Hyundai r260lc 9s Manual de Taller

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

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

Group 2 Main Control Valve -------------------------------------------------------------------------------------------- 2-20
Group 3 Swing Device ---------------------------------------------------------------------------------------------------- 2-55
Group 4 Travel Device ----------------------------------------------------------------------------------------------------- 2-66
Group 5 RCV Lever --------------------------------------------------------------------------------------------------------- 2-76
Group 6 RCV Pedal --------------------------------------------------------------------------------------------------------- 2-83
SECTION 3 HYDRAULIC SYSTEM
Group 1 Hydraulic Circuit ------------------------------------------------------------------------------------------------ 3-1

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

Group 2 Electric Circuit --------------------------------------------------------------------------------------------------- 4-3
Group 3 Electrical Component Specification ---------------------------------------------------------------- 4-38
Group 4 Connectors ------------------------------------------------------------------------------------------------------- 4-46
SECTION 5 MECHATRONICS SYSTEM
Group 1 Outline --------------------------------------------------------------------------------------------------------------- 5-1

Group 2 Mode selection System ----------------------------------------------------------------------------------- 5-5
Group 3 Automatic Deceleration System --------------------------------------------------------------------- 5-11
Group 4 Power Boost System ---------------------------------------------------------------------------------------- 5-13
Group 5 Travel Speed Control System -------------------------------------------------------------------------- 5-15
Group 6 Automatic Warming Up Function -------------------------------------------------------------------- 5-17
Group 7 Engine Overheat Prevention Function ----------------------------------------------------------- 5-19
Group 8 Variable Power Control System ---------------------------------------------------------------------- 5-21
Group 9 Attachment Flow Control System ------------------------------------------------------------------- 5-22
Group 10 Anti-Restart System ----------------------------------------------------------------------------------------- 5-23
Group 11 Self-Diagnostic System ----------------------------------------------------------------------------------- 5-24
Group 12 Engine Control System ------------------------------------------------------------------------------------ 5-31
Group 13 EPPR (Electro Proportional Pressure Reducing) Valve ------------------------------- 5-33
Group 14 Monitoring System ------------------------------------------------------------------------------------------- 5-39
Group 15 Fuel Warmer System --------------------------------------------------------------------------------------- 5-71
SECTION 6 TROUBLESHOOTING
Group 1 Before Troubleshooting ------------------------------------------------------------------------------------ 6-1

Group 2 Hydraulic and Mechanical System ----------------------------------------------------------------- 6-4
Group 3 Electrical System ---------------------------------------------------------------------------------------------- 6-24
Group 4 Mechatronics System -------------------------------------------------------------------------------------- 6-56
SECTION 7 MAINTENANCE STANDARD
Group 1 Operational Performance Test ------------------------------------------------------------------------- 7-1

Group 2 Major Components ------------------------------------------------------------------------------------------- 7-23
Group 3 Track and Work Equipment ------------------------------------------------------------------------------ 7-31
SECTION 8 DISASSEMBLY AND ASSEMBLY
Group 1 Precaution --------------------------------------------------------------------------------------------------------- 8-1

Group 2 Tightening Torque --------------------------------------------------------------------------------------------- 8-4
Group 3 Pump Device ---------------------------------------------------------------------------------------------------- 8-7
Group 4 Main Control Valve ------------------------------------------------------------------------------------------- 8-30
Group 7 RCV Lever --------------------------------------------------------------------------------------------------------- 8-111
Group 8 Turning Joint ------------------------------------------------------------------------------------------------------ 8-125
Group 9 Boom, Arm and Bucket Cylinder -------------------------------------------------------------------- 8-130
Group 10 Undercarriage --------------------------------------------------------------------------------------------------- 8-147
Group 11 Work Equipment ----------------------------------------------------------------------------------------------- 8-159
SECTION 9 COMPONENT MOUNTING TORQUE
Group 1 Introduction guide --------------------------------------------------------------------------------------------- 9-1

Group 2 Engine system -------------------------------------------------------------------------------------------------- 9-2
Group 3 Electric system ------------------------------------------------------------------------------------------------- 9-4
Group 4 Hydraulic system ---------------------------------------------------------------------------------------------- 9-6
Group 6 Structure ------------------------------------------------------------------------------------------------------------ 9-11
Group 7 Work equipment ----------------------------------------------------------------------------------------------- 9-15
FOREWORD
1. STRUCTURE
This service manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to
perform repairs and make judgements. Make sure you understand the contents of this manual and
use it to full effect at every opportunity.
This service manual mainly contains the necessary technical information for operations performed in
a service workshop.
For ease of understanding, the manual is divided into the following sections.
SECTION 1 GENERAL
This section explains the safety hints and gives the specification of the machine and major
components.
This section explains the structure and function of each component. It serves not only to give an
understanding of the structure, but also serves as reference material for troubleshooting.
This section explains the hydraulic circuit, single and combined operation.
This section explains the electrical circuit, monitoring system and each component. It serves not
only to give an understanding electrical system, but also serves as reference material for trouble
shooting.
This section explains the computer aided power optimization system and each component.
This section explains the troubleshooting charts correlating problems to causes
causes.
This section gives the judgement standards when inspecting disassembled parts.
This section explains the order to be followed when removing, installing, disassembling or
assembling each component, as well as precautions to be taken for these operations.
This section shows bolt specifications and standard torque values needed when mounting
components to the machine.
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Contact your HYUNDAI distributor for the latest information.
0-1
2. HOW TO READ THE SERVICE MANUAL
Distribution and updating Revised edition mark
mark(①②③…)
Any additions, amendments or other changes will When a manual is revised, an edition mark is
be sent to HYUNDAI distributors. recorded on the bottom outside corner of the
Get the most up-to-date information before you pages.
start any work.
Revisions
Filing method Revised pages are shown at the list of revised
1. See the page number on the bottom of the pages on the between the contents page and
page. section 1 page.
File the pages in correct order.
2. Following examples shows how to read the Symbols
page number. So that the shop manual can be of ample
Example 1 practical use, important places for safety and
2-3 quality are marked with the following symbols.
Item number(2. Structure and
Function)
Consecutive page number for Symbol Item Remarks
each item.
Special safety precautions are
3. Additional pages : Additional pages are necessary when performing the
indicated by a hyphen(-) and number after the work.
Safety
page number. File as in the example. Extra special safety precautions
10 - 4 are necessary when performing
10 - 4 - 1 the work because it is under
Added pages internal pressure.
10 - 4 - 2
10 - 5 Special technical precautions or
※
other precautions for preserving
Caution
standards are necessary when
performing the work.
0-2
3. CONVERSION TABLE
Method of using the Conversion Table
The Conversion Table in this section is provided to enable simple conversion of figures. For details of
the method of using the Conversion Table, see the example given below.
Example
1. Method of using the Conversion Table to convert from millimeters to inches
Convert 55mm into inches.
(1) Locate the number 50in the vertical column at the left side, take this as ⓐ, then draw a
horizontal line from ⓐ.
(2) Locate the number 5in the row across the top, take this as ⓑ, then draw a perpendicular line
down from ⓑ.
(3) Take the point where the two lines cross as ⓒ. This point ⓒ gives the value when converting
from millimeters to inches. Therefore, 55mm = 2.165 inches.
2. Convert 550mm into inches.

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

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

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

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

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

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

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

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 2863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 5603 2617 2631 2646 2660 2674 2688
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
0-7
TEMPERATURE
Fahrenheit-Centigrade Conversion.
A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice verse
is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
˚C ˚F ˚C ˚F ˚C ˚F ˚C ˚F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

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

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

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

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

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

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

Group 2 Specifications ----------------------------------------------------------------------------------------------------- 1-10
SECTION 1 GENERAL
GROUP 1 SAFETY
FOLLOW SAFE PROCEDURE

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

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

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

Falling is one of the major causes of personal
injury.
When you get on and off the machine, always
maintain a three point contact with the steps
and handrails and face the machine. Do not
use any controls as handholds.
Never jump on or off the machine. Never mount
or dismount a moving machine. 13031GE03
Be careful of slippery conditions on platforms,

steps, and handrails when leaving the machine.
1-1
PREPARE FOR EMERGENCIES
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors,
ambulance ser vice, hospital, and fire
department near your telephone.
13031GE04
PROTECT AGAINST FLYING DEBRIS

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

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

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

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

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

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

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

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

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

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

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

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

Keep sparks, lighted matches, and flame away
from the top of battery. Battery gas can
explode.
Never check battery charge by placing a metal
object across the posts. Use a volt-meter or
hydrometer.
Do not charge a frozen battery; It may explode.
Warm battery to 16˚C (60˚F ). 13031GE21
1-7
PREVENT ACID BURNS
Sulfuric acid in battery electrolyte is poisonous.
It is strong enough to burn skin, eat holes in
clothing, and cause blindness if splashed into
eyes.
Avoid the hazard by:
1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte
is added.
4. Avoiding spilling of dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize
the acid.
3. Flush your eyes with water for 10-15
minutes. Get medical attention immediate-
ly. 13031GE22
If acid is swallowed:
1. Drink large amounts of water or milk.
2. Then drink milk of magnesia, beaten eggs,
or vegetable oil.
3. Get medical attention immediately.
USE TOOLS PROPERLY

Use tools appropriate to the work. Makeshift
tools, parts, and procedures can create safety
hazards.
Use power tools only to loosen threaded tools
and fasteners.
For loosening and tightening hardware, use the
correct size tools. DO NOT use U.S.
measurement tools on metric fasteners. Avoid
bodily injury caused by slipping wrenches. 13031GE23
Use only recommended replacement parts.

(See Parts catalogue.)
1-8
DISPOSE OF FLUIDS PROPERLY
Improperly disposing of fluids can harm the
environment and ecology. Before draining any
fluids, find out the proper way to dispose of
waste from your local environmental agency.
Use proper containers when draining fluids. Do
not use food or beverage containers that may
mislead someone into drinking from them.
DO NOT pour oil into the ground, down a drain,
or into a stream, pond, or lake. Observe 13031GE24
relevant environmental protection regulations
when disposing of oil, fuel, coolant, brake fluid,
filters, batteries, and other harmful waste.
REPLACE SAFETY SIGNS

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

Before returning machine to customer, make
sure machine is functioning properly, especially
the safety systems. Install all guards and
shields.
1-9
GROUP 2 SPECIFICATIONS
1. MAJOR COMPONENT
Battery box Fuel tank Hydraulic tank Main pump
Engine
Radiator
Tooth Bucket Turning joint Swing motor Main control valve Oil cooler
Arm Arm cylinder Boom Boom cylinder Cab Muffler Counterweight
Bucket cylinder Connecting link Idler Carrier roller Sprocket
Side cutter Connecting rod

Connecting rod Track roller Track Travel motor
2609S2SP01
1-10
2. SPECIFICATIONS
1) R260LC-9S
·5.85
5.85 m (19' 2") BOOM and 3.05 m (10' 0") ARM
I(I') D
C
E
G
F
H
J M
K N
A B(L)
2609S2SP02
Description Unit Specification

Operating weight kg (lb) 25200 (55600)
Bucket capacity (SAE heaped), standard m3 (yd3) 1.08 (1.41)
Overall length A 9920 (32' 7")
Overall width, with 600mm shoe B 3180 (10' 5")
Overall height C 3220 (10' 7")
Superstructure width D 2840 ( 9' 4")
Overall height of cab E 2990 ( 9' 10")
Ground clearance of counterweight F 1115 ( 3' 8")
Engine cover height G 2427 ( 8' 0")
Minimum ground clearance H mm (ft-in) 480 ( 1' 7")
Rear-end distance I 2870 ( 9' 5")
Rear-end swing radius I' 2975 ( 9' 9")
Distance between tumblers J 3830 (12' 7")
Undercarriage length K 4640 (15' 3")
Undercarriage width L 3180 (10' 5")
Track gauge M 2580 ( 8' 6")
Track shoe width, standard N 600 (24")
Travel speed (low/high) km/hr (mph) 3.4/5.5 (2.1/3.4)
Swing speed rpm 12.5
Gradeability Degree (%) 35 (70)
Ground pressure (600 mm shoe) kgf/cm2 (psi) 0.51 (7.25)
Max traction force kg (lb) 21600 (47600)
1-11
2) R260NLC-9S
·5.85
5.85 m (19' 2") BOOM and 3.05 m (10' 0") ARM
I(I') D
C
E
G
F
H
J M
K N
A B(L)
2609S2SP04

Overall length A 9920 (32' 7")
Overall width, with 600 mm shoe B 2980 ( 9' 9")
Overall height C 3220 (10' 7")
Undercarriage width L 2980 ( 9' 9")
Track gauge M 2380 ( 7' 10")
1-12
3) R260LC-9S HIGH WALKER
·5.85
5.85 m (19' 2") BOOM and 3.05 m (10' 0") ARM
I(I') D
C
E
G
F
H
J M
K N
A B(L)
2609S2SP05

Overall length A 9760 ( 32' 0")
Overall width, with 600 mm shoe B 3390 ( 11' 1")
Overall height C 3240 ( 10' 8")
Undercarriage width L 3390 ( 11' 1")
Track gauge M 2790 ( 9' 2")
1-13
3. WORKING RANGE
1) R260LC-9S, R260NLC-9S [5.85 m (19' 2") BOOM]

A
A'
F
D
E
C
B'
B
8ft
2609S2SP03
Description 2.10m (6' 11") Arm 2.50m (8' 2") Arm 3.05m (10' 0") Arm 3.60m (11' 10") Arm
Max digging reach A 9550 mm (31' 4") 9870 mm (32' 5") 10360 mm (34' 0") 10870 mm (35' 8")
Max digging reach on ground A' 9360 mm (30' 9") 9680 mm (31' 9") 10190 mm (33' 5") 10700 mm (35' 1")
Max digging depth B 6050 mm (19'10") 6450 mm (21' 2") 7000 mm (23' 0") 7550 mm (24' 9")
Max digging depth (8 ft level) B' 5840 mm (19' 2") 6260 mm (20' 6") 6830 mm (22' 5") 7400 mm (24' 3")
Max vertical wall digging depth C 5480 mm (18' 0") 5640 mm (18' 6") 6150 mm (20' 2") 6830 mm (22' 5")
Max digging height D 9450 mm (31' 0") 9460 mm (31' 0") 9670 mm (31' 9") 9920 mm (32' 7")
Max dumping height E 6360 mm (20'10") 6420 mm (21' 1") 6630 mm (21' 9") 6860 mm (22' 6")
Min swing radius F 4420 mm (14' 6") 4200 mm (13' 9") 3980 mm (13' 1") 3900 mm (12'10")
156.9 [171.2] kN 156.9 [171.2] kN 156.9 [171.2] kN 156.9 [171.2] kN
SAE 16000 [17450] kgf 16000 [17450] kgf 16000 [17450] kgf 16000 [17450] kgf
35270 [38480] lbf 35270 [38480] lbf 35270 [38480] lbf 35270 [38480] lbf
Bucket digging force
178.5 [194.7] kN 178.5 [194.7] kN 178.5 [194.7] kN 178.5 [194.7] kN
ISO 18200 [19850] kgf 18200 [19850] kgf 18200 [19850] kgf 18200 [19850] kgf
40120 [43770] lbf 40120 [43770] lbf 40120 [43770] lbf 40120 [43770] lbf
134.4 [145.9] kN 130.4 [142.3] kN 114.7 [125.2] kN 114.7 [125.1] kN
30200 [32790] lbf 29320 [31990] lbf 25790 [28130] lbf 23370 [25490] lbf
Arm digging force
139.3 [151.2] kN 134.4 [146.6] kN 118.7 [129.4] kN 107.9 [117.7] kN
31310 [33990] lbf 30200 [32950] lbf 26680 [29110] lbf 24250 [26450] lbf
[ ] : Power boost
1-14
2) R260LC-9S HIGH WALKER [5.85 m (19' 2") BOOM]
A
A'
F
D
E
C
B'
B
8ft 2609S2SP09
Description 2.10m (6' 11") Arm 2.50m (8' 2") Arm 3.05m (10' 0") Arm 3.60m (11' 10") Arm
Max digging reach A 9550 mm (31' 4") 9870 mm (32' 5") 10360 mm (34' 0") 10870 mm (35' 8")
Max digging reach on ground A' 9280 mm (30' 5") 9160 mm (31' 6") 10110 mm (33' 2") 10360 mm (34'11")
Max digging depth B 5680 mm (18' 8") 6080 mm (19'11") 6630 mm (21' 9") 7180 mm (23' 7")
Max digging depth (8 ft level) B' 5470 mm (17'11") 5890 mm (19' 4") 6460 mm (21' 2") 7030 mm (23' 1")
Max vertical wall digging depth C 5120 mm (16'10") 5300 mm (17' 5") 5790 mm (19' 0") 6470 mm (21' 3")
Max digging height D 9820 mm (32' 3") 9840 mm (32' 3") 10040 mm (32'11") 10280 mm (33' 9")
Max dumping height E 6730 mm (22' 1") 6790 mm (22' 3") 7000 mm (23' 0") 7220 mm (23' 8")
Min swing radius F 4140 mm (13' 7") 4030 mm (13' 3") 3940 mm (12'11") 3900 mm (12'10")
156.9 [171.2] kN 156.9 [171.2] kN 156.9 [171.2] kN 156.9 [171.2] kN
35270 [38480] lbf 35270 [38480] lbf 35270 [38480] lbf 35270 [38480] lbf
Bucket digging force
178.5 [194.7] kN 178.5 [194.7] kN 178.5 [194.7] kN 178.5 [194.7] kN
40120 [43770] lbf 40120 [43770] lbf 40120 [43770] lbf 40120 [43770] lbf
134.4 [145.9] kN 130.4 [142.3] kN 114.7 [125.2] kN 114.7 [125.1] kN
30200 [32790] lbf 29320 [31990] lbf 25790 [28130] lbf 23370 [25490] lbf
Arm crowd force
139.3 [151.2] kN 134.4 [146.6] kN 118.7 [129.4] kN 107.9 [117.7] kN
31310 [33990] lbf 30200 [32950] lbf 26680 [29110] lbf 24250 [26450] lbf
[ ] : Power boost
1-15
4. WEIGHT
1) R260LC-9S, R260NLC-9S,
R260LC-9S R260NLC-9S
Item
kg lb kg lb
Upperstructure assembly 10500 23150 ← ←
Main frame weld assembly 2360 5200 ← ←
Engine assembly 530 1170 ← ←
Main pump assembly 136 300 ← ←
Main control valve assembly 220 485 ← ←
Swing motor assembly 345 760 ← ←
Hydraulic oil tank assembly 220 485 ← ←
Fuel tank assembly 200 440 ← ←
Counterweight 4600 10140 ← ←
Cab assembly 440 970 ← ←
Lower chassis assembly 9750 21500 9810 21630
Track frame weld assembly 3070 6770 2980 6570
Swing bearing 280 800 ← ←
Travel motor assembly 276 608 ← ←
Turning joint 53 117 ← ←
Track recoil spring 140 309 ← ←
Idler 160 353 ← ←
Carrier roller 20 45 ← ←
Track roller 40 88 ← ←
Track-chain assembly
(600 mm standard triple grouser shoe) 1500 3310 ← ←
Front attachment assembly (5.85 m boom, 4950 10910 ← ←

3.05 m arm, 1.08 m3 SAE heaped bucket)
5.85 m boom assembly 1940 4280 ← ←
3.05 m arm assembly 1020 2250 ← ←
1.08 m3 SAE heaped bucket 910 2010 ← ←
Boom cylinder assembly 240 530 ← ←
Arm cylinder assembly 340 750 ← ←
Bucket cylinder assembly 220 490 ← ←
Bucket control rod assembly 110 240 ← ←
1-16
R260LC-9S HIGH WALKER
Item
kg lb
Upperstructure assembly 10500 23150
Main frame weld assembly 2360 5200
Engine assembly 530 1170
Main pump assembly 136 300
Main control valve assembly 220 485
Swing motor assembly 345 760
Hydraulic oil tank assembly 220 485
Fuel tank assembly 200 440
Counterweight 4600 10140
Cab assembly 440 970
Lower chassis assembly 12000 26460
Track frame weld assembly 5280 11640
Swing bearing 360 800
Travel motor assembly 276 608
Turning joint 53 117
Track recoil spring 200 440
Idler 250 550
Carrier roller 55 120
Track roller 55 120
Track-chain assembly (600 mm standard triple grouser shoe) 1860 4100
Front attachment assembly (5.85 m boom, 3.05 m arm,
4950 10910
1.08 m3 SAE heaped bucket)
5.85 m boom assembly 1940 4280
3.05 m arm assembly 1020 2250
1.08 m3 SAE heaped bucket 910 2010
Boom cylinder assembly 240 530
Arm cylinder assembly 340 750
Bucket cylinder assembly 220 490
Bucket control rod assembly 110 240
1-17
5. LIFTING CAPACITIES
1) R260LC-9S
(1) 5.85 m (19' 2") boom, 3.05 m (10' 0") arm equipped with 1.08 m3 (SAE heaped) bucket and 600
mm (24") triple grouser shoe.
Load radius At max. reach

