4
P1 Proportional valve primary pressure port G 1/4
P2 P2 port G 1/4
Psv Servo assist port G 1/4
Pi1, Pi2 Negative control port G 1/4
a1, a2, a4 Gauge port G 1/4
a5, a6 Gauge port G 3/8
a7, a8 Gauge port G 1/4
A3, A4 Gear pump discharge port G 1/2
B3, B4 Gear pump suction port G 3/4

8001-14
Remote control valves (upper side, travel)
1. Remote control valve (left, right)
Right side Left side
4
2 T
P
1 3
3
P 1
T 2
4
RST-04-06-0001G
Port Right side Left side Location

1 Bucket close Swing right G3/8
2 Boom-down Arm-in G3/8
3 Bucket open Swing left G3/8
4 Boom-up Arm-out G3/8
P Pressure Pressure G1/4
T Return Return G3/8
2. Remote control valve (Travel)
1 3
2 4
RST-04-06-0001M

1 Backward left G1/4
2 Forward left G1/4
3 Backward right G1/4
4 Forward right G1/4
P Pressure G1/4
T Return G1/4

8001-15
Control valve
2
3
4
1
7 10 12
8
11 9
RST-04-06-001C
1 Arm-out 7 Main a (normal use)

2 Arm-in 8 Main b (boosted pressure)
3 Boom-up 9 Standard pressure lock nut
4 Bucket open 10 Boosted pressure lock nut
5 Boom-down 11 Boosted pressure adjusting screw
6 Bucket close 12 Standard pressure adjusting screw

8001-16
Pn2
Pn1
Ps1
pb5 T1
A5
T8
B5
A3
pb8
B3
pb3 B2
pb7
A2
pb6
B1
A1
P1
PH pb1
T2
Ps2
Pbu B8
pa5 pa9 A8
pa4 pa8
B7
A7
pa3
B6
A6
PA
pa7
PT
pa1
P2
DR3 pa6
RST-04-06-0001D

8001-17

P1 Pressure line SAE 6000psi 1
A1 Left travel (forward) line SAE 5000psi 3/4
B1 Left travel (backward) line SAE 5000psi 3/4
A2 Option line SAE 5000psi 1
B2 Option line SAE 5000psi 1
A3 Swing right line SAE 5000psi 3/4
B3 Swing left line SAE 5000psi 3/4
A5 Arm-out line SAE 5000psi 3/4
B5 Arm-in line SAE 5000psi 3/4
T1 Return line G1/4
pb1 Left travel backward pilot line G1/4
pb6 Right travel backward pilot line G1/4
pb3 Left swing pilot line G1/4
pb5 Arm-in pilot line G1/4
pb7 Bucket close pilot line G1/4
pb8 Boom down pilot line G1/4
Pn1 Negative control power save signal G1/4
Pn2 Negative control power save signal G1/4
PH Boosted pressure signal port G1/4
Ps1 Negative control line G1/4
T8 Heat circuit line G1/4
P2 Pressure line SAE 6000psi 1
A6 Right travel (forward) line SAE 5000psi 3/4
B6 Right travel (backward) line SAE 5000psi 3/4
A7 Bucket open line SAE 5000psi 3/4
B7 Bucket close line SAE 5000psi 3/4
A8 Boom up line SAE 5000psi 1
B8 Boom down line SAE 5000psi 3/4
T2 Return line
pa1 Left travel forward pilot line G1/4
pa6 Right travel forward pilot line G1/4
DR3 Straight travel forward drain line G1/4
pa7 Bucket open pilot line G1/4
pa3 Right swing pilot line G1/4
pa8 Boom 1 up pilot line G1/4
pa4 Boom 2 up pilot line G1/4
pa9 Arm 2 out pilot line G1/4
pa5 Arm 1 out pilot line G1/4
PA Upper side signal G1/4
PT Travel signal G1/4
Ps2 Negative control line G1/4
Pbu Swing priority variable metering valve switch signal G1/4

8001-18
5 Way solenoid valve
C2
C3
C1
B
T
3
C5
C4 4
1
P 5
2
RST-04-06-0001F
1 Power save
2 Travel speed
3 Swing brake
4 Boosted pressure
5 Lever lock
Port Location
C2 G1/4
C3 G1/4
C1 G1/4
B G3/8
T G3/8
C5 G1/4
C4 G1/4
P G3/8

8001-19
2 Way solenoid valve
B1 A2
A1
B2
T
RST-04-06-0001X
Port Location
A1 G1/4
B1 G1/4
A2 G1/4
B2 G1/4
T G1/4

8001-20
Cushion valve
5
R V
T T
1 R
A V Pa5
DB Pb5
2 E C 6 Pb8 HF
G 7 Pa4
3 I Q Pb3
L S
4 Pa3
M 8 P J
K Pa7
O 9 U N Pb7
10
Pb
RST-04-06-0001Q
1 2 port (arm-in)
2 4 port (boom up)
3 1 port (swing right)
4 1 port (bucket close)
5 D4 port (filter line)
6 4 port (arm-out)
7 2 port (boom down)
8 3 port (swing left)
9 3 port (bucket open)
10 Pressure sensor

E, F Boom up G3/8
G, H Boom down G3/8
O, P Bucket open G3/8
M, N Bucket close G3/8
C, D Arm-out G3/8
A, B Arm-in G3/8
K, L Swing left G3/8
I, J Swing right G3/8
Q Swing pressure sensor signal G1/4
U - G1/4
S Swing priority metering valve switch G1/4
V - G1/4
T Return G1/4
R Heat circuit G1/4

8001-21
4 way multi-valve
8
6 4
3
2
7
5
1
A
D
A D H
G E F
C B
RST-04-06-0001H
Port Description (ISO format) Location

A Right remote control valve side port / boom-up G1/4
C Right remote control valve side port / boom down G1/4
D Right remote control valve side port / bucket open G1/4
B Right remote control valve side port / bucket close G1/4
E Left remote control valve side port / arm-out G1/4
G Left remote control valve side port / arm-in G1/4
H Left remote control valve side port / swing left G1/4
F Left remote control valve side port / swing right G1/4
1 Cushion valve side port G1/4

8001-22
2 way multi-valve
2
A
1
B
D
C
3 4
Remote control valve side Cushion valve side
RST-04-06-0001I
Port Description (ISO format) Location

A Remote control valve side / swing left port G3/8
B Remote control valve side / arm-in port G3/8
C Remote control valve side / swing right port G3/8
D Remote control valve side / arm-out port G3/8

8001-23
Direction valve / Shut-off valve
1. Direction valve
DR
A B
T2
T1
PP
RST-04-06-0001R
Port Location
A G1
B G1
T1 G1
T2 G3/4
PP G1/4
DR G1/4
2. Shut-off valve
T
PP DR
A
B
RST-04-06-0001S
Port Location
A G1
B G1
T G3/4
PP G1/4
DR G1/4

8001-24
Safety valve
PL
A
DR
B port opening side
RST-04--06-0001Y
Port Remarks Location

Arm HBCV SAE 6000psi 1
A
Boom HBCV SAE J6000psi 3/4
Arm HBCV SAE 6000psi 1
B
Boom HBCV SAE J6000psi 3/4
C G1/4
DR G3/8
PL G1/4
Manifolds
1. Manifold under cab
T2 T5
T1 T3
T4
P2 P5
P1 P3
P4
RST-04-06-0001O
Port Location Port Location

P1 G3/8 T1 G3/8
P2 G3/8 T2 G3/8
P3 G3/8 T3 G3/8
P4 G1/4 T4 G1/4
P5 G1/4 T5 G1/4

8001-25
2. Manifold (accumulator section)
P1 P3
P
P2 P0
RST-04-06-0001T
Port Location
P G1/2
P1 G1/4
P2 G1/4
P3 G1/2
P0 G3/8
3. Manifold (hydraulic oil tank section)
G1 T1
D
D3 T
A
A
D1
G3/4
B N2 D2 D6
RST-04-06-0001U
Port Location Port Location

D G1/2 D6 G1/4
D1 G3/8 T G1/2
D2 G1/4 T1 G3/8
D3 G1/4 N2 G1/4

8001-26
Swing motor - CX210B
Mu Au
GA, GB
Dr
B
P
A
AGr
Dr (RG)
SGr
RST-04--06-0001J

Mu Make-up G1
Dr Drain G3/8
P Brake release G1/4
A Left swing G3/4
B Right swing G3/4
GA, GB Pressure measurement G1/4
Au Air bleed port G1/4
AGr Air bleed port for grease-up Rc1 / 8
Dr (RG) Reduction gear oil drain port G1/2
SGr Reduction gear grease-up port G1/4

8001-27
Swing motor - CX240B
DB
PA
PB
M
GIN
PR
DBG
RST-04--06-0001V

A Main port A G 3/4
B Main port B G 3/4
DB Drain port G1/2
PA, PB Pressure measuring ports G1/4
DBG Gear oil drain port G1/2
M Make-up port G1
PR Brake release port G1/4
GIN Gear oil fill port RC3 / 4

8001-28
Travel motor
P2
T
P2 Ps
P1 T Pm2
P1 Pm1
RST-04--06-0001W

P1, P2 Main pump G1
T Drain port G1/2
Ps Pilot port G1/4
Pm1, Pm2 Pressure detection port G1/4

8001-29
Center joint
C
D
E E
A B
E'
F'
A'
F F
B'
C'
D'
E E
RST-04--06-0001L

A, A' Main port (forward right) G3/4
B, B' Main port (forward left) G3/4
C, C' Main port (reverse right) G3/4
D, D' Main port (reverse left) G3/4
E, E' Drain port G1/2
F, F' Pilot port G1/4

8001-30
PREPARATION BEFORE INSPECTION
WARNING: Hydraulic fluid output under pressure can penetrate the skin. Hydraulic fluid can also cause or
infect a slight skin cut. In the event of being injured by hydraulic fluid under pressure, consult a doctor
immediately. Any delay in obtaining treatment for an injury can cause a serious infection or reaction.
Before pressurizing the circuits, make sure that all the connections are correctly tightened and that the
! hoses and pipes are in good condition. Release pressure in the circuits completely before disconnecting
pipes or carrying out any operation on the hydraulic system. Always use a small piece of cardboard or
wood to detect leaks of fluid under pressure. Never use your hands.
WARNING: Any incorrect use or mainte- WARNING: The accumulator of this machine
nance of a construction machine can cause is charged with nitrogen under pressure. In
accidents. Only persons who have read, the event of incorrect operation of the circuit,
! understood and who observe the instructions
! change the accumulator. Never attempt to
in the operator's manual are accredited to repair it. Non-observance of these instruc-
use or maintain this machine. tions and the procedure shown below can
cause serious or fatal injury.
Releasing pressure in the hydraulic system and Pressure measurement prepa-

rations
NOTE: Operation to be carried out before every service 7. Use the service check to check the hydraulic oil
operation on the hydraulic system. temperature.
1. Position the machine on hard, flat ground.
2. Open the bucket until the cylinder rod is completely 0100
retracted. 0085 0000
3. Extend the dipper until the cylinder rod is com- 0050 0040
pletely retracted. Lower the boom so that the end of
0045 0030
the dipper is resting on the ground. Lower the tool
to the ground. RST-09-01-001K
4. Check with the diagnostic display in "SP" mode that
the following values are shown. 45 to 55°C
Oil temperature
113 to 131°F
001.2
If the oil temperature is low, raise the oil tempera-
2200 001.2 ture according to the warm-up operation procedure
0600 03.05 in the operator’s manual.
0727 04.05 8. Lower the pilot control cancellation lever.
9. Operate each control more than 10 times in both
RST-09-01-001H
directions to release pressure in the circuits.
Eng = Engine rpm 1800 rpm 10. Press the button located on the hydraulic reservoir
breather to release pressure in the reservoir.
Power = Electric current
600 mA (operating)
value
5. Lower the engine speed to idle for 30 seconds, then

shut down the engine.
6. Turn the starter key switch to "ON", without starting
the engine.
RST-09-01-001N

8001-31
Procedures for pressure measurement from the monitor display
• Monitor and switch panel
3
1 2 5
RST-09--01-001A
1 Liquid crystal monitor 4 Design panel

2 Switch panel 5 Installation bracket
3 Hour meter
1. Pressure Measurement Method

The P1, P2, N1, and N2 pressure can be measured from the monitor display.
(The pilot pressure cannot be measured.)
2. Operating Method
If you hold down both the travel mode select switch and the horn volume select switch on the switch panel for 3 sec-
onds, the display switches to the service support screen.
The respective pressures are displayed in the service support screen's "P1" (P1 pump main pressure), "P2" (P2
pump main pressure, "N1" (N1 negative control pressure, and "N2" (N2 negative control pressure) columns.
If you again hold down both the travel mode select switch and the horn volume select switch on the switch panel for
1 second, the display returns to the normal screen.
Normal screen Service support screen
+
001. 2
a 2200 001. 3
0600 03.1 5
b
0727 04.0 5
RST-09--01-001B
a: Hold down for 3 seconds
b: Hold down for 1 second

8001-32
Procedures for measuring hydraulic oil temperature from the monitor display
1. Hydraulic Oil Temperature Measurement Method
The hydraulic oil temperature can be measured from the monitor display.
2. Operating Method
If you hold down both the travel mode select switch and the horn volume select switch on the switch panel for 3 sec-
onds, the display switches to the service support screen.
With the travel mode select switch (mode select switch), set the mode to "CHK".
With the horn volume select switch (section switch), set the section "MAIN".
With the light switch (page +), switch to Page "2".
The hydraulic oil temperature is displayed in the "Hydoil" column.
1 3 4
MAIN / MNT ...
2 5
CHK / DIAG / HR...
6
001.2
2200 001.2
0600 03.15
0727 04.05
7
Page switch operation
0100
0085 0855
0050 0040
0045 0030
RST-09--01-001C
1 Section 5 Page (-)

2 Mode 6 Page (+)
3 Page 7 Mode select switch
4 Section switch A Hydraulic oil temperature (°C)

8001-33
Pressure measuring port
There are the following three ports for measuring the pressure.
• Main pressure: pressure ports (P1, P2)
• Negative control pressure: pressure ports (N1, N2)
• Pilot pressure: pressure port (P3)
2 3
4 5
RST-09-01-001E
1 Pump 4 Negative control pressure: N1

2 Main pressure: P2 5 Negative control pressure: N2
3 Main pressure: P1 6 Pilot pressure: P3

8001-34
Control valve
1. Location of relief valves
Pressure per rota- Measuring

Set pressure tion of port Tools
Position adjusting screw monitor
Lock nut Lock nut Adjusting screw
Main 34.3 MPa 21.3 Mpa Hexagon diagonal Hexagon diagonal
P1
(normal use) 343 bar/4975 Psi 213 bar/3089 Psi 27 mm/1.06 in 27 mm/1.06 in
A
Main 36.8 Mpa 28.4 Mpa Hexagon diagonal Hexagon diagonal
P1
(boosted pressure) 368 bar/5337 Psi 284 bar/4119 Psi 32 mm/1.26 in 27 mm/1.06 in
38.7 Mpa 21.2 Mpa
B Boom-up P2
387 bar/5613 psi 212 bar/3075 Psi
29.4 Mpa 21.2 Mpa
C Boom down P2
294 bar/4264 Psi 212 bar/3075 Psi
Arm-in 23.0 Mpa 21.2 Mpa
CX210B LR 230 bar/3336 psi 212 bar/3075 Psi
D P1
CX240B LR 211 bar/3060 psi 212 bar/3075 Psi
other type 387 bar/5613 psi 212 bar/3075 Psi
38.7 Mpa 21.2 Mpa Hexagon diagonal
E Arm-out P1
387 bar/5613 psi 212 bar/3075 Psi 17 mm/0.67 in Hexagon diagonal
F Bucket close 6 mm/0.24 in
25.0 Mpa 21.2 Mpa
G Bucket open P2
250 bar/3626 psi 212 bar/3075 Psi
CX210B LR
F Bucket close
29.4 Mpa 21.2 Mpa
G Bucket open P2
294 bar/4264 psi 212 bar/3075 Psi
CX240B LR
F Bucket close
38.7 Mpa 21.2 Mpa
G Bucket open P2
387 bar/5613 psi 212 bar/3075 Psi
other type
3.92 Mpa 2.0 Mpa Hexagon diagonal
H Pilot
39.2 bar/568.5 psi 20 bar/290 Psi 24 mm/0.94 in
B
C
3
D F
G E 1
4
2
A
RST-09-01-001F
Main relief valve adjustment location details

1 Boosted pressure lock nut 3 Standard pressure adjusting screw
2 Boosted pressure adjusting screw 4 Standard pressure lock nut

8001-35
PRESSURE MEASUREMENT
Main Pressure Measurement
Pressure gauge installation
1. Install pressure gauges at the pump pressure mea- 3. Install adapters (3) where the caps (2) were
suring ports. removed
(Pressure ports: P1 / P2)
P1
P2 RST-09-01-001R
RST-09-01-001P 4. Install pressure gauges (4) on the adaptors (3) and

fasten.
P1: Can be measured P2: Can be measured
Travel left Travel right
Option Bucket
Swing Boom
Arm
4
2. Use a hexagon wrench (8 mm, 0.31 in) to remove
the caps (2).
RST-09-01-001S
RST-09-01-001Q

8001-36
Attachment pressure measurement
Example: Arm-out pressure measurement
Measure with the following operations.
RST-09-01-001U
When the attachment operates, since the pressure boost operates automatically, you can check the set boosted
pressure for about 8 seconds. After 8 seconds or more, you can check the standard set pressure.
Measure relieving each cylinder with the arm-out and in, the bucket open and closed, and the boom up.
Lever operation Arm-out Arm-in Bucket open Bucket close Boom up Boom down
-1
Engine speed 1800 min
Work mode SP mode
45 to 55°C
Oil temperature
113 to 131°F
1st speed measuring port P1 P1 P2 P2 P2 P2
2nd speed measuring port P2 P2 None None P1 P1
36.8 MPa 36.8 MPa 36.8 MPa 36.8 MPa 36.8 MPa 29.4 MPa
Boosted pressure 368 bar 368 bar 368 bar 368 bar 368 bar 294 bar
5337 Psi 5337 Psi 5337 Psi 5337 Psi 5337 Psi 4264 Psi
34.3 MPa 34.3 MPa 34.3 MPa 34.3 MPa 34.3 MPa 29.4 MPa
Standard pressure 343 bar 343 bar 343 bar 343 bar 343 bar 294 bar
4975 Psi 4975 Psi 4975 Psi 4975 Psi 4975 Psi 4264 Psi
Pressure measurement with boom down

For pressure measurement with the boom down, put the arm cylinder at its out stroke end, open the bucket, put the
bucket tip on the ground, carry out the boom-down operation, and measure.
RST-09-01-001V

8001-37
Travel pressure measurement
1. Install the stopper (5) on the crawler sprocket (6) 2. Measure with the following operations
section and lock the travel motor.
Engine speed 1800 min-1
6 5 Work mode SP mode
Lever operation Travel relief
45 to 55°C
Oil temperature
113 to 131°F
Left travel: P1 port
Measuring port
Right travel: P2 port
34.3 MPa
Set pressure 343 bar
4975 Psi
RST-09-01-001W
Swing pressure measurement

1. Set the swing lock with the monitor. 2. Measure with the following operations

Work mode SP mode
Lever operation Swing relief
45 to 55°C
Oil temperature
113 to 131°F
Measuring port P1 port
Set pressure 29.4 MPa
RST-09-01-001X CX210B 294 bar/4264 Psi
Set pressure 28.9 MPa
CX240B 289 bar/4192 Psi
3. After the end of pressure measurement, release

the swing lock with the monitor.
Swing lock switching
In order to prevent accidental operation under certain special circumstances, sometimes the swing brake need to be
left ON all the time. (Swing lock) At this time, you can switch the swing lock ON to OFF or OFF to ON by holding
down the "horn volume select switch", the "working light switch", and the "auto idle switch" at the same time for 2
seconds. When the swing is locked, an icon "P" appears on the liquid crystal monitor.

8001-38
Option line pressure measurement
1. Close the option line stop valve (7). 3. Measure with the following operations.

Work mode SP mode
Pedal operation Option relief
Oil temperature 45 to 55°C
1st speed: P2 port
Measuring port
2nd speed: P1 port
* 29.4 MPa
Set pressure * 294 bar
* 4264 Psi
7 * Adjust the set pressure to match the specifica-

RST-09-01-001Y
tions of the attachment used.
2. With the option operation select switch in the cab, Factory Pressure Settings
switch to the option line to measure. (Breaker, shut- Breaker circuit: 29.4 MPa (294 bar, 4264 Psi)
tle). Shuttle, combine (crusher) circuit: 17.8 MPa (178
bar, 2582 Psi)
RST-09-01-001Z

8001-39
Pilot pressure measurement
1. Install a pressure gauge (10) at the pump pressure 3. Install the pressure gauge (10) and measure the
measuring port. (Pressure port: P3). pressure.
10
P3
RST-09-01-001AA RST-09-01-001AC
2. Install the adapter (9).
Work mode SP mode
45 to 55°C
Oil temperature
113 to 131°F
3.92 Mpa
Set pressure 39.2 bar
568.5 psi
9
RST-09-01-001AB

8001-40
Negative pressure measurement
1. Remove the pump N1 or N2 pressure sensor (11). 2. Install the adapter (14) and install the pressure
(The pressure sensor location becomes the mea- gauge (15) at the port from which the N1 or N2
surement point.) pressure sensor was removed.
14
11
N2
15
RST-09-01-001AE RST-09-01-001AH

Work mode SP mode
45 to 55°C
Oil temperature
113 to 131°F
P1 port side: N1 port
Measuring port
P2 port side: N2 port
3.9 MPa max.
Set pressure 39 bar max.
565.6 psi max.

8001-41
PRESSURE ADJUSTMENT
Main pressure adjustment
Adjustment preparation work
Pressure is adjusted with control valves.
The following preparations are required for adjusting with control valves.
1. Release the two engine hood lock levers (2). 3. Remove the screws (4), then remove the cover (5).
4
2
5
RI01001-002
RST-09-01-001AI
2. Open the engine hood (1). Always check that the
lock (3) is locked.
RI01001-001

8001-42
Main relief pressure adjustment
3. Standard pressure
Engine speed 1800 min-1 H Loosen the standard pressure lock nut (14) (27
Work mode SP mode mm, 1.06 in).
Lever operation Arm-in relief I Loosen the adjusting screw (13), lower below the
set pressure, then adjust on the tightening side.
45 to 55°C
Oil temperature J After adjustment, tighten the lock nut (14) while
113 to 131°F
fastening the adjusting screw (13) with a spanner.
K After locking, check the pressure. Repeat H), I),
Boosted pressure: and J) until the set pressure is correctly adjusted.
36.8 MPa
L Stop the engine.
368 bar
Measurement 5337 Psi
pressure Standard:
34.3 MPa
343 bar
4975 Psi
Boosted pressure:
28.4 MPa / rotation
284 bar
Pressure per rotation of
adjusting screw Standard:
21.3 MPa / rotation
213 bar / rotation
3089 Psi / rotation
7
1. Before adjusting, remove the pilot hose (10) for the
boosted pressure signal connected to the main
relief valve (7), then plug the hose side. The proce-
dures for boosted pressure and standard pressure
are different.
2. Boosted pressure
A Loosen the standard pressure lock nut (14) (27
mm) and tighten the adjusting screw (13) (27 mm, 1.06
in). Fasten with a spanner (27 mm, 1.06 in) so that the
boosted pressure adjusting screw (12) does not turn.
B After tightening until the adjusting screw (13) stops
turning, tighten the lock nut (14).
C Start the engine and run it at maximum rotation. 10
D Move the arm lever to the in side, set the relief
state, and hold.
E Loosen the boosted pressure lock nut (11) (32
mm, 1.26 in) and adjust the set pressure with the
adjusting screw (12) (27 mm, 1.06 in).
• When lower than the set pressure, tighten.
• When higher than the set pressure, first lower below
the set pressure, then adjust on the tightening side.
F After adjustment, fasten the adjusting screw (12)
with a spanner (27 mm, 1.06 in), then tighten the lock
nut (11).
G After locking, check the boosted pressure side
pressure. Repeat A) to F) until the set pressure is cor-
rectly adjusted.
11 13
12 14
RI01001-003

8001-43
Overload relief pressure adjustment
Engine speed 1800 min-1 15 Control valve

Work mode SP mode 16 Overload relief
45 to 55°C 17 Boom-up
Oil temperature
113 to 131°F 18 Arm-in
Measuring port P1 / P2 port 19 Bucket open
Measurement pressure 20 Spanner 17 mm
29.4 MPa 21 Adjusting screw 6 mm
Boom down:
294 bar/4264 Psi
22 Lock nut 17 mm
Arm in: 23.0 MPa
CX210B LR 230 bar/3336 Psi 23 Hexagon wrench 6 mm
Arm in: 21.1 MPa
CX240B LR 211 bar/3060 Psi 15
Bucket: 25.0 MPa
16
CX210B LR 250 bar/3626 Psi
Bucket: 29.4 MPa
CX240B LR 294 bar/4264 Psi
17
38.7 MPa
Others:
387 bar/5613 Psi
Pressure per rotation of 21.2 MPa 18
adjusting screw 212 bar/3075 Psi 19
1. Since the overload relief pressure is set higher than

the main relief pressure, it is necessary to provi-
sionally set the main relief pressure higher than the
overload relief pressure.
2. Main Relief Pressure Provisional Setting
• Using the main pressure adjustment procedure for 20
reference, temporarily set the boosted pressure and
standard pressure to at least 38.7 MPa.
NOTE: For boom down and for arm in and bucket on LR
types, since the overload set pressure is lower than the
main relief set pressure, there is no need to temporarily
set the main relief pressure.
3. Pressure adjustment
NOTE: For the position of each overload relief, see the
"Control Valve Relief Locations". 21
Example: Arm-in overload relief adjustment
A Loosen the lock nut (22) and adjust by the turning 22
the adjusting screw (21).
• When lower than the set pressure, tighten.
• When higher than the set pressure, first loosen to a
pressure lower than the set pressure, then adjust on
the tightening side.
B After adjustment, lock the lock nut (22).
C After adjusting the overload relief pressure, adjust
the boosted pressure and standard pressure to their
normal values referencing the main pressure adjust-
ment procedure.
23
RI01001-004

8001-44
Swing relief pressure adjustment (CX240B)
2. Loosen the lock nut (26) and adjust by the turning
Engine speed 1800 min-1 the adjusting screw (25).
Work mode SP mode • When lower than the set pressure, tighten.
45 to 55°C • When higher than the set pressure, first loosen to a
Oil temperature pressure lower than the set pressure, then adjust on
113 to 131°F
the tightening side.
28.9 MPa
Measurement pressure 289 bar
4192 Psi
11.6 MPa / rotation
Pressure per rotation of
116 bar
adjusting screw
1682 Psi
1. Using the swing pressure measurement procedure

for reference, lock the swing, and check the swing
pressure.
25 26
RI01001-005
3. After adjustment, lock the lock nut.
Pilot pressure adjustment

1. Install the pressure gauge (29).
2. While holding the plug with a spanner (27) (24 mm,
0.94 in), adjust with a hexagon wrench (28) (6 mm,
0.24 in).
29
28
27
RI01001-007

Lever operation Neutral
Measuring port P3
3.92 MPa
Set pressure 39.2 bar
568.5 Psi

8001-45
HYDRAULIC PUMP FLOW MEASUREMENT PROCEDURE
Work preparations
1. Check that the main unit is in its work posture (arm- 5. Install the vacuum pump (4) on the hydraulic oil
vertical). tank lid (3).
6. After setting the vacuum pump (4), switch on the
power. (If the cable is too short, use an extension
cable.)
RST-09-02-001B
2. Bleed out the pressure. (See the details on Bleed-
ing Pressure in the Pressure Measurement and
Adjustment Procedures.)
NOTE: Check the swing stop.
3. Use a spanner (17 mm, 0.67 in) to remove the feed
port cover (2). RST-09-02-001F
the split flange and hydraulic hose. (This explana-
tion uses flow measurement at the P2 pump.)
2 6
7
RST-09-02-001C
4. Use the bolts removed in step 3 to install the
hydraulic oil tank lid (3).
3 RST-09-02-001G
RST-09-02-001D

8001-46
8. Use the split flange to install the adaptor (flange 14. Install the (prepared) hydraulic hose on the flow
type) on the tip of the hydraulic hose removed in meter OUT side, then fasten with the spanner.
step 7. • When connecting, always check the connection posi-
9. Install the adaptor at the position from which the tions.
hydraulic hose was removed. • Always have the metering valve fully open.
10. When the parts are set as in the figure above, 15. Install pressure gauges on P1 and P2. (See "Main
remove the plug. Pressure Measurement".)
11. Use the spanner to connect the adaptor installed 16. Remove the vacuum pump and re-install the
on the pump in step 9. hydraulic oil tank the same way it was.
12. If necessary, install an "elbow adaptor" on the (pre- 17. Open the engine hood. (See "Main Pressure
pared) hydraulic hose connected to the flow meter Adjustment".)
IN side. 18. Remove the cover.
13. Install the hydraulic hose on the flow meter IN side, 19. Remove the pilot hose for the boosted pressure
then fasten with the spanner. signal, then plug the hose side. (See "Main Relief
Pressure Adjustment".)
10
15
11
12
16
14 17
13
RST-09-02-001H
9 Elbow adaptor 14 Hydraulic hose (OUT)

10 Adapter 15 Hydraulic hose
11 Hydraulic hose (IN) 16 Split flange
12 Flow meter 17 Adapter (flange type)
13 Metering valve

8001-47
Flow measurement
1. When measuring the flow, position the workers as 3. Check the hydraulic oil temperature on the monitor
in the figure below. (50°C, 122°F). Check that the engine rotation and
• Worker 1: Work supervisor, pressure adjustment pump current are normal.
• Worker 2: Operator 4. The operator signals the arm-out relief operation to
• Worker 3: Flow, pressure measurement, recording worker 1.
5. Worker 2 lowers the arm-out port relief. (Min: 24
MPa (240 bar, 3481 Psi) (P1 + P2)
1 6. Start of flow measurement.
7. The arm-out relief operation is carried out.
3 8. Data measured in units of 2.0 MPa (20 bar, 290Psi)
(P1 + P2).
• The measurement is carried out from 24.0 to 76.0
2 MPa (240 to 760 bar, 3481 to 11023 Psi) and ends
when the maximum pressure is reached.
9. Remove the flow meters.
• Because from 40 MPa (400 bar, 5802 Psi) the pres-
sure exceeds the permitted value for the flow meter
pressure gauge maximum pressure.
RST-09-02-001I
10. Reset the arm-in port relief valve to normal pres-
2. At the signal from the work supervisor, the operator sure. (For details on this adjustment, see "PRES-
starts the engine. SURE ADJUSTMENT".)
11. Remove the pressure gauges etc. and put every-
thing back to normal.
RST-09-02-001J

250 L/min
8001-48
66.04 gpm
Lep SC210B8001-1NA
Q
200 L/min
52.83 gpm
150 L/min
39.63 gpm
73.6 MPa
Flow curve - CX210B (LC, LR type)
736 bar
10468 Psi
64 L
16.91 gal
100 L/min
26.42 gpm
Discharge flow Q
50 L/min
13.20 gpm
0
(0) (100) (200) (300) (400) (500) (600) (700)[Kgf/cm2]
0 10 20 30 40 50 60 70 [MPa]
0 100 200 300 400 500 600 700 [bar]
0 1450 2901 4351 5801 7252 8702 10153 [Psi]
Discharge pressure P
Issued 03-07
RC01001-001
250 L/min
66.04 gpm
Lep SC210B8001-1NA
Q
200 L/min
52.83 gpm
150 L/min
39.63 gpm
Flow curve - CX210B (NLC type)
73.6 MPa
736 bar
10468 Psi
60 L
15.85 gal
100 L/min
26.42 gpm
Discharge flow Q
50 L/min
13.20 gpm
0
(0) (100) (200) (300) (400) (500) (600) (700)[Kgf/cm2]
0 10 20 30 40 50 60 70 [MPa]
0 100 200 300 400 500 600 700 [bar]
0 1450 2901 4351 5801 7252 8702 10153 [Psi]
Issued 03-07
8001-49
8001-50
250 L/min
66.04 gpm
Lep SC210B8001-1NA
Q
200 L/min
52.83 gpm
Flow curve - CX240B
150 L/min
39.63 gpm
73.6 MPa
736 bar
10468 Psi
64 L
16.91 gal
100 L/min
26.42 gpm
Discharge flow Q
50 L/min
13.20 gpm
0
(0) (100) (200) (300) (400) (500) (600) (700)[Kgf/cm2]
0 10 20 30 40 50 60 70 [MPa]
0 100 200 300 400 500 600 700 [bar]
0 1450 2901 4351 5801 7252 8702 10153 [Psi]
Issued 03-07
RC01001-001
8001-51
DRAIN VOLUME MEASUREMENT PROCEDURE
Preparations
Measuring conditions

Mode SP mode
About 50°C
Oil temperature
About 122°F
WARNING: The drain volume varies greatly with the oil temperature.
Travel motor drain volume measurement

1. Ground the arm as in the figure below, then make 3. Always lay a rag (2) underneath before removing
the shoe crawler on one side float. the drain hose (5).
4. Use a spanner to remove the drain hose (5).
(Always install a cap on the drain hose.)
RST-09-03-001A
2. Remove the bolts (4), then remove the cover (3).
5 2
RST-09-03-001C
5. Install the extension hose (6) for measurement on
the side of the motor from which the drain hose was
removed.
4
RST-09-03-001B
6
RST-09-03-001D

8001-52
6. Prepare a waste oil receiver (7) and measuring 8. In SP mode at medium speed, relieve the travel
container (8) and set them as in the figure below. operation and at the same time the motor starts,
move the extension hose to the measuring con-
tainer.
(When the motor starts, start measurement with a
stop watch.)
9. After 30 seconds, move the extension hose to the
waste oil can.
10. Measure the volume of oil in the measuring con-
tainer as the drain volume for 30 seconds.
Advance Retreat
1st 2nd 1st 2nd
speed speed speed speed
Right
8 Left
7 • Measure at least three times each for left, right,

RST-09-03-001E advance, and retreat.
7. Catch the stopper (9) between the sprocket section
and the frame and lock the travel motor.
30 seconds
9 RST-09-03-001G
RST-09-03-001F

8001-53
Swing motor drain volume measurement
1. Remove the two drain hoses (1) and put blind plugs 4. In SP mode, relieve the swing operation and at the
in the hose side of each. same time the motor starts, move the extension
hose (3) to the measuring container (5).
(When the motor starts, start measurement with a
stop watch.)
1
5. After 60 seconds, move the extension hose (3) to
the waste oil receiver (6).
6. Measure the volume of oil in the measuring con-
1 tainer (5) as the drain volume for 60 seconds.
• Measure at least three times each for left and right.
Left Right
RST-09-03-001H
2. Install the extension hose (3) for measuring the
drain volume on one side of the T nipple. Install the
hose facing in a direction that makes measurement
easy and install a blind plug (2) on the other side.
2
3
RST-09-03-001I
3. Prepare a waste oil receiver (6) and measuring
container (5) and set them as in the figure below.
NOTE: For details on the method for locking the swing
motor, see "Swing Relief Pressure Adjustment
(CX240B)".
60 seconds
5 6
RST-09-03-001J

8001-54
AIR BLEED PROCEDURE
WARNING: Always bleed off any air in the hydraulic circuits after replacing the hydraulic oil, repairing or
! replacing hydraulic equipment, or removing hydraulic pipes.
Air bleed procedure mode (when bleeding, follow the procedure below
Hydraulic pump air Cylinder air bleed- Swing motor air Travel motor air
Check
bleeding ing bleeding bleeding
Hydraulic oil or
hydraulic pump
replacement
Cylinder replace-
ment
Swing motor
replacement
Travel motor
replacement
NOTE: Failure to completely bleed off all the air can reduce the service life of hydraulic equipment and lead to damage.
Hydraulic pump
1. Loosen the air bleed plug (1) and check that oil
oozes from the air bleed port. 1
2. If oil does not ooze out, remove the air bleed plug
(1), and fill hydraulic oil from the air bleed port into
the pump case.
3. Temporarily tighten the air bleed plug (1).
4. Run the engine at low idle, slightly loosen the air
bleed port, and run until oil oozes from the air bleed
port section.
5. Completely tighten the air bleed plug (1).
2
3
RST-09-04-001B

8001-55
Travel motor
1. Remove the bolt (2), then remove the cover (1). 3. Pour in about 500 cc of hydraulic oil from the air
bleed port.
2
RST-09-04-001C
the air bleed plug (4) as in the figure below.
RST-09-04-001E
4. When inside the motor is filled with hydraulic oil,
tighten the air bleed plug (4).
5. Start the engine and execute a slow travel opera-
tion.
6. Repeatedly travelling forward and back bleeds off
the air.
4
RST-09-04-001D

8001-56
Swing motor
1. Run the engine at low idle, loosen the air bleed
plug, and check that oil oozes from the air bleed
port section.
• Do not execute a swing operation.
2. If oil does not ooze out, stop the engine for now,
remove the air bleed plug, and fill hydraulic oil into
the motor case.
3. Temporarily tighten the air bleed plug.
4. Run the engine at low idle, slightly loosen the air
bleed port section, and run until oil oozes from the
air bleed port section.
5. Completely tighten the air bleed plug.
6. With the engine at low idle, slowly swing evenly left
and right at least two rotations.
2
Check RST-09-04-001F
After the air bleeding is complete, stop the engine

for at least five minutes to allow any air bubbles in
the hydraulic oil tank to dissipate.
RST-09-04-001G

8001-57
Safety valve
WARNING: The safety valve air bleeding work requires two workers: an operator and an air bleed worker.
Decide your signals beforehand and work safely. Set the main unit so that the arm safety valve is at the
! highest position. (See the figure below.)
Boom cylinder safety valve

1. Start the engine and lower the boom without jack-
ing up the main unit.
2. In the above state, loosen the hose mouthpiece at
the position in the figure.
3. Foaming hydraulic oil comes out from the hose
coupling section.
When foaming hydraulic oil stops coming out,
tighten the hose mouthpiece.
4. Execute steps 2 and 3 for the opposite side boom
cylinder too.
5. Check boom operations. If there is a delay in the
operation response, bleed the air again with the
same procedure.
RST-09-04-001H
Arm cylinder safety valve

1. For arm-in operations, bleed the air from the arm
cylinder safety valve using the same procedure as
for boom cylinder safety valve air bleeding.
RST-09-04-001I

8001-58
LEVER PATTERN CHANGE PROCEDURE
The lever pattern operation method (4 patterns) can be changed by changing the connection for the hose on the cushion
valve operator cab side.
Before the work, bleed out the pressure. (See Pressure Measurement.)
Items to prepare
You can change to the following types with the ISO type as the basic type.
• Sumitomo type
• Mitsubishi type
• Shinko type
ISO type
Remote control left Remote control Right
Arm-out Boom down
Swing left Swing right Bucket close Bucket open
Arm-in Boom up
LEVER LEVER
Cushion valve port

Operator cab side hose Cushion valve
A C
E G
I K
M O
CUSHION-ISO
Connection type
Port ATT Hose

C Arm-out A1
A Arm-in A2
K Swing left S1
I Swing right S2
E Boom down V1
G Boom up V2
O Bucket close B1
M Bucket open B2

8001-59
ISO type to Sumitomo type
Swing right Boom down
Arm-out Arm-in Bucket close Bucket open
Swing left Boom up
LEVER LEVER
Cushion valve port
A C
E G
I K
M O
CUSHION-SUMITOMO
Connection type
Hose Hose
Remote control right Cushion valve Remote control right
No. No.
Boom down V1 E V1 Boom up
Boom up V2 G V2 Boom down
Bucket close B1 ISO O Sumitomo B1 Bucket open
Bucket open B2 M B2 Bucket close
Hose Hose
Remote control left Cushion valve Remote control left
No. No.
Arm-out A1 C S2 Swing right
Arm-in A2 A S1 Swing left
Swing left S1 ISO K Sumitomo A1 Arm-in
Swing right S2 I A2 Arm-out

8001-60
ISO type to Mitsubishi type
Boom down Arm-in
Bucket open Bucket close Swing left Swing right
Boom up Arm-out
LEVER LEVER
Cushion valve port
A C
E G
I K
M O
CUSHION-MITSUBISHI
Connection type
Hose Hose
No. No.
Boom up V1 E A1 Arm-out
Boom down V2 G A2 Arm-in
Bucket open B1 ISO O Mitsubishi S2 Swing right
Bucket close B2 M S1 Swing left
Hose Hose
No. No.
Arm-out A1 C V2 Boom down
Arm-in A2 A V1 Boom up
Swing left S1 ISO K Mitsubishi B1 Bucket open
Swing right S2 I B2 Bucket close

8001-61
ISO type to Shinko type
Boom down Arm-out
Bucket open Bucket close Swing left Swing right
Boom up Arm-in
LEVER LEVER
Cushion valve port
A C
E G
I K
M O
CUSHION-SHINKO
Connection type
Hose Hose
No. No.
Boom up V1 E A2 Arm-in
Boom down V2 G A1 Arm-out
Bucket open B1 ISO O Shinko S2 Swing right
Bucket close B2 M S1 Swing left
Hose Hose
No. No.
Arm-out A1 C V2 Boom down
Arm-in A2 A V1 Boom up
Swing left S1 ISO K Shinko B1 Bucket open
Swing right S2 I B2 Bucket close

8001-62
NOTES
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Section
8020
HYDRAULIC FUNCTIONS
8020

CNH Lep SC210B8020-0NA Printed in USA.
February 2007
8020-2
TABLE OF CONTENTS
HYDRAULIC FUNCTIONS.............................................................................................................................................. 3
List of functions ........................................................................................................................................................... 3
TRAVEL CIRCUITS ....................................................................................................................................................... 6
1. Low-speed Travel Circuit ....................................................................................................................................... 6
2. High-Speed Travel Circuit ...................................................................................................................................... 8
3. Straight Travel Circuit ........................................................................................................................................... 10
SWING CIRCUITS ....................................................................................................................................................... 12
1. Swing Speed Limit Control Circuit ........................................................................................................................ 12
2. Swing Relief Cut-off Control Circuit ...................................................................................................................... 14
3. Swing Priority Circuit ............................................................................................................................................ 16
4. Swing Brake Circuit .............................................................................................................................................. 18
5. Swing Parking Circuit (lever in neutral) ................................................................................................................ 20
6. Swing Parking Circuit (brake release) .................................................................................................................. 22
7. Swing Parking Circuit (machine stop) .................................................................................................................. 24
BOOM CIRCUITS ........................................................................................................................................................ 26
1. Boom-Up Circuit (single operation) ...................................................................................................................... 26
2. Boom-Up Circuit (compound boom-up + arm-in) ................................................................................................. 28
3. Boom Down Regenerative Circuit ........................................................................................................................ 30
4. Boom Down Tilting Prevention Circuit .................................................................................................................. 32
5. Boom Down Load Hold Valve Circuit ................................................................................................................... 34
ARM CIRCUITS ........................................................................................................................................................... 36
1. Arm-Out Circuit .................................................................................................................................................... 36
2. Arm-In Forced Regenerative Circuit ..................................................................................................................... 38
3. Arm-In Load Hold Valve Circuit ............................................................................................................................ 40
BUCKET CIRCUITS ..................................................................................................................................................... 42
1. Bucket Open Circuit ............................................................................................................................................. 42
2. Bucket Close Regenerative Circuit ...................................................................................................................... 44
NEGATIVE CONTROL CIRCUITS ............................................................................................................................... 46
1. Negative Control Circuit (power save solenoid OFF) ........................................................................................... 46
2. Negative Control Power save Circuit (power save solenoid ON) ......................................................................... 48
3. Negative Control Circuit (bucket close, power save solenoid OFF) ..................................................................... 50
INCREASED HORSEPOWER CIRCUITS ................................................................................................................... 52
1. Arm-In Increased Horsepower Circuit .................................................................................................................. 52
2. Travel Increased Horsepower Circuit ................................................................................................................... 54
OTHER CIRCUITS ....................................................................................................................................................... 56
1. Cushion Circuit ..................................................................................................................................................... 56
2. Heat Circuit (lever in neutral) ............................................................................................................................... 62
3. Auto Power Boost Circuit (bucket close) .............................................................................................................. 64
OPTION CIRCUITS ...................................................................................................................................................... 66
1. Breaker Circuit (single operation) ......................................................................................................................... 66
2. Shuttle Circuit (hydraulic fork) .............................................................................................................................. 68
3. Combined Circuit ................................................................................................................................................. 70
4. Second Option Circuit (hydraulic rotation fork) .................................................................................................... 74

8020-3
HYDRAULIC FUNCTIONS
List of functions
Functions Description Pages
Travel Circuits
Sets the travel motor two-stage tilt revolution angle to a large angle to set low
Low speed circuit Page 6-7
speed.
Sets the travel motor two-stage tilt revolution angle to a small angle to set high
speed.
The speed is automatically switched to low speed according to the load pressure
High-speed circuit Page 8-9
on the travel motor.
In order to prevent drift at high speed, if the travel pressure becomes 258bar /
25.8 MPa / 3744Psi or higher, the speed is set to low speed.
Straight travel
Traveling with other equipment operation, travel is held straight without curving. Page 10-11
circuit
Swing Circuits
In order to increase the cylinder bore and attachment speed, the pump maximum
Swing speed limit flow was increased, but in order to not increase the swing speed, when swing is
Page 12-13
control circuit operated alone, the pump flow is restricted with the proportional valve installed on
the swing pump (front side).
When swing is operated alone, if swing is started with a sudden lever operation,
the pump flow is reduced with the proportional valve installed on the swing pump
(front side).
Swing relief cut-off
Normally, this control eliminates the excess oil discharged from the swing relief Page 14-15
control circuit
valve and reduces the horsepower consumption.
When the swing speed rises, the pump discharge pressure falls, so the pump flow
is increased gradually while it is detected with the sensor.
1) Swing pushing is obtained by the swing priority variable orifice built into the
Swing priority control valve.
Page 16-17
circuit 2) The wing priority variable orifice also works to secure the arm flow for bed
metering.
Suctions in the oil from the make-up line in order to prevent cavitation when swing
Swing brake circuit Page 18-19
stops.
1) When the swing lever is in neutral, swing parking works and is held at 100%.
2) When there is a swing lever or attachment operation, swing parking is released.
Swing parking 3) Swing parking works about five seconds after the swing lever is put into neutral.
Page 20-25
circuit 4) When an attachment operation is stopped, if there is no swing operation, the
swing parking circuit works about one second later.
5) When the engine is stopped, swing parking works.
Boom Circuits
1) Boom only The flow is merged internally by switching the boom (2) spool to
raise the speed.
Boom-up circuit Page 26-29
2) Compound The swing priority variable metering spool is switched to make
movement in arm-in compound operation smooth.
Boom-down
Regeneration within the boom spool is used to increase speed and prevent cavi-
regenerative Page 30-31
tation.
circuit
Boom-down tilting
High pressure is suppressed with the bleed-off circuit and tilting is mitigated. Page 32-33
prevention circuit
Boom-down load
The load hold valve built into the control valve is speed up. Page 34-35
hold valve circuit

8020-4
Functions Description Pages

Arm Circuits
Arm out circuit The flow is merged internally by switching the arm (2) spool to raise the speed. Page 36-37
Arm-in forced
The speed for compound operation is raised by the forced regeneration release
valve in the control valve.
circuit
Arm-in load hold The load hold valve built into the control valve is released to make the arm-in oper-
Page 40-41
valve circuit ation possible.
Bucket Circuit
Bucket close
Regeneration within the bucket spool is used to increase speed and prevent vac-
uum.
circuit
Negative control circuits
Negative control For no load operation, this circuit sets the hydraulic pump discharge quantity to
Page 46-47
circuit minimum to reduce horsepower consumption.
In the no operation state, this circuit switches the negative control valve set pres-
Negative control
sure to reduce the pump discharge force and further reduce horsepower consump- Page 48-49
power save circuit
tion.
Increased horsepower circuits
Arm-in increased
Increases the hydraulic pump discharge volume for arm-in operations. Page 52-53
horsepower circuit
Travel added
Increases the hydraulic pump discharge volume for travel-only operations. Page 54-55
horsepower circuit
Others
Softens the shock through the work of the cushion valve with heat circuit.
Cushion circuit These circuit is attached to the boom and arm pilot lines. Page 56-61
There is no soft / hard switch.
Auto power boost Boost the main relief pressure from 343 bar /34.3 MPa /4977 Psi to 368 bar / 36.8
Page 64-65
circuit MPa / 5340 Psi according to the engine load ratio and circuit pressure.
Option circuits
The main control valve has an option section as standard so that it can support a
Breaker circuit Page 66-67
breaker, crusher or other special attachment.
Option flow It is possible to set the flow for the breaker, crusher, or other special attachment
Page 70-71
adjustment application by just operating a switch in the cab. Maximum of 5 applications.
Compatible circuit It is possible to switch the circuit between the breaker and the crusher by just oper-
Page 72-73
switch ating the switch in the cab.
Second Option Option valve can be added to the top section of the control valve and a second
Page 74-75
circuit option line can be installed easily.

8020-5
This page has been left blank intentionally

8020-6
Travel Circuits
1. Low-speed Travel Circuit
As an example, this section explains the forward travel operation.
The travel motor two-stage tilt revolution angle is a large angle side. Even if the travel switch is set to the high-speed
side, switching the key switch OFF, then ON again always returns the system to this state.
By operating the travel remote control valve to the forward side, the pilot pressure oil is fed to the control valve Pa1
port and switches the left travel spool to the forward side.
At the same time, the oil is also fed to the Pa6 port to switch the right travel spool to the forward side.
The discharged oil from hydraulic pump A1 enters the control valve P1 port and the discharged oil from hydraulic
pump A2 enters the control valve P2 port. Each flows to the respective travel motor and causes forward travel through
the left and right spools being switched.
The return oil from the travel motor goes through the left and right travel spools and returns to the hydraulic oil tank.
The travel high-speed solenoid valve goes OFF, the travel motor Ps port oil connects with the tank line and the travel
motor revolution tilt angle goes to the large revolution tilt side.
1. Travel motor
2. High speed travel select switch
3. Computer A
4. Control valve
5. Travel (left)
6. Travel (right)
7. Travel speed
8. Lever lock
9. 5-stack solenoid valve
10. Console lever lock switch
11. Hydraulic pump
12. Travel remote control valve
13. Check
14. Oil cooler
15. Backward left
16. Forward left
17. Forward right
18. Backward right
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

8020-7
Low Speed Travel Circuit
4
Pm1 Ps Ps
s Pm2
DR1
ps1 Pn1 T3 T6 T7 T1 T2
2
Pn2
P3
ps2
T2 pcc
prs2
P1 A5
RED
B5 pb9
pb5'
pa9
P2 T
pc3' A8
Pm2 Pm1
B8
pc3
pbu
pb8
pa8
pb4
pa4
15 16 17 18
B7
B3 A7
A3
1 pb3
CLOSE pb7 TRAVEL(L) TRAVEL(R)
OPEN pa7
pa3
B2
B6
A2
pb2
BACKWARD A6
pb6
pa2
P4
ON
FORWARD p
pa6
12
B1
L(L) DR3
A1
pb1 6 1 T 3
P 2 4
2 pa1 FORWARD
T5
5 T4
PT PA
P1 P2
3 13
7 B
T 8
C1 10
14 13
P
2-STAGE RELIEF
C3
A1 A2 A3
C4
C2 SWING BRAKE C5
9
11
RST-04-04-001a

8020-8
2. High-Speed Travel Circuit
As an example, this section explains the forward travel operation.
Sets the travel motor two-stage tilt revolution angle to a small angle to set high speed. The travel motor has an auto
switch function that switches the speed from high speed to low speed according to the load pressure on the travel
motor.
At the same time, the oil is also fed to the Pa6 port to switch the right travel spool to the forward side.
The return oil from the travel motor goes through the left and right travel spools and returns to the hydraulic oil tank.
Electrical signals are sent to the computer A by operation of the high-speed travel select switch and the computer A
sends electrical signals to the high-speed travel solenoid valve. Due to the switching of the high-speed travel solenoid
valve, the pilot pressure (39 bar / 3.9 MPa / 566 Psi) from the C1 port enters the left and right travel motor Ps ports
through the center joint and sets the travel motor revolution tilt angle to a small angle to raise the speed.
1. Travel motor
3. Computer A
4. Control valve
5. Travel (left)
6. Travel (right)
7. Travel speed
8. Lever lock
11. Hydraulic pump
13. Check
14. Oil cooler
15. Backward left
16. Forward left
17. Forward right
18. Backward right
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

8020-9
High Speed Travel Circuit
4
Pm1
Ps Ps Pm2
DR1
T3 T6 T7 T1 T2
2
Pn2
P3
ps2
T2
pcc
39.2MPa at 20L/min prs2
P1 A5
RED
RED
B5 ARM(2)
pb5' pb9
P2 pb5 pa9
pa5
pc3' A8
Pm2 Pm1
pc3 B8
pbu
pb8
pa8
pb4
pa4
15 16 17 18
B7
B3
A3 A7 TRAVEL(R)
TRAVEL(L)
1 pb3
CLOSE
pb7
OPEN
pa3 pa7
B2
B6
A2
pb2
BACKWARD
pb6 A6
pa2
P4
ON
FORWARD p
pa6 12
B1
DR3
A1 pb1
BACKW 6 1 T 3
P 2 4
pa1 FORWARD
2
T5
T4
5
PT PA PH
P1 P2
13
3
B T 8
C1 10
14 13
P
7
2-STAGE RELIE
C3 ECONOMY A1 A2 A3
C4
SWING BRAKE
C2 C5
9
11
RST-04-04-001b

8020-10
3. Straight Travel Circuit
As an example, this section explains simultaneous forward travel and boom up operations.
In the same way, oil is also fed to the Pa6 port to switch the right travel spool to the forward side.
Furthermore, the right forward travel pilot pressure oil separated internally from the control valve Pa6 port switches
the straight travel signal (right). On the other hand, the travel pilot pressure oil separated internally from the Pa1 port
switches the straight travel signal (left) via the straight travel signal (right).
If a boom-up operation is carried out during travel, the pilot pressure oil is fed via the cushion valve to the control valve
Pa4 port and switches the boom (1) and (2) spools to the up side.
The upper side (boom, arm, bucket, swing, option) pilot pressure oil separated internally from the control valve Pa4
port is fed to the straight travel valve via the straight travel signal (left) and the straight travel spool is switched.
The amount of switching of the straight travel spool varies with the upper side pilot pressure.
(Because the pilot pressure is low for slight upper side operation, the amount of switching of the straight travel spool is
slight to prevent sudden reduction in the travel speed.)
Because the straight travel valve is switched, it is possible for the control valve P1 pressurized oil to drive the left and
right travel motors and for the control valve P2 pressurized oil to drive the boom.
Because the left and right motors are driven by one pump, the left and right motors have the same pressure and
straight travel is possible. Furthermore, the P2 excess pressurized oil is fed to the travel side via the check valve with
travel merge orifice to minimize the drop in speed.
The same operations are carried out when travel and an upper side actuator other than for the boom are operated
simultaneously.
1. Travel motor 14. Travel speed

2. Boom (up) 15. Lever lock
3. Boom (down) 16. 5-stack solenoid valve
4. Cushion valve 17. Console lever lock switch
5. remote control valve (boom, bucket) 18. Hydraulic pump
6. Control valve 19. Boom cylinder
7. Travel (left) 20. Travel remote control valve
8. Travel (right) 21. Check
9. Straight travel valve 22. Oil cooler
10. Straight travel signal (left) 23. Backward left
11. Straight travel signal (right) 24. Forward left
12. High speed travel select switch 25. Forward right
13. Computer A 26. Backward right
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

8020-11
Straight Travel Circuit
19
6
Pm1 Ps Ps Pm2
DR1
1 T3 T6 T7 T1 T2
2
Pn2
P3
ps2
2.55MPa at 50L/min
pcc
A5 prs2
RED
RED
IN
pb5' pb9
P1 IN UT
pa9
OUT
pa5
39.2MPa at 20L/min A8
Pm2 Pm1
pb8
B8
pa8
pb4
p
pa4 23 24 25 26
B7
A7 TRAVEL(L) TRAVEL(R)
A3
1 CLOSE
pb7
RIGHT OPEN
pa3 pa7
B2
B6
2 3 A2
pb2
BACKWARD
pb6
A6
F pa2 ON
B D R H J S L N U P P4 FORWARD p
pa6 20
B1
DR3
A1
pb1 8 1
P 2 4 T 3
pa1
9
T4 T5
A C V T G I Q K M O
7
E PT PA
P1 P2
2
4 11 10
21
14
T 15
C1
17
P T
22 21
5
12 P
C3 ECONOMY A1 A2 A3
C4
BOOM BUCKET
OPEN CLOSE SWING BRAKE
C5
C2
2
4 3 1 16
13 18
3 2
RST-04-04-001c

8020-12
Swing Circuits
1. Swing Speed Limit Control Circuit
This control is for suppressing increases in the swing speed accompanying increased pump flow. (Only in SP mode)
For swing-only operation, due to the swing pilot pressure sensor and P1 pressure sensor input electric signal, the
computer A outputs a signal to the P1 hydraulic pump flow control proportional valve.
The discharged oil from the A3 hydraulic pump is fed to the P1 flow control proportional valve.
The hydraulic pump A1 side discharge flow is reduced to 200 L / min by the signal output from the computer A to the
P1 flow control proportional valve.
1) Conditions under which the swing speed limit control is entered
• Swing only full lever operation
• No travel operation
• Work mode SP
2) Conditions under which the swing speed limit control is ended
• Upper side operation other than boom down
=> Gradual end (to reduce shock)
• Travel operation
=> Immediate end (to avoid back lash)
• Option operation
1. Swing motor
2. Swing
3. Cushion valve
4. Right swing
5. Left swing
6. Swing pilot pressure sensor
7. Remote control valve (arm,swing)
8. Control valve
9. Travel pilot pressure sensor
10. Upper side pilot pressure sensor
11. Computer A
12. Lever lock
13. Swing brake
16. N1 negative control pressure sensor
17. P1 pressure sensor
18. P1 flow control proportional valve
19. Hydraulic pump
20. Horse power control proportional valve
22. Check
23. Oil cooler
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

8020-13
Swing speed limit control circuit
T2
DR1
p T3 T6 T7 T1
8 Pn2
P3
ps2
pcc
CX240B CX210B A5
prs2
1 1 pb5'
pb5
pb9
pa9
pa5
pc3'
A8
pc3 B8
pbu
pb8
PR P pa8
pb4
2 B3
pa4
B7
DB Dr A7
A3 CLOSE
pb3 pb7
OPEN
pa7
pa3
29.4MPa 29.4MPa
at 167L/min at 167L/min B2 B6
A2 A6
M GA GB
28.9MPa 28.9MPa pb2 pb6
ON 22
PB PA
P4
pa6
B1
DR3
LEFT A Mu B RIGHT
BACKWAR
pb1
23 22
FORWARD
pa1
T5
T4 N RELIEF V.
LEFT B A RIGHT
3 4 5 20
P1 P2
2
J
B D R F H S L N U P
9 1
10
P1 P2 21
17 a1
11 (FRONT) (REAR)
A C V T E G I K M O
Q 6 16
Pi1 a7 a8 Pi2
15
12
B
7 T
2-STAGE TRAVEL
C1
P T
P P1 P2
M
C3
ECONOMY
18 Dr
C4 B1
ARM a3
SWING
C2 C5
2 4 3
1 A3
5 4 13 B3
14 19
RST-04-04-001d1

8020-14
2. Swing Relief Cut-off Control Circuit
This control aims for an energy saving effect by controlling the pump in such a way as to minimize the excess oil
drained from the swing motor relief valve for the starting pressure boost for a sudden swing-only operation.
When a swing operation starts, due to the swing pilot pressure sensor and P1 pressure sensor input electrical signals,
the computer A outputs a signal to the hydraulic pump P1 flow control proportional valve.
The discharged oil from the A3 hydraulic pump is fed to the P1 flow control proportional valve.
The output signal from the computer A to the P1 flow control proportional valve controls the pilot pressure to reduce
the hydraulic pump A1 side discharge flow. Also, the input signal from hydraulic pump P1 pressure sensor controls the
pilot pressure to gradually increase the discharge flow.
1) Swing relief cut-off control is executed when all the conditions below are satisfied.
• No travel operation
• Swing-only sudden operation or swing + boom down operation
2) Swing relief cut-off control ends when a condition below is satisfied.
• When swing operation is stopped
• Travel, boom-up, arm out / in, or bucket open / closed operation
1. Swing motor
2. Swing
3. Cushion valve
4. Right swing
5. Left swing
7. Remote control valve (arm,swing)
8. Control valve
11. Computer A
12. Lever lock
13. Swing brake
19. Hydraulic pump
20. Horse power control proportional valve
22. Check
23. Oil cooler
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

8020-15
Swing Relief Cut-off Control Circuit
T2
DR1
Pn1 T3 T6 T7 T1
8 Pn2
P3
ps2
CX240B CX210B pcc
A5
prs2
1 1 pb9
pb5'
pa9
pa5
pc3' A8
pc3 B8
pbu
PR P
p
pb8
pa8
pb4
pa4
DB Dr B3 B7
A7
A3 pb3
CLOSE
pb7
OPEN
29.4MPa 29.4MPa pa7
at 167L 7L/min pa3
M GA GB B2 B6
28.9MPa A2 A6
at 201L/min at 201L/min 2 pb2 pb6
PB PA
22
P4
pa6
LEFT A Mu B RIGHT B1
DR3
BACKWARD
pb1
23 22
FORWARD
pa1
LEFT RIGHT T4 T5
B A N RELIEF V.
3 4 5 20
P1 P2
B F H J L N U P
D R
9 1
10
P1 a4 P2 21
17
a1 a2
11 (FRONT) (REAR)
A C V T E G I K M O
Q
6 16
Pi1 a7 a8 Pi2
15
12
7 B T
2-STAGE TRAVEL
C1
P T
P1 P2
P
M
C3
ECONOMY
18 Dr
B1
C4 a3
ARM SWING
OUT C2 C5
2 4 3
1 A3
5 4 13 B3
14 19
RST-04-04-001e1

8020-16
3. Swing Priority Circuit
The swing pilot pressure is fed to the Pc3 port via the shuttle valve and holds the swing priority variable orifice to the
right side.By orifice the parallel circuit, for arm and swing simultaneous operation, the swing pressure is boosted to
secure the swing force for pressing digging.
As an example, this section explains the right swing and arm-in operation.
By moving the remote control valve to the right swing side, the pilot pressure oil is fed via the shuttle valve to the con-
trol valve Pa3 port and switches to the right swing side.
At this time, by moving the remote control valve to the arm-in side, the pilot pressure oil is fed via the cushion valve to
the control valve Pb5 port and switches the spool to the arm-in side.
At the same time, the pilot pressure oil from the shuttle valve S port is fed to the control valve Pc3 port to move the
swing priority variable orifice to the right side and hold it.
The discharged oil from hydraulic pump A1 enters the control valve P1 port and is fed from the parallel passage to the
swing spool.Switching the spool lets the oil flow into the swing motor B port and carries out the swing operation.
The discharged oil from hydraulic pump A2 enters the control valve P2 port, is fed from the parallel passage to the
arm (2) spool and merges upstream of the arm (1) spool.Switching the spool lets the oil flow into the arm cylinder bot-
tom and carries out the arm-in operation.
When the right swing and arm-in operations are carried out at the same time, the swing priority variable orifice on the
control valve P1 port parallel passage moves and narrows, so the pressure is boosted to secure the swing force for
pressing digging.
1. Swing motor 15. Arm cylinder

2. Arm (in) 16. Arm (1)
3. Arm (out) 17. Swing
4. Right swing 18. Arm load hold valve spool
5. Left swing 19. Arm load hold valve check
6. Cushion valve 20. Regeneration release valve
7. Swing pilot pressure sensor 21. Control valve
8. Shuttle valve 22. Swing priority variable orifice
9. Computer A 23. Arm (2)
10. Remote control valve (arm,swing) 24. Upper side pilot pressure sensor
11. Lever lock 25. Hydraulic pump
12. Swing brake 26. Check
13. 5-stack solenoid valve 27. Oil cooler
14. Consol lever lock switch
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

8020-17
Swing Priority Circuit
CX240-B CX210-B
1 1
DR1
21
PR P T2
15 T1
18 20
ps1
19 T3 T6 T7
DB Dr Pn1
Pn2
P3
ps2
29.4MPa 29.4MPa
at 167L/min at 167L/min
GA GB
M A5
28.9MPa
ARM pb9
PB PA B5 pb5'
pa9
pb5 pa5
2
23
LEFT A Mu B RIGHT pc3'
A8
pc3 B8
pbu DOWN
16 UP
pb4
LEFT RIGHT pa4

B A B3 B7
A7
A3
pb3
LEFT 22 CLOSE
pb7
p
pa3 RIGHT OPEN
pa7
2 3 4 5 B2
A2
B6
A6
B D R F H J S L N U P 17 pa2
BREAKE
pb6
ON
P4
pa6
A1 DR3
BACKWARD
pb1
FORWARD
pa1
C G I K M O T4
A T5
Q 3MPa at 126L/min
3MPa at 108L/min
7 8 P1 PT
P2 26
6 24
9 27 26
B 11
10 T
2-STAGE TRAVEL
C1
P T
14
P
25
C3 ECONOMY 13
A1 A2 A3
C4
ARM SWING
C2 C5
4 3
2 1
12
5 4
2 3
RST-04-04-001f1

8020-18
4. Swing Brake Circuit
As an example, this section explains the brake circuit operation after the end of a right swing operation.
When the remote control valve is returned to neutral from a right swing operation, the pilot pressure oil is cut off and
the control valve swing spool returns to neutral.
The pressurized oil fed to the swing motor B port from the control valve A3 port is cut. At the same time, the destina-
tion location is eliminated for the pressurized oil flowing from the swing motor A port to the control valve A3 port, so
the pressure rises to the swing motor relief valve set pressure. The pressure generated here becomes a brake force
and stops the motor.
When the swing is stopped, the swing motor continues to rotate for a while due to inertial force. In order to make up
the shortfall in the oil quantity, oil is supplied from the make-up line connected to the swing motor Mu port from the
control valve T3 port to open the make-up check valve and oil is suctioned in to prevent cavitation.
1. Swing motor
2. Cushion valve
3. Right swing
4. Left swing
6. Remote control valve (arm, swing)
7. Hydraulic pump
8. Check
9. Lever lock
10. Swing brake
13. Computer A
14. Control valve
15. Oil cooler
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

8020-19
Swing Brake Circuit
CX240-B CX210-B
1 1
PR P
14 T1
T2
T3
ps1 Pn1 T6 T7 DR1
Pn2
DB Dr
P3
ps2
pcc
29.4MPa
at 167L/min
GB A5
M GA
B5
ARM(2) IN pb9
28.9MPa 28.9MPa pb5'
OUT
pa9
PB PA
LEFT A Mu B RIGHT A8
pc3 B8
pbu
pb8
pa8
pb4
pa4
LEFT B A RIGHT B3 B7
A7
NG
A3 CLOSE
pb7
pb3
pa3 OPEN
pa7
2 4
3 B2
A2
B6
A6
BACKWARD
pb6
B D R F H J S L N U P
pa2
BREAKER
ON
P4 FORWARD
pa6
B S A1 DR3
pb1
FORWARD
pa1
A C V T E G K M O
I Q T4
T5
5 P1 PT PA PH
P2
8
16
12
9 15 8
B T
2-STAGE TRA
6 C1
P T P
2-STAGE RELIEF 7
C3 ECONOMY
C4 A1 A2 A3
C2 C5
ARM SWING
13
2 4 3
1
10 11
4 3
RST-04-04-001g1

8020-20
5. Swing Parking Circuit (lever in neutral)
When the key is switched ON, the swing brake solenoid valve is switched by the electrical signal from the computer A.
The swing motor P port oil goes from the 5-stack solenoid valve C2 port through the swing brake solenoid, and
returns to the hydraulic oil tank to hold the swing parking brake.
1. Swing motor
2. Cushion valve
3. Right swing
4. Left swing
7. Check
8. Oil cooler
9. Lever lock
10. Swing brake
13. Computer A
14. Control valve
16. Hydraulic pump
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

8020-21
Swing Parking Circuit (lever in neutral)
CX240-B CX210-B
1 1
PR P
ps1 Pn1 T3 T6 T7 DR1 T1 T2

DB Dr
14 Pn2
P3
ps2
pcc
at 167L/min at 167L/min A5
GA GB
M
pb5' IN pb9
28.9MPa 28.9MPa ARM(2)
pb5 OUT pa9
PB PA pa5
pc3'
LEFT A Mu B RIGHT A8
pc3
pbu B8
pb8
pa8
pb4
pa4
LEFT B A RIGHT
A3
B3 B7
A7
NG
pb3 CLOSE
pb7
pa3 RIGHT OPEN
pa7
2
3 4 B2
A2 B6
A6
pb2 BACKWARD
pb6
B D R F H J S L N U P pa2 BREAKER
P4 ON
FORWARD pa6
B1
DR3
pb1 BACKWARD
FORWARD
pa1
A C V T E G I K M O
T4 T5
5 P1 PT
PA 7
PH P2
Q 15
9 8 7
B T
2-STAGE TRAV
6 C1
12
P T P
C3
2-STAGE RELIEF
ECONOMY
16
C4 A1 A2 A3
C2 C5
ARM SWING
10 13
2 4 3
1
11
4 3
RST-04-04-001h1

8020-22
6. Swing Parking Circuit (brake release)
When the engine is started and the swing lever is in neutral, the swing brake solenoid comes ON (24 V input), the
pressure to the swing motor P port is cut, and the swing parking brake works.
When the lever operation raises the reading to 5 bar / 0.5 MPa / 72.5 Psi or higher at the pressure sensor in the swing
pilot line, the output from the computer A to the swing brake solenoid valve goes OFF, the swing motor P port pres-
sure rises, the swing parking brake is released, and swing becomes possible.
As an example, this section explains the right swing operation.
By carrying out the right swing operation on the remote control valve, the pilot pressure oil is fed to the control valve
Pa3 port via the shuttle valve and switches the swing spool to the right swing side.
At the same time, the computer A detects the swing pilot pressure sensor signal, judges that there is a swing opera-
tion, the electrical signal output from the computer A goes OFF, and the swing brake solenoid valve is switched. The
pilot pressure oil is fed to the swing motor P port from the swing brake solenoid valve C2 port to release the swing
parking brake.
swing spool. Switching the spool lets the oil flow into the swing motor B port and carries out the swing operation.
The pressurized oil from the swing motor A port goes through the swing spool and returns to the hydraulic oil tank.
When this is followed by an attachment operation, the pilot pressure is detected by the control valve PA port pressure
sensor and the swing parking brake continues to be released.
After the swing operation ends, if about 5 seconds pass with no upper side operation, the swing brake solenoid valve
output from the computer A comes ON and the swing parking brake works again.
After the swing ends, if this is followed by an upper side operation or there is an upper side operation within about 5
seconds, when about 1 second passes after the end of the upper side operation, the swing parking brake works
again.
The swing parking brake is also released for upper side only operations and when about 1 second passes after the
end of the upper side operation, the swing parking brake works again.
Swing motor
Key Swing pilot Upper side pilot Swing brake
mechanical
switch pressure sensor pressure sensor solenoid valve
brake
OFF 0 bar / 0 MPa / 0 Psi 0 bar / 0 MPa / 0 Psi OFF ON
ON 0 bar / 0 MPa / 0 Psi 0 bar / 0 MPa / 0 Psi ON ON
ON 5 bar / 0.5 MPa / 72.5 Psi min. 0 bar / 0 MPa / 0 Psi OFF OFF
ON 0 bar / 0 MPa / 0 Psi 5 bar / 0.5 MPa / 72.5 Psi min. OFF OFF
ON 5 bar / 0.5 MPa / 72.5 Psi min. 5 bar / 0.5 MPa / 72.5 Psi min. OFF OFF
Pilot pressure sensor judgement standard

When the pressure goes above 5 bar /0.5 MPa / 72.5 Psi, the system judges that an operation is underway.
When the pressure goes below 3 bar /0.3 MPa / 43.5 Psi, the system judges that the operation has ended.
1. Swing motor 10. 5-stack solenoid valve

3. Right swing 12. Computer A
4. Left swing 13. Control valve
5. Swing pilot pressure sensor 14. Upper side pilot pressure sensor
6. Remote control valve (arm, swing) 15. Hydraulic pump
7. Swing 16. Check
8. Lever lock 17. Oil cooler
9. Swing brake
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

8020-23
Swing Parking Circuit (brake release)
CX240-B CX210-B
1 1
T2
PR P T1
ps1 Pn1 T3 T6 T7 DR1
DB Dr
13 Pn2
P3
ps2
pcc
29.4MPa
GA GB A5 2
M
B5 ARM(2)
28.9MPa 28.9MPa pb5'
9
PB PA
LEFT A Mu RIGHT A8
B
pc3 B8
pbu
pb8
pa8
pb4
pa4
LEFT B A RIGHT B3 B7
A7
A3 CLOSE
pb7
pb3
OPEN
pa7
pa3
2
3 4 B2
A2
B6
A6
7 BACKWARD
pb6
B D R F H J S L N U P pa2
BREAKER
ON
P4 FORWARD
pa6
A1 DR3
BACKWARD
pb1
FORWARD
pa1
C V T E G I Q K M O
T4 T5
5 P1 PT PA PH
P2 16
14
8 17 16
B T
C1 2-STAGE TRAVEL
6 11
P T P
C3
2-STAGE RELIEF 15
C4
A1 A2 A3
C5
C2
ARM SWING
9 12
2 4 3
1
10
4 3
RST-04-04-001i1

8020-24
7. Swing Parking Circuit (machine stop)
When the machine is stopped (the key is switched OFF), the swing motor P port oil goes from the swing
brake solenoid C2 port through the lever lock solenoid and returns to the hydraulic oil tank, holding the
swing parking brake hold status.
1. Swing motor
2. Cushion valve
3. Right swing
4. Left swing
7. Check
8. Oil cooler
9. Lever lock
10. Swing brake
13. Computer A
14. Control valve
16. Hydraulic pump
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

8020-25
Swing Parking Circuit (machine stop)
CX240B CX210B
1 1
PR P
T2
T1
DB Dr
Pn1 T3 T6
14 Pn2
29.4MPa
at 167L/min at 167L/min P3
GA GB
M Pa at 50L/min
28.9MPa 28.9MPa
PB PA A5 2
IN
pb5' pb9
IN OUT
pb5 pa9
LEFT A Mu B RIGHT pa5
OUT
pc3'
A8
pc3 B8
pbu
pb8
LEFT B A RIGHT pa8
pb4
pa4
B3 B7
A7
A3 CLOSE
pb7
pb3
RIGHT OPEN
pa7
pa3
2
3 4 B2
A2
B6
A6
BACKWARD
pb2 pb6
pa2 ON
FORWARD
pa6
B1
A1 DR3
BACKWARD
pb1
FORWARD
pa1
A C V T E G I Q K M O T5
T4
5 P1 PH P2
7
15
9 8 7
B T
6 C1
12
P T P
2-STAGE RELIEF 16
C3
ECONOMY
C4 A1 A2 A3
C2 C5
ARM SWING
10 13
2 4 3 1
11
4 3
RST-04-04-001j1

8020-26
Boom Circuits
1. Boom-Up Circuit (single operation)
By operating the remote control valve to the boom-up side, the pilot pressure oil is fed via the cushion valve to the
control valve Pa4 port and the boom (2) spool is switched.
At the same time, the pilot pressure oil from the Pa4 port separated in the internal path is fed to the boom (1) pilot port
and switches the boom (1) spool to the up side.
boom (2) spool and merges downstream of the boom (1) spool.
The discharged oil from hydraulic pump A2 is fed to the boom (1) spool via the parallel passage, merges with the dis-
charged oil from boom (2), flows through the boom load hold valve check valve and into the boom cylinder bottom
side and carries out the boom-up operation.
The boom cylinder rod side return oil goes through the boom (1) spool and returns to the hydraulic oil tank.
1. Cushion valve
2. Boom (up)
3. Boom (down)
4. Boom (2)
5. Remote control valve (boom, bucket)
6. Lever lock
7. Boost relief
9. Control valve
10. Boom load hold valve check
11. Boom (1)
12. Boom cylinder
16. Monitor display
17. Power up
18. Computer A
21. Hydraulic pump
22. Check
23. Oil cooler
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

8020-27
Boom-Up Circuit (single operation)
12
T1
9 T2
ps1 Pn1 T3 T7 DR1
Pn2
P3
ps2
A5
B5
pb5' pb9
pb5 pa9
pa5
1
10
pc3' A8
pc3
pbu B8
pb8
OOM(2)) pa8
1 pa4
pb4
1
11
2 3 B3 B7
A3 A7
4 pb3
LEFT CLOSE
RIGHT OPEN
pa3 pa7
B2 B6
A2 A6
pb2 pb6
BREAKER
pa2 ON
P4
pa6
A C V T E G I Q K M O A1 DR3
BACKWARD
pb1
FORWAR
pa1
T4 T5
3MPa at 126L/min
3MPa at 108L/min
P1 PT H P2
13 14
22
5
B T 6
P T 2-STAGE TRAVEL
C1
19 23 22
15 20
P
C3
3
CONOMY A1 A2 A3
7 16
BOOM BUCKET C4 17 18
OPEN CLOSE
2 3 1
4 C2
C5
21
3
2 8
RST-04-04-001k

8020-28
2. Boom-Up Circuit (compound boom-up + arm-in)
As an example, this section explains the boom-up + arm-in compound operation (leveling work).
For bed digging work, the boom-up pilot pressure oil is fed to the Pbu port, the swing priority variable orifice is moved
to the left side and the restriction on the flow to the arm is ended to smooth the arm movement.
By operating the remote control valve to the boom up side and arm-in side, the pilot pressure oil is fed via the cushion
valve to the control valve Pa4 port and Pb5 port and switches the boom (1) and arm (1) spools.
At the same time, pressurized oil separated from the boom (1) side pilot internal path is fed from the Pa8 port to the
Pbu port and the swing priority variable orifice spool is switched to the left side.
boom (2) and arm (1) spools.
Because the swing priority variable orifice spool in the parallel passage is moved, the restriction on flow to the arm is
released and the oil flows through the arm (1) spool and into the arm cylinder bottom side. This makes arm-in opera-
tion movement smooth.
The arm cylinder rod side return oil goes through the load hold valve check valve and the arm (1) spool and returns to
the hydraulic oil tank.
boom (1) spool.
Switching the spool lets the oil flow through the load hold valve check valve and into the boom cylinder bottom side
and carries out the boom up operation.
The boom cylinder rod side return oil goes through the boom (1) spool and returns to the hydraulic oil tank.
1. Arm cylinder 18. Swing priority variable orifice

2. Arm (in) 19. Arm (2)
3. Arm (out) 20. Boom load hold valve check
4. Boom (up) 21. Boom (1)
5. Boom (down) 22. Boom cylinder
6. Cushion valve 23. Travel pilot pressure sensor
7. Remote control valve (boom, bucket) 24. Upper side pilot pressure sensor
8. Remote control valve (arm, swing) 25. Console lever lock switch
9. Lever lock 26. Monitor display
10. Boost relief 27. Power up
11. 5-stack solenoid valve 28. Computer A
12. Arm (1) 29. P1 pressure sensor
13. Boom (2) 30. P2 pressure sensor
14. Arm load hold valve spool 31. Hydraulic pump
15. Load hold valve check 32. Check
16. Regeneration release valve 33. Oil cooler
17. Control valve
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

8020-29
Boom-Up Circuit (compound boom-up + arm-in)
22
DR1
T1 T2
1 17
14 15
16
ps1 Pn1 T3 T7
Pn2
P3
ps2
1
19
A5
B5
p
pb9
pb5''
pa9
6 2 3 4 5 pa5 20
12
pc3' A8
pc3
pbu B8
pb8
pa8
pb4
p
pa4
B7
A3 A7 21
LEFT CLOSE
13 pa3
OPEN
pa7
C V T G I Q K M O
A E B2 B6
A2 A6
pb6
pa2
ON
P4 pa6
A1 DR3
T BACKWARD
pb1
FORWARD
pa1
T5
T4
7
BOOM BUCKET P1 PT P2
OPEN CLOSE 23 24
2 3 1
4
4 32
5 8 9
B T
2-STAGE TRAVEL
C1
T 25 29 30 33 32
P
C3
3
ONOMY A1 A2 A3
26
10 C4 27 28
ARM
SWING
C5
C2
2
4 3 1
31
11
2 3
RST-04-04-001l

8020-30
3. Boom Down Regenerative Circuit
By moving the remote control valve to the boom down side, the pilot pressure oil is fed via the cushion valve to the
control valve Pb8 port and switches the boom (1) spool to the down side.
boom (1) spool.
Switching the spool lets the oil flow into the boom cylinder rod side and carries out the boom down operation.
The pilot pressure oil from the Pb8 port separated in the internal path is fed to the load hold valve spool and moves
the spool to the left. In this way, the load hold valve check valve spring chamber oil is connected to the tank line
through the load hold valve spool, the spring chamber pressure drops, and the load hold valve check valve is opened.
The boom cylinder bottom side pressurized oil goes through the load hold valve check valve and is metered by the
boom (1) spool regeneration orifice.
Through this, the return oil pushes open the check valve in the spool and is regenerated on the cylinder rod side. The
lower the cylinder rod side load pressure, the greater the quantity of regeneration.
When the cylinder rod side load pressure becomes high, the check valve is closed and the cylinder bottom return oil
goes through the boom spool (1) without regeneration and returns to the hydraulic oil tank.
Because the circuit is configured in such a way that even if the boom (1) spool is at full stroke, negative control pres-
sure is generated by the center bypass bleed-off passage and the pump does not discharge full flow and because the
short fall is made up for with regeneration, engine output can be used effectively.
1. Load hold valve check 13. 5-stack solenoid valve

2. Check 14. Control valve
3. Oil cooler 15. P2 pressure sensor
4. P1 pressure sensor 16. Hydraulic pump
5. Orifice 17. Boom cylinder
6. Bleed-off 18. Boom (1)
7. Cushion valve 19. Travel pilot pressure sensor
8. Boom (up) 20. Upper side pilot pressure sensor
9. Boom (down) 21. Console lever lock switch
10. Remote control valve (boom, bucket) 22. Monitor display
11. Lever lock 23. Computer A
12. Boost relief
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

8020-31
Boom Down Regenerative Circuit
17
14
1
1 T1 T2
2
Pn2
P3
ps2
A8 Details pcc
A5 prs2
B8 pb5'
ARM(2)
pb9
pa9
pa5
pb8
A8
B8
8
pb8
2
pb4 pa8
To tank line
pa4
To A2 pump 6 B3
B7
A7
18
A3
5 pb7
pa3 OPEN pa7
B2 B6
A2 TRAVEL(R) A6
7 8 9 pb2
pa2
BACKWARD pb6
P4
FORWARD pa6
A1 DR3
pb1 BACK
-WARD
WARD
pa1
T4 T5
A C V T E G I Q K M O
P1 PT PA PH P2
19 20
2
10 11
B T
C1
4 15
P T 21 3 2
P
C3
A1 A2 A3
22
BOOM BUCKET
12 C4
23
C2 SWING BRAKE C5
OPEN CLOSE
4 3 1
2 16
13
9 8
RST-04-04-001m

8020-32
4. Boom Down Tilting Prevention Circuit
By operating the remote control valve all the way to the boom down side at once, even if the boom spool goes its full
stroke, negative control pressure is generated by the center bypass bleed-off passage and the circuit is such that the
hydraulic pump does not discharge full flow, so the generation of high pressure is restrained and main unit tilt is
reduced.
Since the shortfall in the oil quantity is compensated by the regeneration circuit, the engine output can be used effec-
tively.
1. Load hold valve check

2. Check
3. Oil cooler
4. Bleed-off
5. Cushion valve
6. Boom (up)
7. Boom (down)
9. Lever lock
10. Boost relief
12. Control valve
14. Hydraulic pump
15. Boom cylinder
16. Boom (1)
20. Monitor display
21. Computer A
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