Load point 1.5 m (5 ft) 3.0 m (10 ft) 4.5 m (15 ft) 6.0 m ( 20ft) 7.5 m ( 25ft) Capacity Reach
height
m (ft)
6.0 m kg *3700 *3700 4400 2660 9.22

(20 ft) lb *8160 *8160 9700 5860 (30.2)
4.5 m kg *5350 *5350 *5060 3830 3880 2280 9.74
(15 ft) lb *11790 *11790 *11160 8440 8550 5030 (32.0)
3.0 m kg *13640 *13640 *8400 *8400 *6540 5360 *5660 3620 3630 2090 9.98
(10 ft) lb *30070 *30070 *18520 *18520 *14420 11820 *12480 7980 8000 4610 (32.7)
1.5 m kg *9450 *9450 *10870 7800 *7820 4950 5750 3400 3580 2040 9.95
(5 ft) lb *20830 *20830 *23960 17200 *17240 10910 12680 7500 7890 4500 (32.6)
Ground kg *10570 *10570 *12490 7280 8010 4640 5560 3230 3730 2130 9.65
Line lb *23300 *23300 *27540 16050 17660 10230 12260 7120 8220 4700 (31.7)
-1.5 m kg *9940 *9940 *13870 *13870 12930 7090 7830 4480 5460 3140 4150 2390 9.05
(-5 ft) lb *21910 *21910 *30580 *30580 28510 15630 17260 9880 12040 6920 9150 5270 (29.7)
-3.0 m kg *13540 *13540 *18430 14860 *12780 7110 7820 4470 5080 2980 8.06
(-10 ft) lb *29850 *29850 *40630 32760 *28180 15670 17240 9850 11200 6570 (26.4)
-4.5 m kg *17830 *17830 *16580 15340 *11360 7340 8020 4640 *5940 4480 6.48
(-15 ft) lb *39310 *39310 *36550 33820 *25040 16180 17680 10230 *13100 9880 (21.3)
Note 1. Lifting capacity are based on SAE J1097 and ISO 10567.
2. Lifting capacity of the ROBEX series does not exceed 75% of tipping load with the machine
on firm, level ground or 87% of full hydraulic capacity.
3. The load point is a hook (standard equipment) located on the back of the bucket.
4. *indicates load limited by hydraulic capacity.
1-18
2) R260NLC-9S
(1) 5.85 m (19' 2") boom, 3.05 m (10' 0") arm equipped with 1.08 m3 (SAE heaped) bucket and 600
mm (24") triple grouser shoe.
height
m (ft)
6.0 m kg *3700 3570 4380 2370 9.22

(20 ft) lb *8160 7870 9660 5220 (30.2)
4.5 m kg *5350 5230 *5060 3440 3860 2020 9.74
(15 ft) lb *11790 11530 *11160 7580 8510 4450 (32.0)
3.0 m kg *13640 *13640 *8400 7780 *6540 4830 *5660 3240 3610 1840 9.98
(10 ft) lb *30070 *30070 *18520 17150 *14420 10650 *12480 7140 7960 4060 (32.7)
1.5 m kg *9450 *9450 *10870 6940 *7820 4420 5720 3030 3560 1790 9.95
(5 ft) lb *20830 *20830 *23960 15300 *17240 9740 12610 6680 7850 3950 (32.6)
Ground kg *10570 *10570 *12490 6430 7980 4120 5530 2850 3710 1860 9.65
Line lb *23300 *23300 *27540 14180 17590 9080 12190 6280 8180 4100 (31.7)
-1.5 m kg *9940 *9940 *13870 12620 12870 6250 7790 3960 5430 2760 4130 2100 9.05
(-5 ft) lb *21910 *21910 *30580 27820 28370 13780 17170 8730 11970 6080 9110 4630 (29.7)
-3.0 m kg *13540 *13540 *18430 12840 *12780 6270 7780 3950 5060 2640 8.06
(-10 ft) lb *29850 *29850 *40630 28310 *28180 13820 17150 8710 11160 5820 (26.4)
-4.5 m kg *17830 *17830 *16580 13290 *11360 6490 7980 4120 *5940 4010 6.48
(-15 ft) lb *39310 *39310 *36550 29300 *25040 14310 17590 9080 *13100 8840 (21.3)
3. The load point is a hook located on the back of the bucket.
1-19
(1) 5.85 m (19' 2") boom, 3.05 m (10' 0") arm equipped with 1.08 m3 (SAE heaped) bucket and 600 mm
(24") triple grouser shoe.

height
m (ft)
6.0 m kg *4140 *4140 *4510 3190 9.37

(20 ft) lb *9130 *9130 *9940 7030 (30.7)
4.5 m kg *5610 *5610 *5180 4650 4590 2830 9.82
(15 ft) lb *12370 *12370 *11420 10250 10120 6240 (32.2)
3.0 m kg *15320 *15320 *9030 *9030 *6850 6450 *5830 4430 4370 2660 9.99
(10 ft) lb *33770 *33770 *19910 *19910 *15100 14220 *12850 9770 9630 5860 (32.8)
1.5 m kg *9310 *9310 *11350 9510 *8090 6050 *6510 4220 4380 2650 9.90
(5 ft) lb *20530 *20530 *25020 20970 *17840 13340 *14350 9300 9660 5840 (32.5)
Ground kg *7350 *7350 *11240 *11240 *12710 9060 *9010 5760 6680 4060 4620 2800 9.53
Line lb *16200 *16200 *24780 *24780 *28020 19970 *19860 12700 14730 8950 10190 6170 (31.3)
-1.5 m kg *10760 *10760 *14820 *14820 *13100 8920 *9410 5640 6610 3990 5220 3180 8.85
(-5 ft) lb *23720 *23720 *32670 *32670 *28880 19670 *20750 12430 14570 8800 11510 7010 (29.0)
-3.0 m kg *14470 *14470 *18710 *18710 *12560 9000 *9310 5660 *6000 4040 7.76
(-10 ft) lb *31900 *31900 *41250 *41250 *27690 19840 *20130 12480 *13230 8910 (25.5)
-4.5 m kg *15670 *15670 *10780 9290
(-15 ft) lb *34550 *34550 *23770 20480
3. The load point is a hook located on the back of the bucket.
1-20
6. BUCKET SELECTION GUIDE
1) GENERAL BUCKET
0.60 m3 SAE 1.27 m3 SAE

1.03 m3 SAE 1.08 m3 SAE
0.79 m3 SAE 1.50 m3 SAE
heaped bucket heaped bucket
heaped bucket heaped bucket
Recommendation
Capacity Width
5.85m (19' 2") boom
Weight
SAE CECE Without With 2.1m arm 2.5m arm 3.05m arm 3.6m arm
heaped heaped side cutter side cutter (6' 11") (8' 2") (10' 0") (11' 10")
0.60 m3 0.55 m3 760 mm 880 mm 720 kg

(0.78 yd3) (0.72 yd3) (29.9") (34.6") (1590 lb)
0.79 m3 0.70 m3 890 mm 1010 mm 790 kg

(1.03 yd ) (0.92 yd3)
3 (35.0") (39.8") (1740 lb)
1.03 m3 0.90 m3 1090 mm 1210 mm 890 kg

(1.35 yd3) (1.18 yd3) (42.9") (47.6") (1960 lb)
1.08 m3 0.95 m3 1130 mm 1250 mm 910 kg

(1.41 yd3) (1.24 yd3) (44.5") (49.2") (2010 lb)
1.27 m3 1.10 m3 1290 mm 1410 mm 1010 kg

(1.66 yd ) (1.44 yd3)
3 (50.8") (55.5") (2230 lb)
1.50 m3 1.30 m3 1490 mm 1610 mm 1080 kg

(1.96 yd3) (1.70 yd3) (58.7") (63.4") (2380 lb)
Applicable for materials with density of 2000 kgf/m3 (3370 lbf/yd3) or less
1-21
2) ROCK AND HEAVY DUTY BUCKET
ľ1.07m3 SAE
ľ1.27m3 SAE ľ1.46m3 SAE Ľ1.16m3 SAE
ľ1.15m3 SAE
heaped bucket heaped bucket heaped bucket
heaped bucket
Recommendation
Capacity Width
5.85 m (19' 2") boom
Weight
SAE CECE Without With 2.1 m arm 2.5 m arm 3.05 m arm 3.6 m arm
heaped heaped side cutter side cutter (6' 11") (8' 2") (10' 0") (11' 10")
ľ1.07 m3 0.95 m3 1150 mm 1120 kg

(1.40 yd3) (1.24 yd3) (45.3") (2470 lb)
ľ1.15 m3 1.00 m3 1210 mm

1160 kg
(1.50 yd3) (1.31 yd3) (47.6") (2560 lb)
ľ1.27 m3 1.10 m3 1310 mm

1240 kg
(1.66 yd3) (1.44 yd3) (51.6") (2730 lb)
ľ1.46 m3 1.28 m3 1460 mm

1320 kg
(1.91 yd3) (1.67 yd3) (57.5") (2910 lb)
Ľ1.16 m3 1.00 m3 1340 mm

1280 kg
(1.52 yd3) (1.31 yd3) (52.8") (2820 lb)
ľ : Heavy duty bucket Ľ: Rock-Heavy duty bucket
1-22
7. UNDERCARRIAGE
1) TRACKS
X-leg type center frame is integrally welded with reinforced box-section track frames. The design
includes dry tracks, lubricated rollers, idlers, sprockets, hydraulic track adjusters with shock absorb-
ing springs and assembled track-type tractor shoes with triple grousers.
2) TYPES OF SHOES
Triple grouser Double grouser
Model Shapes
Shoe width mm (in) 600 (24) 700 (28) 800 (32) 900 (36) -
Operating weight kg (lb) 25200 (55600) 25500 (26200) 25800 (56900) 26100 (57500) -
R260LC-9S
Ground pressure kgf/cm2 (psi) 0.51 (7.25) 0.44 (6.26) 0.39 (5.55) 0.35 (4.98) -
Overall width mm (ft-in) 3180 (10' 5") 3280 (10' 9") 3380 (11' 1") 3480 (11' 5") -
Shoe width mm (in) 600 (24) - - - -
Operating weight kg (lb) 25100 (55300) - - - -

R260NLC-9S
Ground pressure kgf/cm2 (psi) 0.51 (7.25) - - - -
Overall width mm (ft-in) 2980 ( 9' 9") - - - -
Shoe width mm (in) 600 (24) 700 (28) 800 (32) - 700 (28)
R260LC-9S Operating weight kg (lb) 27450 (60520) 28020 (61770) 28400 (62610) - 28620 (63100)
HIGH
Ground pressure kgf/cm2 (psi) 0.53 (7.54) 0.46 (6.54) 0.41 (5.83) - 0.47 (6.68)
WALKER
Overall width mm (ft-in) 3180 (10' 5") 3280 (10' 9") 3380 (11' 1") - 3280 (10' 9")
3) NUMBER OF ROLLERS AND SHOES ON EACH SIDE

Quantity
Item
R260LC-9S, R260NLC-9S R260LC-9S HIGH WALKER
Carrier rollers 2 EA 2 EA
Track rollers 9 EA 9 EA
Track shoes 51 EA 48 EA
1-23
4) SELECTION OF TRACK SHOE
Suitable track shoes should be selected according to operating conditions.
Method of selecting shoes
Confirm the category from the list of applications in table 2, then use table 1 to select the shoe.
Wide shoes(Categories B and C) have limitations on applications. Before using wide shoes,
check the precautions, then investigate and study the operating conditions to confirm if these
shoes are suitable.
Select the narrowest shoe possible to meet the required flotation and ground pressure. Application
of wider shoes than recommendations will cause unexpected problem such as bending of shoes,
crack of link, breakage of pin, loosening of shoe bolts and the other various problems.
öTable
Table 1
Track shoe Specification Category
600mm triple grouser Standard A

700mm triple grouser Option B
700mm double grouser ø1 Option B
800mm triple grouser Option C
900mm triple grouser Option C
ø1 : R260LC-9S HIGH WALKER ONLY
öTable
Table 2
Category Applications Precautions
Rocky ground, Â Travel at low speed on rough ground with large obstacles such as
A river beds, boulders or fallen trees
normal soil
Normal soil, Â These shoes cannot be used on rough ground with large obstacles
soft ground such as boulders or fallen trees
B Â Travel at high speed only on flat ground
Â Travel slowly at low speed if it is impossible to avoid going over
obstacles
Extremely, Â Use the shoes only in the conditions that the machine sinks and it is
soft ground impossible to use the shoes of category A or B
(Swampy ground) Â These shoes cannot be used on rough ground with large obstacles
C such as boulders or fallen trees
Â Travel at high speed only on flat ground
Â Travel slowly at low speed if it is impossible to avoid going over
obstacles
1-24
8. SPECIFICATIONS FOR MAJOR COMPONENTS
1) ENGINE
Item Specification
Model Cummins B5.9

Type 4-cycle turbocharged, charger air cooled diesel engine
Cooling method Water cooling
Number of cylinders and arrangement 6 cylinders, in-line
Firing order 1-5-3-6-2-4
Combustion chamber type Direct injection type
Cylinder boreÝstroke 102Ý120mm(4.0"Ý4.7")
Piston displacement 5880cc(359cu in)
Compression ratio 17.3 : 1
Rated gross horse power (SAE J1995) 178Hp at 2000rpm(133kW at 2000rpm)
Maximum torque 72.2kgfÂm(522lbfÂft) at 1500rpm
Engine oil quantity 24˶ (6.3 U.S. gal)
Dry weight 530 kg(1170 lb)
High idling speed 2250 50rpm
Low idling speed 1050Ü100rpm
Rated fuel consumption 167.0g/HpÂhr at 2000rpm
Starting motor Nippon denso (24V-4.5 kW)
Alternator Delco Remy 24V-70A
Battery 2Ý12VÝ100 Ah
2) MAIN PUMP
Item Specification
Type Variable displacement tandem axis piston pumps
Capacity 2Ý117 cc/rev
Maximum pressure 350 kgf/cm2 (4980 psi) [380 kgf/cm2 (5400 psi)]
Rated oil flow 2Ý228˶/min (60.2 U.S. gpm/ 50.2 U.K. gpm)
Rated speed 1900 rpm
[ ] : Power boost
1-25
3) GEAR PUMP
Item Specification
Type Fixed displacement gear pump single stage
Capacity 15 cc/rev
Maximum pressure 40 kgf/cm2 (570 psi)
Rated oil flow 28.5˶/min (7.45 U.S. gpm / 6.27 U.K. gpm)
4) MAIN CONTROL VALVE

Item Specification
Type 10 spools
Operating method Hydraulic pilot system
Main relief valve pressure 350 kgf/cm2 (4980 psi) [380 kgf/cm2 (5400 psi)]
Overload relief valve pressure 400 kgf/cm2 (5690 psi)
[ ] : Power boost
5) SWING MOTOR
Specification
Item
TYPE 1 TYPE 2
Type Axial piston motor
Capacity 148.5 cc/rev 151 cc/rev
Relief pressure 300 kgf/cm2 (4270 psi)
Braking system Automatic, spring applied hydraulic released
Braking torque 70 kgfÂm (506 lbfÂft) 59 kgfÂm (427 lbfÂft)
Brake release pressure 26 kgf/cm2
Reduction gear type 2 - stage planetary
6) TRAVEL MOTOR
Specification
Item
TYPE 1 TYPE 2
Type Axial piston motor
Relief pressure 350 kgf/cm2 (4980 psi)
Capacity (max / min) 161.5/93.5 cc/rev 182.4/105.4 cc/rev
Reduction gear type Planetary differential
Braking system Automatic, spring applied hydraulic released
Brake release pressure 8.2 kgf/cm2 (116 psi) 18.3 kgf/cm2 (260 psi)
Braking torque 50 kgfÂm (362 lbfÂft) 72 kgfÂm (520 lbfÂft)
1-26
7) CYLINDER
Item Specification
Bore diaÝStroke ͚135Ý1345 mm

Boom cylinder
Cushion Extend only
Arm cylinder
Cushion Extend and retract
Bucket cylinder
Cushion Extend only
ö Discoloration of cylinder rod can occur when the friction reduction additive of lubrication oil spreads on
the rod surface.
ö Discoloration does not cause any harmful effect on the cylinder performance.
8) SHOE
Item Width Ground pressure Link quantity Overall width
Standard 600 mm (24") 0.51 kgf/cm2 (7.25 psi) 51 3180 mm (10' 5")
700 mm (28") 0.44 kgf/cm2 (6.26 psi) 51 3280 mm (10' 9")
R260LC-9S
Option 800 mm (32") 0.39 kgf/cm2 (5.55 psi) 51 3380 mm (11' 1")
900 mm (36") 0.35 kgf/cm2 (4.98 psi) 51 3480 mm (11' 5")
R260NLC-9S Standard 600 mm (24") 0.51 kgf/cm2 (7.25 psi) 51 2980 mm ( 9' 9")
Standard 600 mm (24") 0.53 kgf/cm2 (7.54 psi) 48 3180 mm (10' 5")
R260LC-9S 700 mm (28") 0.46 kgf/cm2 (6.54 psi) 48 3280 mm (10' 9")
HIGH
Option 800 mm (32") 0.41 kgf/cm2 (5.83 psi) 48 3380 mm (11' 1")
WALKER
ø700 mm (28") 0.47 kgf/cm2 (6.68 psi) 48 3280 mm (10' 9")
ø: Double grouser
9) BUCKET
Capacity Tooth Width
Item quantity Without side cutter With side cutter
SAE heaped CECE heaped
0.60 m3 (0.78 yd3) 0.55 m3 (0.72 yd3) 3 760 mm (29.9") 880 mm (34.6")
0.79 m3 (1.03 yd3) 0.70 m3 (0.92 yd3) 3 890 mm (35.0") 1010 mm (39.8")
1.03 m3 (1.35 yd3) 0.90 m3 (1.18 yd3) 4 1090 mm (42.9") 1210 mm (47.6")
1.08 m3 (1.41 yd3) 0.95 m3 (1.24 yd3) 5 1130 mm (44.5") 1250 mm (49.2")
R260LC-9S
1.27 m3 (1.66 yd3) 1.10 m3 (1.44 yd3) 5 1290 mm (50.8") 1410 mm (55.5")
R260NLC-9S
R260LC-9S 1.50 m3 (1.96 yd3) 1.30 m3 (1.70 yd3) 6 1490 mm (58.7") 1610 mm (63.4")
H/WALKER
ľ1.07 m3 (1.40 yd3) 0.95 m3 (1.24 yd3) 5 1150 mm (45.3")
ľ1.15 m3 (1.50 yd3) 1.00 m3 (1.31 yd3) 5 1210 mm (47.6")
ľ1.27 m3 (1.66 yd3) 1.10 m3 (1.44 yd3) 5 1310 mm (51.6")
ľ1.46 m3 (1.91 yd3) 1.28 m3 (1.67 yd3) 5 1460 mm (57.5")
Ľ1.16 m3 (1.52 yd3) 1.00 m3 (1.31 yd3) 5 1340 mm (52.8")
ľ : Heavy duty bucket Ľ : Rock bucket
1-27
9. RECOMMENDED OILS
Use only oils listed below or equivalent.

Do not mix different brand oil.
Ambient temperatureĦC(ĦF)
Capacity
Service point Kind of fluid -20 -10 0 10 20 30 40
˶ (U.S. gal)
(-4) (14) (32) (50) (68) (86) (104)
SAE 30
SAE 10W
Engine
Engine oil 24 (6.3)
oil pan
SAE 10W-30
SAE 15W-40
Swing drive 6.0 (1.6)
3.3Ý2
Final drive Gear oil SAE 85W-140
(0.9Ý2)
8.0Ý2
Final drive (H/W)
(2.1Ý2)
Tank; ISO VG 32
165 (43.6)
Hydraulic tank Hydraulic oil ISO VG 46
System;
285 (75.3) ISO VG 68
ASTM D975 NO.1

Fuel tank Diesel fuel 400 (106)
ASTM D975 NO.2
Fitting NLGI NO.1

Grease As required
(grease nipple)
NLGI NO.2
Mixture of
Radiator antifreeze
35 (9.2) Ethylene glycol base permanent type
(reservoir tank) and water
50 : 50
SAE : Society of Automotive Engineers

API : American Petroleum Institute
ISO : International Organization for Standardization
NLGI : National Lubricating Grease Institute
ASTM : American Society of Testing and Material
1-28
Group 1 Pump Device ------------------------------------------------------------------------------------------------------ 2-1

Group 2 Main Control Valve --------------------------------------------------------------------------------------------- 2-20
Group 3 Swing Device ------------------------------------------------------------------------------------------------------ 2-55
Group 4 Travel Device ------------------------------------------------------------------------------------------------------ 2-66
Group 5 RCV Lever ---------------------------------------------------------------------------------------------------------- 2-76
Group 6 RCV Pedal ---------------------------------------------------------------------------------------------------------- 2-83
GROUP 1 PUMP DEVICE
1. STRUCTURE
The pump device consists of main pump, regulator and gear pump.
Qmax adjusting screw

Pi1
Dr A1 A2
A3
B3
Psv
Pi2
a4
Qmin adjusting screw Qmin adjusting screw
Regulator Regulator
Pi1 Pi2
a4
Psv
B3
Dr
B1
a3
a1 a2
Front pump Rear pump Gear pump
2209S2MP01
A1 A2
Psv a4 Port Port name Port size
A1,2 Delivery port SAE6000psi 3/4"
a1 a2
B1 Suction port SAE2500psi 2 1/2"
Dr Drain port PF 3/4 - 20
Pi1,i2 Pilot port PF 1/4 - 15
Pi1 Pi2 Psv Servo assist port PF 1/4 - 15
a1,2,4 Gauge port PF 1/4 - 15
ENG
a3 Gauge port PF 1/4-14
a3
A3 Gear pump delivery port PF 1/2 - 19
Dr B1 B3 A3
B3 Gear pump suction port PF 3/4 - 20.5
Hydraulic circuit
2-1
1) MAIN PUMP (1/2)
The main pump consists of two piston pumps (front & rear) and valve block.
535 789 732 532 214 548 531 724 702 792 534 808 901 954 717 151 152 211 113
953 A
806
886
717
406
261 04
774
111
127
123
710
824
251 490 212 153 156 468 157
728 313 124 312 114 885 314 141 271 401
466
725
2209S2MP02
04 Gear pump 261 Seal cover (F) 717 O-ring

111 Drive shaft (F) 271 Pump casing 724 O-ring
113 Drive shaft (R) 312 Valve block 725 O-ring
114 Spline coupling 313 Valve plate (R) 728 O-ring
123 Roller bearing 314 Valve plate (L) 732 O-ring
124 Needle bearing 401 Hexagon socket bolt 774 Oil seal
127 Bearing spacer 406 Hexagon socket bolt 789 Back up ring
141 Cylinder block 466 VP Plug 792 Back up ring
151 Piston 468 VP Plug 806 Hexagon head nut
152 Shoe 490 Plug 808 Hexagon head nut
153 Set plate 531 Tilting pin 824 Snap ring
156 Bushing 532 Servo piston 885 Pin
157 Cylinder spring 534 Stopper (L) 886 Spring pin
211 Shoe plate 535 Stopper (S) 901 Eye bolt
212 Swash plate 548 Pin 953 Set screw
214 Bushing 702 O-ring 954 Set screw
251 Support 710 O-ring
2-2
MAIN PUMP (2/2)
544
543
545
541
079
VIEW A
21092MP08
079 Proportional reducing valve 543 Stopper 1 545 Steel ball

541 Seat 544 Stopper 2
2-3
2) REGULATOR (1/2)
412 876 874 755 858

A
897 B
612
614
615
613
A
875
A 611
P2
B Pf
Pi
438
C
B
641 730 643 708 644 645 646 728 924 801
SECTION B-B
2209S2MP03
438 656 413 438

Port Port name Port size
A Delivery port 3/4"
B Suction port 2 1/2"
735
Pi Pilot port PF 1/4-15
722
Pf Power shift port -
P2 Companion delivery port -
496 724 725 436
VIEW C
2-4
REGULATOR (2/2)
655 734 653 654 836 651 652 601 624 629 630 628 802
641
814
898
631
732
733
622
621 623 625 626 887 763 756 753 627

SECTION A-A
21092MP04
412 Hexagon socket screw 630 Lock nut 733 O-ring

413 Hexagon socket screw 631 Sleeve, pf 734 O-ring
436 Hexagon socket screw 641 Pilot cover 735 O-ring
438 Hexagon socket screw 643 Pilot piston 753 O-ring
496 Plug 644 Spring seat (Q) 755 O-ring
601 Casing 645 Adjust stem (Q) 756 O-ring
611 Feed back lever 646 Pilot spring 763 O-ring
612 Lever (1) 651 Sleeve 801 Nut
613 Lever (2) 652 Spool 802 Nut
614 Fulcrum plug 653 Spring seat 814 Snap ring
615 Adjust plug 654 Return spring 836 Snap ring
621 Compensator piston 655 Set spring 858 Snap ring
622 Piston case 656 Block cover 874 Pin
623 Compensator rod 708 O-ring 875 Pin
624 Spring seat (C) 722 O-ring 876 Pin
625 Outer spring 724 O-ring 887 Pin
626 Inner spring 725 O-ring 897 Pin
627 Adjust stem (C) 728 O-ring 898 Pin
628 Adjust screw (C) 730 O-ring 924 Set screw
629 Cover (C) 732 O-ring
2-5
3) GEAR PUMP
887 700 354 351 433
B3
434
311
A3
312
850
732
a3 355
710 435 361 353 307 310 308 309 434 466, 725
21092MP05
307 Poppet 353 Drive gear 466 Plug

308 Seat 354 Driven gear 700 Ring
309 Spring seat 355 Filter 710 O-ring
310 Spring 361 Front case 725 O-ring
311 Screw 433 Flange socket 732 O-ring
312 Nut 434 Flange socket 850 Snap ring
351 Gear case 435 Flange socket 887 Pin
2-6
2. FUNCTION
1) MAIN PUMP
The pumps may classified roughly into the rotary group performing a rotary motion and working as
the major part of the whole pump function: the swash plate group that varies the delivery rates: and
the valve cover group that changes over oil suction and discharge.
(1) Rotary group

The rotary group consists of drive shaft
(F) (111), cylinder block (141), piston 124
313
shoes (151,152), set plate (153), 141
spherical bushing (156) and cylinder 156
153
spring (157). The drive shaft is supported 211
by bearing (123,124) at its both ends. 157
The shoe is caulked to the piston to from 111 151
a spherical coupling. It has a pocket to 152
123
relieve thrust force generated by loading
pressure and the take hydraulic balance
so that it slides lightly over the shoe plate
(211). The sub group composed by a
piston and a shoe is pressed against the 2209S2MP06
shoe plate by the action of the cylinder

spring via a retainer and a spherical bush.
Similarly, the cylinder block is pressed
against valve plate (313) by the action of
the cylinder spring.
(2) Swash plate group 531
The swash plate group consists of swash 548
plate (212), shoe plate (211), swash plate 214
support (251), tilting bush (214), tilting pin
212
(531) and servo piston (532).
The swash plate is a cylindrical part 251
211
formed on the opposite side of the sliding
surface of the shoe and is supported by
the swash support.
If the servo piston moves to the right and
532 ɷ
left as hydraulic force controlled by the
regulator is admitted to hydraulic chamber
located on both sides of the servo piston,
the swash plate slides over the swash ɷ
plate support via the spherical part of the
tilting pin to change the tilting angle (ɷ)
2-7
2-7
(3) Valve block group
The valve block group consists of valve
block (312), valve plate (313) and valve
plate pin(885).
The valve plate having two melon-shaped
312
ports is fixed to the valve block and feeds
and collects oil to and from the cylinder 313
block.
The oil changed over by the valve plate is
connected to an external pipeline by way 885
of the valve block.
Now, if the drive shaft is driven by a prime
21092MP07
mover (electric motor, engine, etc), it
rotates the cylinder block via a spline
linkage at the same time. If the swash
plate is tilted as in Fig (previous page) the
pistons arranged in the cylinder block
make a reciprocating motion with respect
to the cylinder block, while they revolve
with the cylinder block.
If you pay attention to a single piston, it
performs a motion away from the valve
plate (oil sucking process) within 180
degrees, and makes a motion towards the
valve plate (or oil discharging process) in
the rest of 180 degrees. When the
swash plate has a tilting angle of zero, the
piston makes no stroke and discharges
no oil.
2-8
2) REGULATOR
Regulator consists of the negative flow control, total horse power control and power shift control
function.
(1) Negative flow control

By changing the pilot pressure Pi, the
pump tilting angle (delivery flow) is
regulated arbitrarily, as shown in the
figure.
This regulator is of the negative flow
Delivery flow, Q
control in which the delivery flow Q
decreases as the pilot pressure Pi rises.
With this mechanism, when the pilot
pressure corresponding to the flow
required for the work is commanded, the
pump discharges the required flow only,
and so it does not consume the power Pilot pressure, Pi
uselessly.
2-9
Η Flow reducing function
643 654 651 652 613 646
P1 CL
B(E)
874
897
C
Pi(From MCV)
A
875
611
Large diameter Servo piston Small diameter

chamber 548 chamber
D 531
14W92MP12
As the pilot pressure Pi rises, the pilot piston (643) moves to the right to a position where the
force of the pilot spring (646) balances with the hydraulic force.
The groove (A) in the pilot piston is fitted with the pin (875) that is fixed to lever 2 (613).
Therefore, when the pilot piston moves, lever 2 rotates around the fulcrum of point B [fixed by
the fulcrum plug (614) and pin (875)]. Since the large hole section (C) of lever 2 contains a
protruding pin (897) fixed to the feedback lever (611), the pin (897) moves to the right as lever 2
rotates. Since the opposing-flat section (D) of the feedback lever is fitted with the pin (548) fixed
by the tilting pin (531) that swings the swash plate, the feedback lever rotates around the fulcrum
of point D, as the pin (897) moves.
Since the feedback lever is connected with the spool (652) via the pin (874), the spool moves to
the right.
The movement of the spool causes the delivery pressure P1 to connect to port CL through the
spool and to be admitted to the large diameter section of the servo piston. The delivery pressure
P1 that is constantly admitted to the small diameter section of the servo piston moves the servo
piston to the right due to the area difference, resulting in decrease of the tilting angle.
When the servo piston moves to the right, point D also moves to the right. The spool is fitted
with the return spring (654) and is tensioned to the left at all times, and so the pin (897) is
pressed against the large hole section (C) of lever 2.
Therefore, as point D moves, the feedback lever rotates around the fulcrum of point C, and the
spool is shifted to the left. This causes the opening between the sleeve (651) and spool (652) to
close slowly, and the servo piston comes to a complete stop when it closes completely.
2-10
Θ Flow increasing function
643 654 651 652 613 646
P1 CL
B(E)
874
897
C
Pi(From MCV)
A
875
611

chamber 548 chamber
D 531
14W92MP13
As the pilot pressure Pi decreases, the pilot piston (643) moves to the left by the action of the
pilot spring (646) and causes lever 2 (613) to rotate around the fulcrum of point B. Since the pin
(897) is pressed against the large hole section (C) of lever 2 by the action of the return spring
(654) via the spool (652), pin (874), and feedback lever (611), the feedback lever rotates around
the fulcrum of point D as lever 2 rotates, and shifts the spool to the left. Port CL opens a way to
the tank port as the spool moves. This deprives the large diameter section of the servo piston of
pressure, and shifts the servo piston to the left by the discharge pressure P1 in the small
diameter section, resulting in an increase in the flow rate.
As the servo piston moves, point D also moves to the left, the feedback lever rotates around the
fulcrum of point C, and the spool moves to the right till the opening between the spool and sleeve
is closed.
2-11
Ι Adjustment of flow control characteristic
The flow control characteristic can be
adjusted with the adjusting screw.
Adjust it by loosening the hexagon nut 801
(801) and by tightening (or loosening) the 924
hexagonal socket head screw (924).
Tightening the screw shifts the control
chart to the right as shown in the figure.
ö Adjusting value
Adjustment of flow control
characteristic
Speed
Tightening Flow Flow
amount of control change
adjusting starting amount
screw(924) pressure
change
amount
(min -1) (Turn) (kgf/cm2) (˶/min) Delivery flow, Q

1900 +1/4 +1.5 +14.8
Pilot pressure, Pi
2-12
(2) Total horsepower control
The regulator decreases the pump tilting

angle (delivery flow) automatically to limit
the input torque within a certain value with
Delivery flow, Q
a rise in the delivery pressure P1 of the
self pump and the delivery pressure P2 of
the companion pump.
(The input horsepower is constant when
the speed is constant.)
Since the regulator is of the simultaneous
Delivery pressure, (P1+P2)
total horsepower type that operates by the
sum of load pressures of the two pumps
in the tandem double-pump system, the
prime mover is automatically prevented
from being overloaded, irrespective of the
load condition of the two pumps, when
horsepower control is under way.
Since this regulator is of the simultaneous
total horsepower type, it controls the tilting
angles (displacement volumes) of the two
pumps to the same value as represented
by the following equation :
Tin = P1Ýq/2ӕ + P2Ýq/2ӕ
= (P1+P2)Ýq/2ӕ
The horsepower control function is the
same as the flow control function and is
summarized in the following. (For detailed
behaviors of respective parts, refer to the
section of flow control).
2-13
Η Overload preventive function
621 651 652 623 612 601 625 626
P1 CL
B(E)
897
P2 P1
875
611
Large diameter Small diameter

Servo piston chamber
chamber
D
14W92RG03
When the self pump delivery pressure P1 or the companion pump delivery pressure P2 rises, it
acts on the stepped part of the compensating piston (621). It presses the compensating rod
(623) to the right till the force of the outer spring (625) and inner spring (626) balances with the
hydraulic force. The movement of the compensating rod is transmitted to lever 1 (612) via pin
(875).
Lever 1 rotates around the pin (875) (E) fixed to the casing (601).
Since the large hole section (F) of lever 1 contains a protruding pin (897) fixed to the feedback
lever (611), the feedback lever rotates around the fulcrum of point D as lever 1 rotates, and then
the spool (652) is shifted to the right. As the spool moves, the delivery pressure P1 is admitted
to the large diameter section of the servo piston via port CL, causes the servo piston move to the
right, reduces the pump delivery, flow rate, and prevents the prime mover from being overloaded.
The movement of the servo piston is transmitted to the feedback lever via point D. Then the
feedback lever rotates around the fulcrum of point F and the spool is shifted to the left. The
spool moves till the opening between the spool (652) and sleeve (651) is closed.
2-14
Θ Flow reset function
621 651 652 623 612 601 625 626
P1 CL
B(E)
897
P2 P1
875
611
Large diameter Small diameter

Servo piston chamber
chamber
D
14W92RG04
As the self pump delivery pressure P1 or the companion pump delivery pressure P2 decreases,
the compensating rod (623) is pushed back by the action of the springs (625 & 626) to rotate
lever 1 (612) around point E. Rotating of lever 1 causes the feedback lever (611) to rotate
around the fulcrum of point D and then the spool (652) to move to the left. As a result, port CL
opens a way to the tank port.
This causes the servo piston to move to the left and the pump's delivery rate to increase.
The movement of the servo piston is transmitted to the spool by the action of the feedback
mechanism to move it till the opening between the spool and sleeve is closed.
2-15
Ι Low tilting angle (low flow) command preferential function
As mentioned above, flow control and horsepower control tilting angle commands are
transmitted to the feedback lever and spool via the large-hole sections (C & F) of levers 1 and 2.
However, since sections C and F have the pins (͚4) protruding from the large hole (͚8), only
the lever lessening the tilting angle contacts the pin (897) ; the hole (͚8) in the lever of a larger
tilting angle command is freed without contacting the pin (897). Such a mechanical selection
method permits preference of the lower tilting angle command of the flow control and horsepower
control.
Κ Adjustment of input horsepower
a. Adjustment of outer spring
Adjust it by loosening the hexagon nut 625 626 630 628
(630) and by tightening (or loosening)
the adjusting screw C (628).
Tightening the screw shifts the control
chart to the right and increases the
input horsepower as shown in the
figure. Since turning the adjusting
screw C by N turns changes the setting
of the inner spring (626), return the
adjusting stem C (627) by NÝA turns 802 627
at first.(A=1.48)
2107A2MP07
ö Adjusting value
Adjustment of input
horsepower
Speed
Tightening Compensating Input
amount of control torque
Delivery flow, Q
starting
adjusting change
pressure
screw(628) change amount
amount
(min -1) (Turn) (kgf/cm2) (kgfÂm)

1900 +1/4 +16.5 +4.0 Delivery pressure, (P1+P2)
2-16
b. Adjustment of inner spring
625 626 630 628
Adjust it by loosening the hexagon nut
the adjusting stem C (627).
Tightening the screw increases the flow
and then the input horsepower as
shown in the figure.
ö Adjusting valve
Adjustment of input
horsepower
802 627
Speed
Tightening Flow Input 2107A2MP08
amount of change torque
adjusting amount change
stem (C) amount
(627)
Delivery flow, Q
(min -1) (Turn) (˶/min) (kgf·m)
1900 +1/4 +11.3 +4.7
Delivery pressure,
Delivery (P1+P
pressure, P12)
21092MP18
2-17
(3) Variable horsepower control
Variable horsepower control can be obtained by supplying pilot pressure.
621 651 652 623 612 601 625 626
P1 CL
897
Pf
875
P2 P1
611

chamber chamber
D
21092MP14
The set horsepower valve is shifted by varying

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

provided. Pf =
However, the secondary pressure Pf (power shift MIN
Pf =
pressure) is admitted to the horsepower control MAX
section of each pump regulator through the
pump's internal path to shift it to the same set
Delivery pressure,
Delivery (P1+P
pressure, P12)
horsepower level. 21092MP20
This function permits arbitrary setting of the pump output power, thereby providing the optimum
power level according to the operating condition.
The power shift pressure Pf controls the set horsepower of the pump to a desired level, as shown
in the figure.
As the power shift pressure Pf rises, the compensating rod (623) moves to the right via the pin
(898) and compensating piston (621).
This decreases the pump tilting angle and then the set horsepower in the same way as explained
in the overload preventive function of the horsepower control. On the contrary, the set horsepower
rises as the power shift pressure Pf falls.
2-18
(4) Adjustment of maximum and minimum flows
954 808
The regulator can adjust the maximum
and minimum flows with the adjusting
screws.
Η Adjustment of maximum flow
the set screw (954). 21092MP23
The maximum flow only is adjusted

without changing other control
characteristics.
Delivery flow, Q
Adjustment of max flow
Speed
Tightening Flow change
amount of amount
adjusting screw
(954)
(min -1) (Turn) (˶/min)
1900 +1/4 -5.5 Pilot pressure, Pi
21092MP21
Θ Adjustment of minimum flow

806 953
the hexagonal socket head set screw
(953). Similarly to the adjustment of the
maximum flow, other characteristics are
not changed.
However, remember that, if tightened too 21092MP24
much, the required horsepower during

the maximum delivery pressure (or
during relieving) may increase.
Adjustment of min flow
Delivery flow, Q
Speed
Tightening Flow change
amount of amount
adjusting screw
(953)
(min -1) (Turn) (˶/min)
1900 +1/4 +4.4