8020-33
Boom Down Tilting Prevention Circuit
15
12
1
ps1 Pn1 T3 T6 DR1
1 T1 T2
2
Pn2
P3
ps2
A8 Details pcc
A5 prs2
B8 pb5' pb9
pa9
pa5
pb8
A8
B8
8
pb8
pb4 pa8
To tank line
pa4
To A2 pump 4 B3
B7
A7
16
A3
pb7
pa3 OPEN pa7
B2 B6
A2 TRA A6
5 6 7 pb2
pa2
BACKWARD pb6
P4
pa6
A1 DR3
pb1 BACK
-WARD
WARD
pa1 FORWARD
T4 T5
A C V T E I Q K M O
G P1 PT P H P2
2
17 18
8 2
B T 9
C1
22 13
P T 19 3 2
P
C3 OMY A1 A2 A3
10 20
C4
BOOM BUCKET
21
C2 SWING BRA C5
OPEN CLOSE
2 4 3 1
14
11
7 6
RST-04-04-001n

8020-34
5. Boom Down Load Hold Valve Circuit
When the remote control valve boom operation lever is in neutral, the oil at the boom cylinder bottom side is sealed by
the load hold valve check valve, reducing internal leakage from the main spool and reducing the natural drop of the
boom.
By moving the remote control valve to the boom down side, the pilot pressure oil is fed via the cushion valve to the
control valve Pb8 port and switches the boom spool to the down side.
boom (1).
Switching the spool lets the oil flow into the boom cylinder bottom side and carries out the boom down operation.
the spool to the left. In this way, the load hold valve check valve spring chamber oil is connected to the tank line
The boom cylinder bottom side pressurized oil goes through the load hold valve check valve and the boom (1) spool
and returns to the hydraulic oil tank.
1. Boom load hold valve check

2. Load hold valve spool
3. Cushion valve
4. Boom (up)
5. Boom (down)
7. Lever lock
8. Boost relief
10. Control valve
11. Check
12. Oil cooler
13. Boom cylinder
14. Boom (1)
18. Monitor display
19. Computer A
22. Hydraulic pump
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

8020-35
Boom Down Load Hold Valve Circuit
13
10
2 ps1 Pn1 T3 T6 T7 DR1

1 T1 T2
2
Pn2
P3
ps2
1 pcc
Details A5 prs2
A8 pb5' pb9
pa9
pa5
B8
BOOM(1)
DOWN A8
pb8 B8
8
pb8
8
pb4 pa8
pa4
B3
B7
A7
14
A3
pb7
pa3 OPEN pa7
B2 B6
A2 TRA A6
3 4 5 pb2
pa2
BACKWARD pb6
P4
FORWARD pa6
A1 DR3
pb1 BACK
-WARD
WARD
pa1
T4 T5
P1 PT P H P2
2
15 16
6 11
B T
7
C1
20 21
P 17 11
T
12
P
C3 NOMY A1 A2 A3
8 18
BOOM BUCKET
C4 19
SWING BR
OPEN CLOSE C2 C5
4 3 1
2 22
9
5 4
RST-04-04-001o

8020-36
Arm Circuits
1. Arm-Out Circuit
By moving the remote control valve to the arm-out side, the pilot pressure oil is fed via the cushion valve to the control
valve Pa5 port and Pa9 port and switches the arm (1) and (2) spools to the open side.
The discharged oil from hydraulic pump A1 enters the control valve P1 port and is fed from the center bypass pas-
sage to the arm (1) spool.
The discharged oil from hydraulic pump A2 enters the control valve P2 port, flows from the center bypass passage
and through the arm (2) spool front arm merge passage and merges upstream of the arm (1) spool.
Switching the arm spool lets the oil flow through the load hold valve check valve and into the arm cylinder rod side,
carrying out the arm-out operation.
The arm cylinder bottom side return oil goes through the arm (1) and (2) spools and returns to the hydraulic oil tank.
1. Arm cylinder
2. Arm (out)
3. Arm (in)
4. Cushion valve
6. Lever lock
7. Boost relief
9. Control valve
10. Load hold valve check
11. Arm (1)
12. Arm (2)
16. Monitor display
17. Power up
18. Computer A
21. Hydraulic pump
22. Check
23. Oil cooler
24. Cushion valve
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

8020-37
Arm-Out Circuit
9
10
ps1 Pn1 T3 T7 DR1 T1 T2
2
1 Pn2
P3
ps2
pcc
A5 prs2
ARM(2)
pb5' pb9
B5 pb5 pa9
pa5
11
pc3' A8 12
pc3 B8
pbu
pb8
pa8
pb4
pa4
B7
B3
A3 A7
G
pb3 LEFT CLOSE pb7
pa3 RIGHT OPEN pa7
B2 B6
A2 A6
ON
pb2 BACKWARD pb6
pa2 BREAKER
P4 ON
pa6
B1
DR3
2 3 A1
pb1 BACK
-WARD
WARD
pa1 FORWARD
T5
24 T4
34.3MPa at 126L/min
37.3MPa at 108L/min
P1 PT PA PH P2
2
13 14
A C V T E G I Q K M O 4
5 22
B T 6
P T
C1
2-STAGE TRAVEL 19 20
15 23 22
P
C3
CONOMY A1 A2 A3
16
ARM SWING 7 C4 17 18
LEFT RIGHT
3 1
2 4 C2
C5
21
2 3
8
RST-04-04-001p

8020-38
2. Arm-In Forced Regenerative Circuit
By moving the remote control valve to the arm-in side, the pilot pressure oil is fed via the cushion valve to the control
valve Pb5 port and Pb9 port and switches the arm (1) and (2) spools to the in side.
Switching the arm spool lets the oil flow into the arm cylinder bottom side and carries out the arm-in operation.
the spool to the right.
In this way, the load hold valve check valve spring chamber oil is connected to the tank line through the load hold
valve spool, the spring chamber pressure drops, and the load hold valve check valve is opened.
The arm cylinder rod side pressurized oil goes through the load hold valve check valve and the arm (1) spool and is
metered by the forced regeneration release valve.
Through this, the return oil pushes open the check valve in the arm (1) spool and is forcibly regenerated on the cylin-
der bottom side, securing the arm speed for bed excavation work etc.
When the cylinder bottom load pressure becomes high, the forced regeneration release valve is switched to the large
orifice side and the opening becomes larger.
Through this, the check valve in the spool is closed and the cylinder rod side return oil returns to the hydraulic oil tank
via the arm spool (1) and forced regeneration release valve without being regenerated.
1. Load hold valve spool 15. Control valve

2. Load hold valve check 16. Arm cylinder
3. Oil cooler 17. Arm (1)
4. Regeneration check 18. Arm (2)
5. Orifice large 19. Travel pilot pressure sensor
6. Orifice small 20. Upper side pilot pressure sensor
7. Forced regeneration release valve 21. Console lever lock switch
8. Arm (in) 22. Monitor display
9. Arm (out) 23. Power up
10. Cushion valve 24. Computer A
11. Remote control valve (arm, swing) 25. P1 pressure sensor
12. Lever lock 26. P2 pressure sensor
13. Boost relief 27. Hydraulic pump
14. 5-stack solenoid valve 28. Check
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

8020-39
Arm-In Forced Regenerative Circuit
1 2
1 T1 T2
2
Details Pn2
2 P3
ps2
pcc
A5
A5 B5 p
pb9
pb5'
B5 pb9
pb5 pa5
pb5'
pb5 IN pc3' A8
18
B8
pa5 OUT 17
pc3
pbu
4 pb4
M(2)
16 pa4
7 B3
B7
A7
A3
6 pb3 LEFT
G
CLOSE pb7
pa3 OPEN pa7
5
B2 B6
A2 A6
ON
pb2 pb6
BREAKER
P4 ON
pa6
8 9 B1
DR3
pb1 BACK
-WARD
WARD
pa1 FORWARD
T4 T5
34.3MPa at 126L/min
15 37.3MPa at 108L/min
P1 PT PA PH P2
2
19 20
11
28
B T
12
P T C1 2-STAGE TRAVEL 25 26
21 3 28
P
C3 CONOMY A1 A2 A3
22
ARM SWING 13 C4
23 24
LEFT RIGHT
T
4 3 1 C2 C5
2
27
8 9 14
RST-04-04-001q

8020-40
3. Arm-In Load Hold Valve Circuit
When the remote control valve arm operation lever is in neutral, the oil at the arm cylinder rod side is sealed by the
load hold valve check valve, reducing internal leakage from the main spool and reducing the natural drop of the arm.
By moving the remote control valve to the arm-in side, the pilot pressure oil is fed via the cushion valve to the control
valve Pb5 port and Pb9 port and switches the arm (1) and (2) spools to the in side.
Switching the arm spool lets the oil flow into the arm cylinder bottom side and carries out the arm-in operation.
the spool to the right. In this way, the load hold valve check valve spring chamber oil is connected to the tank line
The arm cylinder rod side pressurized oil goes through the load hold valve check valve and the arm (1) spool and
returns to the hydraulic oil tank.
1. Load hold valve spool 13. Arm (1)

2. Load hold valve check 14. Arm (2)
3. Oil cooler 15. Travel pilot pressure sensor
4. Arm (in) 16. Upper side pilot pressure sensor
5. Arm (out) 17. Console lever lock switch
6. Cushion valve 18. Monitor display
7. Remote control valve (arm, swing) 19. Power up
9. Boost relief 21. P1 pressure sensor
10. 5-stack solenoid valve 22. P2 pressure sensor
11. Control valve 23. Hydraulic pump
12. Arm cylinder 24. Check
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

8020-41
Arm-In Load Hold Valve Circuit
1 2
1 T1 T2
2
Details Pn2
2 P3
ps2
pcc
A5
A5 B5
pb5'
pb5' p
pb9
pb9
B5 pa5
pb5'
pb5 IN pc3' A8
14
B8
pa5 OUT 13
pc3
pbu
M(2)
pb4
12 pa4
B7
B3
A3 A7
G
pb3 LEFT CLOSE pb7
pa3 OPEN pa7
B2 B6
A2 A6
ON
pb2 pb6
BREAKER
P4 ON
pa6
4 5 B1
DR3
pb1 BACK
-WARD
WARD
pa1 FORWARD
T4 T5
34.3MPa at 126L/min
11 37.3MPa at 108L/min
P1 PT PA PH P2
2
15 16
7
24
8
B T
P 21
T C1 2-STAGE TRAVEL
22
17 3 24
P
C3 CONOMY A1 A2 A3
18
ARM SWING 9 C4
19 20
LEFT RIGHT
T
4 3 1 C2 C5
2
23
4 5 10
RST-04-04-001r

8020-42
Bucket Circuits
1. Bucket Open Circuit
By moving the remote control valve to the bucket open side, the pilot pressure oil is fed via the cushion valve to the
control valve Pa7 port and switches the bucket spool to the open side.
bucket spool.
Switching the spool lets the oil flow into the bucket cylinder rod side and carries out the bucket open operation.
The bucket cylinder bottom side pressurized oil goes through the spool and returns to the hydraulic oil tank.
1. Cushion valve
2. Bucket (close)
3. Bucket (open)
5. Lever lock
6. Boost relief
8. Control valve
9. Bucket
10. Bucket cylinder
14. Monitor display
15. Power up
16. Computer A
19. Hydraulic pump
20. Check
21. Oil cooler
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

8020-43
Bucket Open Circuit
pa1 pn1 T3 T6 T7 DR1 T1 T2

2
Pn2
P3
ps2
pcc
A5 prs2
B5
ARM(2) pb9
pb5'
pb5 pa9 10
pa5
pc3' A8
pc3 B8
pbu
pb8
pa8
pb4
pa4
B3
B7
A3
pb3
G
CLOSE pb7
p
A7
pa3 OPEN pa7
p
B2 B6
A2 A6
pb2 BACKWARD pb6 9

pa2
P4 ON
FORWARD pa6
1 B1
A1 DR3
2 3 pb1 BACK
-WARD
WARD
B D R F H J S L N U P pa1 FORWARD
T4 T5
P1 PT PA
A P2
2
11 12
A C V T E G I Q K M
O
20
4 5
B T
P T
C1
13 17 18 20
21
P
C3
ECONO A1 A2 A3
BOOM BUCKET
14
6 C4 15 16
DOWN UP
2 4 3 1 SWING BRAKE
C5
C2
19
3 2 7
RST-04-04-001s

8020-44
2. Bucket Close Regenerative Circuit
By moving the remote control valve to the bucket close side, the pilot pressure oil is fed via the cushion valve to the
control valve Pb7 port and switches the bucket spool to the close side.
The discharged oil from hydraulic pump A2 enters the control valve P2 port and is fed from the parallel passage to
the bucket spool. Switching the spool lets the oil flow into the bucket cylinder bottom and carries out the bucket close
operation.
The bucket cylinder rod side oil goes through the bucket spool regeneration orifice. Through this, the return oil pushes
open the check valve in the spool and is regenerated on the cylinder bottom side. The lower the cylinder rod side load
pressure, the greater the quantity of regeneration. When the cylinder rod side load pressure becomes high, the check
valve is closed and the cylinder bottom side return oil goes through the bucket spool without regeneration and returns
to the hydraulic oil tank.
1. Regeneration check
2. Oil cooler
3. Orifice
4. Cushion valve
5. Bucket (close)
6. Bucket (open)
8. Lever lock
9. Boost relief
11. Control valve
12. Bucket
13. Bucket cylinder
17. Monitor display
18. Power up
19. Computer A
22. Hydraulic pump
23. Check
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

8020-45
Bucket Close Regenerative Circuit
11

2
Pn2
P3
ps2
1 pcc
Details A5 39.2MPa at 20L/min prs2

B5
B7 ARM(2) pb9
pb5'
pa9 13
A7
BUCKET pc3' A8
CLOSE pb7 pc3 B8

pbu
pb8
OPEN pa7 pb4

pa8
pa4
B3
B7
A3
A7
p
pb7
pa3 OPEN pa7
3 B2 B6
A2
ION
TRAVE A6
1
12
pb2 BACKWARD pb6
pa2
ON
FORWARD pa6
4 A1 DR3
5 6 pb1 BACK
-WARD
WARD
B D F H J S L N U P
pa1 FORWARD
T4 T5
PH
P1 PT PA P2
14 15
7 23
B T
8
P T C1 2-STAGE TRAVEL
16 20 21 23
2
P
C3
A1 A2 A3
3
BUCKET
17
9
C4
18 19
UP
2 4 C2 SWING BRAKE C5
1
6 22
5 10
RST-04-04-001t

8020-46
Negative Control Circuits
1. Negative Control Circuit (power save solenoid OFF)
When the remote control valve operation lever is set to neutral, the discharged oil from hydraulic pumps A1 and A2
goes from the control valve P1 and P2 ports through the center bypass passage, and through the most downstream
negative control variable relief valve, and returns to the hydraulic oil tank.
The discharged oil from hydraulic pump A3 enters the 5-stack solenoid valve P port, flows through the power save
solenoid valve, is fed to the control valve Pn1 and Pn2 ports, and holds the P1 and P2 negative control relief valves at
the set pressure of 25.5bar / 2.55 MPa / 370Psi.
The negative control pressure oil separated from the center bypass passage is fed from the Ps1 and Ps2 ports to the
hydraulic pump Pi1 and Pi2 ports, moves the pump tilt revolution to the low flow side, and reduces the discharge flow.
1. P1 negative control relief

2. P2 negative control relief
3. Control valve
6. Computer A
8. Lever lock
9. Power save
15. Horsepower control proportional valve
17. Hydraulic pump
18. Check
19. Oil cooler
Legend
Pressure Line
Tank line
Negative control line
Pilot pressure line
Pilot tank line
Electric Line

8020-47
Negative Control Circuit (power save solenoid OFF)
1 2
2
Pn2 7
P3
8
ps2
p
B T
pcc
C1 2-STAGE TRAVEL
A5 39.2MPa at 20L/min
B5
ARM(2) pb9
pb5'
pa5 P
C3
2-STAGE RELIE 9
pc3'
pc3
A8
B8
3
pbu C4
WN
UP
18
pb4 C5
C2 SWING BRAKE
pa4
min B7
B3
A7
A3
pb3 LEFT CLOSE pb7 10 19 18

pa3 OPEN pa7
B2 B6
A2 A6
pb2 pb6
pa2
P4 ON
pa6
B1
DR3
12
pb1 BACK
-WARD
WARD A1 Psv a4 A2
pa1 FORWARD 11 13 14
T5
a1
T4 (FRONT) (REAR)
34.3MPa at 126L/min
37.3MPa at 108L/min
PH
P1 PT P2
Pi1 a7 a8 Pi2
4 5
Servo piston Servo piston

6
High Low Low High
P1 Flow Flow P2
M
Dr
16 B1
a3
A3
17 B3
RST-04-04-001u

8020-48
2. Negative Control Power save Circuit (power save solenoid ON)
The purpose of this control is to reduce fuel consumption during standby by reducing the back pressure for the nega-
tive control signal.
When the remote control valve is set to neutral, the non-operation state signal enters the computer A from the upper
side pilot pressure sensor and the travel pilot pressure sensor installed on the control valve PT port and PA port. After
about one second, the power save solenoid valve is switched ON by the signal output from the computer A.
The pressurized oil from the control valve negative control relief valve Pn1 and Pn2 ports goes through the power
save solenoid valve and returns to the hydraulic oil tank.
Therefore, the negative control relief valve set pressure is switched to low pressure to further reduce the A1 and S2
pump discharge pressure.
With the system running this way, the negative control signal is cut off and the P1 and P2 pump discharged volume
quantity increases.
The discharged oil from pilot pump A3 enters the 5-stack solenoid valve P port, flows through the power save solenoid
valve, is fed to the hydraulic pump P2 port from the C5 port, moves the pump tilt revolution to the minimum flow side,
and reduces the discharge flow.
At the same time, the discharged oil from the A3 pilot pump is fed to the hydraulic pump P1 port by the signal from the
computer A to the hydraulic pump P1 flow restriction proportional valve, moves the A1 side pump tilt revolution to the
minimum flow side, and reduces the discharge flow.
1. Control valve
4. Computer A
6. Lever lock
7. Power save
13. Horsepower control proportional valveor
15. Hydraulic pump
16. Check
17. Oil cooler
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

8020-49
Negative Control Power Save Circuit (power save solenoid ON)

2
Pn2 5
P3
6
p
ps2
B T
pcc
C1
A5 39.2MPa at 20L/min prs2
B5
ARM(2)
pb5'
pb5 OUT
pa5 P
C3
2-STAGE RELIEF 7
pc3'
pc3
A8
B8
1
pbu C4
UP
pb8
pa8
16
pb4
C2 SWING BRAKE C5
pa4
B7
B3
A3 A7
pb3 LEFT CLOSE pb7 8 17 16

pa3 OPEN pa7
B2 B6
A2 TRAVEL(R) A6
pb6
pa2
pa6
B1
A1 DR3
AVEL(L)
pb1 BACK
-WARD
WARD A1 Psv a4 A2
pa1 FORWARD 9 12
10 a1 a2
11
T4 T5
(FRONT) (REAR)
37.3MPa at 108L/min
PH
P1 PT P2
Pi1 a7 3 a8 Pi2
2 3
4
Low flow Low flow
P1 P2
M
Dr
14 B1
a3
A3
15 B3
RST-04-04-001v

8020-50
3. Negative Control Circuit (bucket close, power save solenoid OFF)
As an example, this section explains the bucket close operations.

The discharged oil from the hydraulic pump A2 enters the control valve P2 port, is fed to the bucket spool, flows into
the bucket cylinder bottom side because of the spool switching and carries out the bucket close operation.
At the same time, the upper side pilot pressure sensor signal is detected and through the signal output from the com-
puter A to switch OFF the power save solenoid valve, pilot pressure enters the negative control relief valve, and the
pressure becomes the set 25.5 bar / 2.55 MPa / 370 Psi pressure.
Because the bucket spool switches and the pressurized oil on the center bypass is cut off, the Pi2 pump negative con-
trol pressure oil from the Ps2 port is eliminated, the pump revolution tilt moves to the increase side, and the flow is
increased.
Also, the command current to the pump P1 flow control proportional valve is lowered and the pressurized oil from the
A3 hydraulic pump is cut off, but the negative control pressure is fed from the control valve Ps1 port to the Pi1 port to
reduce the A1 hydraulic pump discharged volume quantity.
1. Control valve
4. Cushion valve
5. Bucket (close)
6. Bucket (open)
7. Bucket cylindeR
8. Computer A
11. Lever lock
12. Power save
19. Hydraulic pump
20. Check
21. Oil cooler
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

8020-51
Negative Control Circuit (bucket close, power save solenoid OFF)

2
Pn2
P3 11 10
ps2
pcc B T
A5 39.2MPa at 20L/min prs2 C1 2-STAGE TRAVEL
B5
ARM(2) pb9
pb5'
pb5 OUT pa9 7
pa5
P
pc3' A8
C3
2-STAGE RELIEF
12
pc3 B8
pbu
UP
pb8
pa8
C4 20
pb4
pa4 C2 C5
B3
B7
A3
pb3 LEFT CLOSE

A7 21 20
pa3 RIGHT OPEN pa7 13
B2 B6
A2 TRAVEL(R) A6
pb6
pa2
pa6
B1
A1 DR3
AVEL(L)
pb1 BACK
A1 Psv a4 A2
-WARD
WARD
15
pa1 FORWARD
14 17
T4 T5
a1 a2
MAIN RELIEF V. 8 (FRONT) (REAR)
37.3MPa at 108L/min
PH
16
P1 PT P2
2 3 Pi1 a7 a8 Pi2
1
Servo piston
Low flow High flow

4 9 P1 P2
5 6 M
P T
Dr
B D R F H J S L N U P 18 B1
a3
A3
BUCKET 19
B3
DOWN
A C V T E G I Q K M O 2 4 3
1
6
5 RST-04-04-001w

8020-52
Increased Horsepower Circuits
1. Arm-In Increased Horsepower Circuit
For the arm-in operation, the increased horsepower signal is output to the hydraulic pump horsepower control propor-
tional valve from the computer A by the arm pilot pressure sensor input signal and P1 pressure sensor and P2 pres-
sure sensor input signals.
The hydraulic pump discharged volume quantity is increased by the increased horsepower signal to the horsepower
control proportional valve from the computer A.
1) Conditions under which the arm-in increased horsepower control is entered
• Arm-in pilot pressure 5 bar / 0.5 MPa / 72.5 Psi or higher (arm-in operation)
• P1 + P2 ≥ 450 bar / 45 MPa / 6530 Psi
2) Conditions under which the arm-in increased horsepower control is ended
• Arm-in pilot pressure 3bar / 0.3 MPa / 43.5 Psi or lower (arm-in operation end)
• P1 + P2 ≤ 450 bar / 45 MPa / 6530 Psi
When either occurs.
1. Arm (in) 13. Travel pilot pressure sensor

2. Arm (out) 14. Upper side pilot pressure sensor
4. Remote control valve (arm, swing) 16. Monitor display
6. Boost relief 18. N1 negative control pressure sensor
8. Arm cylinder 20. P2 pressure sensor
9. Arm pilot pressure sensor 21. N2 negative control pressure sensor
11. Arm (1) 23. Check
12. Arm (2) 24. Oil cooler
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

8020-53
Arm-in Increased Horsepower Circuits
10
T3 T6 T7 DR1
1 T1 T2
2
8 ps1 Pn1
Pn2
P3
ps2
11 pcc
A5 prs2
B5
1 2 pb5'
p
pb9
pb9
pb5
9
A8
1
12
B8
pb8
pa8
pb4
pa4
B7
B3
A3 A7
pa3 OPEN pa7
B2 B6
3 A2
TION
TRAVE A6
4 pa2
BACKWARD pb6
P4
P T pa6
23
A1 DR3
pb1 BACK
-WARD
WARD
pa1 FORWARD 24 23
T4 T5
ARM
2 4 3 1 P1 PT PA PH P2
13 14
1 2
P1 Psv P2
5
a4
20
B T
19 21
C1 2-STAGE TRAVEL a1 a2
(FRONT) (REAR)
15
P 18
C3 Pi1 a7 a8 Pi2
16
C4
17
6 C5
C2 SWING BRAK P2
High flow
7 P1 High flow A3
M a3
Dr
22
B1
RST-04-04-001x

8020-54
2. Travel Increased Horsepower Circuit
For travel single operation, the increased horsepower signal is output to the hydraulic pump horsepower control pro-
portional valve from the computer A by the travel pilot pressure sensor input signal.
The hydraulic pump discharged volume quantity is increased by the increased horsepower signal to the horsepower
control proportional valve from the computer A.
1) Conditions under which the travel increased horsepower control is entered
• Travel pilot pressure 5 bar / 0.5 MPa / 72.5 Psi or higher.
• SP mode
2) Conditions under which the travel increased horsepower control is ended
• Travel pilot pressure 3bar / 0.3 MPa / 43.5 Psi or lower.
• AUTO mode, H mode
1. Travel motor
3. Travel speed
4. Lever lock
8. Computer A
9. Control valve
10. Travel (right)
11. Travel (left)
17. Hydraulic pump
18. Check
19. Oil cooler
20. Backward left
21. Forward left
22. Forward right
23. Backward right
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

8020-55
Travel Increased Horsepower Circuit

2
Pn2
P3
9 ps2
pcc
A5 prs2
Pm1 Ps Ps
s Pm2
B5
ARM(2) b9
pb5'
a9
pa5
T1 8
8
P2 b8
RED
pa8
pb4
P1
pa4
B7
B3
A3 A7
Pm2 Pm1 pb3 CLOSE pb7

pa3 OPEN pa7
B2 B6
A2
A6
20 21 22 23 pb2
BREAKER
BACKWARD pb6
P4 ON 1
11
TRAVEL(L) TRAVEL(R)
1 B1
FORWARD
pa6
A1 pb1 BACK DR3
-WARD
WARD
pa1
T4 T5
2 10
P1 PT P2
1 T 3
P 2 4 12
Psv
P1 a4 P2
14
13 16
3 4 6 a1 a2
B T (FRONT) (REAR) 18
C1
15
P Pi1 a7 a8 Pi2 19 18
C3
ECONOMY
C4
7 P2
C5
C2 SWING BRAKE High flow
5 8 P1 High flow A3
M a3
Dr
17 B1
RST-04-04-001y

8020-56
Other Circuits
1. Cushion Circuit
As examples, this section explains the cases when an arm-out operation is carried out, when an arm-out operation is
stopped, and when an arm-out operation is followed by an arm-in operation.
(1) Arm-out operation
When a remote control valve arm-out operation is carried out, the pilot pressure oil enters from the remote control
valve 2 port into the cushion valve, pushes up the internal check valve, and is fed to the control valve Pa5 port and
Pa9 port.
At the same time, the cushion valve cushion spool is switched to the left.
The arm-in side oil pushed out from the control valve Pa9 and Pb 5 ports passes from the cushion valve B port
through the cushion spool switched to the left and returns to the hydraulic oil tank.
At this time, the warmed oil from the return line enters the remote control valve through the cushion spool from the
cushion valve R port and returns to the hydraulic oil tank, so heat performance is improved.
1. Arm (in)
2. Arm (out)
3. Cushion spool
4. Orifice
5. Check valve
6. Cushion valve
8. Lever lock
10. Control valve
11. Arm (1)
12. Arm (2)
14. Hydraulic pump
15. Check
16. Oil cooler
17. Shut off valve
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line
Cushion line

8020-57
Cushion Circuit (arm-out operation)
10
p
ps1 Pn1 T8 T3 T6 T7 DR1 T1 T2
Pn2
P3
ps2
11 prs1
A5
B5
B
39 2MPa at 20L/min
12
pb5' ARM(2) pb9
pb5
pa9
pc3' A8
pc3 B8
pbu
pb8
UP pa8
pb4
pa4
B7
B3
A3 A7
pb3 CLOSE pb7

pa3 OPEN pa7
B2 B6
A2 TRAVEL( A6
ON
pb2 BACKWARD pb6
pa2
ON
FORWARD pa6
B1
1 2 6 17 A1 DR3
pb1 BACK
4 -WARD
3 pa1 FORWARD
DR4
DR2
T4
4 T5
37.3MPa at 108L/min
PT PA PH
P1 P2
5
15
B T
8
13
7 16 15
P
C3 2-STAGE RELIEF
A1 A2 A3
ARM SWING C4
LEFT RIGHT
C5
2 4 3 1 C2
9
14
1 2
RST-04-04-001z

8020-58
(2) When arm-out operation stopped
When the remote control valve arm-out operation lever is returned to neutral, the oil pushed out from the control valve
Pa5 and Pa9 ports flows to the cushion valve D port through the cushion orifice and returns from the remote control
valve to the hydraulic oil tank.
Through this orifice, the arm spool moves to the neutral position without returning suddenly, so the cushioning is
improved.
1. Arm (in)
2. Arm (out)
3. Cushion spool
4. Orifice
5. Cushion valve
7. Lever lock
9. Control valve
10. Arm (1)
11. Arm (2)
13. Hydraulic pump
14. Check
15. Oil cooler
16. Shut off valve
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line
Cushion line

8020-59
Cushion Circuit (arm-out operation stopped)
9
p
Pn2
P3
ps2
10 prs1
A5
B5
39 2MPa at 20L/min
1
11
ARM(2) 9
pb5'
IN
a9
pc3' A8
B8
pb8
UP pa8
pb4
pa4
B7
B3
A3 A7
pb3 pb7
pa3 pa7
B2 B6
A2 TRAVEL(R A6
N
BACKWARD pb6
pa2
FORWARD pa6
B1
1 2 5 16 A1 DR3
pb1 BACK
4 -WARD
3 pa1
DR4
DR2
T4
4 T5
37.3MPa at 108L/min
PT PA PH
P1 P2
T E G I Q K M O
A C V
14
B T
7
12
6 15 14
P
C3 2-STAGE RELIEF
ONOMY A1 A2 A3
ARM SWING C4
LEFT RIGHT
C5
2 4 3 1 C2
8
13
2
1 RST-04-04-001aa

8020-60
(3) Arm-out => Arm-in operation
When the lever is operating all at once from an arm-out operation to an arm-in operation (arm drift operation), the pilot
pressure oil is fed from the remote control valve 4 port into the cushion valve A port, pushes up the internal check
valve, and reaches the control valve Pb5 port and Pb9 port.
At the same time, the cushion valve cushion spool is switched to the right.
At this time, the oil pushed out from the Pa5 port and Pa9 port does not pass through the cushion orifice, but passes
through the cushion spool that has been switched to the right and returns to the hydraulic oil tank, so response is
improved.
1. Arm (in)
2. Arm (out)
3. Cushion spool
4. Orifice
5. Cushion valve
7. Lever lock
9. Control valve
10. Arm (1
11. Arm (2)
13. Hydraulic pump
14. Check
15. Oil cooler
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

8020-61
Cushion Circuit (arm-out => arm-in operation)
9
p
Pn2
P3
ps2
10 A5 39 2MPa at 20L/min
prs1
B5
B
pb9
1
11
pb5' ARM(2)
pb5
pa9
pc3' A8
pc3 B8
pbu
pb8
UP pa8
pb4
pa4
B7
B3
A3 A7
pb3 CLOSE pb7

pa3 OPEN pa7
B2 B6
A2 TRAVEL( A6
N
pb2 BACKWARD pb6
pa2
ON
FORWARD pa6
B1
1 2 5
A1 DR3
pb1 BACK
4 -WARD
3 pa1 FORWARD
DR4
DR2
T4
4 T5
37.3MPa at 108L/min
PT PH
P1 PA
P2
C E G I Q K M O
A V T
14
7
B T
12
6 15 14
P
C3 2-STAGE RELIEF
A1 A2 A3
ARM SWING C4
LEFT RIGHT
C5
2 4 3 1 C2
8
13
1
2
RST-04-04-001ab

8020-62
2. Heat Circuit (lever in neutral)
The pilot line is equipped with a heat circuit to prevent response delay at low temperatures.
When the remote control valve operation lever is set to neutral, the discharged oil from hydraulic pumps A1 and A2
goes from the control valve P1 and P2 ports through the center bypass passage, and returns to the hydraulic oil tank.
The pressurized oil from the control valve T8 port is fed to the cushion valve R port and returns through the cushion
spool to the hydraulic oil tank.
By circulating the oil inside the cushion spool, the temperature of the oil in the cushion valve is raised to improve heat
performance.
1. Arm (in)
2. Arm (out)
3. Cushion valve
5. Lever lock
7. Control valve
9. Hydraulic pump
10. Check
11. Oil cooler
Legend
Pressure Line
Tank line
Cushion line

8020-63
Heat Circuit (lever in neutral)
7
p
Pn2
P3
ps2
pcc
prs1
A5 39.2MPa at 20L/min prs2
B5
ARM(2) b9
pb5'
a9
pc3' 8
pc3 8
pbu
b8
pa8
pb4
pa4
B7
B3
A3 A7
CLOSE pb7
pa3 OPEN pa7
B2 B6
A2 TRAVEL( A6
ON
pb2 BACKWARD pb6
pa2
ON
FORWARD pa6
1 2 3 A1 DR3
pb1 BACK
-WARD
pa1 FORWARD
DR4
DR2
T4
4 T5
P1 PT PA PH P2
A C V
T E G I Q K M O
10
11 10
5
B T
2-STAGE TRAVEL
8
P T C1
4 A1 A2 A3
C3 2-STAGE RELIEF
ARM SWING C4 9
LEFT RIGHT
C5
2 4 3 1 C2
1 2
RST-04-04-001ac

8020-64
3. Auto Power Boost Circuit (bucket close)
When an attachment is operated, this circuit boosts the control valve main relief pressure from 343 bar / 34.3 MPa /
4977Psi to 368 bar / 36.8 MPa / 5340 Psi according to the engine load ratio and hydraulic load pressure, then ends
the pressure boost after 8 seconds.
As an example, this section explains bucket close operations.
At the same time, the pressurized oil separated from the pilot internal passage is detected and the upper side pilot
pressure sensor output signal is input to the computer A, which judges that there is upper side operation. Further-
more, the computer A judges that there is a boost in the main pump P1 and P2 pressure, outputs the ON (24 V) signal
to the boost relief solenoid, and switches the valve, and the pilot pressure oil is fed to the control valve main relief
valve PH port to hold the boost relief set pressure for 8 seconds.
The option circuit is not boosted during a travel operation.
1. Cushion valve 11. Upper side pilot pressure sensor

2. Bucket (close) 12. Console lever lock switch)
3. Bucket (open) 13. Power up
4. Remote control valve (boom, bucket) 14. Monitor display
6. Boost relief 16. P1 pressure sensor
9. Bucket 19. Check
10. Bucket cylinder 20. Oil cooler
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

8020-65
Auto Power Boost Circuit (bucket close)

Pn2
P3
ps2
pcc
A5 prs2
B5 ARM(2
pb5' pb9
pa9
10
A8
B8
pb8
pa8
pb4
pa4
B3
B7
pb3 CLOSE A7
pa3
3
pb7
pa7
B2 B6
A2 A6
pb2 BACKWARD pb6
BREAKER
P4 ON
FORWARD pa6
9
B1
DR3
1 2 3 pb1 BACK
-WARD
WARD
pa1 FORWARD
T4 T5
P1
PA PH P2
11
A C V E G I Q K M O
4 5 19
B T
12
16 17 20 19
P
C3
14 A1 A2 A3
6 13 15
BOOM BUCKET C4
LEFT RIGHT
C5
2 4 3 1 C2
3 2 18
7
RST-04-04-001ad

8020-66
Option Circuits
1. Breaker Circuit (single operation)
By operating the option remote control valve to the breaker side, the pilot pressure oil is fed to the control valve Pa2
port and switches the option spool.
The discharged oil from hydraulic pump A1 is fed from the control valve P1 port through the parallel passage and fed
to the option spool. Switching the spool lets the oil flow from the relief valve A port through the B port and into the
breaker.
The breaker set pressure is set by this relief valve.
At this time, the option pilot pressure sensor signal is detected, the pump P1 flow control proportional valve is control-
led by the output signals from the computer A to adjust the discharge flow.
The return oil from the breaker goes through the manifold and returns to the hydraulic oil tank.
Because the breaker usage flow can be set to five levels on the service support screen of the monitor display with the
ON signal from the breaker switch in the cab, the optimum usage flow can be selected.
1. Control valve
2. Manifold
3. Relief valve
4. Breaker
7. Computer A
8. Monitor display
9. Breaker switch
10. Option remote control valve
11. Option pilot pressure switch
13. Lever lock
14. 5 stack solenoid valve
20. Hydraulic pump
21. Check
22. Oil cooler
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

8020-67
Breaker Circuit (single operation)
1
Pn2
10
P3
ps2 12
pcc
A5 39 2MPa at 20L/min s2
B5 OPTION
ARM(2) 9
pb5'
9
pa5 Breaker
ON
A8
13
2 pbu
B8
B T
pb8
pa8 C1
2-STAGE TRAVEL
21
pb4
pa4
C1 C2
B7
B3
A3 A7
B P T A P 22 21
CLOSE pb7
pa3 OPEN pa7 11 C3
2-STAGE RELIEF
ECONOMY
B2 B6
A2 TRAVEL( A6 C4
ON
B A BACKWARD pb6
pa2
T C2
C5
FORWARD pa6
A1 DR3
pb1 BACK
-WARD
WARD
3 14
pa1
4 T4 T5
P1 PT
PA PH
P2 16
15
5 6 17 18
(FRONT) (REAR)
8
Flow
Reduce
9 M
19 Dr
B1 20
a3
B3
RST-04-05-001a

8020-68
2. Shuttle Circuit (hydraulic fork)
As an example, this section explains the case in which the hydraulic fork attachment is used.
By operating the option remote control valve to the fork close side, the pilot pressure oil is fed to the control valve Pa2
port and switches the option spool to the close side.
option spool, flows into the hydraulic fork because of the option spool switching and operates to the close side.
The return oil from the hydraulic fork goes through the option spool and returns to the hydraulic oil tank.
1. Control valve
2. Hydraulic fork
5. Monitor display
6. Computer A
7. Lever lock
10. Hydraulic pump
13. Check
14. Oil cooler
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

8020-69
Shuttle Circuit (hydraulic fork)
1
2
Pn2
P3
ps2
2.55MPa at 50L/min
pcc
A5
B5
ARM(2) pb9
pb5'
pa5
pc3' A8
pc3 B8
pbu
WN
UP
pb4
pa4 11
min B7
B3 A7
A3
LEFT
pa3
3 OPEN pa7
B2 OPTION
2 A2 TRAVEL(R)
B6
A6
p
pb2 BACKWARD pb6
Fork Fork
p
pa2
P4 ON
O close open
pa6
A1 DR3
pb1 BACK
-WARD
WARD
pa1 FORWARD
C1 C2
T4 T5
B P T A
34.3MPa at 126L/min
37.3MPa at 108L/min
P1 PT PA PH P2
3 4 12
6 13
B
7
T
9
C1 2-STAGE TRAVEL
14 13
P
2-STAGE RE
C3
A1 A2 A3
C4
C5
C2 SWING BRAKE
10
8
RST-04-05-001b

8020-70
3. Combined Circuit
(1) Breaker Q control
When the switch in the cab is flipped to the breaker side, the ON signal (24 V) is output from the computer A to the
option switch solenoid valve to switch the valve.
The pilot pressure oil flows from the option switch solenoid valve B1 port to the A1 port and is fed to the 3-direction
valve PP port and shut-off valve PP port and each valve is switched.
Always switch the 2-speed select switch to the 1-speed side.
By operating the option remote control valve to the breaker side, the pilot pressure oil is fed to the control valve Pa2
to the option spool. Switching the spool lets the oil flow from the shut-off valve A port through the B port and into the
breaker.
The breaker set pressure is set by the relief valve into the shut-off valve.
The return oil from the breaker returns from the 3-direction valve A1 port through the T1 port and to the hydraulic oil
tank.
Because the breaker usage flow can be set to five levels on the service support screen of the monitor display, the opti-
mum usage flow can be selected.
1. Control valve
2. 3-direction valve
3. Shut-off valve
4. Breaker
7. Compatible circuit switch
8. Computer A
9. Monitor display
10. Option switchover solenoid valve
12. Lever lock
14. Horsepower control proportional valve
20. Hydraulic pump
21. Check
22. Oil cooler
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

8020-71
Combined Circuit (breaker Q control)
11
10 13
1 B1
12
2 PP
A1
Pn2 B T
P3 B2 2-STAGE TRAVEL
C1
ps2
A
A2
A5 t 20L/min
P
B5
21
ARM(2)
ARM 2-STAGE RELIEF
C3
pb5 OUT pa9 ONOMY
pa5
C4
22 21
pc3' 39.2MPa at 20L/min A8
pc3 B8 SWING BRA C5
C2
A pbu
B
DR UP
pb4
pa4
4 T
B3 39.2M B7
A3 A7
3 PP CLOSE
pa3 OPEN pa7
B2
A2 VEL(R)
B6
A6
14 16
pb2 pb6 15 A1
pa2
P4 ON 17
pa6
18
a1 a2
5 B1
A1 DR3
(FRONT) (REAR)
OPTION pb1 BACK

-WARD
WARD
Breaker pa1 FORWARD

Pi1 a7 a8 Pi2
ON
T4 T5
RELIEF V.
a at 126L/min
37.3MPa at 108L/min
P1 PT
PA PH P2
Flow
Reduce
C1 C2
P1 P2
B P T A M
19 Dr
B1 20
a3
7 9
A3
6 8
B3
RST-04-05-001c

8020-72
(2) 2nd confluence crusher
When the 2nd speed marge select switch in the cab is flipped to the 2nd speed merge side, the ON signal (24 V) is
output from the computer A to the 2nd speed merge solenoid valve to switch the valve.
When the compatible circuit switch is flipped to the pulverizer side, the pulverizer circuit is formed without outputting a
signal from the computer A to the option switch solenoid valve and without switching the valve.
At this time, the pilot signal does not go to the 3-direction valve or to the shut-off valve and the 3-direction valve forms
the A <=> B circuit.
By operating the option remote control valve to the pulverizer side, the pilot pressure oil is fed to the control valve Pa2
At the same time, the pilot pressure oil flows from the 2nd speed merge solenoid valve B2 port to the A2 port and is
fed to the control valve Pcc port and the control valve neutral cut valve is switched.
The discharged oil from hydraulic pump A2 enters the control valve P2 port and goes through the center bypass pas-
sage and since the neutral cut valve has cut the port to the tank, the oil goes from the P3 port via the P4 port and
merges on the upstream side of the option spool.
to the option spool. Switching the spool lets the oil flow from the shut-off valve A port through the B port and into the
pulverizer.
The return oil from the pulverizer returns from the 3-derection valve A port through the B port and the option spool
and returns to the hydraulic oil tank.
Because the pulverizer usage flow can be set to five levels on the service support screen of the monitor display, the
optimum usage flow can be selected.
1. 3-direction valve 15. Neutral cut valve