Pilot pressure, Pi
21092MP22
2-19
GROUP 2 MAIN CONTROL VALVE
1. STRUCTURE CK2 Mark Port name Port size Tightening torque
A
Rs Make up for swing motor 20~25 kgf·m
V4
V3 Carry-over P port G1 (145~180 lbf·ft)
MRV
Pu Auto idle signal-attachment
A1 B1 Patt
Pb21 Lock valve pilot port (boom)
P02 P2 T1 Bucket in confluence pilot port
Pcb
A2 B2 ORV-B2 P01 Pilot signal port
P02 Pilot signal port
Pb21 Dr1 V1 P03 Swing logic pilot port
P04 Bucket parallel orifice pilot port
Ptr P05 Option B confluence pilot port 3.5~3.9 kgf·m
ORV-A2 ORV-B4 P06 Option B 2 stage relief valve pilot port G1/4 (25.3~28.2 lbf·ft)
B4
P1 Pc41 Lock valve pilot port (arm)
Pc42 Arm in regen-cut signal selector port
A5 B5 Ptr Auto idle signal-travel
Pu Power boost
ORV-A5 Ck2 ORV-B5 Dr1 Drain port
Dr4 Dr5 Dr2 Drain port
NRV1 NRV2
Dr3 Drain port
Rs
P03 P05
Ck1 Bucket confluence 17~19 kgf·m
Ck2 Bucket confluence G3/4
VIEW A (123~137.4 lbf·ft)
Pa1 Travel pilot port-LH (FW)
Pb1 Travel pilot port-LH (BW)
Pc1 Travel pilot port-RH (BW)
Pd1 Travel pilot port-RH (FW)
P01 Pa20 Boom up pilot port
Dr0
STRAIGHT STRAIGHT Pa21 Boom up confluence pilot port
-TRAVEL -SUPPLY P00 Pb20 Boom down pilot port
Pb1 C1 D1 Pc2 Swing pilot port (LH)
Pc1
TRAVEL LEFT TRAVEL RIGHT Pa1 Pd2 Swing pilot port (RH)
Dr4 P03
Pd1 Patt Pb3 Arm in confluence pilot port
C2 D2 Pa20 Swing priority pilot port
Pc2
Pd2 Pc3
SWING BOOM1 Pa4 Option A pilot port (breaker) G3/8 7~8 kgf·m
Pb20
ORV-D4 Pb4 Arm in regeneration cut port (50.6~57.8 lbf·ft)
Pd41
Dr2
Pc3
BOOM2 V3 ARM2 Pc40 Arm in pilot port
Pb3 ORV-C4 Pa21 Pd40 Arm out pilot port
Pb4 C4 D4 Pd40 Pd41 Arm out confluence pilot port
Pc40 ARM Pa5 Bucket in pilot port
ARM REGENRATION Pa4
Dr3 Pc41 Bucket out pilot port
Pc42 Dr5 ORV-D5 Pd5
Pb5
Pc5 C5 D5 Pc5 Option B pilot port
OPTION BUCKET Option B pilot port
5 P06 Pd5
Pb ORV-C5 P05 Pa5
Dr0 Drain port
Pn1 Negative control signal port (A2 port side)
Pcb Pn2 Negative control signal port (A1 port side)
V1 Carry-over port
V4 Carry-over port
A1 Travel motor port-LH (FW)
B1 Travel motor port-LH (BW)
C1 Travel motor port-RH (BW)
D1 Travel motor port-RH (FW)
A2 Boom up port
B2 Boom down port
C2 Swing motor port (LH)
P06
D2 Swing motor port (RH)
B4 Option A port (breaker) SAE 5000 psi 7.5~9.2 kgf·m
C4 Arm in port 1" (54.2~66.5 lbf·ft)
D4 Arm out port
A5 Bucket in port
CK1
B5 Bucket out port
C5 Option B port
Pn1 Pn2 D5 Option B port
P1 Pump port (A2 side)
P2 Pump port (A1 side)
Dr4 Drain port 1.5~1.9 kgf·m
Dr5 Drain port G1/8 (10.8~13.7 lbf·ft)
T1 Return port SAE 3000 psi 6.4~8.6 kgf·m
300H2MC01 2" (M12) (46.2~62.2 lbf·ft)
2-20
59 52 81,78 1
A A'
B B'
C C1 C1' C'
D D'
E E'
F F'
G G'
59 52 65 24 76
P1 BLOCK SPOOL SECTION

43 88
50
87
44
86
SECTION C1-C1'
59 52 59 52 59 52
1 Housing (P1)
2 Housing (P2)
A A' 24 Plug
43 Orifice-signal
B B' 44 Coin type filter
50 O-ring
C C'
52 Plug
D D' 59 O-ring
64 O-ring
E E' 65 O-ring
76 Socket bolt
F F' 77 Hex socket head bolt
G
78 Hex socket head bolt
G'
81 Spring washer
86 Poppet
81,77 2
64,24
87 Spring check
88 Plug
300H2MC10
2-21
59 52 67 20 23 21
82
61
64 3 Spool-straight
64
3 4 Spool-travel
52,59 15 Cover-pilot A
16 Cover-pilot B1
20 Plug
16
21 Poppet 1-check valve
23 Spring 1-check valve
24 Plug
15 73 ,79 68 71 58 6046 60 56 44 43 68 73 ,79
43 Orifice-signal
44 Coin type filter
A-A' (STRAIGHT-TRAVEL & SUPPLY)
46 Plug
47 Plug
52 Plug
54 Plug
56 Plug
57 O-ring
15 73,79 68 4 61 67 20 61 57 47
58 O-ring
59 O-ring
60 O-ring
61 O-ring
62 O-ring
64 O-ring
65 O-ring
67 O-ring
68 O-ring
71 Back-up ring
72 Back-up ring
79 Washer
54 67 72 62 65 24 67 20 23 21 72 62 67 54 68 73,79 16 82 Main relief valve
B-B' (TRAVEL RIGHT & LEFT)
300H2MC11
2-22
27
27-7 27-2 27-3

21 23 20 67 27-1 27-6 27-4 27-9
88,50 83 6 27-5 C
27-10
27-8 D
34
16
C' D'
15 73,79 68 5 36 68 73,79
C-C' (SWING & BOOM1)
34-6 34-13 34-2 34-3 34-4 34-1 34-7

H
34-5
34-8
H'
34-15 ,34-16 SECTION H-H'
34 DETAIL (HOLDING ASSY)
300H2MC12
5 Spool-swing 27-7 Restrictor-lock valve 34-15 Socket bolt

6 Spool-boom 27-8 O-ring 34-16 Spring washer
15 Cover-pilot A 27-9 O-ring 36 Logic valve
16 Cover-pilot B1 27-10 Back up ring 50 O-ring
20 Plug 34 Holding kit-A1 56 O-ring
21 Poppet 1-check valve 34-1 Block-H/D P1 66 O-ring
23 Spring 1-check valve 34-2 Piston 1-holding 67 O-ring
27 Holding kit-B 34-3 Guide piston-holding 68 O-ring
27-1 Poppet 34-4 Spring 1-lock valve 70 Back-up ring
27-2 Spring 34-5 Piston 2-holding 73 Hex socket head bolt
27-3 Poppet guide 34-6 Plug 79 Washer
27-4 Pilot poppet 34-7 Plug 83 Overload relief valve
27-5 Poppet seat 34-8 Plug 88 Plug
27-6 C-ring 34-13 Plug
2-23
57 45 11 94 21 23 20 67 75 53 85 65 2426 25 61 74 68
19 19-6
19-9 19-5
19-4
73,79
19-3
19-2
19-1 16
19-7,19-8
35
68
27-8
15 27-10
73 27-5
27-3
27-9
61 10 21 23 20 67 25 26 24 65 27-1 27-7 27-6 27-2 27-4
27
E-E' (ARM & ARM REGENRATION)
35-6 35-13 35-2 35-3 35-4 35-1

H
35-8
35-5
H'
35-7 35-15 ,35-16 SECTION H-H'

300H2MC13
10 Spool-arm 27 Poppet-lock valve 35-13 Plug

11 Spool-arm regeneration 27-1 Poppet 35-15 Socket bolt
15 Cover-pilot A 27-2 Spring 35-16 Spring washer
16 Cover-pilot B1 27-3 Poppet guide 45 Orifice-plug
19 Arm-regeneration 27-4 Pilot poppet 53 Flange
19-1 Block-regeneration 27-5 Poppet seat 56 O-ring
19-2 Piston-cut off 27-6 C-ring 57 O-ring
19-3 Stopper-regeneration 27-7 Restrictor-lock valve 61 O-ring
19-4 Spool-regeneration 27-8 O-ring 65 O-ring
19-5 Spring-regeneration 27-9 O-ring 66 O-ring
19-6 Plug 27-10 Back up ring 67 O-ring
19-7 Socket bolt 35 Holding kit-A2 68 O-ring
19-8 Spring wahser 35-1 Block-H/D P2 70 Back-up ring
19-9 Pin-regeneration 35-2 Piston 1-holding 73 Hex socket head bolt
20 Plug 35-3 Guide piston-holding 74 O-ring
21 Poppet 1-check valve 35-4 Spring 1-lock valve 75 Socket bolt
23 Spring 1-check valve 35-5 Piston 2-holding 79 Washer
24 Plug 35-6 Plug 85 O-ring
25 Poppet 2-check valve 35-7 Plug 94 Plug
26 Spring 2-check valve 35-8 Plug
2-24
7 Spool-swing priority
84 61 69 65 24 26 25 9 83
8 Spool-boom 2
61 9 Spool-arm 2
12 Spool-bucket
13 Spool-option
15 14 BC spool
79 ,73 15 Cover-pilot A
68 16 Cover-pilot B1
17 Cover-pilot B2
17
20 Plug
7 21 Poppet 1-check valve
22 Poppet L/C-bucket
84 58 71 60 46 63 55 8 84 68 23 Spring 1-check valve
65,24 24 Plug
D-D' (SWING PRIORITY-BOOM2 & ARM2) 26 Spring 2-check valve
38 Load check valve assy
83 12 22 23 67 42 65 24 61 84 57 68 73,79 16
39 Overload relief valve
26 42 Check valve
90 25
46 Plug
67
48 Spring-BC spool
89
91
49 Plug-BC spool
15 51 Negative control valve
79, 73 52 Plug
68
53 Flange
55 Plug
61
57 O-ring
39 33,66
58 O-ring
13
59 O-ring
60 O-ring
83 53 75 21 23 20 67 38 75 53 85 80 61 O-ring
F-F' (OPTION & BUCKET)
63 O-ring
65 O-ring
67 O-ring
51
68 O-ring
69 O-ring
71 Back-up ring
51 73 Hex socket head bolt
75 Socket bolt
52
79 Washer
59
85 O-ring
61 14 48 63 49
89 Plug
G-G' (CENTER BYPASS CUT-OFF
& NEGATIVE CONTROL) 90 Piston
300H2MC14 91 Pilot cover C1
2-25
2. HYDRAULIC CIRCUIT
CK1 Rs
Pn2 Pn1
Pcb
NRV1
NRV2
ORV-C5 ORV-B5
B5
C5 A5
P06
D5 ORV-A5
P04
Pc5 Pb5
Pd5 Pa5
OPTION BUCKET
CK2
P05 ORV-C4
C4
ORV-B4
B4
D4 ORV-D4
UNLOCK Dr3
SIGNAL Pc41
Pb4(REGENERATION CUT)
Pc40
Pd40 Pa4
ARM 1
Pc42 (ARM REG SEL PILOT)
ARM REGENERATION
(ARM IN PILOT)
(SWING PRIORITY) Pc3 Pb3

Dr2 (FOR CONFLUX)
Pd41 (ARM OUT PILOT)
(BOOM UP PILOT) Pa21 SWING PRIORITY
BOOM 2 ARM 2
ORV-B2
(CARRY OVER PORT) V3 B2
C2 A2
ORV-A2
Dr1
D2 Pb21
Pc2 Pb20
Pd2 Po04
Pa20
SWING BOOM 1
P02
Dr5
P03 Patt
B1
C1
D1 A1
Pc1 Pb1
Pd1 Pa1
TRAVEL TRAVEL
(LEFT) (RIGHT)
V4
Dr0
V1
P01
Ptr MRV
TRAVEL
(STRAIGHT) T1
P1 P2 Pu
300H2MC02
2-26
3. FUNCTION
1) CONTROL IN NEUTRAL
(1) P1 SIDE
The hydraulic fluid from pump flows into the main control valve through the inlet port "P1", pass
the land of the travel straight spool, into the P1 bypass passage and P1parallel passage.
When the straight travel spool is in neutral position, the bypass passage is not shut off. Then the
hydraulic fluid from the pump P1 is directed to the tank through the bypass passage of spools :
travel right, boom 1, arm 2, arm regeneration & option A and bucket, the negative relief valve of
P1, tank passage, and the tank port "T1"
TANK PASSAGE
A A
TRAVEL STRAIGHT
TRAVEL RIGHT
BOOM 1
ARM 2
ARM REGENERATION
BUCKET
P1 NEGATIVE RELIEF VALVE P2 NEGATIVE RELIEF VALVE

P1 SPOOL SECTION
29092MC03B
P1 CENTER BYPASS PASSAGE P1 PARALLEL PASSAGE
TANK PORT "T1"
STRAIGHT TRAVEL SPOOL
P1 PORT
SECTION A - A
29092MC04
2-27
(2) P2 SIDE
The hydraulic fluid from pump flows into the main control valve through the inlet port "P2", pass
the land of the straight travel spool, into the P2 bypass passage and P2 parallel passage.
When the straight travel spool is in neutral position, the bypass passage is not shut off. Then the
hydraulic fluid from the pump P2 is directed to the tank through the bypass passage of spools :
travel left, swing, boom 2 & swing priority, arm 1, option "B" and option "C" of bypass passage
summation, and the negative relief valve of P2, the tank passage and the tank port "T1".
A A
TRAVEL STRAIGHT
TRAVEL LEFT
SWING
BOOM 2
SWING PRIORITY
ARM 1
OPTION "B"
P2 spool section
29092MC06
P2 CENTER BYPASS PASSAGE

P2 PORT
TANK PORT "T1"
P2 PARALLEL PASSAGE
SECTION A - A 29092MC05A
2-28
2) TRAVEL OPERATION
(1) TRAVEL FORWARD OPERATION
During the travel forward operation, the pilot pressure of RCV is supplied to the port of the spring
side, and it shifts travel right and left spools in the left direction against springs. Hydraulic fluid
from the pump flows into the bypass passage of travel spool through the land of the straight travel
spool.
Then the bypass passage is shut off by the movement of the spool, they are directed to the each
travel motor through port B1 and D1. At the same time, the hydraulic fluid from the each travel
motor through port A1 and C1 returns to the tank passage through the travel spools.
P1 BYPASS PASSAGE
B1 A1
FROM RCV
TRAVEL(LH)
TRAVEL(RH)
FROM RCV
TANK PASSAGE
C1 D1
P2 BYPASS PASSAGE
29092MC07
2-29
(2) TRAVEL REVERSE OPERATION
During the travel reverse operation, the pilot pressure of RCV is supplied to the port of the spring
opposite side, and it shifts travel right and left spools in the right direction against springs.
Hydraulic fluid from the pump flows into the bypass passage of travel spool through the land of
the straight travel spool.
Then the bypass passage is shut off by the movement of the spool, they are directed to the each
travel motor through port A1 and C1. At the same time, the hydraulic fluid from the each travel
motor through port B1 and D1 returns to the tank passage through the travel spools.
P1 BYPASS PASSAGE
B1 A1
FROM RCV
TRAVEL(LH)
TRAVEL(RH)
FROM RCV
TANK PASSAGE
C1 D1
P2 BYPASS PASSAGE
29092MC08
2-30
(3) TRAVEL STRAIGHT FUNCTION
Straight travel valve is the valve for keeping traveling straight when boom, arm, bucket or swing is
operated at the time of traveling. Therefore the oil from the P1 and P2 pump flows into the control
valve through the each passage in neutral condition.
When the both travels and any of attachment is switched, the pilot pressure is applied the port of
spring chamber and the travel straight spool is shifted.
When the straight travel spool is switched, the oil pressure from P1 is led to the each attachment
switching section through the P1 and P2 parallel passage. Also some of oil id combined with
bypass of P1 side by opening of check valve of spool inside through the orifice of the straight
travel spool.
On the other hand, the oil from P2 is supplied to the both travel section through P1 and P2
bypass passage.
Therefore, when attachment is switched at the time of both travels, since the oil of P2 mainly
flows to both travels, and the oil of P1 mainly flows to attachments, it can keep traveling straight.
P1 CENTER BYPASS PASSAGE P1 PARALLEL PASSAGE

P2 PORT
TANK PORT "T1"
TRAVEL
STRAIGHT CHECK VALVE
SPOOL
ORIFICE
P1 PORT
P2 CENTER BYPASS PASSAGE
P2 PARALLEL PASSAGE
29092MC09
2-31
3) BOOM OPERATION
(1) BOOM UP OPERATION
During boom up operation, the pilot secondary pressure from RCV is supplied to the port of the
spring side and shifts the boom 1 spool in the left direction. The bypass passage is shut off by the
movement of the spool and the hydraulic oil fluid from pump P1 is entered P1 parallel passage
and then passes through the load check valve, bridge passage and boom holding valve then
flows into the port A2.
Following this it flows into the head side of the boom cylinder.
(In this case, the boom holding valve is free flow condition)
At the same time, the pilot pressure from RCV is supplied to the port of the spring side of boom 2
and shifts the boom 2 spool. The bypass passage is shut off by the movement of the spool and
the hydraulic oil fluid from pump P2 entered boom summation passage via the P2 parallel
passage, the land of the swing priority spool, notch of the boom 2 spool, arm 2 spool and the
check. The flows combine in passage and are directed to port A2 and head side of boom cylinder.
At the same time, the flow from rod side of the boom cylinder return to the boom 1 spool through
the port B2. There after it is directed to the hydraulic oil tank through the tank passage.
P1 PARALLEL PASSAGE
BOOM 1 SPOOL
B2 A2
FROM RCV
P1 BYPASS PASSAGE
TANK PASSAGE
29092MC10A
2-32
ARM 2 SPOOL BOOM SUMMATION PASSAGE
SWING PRIORITY SPOOL
FROM RCV
BOOM 2 SPOOL
P2 BYPASS PASSAGE
P2 PARALLEL PASSAGE
29092MC11
2-33
(2) BOOM DOWN OPERATION
During the boom lowing operation, the pilot pressure from RCV is supplied to the port of the
spring opposite side and shifts the boom 1 spool in the right direction.
The bypass passage is shut off by the movement of the spool and the hydraulic fluid from the
pump P1 enters the parallel passage and is directed to the port B2 through the load check valve.
Following this, it flows into the rod side of the boom cylinder.
At the same time, the return flow from the head side of the boom cylinder returns to the port A2
and boom holding valve. And it is directed to the hydraulic oil tank through opened tank passage
by movement of the boom 1 spool.
Meanwhile some of return flow is directed to P1 parallel passage through the internal passage of
the boom 1 spool. (boom regeneration)
In this case, the holding valve is open condition, for details of the boom holding valve, see page
following page.
During the boom lowering operation, the fluid from P2 pump is not summation.
P1 PARALLEL PASSAGE
BOOM HOLDING RELEASE PRESSURE

BOOM 1 SPOOL B2 A2 FROM RCV
FROM RCV
TANK PASSAGE P1 BYPASS PASSAGE
29092MC12
2-34
4) HOLDING VALVE OPERATION
(1) HOLDING OPERATION
At neutral condition, the pilot piston chamber is connected to drain port through the pilot port.
And the piston "B" is supported with spring "B".
Also, the pressured fluid from actuator entered to inside of the holding valve through the
periphery hole of check, crevice of the check and the plug and the periphery hole of plug.
Then, this pressured oil pushed the poppet to the poppet seat and the check to the seat of body.
So the hydraulic fluid from actuator is not escaped and the actuator is not moved.
POPPET PISTON "A"
SPRING SPRING "B" PILOT PISTON CHAMBER

PISTON "B"
CHECK
PLUG
PILOT PORT
ACTUATOR PORT POPPET SEAT DRAIN PORT FOR RELEASE
HOLDING VALVE
29092MC13
2-35
(2) RELEASE HOLDING OPERATION
The pilot pressure is supplied to the pilot port for release holding valve and shifts the piston "B" in
the left direction against the spring "B", and shifts the poppet in the left direction through piston
"B" and piston "A" against spring "B" and shifts the spool in the left side.
At same time, the return fluid from actuator returns to the drain port through the periphery hole of
check, crevice of the check and the plug, the periphery hole of the plug, in side of holding valve,
crevice of the poppet and the poppet seat, the periphery hole of the poppet seat, crevice of
socket and spool and internal passage of spool.
When the poppet is opened, pressure of inside of holding valve is decreased and the return fluid
from actuator returns to the tank passage through the notch of spool.
POPPET PISTON "A" PILOT PISTON CHAMBER