2. Shut-off valve 16. Travel pilot pressure sensor
3. Pulverizer 17. Upper side pilot pressure sensor
4. Option switchover solenoid valve 18. Lever lock
5. 2-way merge solenoid valve 19. 5-stack solenoid valve
6. Option remote control valve 20. Console lever lock switch
7. Check 21. Horsepower control proportional valve
8. Oil cooler 22. P1 pressure sensor
9. Option pilot pressure switch 23. P2 pressure sensor
10. Monitor display 24. N1 negative control pressure sensor
11. computer A 25. N2 negative control pressure sensor
12. Compatible circuit switch 26. P1 flow control proportional valve
13. 2nd speed merge select switch 27. Hydraulic pump
14. Control valve
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

8020-73
Combined Circuit (2nd confluence crusher)
14 15
1 Pn2
P3
ps2
PP
pcc
T1 A5 prs2
T2
A B
B5
ARM(2) pb9
pb5'
pa9
DR
2 pc3' A8
pc3 B8
pb8
A UP pa8
B pb4
DR
3 pa4
B7
7
B3
A3 A7
T
CLOSE pb7
pa3 OPEN pa7
P 8 7
B2 B6
A2 A6
PTION
BACKWARD pb6
p 2
pa2
ON
FORWARD pa6
A1 DR3
pb1 BACK
-WARD
WARD
pa1 FORWAR
4 T4 T5
B1
A1 P1 PT
PA PH
P2
B2
16 17 21
23
A1 Psv a4 A2
A2
5 10 25
24 22
6 (FRONT)
a1 a2
(REAR)
11
a7
OPTION 18 20
Pi1 a8 Pi2
Pulverizer Pulverizer
close open B T
2-STAGE TRAVEL
C1
Flow
P P1 P2
2-STAGE RELIEF
M
C3
ONOMY Dr
C2 26 B1 27
C4
B T A a3
12 13 C2
C5
A3
9 B3
19
RST-04-05-001d

8020-74
4. Second Option Circuit (hydraulic rotation fork)
As an example, this section explains the case in which the hydraulic rotation fork attachment is used.
By operating the 2nd option remote control valve to the right swing side, the pilot pressure oil is fed to the control valve
Par2 port.
The 4th hydraulic pump OUT discharged oil is fed to the control valve Pr port, goes through the 2nd option spool and
flows to the hydraulic rotation fork to operate to the right swing side.
The return oil from the hydraulic rotation fork goes through the 2nd option spool and returns to the hydraulic oil tank.
The oil in the 2nd option drain line returns to the hydraulic oil tank without going through the control valve.
1. Control valve
4. Lever lock
7. 2nd option remote control valve
8. Check
9. Oil cooler
10. Hydraulic rotation fork
11. 2nd option pilot pressure switch
12. Monitor display
13. Computer A
14. 4th pump
15. Hydraulic pump
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

8020-75
Second Option Circuit (hydraulic rotation fork)
Tr1
BR2
10
AR2
pbr2
1 p
par2
T Pr 7
ps1 Pn1 T3 T6 T7 DR1 T1 T2 MPa at 67L/min
Pn2
P3
ps2 SECOND OPTION
pcc
A5 L/min
Swing Swing
right left
B5
ARM(2)
pb5'
pa5
pc3' A8
pc3 B8
pbu
pb8 C1
pa8
pb4 B P T A
pa4
B3
B7
A3 A7
pa3
3 RIGHT OPEN pa7 11
12
B2 B6
A2 A6
pb2 BACKWARD pb6
pa2
P4
pa6
B1
A1 DR3
pb1 BACK
-WARD
WARD
13
pa1 FORWARD
T4 T5
P1 PH P2
2 3
8
B T
4
C1 2-STAGE TRAVEL 6
9 8
P
C3
2-STAGE RELIEF 14
A1 A2 A3 OUT
C4
C5
C2 SWING BRAKE
15
5
RST-04-05-001e

8020-76
NOTES
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Section
8030
HYDRAULIC COMPONENT FUNCTIONS
8030

CNH Lep SC210B8030-0NA
Printed in USA.
March 2007
8030-2
TABLE OF CONTENTS
HYDRAULIC PUMP ................................................................................................................................................. 3
Hydraulic Pump................................................................................................................................................ 3
Regulator ......................................................................................................................................................... 6
Gear Pump..................................................................................................................................................... 14
MOTOR .................................................................................................................................................................. 16
Travel Motor................................................................................................................................................... 16
Swing Motor ................................................................................................................................................... 36
VALVE .................................................................................................................................................................... 48
Control Valve ................................................................................................................................................. 48
5 Stack Solenoid Valve Operation Explanation ............................................................................................. 81
Upper Pilot Valve (remote control valve) ....................................................................................................... 83
Travel Pilot Valve (remote control valve) ....................................................................................................... 88
Cushion valve ................................................................................................................................................ 93
Selector Valve (4 - Way) ................................................................................................................................ 97
Selector Valve (3-direction valve) ................................................................................................................ 101

8030-3
HYDRAULIC PUMP
1. Hydraulic Pump
1) Explanation of structures and operations
This pump has a structure with two pumps positioned on the same shaft coupled with the 1st
gear (116) and rotation force is distributed to different shafts by the gear structure. The two
pumps are driven by transmitting the rotation of the power source to the front side drive shaft
(111). Auxiliary pumps installed on different shafts can also be driven at the same time.
The pump can be roughly divided into the rotary group, which is the main part of the pump
rotating, the swash plate group, which changes the discharge flow, the valve block group, which
switches between oil suction and discharge, and the PTO group that transmits the gear pump
drive shaft.
The rotary group is made up of drive shaft F (111), cylinder block (141), piston shoes (151, 152),
retainer plate (153), sphere bushing (156), and cylinder spring (157). The drive shaft is
supported at both ends with bearings (123, 124). The shoe is caulked to the piston and forms
the spherical joint, reduces the thrust force generated by the load pressure, and has a pocket
section for balancing the hydraulic pressure for sliding lightly on the shoe plate (211). The piston
shoe sub-group is pressed against the shoe plate by the cylinder spring via the retainer plate
and spherical bushing so that it can slide smoothly on the shoe plate. Also, in the same way the
cylinder block is pressed against the valve plate (313) by the cylinder spring.
The swash plate group comprises the swash plate (212), shoe plate (211), swash plate support
base (251), tilt revolution bushing (214), tilt revolution pin (531), and servo piston (532). The
swash plate is supported by the swash plate support base at the cylindrically shaped section
formed by the opposite side of the shoe slide plate. By leading the hydraulic pressure force
controlled by the regulator into the hydraulic pressure chambers on both sides of the servo
position, the servo piston moves left and right. This moves the swash plate back and forth on
the swash plate support base via the tilt revolution pin spherical section and changes the tilt
revolution angle (α).
he valve block group comprises the valve block (312), valve plate (313), and valve plate pin
(885). The valve plate, which has two hook-shaped ports, is installed on the valve block. Its
function is to feed oil to the cylinder block and recover it from the cylinder block. The oil
switched by the valve plate is connected through the valve block to the outside pipes.
Now when the drive shaft is driven by the power source (motor, engine, etc.), the cylinder block
is also rotated at the same time via the spline coupling. When the swash plate tilts, the piston
located at the center of the cylinder block moves reciprocally relative to the cylinder while
turning with the cylinder block. Therefore, looking at one piston, while the cylinder block turns
one rotation, the piston moves away from the valve plate (oil intake stroke) for 180 °C of the
cylinder block rotation, then moves toward the valve plate (oil discharge stroke) for the
remaining 180 °C When the swash plate tilt revolution angle is 0, the piston does not move
through a stroke and oil is not discharged.

8030-4
1) Hydraulic pump internal structure diagram
1 Right rotation valve plate

2 Left rotation valve plate
Code PART NAME QTY COUNSTITUENT PART(QTY)

04 Gear pump 1 set ZX10LBRZ1-07A-V
011 Piston, sub 2 set 151 (9PC), 152 (9PC)
013 Cylinder, sub (R) 1 set 141 (1PC), 313 (1PC)
014 Cylinder, sub (L) 1 set 141 (1PC), 314 (1PC)
030 Swash plate, sub 2 set 212 (1PC), 214 (1PC)
041 Check valve 1, sub 2 set 541 (1PC), 543 (1PC), 545 (1PC)
042 Check valve 2, sub 2 set 541 (1PC), 544 (1PC), 545 (1PC)
079 Electromagnetic proportional pressure reduction valve, gauging, sub 1 set KDRDE5KR-V3-V
530 Tilt revolution pin, sub 2 set 531 (1PC), 548 (1PC)
Code PART NAME QTY Code PART NAME QTY

111 Drive shaft (F) 1 532 Servo piston 2
113 Drive shaft (R) 1 534 Stopper (L) 2
116 1st gear 1 535 Stopper (S) 2
123 Cylinder roller bearing 2 541 Seat 4
124 Needle roller bearing 2 543 Stopper 1 2
127 Bearing spacer 4 544 Stopper 2 2
141 Cylinder block 2 545 Steel ball 4
151 Piston 18 548 Feedback pin 2
152 Shoe 18 702 O-ring 2
153 Retainer plate 2 710 O-ring 2
156 Spherical bushing 2 717 O-ring 4
157 Cylinder spring 18 724 O-ring 16
211 Shoe plate 2 725 O-ring 6
212 Swash plate 2 726 O-ring 2
214 Tilt revolution bushing 2 728 O-ring 4
251 Swash plate support base 2 732 O-ring 2
261 Seal cover (F) 1 774 Oil seal 1
271 Pump casing 2 789 Backup ring 2
312 Valve block 1 792 Backup ring 2
313 Valve plate (R) 1 806 Hexagon nut 2
314 Valve plate (L) 1 808 Hexagon nut 2
326 Cover 1 824 Stop ring 2
401 Hexagon socket head 8 885 Valve plate pin 2
406 Hexagon socket head 4 886 Spring pin 4
414 Hexagon socket head 4 901 Eye bolt 2
466 VP plug 2 953 Hexagon socket head stop screw 2
467 VP plug 2 954 Stop screw 2
468 VP plug 4 981 Nameplate 1
490 Insert plug 27 983 Strike rivet 2
531 Tilt revolution pin 2

8030-5
1 2
B-B section
A view

8030-6
2. Regulator
1) Regulator operation explanation
Operation explanation (See the Regulator operation explanation diagram.)
1] Flow control
The pump discharge flow is controlled as desired with the pilot pressure Pi as in the figure below.
1- Flow reduction operation
Discharge flow Q
Pilot pressure Pi
When the pilot pressure Pi increases, the pilot piston (643) moves to the right and stops at the
location where the pilot spring (646) force and hydraulic pressure force balance each other.
The pin (875) fixed to lever 2 (613) fits into the crimped groove section of the pilot piston (643),
so lever 2 rotates with the B section (fastened by the support plug (614) and pin (876)) as the
support point. The pin (897) fixed to the feedback lever (611) projects into the large hole sec-
tion (C section) of lever 2 (613), so as lever 2 (613) rotates, the pin (897) moves to the right.
The pin (548) fixed to the tilt revolution pin (531) that moves the swash plate (212) fits with the
feedback lever (611) two-surface width section (D section), so the feedback lever (611) is
rotated by the movement of the pin (897) with the D section as the support point. Since the
spool (652) is linked to the feedback lever (611) via the pin (874), the spool moves to the right
(652).
When the spool (652) moves, the discharge pressure Pd1 is led to the servo piston large-bore
chamber via the spool and CI port. The discharge pressure Pd1 is always led to the servo pis-
ton small-bore chamber. As a result, the servo piston is moved to the right due to the surface
area difference and reduces the flow.
When the servo piston (532) moves to the right, the D section also moves to the right. The
return spring (654) is mounted on the spool (652). Since force pulling the spool to the left is
always operating, the pin (897) is pressed into the large hole section (C section) of lever 2
(613). Because of this, accompanying the D section movement, the feedback lever (611)
rotates around the C section as the support point and the spool (652) moves to the left.
Through this movement, the opening between the sleeve (651) and spool (652) gradually
starts to open. At the location where it is completely closed, the servo piston (532) stops.
2- Flow increase operation
When the pilot pressure Pi decreases, the pilot piston (643) is moved to the left by the pilot
spring (646) force and lever 2 (613) rotates with the B section as the support point. The pin
(897) is pressed in the large hole section (C section) of lever 2 (613) by the return spring (654)
via the spool (652), pin (874), and feedback lever (611), so accompanying rotation of lever 2
(613), the feedback lever (611) rotates with the D section as the support point and the spool
(652) moves to the left.
When the spool (652) moves, the CI port opens to the tank port, so the pressure in the large-
bore chamber of the servo piston drains out, the servo piston (532) is moved to the left by the
discharge pressure Pd1 of the small-bore section and the flow increases.
Accompanying the movement of the servo piston (532), the D section moves to the left, the
feedback lever (611) rotates with the C section as the support point and the spool (652) moves
to the right. This operation continues until the opening between the spool (652) and sleeve
(651) and closes and stops at the location where the opening is completely closed

8030-7
3- High-pressure selection function
As in the figure below, when the load pressure is increased, the pump tilt revolution angle is
reduced to prevent power source over load. Since this regulator is the simultaneous all-horsepower
control type, the tilt revolution angles (displacement volumes) of the two pumps are controlled to be
the same value as in the following equation
KR3G-9Y04-HV selects the higher pressure from Pi1 or the proportional valve 2nd pressure
and KR3G-9X04-HV selects the higher pressure from Pi2 or the external command-pressure
P2.
2] Horsepower control
As in the figure below, when the load pressure is increased, the pump tilt revolution angle is
reduced to prevent power source over load. Since this regulator is the simultaneous all-horse-
power control type, the tilt revolution angles (displacement volumes) of the two pumps are con-
trolled to be the same value as in the following equation
Tin=P1Xq/2π+P2Xq/2π=(P1+P2)Xq2π (q: Displacement volume)
Horsepower control operation is the same as for flow control. Below is a simple explanation.
(For detailed operation of each part, see the Flow control item.)
Discharge flow Q
Discharge pressure (Pd1 + Pd2)

1- Overload prevention operation
When the self pump discharge pressure Pd1 or the partner pump discharge pressure Pd2
rises, since Pd1 and Pd2 operate on the stepped section of the compensation piston (621),
the compensation rod is pressed to the right (623) and moves to the location where the force
of the outer spring (625) and inner spring (626) balance out the hydraulic pressure. The move-
ment of the compensation rod (623) is transmitted to lever 1 (612) through the pin (875) and
lever 1 (612) rotates around the pin (876) (E section) fastened to the casing. The pin (897)
fixed to the feedback lever (611) projects into the large hole section (F section) of lever 1
(612), so as lever 1 (612) rotates, the feedback lever (611) rotates with the D section as the
support point and the spool (652) moves to the right.
When the spool (652) moves, the discharge pressure Pd1 is led to the large-bore chamber of
the servo piston via the CI port, the servo piston (532) is moved to the right, and the pump dis-
charge flow is decreased to prevent over load of the power source.
The servo piston (532) movement is transmitted to the feedback lever (611) via the D section.
The feedback lever (611) rotates with the F section as the support point and the spool (652)
moves to the left. It moves until the opening between the spool (652) and sleeve (651) closes
and stops at the location where the opening is completely closed.
2- Flow return operation
If the self pump discharge pressure Pd1 or the partner pressure pump discharge pressure Pd2
decreases, the compensation rod (623) is pressed back by the outer spring (625) and the
inner spring (626) and lever 1 (612) rotates about the E section. Accompanying the lever 1
(612) rotation, the feedback lever (611) rotates around the D section as the support point and
the spool (652) moves to the left. Because of this, the CI port opens to the tank port, the servo
piston large-bore section pressure drains off, the servo piston (532) moves to the left and the
pump discharge flow increases.
The servo piston (532) movement is transmitted to the spool (652) by the feedback structure
and the operation continues until the opening between the spool (652) and sleeve (651) is
closed.

8030-8
3- Low tilting (low flow) command priority mechanism
As above, the flow control and the pressure control tilt revolution command is transmitted to
the feedback lever (611) and spool (652) via the large hole sections (C and F sections) of lever
1 (612) and lever 2 (613), but since the C and F sections have a structure in which a pin (Ø5)
projects into a large hole (Ø9), the pin (897) only contacts the lever that makes the tilt revolu-
tion smaller and the Ø9 hole for the lever on the side that has the larger tilt revolution com-
mand state does not contact the pin (897), but is free. With this type of mechanical selection
method, the flow control and horsepower control low tilt revolution side command has priority.
4- Power shift control (horsepower reduction control)
The pump set horsepower is controlled as desired with the power shift pressure Pf as in the
figure below.
When the power shift pressure Pf increases, the compensation rod (623) is moved to the right
via the pin (898) and the compensation piston (621), so the minimum horsepower setting for
the pump tilt revolution angle is reduced the same as was explained for the operation to pre-
vent overload. On the other hand, if the power shift pressure Pf is reduced, the horsepower
setting rises
Discharge flow Q
Discharge pressure (Pd1 + Pd2)

8030-9
2) Regulator operation explanation diagram
KR3G-9Y04-HV KR3G-9X04-HV
Pi1 P P A A P PPi2
1
1 a p
p a
Hydraulic circuit diagram Front Hydraulic circuit diagram Rear
side B B side
1 C1 port

8030-10
3) Front side regulator internal structure diagram
1 Front side regulator

2 Rear side regulator
Component part number

Code Part name Qty
(quantities) or model
050 Shuttle valve, sub 1st 545 (1PC9), 546 (1PC), 547 (1PC)
079 Electromagnetic proportional pressure reduction valve 1st KDRDE5K-31 / 30C50-1-2

- Regulator, sub 1 651 Sleeve 1
412 Hexagon socket head bolt 2 652 Spool 1
413 Hexagon socket head bolt 2 653 Spring seating 1
418 Hexagon socket head bolt 2 654 Return spring 1
436 Hexagon socket head bolt 4 655 Set spring 1
438 Hexagon socket head bolt 8 656 Blind cover 1
466 VP plug 1 708 O-ring 1
496 Insert plug 12 724 O-ring 9
545 Steel ball 1 725 O-ring 1
546 Seat 1 1 727 O-ring 1
547 Seat 2 1 728 O-ring 1
601 Casing 1 730 O-ring 1
611 Feedback lever 1 732 O-ring 1
612 Lever 1 1 733 O-ring 4
613 Lever 2 1 734 O-ring 1
614 Support point plug 1 735 O-ring 1
615 Adjusting plug 1 753 O-ring 1
621 Compensation piston 1 755 O-ring 3
622 Piston case 1 756 O-ring 1
623 Compensation rod 1 763 O-ring 1
624 Spring seating (C) 1 801 Hexagon nut 1
625 Outer spring 1 802 Hexagon nut 1
626 Inner spring 1 814 Stop ring 1
627 Adjusting ring (C) 1 836 Stop ring 1
628 Adjusting screw (C) 1 858 Locking ring 2
629 Cover (C) 1 874 Pin 1
630 Lock nut 1 875 Pin 2
631 Pf sleeve 1 876 Pin 2
641 Pilot cover 1 887 Pin 1
643 Pilot piston 1 897 Pin 1
644 Spring seating (Q) 2 898 Pin 1
645 Adjusting ring (Q) 2 924 Hexagon socket head stop screw 1
646 Pilot spring 2

Lep SC210B8030-0NA
1
2
C view B-B section
A-A section
D-D section
Issued 03-07
8030-11
8030-12
4) Rear side regulator internal structure diagram

Code Part name Qty Component part number (quantities) or model
050 Shuttle valve, sub 1st 545 (1PC), 546 (1PC), 547 (1PC)

- Regulator, sub 1 651 Sleeve 1
412 Hexagon socket head bolt 2 652 Spool 1
413 Hexagon socket head bolt 2 653 Spring seating 1
436 Hexagon socket head bolt 4 654 Return spring 1
438 Hexagon socket head bolt 8 655 Set spring 1
466 VP plug 1 656 Blind cover 1
496 Insert plug 6 722 O-ring 3
545 Steel ball 1 724 O-ring 9
546 Seat 1 1 725 O-ring 1
547 Seat 2 1 727 O-ring 1
601 Casing 1 728 O-ring 1
611 Feedback lever 1 730 O-ring 1
612 Lever 1 1 732 O-ring 1
613 Lever 2 1 733 O-ring 4
614 Support point plug 1 734 O-ring 1
615 Adjusting plug 1 735 O-ring 1
621 Compensation piston 1 753 O-ring 1
622 Piston case 1 755 O-ring 3
623 Compensation rod 1 756 O-ring 1
624 Spring seating (C) 1 763 O-ring 1
625 Outer spring 1 801 Hexagon nut 1
626 Inner spring 1 802 Hexagon nut 1
627 Adjusting ring (C) 1 814 Stop ring 1
628 Adjusting screw (C) 1 836 Stop ring 1
629 Cover (C) 1 858 Locking ring 2
630 Lock nut 1 874 Pin 1
631 Pf sleeve 1 875 Pin 2
641 Pilot cover 1 876 Pin 2
643 Pilot piston 1 887 Pin 1
644 Spring seating (Q) 1 897 Pin 1
645 Adjusting ring (Q) 1 898 Pin 1
646 Pilot spring 1 924 Hexagon socket head stop screw 1

Lep SC210B8030-0NA
C view B-B section
A-A section
D-D section
Issued 03-07
8030-13
8030-14
3. Gear Pump
1) Gear pump internal structure diagram
To main pump
Hydraulic circuit diagram
Code PART NAME QTY Component part number (quantities) and model
350 Gear case, sub 1st 307 (1PC), 308 (1PC), 351 (1PC), 353 (1PC), 354 (1PC), 361 (1PC)

307 Poppet 1 361 Front case 1
308 Seat 1 433 Flange socket 2
309 Ring 1 434 Flange socket 2
310 Spring 1 435 Flange socket 4
311 Adjusting screw 1 466 VP plug 1
312 Lock nut 1 700 Angle ring 1
351 Gear case 1 710 O-ring 1
353 Drive gear 1 725 O-ring 1
354 Driven gear 1 732 O-ring 1
355 Filter 1 850 Locking ring 1

8030-15
2) Explanation of structures and operations
Structure
The casing comprises the front case (361) and gear case (351). Inside the casing are installed
the drive gear (353) and driven gear (354) pair and the relief valve for setting the discharge
pressure.
The relief valve comprises the filter (355), poppet (307), seat (308), spring (310), ring (309),
adjusting screw (311), and lock nut (312).
In order to prevent oil leaking to the outside, an angle ring (700) and O-ring (710) are mounted
on the front case (361).
Operation
Oil suctioned in from suction port B 3 is discharged from discharge port A 3 by the drive and
driven gears.
The discharged oil is held at the set pressure of 3.9 MPa (39 bar/566PSI) by the relief valve.
Unnecessary discharge oil is drained from the drain port via the relief valve.

8030-16
MOTOR
1. Travel Motor
1) Travel motor operation explanation
1] Structural diagram
Figure 2 Hydraulic circuit diagram

Automatic 2-speed type
1 Double counter balance valve 4 Parking brake

2 Crossover relief valve 5 Piston motor
3 2-speed switching mechanism 6 Reduction gear

8030-17
2] Structure
The swash plate type piston motor with case rotation type reduction gear for the open circuit
comprises
1- the double counter balance valve for controlling the speed of the motor according to the
feed flow
2- he crossover relief valve for determining the motor drive force and braking force
3- the 2-speed switching mechanism for switching the motor speed between two speeds, low
speed and high speed
4- the parking brake function that locks the motor shaft with a mechanical brake when the
motor is stopped,
5- the piston motor that converts the fluid energy of the pressurized oil sent from the
hydraulic pump into mechanical energy and outputs high-speed, low-torque power
6- the reduction gear that converts the high-speed, low-torque power output from the piston
motor into low-speed, high-torque power and outputs it
The fluid energy of the pressurized oil sent from the hydraulic pump is converted into mechan-
ical energy by the piston motor and the high-speed, low-torque rotation power is transmitted to
the reduction gear.
At the reduction gear, the rotation power transmitted from the piston motor is converted into
low-speed, high-torque rotation power and this power is transmitted to the devices that use the
MAG-170VP-3800G series for this open circuit.
Structure functions
1- Double counter balance valve
The purpose of this valve is to control the speed of the motor according to the feed flow.
Therefore, motor rotation getting away due to external load is prevented.
2- Crossover relief valve
The purpose of this valve is to determine the motor drive force and braking force. Therefore,
this valve has a shockless function to soften the shock of motor starting and stopping and pro-
vide good operability. Also, this valve is formed into one compact unit with the double counter
balance valve to make up the brake circuit.
3- The 2-speed switching mechanism
This motor has a 2-speed switching mechanism that can switch the motor speed between two
speeds, low speed and high speed.
Automatic 2-speed function
The low-speed mode fixed position and automatic 2-speed position can be selected. When the
automatic 2-speed position is selected, the motor capacity is selected according to the motor
load pressure and the motor is switched automatically between low speed and high speed.
4- Parking brake
The parking brake function is built into the piston motor. When the motor is stopped, the
mechanical brake operates to prevent the motor from being rotated by external load.
5- Piston motor
A swash plate type piston motor is used as the piston motor. This piston motor converts the
fluid energy of the pressurized oil sent from the hydraulic pump into mechanical energy and
outputs high-speed, low-torque power.
6- Reduction gear
As the reduction gear structure, a simple planetary two-stage reduction gear structure of the
casing rotation type is used. This reduction gear converts the high-speed, low-torque power
output from the piston motor into low-speed, high-torque power and outputs it from the reduc-
tion gear casing.
Also, a floating seal is used to prevent mud, sand, water, etc. from infiltrating from the outside.
The component devices above are formed into one compact unit that provides high reliability
and superior performance.

8030-18
3] Explanation of operation of functions
a) Double counter balance valve
As the roles of the double counter balance valve, there are:
1- the overrun prevention function that controls the piston motor speed to match feed quantity
in the state of rotation at or higher than the speed determined by the flow feed from the
piston motor for the external load (below, pumping action),
2- the brake function used together with the crossover relief valve to make up the brake
circuit that gradually stops the rotation of the piston motor by applying braking force to the
piston motor rotation,
3- high-pressure selection shuttle valve function for releasing the parking brake through its
own pressure
Figure 3 shows a structural diagram of the standard double counter balance valve.
This section explains the operations of each function using this standard double counter bal-
ance valve.
Figure 3 Double counter balance valve structural diagram (stopped state)
1 Oil path C1 5 Spring chamber 1 9 Damper chamber A2

2 Orifice D1 6 Oil path B 10 Orifice D2
3 Damper chamber A1 7 Oil path C2 11 Spring chamber 2
4 Orifice D2 8 Orifice D3
A. Stopped state (Figure 3)
When the control valve is in neutral (the motor stopped), since pressure is generated at neither
the P1 port nor the P2 port, the M1 and M2 ports are locked (hydraulically) with the spool (1)
and the check valve (2) and the piston motor does not rotate.

8030-19
B. Motor starting (Figure 4)
When the pressurized oil discharged from the hydraulic pump is led to the double counter bal-
ance valve P1 port, the check valve (2-1) moves to the left against the spring (3), the oil path
C1 is opened, pressurized oil flows from the M1 port into the piston motor and attempts to
rotate the piston motor.
On the other hand, the return oil from the piston motor, flows from the M2 port into the double
counter balance valve, but the flow is prevented by the check valve (2-2) and the hydraulic
pump discharge pressure rises.
Therefore, the P1 port side goes to high pressure, the pressurized oil operates through the ori-
fice (4-1) and the ball check (5-1) on the spring chamber 1 and the damper chamber A1, and
that oil pressure moves the plunger (1) to the right against the opposite side spring (7-2) with
force proportional to the pressure.
At this time, the M2 port return oil flows through the oil path B in the circumferential notch sec-
tion of the plunger (1) and into the P2 port while generating back pressure at the M2 port and
this return oil returns to the tank through the control valve and the piston motor starts rotating.
Figure 4 Double counter balance valve when motor rotating


8030-20
C. Counter balance function (Figure 4)
During piston motor rotation, if the piston motor is forced to rotate by the external load, pump-
ing action occurs in the piston motor, and it runs wild. In this case, since the P1 port section
becomes the suction side of the pump action, that pressure drops. At the same time, the pres-
sure also drops in the spring chamber 1 and the damper chamber A1. Therefore, the plunger
(1) is moved to the left by the spring (7-2), oil path B is closed, and when the return oil flow
stops, the suction side flow stops at the same time.
When the flow of oil through oil path B is stopped, in an instant, the P1 port side pressure rises
again due to the hydraulic pump discharge oil and this moves the plunger (1) to the right.
In this way, the plunger (1) moves in small steps when there is pumping action due to the
external load to hold the opening surface area of oil path B in an appropriate state. Therefore,
rotation of the piston motor at a speed appropriate to the feed flow from the hydraulic pump is
maintained and vacuum in the hydraulic circuit is prevented. This prevents the piston motor
from running wild.
D. Piston motor braking (Figure 5)
The double counter balance valve makes up the brake circuit together with the crossover relief
valve.
When the control valve is returned to neutral, the pressurized oil from the hydraulic pump is cut
off and the P1 and P2 ports go to the same pressure. Therefore, the plunger (1) moves to the
neutral position, and the oil path B opening surface area becomes small.
On the other hand, because the piston still attempts to rotate due to the inertial energy of the
external load (piston motor pumping action), the M2 port pressure rises and acts as a braking
force on the rotation of the piston motor.
At this time, when the M2 port side pressure reaches the set pressure for the relief valve (8),
the M1 port side poppet (8-1) moves to the left against the spring (8-2) and the pressurized oil
escapes to the M1 port side. In this way, the shock pressure due to the M2 port side inertial
energy is controlled and at the same time the occurrence of a vacuum on the M1 port side is
prevented.
Figure 5 Double counter balance valve and relief valve during piston motor control


8030-21
E. High-pressure selection shuttle valve function (Figure 6 and Figure 7)
The double counter balance valve has a high-pressure selection shuttle valve function added
for releasing the parking brake through its own pressure.
When pressurized oil is fed from the P1 port, the plunger (1) moves to the right side creating
the state in Figure 6. Therefore, the motor case drain oil path F is closed, the oil path D to the
parking brake cylinder chamber E is opened, the pressurized oil is led into oil path G via the
orifice and flows into the parking brake cylinder chamber E, releasing the parking brake.
Also, when the piston motor stops, the plunger (1) returns to the neutral state of Figure 7, the
oil path D closes, and the motor case oil path F opens, so the oil in the parking brake cylinder
chamber E is led to the motor case drain and the parking brake operates.
2
1 3 4 5
Figure 6 High-pressure selection function High-pressure selection
1 Oil path D 4 Oil path G
2 Oil path F 5 Cylinder chamber E
3 Orifice

8030-22
Figure 7 High-pressure selection function. Release to motor case drain

1 Oil path D 4 Oil path G
2 Oil path F 5 Cylinder chamber E
3 Orifice

8030-23
b) Crossover relief valve
Figure 8 shows the structure of the relief valve. This relief valve has a shockless function for
reducing the shock that occurs at the start of startup and braking of the differential surface
area type direct action relief valve.
Figure 8 Structure of relief valves

A. Relief valve operation and functions (Figure 9)
When the control valve moves and the piston motor is started up or braked, when the poppet
(2-9-2) front surface pressure rises above the set pressure, this pressure wins out over the
spring (2-9-5), the poppet (2-9-2) moves to the right and separates from the poppet (2-9-3),
and the high-pressure oil at the poppet (2-9-2) front surface bypasses to the low-pressure oil
path. In this way, by allowing the high-pressure oil to bypass to the low-pressure oil path, the
shock pressure due to the inertial energy of the high-pressure oil path is controlled and at the
same time the occurrence of a vacuum in the low-pressure oil path is prevented.
B. Shockless function (Figure 10)

When the relief valve starts to operate, the shockless piston (2-9-2) moves to the left. There-
fore, inside the spring chamber D, the pressure is held low. Therefore, the surface of the pop-
pet (2-9-2) pressurized area becomes S1, a quite large pressurized area compared to the
pressurized area S1-S2 for the normal relief valve setting.
Therefore, while the shockless piston (2-9-9) movement is completing, the relief valve operat-
ing pressure is held to about 1/3 of the normal set pressure, absorbing the shock pressure due
to the inertial energy of the high-pressure oil path.
When the shockless piston movement is complete, the pressure inside the spring chamber D
rises, the pressure in front and behind the poppet (2-9-2) become equal, and the relief valve
operates with its normal set pressure.
Operating the relief valve in two stages in this way reduces the shock that occurs when the
piston motor is started or braked and provides good operability. Figure 10 compares the pres-
sure waveforms of the conventional type and the shockless type.

8030-24
Figure 10 Shockless function and pressure wave comparison

1 Area S2
2 Area S1
3 Spring chamber D

8030-25
c) Automatic 2-speed function
A. Motor low-speed (high-capacity) position
Figure 11 shows the state with the motor capacity fixed to the low-speed (high-capacity) posi-
tion.
When the speed control switch is set to low speed and the pilot pressure acting on the Ps port
is released to the tank, the motor capacity control valve built into the motor is fixed to the low-
speed (high-capacity) position.
Figure 11 Motor low-speed (high-capacity) fixed mode

1 Pilot pressure
2 Pm2 pressure in motor
4 Pin motor load pressure

8030-26
B. Automatic 2-speed position that selects the motor capacity according to the load
pressure
Figure 12 shows the state of the automatic 2-speed position that selects the motor capacity
according to the load pressure.
When the speed control switch is set to high speed and the regulation pressure is allowed to
operate on the Ps port, the pressurized oil operating on the Ps port operates on the front sur-
face of the motor capacity control valve built into the motor and the position becomes the auto-
matic 2-speed position that switches the motor capacity according to the load pressure on the
motor.
Figure 12 Automatic 2-speed control mode using load pressure

1 Pilot pressure
4 Pin motor load pressure

8030-27
C. High-speed motor state for automatic 2-speed position
Figure 13 shows the high-speed motor state for the automatic 2-speed position.
When the regulation pilot pressure is allowed to operate on the Ps port, the pilot pressurized
oil operates on the pilot hydraulic chamber on the motor capacity control valve front surface
via oil path A and this pushes the motor capacity control valve to the right. Also, the load pres-
sure Pin on the motor operates on the motor load pressure chamber via oil path B and pushes
the motor capacity control valve to the left. When Pin is lower than the motor capacity control
pressure P determined by the ratio of the pilot pressure pressurized area and the motor load
pressure pressurized area, the motor capacity control valve is held in the state in Figure 13
and the motor operates in high-speed (low-capacity) mode.
Figure 13 Motor high-speed (low-capacity) position for automatic 2-speed mode

1 Pilot oil pressure chamber 5 Oil path B
2 Oil path A 6 Pm2 pressure in motor
3 Pilot pressure 7 Pm1 pressure in motor
4 Motor load pressure chamber 8 Pin motor load pressure
D. Low-speed motor state for automatic 2-speed position
Figure 14 shows the low-speed motor state for the automatic 2-speed position.
When the load pressure Pin on the motor rises and becomes higher than the motor capacity
control pressure P discussed above, the motor capacity control valve moves to the left, switch-
ing the motor to low-speed (high-capacity) mode, so the motor operates at low speed.

8030-28
Figure 14 Motor low-speed (high-capacity) position for automatic 2-speed mode

1 Pilot oil pressure chamber 5 Oil path B
2 Oil path A 6 Pm2 pressure in motor
3 Pilot pressure 7 Pm1 pressure in motor
4 Motor load pressure chamber 8 Pin motor load pressure

8030-29
d) Parking brake function
Figure 15 shows a structural diagram of the parking brake section.
The parking brake is made up of the disks (1) coupled with the cylinder block, the friction plate
(2) mounted between the disks, the brake piston (3), and the spring (4) that applies force to
the brake piston.
A. Releasing the parking brake (Figure 15)
When pressurized oil is fed from the P1 port and attempts to start driving the piston motor,
when the «high-pressure selection shuttle valve function» explained in Item E of (3) 1) «Dou-
ble counter balance valve» leads pressurizes oil to the parking brake cylinder chamber E via
oil path D, the hydraulic force operates on the brake piston (3) and moves it to the left against
the spring (4). As a result, the force pressing the disks (1) disappears, the disks (1) enter the
free state, and the parking brake is released.
B. Operating the parking brake (Figure 16)
When the control valve is returned to the neutral position, the feed of pressurized oil to the P1
port is cut off, and an attempt is made to stop the piston motor, because the «high-pressure
selection shuttle valve function» explained in Item E of (3) 1) «Double counter balance valve»
connects oil path D to motor case drain oil path F, the pressurized oil in the parking brake cyl-
inder chamber E is led to the motor case drain and the pressure drops. Therefore, the brake
piston (3) is moved to the right side by the spring (4), the disks (1) are tightened with the force
of the spring (4) by the brake piston (3) and motor case, so the piston motor shaft is locked
and the parking brake operates
1 1
2 5
3 3
4 4
Figure 15 Parking brake released state Figure 16 Parking brake engaged state
1 Cylinder block 4 Cylinder chamber E

2 Hydraulic pressure force 5 Spring force
3 Motor case

8030-30
e) Piston motor
A swash plate type piston motor is used as the piston motor.
Figure 17 shows a structural diagram of the piston motor.
Nine pistons (4-2) are incorporated in the cylinder block (4-1) and the end of the cylinder block
(4-1) touches a valve plate (22) that has two sausage-shaped ports, B and C. The pressurized
oil discharged from the hydraulic pump flow in from the P1 port or the P2 port and while the
piston motor rotates, flows out from the P2 port or P1 port.
Also, the drain oil in the case that has leaked from the sliding sections and the gap returns to
the hydraulic tank from the base plate (2-1) T1 or T2 port.
Figure 17 Piston motor structural diagram

1- The high-pressurized oil from the P1 port enters the valve plate (22) sausage-shaped B
port, the piston (4-2) is pressurized, and the top of the swash plate (5) rotates and moves
from top dead center to bottom dead center.
2- The P2 port becomes the low pressure side and while the piston (4-2) rotates and moves
from bottom dead center to top dead center, the oil is discharged to the P2 port via the
valve plate (22) sausage-shaped C port.
3- Accompanying the reciprocal movement of the piston (4-2), the cylinder block (4-1) and
the shaft (3) spline coupled to it rotate in the counter-clockwise direction of the arrow in the
figure.
4- When the piston motor rotates clockwise, the P1 port side becomes the low-pressure side
and the P2 port side becomes the high-pressure side.
In this way, the piston motor converts the fluid energy of the pressurized oil sent from the
hydraulic pump into mechanical energy and outputs high-speed, low-torque rotation power.
Also, the piston motor torque and speed are determined by the pressure and flow. Therefore,
the larger the pressure and flow, the higher the piston motor torque and speed.

8030-31
f) Reduction gear
Figure 18 shows a structural diagram of the reduction gear.
The reduction gear structure combines in two stages the simply planetary reduction gear unit
made up of the drive gear, sun gear, holder, planetary gear, and ring gear (with teeth cut in the
inner diameter of the housing).
When pressurized oil flows into the piston motor, the piston motor shaft rotates at high speed
and power is input to the reduction gear section. In the reduction gear section, this high-speed
rotation has its speed reduced in two stages by the simple planetary 2-stage reduction system.
Low-speed, high-torque output is obtained from the rotation of the housing with ring gears (1-
3) and (2-3).
A. 1st stage reduction section operation
The 1st stage reduction section comprises the drive gear (1-1), planetary gear A (1-2), ring
gear (1-3), holder (1-4), needle bearing (1-5), and inner race (1-6).
The planetary gear A (1-2) meshes with the drive gear (1-1). When the drive gear (1-1) rotates
clockwise, the planetary gear A (1-2) rotates counter-clockwise. On the other hand, since it
meshes with the ring gear, it kicks the ring gear and tries to revolve clockwise around the cir-
cumference of the drive gear (1-1).
Because the planetary gear (1-2) is fixed in a state in which it rotates freely on the holder (1-4)
via the needle bearing (1-5), this clockwise revolution movement is transmitted to the holder
(1-4) and the holder (1-4) starts to rotate in the clockwise direction.
Also, since the holder (1-4) is spline coupled with the 2nd stage sun gear (2-1), this holder (1-
4) rotation is transmitted to the 2nd stage sun gear (2-1).
B. 2nd stage reduction section operation
The 2nd stage reduction section comprises the sun gear (2-1), planetary gear B (2-2), ring
gear (2-3), holder (2-4), needle bearing (2-5), and inner race (2-5).
The planetary gear B (2-2) meshes with the sun gear (2-1). When the sun gear (2-1) rotates
clockwise, the planetary gear B (2-2) rotates counter-clockwise.
The planetary gear B (2-2) is fixed in a state in which it rotates freely on the holder (2-4) via the
needle bearing (2-5). Furthermore, the holder (2-4) is coupled to the flange (5) by the bolts (3)
and (4) and the flange (5) is fastened to the frame of the machine main unit, so it cannot
rotate.
Therefore, the planetary gear B (2-2) cannot revolve as in the 1st stage reduction section and
rotates counter-clockwise at the position at which it was incorporated. Also, because the plan-
etary gear B (2-2) is meshed with the ring gear, the counterclockwise revolution of the plane-
tary gear B (2-2) is transmitted to the ring gear and the ring gear is rotated counter-clockwise.
Through the above action, the housings (1-3) and (2-3) with the ring gear cut into their inner
diameters receive the force of the planetary gears (2-2) and (1-2) and rotate. This transmits
power to the driven section of the machine main unit which is coupled with the housings (1-3)
and (2-3).