SPRING
SPRING "B" PISTON "B"
CHECK
PLUG
DRAIN PORT PILOT PORT

ACTUATOR PORT POPPET SEAT FOR RELEASE
HOLDING VALVE
29092MC14
2-36
5) BUCKET OPERATION
(1) BUCKET IN OPERATION
① Bucket operation only
During the bucket in operation, the pilot secondary pressure from RCV is supplied to port of the
spring side and shifts the bucket spool in the left direction.
The bypass passage is shut off by the movement of the spool and the hydraulic fluid from pump
P1 entered P1 parallel passage and is directed to the port A5 through the check2.
At the same time, the hydraulic fluid from P1 bypass passage is directed to the port A5 through
the check1.
Following this it flows into the head side of the bucket cylinder.
The return flow from the rod side of the bucket cylinder returns to the bucket spool through the
port B5. Thereafter it is directed to the hydraulic oil tank through the tank passage.
② Bucket operation with arm or boom operation
When combined operation, mostly same as above but the fluid from bypass passage is empty.
So only the fluid from parallel passage is supplied to the bucket cylinder. Also, parallel passage
is installed the orifice for supplying the fluid from pump to the boom or the arm operation prior to
the bucket operation.
CHECK POPPET 1
P1 PARALLEL PASSAGE
B5 A5
FROM RCV
BUCKET SPOOL
P1 BYPASS PASSAGE
TANK PASSAGE
300H2MC16
2-37
(2) BUCKET OUT OPERATION
① Bucket operation only
During the bucket out operation, the pilot secondary pressure from RCV is supplied to port of the
spring opposite side and shifts the bucket spool in the left direction.
P1 entered P1 parallel passage and is directed to the port B5 through the check1.
The return flow from the rod side of the bucket cylinder returns to the hydraulic oil tank through
the tank passage and the port A5.
② Bucket operation with arm or boom operation
When combined operation, the same as above.
CHECK POPPET 1
P1 PARALLEL PASSAGE
B5 A5
FROM RCV
BUCKET SPO
P1 BYPASS PASSAGE
TANK PASSAGE
29092MC16
2-38
(3) BUCKET SLOW OPERATION
This function is used to speed up of the boom by reducing the bucket speed when bucket
operation with boom operation simultaneously.
When the boom up operation, the boom up pilot pressure is supplied the pilot port of bucket spool
stroke limit and the piston is shifted to the right and then the bucket spool stroke is limited and the
open of the bucket spool is reduced.
Accordingly, the oil of the bucket spool is reduced and the boom speed up.
CHECK POPPET 1
P1 PARALLEL PASSAGE
B5 A5
FROM RCV
BUCKET SPEED DOWN

PILOT PRESSURE
PISTON
300H2MC17
2-39
6) SWING OPERATION
(1) SWING LEFT & RIGHT OPERATION
During the swing left operation, the pilot secondary pressure from the RCV is supplied to the port
of the spring side and shift the swing spool in left direction. The bypass passage is shut off by the
movement of the spool and the hydraulic fluid from pump P2 flows into swing spool through the
parallel passage. Then it is directed to swing motor through the port D2.
As the result, swing motor turns and flow from the swing motor returns to the hydraulic oil tank
through the port C2, swing spool and the tank passage.
In case of swing right operation, the operation is similar to swing left operation but the pilot
secondary pressure from the RCV is supplied to the port of the spring opposite side.
Accordingly, the hydraulic fluid from pump P2 flows into swing motor through the port C2 and
returns to the hydraulic oil tank through the port D2 and the tank passage.
BOOM 1 SPOOL
SWING SPOOL
FROM RCV
P2 BYPASS PASSAGE
TANK PASSAGE C2 D2 P2 PARALLEL PASSAGE
29092MC18
2-40
(2) SWING SLOW DOWN OPERATION
This operation is used to speed up the boom or arm by reducing the swing speed when swing
operation with boom or arm operation.
The poppet of swing logic valve is closed by the pilot pressure of swing speed down is supplied to
the port, the fluid from the port P2 is drained through orifice. Accordingly, the fluid from the port
P2 is reduced and swing speed is slow down.
ORIFICE
SWING SPEED DOWN

PILOT PRESSURE
29092MC19
2-41
7) ARM OPERATION
(1) ARM IN OPERATION
During arm in operation, the pilot secondary pressure from the RCV is supplied to the port of
spring opposite side and shifts arm 1 spool in the right direction.
The bypass passage is shut off by the movement of the arm 1 spool and the hydraulic oil from the
pump P2 flows into the arm cylinder head side through P2 parallel passage, the load check valve,
bridge passage and the port C4.
At same time, the pilot secondary pressure from the RCV is supplied to the port of spring
opposite side and shifts arm 2 spool in the right direction. The bypass passage is shut off by the
movement of the spool and the hydraulic fluid from the pump P1 flows into the arm summation
passage through parallel passage, the check valve, the arm 2 spool and the boom 2 spool. Then
it entered the arm cylinder head side with hydraulic fluid from arm 1 spool.
ARM 2 SPOOL P1 BYPASS PASSAGE P1 PARALLEL PASSAGE
FROM RCV
BOOM 2 SPOOL
29092MC20
TANK PASSAGE
SELECTOR SPOOL ARM REGENERATION SPOOL

PISTON C
ARM
REGENERATION
CUT PRESSURE
ARM PILOT
PRESSURE
ARM 1 SPOOL
P2 BYPASS PASSAGE
C4 D4
ARM HOLDING RELEASE
PILOT PRESSURE
29092MC21
2-42
ARM REGENERATION
The return flow from the arm cylinder rod side is pressurized by self weight of arm and so, returns to
port D4. The pressurized oil returning to port D4 enters the arm regeneration spool through the arm
holding valve and the arm 1 spool. It is supplied the arm cylinder head through internal passage. This
is called the arm regeneration function.
The amount of regeneration fluid is changed by movement of the arm regeneration spool. A few
fluids after P2 parallel passage is push piston "C" through the notch of arm regeneration spool and
selector spool. At this time, the selector spool is opened by pilot pressure from RCV.
Then, the arm regeneration spool shifts to right side and flow to tank pass increases and regeneration
flow decreases. Therefore, pressure of arm cylinder head increases, then, arm regeneration flow
decreases.
(CLUSTER TYPE 1 ONLY)
The arm regeneration cut pressure is supplied to the port of spring opposite side and arm
regeneration spool is move into the right direction fully. The flow from the arm cylinder rod is returned
to the hydraulic oil tank and regeneration function is not activated. (The return fluid is maximum
condition)
TANK PASSAGE
SELECTOR SPOOL ARM REGENERATION SPOOL

PISTON C
ARM
REGENERATION
CUT PRESSURE
ARM PILOT
PRESSURE
ARM 1 SPOOL
P2 BYPASS PASSAGE
C4 D4
ARM HOLDING RELEASE
PILOT PRESSURE
29092MC21
2-43
(2) ARM OUT OPERATION
During arm out operation, the pilot secondary pressure from RCV is supplied to the port of spring
side and shifts arm 1 spool in the left direction.
P2 flows into arm 1 spool through the parallel passage. Then it enters into the arm cylinder rod
side through the load check valve, bridge passage, arm holding valve and the port D4.
Also, the pilot secondary pressure from RCV is supplied to the port of spring side and shifts arm
2 spool in the left direction.
The bypass passage is shut off by the movement of the spool and some of the hydraulic fluid
from pump P2 bypassed through bypass notch. The rest of hydraulic fluid from pump P2 flows
into the arm summation passage through P1 parallel passage the check valve arm 2 spool and
boom 2 spool.
Then it enters into the arm cylinder rod side with the fluid from the arm 1 spool.
The return flow from the arm cylinder head side returns to the hydraulic tank through the port C4
the arm 1 spool and tank passage.
ARM 2 SPOOL P1 BYPASS PASSAGE P1 PARALLEL PASSAGE
FROM RCV
BOOM 2 SPOOL
ARM SUMMATION PASSAGE 29092MC22
ARM REGENERATION SPOOL
FROM RCV
ARM 1 SPOOL
TANK PASSAGE C4 D4
P2 BYPASS PASSAGE
29092MC23
2-44
8) SWING PRIORITY FUNCTION
During swing priority operation, the pilot secondary pressure is supplied to the port of the spring
side of the swing priority spool and shift swing priority spool in the right direction.
The hydraulic fluid from P2 parallel passage flows into the parallel passage of arm 1 side through
swing priority spool and the passage "A" and also flows into the boom 2 spool.
When the swing priority spool is neutral condition, the passage is same as normal condition. But
due to shifting of the swing priority spool, the fluid from pump P2 flows to swing side more then the
boom 2, arm 1, option B and bucket summation spools to make the swing operation most
preferential.
ARM 2 SPOOL
SWING PRIORITY
PILOT PRESSURE
BOOM 2 SPOOL
P2 PARALLEL PASSAGE ARM 1 PARALLEL PASSAGE
29092MC24
2-45
9) OPERATION OF OPTION
(1) OPERATION BY PUMP P2 (CLUSTER TYPE 1)
The pilot secondary pressure from RCV is supplied to the port of spring side and shifts option
spool as the figure.
P2 flows into actuator through the load check valve, bridge passage and port D5.
If the pilot pressure is not supplied to P1 summation pilot port and is not shifts arm 2 spool.
Accordingly, the pump P1 fluid connected the parallel passage is not flowing the check poppet of
option ON/OFF valve and the fluid from pump is not joined the fluid from P2.
At the same time, the fluid from actuator returns to the tank passage through port C5 and notch of
the option spool.
In case of reverse operation, the operating principle is same as above.
P2 BYPASS PASSAGE
FROM RCV
OPTION SPOOL
TANK PASSAGE C5 D5
P1 SUMMATION PASSAGE
P2 PARALLEL PASSAGE CHECK POPPET
OPTION
ON / OFF VALVE
P1 SUMMATION
PILOT PRESSURE
29092MC26
2-46
(2) OPERATION BY PUMP P2 (CLUSTER TYPE 2)
The pilot secondary pressure from RCV is supplied to the port of spring side and shifts option
spool as the figure.
P2 flows into actuator through the load check valve, bridge passage and port D5.
At the same time, the fluid from actuator returns to the tank passage through port C5 and notch of
the option spool.
In case of reverse operation, the operating principle is same as above.
P2 BYPASS PASSAGE
FROM RCV
OPTION SPOOL
TANK PASSAGE C5 D5
P1 SUMMATION PASSAGE
P2 PARALLEL PASSAGE CHECK POPPET
OPTION
ON / OFF VALVE
P1 SUMMATION
PILOT PRESSURE
29092MC26
2-47
10) SUMMATION OPERATION WITH PUMP P1 (CLUSTER TYPE 1)
The pilot pressure from RCV is supplied to option pilot port and one of arm 2 pilot port at the
same time, the fluid for the arm summation is build up. This fluid flows into the arm 1 spool priority
but the arm is not operated, the fluid flows into P1 summation passage. Now the pilot pressure of
RCV is supplied to the P1 summation pilot port of option ON/OFF valve, the fluid from pump P1
opens the load check valve and flows into port D5 with the fluid of pump P2.
P2 BYPASS PASSAGE
FROM RCV
TANK PASSAGE C5 D5 OPTION SPOOL
P2 PARALLEL PASSAGE P1 SUMMATION PASSAGE
CHECK POPPET
OPTION
P1 SUMMATION ON / OFF VALVE
PILOT PRESSURE
29092MC27
2-48
11) NEGATIVE RELIEF VALVE OPERATION
When no function is being actuated on P1 side, the hydraulic fluid from the pump P1, flows into the
tank passage through the bypass passage and orifice. The restriction caused by this orifice thereby
pressurizes. This pressure is transferred as the negative control signal pressure Pn1 to the pump
P1 regulator.
It controls the pump regulator so as to minimize the discharge of the pump P1.
The bypass passage is shut off when the shifting of one or more spools and the flow through
bypass passage became zero. The pressure of negative control signal becomes zero and the
discharge of the pump P1 becomes maximum.
The negative control pressure reaches to the set level, the hydraulic fluid in the passage pushes
open negative control valve and escapes into the return passage.
For the pump P2 the same negative control principle.
BUCKET SPOOL
P2 TANK PASSAGE
P1 NEGATIVE
RELIEF VALVE
P2 NEGATIVE
RELIEF VALVE
NEGATIVE ORIFICE Pn1 PORT Pn2 PORT
CONTROL
SPRING P1 BYPASS PASSAGE P2 BYPASS PASSAGE
BRIDGE PATH
29092MC28
2-49
12) OPERATION OF MAIN RELIEF VALVE
(1) The pressurized oil passes through the orifice (A) of the plunger is filled up in chamber A of the
inside space, and seats the plunger against the housing securely.
CHAMBER A
SPRING PISTON B
PISTON A POPPET HOLE A
SOCKET
HOUSING
TANK
PASSAGE
T
ORIFICE A
PLUNGER
29092MC29
(2) When the pressure at (P) becomes equal to the set pressure of the spring the hydraulic oil
passes through the piston (A) pushes open the poppet and flows to tank passage (T) through the
plunger internal passage, periphery orifice A, chamber A, periphery orifice B and the hole (E).
PERIPHERY ORIFICE B
TANK
PASSAGE
T
HOLE E
29092MC30
(3) Opening the poppet causes the pressure in chamber A to fall and the plunger to open. As the
result the pressurized oil at port P runs into tank passage (T).
TANK
PASSAGE
T
29092MC31
2-50
(4) The pressure at port P becomes lower than set pressure of the spring, the poppet is seated by
spring force. Then the pressure at port P becomes equal to set pressure of the spring and the
plunger is seated to the socket.
POPPET SPRING
SOCKET
HOUSING
TANK
PASSAGE
T
PLUNGER
29092MC29-2
(5) When the power boost switch is ON, the pilot pressure enters through hole A.
It pushes the piston (B) in the left direction to increase the force of the spring and change the
relief set pressure to the high pressure.
HOLE A SPRING PISTON B
TANK
PASSAGE
T
29092MC29-1
2-51
13) OPERATION OF OVERLOAD RELIEF VALVE
FUNCTION AS RELIEF VALVE
(1) The pressurized oil passes through the piston and orifice A is filled up in chamber A of the inside
space and seat the plunger against the socket and the socket against the housing securely.
SOCKET
PISTON CHAMBER A
POPPET SPRING
HOUSING
ORIFICE A
TANK PLUNGER
PASSAGE
T
29092MC32
(2) When the pressure at port P becomes equal to the set pressure of the spring, the pressurized oil
pushes open the poppet and flows to tank passage (T) through the plunger internal passage,
orifice A, chamber A, periphery orifice B and hole E.
HOLE E
HOUSING
TANK PERIPHERY ORIFICE B

PASSAGE
T
29092MC33
2-52
(3) Opening of the poppet causes the pressure in chamber A to fall and the plunger to open. As the
result the pressurized oil at port P runs into tank passage (T).
PLUNGER CHAMBER A
HOUSING
TANK
PASSAGE
T
29092MC34A
(4) The pressure at port P becomes lower than set pressure of the spring, the poppet is seated by
spring force. Then the pressure at port P becomes equal to set pressure of the spring and the
plunger is seated to the socket.
TANK
PASSAGE
T
29092MC32-1
2-53
MAKE-UP FUNCTION
(5) When negative pressure exists at port P, the oil is supplied through tank passage (T). When the
pressure at tank passage (T) becomes higher than that of at port P, the socket moves in the right
direction. Then, sufficient oil passes around the socket from tank passage (T) to port P and fills up
the space.
SOCKET
HOUSING
TANK
PASSAGE
T
29092MC35
14) BREAKER OVERLOAD RELIEF VALVE FUNCTION

(1) The structure and function of 2 stage relief valve is similar with the overload relief but it can set
the higher pressure by pilot pressure.
LOCK NUT 1
LOCK NUT 2
PILOT
PRESSURE
ADJUST SCREW 1
BOOST PISTON ADJUST SCREW 1
29092MC46
Boost function
(1) When the pilot pressure is supplied, the spring is a little compressure by moving of the boost
piston and the set pressure is higher as length of spring compressed.
Pressure set method

(2) Loosen lock nut 1 and 2 and then full tighten adjust screw 2.
(3) Set the high pressure by adjusting the adjust screw 1 and 2 and then fix it by the lock nut 1.
Keep the adjust screw 1 do not move when fixing the lock nut 1.
(4) Set the low pressure by adjusting the adjust screw 2 and then fix it by the lock nut 2.
Keep the adjust screw 2 do not move when fixing the lock nut 2.
2-54
GROUP 3 SWING DEVICE
1. STRUCTURE
Swing device consists swing motor, swing reduction gear.
Swing motor include mechanical parking valve, relief valve, make up valve and time delay valve.
Reduction gear
air bleed port(PT 1/4) Swing motor A B
Reduction gear oil
drain port(PT 1/2) Swing reactionless
valve block Level guage
Fill port(PF 3/4)
PA PB
Relief valve
PG C DB
Reduction gear grease SH
Time delay valve
fill port(PT 1/4)
Reduction gear
SH
PG
A Main port ͚20
DB
B Main port ͚20
DB Drain port PF 1/2
C Make up port PF 1
PG Brake release port PF 1/4
C
PA PB SH Stand by port PF 1/4
PA, PB Gauge port PF 1/4
A B
Hydraulic circuit
25092SM01
2-55
1) SWING MOTOR
2507A2SM02
031 Time delay valve 303 Valve casing 485 O-ring

051 Relief valve 304 Front cover 487 O-ring
052 Shockless valve assy 351 Plunger 488 O-ring
101 Drive shaft 355 Spring 491 Oil seal
106 Spacer 401 Socket bolt 702 Brake piston
111 Cylinder block 432 Snap ring 706 O-ring
113 Spherical bush 433 Snap ring 707 O-ring
114 Spring 437 Snap ring 712 Brake spring
116 Push rod 438 Snap ring 742 Friction plate
117 Spacer 443 Roller bearing 743 Separate plate
118 Spacer 444 Roller bearing 744 Dust plug
121 Piston 451 Spring pin 745 Dust plug
122 Shoe 464 Plug 746 Dust plug
123 Retainer 468 Plug 747 Name plate
124 Shoe plate 469 Plug 748 Rivet screw
131 Valve plate 471 O-ring 993 Level gauge
301 Casing 472 O-ring 994 Plug
2-56
2) REDUCTION GEAR
25092SM03
1 Casing 14 Spring pin 27 Lock washer

2 Drive shaft 15 Thrust washer 28 Hexagon bolt
3 Spacer 16 Carrier 1 29 Plug
4 Roller bearing 17 Sun gear 1 30 Plug
5 Cover plate 18 Planet gear 1 31 Side plate 2
6 Hexagon bolt 19 Pin 1 32 Stop ring
7 Oil seal 20 Needle cage 33 Spring pin
8 Roller bearing 21 Side plate 1 34 Spring pin
9 Carrier 2 22 Ring gear 35 Gauge bar
10 Sun gear 2 23 Knock pin 36 Gauge pipe
11 Planet gear 2 24 Socket bolt 37 Air breather assy
12 Pin 2 25 Pinion gear
13 Bushing 2 26 Lock plate
2-57
2. FUNCTION
1) ROTARY PART
When high pressurized oil enters a cylinder through port(a), which is the inlet of balance
plate(131), hydraulic pressure acting on the piston causes axial force F. The pressure force F
works via the piston(121) upon the return plate(123) which acts upon the swash plate(124) via an
hydrostatic bearing. Force F1 perpendicular to swash plate(124) and force F2 perpendicular to cyl-
inder center.
Being transferred to the cylinder block(111) through piston, force F2 causes rotational moment at
surroundings of cylinder.
Since cylinder block has 9 equidistantly arrayed pistons, rotational torque is transmitted to cylinder
shaft in order by several pistons connected to the inlet port of high pressurized oil. When the direc-
tion of oil flow is reversed, rotational direction of cylinder is also reversed. Output torque is given by
the equation.
pÝq F
T= , q=ZÂAÂPCDÂtanɾ, F1 = , F2=F tanɾ , S=PCDÝtanɾ
2ӕ COSɾ
Where p : Effective difference of pressure(kgf/cm2)
q : Displacement(cc/rev)
T : Output torque(kgfÂcm)
Z : Piston number(9EA)
A : Piston area(cm2)
ɾ : Tilting angle of swash plate(degree)
S : Piston stroke(cm)
Low High
pressure oil pressure oil
F1 F2
131
124 123 121 111
R290SM05(2)
2-58
2) MAKE UP VALVE
In the system using this type of motor, there is no counter balance functioning valve and there
happens the case of revolution exceeding hydraulic supply of motor. To prevent the cavitation
caused by insufficient oil flow there is a make up valve to fill up the oil insufficiency.
A make up valve is provided immediately before the port leading to the hydraulic oil tank to secure
feed pressure required when the hydraulic motor makes a pumping action. The boost pressure
acts on the hydraulic motor's feed port via the make up valve.
Pressurized oil into the port B, the motor rotate counterclockwise.
If the plunger of MCV moves neutral position, the oil in the motor is drain via left relief valve, the
drain oil run into motor via right make up valve, which prevent the cavitation of motor.
A B
29072SM09
2-59
3) RELIEF VALVE
3
5
1 Body
4 2 O-ring
3 Plug
15
11
4 O-ring
14 5 Back up ring
6 Plunger
13
7 7 Piston
12 9 8 Spring
2
9 Seat spring
10 Seat
1
11 Sleeve
8
12 Adjust plug
13 O-ring
6 14 Back up ring
15 Nut
10 29072SM03
(1) Construction of relief valve