8030-32
Figure 18 Reduction gear structural diagram

1 Piston motor shaft
2 Connection to driven section of machine
3 Fastened to machine main unit frame

8030-33

8030-34
2) Travel motor part table
Code Part name ......................................Qty Code Part name ......................................Qty
1 Piston motor...................................... 1 1-8 Ball bearing ....................................... 1
1-1 Flange ............................................... 1 1-9 Ball bearing ....................................... 1
1-2 Base plate assembly ......................... 1 1-10 Pin .................................................... 1
1-2-1 Base plate ......................................... 1 1-11 Hexagon socket head bolt............... 10
1-2-2 Spool assembly................................. 1 1-12 Oil seal .............................................. 1
-1 Spool................................................. 1 1-13 Disk plate .......................................... 3
-2 Check valve....................................... 2 1-14 Friction plate ..................................... 2
-3 Spring................................................ 2 1-15 Brake piston ...................................... 1
-4 Plug................................................... 2 1-16 O-ring ................................................ 1
-5 O-ring ................................................ 2 -17 O-ring ................................................ 1
1-2-3 Spring seat........................................ 2 1-18 Spring................................................ 8
1-2-4 Spring................................................ 2 1-19 Pin .................................................... 4
1-2-5 Spring seat........................................ 2 1-20 Spring................................................ 2
1-2-6 Cap assembly ................................... 2 1-21 Valve plate......................................... 1
-1 Cap .................................................. 1 1-22 O-ring ................................................ 4
-2 O-ring ................................................ 1 1-23 O-ring ................................................ 1
-4 Hexagon socket head bolt................. 4 1-24 Nameplate......................................... 1
-5 Steel ball ........................................... 1 1-25 Rivet .................................................. 2
-6 Spring................................................ 1 1-26 Plug................................................... 2
-7 Plug................................................... 1 1-27 Plug................................................... 1
-8 O-ring ................................................ 1 1-28 Plug................................................... 1
1-2-7 Relief valve assembly ....................... 2 1-29 Spacer............................................... 1
-1 Relief housing ................................... 1 2 Floating seal...................................... 2
-2 Poppet............................................... 1 3 Angular bearing................................. 2
-3 Poppet seat ....................................... 1 4 Housing............................................. 1
-4 Spring seat........................................ 1 5* Shim t = 3.6....................................... 1
-5 Spring................................................ 1 5* Shim t = 2.3....................................... 1
-6 Plug................................................... 1 5* Shim t = 2.8....................................... 1
-7 O-ring ................................................ 1 5* Shim t = 3.0....................................... 1
-9 Free piston ........................................ 1 5* Shim t = 3.2....................................... 1
-10 O-ring ................................................ 1 6 Holder C............................................ 1
-11 Backup ring ....................................... 2 7 Washer.............................................. 8
-13 Spring guide...................................... 1 8 Bolt.................................................... 8
-14 O-ring ................................................ 1 9 Thrust plate ....................................... 4
-15 Stop screw ........................................ 1 10 Inner race.......................................... 4
-16 Nut .................................................... 1 11 Needle bearing.................................. 4
-17 O-ring ................................................ 1 12 Planetary gear C ............................... 4
-18 Backup ring ....................................... 2 13 Thrust plate ....................................... 4
1-2-8 Plug................................................... 8 14 Bolt.................................................... 4
1-2-9 Spool assembly................................. 1 15 Sun gear C........................................ 1
-1 Spool A ............................................. 1 16 Snap ring........................................... 1
-2 Spool C ............................................. 1 17 Holder B ............................................ 1
1-2-10 Spring................................................ 1 18 Thrust plate ....................................... 3
1-2-11 Plug................................................... 1 19 Inner race.......................................... 3
1-2-12 O-ring ................................................ 2 20 Needle bearing.................................. 3
1-2-13 Spring guide...................................... 1 21 Planetary gear B ............................... 3
1-2-14 Plug................................................... 1 22 Thrust plate ....................................... 3
1-2-19 Orifice................................................ 2 23 Thrust plate ....................................... 1
1-2-20 Plug................................................... 5 24 Screw ................................................ 3
1-2-21 O-ring ................................................ 5 25 Drive gear ......................................... 1
1-3 Seat................................................... 1 26* Thrust plate t = 3.6............................ 1
1-4 Cylinder block assembly ................... 1 26* Thrust plate t = 2.3............................ 1
-1 Cylinder block.................................... 1 26* Thrust plate t = 2.8............................ 1
-2 Piston assembly ................................ 9 26* Thrust plate t = 3.0............................ 1
-3 Retainer plate.................................... 1 26* Thrust plate t = 3.2............................ 1
-4 Retainer holder ................................. 1 27 Cover................................................. 1
-5 Snap ring........................................... 1 28 Hexagon socket head bolt............... 16
-6 Spring seat........................................ 1 29 Plug................................................... 3
-7 Spring................................................ 1 30 O-ring ................................................ 3
-8 Collar................................................. 1 31 Pin .................................................... 4
-9 Pin .................................................... 3 * One is selected and used.
1-5 Swash plate ...................................... 1
1-6 Steel ball ........................................... 2
1-7 Piston assembly ................................ 2

8030-35
3) Travel motor internal structure diagram

8030-36
2. Swing Motor
CX210B
1) Equipment configuration
Swing unit SG08E
Planetary two-stage MFC160 swash plate type axial piston motor

reduction gear RG08S
Mechanical brake
Make-up valve
Shockless relief valves
Structure and operating principles (The numbers in parentheses correspond to the section
structural diagram.)
1] Hydraulic motor
The rotary group is made up of the one-piece drive shaft and cylinder (24) and the nine pistons
AS (7) positioned in the cylinder (24). Also, the cylinder (24) is supported at both ends with bear-
ings (3, 22). The piston AS (7) is guided by the return plate (6) and receiving spring (4) so that it
slides smoothly on the cam plate (5).
Also, the balance plate (21) is pressed against the end of the cylinder (24) by the hydraulic pres-
sure operating on the bushing (20) and the force of the Scrowave spring (18).
As parking brakes, it is equipped with mechanical brakes (8), (9), (11), and (13)
between the cylinder (24) outer circumference and the housing (25).
Also, a relief valve (35) for the cushion function and the make-up valves (38), (39), and (40) for
preventing cavitation are built into the cover (32) section.

8030-37
2] Hydraulic motor operation explanation
The pressurized oil fed by the pump through the control valve or the like enters from the A port
(or B port) on the cover (32) and is discharged from the B port (or A port).
Also, the oil that has leaked from the sliding sections and the gap returns to the hydraulic tank
from the drain port «a» on the cover (32).
The pressurized oil fed to the A port is fed to the cylinder (24) piston hole «f» through path «b» in
the cover (32), path «c» the bushing (20) section in the cover (32), balance plate (21) path "d"
that has a crescent shaped port that switches between feed and discharge every 180° of rotation
of the motor, and the cylinder (24) path «e».
The pressurized oil operates on the piston AS (7) and the piston AS (7) is pressed against the
cam plate (5). The cam plate (5) shoe sliding surface has a constant angle slope, so the piston
AS (7) pressing force created by the action of the pressurized oil is converted into force making
the shoe slide on the plate. The piston AS (7) shoe spherical section is coupled as a free joint, so
the force of the shoe sliding on the plate is transmitted to the motor output shaft section as rota-
tion force via the cylinder (24).
In this way, each piston AS (7) receives pressurized oil in the stroke from the slope surface top
dead center to bottom dead center, converts this hydraulic force to rotation force, rotates the cyl-
inder (24), and discharges oil in the stroke from the bottom dead center to the top dead center.
The discharge path is the reverse of the above pressurized oil feed path and the oil is discharged
from the B port.
In this way, the hydraulic motor operates. The hydraulic motor output torque is determined by the
hydraulic pressure force and speed is determined by the feed oil quantity.
3] Reduction gear structure and operation explanation
The power transmitted from the hydraulic motor output shaft is transmitted to the 2nd stage sun
gear (72) via the 1st stage sun gear (76), planetary gear (79), and holder 1 (81). At the same
time, the power is transmitted to the output shaft (61) via 2nd stage sun gear (72), planetary gear
(84), and holder 2 (87). The output shaft (61) is supported in the gear case (66) by two bearings
(65, 71). Also, in order to protect the output side bearing (65), which faces severe load condi-
tions, from gear wear powder, there is an oil seal (70) in the center section in the gear case (66),
the A chamber side is lubricated with gear oil, and the B chamber side is lubricated with grease.
4] Mechanical brake operation explanation
The friction plate (8) is spline coupled with the exterior circumference section of the cylinder (24).
Also, the partner plate (9) is coupled with the housing (25). When the mechanical brake release
chamber pressure is zero, the brake piston (11) presses the friction plate (8) and partner plate (9)
with the force of the spring (13) to load rotation of the cylinder (output shaft).
On the other hand, when the oil pressurized to 3.2 - 4.9 MPa (32 - 49 bar/4641 - 7107 PSI) oper-
ates on the brake release chamber, the brake piston (11) wins out over the spring force, the pis-
ton stroke proceeds until the cover (32) end, a gap is generated between the friction plate (8) and
partner plate (9) and the mechanical brake is released.

8030-38
5] Make-up valve operation explanation
1- Half brake state (state in which the shockless relief valve (35) is not operating)
After the swing body is accelerated, when it is decelerated by the control valve with the half
lever, the oil feed quantity from the pump to the A port drops, but if the swing body was rotating
at relatively high speed, the pressure comes close to negative at the «c» section due to the
motor pump operation, so oil supply becomes necessary. However, if the B port pressure is
lower than the operating pressure of the shockless relief valve (35), all the oil flowing into the
«c» section from the A port is drained to the control valve via the B port, so with just the quan-
tity of oil from the control valve, the quantity of oil is insufficient for what is absolutely required
at the «c» section. (Because the valve is at the half lever position, the quantity of oil from the
pump is restricted.) In order to prevent this, the make-up check valve (38) is set up to make up
the quantity of the oil shortfall to the «c» section from the make-up port.
2- When the brake operates (state in which the shockless relief valve (35) is operating)
In the state in (1), if the lever is suddenly operated to neutral, the quantity of oil fed from the
pump to the A port becomes zero, but the swing body rotates due to inertial force. In this case,
the B port side shockless relief valve (35) operates, the oil blown out in relief passes through
oil paths «i» and «h», pushes open the A port side make-up check valve (38), and is fed to oil
paths «b» and «c», but the quantity of this oil falls short by the quantity of oil that leaked to the
motor case drain. In order to prevent that, the make-up check valve (38) is opened from the
make-up port, oil is supplied to oil paths «b» and «c» to prevent cavitation.
6] Relief valve operation explanation (relief valve internal structure diagram)
1- Starting
For the pressurized oil fed to the A port by the operation of the control valve, constant rotation
is not reached because the swing body inertial force is large and part of the oil passes through
the shockless relief valve (35) which operates as a safety valve, passes through oil paths «g»
and «h», pushes open the B port side check valve (38), and flows out to the B port.
The A port oil resists the force of the spring (47), pushes open the poppet (46), passes through
the path "g" from between the seat (45) and the poppet (46), and flows out to the path «h».
2- Braking (cushion)
When the control valve is returned to neutral, the motor discharge oil return path is closed.
Immediately after this operation, the motor rotates with a large inertial force and pump opera-
tion is caused, which tries to suction in the oil from the A port and discharge it from the B port,
but because the control valve return path is closed, the B port pressure rises.
The B port pressure that rises pushes open the poppet (46) resisting the force of the spring
(47), so it pushes up the make-up check valve (38) via the oil paths «i» and «h», the oil flows
into the path «c», and through this process, the swing body inertial force is absorbed and the
swing body comes to a stop.
Also, in the above pressure rise process, the pressurized oil at the B port passes through the
poppet (46) outer circumference orifice «i», passes through the small hole path at the center of
the piston (51), and enters the piston chamber, moving the piston (51) to the position where it
contacts the end of the liner (50). During this time, because the poppet (46) is already pushed
open, the cushion action operates at first with somewhat low pressure and after a slight time,
rises to the regulation pressure. This two-stage operation provides a function that reduces the
shock of motor starting and stopping.

8030-39
2) Internal structure diagram

8030-40
3) Swing reduction gear internal structure diagram(CX210B)
1 2
1 Chamber A
2 Chamber B
4) Relief valve internal structure diagram

8030-41
1) Swing motor operation explanation CX240B
1] Hydraulic motor section (CX240B)
As the figure below shows, when the high-pressure oil passes through the valve plate (1) intake
side port (a) and flows into the cylinder, the hydraulic pressure operates on the piston and a force
F is generated in the axial direction. This force F is divided into two vectors, a force F1 perpendic-
ular to the swage plate (3) via the shoe (2) and a force perpendicular to the shaft. This force F2 is
transmitted to the cylinder block (4) via the piston, generating a rotational couple around the out-
put shaft.
Nine pistons are arrayed in the cylinder block. Rotation torque is transmitted to the output shaft
by multiple pistons sequentially linked with the high-pressure oil intake side port.
When the oil in and out directions are reversed, the rotation of the output shaft also reverses.
The theoretical output torque [Nm] is given by the following equation.
Figure 1 Motor section operation explanation diagram

1 Piston
2 Drive shaft
2] Valve casing section
1- Anti-cavitation check valve section
Because the system using this type of motor does not have a valve with a counter-balance
function, the motor sometimes rotates more than the quantity of oil fed.
In order to prevent cavitation due to insufficient oil, there is a check valve to take in the oil
shortfall
Figure 2 Hydraulic circuit diagram

1 M port
2 Control valve

8030-42
3] Brake section
The cylinder (111) is coupled with the drive shaft (101) by the gear. Also, the separator plate
(743) is constrained for circumferential rotation by the arc groove cut into the casing (301).
When the friction plate (742) that is gear coupled to the cylinder outer circumference section is
pressed to the casing (301) by the brake spring (712) via the separator (743) and the brake pis-
ton (702), friction force is generated between the friction plate and casing and between the sepa-
rator plate and the brake piston. The drive shaft is constrained and braked by this friction force.
On the other hand, when brake release pressure is applied to the oil chamber formed between
the brake piston and the casing and the hydraulic pressure wins out over the spring force, the
brake piston moves, the force pressing the friction plate against the casing disappears, and the
brake is released.
Figure 3 Brake operation diagram

1 Oil chamber

8030-43
4] Relief valve operation explanation (Relief valve model: KRD22EK10)
1- Operation explanation when the relief valve is pressurized
Think of the case in which the P port is pressurized with the tank pressure.
The P and R ports are at the tank pressure at first and go into the states in Figure 4 - (1).
At the pressure where there is balance between the hydraulic pressure determined by the
product of the pressure P and the pressurized area A1 of the plunger (301) on the one hand
and the hydraulic pressure determined by the spring (321) load FSP and plunger (301) pres-
surized area A2 and the g chamber pressure Pg on the other hand, the relief valve starts to
operate.
After that, the g chamber pressure rises and the piston (302) starts its stroke. Accompanying
this movement, the load on the spring (321) increases.
Through the operation above, the relief pressure P is controlled to rise from P1 to Ps in the
pressure rise time t1.
This process is explained below in terms of the relationship between the movement state of
the parts in Figures 4 - (2) through (4) and the relief pressure.
A. State shown in Figure 4 - (2)
When the relief valve P port is pressurized, pressure is generated in the g chamber via the
metering valve m in the plunger (301).
When the hydraulic pressure operating on the plunger (301) increases and reaches the pres-
sure at which it balances the spring (321) load FSP, the relief valve carries out the relief oper-
ation at pressure P1.
The relationship at this time is expressed by the following equation.
P1 X A1 = FSP1 + Pg1 X A2FSP1: Initial set load for the spring (321)
B. State shown in Figure 4 - (3)
The g chamber pressure operates on pressurized areas A3 and A4 of the piston (302). When
this hydraulic pressure force becomes larger than the load on the spring (321), the piston
starts to move to the left.
At this time, the oil in the h chamber formed between the piston and the adjusting plug (401) is
discharged into the g chamber via the metering valve n set up on the piston (302) while the
piston moves to the left, so the h chamber functions as a damping chamber.
Through this, the spring load gradually increases until the piston reaches the adjusting plug
end section and the relief pressure P rises smoothly.
C. State shown in Figure 4 - (4)
When the piston (302) reaches the adjusting plug (401) end section, it does not move farther
to the left, so the constant relief state is reached and the relief pressure is held at P2.
Through the processes (1) through (4) above, the relief pressure varies as in Figure 5.
2- Operation explanation when the relief valve is depressurized
Think of the case in which the P port pressure falls.
When the pressurization of the P port ends, the P port pressure and the g chamber pressure
fall together to the tank pressure. Through this, the plunger (301) which was open, moves to
the left and seats in the seat (401). At the same time, the piston (302) also is moved to the
right by the spring (321) and returns to the state in Figure 4 - (1).

8030-44
1 2 34
(1)
P
R
A3 A2 7 8 A4
5 6
(2)
P
(3)
P
(4)
P
Figure 4 Relief valve operation explanation diagram

1 Metering m 5 A1 pressurized area
2 Spring (321) 6 Plunger (301)
3 Chamber h 7 Metering n
4 Piston (302) 8 Chamber g
(4)
Ps
(3)
P1
(2)
(1)
t1
Figure 5 Boosted pressure characteristic

8030-45

8030-46
2) Swing motor internal structure diagram (CX240B)
Code Part name Qty
051 Relief valve 2 set
051-1 O-ring 2
10 Piston, sub 1 set
101 Drive shaft 12 1
111 Cylinder 1
114 Plate spring 1
121 Piston 9
122 Shoe 9
123 Retainer plate 1
124 Shoe plate 1
131 Valve plate B 1
20 Valve casing H2, sub 1 set
301 Casing K1 1
303 Valve casing H2 1
351 Plunger H2 2
355 Spring H2 2
390 Nameplate 1
391 Driving tack 2
401 Hexagon socket head bolt 4
443 Cylinder roller bearing 1
444 Cylinder roller bearing 1
451 Pin 2
469 ROMH plug 2
472 O-ring 1
488 O-ring 2
491 Oil seal 1
702 Brake piston 1
706 O-ring 1
707 O-ring 1
712 Brake spring 14
742 Friction plate 3
743 Separator plate 4
983 Masking plug 2 set

Lep SC210B8030-0NA
A-A section
Brake spring location of components
Issued 03-07
8030-47
8030-48
VALVE
1. Control Valve
Basic configuration
This valve is based on the main unit housing which combines the P1 side housing and P2 side
housing with the rear surfaces against each other and has a configuration that makes it possible
to mount the inlet, add-on section, and outlet on the P2 side housing top.
1) Operation
1] When all spools in neutral, Neutral path [Fig. 1, Fig. 2]
1- When Pn1 and Pn2 ports pressurized
The oil fed from the P1 port enters the tank path (Ta) from the neutral path (L1) through the
low-pressure relief orifice (Lc1) and returns to ports T1 to T8.
The oil fed from the P2 port enters the tank path (Ta) from the neutral path (R1) through the
low-pressure relief orifice (Rc1) and returns to the T1 to T8 ports.
The pressure in the pressure chambers (L2) and (R2) upstream from the low-pressure relief
valve is led into the pump from the ps1 and ps2 ports and controls the P1 and P2 pump dis-
charge volume.
Also, if excess oil flows into the neutral path (L1), the poppet opens to provide low-pressure
relief. This prevents the ps1 and ps2 port pressures from becoming abnormally high.
2- When Pn1 and Pn2 ports not pressurized
In this case, the low-pressure relief poppets open at lower pressure than in (a).
Therefore, the oil fed from the P1 port enters the tank path (Ta) from the neutral path (L1) pri-
marily through the low-pressure relief valve discharge port (L3) and returns to the T1 to T8
ports.
Also, the oil fed from the P2 port enters the tank path (Ta) from the neutral path (R1) primarily
through the low-pressure relief valve discharge port (R3) and returns to the T1 to T8 ports.
Valve (see following page)
1 Low-pressure relief valve (L) 9 Inlet

2 Arm 1 10 Attachment 1
3 Boom 2 11 Arm 2
4 Swing 12 Boom 1
5 Option 13 Bucket
6 Travel 14 Straight travel
7 Outlet 15 Low-pressure relief valve (R)
8 Attachment 2

8030-49

8030-50
Valve (see following page)
1 Variable arm regeneration orifice 8 Attachment 1

2 Arm 1 9 Neutral cut
3 Boom 2 10 Arm 2
4 Swing 11 Boom 1
5 Option 12 Bucket
6 Travel 13 Travel
7 Attachment 2 14 Straight travel

8030-51

8030-52
2] Signal, straight travel signal control valve, plate assembly [Fig. 3]
There are 2 signals, (a) and (b) below. The pilot signal for each spool for which a lever is oper-
ated is used to generate the pressure that is output.
The straight travel signal control valve integrates the signal pressures and controls straight travel
spool switchover. Also, the plate assembly has a function for picking up the pilot pressures with
the built-in shuttle.
1- Travel signal (PT)
The highest of the pilot pressures applied to the travel section 1 (pa1, pb1) and travel section 6
(pa6, pb6) is selected and output to the PT port.
Therefore, when the travel spool is in the neutral position (no-load pilot pressure), no pressure
is generated at the PT port.
2- Front signal (PA)
The highest of the pilot pressures (pa2 to 9 and pb2 to 9) applied to sections 2 to 9 that use the
pressurized oil from the P1 and P2 pumps, except for the travel sections, is selected and out-
put to the PA port. (Note: 1)
Therefore, when all the spools are in the neutral position (no-load pilot pressure), no pressure
is generated at the PA port.

8030-53
NOTE: When an add-on (main pump add-on) is used through the feed from P2, the branches for the add-on pilot sig-
nals par1 and pbr1 are connected to the respective main unit valves, prs1 and prs2 ports, and thus incorporated in the
front signal PA selection area.
NOTE: Be careful. If the above pipes are not used, the PA pressure does not rise due to add-on selection.
NOTE: Also, when using 2 main pump add-ons, set the circuit so that maximum of the add-on pilot pressures (par1 and
2, pbr1 and 2) can be taken out as desired and connect to either prs1 or prs2.
1 Straight travel signal control valve 6 Arm

2 Travel 7 Bucket
3 Main unit housing section (option) 8 Swing
4 Plate assembly 9 Option
5 Boom 10 Add-on (main pump)

8030-54
2) Single operation
1] Travel spool switchover [Fig. 4 and Fig. 5]
When a travel spool is switched by pressurizing from the travel (section 1) pilot port Pb1 (Pa1),
the oil fed from the P1 port flows from the neutral path (L1) through the spool neck section and
into the B1 (A1) port. The return oil returns to the tank path (Ta) from the A1 (B1) port through the
spool neck section.
When a travel spool is switched by pressurizing from the travel (section 6) pilot port Pb6 (Pa6),
the oil fed from the P2 port flows from the neutral path (R1) through the spool neck section or
path (S6-1) and into the B6 (A6) port.
When only travel is operated, the parallel path (R3) and the path (S6-1) have the same pressure,
so the poppet (S6-2) does not open. The return oil returns to the tank path (Ta) from the A6 (B6)
port through the spool neck section.
2] Option spool switchover [Fig. 4]
When the option spool is switched by pressurizing from the option (section 2) pilot port Pb2
(Pa2), the neutral path (L1) is closed. The oil fed from the P1 port flows from the parallel path (L3)
through the load check valve (S2-2), path (S2-1), and the spool neck section, and into the B2
(A2) port.
The return oil returns to the tank path (Ta) from the A2 (B2) port through the spool neck section.
Also, when oil is fed from the p4 port, it passes through the inside of the load check valve (S2-2)
and merges with path (S2-1).

8030-55
1 Switching state 3 Option

2 Neutral state 4 Travel
1 Switching state 3 Option

2 Neutral state 4 Straight travel

8030-56
3] Swing spool switchover [Fig. 6]
When the swing spool is switched by pressurizing from the swing (section 3) pilot port Pb3 (Pa3),
the neutral path (L1) is closed. The oil fed from the P1 port flows from the parallel path (L3)
through the load check valve (S3-2), path (S3-1), and the spool neck section, and into the B3
(A3) port.
The return oil returns to the tank path (Ta) from the A3 (B3) port through the spool neck section.
1 Switching state 3 Swing

2 Neutral state 4 Bucket

8030-57
4] Bucket spool switchover [Fig. 7 and Fig. 8]
1- Close (regeneration) [Fig. 7]
When the bucket spool is switched by pressurizing from the bucket (section 7) pilot port Pb7,
the neutral path (R1) is closed. The oil fed from the P2 port flows through the parallel path
(R3), the load check valve (S7-2), path (S7-1), and the spool neck section, and into the B7
port.
At the same time, the return oil from the A7 port returns to the tank path (Ta).
After part of the return oil pushes open the poppet (S7-3) inside the bucket spool, it merges
into the B7 port to prevent cylinder head cavitation.
Cylinder speed increase and P2 port pressure reduction effects also accompany depending
on the port pressure conditions.
Bucket close (regeneration)
1 Neutral state 3 Swing

2 Switching state 4 Bucket

8030-58
2- Open [Fig. 8]
When the bucket spool is switched by pressurizing from the bucket (section 7) pilot port Pa7,
(R3),
the load check valve (S7-2), path (S7-1), and the spool neck section, and into the A7 port.
The return oil returns to the tank path (Ta) from the B7 port through the spool neck section.
Bucket open
1 Neutral state 3 Swing

2 Switching state 4 Bucket

8030-59
5] Boom spool switchover [Fig. 9, Fig. 10, and Fig. 11]
1- Neutral [Fig. 9]
This valve mounts an anti-drift valve on the boom 1 cylinder head (A8) side.
In neutral, the poppet (AD1) is reliably seated by the pressure of the A8 port itself led through
path (AD2) and the spool (AD3) into the spring chamber (AD4) to cut off the return oil from the
A8 port.
Neutral
1 Boom 2
2 Boom 1

8030-60
2- Boom up (2 pumps flow) [Fig. 10]
hen the boom 1 spool is switched by pressurizing from the boom 1 (section 8) pilot port Pa8,
(R3), the load check valve (S8-2), and the spool neck section and into the A8 port.
When the boom 2 spool is switched by pressurizing from the boom 2 (section 4) pilot port Pa4,
the neutral path (L1) is closed. The oil fed from the P1 port flows through the parallel path (L3),
the load check valve (S4-2), the spool neck section, and path (4) and merges into the A8 port.
The return oil returns to the tank path (Ta) from the B8 port through the spool neck section.
Up (2 pumps flow)
1 Boom 2
2 Boom 1

8030-61
3- Boom down (regeneration) [Fig. 11]
hen the boom 1 spool is switched by pressurizing from the boom 1 (section 8) pilot port pb8,
(R3), the load check valve (S8-2), and the spool neck section and into the B8 port.
The pilot pressure applied to pb8 at this time moves the anti-drift valve spool (AD3) through
the path built into the housing at the same time that the spool is switched and reduces the
pressure of the spring chamber (AD4) to open the poppet (AD1).
Through this movement, the cutoff of the A8 port is released before the spool is switched.
After that, the return oil from the A8 port returns to the tank path (Ta).
Part of the return oil pushes open the poppet (S8-3) inside the boom 1 spool, passes through
path (S8-1), and merges into the B8 port to prevent cylinder rod cavitation.
Cylinder speed increase and P2 port pressure reduction effects also accompany depending
on the port pressure conditions.
Down (regeneration)
1 Boom 2
2 Boom 1

8030-62
6] Arm spool switchover [Fig.12 to 15]
1- Neutral [Fig.12]
his valve mounts an anti-drift valve on the arm 1 cylinder rod side.
In neutral, the poppet (AD1) is led through path (AD2) and the spool (AD3) into the spring
chamber (AD4). It is reliably seated by the pressure of the A5 port itself to cut off the return oil
from the A5 port.
Neutral
1 Arm 1
2 Arm 2

8030-63
2- Arm in (2 pumps flow) [Fig. 13]
When the arm 1 spool is switched by pressurizing from the arm 1 (section 5) pilot port Pb5, the
oil fed from the P1 port flows from the neutral path (L1) through the load check valve (S5-2),
path (S5-1), and the spool neck section and into the B5 port. When the arm 2 spool is switched
by pressurizing from the arm 2 (section 9) pilot port Pb9, the oil fed from the P2 port flows from
the neutral path (R1) through the load check valve (S9-2), path (S9-1), the spool neck section,
and path (6) and merges into the B5 port.
The pilot pressure applied to pb5 at this time moves the anti-drift valve spool (AD3) through
the path built into the housing at the same time that the spool is switched and reduces the
pressure of the spring chamber (AD4) to open the poppet (AD1). Through this movement, the
cutoff of the A5 port is released before the spool is switched.
After that, the return oil from the A5 port splits into the flow through the regeneration check
valve in the spool that is regenerated at the B5 port and the flow returning to the tank path (Ta)
through the regeneration control valve.
(For details on the regeneration function, see the Regeneration valve operation explanation in
next item 3) below).
Arm (2 pumps flow)
1 Arm 1
2 Arm 2

8030-64
3- Arm in (variable regeneration) [Fig. 14]
For an arm-in operation, after the return oil from the A5 port passes through the notch (a), it
divides into two paths:
A. The return oil returns to the tank path (Ta) through the fixed orifice (d) in the regeneration control
valve, path (e), and the variable orifice (f).
B. The return oil passes through the fixed orifice (b) in the arm 1 spool, the regeneration check
valve (c), and the fixed orifice (i), then merges into the bridge path (S5-1).
Here, when the bridge path (S5-1) pressure goes higher due to the port B5 load pressure, the
regeneration control valve spool (h) is pressed through the regeneration control valve piston
(g), and the variable orifice (f) section opening surface area increases, so the quantity of oil
returning to the tank path (Ta) increases.
On the other hand, the quantity of oil regenerated in the B5 port decreases.
Though this variable mechanism, both the regeneration ratio for low loads is secured and
reduction in the return back pressure for high loads is established.
Arm in (variable regeneration)
1 Regeneration control valve (variable)

2 Arm 1

8030-65
4- Arm out (2 pumps flow) [Fig. 15]
When the arm 1 spool is switched by pressurizing from the arm 1 (section 5) pilot port Pa5, the
oil fed from the P1 port flows from the neutral path (L1) through the load check valve (S5-2),
path (S5-1), and the spool neck section and into the A5 port.
When the arm 2 spool is switched by pressurizing from the arm 2 (section 9) pilot port Pa9, the
oil fed from the P2 port flows from the neutral path (R1) through the load check valve (S9-2)
and path (S9-1), merges into the arm 1 section path (S5-1) and heads toward the A5 port
through the arm 1 spool neck section. The return oil from the B5 port returns to the tank path
(Ta) from the B5 port through the spool neck section.
Arm out (2 pumps flow)
AD2 AD1 S5-1 S5-2

AD3 AD4
A5 B5
L3
pb5 pa5 1
(Section 5)
L1 Ta
R1
Ta
pb9 pa9 2
(Section 9)
R3
S9-1
S9-2 [Fig.15]
prs1 prs2
RST-04-02-001az
1 Arm 1
2 Arm 2

8030-66
7] Arm parallel orifice [Fig. 16]
Metering by the spool is installed in the arm 1 parallel path of this valve to control the quantity of
oil fed to arm 1 for compound operations.
The oil fed from the arm 1 (Section 5) parallel path (L3) pushes open the poppet (S5-3) and
passes through the variable metering spool orifice (Lc8), then is connected to path (L5).
Here, the quantity metered by the orifice (Lc8) is adjusted by pressurizing the pilot port (Pbu)
L2
1 Lc1 ps1 T1 S5-3
L4
L3 3
Pn1
pc3
Lc8
Ta Lc8 4
2
[Fig.16]
1 Low-pressure relief valve (L) 3 For boom up (for Pbu pressurization)
2 Pbu signal path 4 For neutral

8030-67
8] Relief valve
1- Main relief valve [Fig. 17]
The oil fed from the P1 port passes through the poppet (LP) and the oil fed from the P2 port
passes through the poppet (RP) and path (3) and is led to the main relief valve. The maximum
pressure of the P1 and P2 pumps is controlled by the operation of the main relief valve.
2- Overload relief valve [Fig. 18]

There is an overload relief valve at the boom 1, arm 1, bucket, and add-on cylinder ports to
prevent any abnormal rise in actuator pressure, for example due to an external force.
This relief valve is also equipped with a function for preventing cavitation (suction function) by
taking in oil from the tank when there is a load on the cylinder port pressure.

8030-68
3) Compound operation
1] Travel compound operation [Fig. 19, Fig. 20]
Under the conditions below when the travel left/right and the front system are operated at the
same time, the straight travel spool is switched, and the straight travel characteristic is main-
tained.
A. When the front is operated during travel left/right simultaneous operation (forward, backward, or
pivot turn)
B. When the left/right are operated simultaneously during front system operation
Front system operation is not affected by the quantity of switches and switchover sections.
1- Signal circuit [Fig. 19]
A. (When the [Travel 1] side lever is operated, the pressure branched off from the valve main unit
pilot port passes through the filter and the shuttle, then switches the switch valve [V1].
B. When the [Travel 2] side lever is operated, the pressure branched off from the valve main
unit pilot port passes through the filter and the shuttle, then if the switch valve [V1] is
switched, it switches the switch valve [V2] through the path. On the other hand, if the switch
valve [V1] is in the neutral state, the path is cut off by the switch valve [V1]. Therefore, if
both (A) and (B) are established at the same time, the straight travel spool internal path
(Pst) is conducted to PA. Also, if either (A) or (B) are established, the travel signal (PT)
pressure rises.
C. If at least one of the front systems is switched, the highest pressure of all the pilot pressures
in the front system is selected and is connected to the front signal port (PA). Therefore, if
(A), (B), and (C) are established at the same time, the straight travel spool switchover quan-
tity is determined proportional to the front signal (PA) pressure through the internal straight
travel signal path (Pst). [Fig. 19] shows the example of a case of travel left/right for-
ward+boom up.

8030-69
PA
V2
Up
Pst Down
V1 Close
Open
Advance
Close
Reverse
Open
Right
PT
Left
Advance
Reverse
prs1
prs2
DR2
[Fig.19]
1 Straight travel signal control valve 7 Bucket

2 Travel 1 8 Swing
3 Travel 2 9 Option
4 Plate assembly 10 Add-on (main pump)
5 Boom 11 Main unit housing section (option)
6 Arm

8030-70
2- Main unit circuit [Fig. 20]
When the straight travel spool is switched, the oil fed from the P1 port flows from the neutral
path (L1) to travel (section 1) and at the same time passes through path (2), the straight travel
spool neck section, and the neutral path (R1) and into travel (section 6) and feed to travel left
and right becomes possible.
On the other hand, when the oil fed from the P2 port flows to the parallel path (R3), at the
same time it passes through the straight travel spool neck section and path (1) and into the
parallel path (L3), so it becomes possible to feed oil to the entire front system.
When the front system is switched during travel and that pressure becomes higher than the
load pressure on travel (section 6), part of the oil fed from the P2 port pushes up the poppet
(S6-2) from the parallel path (R3) and the oil flows through the orifice at the poppet tip and
merges into path (S6-1).
This softens the shock on the machine body of the sharp drop in speed caused by the switch-
over to 1 pump travel.
Because as described above, travel (sections 1 and 6) operates with the oil fed from the P1
port and operating machines other than travel are operated with oil fed from the P2 port, travel
curving is prevented and the straight travel characteristic maintained during compound opera-
tions.
1 Switching state 3 Straight travel

2 Travel 4 Travel

8030-71
4) Anti-drift valve
The anti-drift valve is mounted on the arm rod (boom bottom) side cylinder port to prevent the
arm (boom) cylinder from dropping naturally.
Also, the release signal operates led by the internal path from the pilot signal.
(The arm side (A5) is shown as a typical example.)
1] Neutral (A5 port hold)
1- The A5 port hold pressure passes from path (a) through path (b), through path (c), and is
conducted to the poppet (1) spring chamber (d).
2- Therefore, the A5 port pressurized oil is cut off by the seat section (S1) and the seat
section (S2).
1 Main spool
2] Release signal application
1- When the pi port is pressurized, the piston (2) moves and the spool (3) operates.
2- Furthermore, the spool (3) operates the poppet (4).
3- Then, the operation of the poppet (4) cuts off the connection between the A5 port and the
spring chamber (d).
1 Main spool

8030-72
3] Ending hold status
1- When the piston (2) operates further, the spring chamber (d) is connected by the (T2)
section from path (c) through path (e) to the drain chamber [DR].
2- The spring chamber (d) pressure becomes the drain pressure and the main poppet (1)
operates.
1 Main spool

8030-73
5) Relief valve
1] Main relief valve operation
1- This relief valve is incorporated between the neutral path "HP" and the low-pressure path
"LP". The oil passes through the metering hole of the main poppet (C) and charges the
interior space (D). Also, the sleeve [E] and the main poppet [C] seat securely operating on
the different surface areas [A] and [B].
2- When the neutral path "HP" pressure reaches the set pilot poppet spring force, the pilot
poppet (F) opens. The oil flows around the poppet, passes through the notch hole (G), and
is led to the low-pressure path "LP".
3- Because the pilot poppet has opened, the (D) pressure drops and the main poppet (C)
opens, so the oil flows directly into the path "LP".

8030-74
"Boosted pressure operation"
When pressure is applied to the pilot port "PH", the piston (H) is moved to the set position by
the plug (I). Because of this, the pilot spring force rises and the "HP" pressure rises.
2] Overload relief valve operation

1- This relief valve is incorporated between the cylinder port "HP" and the low-pressure path
"LP". The oil passes through the metering hole of the piston (C) and charges the interior
space (G). The sleeve (K) and the main poppet (D) seat securely operating on the different
surface areas (A) and (B).
2- When the cylinder port "HP" pressure reaches the set pilot poppet spring force, the pilot
poppet (E) opens. The oil flows around the poppet, passes through the notch hole (H), and
is led to the low-pressure path "LP".

8030-75
3- Because the pilot poppet (E) has opened, oil flow is generated through the orifice (I) of the
piston (C), a pressure difference is generated between the path "HP" and the rear side of
the piston (C), and the piston (C) moves and seats with the poppet (E).
4- The flow of oil from the path "HP" to the rear side of the poppet (D) is only through the
ring-shaped gap between the poppet (D) and the piston (C) and through the orifice (F), so
the pressure difference increases.
Because of this, the poppet (D) opens and the oil flows directly into the path "LP".
3] Overload relief valve intake operation

1- This relief valve has a built-in anti-void unit that supplies oil if cavitation occurs at the
cylinder port "HP"
When the cylinder port "HP" pressure is lower than the low-pressure side "LP", the sleeve (K)
is opened by the surface area difference between (A) and (B). Oil enters the cylinder port "HP"
from the low-pressure side "LP" to prevent cavitation.

8030-76
6) Neutral cut spool [Fig. 21]
This valve is equipped as standard with a neutral cut spool in the P2 side housing neutral path
(R1) minimum flow (low-pressure relief valve upstream).
When the pcc port is pressurized and the neutral cut spool is switched, the path through the
orifice [Lc7] to low-pressure relief valve is cut off and output to the outside from the P3 port
becomes possible.
1 Low-pressure relief valve (R)

7) Plate assembly [Fig. 22]
This valve is equipped with a plate assembly hermetically sealed with a gasket piling a plate on
the housing side surface.
The shuttle is built into the inside and this valve has a function for selecting and controlling the
spool pilot pressure.
Also, in order to protect the shuttle section from contamination from the outside, a filter is
mounted between the plates.
When removing, do not loosen the indicated screw and be careful that internal parts are not
dispersed.
1
1
(Long cap side) (Short cap side)

[Fig.22]
1 Subassembly screw

8030-77
8) Straight travel signal control valve [Fig. 19, Fig. 23]
This valve integrates the pilot pressure for the spool of the front system and travel selected with
the plate assembly and is used to switch the straight travel spool.
When the Travel 1 pilot pressure is pressurized, the spool [V1] is switched.
When the Travel 2 pilot pressure is pressurized at the same time, the spool [V2] is switched.
Here, when the front system pilot pressure [PA] is pressurized, the PA pressure flows into Pst
and is led to the straight travel spool pilot chamber and the spool is switched.
PA
V2
Up
Pst Down
V1 Close
Open
Advance
Close
Reverse
Open
Right
PT
Left
Advance
Reverse
prs1
prs2
DR2
[Fig.19]
1 Straight travel signal control valve 7 Bucket

2 Travel 1 8 Swing
3 Travel 2 9 Option
4 Plate assembly 10 Add-on (main pump)
5 Boom 11 Main unit housing section (option)
6 Arm

8030-78
9) Add-on [Fig. 24, Fig. 25]
1] Add-on main relief valve
The oil fed from the Pr port is led to the main relief valve. The Pr pump maximum pressure is reg-
ulated by the operation of the main relief valve.
2] Spool section
When the spool is pressurized from the add-on (Section 10) pilot port par1 (pbr1) and switched,
the neutral path [Pg] is closed. The oil fed from the Pg port flows from the parallel path [Rg]
through the load check valve [S10-1], the path [S10-2], and the spool neck section, and into the
AR1 (BR1) port.
The return oil returns to the tank path [Ta] from the BR1 (AR1) port through the spool neck sec-
tion.

8030-79
3] Low-pressure relief valve operation [Fig. 26, Fig. 27]
1- Signal pressure generation (when pin1 (pin2) port pressurized)
The oil fed from the pump port (P1 (P2)) flows through the neutral path (L1 (R1)), then flows
from the low-pressure relief path (L2 (R2)) through the orifice (Lc1 (Rc1)) and out into the tank
path (Ta).
At this time, the pressure generated in path (L2 (R2)) by the orifice (Lc1 (Rc1)) is led to the
low-pressure relief signal port (Ps1 (Ps2)).
When the (L2 (R2)) upstream main spool operates, the oil flowing through (L2 (R2)) is
reduced, so the (Ps1 (Ps2)) signal pressure becomes lower.
2- Relief operation
When excess oil flows in path (L2 (R2)), the poppet is operated by the pressure generated in
path (L2 (R2)) by the orifice (Lc1 (Rc1)).
Through this poppet operation, the oil flows from the path, through the notch hole path, and
out to the tank path [Ta]. This prevents the generation of excess pressure at the low-pressure
relief signal port.

8030-80
4] Add-on main relief valve
1- Add-on main relief valve operation
This relief valve is incorporated between the neutral path "HP" and the tank path "LP". The oil
passes through the metering hole of the main poppet [1] and charges the interior space [C].
Also, the sleeve [2] and the main poppet [1] seat securely operating on the different surface
areas "A" and "B".
2- When the neutral path "HP" pressure reaches the set pilot spring force, the pilot poppet [3]
opens.
The oil flows around the pilot poppet [3], passes from the notch hole [E] and through the ring-
shaped gap [D] and is led to the tank path "LP".
3- Because the pilot poppet [3] has opened, the interior space [C] pressure drops and the
main poppet [1] opens, so the "HP" oil flows directly into the path "LP".

8030-81
2. 5 Stack Solenoid Valve Operation Explanation
1) External shape diagram (Figure 1) and configuration diagram (Figure 2)
1 Electromagnetic switch valve

2 body
2) Main component parts
This valve is made up of the body and the electromagnetic switch valve.

8030-82
3) Operation explanation

The pressurized oil fed from the P port feeds pressurized oil to the C1 to C5 ports according to
the excitation or non-excitation of electromagnetic switch valves S1 to S4 resulting from exciting
electromagnetic switch valve SP.
Electromagnetic switch valves S1 and S3 => Oil passing through when valve excited
Electromagnetic switch valve S2 => Oil passing through when valve not excited
Oil passing to C5 when valve excited
Electromagnetic switch valve S4 =>
Oil passing to C4 when valve not excited
4) Structural diagram

8030-83
3. Upper Pilot Valve (remote control valve)
1) Structure
The remote control valve structure is as shown in the assembly section diagram (Page 84).
There is a longitudinal axial hole in the casing and the pressure reduction valve is installed in it.
The pressure reduction valve comprises the spool (201), secondary pressure setting spring
(241), return spring (221), spring seating (216), and washer 2 (217). The secondary pressure
setting spring (241) is set so that the secondary pressure calculation is 0.5 - 1 MPa (5 - 10 bar/
73 - 145 PSI) (depending on the model). The spool (201) is pressed against the push rod (212)
by the return spring (221).
When the push rod (212) is pushed down by tilting the handle or other operation section, the
spring seating goes down at the same time and the secondary pressure setting spring (241)
setting is changed.
The casing (101) has the oil inlet (primary pressure) port P and the outlet (tank) port T and
furthermore the secondary pressure is taken out from the 1, 2, 3, and 4 ports.
2) Function
1] Basic functions
The remote control valve is for controlling the control valve spool stroke quantity, direction, etc.
This is done by operating the pilot valve output pressure on the control valve spool end section.
In order to satisfy this function, the remote control valve is made up of the following elements.
1- Inlet port (P) to which the oil is fed from the hydraulic pump
2- Multiple output ports (1, 2, 3, 4) for operating the feed pressure from the inlet port on the
control valve spool end.
3- Tank port (T) required for controlling the above output pressure
4- Spool connecting the output port to the inlet port or tank port.
5- Mechanical means including a spring operating on the above spool in order to control the
output pressure.
2] Main part functions
The function of the spool (201) is to switch the oil path either to receive the hydraulic pressure
fed from the hydraulic pump with the P port and lead the P port pressurized oil to the output ports
(1, 2, 3, and 4) or to lead the output port pressurized oil to the T port. The output pressure oper-
ating on this spool (201) is determined by the secondary pressure setting spring (241).
In order to change the deflection quantity of the secondary pressure setting spring (241), the
push rod (212) is inserted into the plug (211) in such a way that it can slide.
The return spring (221) operates on the casing (101) and spring seating (216) and operates to
return the push rod (212) in the displacement zero direction regardless of the output pressure
and makes the spool (201) neutral return reliable. It also has the effect of a counter-force spring
for giving an operator an appropriate operation feel.

8030-84
3) Operation
Operation of the remote control valve is explained based on the hydraulic circuit diagram (Figure
1) and operation explanation diagrams (Figure 2 to Figure 4). Figure 1 is a typical usage
example for the remote control valve.
5 6
P T
4
2
Figure 1: Remote control valve usage example
1 Pilot valve 4 Control valve

2 Pilot pump 5 Hydraulic motor
3 Main pump 6 Hydraulic cylinder

8030-85
1] [When handle in neutral (See Figure 2.)
The force of the secondary pressure setting spring (241) that determines the remote control
valve output pressure does not operate on the spool (201). Therefore, the spool (201) is pushed
up by the return spring (221) (spring seating (216)) and the output ports (2 and 4) are connected
with the T port. Therefore, the output pressure is the same as the tank pressure.
Figure 2: When handle in neutral

2] When handle is tilted (See Figure 3.)
When the handle is tiled and the push rod (212) is moved through a stroke, the (spring seating
(216)) spool (201) moves down and the oil fed from the pilot pump flows out to the (2 and 4) ports
through the P port and the (2 and 4) ports and pressure is generated.
Figure 3: When handle tilted

8030-86
3] When handle held (See Figure 4.)
When the handle is tilted and the port (2 and 4) pressure rises to the pressure equivalent to the
set spring force (241), the hydraulic pressure force and the spring force are in balance. When the
(2 and 4) ports pressure becomes higher than the set pressure, the (2 and 4) ports and the P port
close and the (2 and 4) ports and the T port open. When the (2 and 4) ports pressure becomes
lower than the set pressure, the (2 and 4) ports and the P port open and the (2 and 4) ports and
the T port close, so the secondary pressure is held constant.
Figure 4: When handle held

(secondary pressure at or above set pressure)
1 T port
2 P port
4] Operation in area in which the handle tilt is large (depends on the model)
For certain models, when the handle is flipped down beyond a certain angle, the spool top end
section touches the push rod bore bottom section and the output pressure goes into the state of
still being connected with the P port pressure.
Furthermore, with the structure in which the spring seating and spring are installed inside the
push rod, when the handle is flipped down beyond a certain angle, the push rod bore bottom sec-
tion and the spring touch, that spring force changes the 2nd pressure gradient and after that the
push rod bore bottom section and the spring seating top end section touch and the output pres-
sure goes into the state of remaining connected with the P port.

8030-87
Code Part name Qty Code Part name Qty

101 Casing 1 217 Washer 2 4
151 Plate 1 221-1 Spring (port 1) 1
201 Spool 4 221-2 Spring (port 3) 1
211 Plug 4 221-3 Spring 2
212-1 Push rod 2 241-1 Spring 2
212-2 Push rod 2 241-2 Spring 2
213 Seal 4 301 Joint 1
214 O-ring 4 302 Disk 1
216-1 Spring seating 1 2 312 Adjusting nut 1
216-2 Spring seating 1 2 501 Bellows 1

8030-88
4. Travel Pilot Valve (remote control valve)
1) Operation
The remote control valve with built-in damper (below, remote control valve with damper) is a
remote control valve that incorporates into the remote control valve main unit a damping
function for preventing the man-machine system hunting (lever hunting) phenomenon.
Operation of the remote control valve with damper is divided into 4.-(1)-1) Pressure reduction
valve section and 4.-(1)-2) Operation section damping mechanism section. The explanations in
these 2 sections are based on the hydraulic pressure circuit diagram, assembly section
diagram, and damping operation explanation diagram below. The figure below is a typical usage
example for the remote control valve.
1 Remote control valve 4 Control valve

2 Pilot pump 5 Hydraulic motor
3 Main pump 6 Hydraulic cylinder
1] Pressure reduction valve section
1- For neutral state
The spool (301) is pushed up by the return spring (335) via the spring seating (311) and
washer 1 (215) and is in the neutral position shown in the assembly section diagram.
Therefore, since the output port is connected only to the port T by the spool switching function,
the pressure at output ports 1 and 2 is the same as the pressure at the port T.
2- When the remote control valve operation section is tilted from the neutral state
In the assembly section diagram, when the cam (420) is rotated clockwise, the port 1 side
push rod (214) is pushed down, the spool moves down via washer 1, the spring seating, the
secondary pressure setting spring (324), washer 2 (217), and washer 3 (313), the port P and
port 1 are connected, and the oil fed from the pilot pump flows to port 1 and generates pres-
sure.
When the port 1 pressure rises to the pressure equivalent to the secondary pressure setting
spring force that has been set by tilting the operation section, the hydraulic pressure on the
spool and the spring force come into balance and the port 1 output pressure is held constant.
The port 2 spool holds the neutral state and the oil from the control valve is discharged via the
port T.
Some specifications are of the type that near the maximum angle of the operation section, a
push rod directly touches the spool top section and forcibly pushes in the spool to connect the
port P and the output port so that they have the same pressure.

8030-89
2] Operating section damping mechanism section
1- For neutral state
The push rod is pushed up by the damping springs (333 and 337) via the piston (224) and is in
the position shown in the assembly section diagram.
2- When the operation section is tilted from the neutral state (See Damping operation
explanation diagram (1).
In the assembly section diagram, when the cam is rotated clockwise, the port 1 side push rod
is pushed down and the piston moves down.
At this time, the oil in the damping piston chamber is discharged from the piston metering hole
and the pressure generated at this time generates damping force.
On the other hand, the port 2 side push rod is moved up by the damping spring via the piston.
At this time, the tank chamber oil is suctioned in through the 3 ball check sections made up of
bushings (223) and steel balls (225) and into the damping piston chamber. The oil outside the
piston chamber drains out from the path that leads from the casing top end section to the port
T.
3- When the operation section is tilted back from a full tilt (See Damping operation
explanation diagram (2).
In the assembly section diagram, after the cam is fully tilted clockwise, then rotated counter-
clockwise, the port 2 push rod is pushed down and the piston moves down.
At this time, as described above, the oil in the damping piston chamber is discharged from the
piston metering hole and the pressure generated at this time generates damping force.
On the other hand, the port 1 push rod is moved up by the return spring (335) and the damping
spring.
At this time, the tank chamber oil is suctioned in through the 3 ball check sections made up of
bushings and steel balls and into the damping piston chamber. Also, the oil outside the piston
chamber drains out from the path that leads from the casing top end section to the tank port.
In other words, the structure is such that damping force works for either tilt operation, from the
neutral position to the full tilt position or from the full tilt position to the neutral position.

8030-90
Damping operation explanation diagram (see the following page)
1 Push rod 4 Piston chamber

2 Orifice 5 Oil
3 Piston

8030-91

8030-92
1) Assembly and section diagram
Code Part name Qty Code Part name Qty
101 Casing 1 271 Hexagon socket head bolt 2
151 Plug 2 301 Spool 4
201 Cover 2 311 Spring seating 4
202 Plug 4 313 Washer 3 4
203 Grease cup 4 324 Spring 4
210 NHU packing 4 335 Spring 4
212 O-ring 4 336 Spring 4
214 Push rod 4 337 Spring 4
215 Washer 1 8 412 Bushing 4
217 Washer 2 4 413 Camshaft 2
218 Spring seating 4 420 Cam 2
221 Locking ring 4 423 Hexagon socket head stop screw 2
223 Bushing 4 471 Stop screw 4
224 Piston 2D085 4 472 Lock nut 4
225 Steel ball 12 501 Bellows 2

8030-93
5. Cushion valve
1) Valve summary
This valve is made up of a shuttle valve section and cushion valve section with heat circuit.
The cushion valve with heat circuit is connected between the hydraulic shovel control valve and
the pilot operation valve to reduce body shaking (cushion function) caused by emergency stop
operations by the operator.
This valve is equipped with a circuit with which the operator can deliberately disable the cushion
function for reverse operations.
The shuttle valve selects the high-pressure signal pressure from 2 signal pressure systems.
This valve has 2 circuits.
Figure 1
Figure 2

8030-94
1] Normal operation
The pressurized oil fed from the A port (or C, E, or G port) pushes up the check plunger and is
sent to the B port (or D, F, or H port). The pressurized oil that has passed through the B port oper-
ates on the control valve spool and operates the actuator. The oil pushed out from the control
valve spool passes through the D port (or B, F, or H port) and flows out to the T port.
Figure 3
2] Cushion operation
When the pressurized oil fed from the pilot operation valve to the A port (or C, E, or G port) is
closed by the pilot operation valve, the pressurized oil that has operated on the control valve
spool is pushed back to the B port (or the D, F, or H port) by the return spring on the spool. The
returned oil passes through the check plunger metering orifice, is sent to the A port (or the C, E,
or G port), and is drained from the pilot operation valve. At this time, by passing through the
metering orifice, the pressurized oil holds down the control valve spool speed and reduces shak-
ing of the body. (Cushion function)
Figure 4

8030-95
3] Reverse operation
When the pressurized oil fed from the pilot operation valve to the A port (or C, E, or G port) is
switched to the C port (or A, E, or G port), the pressurized oil that has operated on the control
valve spool is pushed back to the B port. Because the pushed back oil flows out to the T port
without passing through the check plunger metering orifice, it does not hold down the control
valve spool speed, so the cushion function does not work.
Figure 5
4] Heat circuit
When the pilot operation valve is in the neutral position, the oil fed to the R port passes through
the inside of the reverse operation spool, flows out to the T port, and heats up the inside of the
valve.
When pressurized oil is being fed from the pilot operation valve to the A port (or C, E, or G port),
the oil fed to the R port flows out to the C port (or A, E, or G port) and heats up the circuit to the
pilot operation valve and inside the valve.
Figure 6 Figure 7

8030-96
5] Shuttle valve
The steel ball is pressed from the high pressure to the low pressure, of the pressure between the
I and J ports and the pressure between the K and L ports. Through this, the high-pressure oil is
fed to the S port or the Q port. In the same way, oil is fed to the U port at the higher of the pres-
sures between the M and N ports and between the O and P ports.
Figure 8 Figure 9

8030-97
6. Selector Valve (4 - Way)
1) Structure
Pattern I: Pattern S: Pattern M: Pattern K:
ISO Old Sumitomo Old Mitsubishi Old Kobelco
Circuit diagram
Operation, work
A Right valve Pull in 1 Bucket in
B Right valve Left side 2 Boom down
C Right valve Push out 3 Bucket dirt removal
D Right valve Right side 4 Swing right
E Left valve Push out 5 Arm in
F Left valve Right side 6 Swing left
G Left valve Pull in 7 Arm dirt removal
H Left valve Left side 8 Bucket in
Circuit combination table

I type S type M type K type
ISO Old Sumitomo Old Mitsubishi Old Kobelco
A-1 A-1 A-8 A-6
B-2 B-2 B-7 B-7
C-3 C-3 C-6 C-8
D-4 D-4 D-5 D-5
E-8 E-5 E-3 E-3
F-5 F-6 F-2 F-2
G-6 G-7 G-1 G-1
H-7 H-8 H-4 H-4

8030-98
15
16
Z 1 14
10 13 19 21 8 7 20 11 6 17 21
3
5
2
22
4
18
9
12
Z-Z section
Figure 1 Valve structural diagram and circuit diagram
1 Name plate 9 Cover 17 Steel ball

2 Pin 10 Lever 18 Oil seal
3 Spring 11 Plug with flange 19 O-ring
4 Knob 12 Hexagon socket head bolt 20 O-ring
5 Cover 13 Hexagon socket head bolt 21 O-ring
6 Spring 14 Rivet screw 22 Hexagon socket head plug
7 Casing 15 Spring pin
8 Shaft 16 Spring pin

8030-99
This valve is a rotation type switch valve.
By connecting a pipe between the hydraulic shovel work remote control valve and the main con-
trol valve and changing the lever (10) to the position for each pattern (rotating the shaft (8)), the
valve circuit has been changed and the operation pattern changed to that in Figure 2.
For details on the valve structure (circuit diagram), see Figure 1.
Arm dirt
removal Boom-down
Pattern I Left Right Bucket Bucket dirt

L R
(ISO) swing swing digging removal
Arm Boom-up
digging
Right
swing Boom-down
Pattern S Arm dirt Arm Bucket Bucket dirt

L R
(old Sumitomo) removal digging digging removal
Left Boom-up
swing
Arm
Boom-down digging
Pattern M Bucket dirt Bucket Left Right

(old Mitsubishi) removal L digging swing R swing
Boom-up Arm dirt

removal
Arm dirt
Boom-down removal
Pattern K Bucket dirt Bucket Left Right

L R
(old Kobelco) removal digging swing swing
Boom-up Arm
digging
Figure 2 Operation method by pattern

8030-100
3) Development diagram

8030-101
7. Selector Valve (3-direction valve)
1) Structure
11 2 11
Z
B T1
T2
DR
PP
A
Z
B T1
10 7 5
9
3
1
9
12
10 6
4 12
Z-Z section
B T1 T2
DR PP
circuit diagram
Figure 1
1 Cover 5 Body 9 Hexagon socket head bolt

2 Name plate 6 Cover 10 Hexagon socket head bolt
3 Spool 7 Spring 11 Rivet screw
4 Spring 8 O-ring

8030-102
This valve switches the direction with the pilot pressure.
1] When the spool is neutral (PP port no load) Shuttle circuit, 2 pumps flow circuit selected
When the pilot pressure is not fed to the PP port, the spool (3) is held in the neutral position by
the spring (4), (7). The A port and the B port are connected and the T1 and T2 port pressurized
oil are cut off by the spool (3).(See Figure 2).
Figure 2
2] When the spool operates (PP port pressurized) Breaker circuit selected.
When pressure is fed to the PP port, force [F] (PP port pressure x spool cross-sectional area)
works on the spool (3) to the left direction.When F becomes larger than the spring (4), (7) set
load, the spool (3) moves to the left and the A port is connected with the T1 and T2 ports.
Also, at this time, the pressurized oil at the B port is cut off by the spool (3).(See Figure 3).
Figure 3

Section
9006
AIR CONDITIONER FUNCTIONS

AND TROUBLESHOOTING
9006

Printed in USA.
9006-2
TABLE OF CONTENTS
AIR CONDITIONNER OVERALL DIAGRAM 3

Hose connection 3
Hose Connection (CX160B to CX240B) 4
Hose Connection (CX290B) 5
CAB 6
Air conditioner unit 7
Air Conditioner Circuit Diagram 8
EXPLANATION OF CONTROL 10
Back-up function 10
Air Mix Motor Actuator Control 11
Blow Mode Motor Actuator Control 11
Refresh / Recirculate Switch Motor Actuator Control 12
Blower Amp Control 13
Compressor Clutch Control 16
COOLMAX Control and HOTMAX Control 17
Trouble Detection and Control after Trouble Detected 18
Monitor Mode 20
Door Switch Control 22
Inside Air Filter Clogging Detection Control 23
ACTUATOR INSPECTION 24
Air Mix Motor Actuator Inspection 24
Refresh / recirculate Motor Actuator Inspection 26
Mode Motor Actuator Inspection 28
SELF-DIAGNOSIS FUNCTION WITH PANEL DISPLAY 30
Trouble Display and Self-Check Procedure 30
Air Conditioning troubleshooting 34
PART FUNCTION 40
Control Panel and Control Unit 40
Blower Amp 40
Relay 41
Air Mix Actuator 41
Refresh / Recirculate Actuator 42
Blow Mode Actuator 42
Evaporator Sensor 42
Dual Pressure Switch 43
Solar Radiation Sensor 43

9006-3
AIR CONDITIONNER OVERALL DIAGRAM
Hose connection
14 RETURN OUT
4
2
3
SUC
5
DIS
OUT IN IN OUT 6
IN
13
1
10
OUT
OUT IN
11
Hose connection (refer to the following pages)

Item Description Qty
1 Air conditioner condenser 1
2 Cooler hose (LIQUID2) 1
3 Cooler hose (SUCTION) 1
4 Rubber hose 1
5 Air conditioner compressor 1
6 Cooler hose (DISCHARGE) 1
7 Tension pulley (with cover) 1
8 Compressor bracket 1
9 Slide shaft 1
10 Cooler hose (LIQUID1) 1
11 Dryer receiver 1
12 Belt 1
13 Air conditioner unit 1
14 Engine 1

9006-4
Hose Connection (CX160B to CX240B)
A
10
2
11
3
1
3
Heater (ENG.RETURN)
C
4
5
8
4
9
D 5
7
6
3
E
LIQUID 2 2 3 SUCTION
3
F
B
Heater (ENG. OUT) 4 4 1

6
Heater
(ENG.RETURN).
D
3
3 11 10
11
C
Heater (ENG.RETURN) F
E
12
4
5
9 7 4
A
9006-5
Hose Connection (CX290B)
KBR10450-E03
10
1
11
6 2
4
4
2
1
4
6
6
10
6
4
3
6
6
9
3
2
7
4
5
5
6
6
12
3
2

9006-6
CAB
6 9
15
G H
9
6
A
1 B
I
Suction duct
15 D C Filter Interior air
2 8
Duct flange
6 Heater hose
Cooler hose Heater hose
Cooler hose
C
9
5
5
Operator's cab F 4
10
3
17
Cushion seal
Rubber grommet I
Filter case
H 10
11
12
13 4
14
Sensor air conditioner
(solar radiation)
2
Trim side (front upper) 13
Cover top (console left)
Duct DEF-A
7 8
Must be connected with console left harness. D 12
Wire harness (console left)
Duct FACE-A
B
Trim side (front lower) 11
Floor
A
16
KHR13970-D02
G Duct E

9006-7
Cab Description (refer to the previous page)

Item Description Qty
1 Face grille 1
2 Control panel 1
3 Duct FACE-B 1
4 Duct FACE-C 1
5 Duct H & C BOX 1
6 Box HOT & COOL 1
7 Duct VENT (RIGHT) 1
8 Duct VENT (LEFT) 1
9 Box REAR 1
10 Duct; intake (FRESH) 1
11 Air conditioner unit 1
12 Duct FOOT 1
13 Duct DEF-C 1
14 Duct DEF-B 1
15 Face grille 6
16 Drain hose 2
17 Air filter 1
18 Box bracket (left) 1
Air conditioner unit
Item Description
1 Motor actuator (mode)
2 3 2 Compressor relay
1 4 3 Blower OFF relay
4 Motor actuator (refresh / recirculate switch)
5 Interior temperature sensor
6 Blower motor
7 Blower amp
8 Motor actuator (air mix)
9 Evaporator sensor
9
5
6
7

9006-8
Air Conditioner Circuit Diagram
OFF ACC CONNECTION
RELAY BATTERY HEAT B G1 ST
G2 ACC M
G1 K7 S1 ON
HEAT
OFF
ACC
ON
- + - + ST
F12
KEY SWITCH
15A
1
1
3
2
6
4
F23 12V 12V 4
LgR
g
(CN.34)
BATTERY
1
2
LgR
RW
g
1
65A
TEMPERATURE SIGNAL
DOOR SWITCH SIGNAL
WINDOW SWITCH SIGNAL
FUSIBLE LINK F1 KEY SWITCH SIGNAL 2 P6 A9 1 LW LR
TEMP SENSOR(FRESH)
MODE_POTENTIO (SIG)
WINDOW-OPEN SW. IN
MODE M.ACT. LIMITER
R/F M.ACT.(RECYCLE)
BLOWER FEED-BACK
(F14) 5A
(F5) 15A
(
(F13)
AIR-MIX M.ACT.OUT1
AIR-MIX M.ACT.OUT2
SUNLOAD SENSOR2
SUNLOAD SENSOR1
R/F M.ACT.LIMITER
DOOR-OPEN SW.IN
MODE M.ACT.OUT2
R/F M.ACT.(FRESH)
MODE M.ACT.OUT1
SIG.WATER TEMP.
CCU POWER(IGN)
POWER(ILLUMI)
BLOWER GATE
POTENTIO (5V)
) 5A
15A
CCU GND
S53 S54
(
(
( )
)
)
COMPRESSOR
AIRCON
8
8
9
9
2
5
3
6
3
HEATER UNIT
AIRCON
AIRCON
BLOWER
K10
LgR
WG
W
WL
WY
BrW
G
Sb
BL
LG
YL
BrY
B
LB
GR
YW
YR
LW
GW
BG
GL
LY
VW
LR
VY
OL
VR
VG
Y
(UPPER)
RELAY LAMP
LgR
g LgR
g
VG
VY
VR
WR
LR
OL OL
POWER (ILLUM.)
( ) Y Y
WR
LR LR
VR
WY
WL
2 WY
B61 1 WL
WY WL
SUNLOAD
SENSOR 8
BG
GW 2 GW
S52 1 W 3 B
(CN.D12)
DUAL SWITCH
GW W
(RECIVER DRYER)
12 (CN.26)
BrW
WR
VW
BrY
VR
YW
LB
LW
LR
R
BL
16 Sb
W
B
13
11
15
7
9
8
5
3
2
8
9
1
W
Y8
BrW
GW
YW
WR
BrR
VW
BrY
LW
BG
LY GR B
YR
LG
RL
LY
17
YL
Sb
W
Y
V
YL GL Y G W WG L BG
MAGNET CLUTCH
13
W
(CN.D5)
(COMPRESSOR)
6
BG
L
WR
B5
(CN.D2)
VW
V WR
VW LR
TEMP.SENSOR
3 K17 V
LR
(CN.D6)
Sb
BLOWER-OFF RELAY. 7
BG
Sb
BG
WG
R4
3W
SHUNT RESISTOR
GW GR
GR 6
M
(CN.D8)
3WG
G
GW 7
LY 2
G
GL 3
GL LY
B 1
9
B
MOTOR ACT
B
(CN.D3)
LR M7 (AIR MIX)
4 M8
LR
RL
M 2 RL
YW YR
YR 6
BLOWER MOTOR
(CN.D9)
Y 4
YW
LY 2
Y
RL
YL 3
YL LY
B
5 A6 1 BrY
B 1 10
5
B
MOTOR ACT
BLOWER AMPLIFIER M6 (MODE)
LW LR
LR
M
(CN.D10)
LG 4
1 BrR LW 7
(CN.D1)
BrW LgR
R BrR
BrW
LG
15 K6 R 3
LgR
g
M5 1 11
COMPRESSOR RELAY E52 MOTOR ACT
AIR CONDITIONER UNIT (RECYCLE / FRESH)

9006-9
Air conditioner circuit diagram (refer to the previous page)
Item Description
A6 BLOWER (AMP) CONTROLLER
A9 AIR CONDITIONER CONTROLLER
B5 EVA SENSOR
B61 SUNLOAD SENSOR
E52 AIR CONDITIONER UNIT
F5 FUSE 10A; AIR CONDITIONER CONDENSER FAN
F12 FUSE KEY SWITCH
F13 FUSE 5A; HEATER / AIR CONDITIONER
F14 FUSE 5A; AIR CONDITIONER COMPRESSOR
F23 FUSE 65A
G1 BATTERY
K6 RELAY-AIR CONDITIONER CONDENSER FAN
K7 RELAY BATTERY
K10 RELAY WORKING LIGHT (UPPER)
K17 BLOWER OFF RELAY
M5 MOTOR (AIR CHANGING)
M6 AIR VENT DIRECTION CONTROL MOTOR
M7 MOTOR ACT (AIR-MIX)
M8 BLOWER MOTOR
P6 AIR CONDITIONER CONTROL PANEL
R4 THERMISTOR INNER TEMPERATURE
S1 KEY SWITCH
S52 AIR CONDITIONING COMPRESSOR CLUTCH SWITCH
S53 DOOR LIMIT SWITCH
S54 FRONT WINDOW LIMIT SWITCH
Y8 AIR CONDITIONER MAGNET CLUTCH
1 CONNECTOR (CN.29)
2 CONNECTOR (CN.28
3 CONNECTOR (CN.D2)
4 CONNECTOR (CN.D3)
5 CONNECTOR (CN.D4)
6 CONNECTOR (CN.D5)
7 CONNECTOR (CN.D6)
8 CONNECTOR (CN.D11)
9 CONNECTOR (CN.D8)
16 CONNECTOR (CN.26)
17 CONNECTOR (CN.27)

9006-10
EXPLANATION OF CONTROL
Back-up function
Even when air conditioner operation is stopped (switched OFF) with the ignition key power supply or operation
panel ON/OFF switch, the set temperature and all the other setting states are stored in memory, so the next
time air conditioner operation starts, it goes into the same state as before it was stopped.
When the ignition key power supply is cut off, the data is backed up by storing it in the internal EEPROM.
However, if the main key power supply is cut off within 0.5 seconds of switch input, that switch input is not
stored into memory. Also, the data read out from EEPROM when the power is switched ON is judged to see if
it is within the valid range. If data outside the valid range was written into memory, for example due to noise,
then operation starts from the default settings to avoid abnormal operation.
Fahrenheit temperature display

To switch, hold down both the temperature setting UP and DOWN switches for 5 seconds. The display toggles
between Celsius and Fahrenheit display each time the switches are both held down for five seconds.
The Fahrenheit display is a two-digit integer and below the decimal point is not used, so "F" is displayed.
However, in case of trouble, this display takes priority.
When this display is switched, the new status is backed up in memory, so even if the main key power supply is
switched OFF, the display status is retained. Internal calculations are all done in Celsius. Only the operation
panel display is in Fahrenheit. Therefore, the display may differ slightly from the exact Fahrenheit
temperature.
Below is shown the Fahrenheit temperature and the corresponding Celsius temperature used in internal
processing.
CAUTION: Th es e speci fi cat ions are w r it ten w i th C els iu s as t he st andard. Th eref or e, if t he temperat ur e i s
displayed in Fahrenheit, convert the temperature to centigrade by using the table below.
Fahrenheit and Celsius correspondence

Fahrenheit display [F] Interior recognition set temperature
(Celsius) [°C]
63 18.0
64 18.5
65 19.0
77 25.0
91 32.0

9006-11
1. Air Mix Motor Actuator Control

1) Summary explanation
The provisional target degree of opening is determined from the target blow temperature and the current blow
mode, various restrictions are applied, and the target degree of opening is calculated. Then drive is output to
move the motor actuator position to the target degree of opening.
Below are the details.
2) Restrictions on operation angle according to the blow mode
When the blow mode motor actuator is in the B / L, FOOT, or DEF position, it is prohibited for this motor
actuator degree of opening to be less than 20°C.
3) Heater unit hysteresis correction operation (motor actuator one-direction stop)
After the actuator moves to the target degree of opening, it returns to the specified position. However, if the
target degree of opening is less than 0°C, the actuator is treated as having reached the target degree of
opening when it reaches 0°C, then it moves to the specified position.
(A stop in the fully-open direction is used as the standard.)
4) Operation start / stop judgment
1) The operating motor actuator stops when the current position comes within the target position.
2) The stopped motor actuator operates when the current position goes beyond the target position.
5) Motor actuator operation priority order
The operation priority for this motor actuator is No. 1. This means that if the target degree of opening for this
motor actuator changes and operation becomes necessary, even if some other motor actuator is operating,
that other motor operation is paused, and this motor actuator operates.
2. Blow Mode Motor Actuator Control

The blow mode is switched by rotating the diffuser switching damper with the motor actuator. There are two
types of control: auto and manual.
2) Auto control
When the AUTO blow mode signal is recognized, the blow mode changes to auto control. During auto control,
the diffuser is switched according to the target blow temperature Auto control continues until operation of the
blow mode select switch is recognized.
Blow mode
MODE 2
MODE 3
MODE 4
Target blow temperature
AUTO blow mode

9006-12
3) Manual control
a) When operation of the blow mode select switch is recognized, the motor actuators are driven to attain the output
shaft angle below and the display is switched too. Each time operation of the switch is recognized, the display
switches MODE1 => MODE2 => MODE3 => MODE4 => MODE1 => ... However, if this switch is pressed during
auto control, auto control is ended and the diffuser is fixed at its current position.
b) MODE5 in the table below only occurs when operation of the DEF select switch is recognized. After that, when
operation of the blow mode select switch is recognized, the blow mode becomes the one that was in effect just
before operation of the DEF switch was recognized.
Blow mode and display and motor actuator angle

Blow mode MODE 1 MODE 2 MODE 3 MODE 4 MODE 5
Blow mode motor actuator degree of opening 90° 65.5° 46.5° 26.6° 0°
Panel display FACE VENT B/L FOOT DEF
4) Mode unit hysteresis correction operation (motor actuator one-direction stop)

After the actuator moves to the target degree of opening (a), it returns to the specified position. However, if (a)
is less than 0°C, the actuator is treated as having reached the target degree of opening (a) when it reaches
0°C, then it moves to the specified position.
(A stop in the VENT or FACE direction is used as the standard.)
5) Operation start / stop judgment
a) The operating motor actuator stops when the current position comes within the target position.
b) The stopped motor actuator operates when the current position goes beyond the target position.
6) Blow mode control priority order
The priority order for auto control and manual control is as follows.
Control priority order

Priority order Control
1 Manual control
2 Auto control
3. Refresh / Recirculate Switch Motor Actuator Control

1) Recirculate mode
In refresh mode, when it is recognized that the refresh / recirculate switch on the operation panel has been
closed, the system goes into recirculate mode. At this time, the display switches to recirculate and the refresh
/ recirculate switch motor actuator operates to the recirculate angle.
2) Refresh mode
In recirculate mode, when it is recognized that the recirculate / refresh select switch on the operation panel
has been closed, the system goes into refresh mode. At this time, the display switches to refresh and the
refresh / recirculate switch motor actuator operates to the refresh angle.
3) Operation stop judgment
When one of the limiters is detected, operation stops.
Refresh / recirculate mode and refresh / recirculate display and motor actuator angle
Refresh / recirculate mode Recirculate Refresh
Refresh / recirculate motor actuator degree of opening 0° 90 °
Panel display

9006-13
4. Blower Amp Control

The air flow is controlled by outputting to the blower amp connected in series with the blower motor. The air
flow is switched by varying the analog voltage output by changing the PWM output duty ratio and increasing or
decreasing the blower motor speed.
There are two types of air flow control: auto air flow control and manual air flow control. Also, in auto air flow
control, the air flow is restricted by the cold blast prevention control etc.
Auto air flow control has no levels and manual control has four levels.
2) Manual air flow control
Each time it is recognized that the air flow UP switch has been closed, Lo => M1 => M2 => HI the air flow is
fixed to the next higher level of air flow. When Hi is already displayed, the air flow is not changed.
In the same way, each time it is recognized that the air flow DOWN switch has been closed, HI => M2 => M1
=> Lo the air flow is fixed to the next lower level of air flow. When Lo is already displayed, the air flow is not
changed.
The same is true when air flow control is switched from auto to manual. For example, when AUTO M1 is
displayed, if it is recognized that the air flow DOWN switch has been closed, the display becomes Lo and
AUTO is no longer displayed.
Also, the change speed for air flow output switch over is the same as discussed for auto below.
Relationship between air flow and PWM output

Air flow Display Target % (approx.)
Hi (maximum air flow) 100%
M2 75%
M1 59%
Lo (minimum air flow) 40%

9006-14
3) Auto air flow control

When it is recognized that the AUTO switch has been closed, the air flow is controlled automatically and
AUTO is displayed.
a) During auto air flow control, the air flow is set according to the target blowing temperature as in Figure 3.
b) Auto air flow control continues until closing of either the air flow UP or air flow DOWN switch is recognized.
c) The auto air flow amount calculation results are continuous, not divided into levels.
d) When it is recognized that the AUTO switch has been closed, the display becomes as in Table 10 according to
the results of the auto air flow amount calculation.
e) The normal auto air flow output change is roughly 5 V / second.
f) Auto air flow control is restricted by the cold blast prevention control described in (4), which is the next item.
Air Flow
Hi
M2
M1
Lo
Relationship between air flow and target blow temperature
Display refreshing and air flow output correspondence table

Current display Item Target% (approx.)
Lo display Output range changed to M1 When 53% or higher
M1 display Output range changed to Lo When 46% or lower
Output range changed to M2 When 70% or higher
M2 display Output range changed to M1 When 64% or lower
Output range changed to Hi When 92% or higher
Hi display Output range changed to M2 When 83% or lower

9006-15
4) Cold blast prevention control

The air flow is restricted according to the value of the coolant temperature and other parameters sent from the
vehicle side. The air flow restriction has two levels - air flow 0 and air flow Lo. Whether or not to use the
restriction is determined from the judgment results.
a) Conditions under which cold blast prevention control is used
1. Auto air flow
2. When set temperature - inside air sensor temperature > 11°C
3. When the coolant temperature signal from vehicle is the less than 35°C signal or the 35°C or higher but
less than 45°C signal
Under the condition above, the inside air sensor temperature is the value immediately after the ignition key
power is switched ON and AUTO and Test are according to the current switch states. Therefore, when the
AUTO switch is pressed after the air flow has been set manually, if the coolant temperature is within the
cold blast prevention range, the air flow is restricted. In the same way, even if the set temperature is
changed, if the conditions are met, the air flow is restricted.
While cold blast prevention control is being executed, the display corresponds to the restricted air flow.
b) Air flow 0 control
When the coolant temperature signal from vehicle is the less than 35°C signal, the air flow is set to 0. This
continues until a coolant temperature signal of 30°C or higher is received. Once a coolant temperature
signal of 30°C or higher is received and these conditions are no longer met, air flow 0 is ended.
c) Air flow Lo control
When the coolant temperature signal from vehicle is the 35°C or higher but less than 45°C signal, the air
flow is set to Lo. This continues until a coolant temperature signal of 45°C or higher is received. Also, the
same as for (b), this shift is irreversible. Once a coolant temperature signal of 45°C or higher is received,
control is normal.
Coolant temperature signal sent from the vehicle (one cycle)

* Finalized by the same waveform for three cycles. However, for the first combustion after the
ignition switch is switched ON, judged with the latest one cycle.
* The default state for the coolant temperature signal when the ignition is switched ON is 45°C or
higher.
100 100 100 100 100 100 100 100 100 100 100 100 100
ms ms ms ms ms ms ms ms ms ms ms ms ms
5V
Coolant temperature < 30°C
0V
5V
30°C < Coolant temperature < 45°C
0V
5V
45°C < Coolant temperature
0V

9006-16
5) Air flow control priority order

The priority order for auto air flow control, manual air flow control, and cold blast prevention control is as
follows.
Control priority order

Priority order Control
1 Blower air flow control when mode motor actuator angle switched
2 Manual air flow control
3 COOLMAX control
4 Cold blast prevention control
5 HOTMAX control
6 Auto air flow control
5. Compressor Clutch Control

The compressor clutch is controlled by the power to the clutch coil being switched ON / OFF by an external
relay. This control is executed by thermo operation, the condensation prevention function, and the fretting
prevention function. Thermo operation has control mode 1 and control mode 2. These modes are applied
according to the blow mode and other conditions. However, for blower air flow 0, the compressor clutch is
switched OFF. The operation temperature does not include the thermistor variation.
2) Thermo operation (AC switch ON)
a) Control mode switch over
• When the blow mode is B / L and the target blow temperature is as in the figure below, control mode 2 is
used.
As the figure shows, there is hysteresis between control modes 1 and 2.
• Other than the above is all control mode 1.
Control mode 1
Control mode 2
Relationship between control mode

and target blow temperature for B / L
b) Control mode 1
• OFF temperature: 5 ± 1°C
When this temperature or lower is detected, the compressor clutch is switched OFF.
(It is kept OFF until a temperature at or above the ON temperature is detected.)
• ON temperature: OFF temperature + 2 ± 0.5°C
When this temperature or higher is detected, the compressor clutch is switched ON.
(It is kept ON until a temperature at or below the OFF temperature is detected).
c) Control mode 2
• OFF temperature: 5 ± 1°C
• ON temperature: OFF temperature + 2 ± 0.5°C.

9006-17
3) Condensation prevention function

a) Timer set temperature: 8 ± 2°C
When this temperature or lower is detected, the timer is set and starts counting.(It is not reset until a
temperature at or above the timer cancel temperature is detected.)
b) Timer cancel temperature: Timer set temperature + 1 ± 1°C
When this temperature or higher is detected, the timer is reset.
c) Count-up time: 10 ± 1 minutes
When the timer count reaches this time, the compressor clutch is switched OFF. After this, when the timer
recovery temperature or higher is detected, the compressor clutch is switched ON and timer setting is
prohibited.
d) Timer recovery temperature: Timer set temperature + 2 ± 1°C
When this temperature or higher is detected, the compressor clutch is switched ON and timer setting is
permitted.
4) Fretting prevention function
Compressor main shaft has a possibility to suffer by corrosion as fretting corrosion according to the engine
vibration mainly. To avoid this corrosion, this system has fretting prevention function.
a) Operation conditions
After the end of initial operation, if 5 ± 1 minutes continue with the air flow M2 or higher and the compressor
clutch not coming ON even once, the compressor clutch is switched ON one time.
This control is cleared by the ignition key power being switched OFF and this control starts again when this
power supply is switched ON again.
Compressor clutch ON time: 1 ± 0.6 seconds
b) This control takes priority over all other control.
5) AUTO switch link function
When operation of the AUTO switch is recognized, compressor clutch control comes ON and AUTO is
displayed.
a) Compressor clutch control is the same control as for the AC switch being switched ON.
b) When it is recognized that the AC switch has been switched OFF, the AUTO display goes out. Even when it is
recognized that the AC switch has been switched ON again, AUTO is not displayed.
However, at this time, if the main key power is switched OFF, then ON again, since the AC ON, air flow AUTO,
and blow mode AUTO conditions are all met, AUTO is displayed.
6. COOLMAX Control and HOTMAX Control

1) When the set temperature is 18.0°C [COOLMAX] (or 18. E)
a) The air mix motor actuator is set to the 0° limiter position (fully closed).
b) For auto air flow control, the air flow is set to Hi.
c) For AUTO blow mode control, the blow mode is set to VENT.
2) When the set temperature is 32.0°C [HOTMAX]
a) The air mix motor actuator is set to the 90° limiter position (fully open).
b) For auto air flow control, the air flow is set to M2.
c) For auto blow mode control, the blow mode is set to FOOT.

9006-18
7. Trouble Detection and Control after Trouble Detected

If there is trouble in a motor actuator drive line or sensor controller input circuit, the trouble is detected and
control from then on changed as described below.
In any of these cases, once trouble has been detected, even when that location is returned to normal, trouble
control is not ended. Trouble control is only ended when the ignition key power supply is switched OFF or
when air conditioner operation is stopped with the ON / OFF switch on the operation panel. However, motor
actuator restriction is only ended by switching OFF the main key power supply.
2) Trouble in a motor actuator and its input / output circuits
a) Disconnection detection
Immediately after the main key power supply is switched ON, if a motor actuator potentiometer line is
disconnected or shorted, the display in the table below for that motor actuator is carried out and that motor
actuator is not driven until the main key power is switched OFF, then ON again.
Disconnection detection display

Trouble location Trouble display
Air mix motor actuator HL.E is displayed on the set temperature display
LCD. (See the figure below.)
Blow mode motor actuator The passenger icon display flashes.
Refresh / recirculate motor actuator Potentiometer line not used
b) Motor lock detection

If the output shaft rotation angle for a motor actuator does not reach its target value within 15 seconds, this
is treated as lock detection, output to that motor is stopped, and trouble is displayed on the controller
according to the trouble location.
Motor lock detection display

Trouble location Operation panel trouble display
Air mix motor actuator HL.E is displayed on the set temperature display
LCD. (See the figure below.)
Blow mode motor actuator The passenger icon display flashes.
R e f r e s h / r e c i r c u l a t e s w i tc h m o t o r The refresh / recirculate mark flashes.
actuator

9006-19
3) Trouble in a sensor or its input / output circuits (disconnection or short)

a) Disconnection or short in the inside air sensor or its input / output circuits
1. Operator compartment temperature control end
• All control related to the operator compartment temperature (target blow temperature) is stopped and
the air mix degree of opening is directly adjusted according to the temperature adjustment switch input.
• Accompanying this, the operation panel set temperature display changes as H L . * ,
* is a value from 0 to 9. Each time the DOWN switch is closed, this value decreases by 1; each time the UP
switch is closed, this value increases by 1.
For any blow mode other than FACE or VENT, the minimum value is set to 1.
Display and control for inside air sensor trouble

* value Motor actuator degree of opening (°)
0 0°
1 to 8 * value X 10 °
9 90 °
2. Auto air flow control end

• The air flow is temporarily fixed at that in effect when the inside air temperature sensor trouble was
detected.
• The AUTO display is set flashing.
• After this, the air flow is switched by the manual air flow switch.
3. AUTO blow mode control end
• The blow mode is temporarily fixed at that in effect when the inside air temperature sensor trouble was
detected.
• The AUTO display is set flashing.
• After this, the blow mode is switched by the manual blow mode switch.
4. Air mix damper degree of opening display priority
• Even if the trouble shown by one of the items below occurs during inside air sensor trouble, E is not
displayed in the * section below the decimal point and the air mix damper degree of opening display is
given priority.
• HL.E is only displayed for air mix motor actuator trouble.
5. Thermo operation control mode fixed
• Switching of the control mode according to the blow mode and target blow temperature is stopped and
the control mode is fixed at control mode 1.
b) Disconnection or short in evaporator sensor or its input / output circuits
1. Compressor control is not executed and the compressor clutch is always OFF. However, fretting
prevention control is executed.
2. E is displayed in the first fraction position of the set temperature display LCD (See the figure below).
(The temperature setting is in 1°C steps.)
However, E is not displayed for inside air sensor trouble.
3. The AC mark flashes.
The AC mark flashes

E is not displayed
c) Disconnection or short in solar radiation sensor or its input / output circuits

1. The solar radiation compensation data is set to 0.
2. E is not displayed in the first fraction position of the set temperature display LCD as it is for other
sensors.
d) Coolant temperature signal trouble
Cold blast prevention control does not work and normal control is used.