The valve casing contains two cartridge type relief valves that stop the regular and reverse
rotations of the hydraulic motor. The relief valves relieve high pressure at start or at stop of swing
motion and can control the relief pressure in two steps, high and low, in order to insure smooth
operation.
(2) Function of relief valve

Figure illustrates how the pressure acting P P=pressure, T=time
on the relief valve is related to its rising PS
process. Here is given the function, 4
referring to the figure following page.
P1 3
T
1
29072SM05
2-60
Η Ports (P,R) at tank pressure.
A1 m 6 7
8 A2
29072SM04
Θ When hydraulic oil pressure(P×A1) reaches the preset force(FSP) of spring(8), the plunger (6)
moves to the right as shown.
P1×A1 = Fsp + P1×A2

Fsp
P1=
A1 - A2
P=P1
8
29072SM06
2-61
Ι When the pressure of chamber g reaches the preset force(Fsp) of spring(8), the piston(7) moves
right and stop the piston(7) hits the end of body.
m 6 7 f g
P=P2
8 12
29072SM07
Κ When piston(7) hits the end of body, it stops moving to the right any further. As the result, the
pressure in chamber(g) equals(Ps).
Ps×A1 = Fsp + Ps×A3

Fsp
Ps=
A1 - A3
m 6 7 12 g
P=Ps
8 12
29072SM08
2-62
4) BRAKE SYSTEM
(1) Control valve swing brake system
This is the brake system to stop the swing motion of the excavator during operation.
In this system, the hydraulic circuit is throttled by the swing control valve, and the resistance
created by this throttling works as a brake force to slow down the swing motion.
Work Deceleration Stop
A B A B A B
MCV MCV MCV
MCV A, B opened MCV A, B throttled MCV A, B closed

2-48(1)
(2) Mechanical swing parking brake system

The mechanical swing parking brake system is installed to prevent the upper structure from
swinging downhill because of its own weight when the excavator is parked on a slope since it
completely eliminates the hydraulic drift of swing motion while the excavator is on a slop, work
can be done more easily and safely.
Η Brake assembly
Circumferential rotation of separate
plate(743) is constrained by the groove
located at casing(301). When housing is 712
pressed down by brake spring(712)
through lining plate(742), separate 702
plate(743) and brake piston(702), friction 743
force occurs there. 742
Cylinder(111) is constrained by this 111
friction force and brake acts, while brake 301 Groove
releases when hydraulic force exceeds
spring force.
25092SM15
111 Cylinder 712 Brake spring

301 Casing 742 Lining plate
702 Brake piston 743 Separate plate
2-63
Θ Operating principle
a. When one of the RCV lever (1) is set to the operation position, the each spool is shifted to left
or right and the pilot oil flow is blocked. Then the pilot oil go to SH of the time delay valve (3).
This pressure moves spool (5) to the leftward against the force of the spring(8), so pilot pump
charged oil (P3) goes to the chamber G through port PG.
This pressure is applied to move the piston (702) to the upward against the force of the spring
(712). Thus, it releases the brake force.
712 5
702 G SH
PG
1 RCV lever
2 Main control valve
3 Time delay valve
5 Spool P3
8 Spring
702 Brake piston 2
712 Brake spring
25092SM16
2-64
b. When all of the RCV lever (1) are set the neutral position, the spool (5) returns to right.
Then, the piston (702) is moved lower by spring force and the return oil from the chamber G
flows back to tank port.
At this time, the brake works.
712 5
702 G SH
PG
1 RCV lever
3 Time delay valve
5 Spool P3
8 Spring
702 Brake piston 2
712 Brake spring
25092SM17
2-65
GROUP 4 TRAVEL DEVICE
1. CONSTRUCTION
Travel device consists travel motor and gear box.
Travel motor includes brake valve, parking brake and high/low speed changeover mechanism.
P1 A D1 P5
Level check port(PF 1/2)
Fill port(PF 1/2)
P Drain port(PF 1/2)
P2 B D2
VIEW X

D1 D2
P1 P2 A Main port SAE 5000psi 1"
P5 B Main port SAE 5000psi 1"
P P1, P2 Gauge port PT 1/4
D1, D2 Drain port PT 1/2
Parking brake
P5 PT 1/8
release port
A B
Hydraulic circuit
25092TM01
2-66
1) BASIC STRUCTURE
25092TM02
2-67
2) STRUCTURE
25092TM03
1 Rear flange 46 O-ring 106 Distance piece 126 O-ring 212 Piston (parking) 275 O-ring
23 Main spool 52 Plug 107 Shaft bearing (R) 128 Plug 213 Spring (parking) 401 Plunger
24 Plug (for main) 54 Plug 108 Planetary gear (F) 129 Seal ring 214 Spring (cylinder) 402 Piston seal
25 Stopper-A 55 Plug 109 Thrust washer (F) 130 O-ring 215 Friction plate 403 Body
26 Stopper-B 63 Plug 110 Pin spring 131 Thrust washer (R) 216 Mating plate 404 Back up ring
27 Spool 65 Spool (2 speed) 111 Needle bearing 132 Thrust washer (M) 232 Oil seal 405 O-ring
28 Spring 66 Spring (2 speed) 112 Floating bushing 133 Thrust washer 235 O-ring 406 O-ring
29 Plug (for check) 68 Steel ball 113 Shaft bearing (F) 134 Carrier No.1 239 O-ring 407 Spring retainer
30 Check valve 71 Orifice 114 Sun gear 136 Shim plate 242 Parallel pin 408 Spring
31 Spring (for main) 74 O-ring 115 Snap ring 202 Drive shaft 247 Back up ring 409 Piston
32 Spring (for check) 79 Filter 117 Planetary gear (R) 203 Swash plate (D type) 248 Back up ring 410 O-ring
36 O-ring 91 Plug 118 Needle bearing 204 Cylinder block 249 Ball bearing 411 Back up ring
37 O-ring 101 Spindle 121 Driver gear 205 Piston 250 Ball bearing 412 Adjust plug
38 O-ring 102 Floating seal 122 Pin spring 206 Shoe 260 Spring (2 speed) 413 Lock nut
41 Parallel pin 103 Carrier No.2 123 Cover 207 Retainer plate 261 Piston (2 speed)
43 Socket bolt 105 Hub 124 Socket bolt 208 Thrust ball 262 Shoe (2 speed)
125 Angular ball bearing 209 Timing plate 267 Pivot
2-68
2. HYDRAULIC MOTOR ASSEMBLY
With brake valve, parking brake and high/low speed changeover mechanism.
1) FUNCTION
UNCTION
(1) Hydraulic motor
This hydraulic motor is a swash plate type piston motor and converts the force of pressurized oil
delivered from the pump into a rotational movement.
(2) Brake valve
This brake valve is incorporated in the hydraulic motor assembly and has the following four
functions.
Η Smoothly brakes and stops the motor by controlling inertial rotation of the motor due to inertia of
the main body.
Θ Check valve function to prevent cavitation of the hydraulic motor.
Ι Relief valve function to control the brake pressure of hydraulic motor and anti-cavitation valve
function to prevent cavitation.
Κ Opens a port which releases the parking brake force upon running of the motor and closes the
upon stopping.
(3) Parking brake
The parking brake prevents overrunning or slippage upon parking or stopping the machine on a
slope with friction plate type brake mechanism, and combined with the hydraulic motor assembly
into an integral structure.
(4) High/low speed changeover mechanism
This mechanism changes over the tilt angle of swash plate between high-speed/low-torque rotation
and low-speed/high-torque rotation with the changeover valve and control piston.
2-69
2) OPERATING PRINCIPLE
(1) Hydraulic motor
1 209 204 203 2
F1
A P
F3
F2
(Y1)
F3
F3
ri
F3
F3
205
( Y2)
25092TM05
The pressurized oil delivered from the hydraulic pump flows to rear flange (1) of the motor, passes
through the brake valve mechanism and is introduced into cylinder block (204) via timing plate (209).
This oil constructively introduced only to one side of (Y1) - (Y2) connecting the upper and lower dead
points of stroke of piston (205). The pressurized oil fed to one side in cylinder block (204) pushes each
piston (205)(four or five) and generates a force (F kgf = P kgf/cm2 × A cm2). This force acts on swash plate
(203) and is resolves into components (F2 and F3) because swash plate (203) is fixed at an angle (α˚)
with the axis of drive shaft (202). Radial component (F3) generates respective torques ( T = F3 × ri) for (Y1)
- (Y2). This residual of torque (T = S (F3 × ri)) rotates cylinder block (204) via piston (205). Cylinder block
(4) is spline coupled with drive shaft (202). So the drive shaft (202) rotates and the torque is transmitted.
2-70
(2) Brake valve
Η Brake released
When the pressurized oil supplied from
port (A), the oil opens valve (30) and flows
212
into port (C) at the suction side of hydrau-
lic motor to rotate motor.
At the same time, the pressurized oil
D C
passes through pipe line (a) from a small
hole in spool (23) and flow into chamber
(b). The oil acts on the end face of spool 23
a
(23) which is put in neutral position by the
31 b
force of spring (31), thus causing spool (23)
to slide to the left. When spool (23) slides,
port (D) on the passage return side of hy-
draulic motor, which is closed by the spool
groove during stoppage, communicates P,S
30
with port (B) at the tank side and the return
oil from the hydraulic motor runs into the
tank. In consequence, the hydraulic motor
B A
rotates. 25092TM06
Moreover, sliding of spool (23) causes the

pressurized oil to flow into ports (P) and (S).
The pressurized oil admitted into port (P)
activates piston (212) of the parking brake
to release the parking brake force. (For
details, refer to description of the parking
brake.) When the pressurized oil is sup-
plied from port (B), spool (23) and valve
(30) move reversely and the hydraulic mo-
tor also rotates reversely.
2-71
② Stopping and stalling (brake applied)
When the pressurized oil supplied from

port (A) is stopped during traveling, no D C
hydraulic pressure is applied and spool g
(23) which has slid to the left will return on
the right (neutral) via stopper (25, 26) by f
the force of spring (31). At the same time,
the hydraulic motor will rotate by the iner- 409
tia even if the pressurized oil stopped, so 23
the port (D) of the motor will become high 401
25,26
pressure. This pressurized oil goes from
chamber (f) to chamber (g) through the 31
left-hand valve (401). When the oil enters
chamber (g), the piston (409) slides to 30
the right so as not to rise the pressure, as
shown in the figure. Meanwhile, the left- 32
hand valve (401) is pushed open by the

B A
pressurized oil in port (D). Therefore, the 25092TM07
pressurized oil in port (D) flows to port (C)
at a relatively low pressure, controlling the
pressure in port (D) and preventing cavi-
tation in port (C). When the piston (409)
reaches the stroke end, the pressure in
chamber (g) and (f) increase and the left-
hand valve (401) closes again, allowing the
oil pressure in port (D) to increase further.
Then, the right-hand valve opens port (C)
with pressure higher than that machine re-
lief set pressure. In this way, by controlling
the pressure in port (D) in two steps, the
hydraulic motor is smoothly braked and to
a stop.
2-72
(3) Parking brake
Η Running
When the pressurized oil is supplied from
213 212 a 216 215 101
the valve, the spool of brake valve in the
hydraulic motor assembly actuates to open 1 204
the passage to the parking brake and the
pressurized oil is introduced into cylinder
chamber (a) which is composed of the
spindle of reduction gear assembly and
piston (212). When the hydraulic pressure
reaches 9.5 kgf/cm2 or more, it overcomes
the force of spring (213) and shifts piston
(212). With shift of piston (212), no press-
ing force is applied to mating plate (216)
and friction plate (215) and movement of
friction plate (215) becomes free. Whereby
the brake force to the cylinder in the hy-
draulic motor assembly is released.
25092TM08
② Stopping 213 212 a 216 215 101

When the pressurized oil from the brake
valve is shut off and the pressure in cylin- 1 204
der chamber (a) drops 9.5 kgf/cm2 or less,
piston (212) will return by the force of
spring (213). Piston (212) is pushed by this
force of spring (13), and mating plate (216)
and friction plate (215) in free condition
are pressed against the spindle of reduc-
tion gear assembly. The friction force pro-
duced by this pressing stops rotation of the
cylinder and gives a braking torque 40.6
kgf·m to the hydraulic motor shaft. Note
that oil control through a proper oil pas-
sage ensures smooth operation.
25092TM09
2-73
(4) High/low speed changeover mechanism
Η At low speed - pilot pressure of less than 10 kgf/cm2
When no pilot pressure is supplied from (D) (at a pressure of 10 kgf/cm2 or less), valve (65) is
pressed toward the top by the force of spring (66) and (A) port or (B) port, the pressurized oil
supply port (C) is shut off, and oil in chamber (P) is released into the motor case via
valve(65). Consequently, swash plate (203) is tilted at a maximum angle (θ1) and the pis-
ton displacement of hydraulic motor becomes maximum, thus leading to low-speed rotation.
25092TM10
Θ At high speed - pilot pressure of 10 kgf/cm2 or more

When a pilot pressure is supplied from port (D) (at a pressure of 20 kgf/cm2 or more), the pres-
sure overcomes the force of spring (66) and (A) port or (B) port of valve (65) is pressed toward
the down. The pressurized oil at supply port (C) is then introduced into chamber (P) via valve (65).
Piston (261) pushes up swash plate (203) until it touches side Y of the spindle. At this time, swash
plate (203) is tilted at a minimum angle (θ2) and the piston displacement of hydraulic motor be-
comes minimum, thus leading to high-speed rotation.
25092TM11
2-74
3. REDUCTION GEAR
1) The reduction gear is composed of a two-stage planetary gear mechanism shown in the following
figure.
Hub Carrier No.1 Drive gear Carrier No.2 Sun gear Hub
Planetary gear(R) Planetary gear(F)

1st stage 2nd stage 25092TM04
2) The rotating motion of the hydraulic motor is transmitted to drive gear of 1st stage, and the drive gear
rotate planetary gears (R). Then planetary gears (R) revolves inside fixed hub. This rotation becomes
the output of 1st stage and is transmitted to carrier No.1 and sun gear. Similary the revolution of plan-
etary gears (F) are transmitted to spindle. Then planetary gears (F) do not revolve, but rotate to hub.
Therefore, the rotating case is driven by the overall driving torque of hub.
This reduction ratio is expressed as shown below :
Reduction ratio (I) = (Hub teeth / Drive gear teeth + 1) x (Hub teeth / Sun gear teeth + 1) - 1
2-75
GROUP 5 RCV LEVER
1. STRUCTURE
The casing has the oil inlet port P (primary pressure) and the oil outlet port T (tank). In addition the
secondary pressure is taken out through ports 1, 2, 3 and 4 provided at the bottom face.
19 Switches
No. LH RH
5 One touch decel Horn
6 Power boost Breaker
5
B
19
25
Single
operation Simultaneous
operation
6
DETAIL B
Tilted direction of
handle(RH)
1 P
T Tilted direction of
connector(LH, RH)
2 3
Tilted direction of
handle(LH)
A VIEW A
Port LH RH Port size

P T
P Pilot oil inlet port Pilot oil inlet port
T Pilot oil return port Pilot oil return port
1 Left swing port Bucket out port
PF 3/8
2 Arm in port Boom down port
3 Right swing port Bucket in port
1 3 2 4 4 Arm out port Boom up port
Hydraulic circuit
3009SH2RL01
2-76
CROSS SECTION
The construction of the pilot valve is shown in the attached cross section drawing. The casing has
vertical holes in which reducing valves are assembled.
The pressure reducing section is composed of the spool (4), spring (6) for setting secondary pres-
sure, return spring (10), stopper (8), spring seat (7, 13) and shim (5). The spring for setting the sec-
ondary pressure has been generally so preset that the secondary pressure is 5 to 20.5 kgf/cm2
(depending on the type). The spool is pushed against the push rod (9, 11) by the return spring.
When the push rod is pushed down by tilting the handle, the spring seat comes down simultaneously
and changes setting of the secondary pressure spring.
2-77
CROSS SECTION
23
25
26
24
22
21
9
19
20 16
17,27
18
14
11 15
8
7
28 10
6
13
5
12
4
3
1
2
Port 1,3 Port 2,4 300E2RL02
1 Case 8 Stopper 15 O-ring 22 Lock nut

2 Plug 9 Push rod 16 Rod seal 23 Handle assembly
3 Bushing 10 Spring 17 Plate 24 Handle bar
4 Spool 11 Push rod 18 Boot 25 Nut
5 Shim 12 Spring 19 Joint assembly 26 Boot
6 Spring 13 Spring seat 20 Swash plate 27 Spring pin
7 Spring seat 14 Plug 21 Adjusting nut 28 Bushing
2-78
2. FUNCTIONS
1) FUNDAMENTAL FUNCTIONS
The pilot valve is a valve that controls the spool stroke, direction, etc of a main control valve. This
function is carried out by providing the spring at one end of the main control valve spool and apply-
ing the output pressure (secondary pressure) of the pilot valve to the other end.
For this function to be carried out satisfactorily, the pilot valve is composed of the following
elements.
(1) Inlet port (P) where oil is supplied from hydraulic pump.
(2) Output ports (1, 2, 3 & 4) to apply pressure supplied from inlet port to ends of control valve spools.
(3) Tank port (T) necessary to control the above output pressure.
(4) Spool to connect output port to inlet port or tank port.
(5) Mechanical means to control output pressure, including springs that work on the above spools.
2) FUNCTIONS OF MAJOR SECTIONS
The functions of the spool (4) are to receive the supply oil pressure from the hydraulic pump at its
port P, and to change over oil paths to determine whether the pressure oil of port P is led to output
ports 1, 2, 3 & 4 or the output port pressure oil to tank port T.
The spring (6) works on this spool to determine the output pressure.
The change the deflection of this spring, the push rod (9,11) is inserted and can slide in the plug
(14).
For the purpose of changing the displacement of the push rod through the swash plate (20) and
adjusting nut (21) are provided the handle (23) that can be tilted in any direction around the fulcrum
of the universal joint (19) center.
The spring (10) works on the case (1) and spring seat (7, 13) and tries to return the push rod
(9,11) to the zero-displacement position irrespective of the output pressure, securing its resetting to
the center position.
This also has the effect of a reaction spring to give appropriate control feeling to the operator.
2-79
3) OPERATION
The operation of the pilot valve will be described on the basis of the hydraulic circuit diagram
shown below and the attached operation explanation drawing.
The diagram shown below is the typical application example of the pilot valve.
5 6
3
1
3
P T
2 4
2-70
1 Pilot valve 3 Main pump 5 Hydraulic motor

2 Pilot pump 4 Main control valve 6 Hydraulic cylinder
2-80
(1) Case where handle is in neutral position
10
T 6
P
4
1 3
21092RL03
The force of the spring (6) that determines the output pressure of the pilot valve is not applied to
the spool (4). Therefore, the spool is pushed up by the spring (10) to the position of port (1, 3) in
the operation explanation drawing. Then, since the output port is connected to tank port T only,
the output port pressure becomes equal to tank pressure.
2-81
(2) Case where handle is tilted
11
1 3
21092RL04
When the push rod (11) is stroked, the spool (4) moves downwards.
Then port P is connected with port (1) and the oil supplied from the pilot pump flows through port
(1) to generate the pressure.
When the pressure at port (1) increases to the value corresponding to the spring force set by tilt-
ing the handle, the hydraulic pressure force balances with the spring force. If the pressure at port
(1) increases higher than the set pressure, port P is disconnected from port (1) and port T is con-
nected with port (1). If it decreases lower than the set pressure, port P is connected with port (1)
and port T is disconnected from port 1.
In this manner the secondary pressure is kept at the constant value.
Besides, in some type, when the handle is tilted more than a certain angle, the upper end of the
spool contacts with the inside bottom of the push rod and the output pressure is left to be con-
nected with port P.
2-82
GROUP 6 RCV PEDAL
1. STRUCTURE
The casing (spacer) has the oil inlet port P (primary pressure), and the oil outlet port T (tank). In
addition the secondary pressure is taken out through ports 1,2, 3 and 4 provided at the bottom face.
12.4 12.4
2 1
4 3
Port Port Port size
P T P Pilot oil inlet port