9006-20
8. Monitor Mode
Monitor mode is a mode for understanding trouble in the controller itself or in other control. The system goes
into monitor mode when there is the special switch input below on the operation panel.
2) Starting monitor mode
When the air conditioner is operating with basic control, if the operation panel ON / OFF switch closed path
continues for one second while the refresh / recirculate switch closed path is ongoing, monitor mode is
started.
3) Monitor contents
a) LCD segment diagnosis
When monitor mode is entered, the target LCD lights up for one second. An LCD with trouble does not light
up.
b) Sensor diagnosis
The detection value (AD value or °C) for each sensor is displayed.
c) Coolant temperature signal recognition value
This displays the reception status for the coolant temperature signal sent from the vehicle.
4) Monitor contents
a) LCD segment diagnosis
When monitor mode is entered, the target LCD lights up for one second. An LCD with trouble does not light
up.
b) Sensor diagnosis
The detection value (°C) for each sensor is displayed.
5) Display contents in monitor mode
In monitor mode, the data (detection value for each sensor, coolant temperature signal recognition, etc.) is
displayed in the three digits of the 7-segment display for the temperature setting. The data displayed is
selected with the blower UP / DOWN switches and AUTO switch. The blower UP / DOWN switches move the
display on the dedicated monitor mode 7-segment display through 16 displays, 0 to F, and the corresponding
data is displayed (Table A on next page). Hexadecimal data display and decimal data display can be selected
with the AUTO switch. Only for the coolant temperature signal recognition value, the value detected
immediately before entry into monitor mode is displayed.
The difference between hexadecimal data and decimal data is indicated by the third digit of the 7-segment
display. For hexadecimal data, "H" is displayed there and for decimal data, numbers (0 to 9) are displayed
there.
a) Hexadecimal display
AD values 00H through FFH are displayed. When the AD value corresponds to that in Table B on the next
page (or Table C for the solar radiation sensor), this indicates a disconnection or short. In the hexadecimal
display, when the value of a sensor changes in monitor mode, the hexadecimal display changes with it. If
the display before entering monitor mode was H L . * , the error judgment value is displayed (In other
words, the value detected before the trouble was detected). In the same way, if the display before entering
monitor mode was * *. E , the display becomes **.E and the error judgment value is displayed.
b) Decimal display
From -99.9°C to 99.9°C is decimal display. Also, the "-" minus display displays the arrow mark for FOOT
mode.
6) Air conditioner operation in monitor mode
When the system enters monitor mode, all output (operation) through control is stopped and until monitor
mode is ended, operations and settings of basic control through all the switches are not possible.

9006-21
7) Ending monitor mode

In monitor mode, if the operation panel ON / OFF switch closed path continues for one second while the
refresh / recirculate switch closed path is ongoing, monitor mode is ended and the system returns to the basic
control state. The same also occurs if the ignition key power supply is switched OFF.
Table A
Dedicated monitor mode Display contents
7-segment display
0 Inside air sensor temperature data
1 Evaporator sensor temperature data
2 Solar radiation compensation data
C Coolant temperature signal status data
Trouble Lower than 30°C 30°C or higher 45°C or higher
and lower than
45°C
4 1 2 3
3 to 9 and B to F Data (sensor diagnosis etc.)
Table B
Sensor name Short Disconnection
Inside air sensor F6H 0CH
Evaporator sensor F6H 0CH
Table C
Sensor name 5 V short Ground short
Solar radiation sensor C7H 0CH

9006-22
9. Door Switch Control

This control adds a restriction to air conditioner operation with the door switch or front window switch. Its
purpose is to prevent overheating of the ignition unit. Concretely, it suppresses condenser heating and
controls in a way restricted in order to obtain a feeling of comfort.
2) Door switch / front window switch signal
The signal input into the controller is as follows for both the door and front window switches.
a) When door / front window open
Contact closed, the control controller input is at ground level.
b) When door / front window closed
Contact open, pulled up to 5 VDC inside the control controller
3) Control restricted by door switch / front window switch
a) Starting restricted control
When either the door or front window is open continuously for one second or longer, it is recognized that the
switch is open. At the count of 60 seconds, the buzzer buzzes the same way as for switch input to tell the
operator that restricted control is starting and that control starts.
b) Restricted control
1. For both auto and manual blow mode control:
Even if auto or manual blow mode is selected, unless the blow mode is FACE, the following air flow
restriction is executed.(If the blow mode is FACE, the air flow is not restricted.)
I. If the target blow temperature < 20°C, the air flow upper limit is set to M1.
II. If the target blow temperature > 25°C, the air flow restriction in I is ended.
2. When the current blow mode control is AUTO
Auto control with the AUTO blow mode VENT changed to FACE is used.
3. When the current blow mode control is manual selection
Only if the blow mode is VENT immediately after the open switch is recognized, that mode is changed to
FACE. After this, all the blow modes can be selected with manual operation.
c) Ending the restriction
When both the door and front window are closed continuously for one second or longer, it is recognized that
the switches are closed. After a count of 1 second, the buzzer buzzes the same way as for switch input to
tell the operator that restricted control has been ended.
When the restricted control is ended, the restriction on the air flow discussed in 1. above and the change
from VENT to FACE in 3. are ended and control returns to normal. However, if the blow mode has been
manually selected, even if the mode was changed from VENT to FACE by the above restriction, it does not
return to VENT when the restricted control is ended.

9006-23
10. Inside Air Filter Clogging Detection Control

This control recognizes the blower current with the dedicated shunt resistor voltage input, judges from that
value whether or not the AC unit inside air filter is clogged and if it judges that filter is clogged, it issues a
warning to encourage the operator to replace the filter.
2) Filter detection control
a) Starting detection control (detection timing)
Five seconds after the end of initial operation, if the air conditioner is operating and the cold blast
prevention conditions are not present, this control is started. Also, this control is executed every 50 hours of
air conditioner (blower) operation. However, during a temporary filter clog or filter clog, it is executed every
time.
b) Detection method
Cooling / heating is judged from the operation mode and in this way the air mix motor actuator target
position is determined. Also, the mode motor actuator target value is set to FOOT, the blower air flow target
value is set to M1, and output is made to attain the target values. When all the target values are attained,
the blower current from the shunt resistor voltage is recognized, and the filter clog is judged by comparing
this current with the default current value.
(Cooling / heating judgment)

When the operation mode is FACE or VENT, : Cooling (COOLMAX)
When FOOT or DEF : Heating (HOTMAX)
When B / L: Final inside air temperature If < 22°C, heating
When B / L: Final inside air temperature If > 22°C, cooling
(Detection current threshold)
Relative to the default current value For cooling : 0.37 ± 0.02 A min.
For heating : 0.51 ± 0.03 A min.
If the value is below this three times in a row, it is judged that there is a clog.
(Default current value)
Current found in the initialization operation described below.
3) Clog warning
(Buzzer)
The buzzer buzzes intermittently at 1 Hz for 10 seconds.
(Display)
"FIL" is displayed on the 7-segment display for the set temperature for 10 seconds. Other marks go out.
However, if there is any switch input, the "FIL" display is ended immediately.
4) Alarm reset
If a reset detection value is recognized during the clog state, the clog state is reset.
The reset detection value is 50% of the clog detection threshold.
5) ON / OFF switching
This function is switched ON / OFF by pressing the [Refresh / Recirculate], [MODE], and [DEF] switches at the
same time. The factory setting for this function is OFF. This function does not come ON until the initialization
operation discussed below is executed.
(Buzzer)
When operation of this switch is recognized, there is the normal switch input sound.
(Display)
ON or OFF is displayed on the set temperature 7-segment display, whichever is the state after switching.
Other marks go out.

9006-24
ACTUATOR INSPECTION
Air Mix Motor Actuator Inspection
1 2
G/W G/W
G
G/R
B G
3
G/L
L/Y 4 M
G/R
G/L
L/Y
Air mix damper operation defect
See the Chart.
Specifying the trouble location
1 Control panel
2 Air mix motor actuator
3 Connector 1
4 Connector 9

9006-25
Chart
IGN OFF¨ON (when the engine starts)
Does Is an error
the actuator operate at all in NO displayed after the end of NO
initial operations? initial operation?
Control panel defect

YES YES
Does it Is there
operate according to the NO conductance in the harness NO
initial operation table below? between the actuator and
controller amp?
Harness defect
YES YES
Actuator defect or damper

Is an error lock or link defect
displayed after the end of NO
initial operation
Damper lock or link

defect
Disconnect the actuator connector (9)
Is the resistance NO
between L/Y and B of the
actuator about 4 k Ohms
Initial operation table

Actuator position before Air mix motor actuator
YES initial operation start
(1) COOLMAX position (0°) 0° => 90° => 0°
(2) HOTMAX position (90°) 90° => 0°
Is there (3) Other than the above Current position => 90° => 0°
conductance between the G / NO
L and L / Y of the actuator
and between G / L and B?
YES Actuator defect

9006-26
Refresh / recirculate Motor Actuator Inspection
1 2
L/W L/W
3 L/G
5 M
L/R L/R
L/G
4
Refresh/recirculate operation defect
See the Chart.
1 Control panel
2 Air mix motor actuator
3 Connector 1
4 Connector 2
5 Connector 11

9006-27
Chart
Switch the ignition OFF=>ON (to start the engine) and

complete the air mix and mode initial operation.
Press the refresh /

recirculate switch. Does the NO
actuator operate at all?
YES
Switch the
setting to recirculate. Does NO
the actuator become about
0°?
YES
Switch the
setting to refresh. Does the NO
actuator become about 90°?
NO
Is a refresh/recirculate error
Damper lock or link displayed?
defect
YES
Is there
conductance in the harness NO
between the actuator and
controller amp?
Harness defect
YES

lock or link defect

9006-28
Mode Motor Actuator Inspection
1 2
Y/W Y/W
Y
Y/R
B Y
3
Y/L
L/Y 4 M
Y/R
Y/L
L/Y
Inside / outside air mix damper operation defect
See the Chart.
1 Control panel
2 Mode motor actuator
3 Connector 1
4 Connector 10

9006-29
Chart
IGN OFF¨ON (when the engine starts)
Does Is an error
the actuator operate at all in NO displayed after the end of NO
initial operations? initial operation?

YES YES
Does it Is there
operate according to the NO conductance in the harness NO
initial operation table below? between the actuator and
controller amp?
Harness defect
YES YES

Is an error
lock or link defect
displayed after the end of NO
initial operation
Damper lock or link

defect
Disconnect the actuator connector (10)
Is the resistance NO
between L/Y and B of the
actuator about 4 k Ohms
Initial operation table

Actuator position before Air mix motor actuator
YES initial operation start
(1) COOLMAX position (0°) 0° => 90° => 0°
(2) HOTMAX position (90°) 90° => 0°
Is there (3) Other than the above Current position => 90° => 0°
conductance between the Y/ NO
L and L/Y of the actuator and
between Y/L and B?
Actuator defect
YES

9006-30
SELF-DIAGNOSIS FUNCTION WITH PANEL DISPLAY
Trouble Display and Self-Check Procedure

Motor actuator and sensor troubles can be checked on the panel display.
1) Trouble Display Position
• Error is displayed on 3 digit 7-segment display.

2) Explanation of Trouble Display
a) Motor actuator trouble
1. HL.E displayed on three-digit 7-segment display
Check the air mix damper motor actuator for
harness disconnection or disconnected
connector.
2. MODE flashes.
Check the blow mode damper motor actuator for

connector.
3. The R / F flashes.
Check the refresh / recirculate motor actuator for

connector.
CAUTION: With the panel ON / OFF switch

ON, the above display and flashing does
not function even if a harness
disconnection or disconnected connector
occurs.
After trouble occurs, when the panel ON /
OFF switch is switched ON, the function is
displayed.
After trouble occurs, the trouble display
and flashing are not ended until the main
switch is switched OFF=>ON.

9006-31
b) Sensor trouble
1. HL.* displayed on three-digit 7-segment display
Check the inside air sensor and check its harness

for disconnection, short, or connector connection
defect.
(* is any number 0 to 9)
(*)
2. **.E and the mark flashing display are displayed on the three-digit 7-segment.
(** displays the set temperature value at that time still remaining.)
Check the evaporator sensor and its harness for

** disconnection, short, or connector connection
defect.
CAUTION: The display in [1] and [2] above is displayed on the three-digit 7-segment display when trouble
occurs with the panel ON / OFF switch ON.
After the trouble section is repaired, end the trouble display by switching the panel ON / OFF switch
OFF=>ON.

9006-32
3) Explanation of Monitor Mode

When sensor trouble is displayed, the sensor status (disconnection, short) can be checked in monitor mode.
a) Monitor mode display position
• (25.5) = Three-digit 7 segment (°) = 7 segment dedicated to monitor display

b) Monitor mode display operation method
1 2
3 1 Refresh / recirculate switch

2 Blower switch UP / DOWN switch
3 ON / OFF switch
1. Hold down the refresh / recirculate switch and the ON / OFF switch at the same time for one second or
longer.
2. Press the AUTO switch.
(All the segments light up for one second, then the system enters monitor mode.)
3. Numbers 0 to 9 or letters A to F are displayed in the first and second digit of the three-digit 7-segment
display.
"H" is displayed in the third digit.
4. The 0 to 2 display on the dedicated 7-segment display is carried out with the blower UP / DOWN
switches. The necessary sensor is selected from the table below.
7-segment display table indicated to monitor
0 Inside air sensor

1 Evaporator sensor
2 Solar radiation sensor
(Display other than the above (3 to 9, B to F) is not

used during service)
5. To end the monitor display, either hold down the refresh / recirculate switch and the ON / OFF switch at
the same time for one second or longer or switch the vehicle main switch OFF.
CAUTION:
1. During monitor mode, operations and settings of basic control through all the switches are not possible
until the air conditioner control operation is stopped and monitor mode ended.
2.During monitor mode, even if a sensor is repaired, the trouble display is recorded in memory, and until
the ON / OFF switch is switched OFF, then ON again, the trouble display is not ended.

9006-33
c) Display contents in monitor mode
See the dedicated monitor 7-segment display table and three-digit 7-segment table.
1. Display example 1
The dedicated monitor 7-segment display is 0

(indicates the inside air sensor state).
0 From the three-digit 7-segment table 3F=>The
sensor is normal.
=>The inside air sensor is normal.

(indicates the evaporator sensor state).
1 From the three-digit 7-segment table 00=>The
sensor is disconnected.
=>The evaporator sensor is disconnected.

(indicates the solar radiation sensor state).
2 From the three-digit 7-segment table FF => The
sensor is shorted.
=>The solar radiation sensor is shorted.
Three-digit 7-segment table
Second digit of 7-segment display

0 1 2 3 4 5 6 7 8 9 A B C D E F
Inside air sensor disconnection OCH0 display
0 Evaporator sensor disconnection OCH1 display
Solar radiation sensor short OCH2 display
1
2
3
4 1 0
3rd-digit of 7-segment display
5 Sensors normal
6
7
8
9
A
B
C
D 2
Solar radiation sensor 5V side short C7H2 display
E
F Inside air sensor short F6H0 display

Evaporator sensor short F6H1display

9006-34
Air Conditioning troubleshooting
The blow temperature does not go down

When the AUTO switch or AC switch is pressed, HL. E is displayed in
the panel set temperature display section.
YES
NO
“HL.*” is displayed on the panel set
temperature display section. 1) The air mix motor actuator connector is
(*) is a number 0 to 9. disconnected or has a contact defect.
2) Air mix motor actuator defect.
NO YES 3) E Main harness conduction defect.
The panel snow mark The panel snow mark
flashes. flashes. Inspect and repair or replace the
parts
NO
YES
1) Inside air sensor or harness
1) Inside air sensor and evaporator
disconnection or short
sensor simultaneous disconnection or
2) The inside air sensor connector is
short.
disconnected or has a contact defect
2) Computer breakdown.
See the «Monitor Mode» item too. See the «Monitor Mode» item too.
Inspect and repair or replace the

parts
YES
NO
When the setting temperature is set to 18.0 and the blow 1) The evaporator sensor connector is
mode is set to vent mode, the blow temperature drops. disconnected or there is a contact defect
2) Evaporator sensor simultaneous
disconnection or short
NO
YES See the «Monitor Mode» item too.
The air mix damper is at the Cool air is blowing into the Inspect and repair or replace the
COOLMAX position. inside air sensor section parts
NO YES NO
Switch compressor clutch ON/ Computer breakdown

If motor actuator operation or inside air sensor
OFF and inspect and repair the
stops midway, find the cause defect
power supply circuit
and correct it, measure the
operating force. Is it 1.5 kgf or
less? See the cooling cycle Inspect and replace
troubleshooting.
YES
NO YES Inspect the duct or
Motor actuator or computer eliminate the cause of the
1) Inspect, repair, or replace the cool air infiltration.
breakdown
motor actuator lever link section.
2) Clean the lever link section, then
apply grease. Replace

9006-35
The blow temperature does not go up
HL.E is displayed on the panel set temperature
display section.
YES
NO
“HL.*” is displayed on the panel set
temperature display section. 1) The air mix motor actuator
(*) is a number 0 to 9. connector is disconnected or has a
contact defect.
2) Air mix motor actuator defect.
3 ) E Ma i n ha r n e s s c on d uc ti o n
defect.
YES
NO
1) Inside air sensor or harness disconnection
or short
2) The inside air sensor connector is Inspect and repair or
disconnected or has a contact defect replace the parts
See the «Monitor Mode» item too.

parts
When the setting temperature is set to 32.0 and the

blow mode is set to foot mode, the blow temperature
rises.
NO YES
The air mix damper is at the Warm air is flowing into the
HOTMAX position. inside air sensor section
NO YES NO
Inspect the warm
If motor actuator operation YES
coolant lines Control panel
stops midway, find the cause
and correct it, measure the breakdown or inside Inspect the duct or
operating force. Is it 1.5 kgf or air sensor defect eliminate the cause of
less? the warm air infiltration.
Inspect and replace
NO
1) Inspect, repair, or replace YES

the motor actuator lever link Motor actuator or computer
section. breakdown
2) Clean the lever link
section, then apply grease.
Replace

9006-36
The blower motor does not rotate
With the flow set to HI, battery voltage is applied to
both terminal(+ and -) of the blower motor. (See the
“Note 1”).
NO YES
The battery voltage is applied between the blower Replace the

motor (+) power supply red/blue and the body. blower motor
YES
NO
Voltage of about 10 V is applied between the
1) Inspect the blower motor relay blower amp brown / yellow line and ground.
2) When the blower motor relay white/red
and blue/ red are directly connected, the
blower motor rotates. (See the “Note 2”).
NO YES
There is conductance between

Replace control
brown/yellow and black.
panel
NO YES
Inspect, replace or The voltage is applied between

repair the wire NO YES
the blower motor relay white/
harness red and the body.
Eliminate the cause of Inspect, replace or
the trouble, then repair the wire
replace the blower harness
amp.
YES
NO
When the blower motor relay
Inspect, replace or purple/white is dropped to ground,
repair the wire the blower motor rotates.
harness.
NO YES
Replace the relay. Inspect, replace or repair

the wire harness or
replace the control panel
(Note 1) measure with the connector connected

(Note 2) For the sake of safety, have the air conditioner, vehicle key, and light
switches all OFF when working with direct connections in place.

9006-37
The blower motor speed does not change
(1)
“HL.*” is displayed on the panel set temperature display section.
(*) is a number 0 to 9.
YES
1) Inside air sensor or harness

NO disconnection or short
2) The inside air sensor connector is
Replace the blower amp disconnected or has a contact defect
or control panel
See the «Monitor Mode» item too.

parts
(2)
Does the blower motor fail to change speed when the mode is other
than face?
YES
Is the door or front window open?
NO
YES
While operating under restrictive control See (1)

by door switch or front window switch.

9006-38
The magnetic clutch does not engage
When the AUTO switch or AC switch is pressed, the
snow mark lights up.
NO YES
The snow mark flashes and E is displayed Voltage is applied to the clutch.
on the panel display section.
YES
1) The evaporator sensor connector is
connected or there is a contact defect Clutch defect. Replace the
2) Evaporator sensor simultaneous compressor.
disconnection or short NO
See the «Monitor Mode» item too. Voltage is applied to the

harness for the pressure
Inspect and repair or replace the switch.
parts
NO YES
Voltage is applied between the vehicle side Pressure switch defect or coolant pressure
harness connector brown/red and ground abnormally high or low.
(black)
See the cooling cycle

NO YES troubleshooting.
Inspect the clutch fuse Is there trouble in the air
conditioner harness?
NO YES
Replace the harness. Replace control panel.
Refresh/recirculate mode does not switch

The refresh/recirculate mode display on the operation panel
LCD display section is flashing.
NO
YES
There is foreign matter on the motor actuator The refresh / recirculate motor actuator
lever or the motor actuator lever section is connector is disconnected, there is a contact
broken. defect, or there is trouble with the motor
actuator or the main.
YES
NO
Remove the foreign matter or replace
Replace the motor actuator. the part.

9006-39
The mode is not switched
The passenger icon display on the operation panel LCD
display section flashes.
NO YES
The inside/outside air motor actuator
Inspect or replace connector is disconnected or has a contact
defect or the motor actuator is broken or the
main harness is broken.
NO YES
Repair Is a damper lever out of place?

Inspect or replace
NO NO
Repair When the cam with the rod removed is

moved by hand, it is sluggish (2 kgf or
more)
NO YES
1) Foreign matter or breakage at cam

section or damper shaft section.
Replace the motor actuator or
2) Operation defect due to soiling with
control panel.
grease or the like
1) Eliminate the foreign matter or replace

the part.
2) Clean the cam section, then apply
grease.

9006-40
PART FUNCTION
Control Panel and Control Unit

The control panel and control unit are formed into one piece. The operation of its built-in microcomputer compares,
operates on, and processes the sensor input signals and control panel switch input signals, switches the output side
actuators (refresh / recirculate switching, air mix) and comprehensively controls the fan motor and compressor.
It is equipped with self-diagnosis functions to make trouble diagnosis easier.
(For details see the control specifications.)
Blower Amp
The blower amp receives the control signals from the control unit and changes the speed of the blower motor.
Terminal
number
Conductance
1 2 3
+ - Conductance (4.7 k Ohms ±5%)

- + No conductance
Tester
Conductance
+ -
(diode parallel forward direction)
1) Remove the blower amp connector.

2 2) Check the conductance between the blower amp side terminals.
* The installation position is on the left side of the air conditioner

3 unit.

9006-41
Relay
4-pole relays are used for the blower OFF relay and compressor relay.
Blower OFF relay

This relay receives the signal from the control amp and switches the blower OFF relay ON.
When the blower OFF relay is switched ON, the power supply voltage is fed to the blower motor via the
blower amp and the blower motor is started.
Compressor relay
The compressor relay is switched ON / OFF by the control amp compressor control;
Relay inspection contents
1. Relay
2. Coil resistor: 320
3. Specification voltage: 20 to 30 VDC
4. Be careful. The coil side of this relay must be installed with the poles facing correctly.
5. Inspection: Inspect the conductance between 3 and 4 under the conditions below.
20 - 30 V applied between Terminals 1 and 2 : Conductance

No voltage applied between Terminals 1 and 2 : No conductance
Air Mix Actuator

The air mix actuator is installed at the center of the air conditioner unit. It opens and closes the air mix damper via the
link.
Built into the air mix actuator is the potentio-meter which varies linked with the actuator shaft.
When the target air mix door position is determined by the temperature control switch, the control unit reads in the
potentio-meter position in the actuator and determines whether the motor turns forward or reverse.The contacts move
linked with the motor. When the contacts move open or the target potentio-meter position is reached, the control unit
output signal goes OFF and the motor stops.
(See "Air Mix Motor Actuator Inspection".)

9006-42
Refresh / Recirculate Actuator
The refresh/recirculate switch actuator is installed on the blower intake unit. It opens and closes the refresh/recirculate
damper via the link.
Built into the refresh/recirculate switch actuator is the position detection switch that changes linked with the actuator
shaft.
When the refresh/recirculate damper position is determined by the refresh / recirculate switch on the control panel, the
control unit reads in the signal of the position detection switch in the actuator and determines whether the motor turns
forward or reverse.The contact moves linked with the motor and when the contact reaches the position detection switch
and separates, the motor stops.
(See "Refresh / Recirculate Motor Actuator Inspection".)
Blow Mode Actuator

The blow mode actuator is installed on the back surface of the air conditioner unit. It opens and closes the blow damper
via the link.
Built into the blow mode actuator is the potentio-meter which varies linked with the actuator shaft.
When the blow mode position is determined by the temperature control switch, the control unit reads in the potentio-
meter position in the actuator and determines whether the motor turns forward or reverse.The contacts move linked with
the motor. When the contacts move open or the target potentio-meter position is reached, the control unit output signal
goes OFF and the motor stops.
(See "Mode Motor Actuator Inspection".)
Evaporator Sensor
In order to prevent the evaporator freezing, the evaporator blow temperature is detected and the compressor ON / OFF
controlled.
Evaporator sensor inspection method

(specifications value)
Disconnect the evaporator connector from the main harness and measure the resistance between the sensor
side connector terminals using the tester.
Resistance between When the sensor section detection temperature is 0°C : 7.2 kW
terminals
When the sensor section detection temperature is 25°C : 2.2 kW

9006-43
Dual Pressure Switch
The dual pressure switch is installed on the receiver drier. When there is pressure trouble in the coolant high-pressure
side line (abnormally high pressure or abnormally low pressure), the dual pressure switch contacts open up to cut off the
compressor power and protect the cooling cycle.
Dual pressure switch specifications
0.02 MPa, 0.59 MPa,

(0.2 bar, 2.9 Psi) (5.9 bar, 85 Psi)
ON
OFF
0.20 MPa, 3.14 MPa,
(2 bar, 29 Psi) (31.4 bar, 455 Psi)
(Low pressure side) (High pressure side)
Simple inspection method for dual pressure switch:

1. With the cooling cycle stopped, disconnect the connector from the switch and check the conductance
between the switch side connector terminals using the tester. If there is conductance, the switch is
normal (When the outside air temperature is 0°C or higher).
2. Connect the gauge manifold high-pressure side hose to the high-pressure side charge port. With the
cooling cycle operating, the condenser front surface is covered with the plate top and the high-pressure
rises.If the compressor stops around 3.14 MPa (31.4 bar, 455 Psi), the switch is normal.
3. With the coolant removed, check the conductance between the switch side connector terminals using the
tester. If there is no conductance, the switch is normal.
Solar Radiation Sensor

This is the air conditioner solar radiation correct sensor. It detects the strength of sunlight with a photo diode, converts it
into current and sends that to the control panel.
Solar radiation sensor inspection method:

• Disconnect the solar radiation sensor connector from the harness and measure the resistance between
the sensor side connector terminals using the tester's voltage measurement mode.
• The voltage must be different when light is striking the photo receiver section and when it is not. (The
voltage is 0 V when absolutely no light is striking the photo receiver.)
CAUTION:
Always measure with the tester in voltage measurement mode (V mode).
Measuring with the tester in resistance mode (mode) would destroy the sensor.
Motor actuator and sensor troubles can be checked on the panel display.

9006-44
NOTES
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ITEM DESCRIPTION PRESSURE SETTING ITEM DESCRIPTION
Pm1 Ps Ps Pm2
1 HYDRAULIC RESERVOIR
A MAIN RELIEF (STANDARD) 34.3 MPa / 343 bar / 4977 psi 2 BREATHER
26 25 A MAIN RELIEF (BOOST) 36.8 MPa / 368 bar / 5337 psi 4 BY-PASS VALVE
22 5 SCREEN FILTER
B45
* 28 B1/B2
B BOOM RAISING PORT SECONDARY RELIEF
RELIEF ON BOOM HBCV

38.7 MPa / 387 bar / 5613 psi
38.7 MPa / 387 bar / 5613 psi

6
10
15
RETURN FILTER
MAIN HYDRAULIC PUMP
MAIN CONTROL VALVE
P * 29 B2 B1
*
BB C BOOM LOWERING PORT SECONDARY RELIEF
D DIPPER OUT PORT SECONDARY RELIEF

29.4 MPa / 294 bar / 4264 psi
38.7 MPa / 387 bar / 5613 psi

16
21
HYDRAULIC SWIVEL
TRAVEL MOTOR
83 D1 RELIEF ON DIPPER HBCV 38.7 MPa / 387 bar / 5613 psi
22
23
SWING MOTOR
TRAVEL MOTOR BRAKE
G1 (G3) (G3) G1 AA 25 RIGHT BOOM CYLINDER
T2 T1 E DIPPER IN PORT SECONDARY RELIEF 38.7 MPa / 387 bar / 5613 psi
26 LEFT BOOM CYLINDER
F BUCKET OPEN PORT SECONDARY RELIEF 38.7 MPa / 387 bar / 5613 psi 27 DIPPER CYLINDER
Dr C B B
Au C 28 BUCKET CYLINDER
27 A A G BUCKET CLOSE PORT SECONDARY RELIEF 38.7 MPa / 387 bar / 5613 psi 29 BOOM SAFETY VALVE
H PILOT PRESSURE RELIEF 3.92 MPa / 39.2 bar / 568 psi 30 DIPPER SAFETY VALVE
31 DIPPER LOAD HOLDING VALVE
J I
30 * K1
P1
P2
P2
P1
K2 PL PL
I RIGHT-HAND SWING PORT SECONDARY RELIEF
J LEFT-HAND SWING PORT SECONDARY RELIEF

29.4 MPa / 294 bar / 4264 psi
29.4 MPa / 294 bar / 4264 psi

32
42
BOOM LOAD HOLDING VALVE
OIL COOLER
RED
RED
44 OIL COOLER BY-PASS VALVE
GB K1/K2 TRAVEL REVERSE PORT SECONDARY RELIEF ....... Mpa / ...... bar / ....... psi 45 NON-RETURN CHECK VALVE
GA
L1 L2
G1 (G3)
B
DR DR * 71 *
L1/L2 TRAVEL FORWARD PORT SECONDARY RELIEF
N1/N2 NEGATIVE CONTROL RELIEF

...... .Mpa / ...... bar / ....... psi
2.55 MPa / 25.5 bar / 370 psi

51
53
54
ACCUMULATOR
BOOM & BUCKET CONTROL LEVER
SWING & DIPPER CONTROL LEVER
55 TRAVEL CONTROL PEDAL
C
D1 O/P PORT SECONDARY RELIEF (2eme OPTION) ....... Mpa / ....... bar / ......psi 56 DIPPER CONTROL SHOCK ABSORBER
A
134 R MAIN RELIEF (2eme OPTION) 20.6 MPa / 206 bar / 2989 psi 57 BOOM & DIPPER CONTROL SHOCK ABSORBER
29 *
58 PILOT AND RETURN SYSTEM MANIFOLD
15 1 SECOND Y26 W1/W2 CRUSHER OPTION SECONDARY RELIEF VALVE (factory) 17.8 Mpa / 178 bar / 2582 psi 59 FILTER
15 PL pb8 N2 OPTION W4 BREAKER OPTION SECONDARY RELIEF VALVE (factory) 29.4 Mpa / 294 bar / 4264 psi
60 PILOT SYSTEM MANIFOLD
LEFT A Mu B RIGHT
pb5 65 CALIBRATED ORIFICE
T 71 SECOND OPTION CONTROL VALVE
Pm2 Pm1 Y25 72 CONTROL PEDAL (OPTIONAL)
1
DR
A
B 16 23 * 83 G
P
73
75
SECOND OPTION CONTROL VALVE
HAMMER/CRUSHER SELECTOR
D6 23 21 C D
21 76
82
HAMMER/CRUSHER SELECTOR
PILOT CIRCUIT FILTER
65 *
E F 83 SHUT-OFF VALVE (OPTIONAL)
LEGEND 85 PILOT FILTER
RH FORWARD 86 PILOT FILTER BY-PASS VALVE
RH REVERSE P1 PUMP 90 HYDRAULIC BREAKER VERSION, PLUG
3 LH FORWARD C1 C2 108 STRAIGHT TRAVEL VALVE
132 HAMMER/CRUSHER 2 SOLENOID VALVE BANK
A LH REVERSE B P T A P2 PUMP 133 5 SOLENOID VALVE BANK
*85 A1 A2
PILOT SYSTEM PUMP
134
139
2 SOLENOID VALVE BANK (SECOND OPTION)
2 SOLENOID VALVE BANK (OPTION 1)
T P *
Y18
140
141
B22
2 SOLENOID VALVE BANK (OPTION 1)
1 SOLENOID VALVE BANK
SWING PILOT PRESSURE SWITCH
RETURN TO RESERVOIR B23 BREAKER / CRUSHER PILOT PRESSURE SWITCH
B26 UPPER PILOT PRESSURE SENSOR
P
73 * B1
LEAK-OFF RETURN B27
B28
B33
TRAVEL PILOT PRESSURE SENSOR
SECOND OPTION PILOT CIRCUIT 1 PRESSURE SWITCH
ARM CLOSE PRESS. SENSOR
Tr1
Y27
0.1 MPa
BR2
*B28 SUPPLY CIRCUIT B40
B42
PRESSURE SENSOR (NEGA-CONT. P2)
PUMP PRESSURE SENSOR (P1)
14.5 psi ON 0.5 MPa B43 PRESSURE SENSOR (NEGA-CONT. P1)
1 bar 72.51 psi A1 PILOT SYSTEM CIRCUIT B44 PUMP PRESSURE SENSOR (P2)
AR2 5 bar B45 OVERLOAD INDICATOR PRESSURE SWITCH
B2
45 OFF 0.3 MPa Y9 COMPONENT BOUNDARY
S71
Y2
PRESS.SWITCH FILTER INDICATOR (BREAKER OPTION)
PILOT PRESSURE SOLENOID VALVE
pbr2
0.29 MPa O 43.51 psi Y3 SWING BRAKE SOLENOID VALVE
10µ *S71
29 psi
2 bar * 83 3 bar
*132 A2
HOSE
Y4
Y5
2 STAGE TRAVEL SOLENOID VALVE
POWER-UP SOLENOID VALVE
R par2
Y6
Y7
POWER SAVE SOLENOID VALVE
MAIN PUMP POWER PROPORTIONAL SOLENOID
0.03 MPa 0.004 MPa

ON 0.1 MPa 42 57 T
PIPING CONNECTION Y9 CRUSHER/BREAKER OPTION TWO FLOW SOLENOID VALVE
0.58 psi
14.50 psi 15 Y11 MAIN PUMP FLOW PROPORTIONAL SOLENOID
4.35 psi 1 bar R
0.3 bar 0.04 bar
OFF 0.08 MPa
44 133 15 DR2
Tr2
Pr PIPING CROSS-OVER Y18
Y23
FREE SWING SOLENOID VALVE
OPTION 1 SOLENOID VALVE
11.60 psi
T N1 Y24 OPTION 1 SOLENOID VALVE
2 0.8 bar ps1 pn1 T8 T3 T6 T7 DR1 T1 T2 41 COMPONENT ITEM NO. Y25

Y26
D1 Y27 HAMMER RETURN CIRCUIT SOLENOID VALVE
Pn2 COMPONENT NUMBER
T1
N2 P3
6 D6 ps2 9
al1
1 D 30
PL 31 pcc 1 CONNECTION ITEM NO.
0.103 MPa D2 57 D N2
HYDRAULIC SCHEMATIC
14.9 psi
T OPTIONAL ITEM NO.
150 MESH
1.03 bar
6µ
T
57 A5 prs1
prs2 133
1 *
N2 B D1
CX210B EXCAVATOR
B5
4 DIPPER (2) IN pb9 B T
57 pb5' DIPPER (1)
5 15 29 D pb5 IN OUT pa9 15
D2
pcc pa5
C1
Y4 Y2
DR pa5 OUT C 32
15 15
pb2 pa2 EE
15
pa9 56 E A8 A2 A1
132
* A2 A1
B33
83
* 15
pc3
pbu
B8 C3
Y5 Y6 Y23 Y24 Y27 Y9
BOOM (1)
pa8 LOWER pb8
B A BOOM (2) RAISE pa8

pb4
B
C4
*139 G
P
15 29 G
pa4 pbu PL C5
30
C2
Y3 P
T T
DR B7
T B3
A7
A3
SWING
W4 * pb3 LEFT
BUCKET
CLOSE pb7 57
pa3 RIGHT F OPEN pa7 N
15 15
57 pb2 pa2
141
*
B2
A2
90 * B6
P
1.5 MPa
217.5 psi
51 82 A2 A1
TRAVEL (RH) A6
15 bar P3
PP pb2
OPTION G REVERSE pb6 55
Y23 Y24 Y9
* 75 pa2 3 P0
8µ
P
T1
P4
HAMMER
ON
0.02 MPa
2.9 psi *140 T
P
A
0.2 bar
T2
72 FORWARD pa6 55 G
A
B
BB * 72
B
139
B1
4 60 0.15 MPa
21.7 psi 86
P
A1 DR3 1.5 bar
A A1 TRAVEL (LH) T
83 * DR
139 140 55 pb1 P1 P2
A2 A1 1 REVERSE 108
B A AA * 140
A2 FORWARD
55 pa1
DR DR4
2
DR2
T4
T5 Y7
* 76 T
*W1 * W2 a4
W4 *
A1 Psv A2
A 15
EE
DR1
P1 PT PA PH P2
PP 10 B42 B44 B40

15 B43
T8 B27 B26 (FRONT)
a1 a2
(REAR)
P4 P5 T4 T5
P3 P2 P1 T3 T2 T1
Pi1 a7 a8 Pi2
58 15 15
pb7 pa7
* 72
85 54 85 53 TRAVEL (LEFT) TRAVEL (RIGHT)
CLOSE
P T P T
15 59 OPEN P2
pb5 OPTION
Y11
15 31µ HAMMER
pa5 REVERSE FORWARD FORWARD REVERSE ON P1 A3
55 M a3
57 IN OUT LOWER RAISE RIGHT LEFT
DIPPER SWING BOOM BUCKET ISUZU
IN OUT LEFT RIGHT LOWER RAISE OPEN CLOSE 4HK1S Dr
2 4 3 1 2 4 3 1 113.6 Kw
B1
H
à 1800 tr/mn
C1 C2
85 85 B P T A
B3
OUT
1 P 2 4 T 3 15
A C V T E G I Q K M O pa2
85
15
1 pb2
D2
IN
B22 ON 0.5 MPa OFF 0.3 MPa

72.51 psi 43.51 psi
15 15 15 15 5 bar 3 bar
pb1 pa1 pa6 pb6
B23/B25
* CX210B EXCAVATOR
HYDRAULIC SCHEMATIC
Number 87598354A
ITEM DESCRIPTION PRESSURE SETTING ITEM DESCRIPTION
Pm1 Ps Ps Pm2
A MAIN RELIEF (STANDARD) 34.3 MPa / 343 bar / 4977 psi 1 HYDRAULIC RESERVOIR
26 25 A MAIN RELIEF (BOOST) 36.8 MPa / 368 bar / 5337 psi
2 BREATHER
22 4
5
BY-PASS VALVE
SCREEN FILTER
B45
* 28 B1/B2
B BOOM RAISING PORT SECONDARY RELIEF
RELIEF ON BOOM HBCV

38.7 MPa / 387 bar / 5613 psi
38.7 MPa / 387 bar / 5613 psi

6
10
RETURN FILTER
MAIN HYDRAULIC PUMP
15 MAIN CONTROL VALVE
Pa * 29 B2 B1 C BOOM LOWERING PORT SECONDARY RELIEF
D DIPPER OUT PORT SECONDARY RELIEF

29.4 MPa / 294 bar / 4264 psi
38.7 MPa / 387 bar / 5613 psi

16
21
HYDRAULIC SWIVEL
TRAVEL MOTOR
BB 22 SWING MOTOR
T2 T1
G1 (G3) (G3) G1 * 83
D1 RELIEF ON DIPPER HBCV
E DIPPER IN PORT SECONDARY RELIEF

38.7 MPa / 387 bar / 5613 psi
38.7 MPa / 387 bar / 5613 psi

23
25
TRAVEL MOTOR BRAKE
RIGHT BOOM CYLINDER
26 LEFT BOOM CYLINDER
C B B C AA F BUCKET OPEN PORT SECONDARY RELIEF 38.7 MPa / 387 bar / 5613 psi 27 DIPPER CYLINDER
DB 27 A A G BUCKET CLOSE PORT SECONDARY RELIEF 38.7 MPa / 387 bar / 5613 psi 28
29
BUCKET CYLINDER
BOOM SAFETY VALVE
H PILOT PRESSURE RELIEF 3.92 MPa / 39.2 bar / 568 psi 30 DIPPER SAFETY VALVE
30 * K1
P1
P2
P2
P1
K2 PL PL
I RIGHT-HAND SWING PORT SECONDARY RELIEF
J LEFT-HAND SWING PORT SECONDARY RELIEF

28.9 MPa / 289 bar / 4191 psi
28.9 MPa / 289 bar / 4191 psi

31
32
42
DIPPER LOAD HOLDING VALVE
BOOM LOAD HOLDING VALVE
OIL COOLER
RED
RED
44 OIL COOLER BY-PASS VALVE
K1/K2 TRAVEL REVERSE PORT SECONDARY RELIEF ....... Mpa / ...... bar / ....... psi
L1 L2 45 NON-RETURN CHECK VALVE
J M
G1 (G3)
B
DR DR * 71 *
L1/L2 TRAVEL FORWARD PORT SECONDARY RELIEF
N1/N2 NEGATIVE CONTROL RELIEF

...... .Mpa / ...... bar / ....... psi
2.55 MPa / 25.5 bar / 370 psi

51
53
ACCUMULATOR
BOOM & BUCKET CONTROL LEVER
54 SWING & DIPPER CONTROL LEVER
C 55 TRAVEL CONTROL PEDAL
PB PA
D1 O/P PORT SECONDARY RELIEF (2eme OPTION) ....... Mpa / ....... bar / ......psi
56 DIPPER CONTROL SHOCK ABSORBER
A
134 R MAIN RELIEF (2eme OPTION) 20.6 MPa / 206 bar / 2989 psi 57 BOOM & DIPPER CONTROL SHOCK ABSORBER
29 * Y26 58 PILOT AND RETURN SYSTEM MANIFOLD

15 1 SECOND W1/W2 CRUSHER OPTION SECONDARY RELIEF VALVE (factory) 17.8 Mpa / 178 bar / 2582 psi
59 FILTER
15 PL pb8 N2 OPTION W4 BREAKER OPTION SECONDARY RELIEF VALVE (factory) 29.4 Mpa / 294 bar / 4264 psi 60 PILOT SYSTEM MANIFOLD
I pb5
T
62 STRAIGHT LINE TRAVEL PEDAL
63 SHUTTLE VALVE BLOCK
Pm2 Pm1 Y25 65 CALIBRATED ORIFICE
1
DR
A
B 16 23 * 83 G
P
71
72
SECOND OPTION CONTROL VALVE
CONTROL PEDAL (OPTIONAL)
D6 23 21 C D
21 73 SECOND OPTION CONTROL VALVE
75 HAMMER/CRUSHER SELECTOR
E F 76 HAMMER/CRUSHER SELECTOR
LEGEND 82 PILOT CIRCUIT FILTER
RH FORWARD
83 SHUT-OFF VALVE (OPTIONAL)
RH REVERSE P1 PUMP 85 PILOT FILTER
LEFT B A RIGHT LH FORWARD C1 C2 86 PILOT FILTER BY-PASS VALVE
90 HYDRAULIC BREAKER VERSION, PLUG
LH REVERSE B P T A P2 PUMP
108 STRAIGHT TRAVEL VALVE
*85 A1 A2
PILOT SYSTEM PUMP
132
133
HAMMER/CRUSHER 2 SOLENOID VALVE BANK
5 SOLENOID VALVE BANK
134 2 SOLENOID VALVE BANK (SECOND OPTION)
139 2 SOLENOID VALVE BANK (OPTION 1)
RETURN TO RESERVOIR
65 *
140 2 SOLENOID VALVE BANK (OPTION 1)
141 1 SOLENOID VALVE BANK
B22 SWING PILOT PRESSURE SWITCH
3 * P
73 * B1
LEAK-OFF RETURN B23
B26
BREAKER / CRUSHER PILOT PRESSURE SWITCH
UPPER PILOT PRESSURE SENSOR
Y18 Tr1
Y27
A
0.1 MPa
BR2
*B28 SUPPLY CIRCUIT
B27
B28
B33
TRAVEL PILOT PRESSURE SENSOR
SECOND OPTION PILOT CIRCUIT 1 PRESSURE SWITCH
ARM CLOSE PRESS. SENSOR
14.5 psi ON 0.5 MPa B40 PRESSURE SENSOR (NEGA-CONT. P2)
1 bar 72.51 psi A1 PILOT SYSTEM CIRCUIT B42 PUMP PRESSURE SENSOR (P1)
T P AR2 5 bar B2 B43 PRESSURE SENSOR (NEGA-CONT. P1)
45 OFF 0.3 MPa Y9 COMPONENT BOUNDARY B44 PUMP PRESSURE SENSOR (P2)
pbr2
0.29 MPa O 43.51 psi B45
S71
OVERLOAD INDICATOR PRESSURE SWITCH
PRESS.SWITCH FILTER INDICATOR (BREAKER OPTION)
3 bar
10µ
*S71
29 psi
2 bar * 83 R *132 A2
HOSE Y2
Y3
Y4
PILOT PRESSURE SOLENOID VALVE
SWING BRAKE SOLENOID VALVE
2 STAGE TRAVEL SOLENOID VALVE
par2
ON 0.1 MPa 42 T
PIPING CONNECTION Y5 POWER-UP SOLENOID VALVE
0.03 MPa 0.004 MPa 14.50 psi 57 15
Y6 POWER SAVE SOLENOID VALVE
0.58 psi Y7 MAIN PUMP POWER PROPORTIONAL SOLENOID
4.35 psi 1 bar R
0.3 bar 0.04 bar 44 133 15 DR2
Tr2
Pr PIPING CROSS-OVER Y9 CRUSHER/BREAKER OPTION TWO FLOW SOLENOID VALVE
OFF 0.08 MPa
11.60 psi
T N1 Y11
Y18
MAIN PUMP FLOW PROPORTIONAL SOLENOID
FREE SWING SOLENOID VALVE
2 0.8 bar ps1 pn1 T8 T3 T6 T7 DR1 T1 T2 41 COMPONENT ITEM NO. Y23 OPTION 1 SOLENOID VALVE
D1 Y24 OPTION 1 SOLENOID VALVE
Pn2 COMPONENT NUMBER Y25 OPTION 2 SOLENOID VALVE
Y26 OPTION 2 SOLENOID VALVE
T1 Y27 HAMMER RETURN CIRCUIT SOLENOID VALVE
N2 P3
6 D6 ps2 9
al1
1 D 30
PL 31 pcc 1 CONNECTION ITEM NO.
0.103 MPa D2 57 D N2
HYDRAULIC SCHEMATIC
14.9 psi
T OPTIONAL ITEM NO.
150 MESH
1.03 bar
6µ
T
57 A5 prs1
prs2 133
1 *
N2 B D1
CX240B EXCAVATOR
B5
4 DIPPER (2) IN pb9 B T
57 pb5' DIPPER (1)
5 15 29 D pb5 IN OUT pa9 15
D2
pcc pa5
C1
Y4 Y2
DR pa5 OUT C 32 15 15
pb2 pa2 EE
15 A2 A1
132
* A2 A1
pa9 56 E A8
B33 Y23 Y24 Y27 Y9
83
* 15
pc3
pbu
B8 C3
Y5 Y6
BOOM (1)
pa8 LOWER pb8
B A BOOM (2)
B
RAISE pa8 C4 *139 G
P
pb4 G
15 29
pa4 pbu PL C5 P
T T
30
C2
Y3
DR B7
T B3
A7
A3
SWING
W4 * pb3 LEFT
BUCKET
CLOSE pb7 57
pa3 RIGHT F OPEN pa7 N
15 15
57
pb2 pa2
141
*
B2
A2
90 * B6
P
1.5 MPa
217.5 psi
51 82 A2 A1
A6
TRAVEL (RH) 15 bar P3 Y23 Y24 Y9
PP pb2
OPTION G REVERSE pb6 63
* 75 S2 P0
8µ
P
T1
pa2
HAMMER 0.02 MPa *140 T
P
A
ON 2.9 psi G
P4 0.2 bar
T2
72 FORWARD pa6 63 P
A
B
BB * 72
B
139
B1
S1 60 0.15 MPa
21.7 psi 86 T
A1 DR3 1.5 bar
A A1 TRAVEL (LH)
83 * DR
139 140 63 pb1 P1 P2
A2 A1 S4 REVERSE 108
B A
AA * 140
A2 FORWARD
63 pa1
DR DR4
S3
DR2
T4
T5 Y7
* 76 T
*W1 * W2 a4
W4 *
A1 Psv A2
EE
A 15
DR1
P1 PT PA PH P2
PP 10 B42 B44 B40

15 B43
T8 B27 B26 (FRONT)
a1 a2
(REAR)
P4 P5 T4 T5
* 72
P3 P2 P1 T3 T2 T1
Pi1 a7 a8 Pi2
58 15 15 TRAVEL (RIGHT) TRAVEL (RIGHT)
pb7 pa7 OPTION
HAMMER
1 PEDAL TRAVEL 55 ON
85 54 85 53
REVERSE FORWARD REVERSE FORWARD FORWARD REVERSE
CLOSE
P T P T
15 59 OPEN P2
pb5
* 62 Y11
15 31µ
pa5
P1 A3
C1 C2
57 IN OUT LOWER RAISE RIGHT LEFT C1 C2

B P T A M a3
DIPPER SWING BOOM BUCKET A P T B ISUZU
IN OUT LEFT RIGHT LOWER RAISE OPEN CLOSE 4HK1X Dr
2 4 3 1 2 4 3 1 85 1 P 2 4 T 3
134.4 Kw
B1
H
15 à 2000 tr/mn
85 ON 0.5 MPa
pb2
85 85 72.51 psi
5 bar B3
15 OUT
OFF 0.3 MPa
pa2 43.51 psi
A C V T E G I Q K M O 3 bar
A4 B2 A3 A1 B1 A2
1
D2 B23/B25
*
IN
B22 * 63
S4 S3 S1 S2
15 15 15 15
CX240B EXCAVATOR
pb1 pa1 pa6 pb6
HYDRAULIC SCHEMATIC
Number 87600992A
F34 ITEM DESCRIPTION
F1 F2
BOX FUSE (ATTACHMENT FOR CAB MAIN HARNESS) FUSIBLE LINK F1 FUSIBLE LINK F2
65A 50A A1. COMPUTER
A2. ENGINE CONTROLLER
1 1
3R 112
3R 111
3R 110
3R 109
3R 108
3R 107
A4. WIPER CONTROLLER
2
1
1
2
2 2
A6. BLOWER CONTROLLER
A9. AIR CONDITIONER CONTROLLER
5WR 003
8R 106
8R 105
5R 002
(F24) 15A
(F19) 15A
(F18) 10A
(F11) 15A
(F23) 10A
(F21) 10A
(F16) 15A
(F13) 10A
(F25) 10A
(F22) 15A
(F20) 10A
(F14) 15A
(F26) 15A
(F17) 20A
8R 106 8R 106 8R 106
(F15)10A
(F12) 5A
(F10) 5A
(F8) 30A
(F9) 10A
(F7) 10A
0.85RW 121 0.85RW 121 1 B1. COOLANT TEMPERATURE SENSOR
600,700 B2. HYDRAULIC OIL TEMPERATURE SENSOR
HORN LOW (LEFT) 5WR 003
(CN.B1)
1 2 3 1 LR 907 B3. FUEL TEMPERATURE SENSOR
130,215,225,230,250,260,400,411,412,420,421,422,423,424,425,426,427,428,440$463,464,470,471,472,520,630,661,800,801,802,803,805,806,807,820,840,940,941,942,943
24V,370Hz 111dB 8R 030 DIESEL ENGINE
1
2
(CN.23) 10 9 8 7 6 5 4 3 2 1
B81
1.25B 748
B 705
1.25BG 600
JOINT CONNECTOR 20 19 18 17 16 15 14 13 12 11 148 8R 105 B5. EVAPORATOR SENSOR
B 747
OPTIONAL ALTERNATOR
1 1.25B 700
B6. AIR INTAKE TEMPERATURE SENSOR
POWER (CN.24) 8B 797 E
2 0.85B 701 GPS UNIT RELAY R1 RELAY R2 RELAY R11 RELAY R3 RELAY R4 24V 50A B21. ENGINE OIL PRESSURE SWITCH
BACK MONITOR
HORN HIGH (RIGHT)
CIGAR LIGHTER
(BOOM,HOUSE)
COMPRESSOR
MAIN GLOW STARTER CUT LAMP(UPPER) M6
LAMP (SPARE)
X3 LAMP(CAB)
LEVER LOCK
FUEL FILLER
HEATER UNIT
CONVERTER
3 1.25B 708
F6 F4 F3 F5
LAMP (CAB)
B22. SWING PILOT PRESSURE SWITCH
OPTION LINE
24V,415Hz 111dB M8
FUEL PUMP
(CN.10) (CN.11) (CN.20) (CN.12) (CN.13)
PRE-HEAT
KAB SEAT
10
11
12
13
14
15
16
17
18
19
20
SOLENOID
4
ALARM /
BEACON
0.85B 710 YR 909
BACK UP
1
2
3
4
5
6
7
8
9
BLOWER
K33 K2 K34 K10 K11
TRAVEL
WASHER
1 2 3 4 5 6 7 8 TRAVEL ALARM IC B23. BREAKER / CRUSHER PILOT PRESSURE SWITCH
AIRCON
AIRCON
ENGINE
AIRCON
CRANE
ELECT.
PUMP
CLOCK
(GATE)
5 1.25B 720
SPARE
WIPER
1
2
3
4
B81 FUSE F5 (CONT) REGULATOR
DC/DC
24V,107dB FUSE F6 (GPS) FUSE F4 (ECM) FUSE F3 (KEY)
HORN
LAMP
B26. UPPER PILOT PRESSURE SENSOR
R 151
6
1.25BG 601
0.85BG 620
1.25R 150
BG 610
BG 630
BG 636
R 152
R 153
R 157
0.85B 737 B 749 (BLUE TAPE)
0.85LgR 520
0.85LgR 530
0.85LgR 531
0.85LgR 532
0.85LgR 338
(YELLOW TAPE) (RED TAPE) (NO TAPE)
1.25BG 600
0.85BG 615
0.85BG 632
1.25BG 634
0.85BG 608
2 3 4
6 7 8
0.85BrR 526
(CN.B2)
1.25RB 148
1.25B 748
15A 20A 15A 20A B27. TRAVEL PILOT PRESSURE SENSOR
W 840 1 B 1.25G 015 1 0.75L R
G2 B28. SECOND OPTION PILOT CIRCUIT 1 PRESSURE SWITCH
(CN.25)
H2
1
5
VW 170
2
PW 230
1 2 3
4 5 6
1.25GR 240
GW 225 2 R 1.25Br 016 L

1.25GrR 185
1 4 2
0.85BrW 236
0.85BrW 235
B33. ARM CLOSE PRESS. SENSOR

GW 226
GW 228
0.85BrW 235
OR 220
1.25B 708
GW 225
GR 250
3WR 020
LW 260
1.25R 155
0.85YR 211
1.25WR 200
LgR 160
2
1
2
1
2
1
2
1
1.25R 150
0.85YR 210
1.25GR 240
LgR 161
0.85BrR 190
0.85VR 195
LgW 175
0.85LR 205
1.25GW 215
1.25LW 180
1 2
3 B42. PUMP PRESSURE SENSOR (P1)
6 1.25B 703 1 1 1 1
1 2
SUMITOMO 1.25B 700 7 2B 700 2 2 2 2 B43. PRESSURE SENSOR (NEGA-CONT)
1.25RB 148
0.85RW 120
1.25W 130
1.25RG 125
1.25R 115
1.25R 103
1.25R 102
1.25YR 145
0.5™F
1.25LR 104
1.25BG 600 8 2BG 600
B44. PUMP PRESSURE SENSOR (P2) (BLUE BAND)
3
1
2
5
4
3
1
2
5
4
3
1
2
5
4
3
1
2
5
4
3
1
2
5
4
1.25W 130 2 1.25W 130 8R 030 B M6
B47. BOOST PRESSURE SENSOR
(CN.148)
(CN.149)
1.25GW 215 4 1.25GW 215 WV 842 1
0.85LgR 338
0.85GrR 010
1.25GrR 185
1.25LW 181
1.25WR 330
3L 021
0.85BG 608
3WR 020
WR 823
WR 824
0.85BrR 339
0.85BrR 009
0.85YR 332
1.25Y 900
1.25GrR 186
1.25RG 125
1.25LW 180
1.25GR 903
OR 853
BG 609
1 2
130,400,411,412,420,421,422,423,424,425,426,427,428,440,463,464,470,471,472,531$601,701,800,801,802,803,805,806,807,820,840,940,941,942,943 1.25RB 145 5 1.25YR 145 B 743 2 B48. AMBIENT AIR (BAROMETRIC) PRESSURE SENSOR
1.25WR 521
3L 021 3 3L 021 STARTER MOTOR B49. CRANKSHAFT POSITION SENSOR
1.25Y 904
0.85Y 905
055,056,135,151,340,410,430,450,475,488,489,491,492,523,632,634,737,817,821,822 520 1.25RG 125 1 1.25RG 125 60R 001 B
(CN.C1) (CN.C2) (CN.C3) (CN.C4) M B50. CAMSHAFT POSITION SENSOR
330,332,336,337,339 126 WASHER RELAY BATTERY M10
B51. BOOST TEMPERATURE SENSOR
13 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 6 5 4 3 2 1 11 10 9 8 7 6 5 4 3 2 1 608 5Y 004 S M1
26 25 24 23 22 21 20 19 18 17 16 15 14 16 15 14 13 12 11 10 9 12 11 10 9 8 7 22 21 20 19 18 17 16 15 14 13 12
OPERATOR'S CAB 336 WV 841 1 M4 B52. EXHAUST GAS RECIRCULATION VALVE POSITION SENSOR
M M4
0.85RW 121
WIPER CONTROLER 020,180,185 B 742 2 60R 100 60R 101 B61. SUNLOAD SENSOR
SPEAKER(R) 24V 24V 5.0kw
A4
1
(CN.147)
1.25GR 332,330,338,339 M8 M8
BATTERY B81. HORN
(CN.63)
0.85BG 661
WIPER SW.IN(INT) 11 LR 1 BY 1.25B 823,903
2
1
1
2
3
1.25W 135
1.25W 130
CONTROLLER A M10 M10 M10 M10 B82. REFUEL PUMP STOP ALARM
WIPER SW.IN(CNT) 12 YR R 2 YW S54 1.25B 337 0.85RW 120 1 0.85RW 120
- + - +
M4 3L 021 1 5BW
GLOW PLUG
WASHER SW. IN 13 GrR 0.85LgR 520 0.85LgR 520 2 0.85LgR 520 E1. WORKING LIGHT (UPPERSTRUCTURE)
2BG 600
2B 700
M8
POWER 24V 1 1.25W 130 POWER (24V) IN 1 0.85BrR LIMIT SW. (F-WINDOW) 1.25WR 521 1.25WR 521 3 1.25WR 521 BG 662 1 B M4
A1 E2. CAB LIGHT
60B 799
(CN.64)
S55 R1 EGR MOTOR
(CN.76)
12 2 0.85BrR 523 4 2 B
1.25WR 521
1.25W 131 WASHER CONT.(+) WV 523 0.85BrR 523 0.85BrR 523 GrW 470
7 8 9 10 11 12 13
1
2
0.85LgR 520
1 2
3 4
E51. CIGARETTE LIGHTER
4 5 6
B
POWER 24V 11 1.25W 132 WASHER CONT.(-) 3 1 YG 1.25GR 0.85GrR 010 0.85GrR 010 5 0.85GrR 010
(CN.138)
1.25W 140
1
K7 E52. AIR CONDITIONER
(CN.57)
5 6 7 8
0.85BrR 524
1 2 3 4
1 2
22 1.25W 133 WINDOW CONTROL 9 2 VG 1.25B 0.85BrW 525 0.85OR 850 0.85OR 850 6 0.85OR 850
SINGLE CHIP CPU LIMIT SWITCH 12V 12V
1
11 12 13 14 15 16 17 18 19 20 21 22
M
6 7 8 9 10
H8S/2626F(20MHz) GND_3 2 1.25BG 601 REV. SIG. 7 VW BY 1 BY 3 BG GR 250 7 0.85GR 250 M8 V M15 F1. FUSE 65A ; MAIN FUSE FOR F8 TO F26
5 6 7 8
1 2 3 4
SPEAKER(L) (RESERVE TANK)
1 2 3
13 1.25BG 602 STOP SIG. 8 VR YW 3 YW 009,120,145,809,841,850,855,856,861,862,863,864,904,980 VG 800 8 0.85VG 800 W F2. FUSE 50A ; MAIN FUSE FOR F1
P-G G1
(CN.136)
GND_2 5 4 BL 9
1.25GR
0.85B 701 WINDOW LIMIT SW. 1 BL 2 BL
RELAY R9 RELAY R8 RELAY R7 GW 225 GW 225
RELAY R5 RELAY R6 RELAY R10 F3. FUSE 15A ; KEY SWITCH AND MAIN FUSE FOR F7
1.25B
16 0.85B 702 WIPER MOTOR(CW) 5 GW L 2 LW LW 4 LW WINDOW OPEN-GND 5B W 840 10 W 840 0.85B 779 0.75WR 360 8 0.75WR 5
BG
VG
YG
(CN.1)
ROOM LAMP SPEAKER(L) SPEAKER(R)
1 2
N-G GND 9 WIPER MOTOR(CCW) 6 GR
K35 K36 K37 HORN(L) K38 HORN(R) K39 BEACON K5 LR 907 11 LR 907 ELEC.FUEL PUMP 0.75WB 361 7 0.75WB 6 F4. FUSE 20A ; MAIN RELAY AND ENGINE STOP
(CN.18) (CN.17) (CN.16) (CN.14) (CN.15) (CN.19) EGR POSITION SENSOR F5. FUSE 20A ; COMPUTEUR CONTROL AND INSTRUMENT PANEL
1 2 3 4 5
20 GND 10 1.25B M8 M8 YR 909 12 YR 909 0.75WL 362 6 0.75WL 7
(CN.106)
3
6
5
1
4
2
(CN.65)
L-G GND_A 10 WV 841 13 WV 841 0.85PW 230 1 2BY 5 0.75LW 8
5WR 003
F6. FUSE 15A ; CONTROLLER S
M
2 3
1
1 2 3
1
2
1.25Br 016
CAB FLOOR GND
1
RELAY SAFETY
5Y 004
2 M20
BG
VG
YG
21 4 5 6 GrW 470 14 GrW 470 0.85B 753 2B 0.75GB 363 4 0.75GB 1
U F7. FUSE 10A ; BACK UP
1.25GR
1.25B
A-G 6 15 24V B 3 2
NPN_OUT1
NPN_OUT2
S/V SWING BRAKE
S/V TRAVEL 4
VG 800
LG 801
M3 WIPER MOTOR ACCESSORY SOCKET X15 (CN.75)
1.25GR 20 1.25GR 903
LW 471
YL 820 16
0.85LW 471
YL 820 0.85GrR 010 3 1.25BW S
5B 0.75GW 364
0.75GR 365 2
0.75GW
0.75GY 3
V B53 F8. FUSE 30A ; ENGINE PRE-HEAT
W
NPN_OUT3 S/V RELIEF 7 YG 802 3 GR 0.85BW 0.85WR 0.85WR 10 0.85WR 282 GL 910 17 GL 910 0.85BrR 523 2 1.25WG R 1 0.75L 4 F9. FUSE 10A ; OPTION LINE
12V VCC
(CN.137)
NPN_OUT4 S/V POWER SAVE 3 BrG 803 1 GW 0.85BW 22 0.85BW 707 18 0.85BG 633 0.85PW 231 1 1.25B 750 1 1.25B E C 5BW F10. FUSE 5A ; AIR CONDITIONER HEATER UNIT
1 2
NPN_OUT5 S/V FAN REVERSE 8 OG 805 M 5 1.25B BY 16 BY 971 0.85B 754 2
(CN.58)
I/O
3
1
2
5
4
4 5 6
1 2 3
3
1
2
5
4
3
1
2
5
4
3
1
2
5
4
3
1
2
5
4
3
1
2
5
4
(CN.69) (CN.68) F11. FUSE 15A ; AIR CONDITIONER BLOWER
NPN_OUT6 S/V FREE SWING 14 VY 806 6 VR YW 17 YW 970
COMMONRAIL PRESS. SENSOR F12. FUSE 5A ; AIR CONDITIONER COMPRESSOR
1
9 10 11 12 13 14 15 16 17 18
S/V BREAKER / CRUSHER 15 4 18
(CN.139)
NPN_OUT7 LY 807 VW BL BL 973
5 6 7 8
24V
LG 831
GL 910
GW 226
GW 227
LW 972
G 851
LR 906
LR 975
WR 290
WR 293
WR 292
R 153
R 154
YL 829
LY 830
YW 970
VW 858
YR 974
YR 909
LG 832
LgW 175
LgW 176
LgW 177
LR 907
LR 908
18 19 1 F13. FUSE 10A ; SOLENOID
2 1
NPN_OUT8 TRAVEL ALARM W 840 2 LW LW 972
(CN.A10)
1 2 3
NPN_OUT9 FUEL PUMP 17 YL 820 WV 6 WV 841 0.85B 760 0.85BG 663
K8 3
B52 F14. FUSE 15A ; WINDSHIELD WIPER / WASHER
(CN.B3)
NPN_OUT10 AIR-CON 19 OL 822 0.85BrR 5 0.85BrR 190 2
0.85LW 471 2 1.25Y F15. FUSE 10A ; HORN
1.25BG 21 0.85BG 615 153,175,226 M8 PRESS.SWICH 0.75W 307 12 0.5L
1 2
1 S62
1 2 3 4
MONITOR DISPLAY 0.85BG 661 1.25B F16. FUSE 15A ; LAMP (BOOM, HOUSE)
PWM_OUT1 0.85BrW 11 906,829,972 (AIR CLEANER) 0.75L 317 13 0.5Br
PWM_RTN1 PL 12 PL 056 831,970,830 0.75G 327 14 0.5LW
CAM ANGLE SENSOR F17. FUSE 20A ; FUEL FILLER PUMP
PWM_OUT2 P1 HOUR METER PW 13 PW 055 G 851 0.85OR 850 1 0.75R LEVER 0.75W 373 4 0.5Y 1 +
P9 Y2 F18. FUSE 10A ; CLOCK, BACK MONITOR
(CN.A11)
1 2 3 4
5 6 7 8
P5
(CN.C6)
1 2 3
3 14 5 2
PWM_RTN2 PUMP POWER(OUT) 0.85YR 940 BACK-LIGHT(LCD) CPU
CLOCK
LY LY 830 290,975,974,858 0.85B 760 2 0.75B LOCK GL 910 1 1.25GL 910
(CN.151)
0.75L 374 0.5VW
- B50 F19. FUSE 15A ; CIGAR. LIGHTER, CAB SEAT
PWM_OUT3 PUMP POWER(RTN) 6 0.85BY 941 BUILT-IN WR 15 WR 823
KEY SWITCH
(CN.127) (BLUE TAPE) B 755 2 1.25B 755
(CN.152) X2 FOR BEACON 0.75BL 686 6 0.75BW 3 SHIELD
PWM_RTN3 FAN SPEED(OUT) 1 LCD DRIVE HOUR 7 0.85BrW 1.25W 2 1.25W 135 0.75G 372 1 0.5Y F20. FUSE 10A ; DC /DC CONVERTER
4 2 2 2 1 ANTENNA CONNECTION 1 SWING 2
FAN SPEED(RTN) BATT. 1.25R BACK UP R R 1.25R 1.25R 155 OFF 0.85R 251 0.75R 0.75L 371 0.5VW
CRANK ANGLE SENSOR F21. FUSE 10A ; TRAVEL ALARM
PUMP FLOW(OUT) 2 0.85LR 942 iGN 1 1.25W IGN 1 LgR 1 LgR LgR 3 LgR 160 W1 HEAT
ACC
B G1 G2 ACC M ST
JOINT CONNECTOR
0.85VG 800 2 0.75B BRAKE
Y3 0.75BW 688 3 0.75B
ON F22. FUSE 15A ; SPARE
+
(CN.A12)
PUMP FLOW(RTN) 5 0.85BL 943 BZ. TxD(UART) 4 PL OUT1(ROOM LAMP) 3 YL 3 YL YL 7 YL 829 HEAT 8 0.85GR 250 (CN.128) (WHITE TAPE) 18 2
BACK-LIGHT(LCD) THROTTLE VOL. RELAY R12 RELAY R13 F23. FUSE 10A ; FUEL SUPPLY PUMP
1 2
SHLD GND 8 RxD(UART) 13 PW OU2(RADIO MUTE) 4 LG 4 LG LG 8 LG 831 RADIO AM/FM STEREO 24V,2A ST 1 0.85R 251 19 1 - B49
5V
7 OUT5(HORN VOL) 8 LY ILLUMI 8 G 9 G 0.85YR 4 0.85YR 210
OFF
2 0.85R 252 0.85R 252 1 0.75R 2STAGE FUEL PUMP K30 AUTO STOP K31 S61 20 F24. FUSE 15A ; SPARE
BACK UP
S-G ACC Y4 (CN.158) (CN.159)
MD2
BOOT_CNT 11 WR 062 OUT4(LAMP) 9 WR IN1(DOOR SW.) 6 Y 7 Y LR 9 LR 906
R3 X8 3 0.85R 253 0.85LG 801 2 0.75B TRAVEL 0.75WB 303 9 0.75WB F25. FUSE 10A ; LEVER LOCK (GATE)
CPU_CNT
MANUAL/AUTO
GND
ACC
R(+)
CPU
L(+)
12 WR 063 8 10
R(-)
ON 4
FWE
H1 ILLUMI-OUT 14 IN2(MUTE SW.) 7 L L 0.85R 254 0.75Y 313 0.75LY
L(-)
MD1 (CN.129) (RED TAPE) F26. FUSE 15A ; LAMP (CAB)
OIL PRESS.SENSOR
3
2
1
MD0 SW_IN12 9 OUT3(WASHER) 3 GrR GND 5 BG 6 BG 5 0.75BY 323 11 0.75BY
ST
STBY 1 2 F34. FUSE BOX
(CN.126)
2STAGE
1 2 3 4
5 6 7 8
LCD DISPLAY
0.85Y
0.85B
10 18 11 6 1 8 1
0.85L
SW_IN13 OUT2(WIPER_CNT) YR WY 0.85R 253 0.75R 0.75RW 304 0.75RW
VY 809
(CN.78)
Y5
(CN.A13)
FWE
GrR
OW
1 4 2
GR
1 2 3
Gr
G1. BATTERY
G
10 7 2 16 2
R
19
B
OUT1(WIPER_INT) LR WL 0.85YG 802 0.75B 0.75L 314 0.75L
RELIEF
1 2
3 4
5
IN1(SW:WINDOW) 6 YG 5 0.85YR LIMIT SW. S53
3 2 1
3 (CN.175) 0.75GW 324 17 0.75RL 3 B21 G2. ALTERNATOR
P4
(CN.45)
(CN.46)
(CN.47)
(CN.130)
S1 (YELLOW TAPE)
10 11 12 13 14 15 16 17 18 19 20
5 6 7 8 9
SUNLOAD SENSOR (CN.35) 1 2 3
1
2
3
(DOOR)
1
2
3
4
5
6
7
8
9
4
2
5
3
6
1
IN2(SW:BREAKER) 16 LW 12 0.85B 0.75RG 316 7 0.75RB
4 5 6 H1. AUDIBLE WARNING DEVICE
0.75BY
0.75BY
1
TXD0
IN3(SW:CRUSHER) 17 GW B61 3 0.85R 254 1 0.75R POWER
Y6 2 3 0.75GR 312 15 0.75BR
1
2
3
2 (CN.34) BOOST PRESS.SENSOR
(CN.D11)
WY H2. TRAVEL ALARM
3
1
2
5
4
3
1
2
5
4
2
1
4 1 2
R 152
15 2 1
YR 974
MON_TXD IN4(SW:2SPEED)
BY 971
Y Y LG 801 0.85LG 801 0.85BrG 803 0.75B
LR 975
BL 973
SCI
1 2 3 4 SAVE
0.85LgR 530
(CN.7)
0.85BrR 009
RXD0
0.85WR 291
0.85RW 120
0.85WR 290
0.85BO 450
1
0.85Y 410
0.85B 710
WL
0.85LY 430
RS232C DRIVER 12V OUTPUT K2. RELAY-GLOW PLUG
(CN.A14)
6 7 8 9 10 11 12
MON_RXD 12 5 4 2 2 1
3 4 5
IN5(UPDATE_SW) 5 6 7 8 9
1.25GW 215
0.85GW 216
PL 056 VW VY VY YG 802 0.85YG 802
1.25LR 915
0.85L 867
0.85L 867
0.85WR 917
0.85WR 917
0.85YL 820
0.85BrR 916
0.85VR 866
0.85B 758
0.85VR 918
0.85VR 866
(CN.131)
0.85L 868
SWITCH PANEL (GREEN TAPE)
17 18 19 20
13 14 15 16
1 2
9 10 11 12
(FOR RADIO)
1 2 3 4
(CN.A2)
5 6 7 8
1 2 3
3 10 1 3 3 2
TXD2 T_IN T_OUT
PC/BOOT_TXD W 060
P10 TxD(RS232C) BG BG (CN.36) BrG 803 0.85BrG 803
B47 K5. RELAY-ROTARY LIGHT
(CN.74)
1 2 3 4
PC/BOOT_RXD 10 WL 061 RxD(RS232C) 11 4 3
RXD2 R_OUT R_IN K6. RELAY-AIR CONDITIONER CONDENSER FAN
GND 2 BW 064 S11 (WIPER) GND(RS232C) 12 OG 805 5 GR 257 1 GR 257 1 0.75R FREE
V+ V- CIGAR LIGHTER Y18 B82
0.75RL
K7. RELAY BATTERY
1 2
DOOR OPEN-GND
CAN DRIVER
GND 5 S12 (WASHER) GND 20 1.25BG E51 VY 806 6 VY 806 2 VY 806 2 0.75B SWING
WATER TEMP.SENSOR
(CN.62)
24V,5A
0.85WR 281
0.85BW 706
0.85RY 280
K8. RELAY SAFETY
4 5 6 7 8
1
GND 13 7
(CN.A15)
VREF VCC S10 (W.LAMP)
0.85B 710
3
2
1
(CN.38)
E4 KNOB (RIGHT) t
1 2
CAN_H 6 P 040 0.85B 0.85YR 0.85RW 120 1 0.85RW 120 8 1
P3 K10. RELAY- WORKING LIGHT (UPPERSTRUCTURE / ATTACHMENT)
3
HTXD TXD CANH S2 (T.MODE)
HCAN
10 11 12 13 14 15 16 17 18 19 20
1 2
1 2
5 6 7 8 9
CAN_L 14 PG 041 R 152 2 R 152 (4 SWITCH) 9 FREE SWING SOLENOID 0.85BrR 916 R 2
B1
2 3
HRXD RXD CANL ROOM LAMP K11. RELAY- WORKING LIGHT (CAB)
+5V_OUT 11 S4 (A-IDLE) WR 290 3 0.85WR 290 10 0.85B 759 B 3
RS_CNT RS GND K17. BLOWER OFF RELAY
(CN.146)
FREQUENCY_IN 1 S70 (HORN VOL.) 24V,10W 0.85LgR 530 4 0.85LgR 530 PW 230 11 0.85PW 230
S16 IDLE SW
(CN.C5)
1 2
LAMP (BOOM) K30. REFUEL PUMP RELAY
2
1
FREQUENCY_GND 9 0.85BrR 009 5 0.85BrR 009 YL 475 6 L 12
(CN.155)
LED1 (WIPER INT) BOOST TEMP.SENSOR
G
COUNTER
AVcc THROTTLE 7 0.85Y 410

LED2 (WIPER CNT)
LR 1 LR 2 OFF 0.85Y 410 6 0.85Y 410 BG 610 7 L 13 AUTO STOP ALARM K31. REFUEL PUMP STOP RELAY
1 2
3
(CN.A16)
15 DOOR 7 4 14 1 1 t
1 2 3 4
1 2
SW_1 IDLE YL 475 VY 2 VY 1 0.85LY 430 0.85LY 430 BrY 476 Y 1.25Y 900 1.25Y 900 1.25Y 900 1.25Y 900 0.85R
TCLKA LED3 (W.LAMP) 24V K33. MAIN RELAY
1 2
E2 B51
0.85B 759
SW_2 ANTI-THEFT 16 0.85VG 481 0.85BO 450 8 0.85BO 450 BG 614 5 Y 1.25Y 901 15 1.25L 901 1.25B 740 2 1.25B 740 2 0.85W 2
LED4 (T.MODE)
ON 70W REFUEL PUMP K34. RELAY STARTER CUT
SW_3 COOLANT 8 GrW 470
M8 YL 475 9 YL 475 GL 861 3 G 16 1.25GW 215 1
(CN.77)
LED5 (A-IDLE)
1 2
K35. RELAY ROOM LAMP

EEPROM YR 974 10 YR 974 B 714 8 G
S31 0.85YR 940 17 0.85YR 940 YL 820 3 1.25LR 915 2 1.25R
M
(CN.61)
L-G LED6 (HORN VOL.) 1ST.ACT S/V(R)
(CN.144)
1 FUEL TEMP.SENSOR
S35 S14 BY 971 11 BY 971 GW 862 O 0.85BY 941 18 0.85BY 941 1.25B 757 2 1.25B 757 1 1.25B K36. RELAY SPEAKER LEFT
2
1
2
1
(CN.A17)
5V(AVcc_O) LR 975 12 LR 975 B 713 2 O 0.85LR 942 19 0.85LR 942 LAMP (HOUSE) 1 t
OPT.2 SPEED OPT.LINE SELECT K37. RELAY SPEAKER RIGHT
1 2
9 10
6 3 BREAKER CRUSHER 9 10
BL 973 13 BL 973 S32 1ST.ACT S/V(L) 0.85BL 943 20 0.85BL 943
24V
2 B3 K38. RELAY HORN LEFT
1 1.25RB GL 861 14 GL 861 21 1.25L 901 1 1.25RG
5 2 6 3 24V
SENSOR_IN1 HYD.TEMP 2 0.85BrW 411 2 1.25RB 4 1 5 2 GW 862 15 GW 862 22 1.25B 741 2 1.25RB E1 K39. RELAY HORN RIGHT
70W M14
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
SENSOR_IN2 FUEL LEVEL 15 0.85GL 412 3 7 8 4 1 LG 491 16 0.85YR 211 0.85BG 663 2 1.25B PRESS.SW 0.75YG 315 1 0.75YG SUCTION CONT.VALVE
M1. STARTER MOTOR
7 8 S71
(CN.A18)
POTENTIO_IN1 P1 SENSOR 21 0.85Y 420 4 YG 492 17 0.85B 711 0.85YL 472 1 1.25R (FILTER INDICATOR) 0.75RW 368 2 0.75RW 2
10
10
(CN.60)
1
2
3
4
5
6
7
8
9
4
5
6
1
2
3
7
8
9
M3. WIPER MOTOR
1 2
POTENTIO_IN2 P2 SENSOR 9 0.85L 421 12 1.25B (CN.59) 0.85YR 211 18 0.85YR 211 0.75RG 366 3 0.75RB 1 Y35
(CN.134)
M4. WASHER MOTOR
(CN.B4)
LW
BG
BG
22 13 19 4
Y
LG
N1 SENSOR
GW
POTENTIO_IN3
1 2
0.85Lg 422 1.25B 0.85B 710 0.85B 710 0.75G
BrY
0.85WR 282
1
0.85BW 707
1.25R
POTENTIO_IN4 N2 SENSOR 10 0.85Br 423 14 BG 610 20 YR 212 1 M 0.85YR 940 1 PUMP
Y7 5 M5. MOTOR (AIR CHANGING)
(CN.A5)
(CN.44)
1 2
2
4 5 6
1 2 3
1.25B
1 2

Lep 87637609NA - S.S. CX210B & CX240B (ENG) PDF

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Lep 87637609NA - S.S. CX210B & CX240B (ENG) PDF

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REPAIR MANUAL REPAIR MANUAL

SCHEMATIC SET SCHEMATIC SET

REPAIR MANUAL REPAIR MANUAL

CNH AMERICA LLC North American English

Copyright © 2007 CNH America LLC.

SAFETY, GENERAL INFORMATION

Copyright © 2006 CNH America LLC.

Lep 7-27691NA Issued 02-06

Lep 7-27691NA Issued 02-06

To prevent injury always follow the Warning, Caution

WARNING: If you wear clothing that is too

WARNING: When working in the area of the

WARNING: When doing checks and tests

WARNING: When putting the hydraulic

Lep 7-27691NA Issued 02-06

WARNING: When the battery electrolyte is

WARNING: Use suitable floor (service)

Lep 7-27691NA Issued 02-06

STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS

Lep 7-27691NA Issued 02-06

AND SPECIAL TORQUE SETTINGS

Copyright © 2007 CNH France S.A.

TYPE, SERIAL NUMBER

FLUIDS AND LUBRICANTS ............................................................................................................................................ 4

SPECIAL TORQUE SETTINGS..................................................................................................................................... 28

MACHINE OVERALL DIMENSIONS ............................................................................................................................. 32

Lep SC210B1002-0NA Issued 02-07

Serial numbers of the components

Lep SC210B1002-0NA Issued 02-07

Transmission component oil

Lep SC210B1002-0NA Issued 02-07

Oil viscosity / Oil range

1) With mineral base

Lep SC210B1002-0NA Issued 02-07

Lep SC210B1002-0NA Issued 02-07

Plastic and resin parts

Lep SC210B1002-0NA Issued 02-07

Complete machine dimensions

Lep SC210B1002-0NA Issued 02-07

Lep SC210B1002-0NA Issued 02-07

Lep SC210B1002-0NA Issued 02-07

Capacity of coolant and lubricants

Lep SC210B1002-0NA Issued 02-07

Horn: electric horn (x2)

Lep SC210B1002-0NA Issued 02-07

Lep SC210B1002-0NA Issued 02-07

Lep SC210B1002-0NA Issued 02-07

Secondary pressure (MPa)

Lep SC210B1002-0NA Issued 02-07

Secondary pressure (MPa)

Lep SC210B1002-0NA Issued 02-07

Lep SC210B1002-0NA Issued 02-07

Lep SC210B1002-0NA Issued 02-07

Lep SC210B1002-0NA Issued 02-07

Lep SC210B1002-0NA Issued 02-07

Lep SC210B1002-0NA Issued 02-07

Lep SC210B1002-0NA Issued 02-07

Lep SC210B1002-0NA Issued 02-07

Lep SC210B1002-0NA Issued 02-07

Lep SC210B1002-0NA Issued 02-07

Lep SC210B1002-0NA Issued 02-07

Lep SC210B1002-0NA Issued 02-07

Lep SC210B1002-0NA Issued 02-07