T Pilot oil return port
1 Travel (LH, Forward)
PF 1/4
2 Travel (LH, Backward)
3 Travel (RH, Forward)
1 2 3 4 4 Travel (RH, Backward)
Hydraulic circuit
21092RP01
2-83
CROSS SECTION
The construction of the RCV pedal is shown in the below drawing. The casing has vertical holes in
which reducing valves are assembled.
The pressure reducing section is composed of the spool (8), spring (6) for setting secondary
pressure, return spring (10), stopper (9), and spring seat (7). The spring for setting the secondary
pressure has been generally so preset that the secondary pressure is 5 to 19 kgf/cm2 (depending on
the type). The spool is pushed against the push rod (14) by the return spring.
When the push rod is pushed down by tilting pedal, the spring seat comes down simultaneously and
changes setting of the secondary pressure spring.
27 31 30 29 28 33 36 3
32
24
23 25,26
22
16
21 14
38 17
15 18
13
19
12 20
11
9
5 6
35
4 7
10
3
8
37 1 34 2
21092RP02
1 Body(1) 14 Push rod 27 Cam

2 Body(2) 15 Spring pin 28 Bushing
3 Plug 16 Seal 29 Cam shaft
4 Plug 17 Steel ball 30 Set screw
5 Spring seat 18 Spring 31 Set screw
6 Spring 19 Plate 32 Nut
7 Spring seat 20 Snap ring 33 Bellows
8 Spool 21 Plug 34 Space
9 Stopper 22 O-ring 35 O-ring
10 Spring 23 Rod seal 36 O-ring
11 Rod guide 24 Dust seal 37 Socket bolt
12 O-ring 25 Cover 38 Piston
13 Snap ring 26 Socket bolt
2-84
2. FUNCTION
1) FUNDAMENTAL FUNCTIONS
The pilot valve is a valve controls the spool stroke, direction, etc of a main control valve. This
function is carried out by providing the spring at one end of the main control valve spool and
applying the output pressure (secondary pressure) of the pilot valve to the other end.
For this function to be carried out satisfactorily, the pilot valve is composed of the following
elements.
(1) Inlet port (P) where oil is supplied from hydraulic pump.
(2) Output port (1, 2, 3 & 4) to apply pressure supplied from inlet port to ends of control valve spools.
(3) Tank port (T) necessary to control the above output pressure.
(4) Spool to connect output port to inlet port tank port.
(5) Mechanical means to control output pressure, including springs that work on the above spools.
2) FUNCTIONS OF MAJOR SECTIONS
The functions of the spool (8) are to receive the supply oil pressure from the hydraulic pump at its
port P, and to change over oil paths to determine whether the pressure oil of port P is led to output
ports 1, 2, 3 & 4 or the output spool to determine the output pressure.
The spring (6) works on this spool to determine the output pressure.
The change the deflection of this spring, the push rod (14) is inserted and can slide in the plug (21).
For the purpose of changing th displacement of the push rod through the cam (27) and adjusting
nut (32) are provided the pedal that can be tilted in any direction around the fulcrum of the cam (27)
center.
The spring (10) works on the casing (1) and spring seat (7) and tries to return the push rod (14) to
the zero-displacement position irrespective of the output pressure, securing its resetting to the
center position.
This also has the effect of a reaction spring to give appropriate control feeling to the operator.
2-85
3) OPERATION
The operation of the pilot valve will be described on the basis of the hydraulic circuit diagram shown
below ant the attached operation explanation drawing.
The diagram shown below is the typical application example of the pilot valve.
36072SF01
1 Pilot valve 3 Main pump 5 Hydraulic motor

2 Pilot pump 4 Main control valve 6 Hydraulic cylinder
2-86
(1) Case where pedal is in neutral position
T 8
P 10
21092RP03
The force of the spring (6) that determines the output pressure of the pilot valve is not applied to
the spool (8). Therefore, the spool is pushed up by the spring (10) to the position of port 2 in the
operation explanation drawing. Then, since the output port is connected to tank port T only, the
output port pressure becomes equal to tank pressure.
2-87
(2) Case where pedal is tilted
14
21092RP04
When the push rod (14) is stroked, the spool (8) moves downwards.
Then port P is connected with port 1, and the oil supplied from the pilot pump flows through port
1 to generate the pressure.
When the pressure at port 1 increases to the value corresponding to the spring force set by tilting
the handle, the hydraulic pressure force balances with the spring force. If the pressure at port 1
increases higher than the set pressure, port P is disconnected from port 1 and port T is
connected with port 1. If it decreases lower than the set pressure, port P is connected with port
1 and port T is disconnected from port 1.
In this manner the secondary pressure is kept at the constant value.
Besides, in some type, when the handle is tilted more than a certain angle, the upper end of the
spool contacts with inside bottom of the push rod and the output pressure is left to be connected
with port P.
2-88
Group 1 Hydraulic Circuit ------------------------------------------------------------------------------------------------ 3-1

Group 2 Main Circuit -------------------------------------------------------------------------------------------------------- 3-3
Group 3 Pilot Circuit -------------------------------------------------------------------------------------------------------- 3-6
Group 4 Single Operation ----------------------------------------------------------------------------------------------- 3-15
Group 5 Combined Operation ---------------------------------------------------------------------------------------- 3-25
GROUP 1 HYDRAULIC CIRCUIT (CLUSTER TYPE 1)
3 10 11 8 9
SH 36 40
PG
37 35 Pn2 Pn1
37 (Pi1, Pump) (Pi2, Pump)
Au B
C
PS 23 PS 23
GA GB CK1 Rs 2
Mu
Pcb
B(CW) A(CCW) Pc6

B5
A5
C5
D5
PC5 Pb5
32
4 L/H R/H Pd5 CK2
Pa5
RED RED DR5
D1 D2 D2 D1 P05
P04 1 Main pump
P1 P2 P2 P1 C4
P5 P5
P D4 B4
P
DR3 Pc41 3 Swing motor
Pb4 4 Travel motor
Pd40 Pa4
5 RCV lever(LH)
38 Pd5 PC40
A1
Pc42 6 RCV lever(RH)
7 RCV pedal
P3 P4 P4 P3 A2 PC3
Pb3
33 8 Boom cylinder(LH)
A B B A DR2
T
Pi
9 Boom cylinder(RH)
Pa21 42 10 Arm cylinder
P Pd41 P
A
A P B V3
B2
T 11 Bucket cylinder
C Dr D 12 C2
D2
A2
12 Turning joint
Pb21
Pk Pc2
Pd2 DR1
13 Check valve
Pb20
DR4 Pa20
14 Check valve
P02
15 Hydraulic tank
P03
PS 24 Patt
PS 24 16 Oil cooler
42 A1 A2 P2 A3 C1 B1
17 Air breather
26 D1 A1
P T Pc1 Pb1
40 18 Bypass valve
Pd1 Pa1
T
19 Strainer
20 Drain filter
P DR0 V1
Pd5 PC5
P01
21 Solenoid valve
24 PS
Ptr
22 Pressure sensor
5 6
SWING P T ARM BUCKET P T BOOM 7 26 P T TRAVEL 23 Pressure sensor
P1 P2 Pu T1
44 24 Pressure sensor
25 Terminal
(2) (1) (4) (3)
T B 26 Last guard filter
(1, A) (3, B) (2, D) (4, E) (3, F) (1, G) (2, H) (4, J)
Pa1 Pb1 Pd1 Pc1 P A 27 Last guard filter
a4 24
A1 Psv PS A2 28 Screw coupling
a1 a2 32 Shuttle valve
14 13 1 24 PS PS 24
DR#, dr# 33 Shuttle valve
a b d e f g h j
25 16 34 EPPR valve
24 c d1 h1 35 Accumulator
Pc2 Pd2 Pd40 Pa5 Pb5 PS
Pc40 Pa20 Pb20
36 Accumulator
34 27
39 27
Pc3 1
(MCV) PS 2 17 Pi2 37 Stop valve
(Pn1, MCV)
3 Pi1
38 Solenoid valve
(Pn2, MCV)
39 Shuttle valve
P03
(MCV)
Pb4
(MCV)
Pk
(T/Joint)
Pu
(MCV)
E a3 40 2-way pedal(option)
21 15 20
18 PG 28
A5 A4 A3 A2 A1 41 3-way joint
Dr B1 B3 Dr3 A3
P4
P01(MCV) 42 Pilot selector valve
19
P3
PG(S/Motor) 43 Solenoid valve
P2
44 Solenoid valve(option)
P1
T(dr1)
2609S3HC01P
3-1
■ HYDRAULIC CIRCUIT (CLUSTER TYPE 2)
3 10 11 8 9
SH 36 40
PG
37 35 Pn2 Pn1
37 (Pi1, Pump) (Pi2, Pump)
Au B
GA GB CK1 Rs 2
Mu
Pcb
B(CW) A(CCW)
Pc6
B5
A5
C5
D5
PC5 Pb5
4 L/H R/H Pd5 CK2

Pa5
RED
D2
RED DR5
D1 D2 D1 P05
P04
P1 P2 P2 P1 C4
P5 P5 D4
P P B4
DR3 Pc41
Pb4
Pd40 Pa4 1 Main pump
38 Pd5 PC40 2 Main control valve
Pc42
A1
3 Swing motor
Pb3
4 Travel motor
P3 P4 P4 P3 PC3
A B B A
A2
T DR2 5 RCV lever(LH)
Pa21 6 RCV lever(RH)
P Pd41
7 RCV pedal
A P B V3
C Dr D 12 C2
B2
A2
8 Boom cylinder(LH)
D2
Pk Pc2 Pb21 9 Boom cylinder(RH)
Pd2 DR1
Pb20 10 Arm cylinder
DR4 Pa20
P02
11 Bucket cylinder
P03 12 Turning joint
Patt
PS 24
C1 B1 13 Check valve
26
P T Pc1
D1 A1
Pb1 14 Check valve
39 Pd1 Pa1 15 Hydraulic tank
16 Oil cooler
Pd5 PC5
DR0 V1 17 Air breather
P01
18 Bypass valve
24 PS
5 6 Ptr
19 Strainer
SWING P T ARM BUCKET P T BOOM 7 26 P T TRAVEL
P1 P2 Pu T1 20 Drain filter
44
21 Solenoid valve
24 Pressure switch
T B
(1, A) (3, B) (2, D) (4, E) (3, F) (1, G) (2, H) (4, J)
(2) (1) (4) (3) 25 Terminal
Pa1 Pb1 Pd1 Pc1 P A
a4 28 26 Last guard filter
A1 Psv PG A2
27 Last guard filter
a1 a2
14 13 1 28 PG PG 28 28 Screw coupling
DR#, dr#
35 Accumulator
16
36 Accumulator
25 B A D E G F H J 37 Stop valve
Pc2 Pd2 Pd40 Pc40 Pa5 Pb5 Pa20 Pb20
27 27 38 Solenoid valve
Pi2
17 Pi1
(Pn2, MCV) (Pn1, MCV) 39 2-way pedal(option)
40 3-way joint
P03
(MCV)
Pk
(T/Joint)
Pu
(MCV)
E a3
44 Solenoid valve(option)
21 15 20
18 PG 28
A5 A4 A3 A2 A1
Dr B1 B3 Dr3 A3
P4
P01(MCV)
P3
19
PG(S/Motor)
P2
P1
T(dr1)
2609S3HC01S
3-2
GROUP 2 MAIN CIRCUIT
The main hydraulic circuit consists of suction circuit, delivery circuit, return circuit and drain circuit.
The hydraulic system consists of one main pump, one control valve, one swing motor, four cylinders
and two travel motors.
The swash plate type variable displacement tandem axial piston pump is used as the main pump
and is driven by the engine at ratio 1.0 of engine speed.
1. SUCTION AND DELIVERY CIRCUIT
To cylinders To motors
Main control valve To oil cooler
To hydraulic oil tank
Main pump
Suction filter
Hydraulic oil tank
3-02
The pumps receive oil from the hydraulic tank through a suction filter. The discharged oil from the
pump flows into the control valve and goes out the tank ports.
The oil discharged from the main pump flows to the actuators through the control valve.
The control valve controls the hydraulic functions.
The return oil from the actuators flows to the hydraulic tank through the control valve and the oil
cooler.
3-3
2. RETURN CIRCUIT
Check valve(2)
Full flow filter Oil cooler 1.5kgf/cm2
Main control valve Actuators
Check valve(1)
3.0kgf/cm2
Check valve(3)
1.5kgf/cm2
29073CI01
All oil from each actuator returns to the hydraulic tank through the control valve.
The bypass check valves are provided in the return circuit.
The setting pressure of bypass check valves are 1.5 kgf/cm2 (21psi) and 3.0 kgf/cm2 (43psi). Usually, oil
returns to the hydraulic tank from the left side of control valve through oil cooler.
When oil temperature is low, viscosity becomes higher and flow resistance increases when passing
through the oil cooler. The oil pressure exceeds 3.0 kgf/cm2 (43psi), the oil returns directly to the
hydraulic tank, resulting in the oil temperature being raised quickly at an appropriate level.
When the oil cooler is clogged, the oil returns directly to the hydraulic tank through bypass check
valve (1).
The full-flow filter and bypass relief valve are provided in the hydraulic tank.
The oil from right and left side of control valve is combined and filtered by the return filter. A bypass
relief valve is provided in the full-flow filter.
When the filter element is clogged, the bypass relief valve opens at 1.5 kgf/cm2 (21psi) differential
pressure.
3-4
3. DRAIN CIRCUIT
Travel motor Swing motor
Turning Main pump

joint From return line
dr2 ~ dr8
Hydraulic Spin filter

oil tank
dr1
Check valve
1.5kgf/cm2
R29073CL02
Besides internal leaks from the motors and main pump, the oil for lubrication circulates. These oil
have to be fed to the hydraulic tank passing through spin filter and full flow filter in the hydraulic tank.
When the drain oil pressure exceed 1.5 kgf/cm2 (21psi), the oil returns to the hydraulic tank directly.
1) TRAVEL MOTOR DRAIN CIRCUIT

Oil leaking from the right and left travel motors comes out of the drain ports provided in the
respective motor casing and join with each other. These oils pass through the turning joint and
return to the hydraulic tank after being filtered by full flow filter in the hydranlic tank.
2) SWING MOTOR DRAIN CIRCUIT
Oil leaking from the swing motor come out and return to the hydraulic tank passing through a spin
filter.
3) MAIN PUMP DRAIN CIRCUIT
Oil leaking from main pump come out and return to the hydraulic tank passing through spin filter.
3-5
GROUP 3 PILOT CIRCUIT
Remote control valve Remote control valve

RCV pedal (RH lever)
(LH lever)
Safety lock
solenoid valve Swing parking brake
MCV
Travel speed solenoid valve
Arm regeneration cut
• • solenoid valve
Power boost solenoid valve
•
Boom priority EPPR valve
• Line filter
Main pump
Relief valve
40kgf/cm2
•
Pilot pump
Suction filter
(210-7) 3-05
The pilot circuit consists of suction circuit, delivery circuit and return circuit.
The pilot pump is provided with relief valve, receives the oil from the hydraulic tank through the
suction filter.
The discharged oil from the pilot pump flows to the remote control valve through line filter, EPPR
valve, solenoid valve assemblies, swing parking brake, main control valve and safety lock solenoid
valve.
3-6
1. SUCTION, DELIVERY AND RETURN CIRCUIT
ARM BUCKET BOOM
CYLINDER CYLINDER CYLINDER
Pn2 Pn1
SWING MOTOR PS PS
CK1 Rs
Pcb
Pc6
B5
C5 A5
D5
Pc5 Pb5
Pa5
OPTION BUCKET
Dd5 CK2
DR5
P05
C4 P04
TRAVEL MOTOR
D4
B4
DR3
Pc41
Pc40 Pb4
Pd40
Pa4
ARM 1
ARM REGENERATION
Pc42
Pb3
Pc3
DR2
Pa21
ARM 2
BOOM 2
Pd41
TURNING
JOINT B2
C2 V3
A2
D2
Pc2 Pb21
Pd2 DR1
Pb20
SWING
DR4 Pa20
BOOM 1 P02
P03
Patt
C1 B1
D1 A1
Pc1 Pb1
Pd1 Pa1
TRAVEL(LH)
TRAVEL(RH)
DR0 V1
P01
RCV PEDAL P T TRAVEL PS

Ptr
P1 P2 Pu T1
(2) (1) (4) (3)

DR#, dr#
Pa1 Pb1 Pd1 Pc1
SWING P T ARM BUCKET P T BOOM FRONT REAR PILOT

PUMP PUMP PUMP
SAFETY
SOLENOID
P03 Pb4 Pk Pu VALVE
(MCV) (MCV) (T/Joint) (MCV)
(1) (3) (2) (4) (3) (1) (2) (4) A5 A4 A3 A2 A1

P4 P01(MCV)
P3 PG(S/Motor)
A B D E F G H J
P2 HYDRAULIC TANK
T P1
a c b d e d1 f g h h1 j
Pc2 Pd2 Pd40 Pc40 Pa5 Pb5 PS LINE FILTER
Pc3 Pa20 Pb20
(MCV)
PS 2609S3HC02
The pilot pump receive oil from the hydraulic tank. The discharged oil from the pilot pump flows to
the safety solenoid valve through the line filter. The oil is filtered by the line filter. The pilot relief
valve is provided in the pilot pump for limiting the pilot circuit pressure.
The oil filtered by line filter flows remote control valve through safety solenoid valve.
The return oil from remote control valve returned to hydraulic tank.
3-7
2. SAFETY SOLENOID VALVE (SAFETY LEVER)
ARM BUCKET BOOM
Pn2 Pn1
SWING MOTOR PS PS
CK1 Rs
Pcb
Pc6
B5
C5 A5
D5
Pc5 Pb5
Pa5
OPTION BUCKET
Dd5 CK2
DR5
P05
C4 P04
TRAVEL MOTOR
D4
B4
DR3
Pc41
Pc40 Pb4
Pd40
Pa4
ARM 1
ARM REGENERATION
Pc42
Pb3
Pc3
DR2
Pa21
ARM 2
BOOM 2
Pd41
TURNING
JOINT B2
C2 V3
A2
D2
Pc2 Pb21
Pd2 DR1
SWING Pb20
DR4 Pa20
BOOM 1 P02
P03
Patt
C1 B1
D1 A1
Pc1 Pb1
Pd1 Pa1
TRAVEL(LH)
TRAVEL(RH)
DR0 V1
P01

Ptr
P1 P2 Pu T1
(2) (1) (4) (3)

DR#, dr#
Pa1 Pb1 Pd1 Pc1

PUMP PUMP PUMP
SAFETY
SOLENOID
P03 Pb4 Pk Pu VALVE
LEVER UP
(1) (3) (2) (4) (3) (1) (2) (4) A5 A4 A3 A2 A1
P4 P01(MCV)
P3 PG(S/Motor)
A B D E F G H J
P2 HYDRAULIC TANK
T P1
Pc3 Pa20 Pb20 LEVER DOWN
(MCV)
PS
2609S3HC03
When the lever of the safety solenoid valve is moved downward, oil flows into the remote control
valve through solenoid valve and line filter.
When the lever of the safety solenoid valve moved upward, oil does not flows into the remote control
valve, because of blocked by the spool.
3-8
3. BOOM PRIORITY SYSTEM
ARM BUCKET BOOM
Pn2 Pn1
PS PS
SWING MOTOR
CK1 Rs
Pcb
Pc6
B5
C5 A5
D5
Pc5 Pb5
Pa5
Dd5
OPTION BUCKET
CK2
DR5
P05
C4 P04
TRAVEL MOTOR
D4
B4
DR3
Pc41
Pc40 Pb4
Pd40
Pa4
ARM 1 ARM REGENERATION

Pc42
Pb3
Pc3
DR2
Pa21
ARM 2
BOOM 2 Pd41
TURNING
JOINT B2
C2 V3
A2
D2
Pc2 Pb21
Pd2 DR1
Pb20
SWING
Boom speed(Cluster type 1) DR4 Pa20
BOOM 1 P02
P03
Patt
C1 B1
D1 A1
Pc1 Pb1
Pd1 Pa1
TRAVEL(LH)
TRAVEL(RH)
DR0 V1
P01
PS
RCV PEDAL P T TRAVEL Ptr
P1 P2 Pu T1
(2) (1) (4) (3) DR#, dr#

Pa1 Pb1 Pd1 Pc1

PUMP PUMP PUMP
BOOM PRIORITY
EPPR VALE
P03 Pb4 Pk Pu
(1) (3) (2) (4) (3) (1) (2) (4) A5 A4 A3 A2 A1

P4 P01(MCV)
A B D E F G H J P3 PG(S/Motor)
P2 HYDRAULIC TANK
T P1
Pc3 Pa20 Pb20
(MCV)
PS
2609S3HC04
When carrying out the combined operation of swing and boom up, the boom up operating speed is
lowered then normal operation.
To increase working efficiency, swing speed reducing system is used.
The pilot oil from pilot pump flow into P03 port in main control valve through boom EPPR valve. P03
oil pressure moves swing reducing spool to upper position and oil flow rate to the swing motor
decreased.
Then, the boom up speed is increased. This is called the boom priority system.
The boom up speed can be adjusted by the cluster. Refer to page 3-12 of the operator's manaul.
3-9
4. TRAVEL SPEED CONTROL SYSTEM
ARM BUCKET BOOM
SWING MOTOR
Pn2 Pn1
PS PS
CK1 Rs
Pcb
Pc6
B5
C5 A5
D5
Pc5 Pb5
Pa5
TRAVEL MOTOR(LH) TRAVEL MOTOR(RH) OPTION BUCKET

Dd5 CK2
RED RED
D1 D2 D2 DR5
D1
P05
P1 P2 P2 P1 C4 P04
P5 P5 D4
P P
B4
DR3
Pc41
Pc40 Pb4
Pd40
Pa4
Pc42
P3 P4 P4 P3 Pb3
Pc3
A B B A DR2
Pa21
ARM 2
BOOM 2
Pd41
A P B TURNING B2
D C2 V3
C Dr JOINT
A2
D2
Pk Pc2 Pb21
Pd2 DR1
Dr3
Pb20
SWING
DR4 Pa20
BOOM 1 P02
P03
Patt
C1 B1
D1 A1
Pc1 Pb1
Pd1 Pa1
TRAVEL(LH)
TRAVEL(RH)
DR0 V1
P01

Ptr
P1 P2 Pu T1
(2) (1) (4) (3)

DR#, dr#
Pa1 Pb1 Pd1 Pc1

TRAVEL SPEED PUMP PUMP PUMP
SOLENOID VALVE
P03 Pb4 Pk Pu
(1) (3) (2) (4) (3) (1) (2) (4) A5 A4 A3 A2 A1

P4 P01(MCV)
P2 HYDRAULIC TANK
T P1
Pc3 Pa20 Pb20
(MCV)
PS
2609S3HC05
When the travel speed solenoid valve was placed in the Hi position, the pressure oil from pilot pump
through line filter flows to port P of travel speed change over valve, and the control piston is pushed
up, thus minimizing the displacement.
When the travel speed solenoid valve was placed in the Lo position, the oil of P port return to the
tank and the control piston is returned, thus maximizing the displacement.
3-10
5. MAIN RELIEF PRESSURE CHANGE CIRCUIT
ARM BUCKET BOOM
Pn2 Pn1
PS PS
SWING MOTOR
CK1 Rs
Pcb
Pc6
B5
C5 A5
D5
Pc5 Pb5
Pa5
Dd5
OPTION BUCKET
CK2
DR5
P05
C4 P04
TRAVEL MOTOR
D4
B4
DR3
Pc41
Pc40 Pb4
Pd40
Pa4

Pc42
Pb3
Pc3
DR2
Pa21
ARM 2
BOOM 2 Pd41
TURNING
JOINT B2
C2 V3
D2 A2
Pc2 Pb21
Pd2 DR1
Pb20
SWING
DR4 Pa20
Auto power boost(Cluster type 1)
BOOM 1 P02
P03
Patt
C1 B1
D1 A1
Pc1 Pb1
Pd1 Pa1
TRAVEL(LH)
TRAVEL(RH)
DR0 V1
P01 MAIN RELIEF
PS
VALVE
RCV PEDAL P T TRAVEL Ptr
P1 P2 Pu T1
(2) (1) (4) (3)

DR#, dr#
Pa1 Pb1 Pd1 Pc1

POWER MAX PUMP PUMP PUMP
SOLENOID VALVE
P03 Pb4 Pk Pu
(1) (3) (2) (4) (3) (1) (2) (4) A5 A4 A3 A2 A1

P4 P01(MCV)
P2 HYDRAULIC TANK
T P1
Pc3 Pa20 Pb20
(MCV)
PS 2609S3HC06
When the power max switch on the left control lever is pushed ON, the power max solenoid valve is
actuated, the discharged oil from the pilot pump into Pu port of the main relief valve of main control
valve ; Then the setting pressure of the main control valve is raises from 350 kgf/cm2 to 380 kgf/cm2 for
increasing the digging power. And even when press continuously, it is canceled after 8 seconds.
When the auto power function is selected to enable on the cluster, the pressure of the main relief
pressure is automatically increased to 380 kgf/cm2 as working condition by the MCU. It is operated
max 8 seconds.
3-11
6. ARM REGENERATION CUT SYSTEM (CLUSTER TYPE 1)
ARM BUCKET BOOM
Pn2 Pn1
PS PS
SWING MOTOR
CK1 Rs
Pcb
Pc6
B5
C5 A5
D5
Pc5 Pb5
Pa5
Dd5
OPTION BUCKET
CK2
DR5
P05
C4 P04
TRAVEL MOTOR
D4
B4
DR3
Pc41
Pc40 Pb4
Pd40
Pa4

Pc42
Pb3
Pc3
DR2
Pa21
ARM 2
BOOM 2 Pd41
TURNING
JOINT B2
C2 V3
A2
D2
Pc2 Pb21
Pd2 DR1
Pb20
SWING
DR4 Pa20
Arm regeneration(Cluster type 1)
BOOM 1 P02
P03
Patt
C1 B1
D1 A1
Pc1 Pb1
Pd1 Pa1
TRAVEL(LH)
TRAVEL(RH)
DR0 V1
P01

Ptr
P1 P2 Pu T1
(2) (1) (4) (3)

DR#, dr#
Pa1 Pb1 Pd1 Pc1

ARM REGENERATION PUMP PUMP PUMP
SOLENOID VALVE
P03 Pb4 Pk Pu
(1) (3) (2) (4) (3) (1) (2) (4) A5 A4 A3 A2 A1

P4 P01(MCV)
P2 HYDRAULIC TANK
T P1
Pc3 Pa20 Pb20
(MCV) 2609S3HC07
PS
When the arm regeneration is selected to disable on the cluster, the arm regeneration solenoid
valve is activated. The pilot oil from pilot pump flow into Pb4 port in main control valve through
solenoid valve and the arm regeneration spool is shifted to right.
Then, the oil from arm regeneration passage returns to tank and the arm regeneration function is
deactivated.
When the arm regeneration is selected to enable on the cluster, the arm regeneration function is
activated and arm in operation speed is increased.
Refer to page 2-43 for the arm regeneration function.
3-12
7. SWING PARKING BRAKE RELEASE
ARM BUCKET BOOM
BRAKE VALVE
SWING MOTOR
SH
Pn2 Pn1
PG
PS PS
Au
CK1 Rs
Pcb
GA GB
Mu
Pc6
B5
B(CW) A(CCW)
C5 A5
D5
Pc5 Pb5
Pa5
Dd5
OPTION BUCKET
CK2
DR5
P05
C4 P04
TRAVEL MOTOR
D4
B4
DR3
Pc41
Pc40 Pb4
Pd40
Pa4

Pc42
Pb3
Pc3
DR2
Pa21
ARM 2
BOOM 2 Pd41
TURNING
JOINT V3 B2
C2
A2
D2
Pc2 Pb21
Pd2 DR1
Pb20
SWING
DR4 Pa20
BOOM 1 P02
P03
PS
Patt
C1 B1 SH
D1 A1
Pc1 Pb1
Pd1 Pa1
TRAVEL(LH)
TRAVEL(RH)
DR0 V1
P01

Ptr
P1 P2 Pu T1
(2) (1) (4) (3)

DR#, dr#
Pa1 Pb1 Pd1 Pc1

PUMP PUMP PUMP
P03 Pb4 Pk Pu
(1) (3) (2) (4) (3) (1) (2) (4) A5 A4 A3 A2 A1

P4 P01(MCV)
P2 HYDRAULIC TANK
T P1
Pc3 Pa20 Pb20
(MCV) 2609S3HC08
PS
When one of the RCV lever (except travel lever) is tilted, the pilot oil flows into SH port through main
control valve.
This pressure moves spool so, discharged oil from pilot valve flows to swing motor PG port.
This pressure is applied to swing motor disc, thus the brake is released.
When all of the RCV lever are set in the neutral position, oil in the swing motor disc cylinder is
drained, thus the brake is applied.
3-13
8. SWING PRIORITY SYSTEM
ARM BUCKET BOOM
Pn2 Pn1
PS PS
SWING MOTOR
CK1 Rs
Pcb
Pc6
B5
C5 A5
D5
Pc5 Pb5
Pa5
Dd5
OPTION BUCKET
CK2
DR5
P05
C4 P04
TRAVEL MOTOR
D4
B4
DR3
Pc41
Pc40 Pb4
Pd40
Pa4

SWING
PRIORITY Pc42
SPOOL
Pb3
Pc3
DR2
Pa21
ARM 2
BOOM 2 Pd41
TURNING
JOINT V3 B2
C2
A2
D2
Pc2 Pb21
Pd2 DR1
Pb20
SWING
DR4 Pa20
BOOM 1 P02
P03
Patt
C1 B1
D1 A1
Pc1 Pb1
Pd1 Pa1
TRAVEL(LH)
TRAVEL(RH)
DR0 V1
P01

Ptr
P1 P2 Pu T1
(2) (1) (4) (3)

DR#, dr#
Pa1 Pb1 Pd1 Pc1

PUMP PUMP PUMP
P03 Pb4 Pk Pu
(1) (3) (2) (4) (3) (1) (2) (4) A5 A4 A3 A2 A1

P4 P01(MCV)
P2 HYDRAULIC TANK
T P1
Pc3 Pa20 Pb20
(MCV)
PS 2609S3HC09
When carrying out the combined operation of swing and arm of the left control valve, the swing
speed can be lowered than operating speed of arm.
Pc3 pressure from the swing shuttle block change the swing priority spool and decreases the oil flow
rate to the next section to make the swing operation most preferential.
This is called the swing priority system. For details, refer to page 2-45.
3-14
2. BOOM DOWN OPERATION
ARM BUCKET BOOM
Pn2 Pn1
PS PS
SWING MOTOR
CK1 Rs
Pcb
Pc6
B5
C5 A5
D5
Pc5 Pb5
Pa5
OPTION BUCKET
Dd5 CK2
DR5
P05
C4 P04
TRAVEL MOTOR
D4
B4
DR3
Pc41
Pc40 Pb4
Pd40
Pa4
Pc42
Pb3
Pc3
DR2 BOOM
Pa21 HOLDING
ARM 2 VALVE
BOOM 2 Pd41
TURNING
JOINT B2
C2 V3
A2
D2
Pc2 Pb21
Pd2 DR1
SWING Pb20
DR4 Pa20
BOOM 1 P02
P03
Patt
C1 B1
D1 A1
Pc1 Pb1
Pd1 Pa1
TRAVEL(LH)
TRAVEL(RH)
DR0 V1
P01
PS
Ptr
P1 P2 Pu T1
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
2609S3HC11
When the RH control lever is pushed forward, the boom spools in the main control valve are moved
to the down position by the pilot oil pressure from the remote control valve.
The oil from the A2 pump flows into the main control valve and then goes to the small chamber of
boom cylinders. At the same time, the oil from the large chamber of boom cylinders returns to the
hydraulic tank through the boom spool in the main control valve.
When the down speed of boom is faster, the oil returned from the large chamber of boom cylinder
combines with the oil from the rear pump, and flows into the small chamber of the boom cylinder.
This prevents cylinder cavitation by the negative pressure when the rear pump flow can not match
the boom down speed. And the excessive pressure in the boom cylinder rod end circuit is prevented
by the relief valve.
3-16
3. ARM IN OPERATION
ARM BUCKET BOOM
Pn2 Pn1
PS PS
SWING MOTOR
CK1 Rs
Pcb
Pc6
B5
C5 A5
D5
Pc5 Pb5
Pa5
ARM OPTION BUCKET

Dd5 CK2
DR5
HOLDING RELIEF
P05
VALVE VALVE
C4 P04
TRAVEL MOTOR
D4
B4
DR3
Pc41
Pc40 Pb4
Pd40
Pa4
Pc42
MAKE UP
VALVE
Pb3
Pc3
DR2
Pa21
ARM 2
BOOM 2 Pd41
TURNING
JOINT B2
C2 V3
A2
D2
Pc2 Pb21
Pd2 DR1
SWING Pb20
DR4 Pa20
BOOM 1 P02
P03
Patt
C1 B1
D1 A1
Pc1 Pb1
Pd1 Pa1
TRAVEL(LH)
TRAVEL(RH)
DR0 V1
P01
PS
Ptr
P1 P2 Pu T1
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
2609S3HC12
When the LH control lever is pulled back, the arm spools in the main control valve are moved to the
roll in position by the pilot oil pressure from the remote control valve.
The oil from the A1 and A2 pump flows into the main control valve and then goes to the large
chamber of arm cylinder.
At the same time, the oil from the small chamber of arm cylinder returns to the hydraulic oil tank
through the arm spool in the main control valve. When this happens, the arm roll in.
When the roll in speed of arm is faster, the oil returned from the small chamber of arm cylinder
combines with the oil from both pump, and flows into the large chamber of the arm cylinder by a
make up valve.
The excessive pressure in the arm cylinder bottom end circuit is prevented by relief valve.
Refer to page 3-12 for the arm regeneration.
3-17
4. ARM OUT OPERATION
ARM BUCKET BOOM
Pn2 Pn1
PS PS
SWING MOTOR
CK1 Rs
Pcb
Pc6
B5
C5 A5
D5
Pc5 Pb5
Pa5
ARM OPTION BUCKET

Dd5 CK2
DR5
HOLDING RELIEF
P05
VALVE VALVE
C4 P04
TRAVEL MOTOR
D4
B4
DR3
Pc41
Pc40 Pb4
Pd40
Pa4
Pc42
MAKE UP
VALVE
Pb3
Pc3
DR2
Pa21
ARM 2
BOOM 2 Pd41
TURNING
JOINT B2
C2 V3
A2
D2
Pc2 Pb21
Pd2 DR1
SWING Pb20
DR4 Pa20
BOOM 1 P02
P03
Patt
C1 B1
D1 A1
Pc1 Pb1
Pd1 Pa1
TRAVEL(LH)
TRAVEL(RH)
DR0 V1
P01
PS
Ptr
P1 P2 Pu T1
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
2609S3HC13
When the LH control lever is pushed forward, the arm spools in the main control valve are moved to
the roll out position by the pilot oil pressure from the remote control valve.
The oil from the A1 and A2 pump flows into the main control valve and then goes to the small
chamber of arm cylinder. At the same time, the oil from the large chamber of arm cylinder returns to
the hydraulic oil tank through the arm spool in the main control valve.
When this happens, the arm roll out. When the roll out speed of arm is faster, the oil returned from
the large chamber of arm cylinder combines with the oil from both pump, and flows into the small
chamber of the arm cylinder by a make up valve.
The excessive pressure in the arm cylinder rod end circuit is prevented by relief valve.
When the arm is rolled out and the control lever is returned to neutral position, the circuit for the
holding pressure at the rod end of the arm cylinder is closed by the arm holding valve.
This prevents the hydraulic drift of arm cylinder.
3-18
5. BUCKET IN OPERATION
ARM BUCKET BOOM
CK2 Pn2 Pn1

PS PS
SWING MOTOR
CK1 Rs
Pcb
CENTER
BYPASS
VALVE
RELIEF
Pc6 VALVE B5
C5 MAKE UP A5
D5
VALVE
Pc5 Pb5 Pcb
Pa5
OPTION BUCKET
Dd5 CK2
DR5
P05
C4 P04
TRAVEL MOTOR
D4
B4
DR3
Pc41
Pc40 Pb4
Pd40
Pa4
Pc42
Pb3
Pc3
DR2
Pa21
ARM 2
BOOM 2 Pd41
TURNING
JOINT B2
C2 V3
A2
D2
Pc2 Pb21
Pd2 DR1
SWING Pb20
DR4 Pa20
BOOM 1 P02
P03
Patt
C1 B1
D1 A1
Pc1 Pb1
Pd1 Pa1
TRAVEL(LH)
TRAVEL(RH)
DR0 V1
P01
PS
Ptr
P1 P2 Pu T1
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
2609S3HC14
When the RH control lever is manually placed in the bucket roll in position. Then the oil flows from
pilot pump through the pilot valve to bucket section of the main control valve. Here the spool position
is moved to bucket roll in position.
The center bypass valve is change over by the pilot pressure (Pcb) and then the oil from A2 pump is
joint to the flow of A1 pump via check 1 and external piping.
The oil flows from both pump through rod end of the cylinder through the bucket section returned to
the hydraulic tank.
The cavitation which will happen to the bottom of the bucket cylinder is prevented by a make up
valve, on other hand. The excessive pressure is also prevented by an overload relief valve in the
main control valve.
3-19
6. BUCKET OUT OPERATION
ARM BUCKET BOOM
Pn2 Pn1
PS PS
SWING MOTOR
Rs
CK1 MAKE UP
Pcb VALVE
CENTER
BYPASS
VALVE
RELIEF
Pc6 VALVE B5
C5 A5
D5
Pc5 Pb5
Pa5
OPTION BUCKET
Dd5 CK2
DR5
P05
C4 P04
TRAVEL MOTOR
D4
B4
DR3
Pc41
Pc40 Pb4
Pd40
Pa4
Pc42
Pb3
Pc3
DR2
Pa21
ARM 2
BOOM 2 Pd41
TURNING
JOINT B2
C2 V3
A2
D2
Pc2 Pb21
Pd2 DR1
SWING Pb20
DR4 Pa20
BOOM 1 P02
P03
Patt
C1 B1
D1 A1
Pc1 Pb1
Pd1 Pa1
TRAVEL(LH)
TRAVEL(RH)
DR0 V1
P01
PS
Ptr
P1 P2 Pu T1
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
2609S3HC15
When the RH control lever is manually placed in the bucket roll out position. Then the oil flows from
pilot pump through the pilot valve to bucket section of the main control valve. Here the spool position
is moved to bucket roll out position.
The oil flows from A2 pump through bucket section of main control valve to the rod end of the bucket
cylinder, and to roll out bucket.
The return oil flows from the bottom end of the cylinder through the bucket section returned to the
hydraulic tank.
The cavitation which will happen to the rod of the bucket cylinder is prevented by a make up valve,
on other hand. The excessive pressure is also prevented by an overload relief valve in the main
control valve.
3-20
7. SWING OPERATION
ARM BUCKET BOOM
Pn2 Pn1
PS PS
SWING MOTOR
CK1 Rs
Pcb
Pc6
B5
C5 A5
D5
Pc5 Pb5
Pa5
OPTION BUCKET
Dd5 CK2
DR5
P05
C4 P04
TRAVEL MOTOR
D4
B4
DR3
Pc41
Pc40 Pb4
Pd40
Pa4
Pc42
Pb3
Pc3
DR2
Pa21
ARM 2
BOOM 2 Pd41
TURNING
JOINT B2
C2 V3
A2
D2
Pc2 Pb21
Pd2 DR1
SWING Pb20
DR4 Pa20
BOOM 1 P02
P03
Patt
C1 B1
D1 A1
Pc1 Pb1
Pd1 Pa1
TRAVEL(LH)
TRAVEL(RH)
DR0 V1
P01
PS
Ptr
P1 P2 Pu T1
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
2609S3HC16
When the LH control lever is manually placed in the left (right) swing position. Then the oil flows from
A1 pump through the swing section of the main control valve to swing motor to left (right) swing the
superstructure. The return oil flows from swing motor through the swing section of the main control
valve returned to the tank.
When the control lever placed in the neutral position, the pressure of the pilot oil passage down.
Then the brake release valve returned to the neutral position and the oil is returned from the brake
piston to the tank. And the brake is set to "ON". The swing parking brake, make up valve and the
overload relief valve are provide in the swing motors. The cavitation which will happen to the swing
motor is prevented by the make up valve in the swing motor itself.
3-21
SWING CIRCUIT OPERATION
25093HC09
1) MOTOR BRAKE VALVE

Motor brake valve for the swing motor limits to cushion the starting and stopping pressure of swing
operation and controls the swing motor operating pressure.
2) MAKE UP VALVE
The make up valves prevent cavitation by supplying return oil to the vacuum side of the motor.
3) PARKING BRAKE
This is function as a parking brake only when all of the RCV lever (except travel pedal) are not
operated.
PARKING BRAKE "OFF" OPERATION
The parking brake is released by the pilot pressure oil from the pilot pump.
When the RCV lever placed in the operating position, the pilot oil flows into SH port through the
MCV. This pressure transferred to the brake release valve and the brake release valve is change
over. Then the pilot oil pressure PG lift the brake piston and release the parking brake.
PARKING BRAKE "ON" OPERATION
When all of the RCV lever placed in the neutral position, the pressure of the pilot oil passage down.
Then the brake release valve returned to the neutral position and the oil is returned from the brake
piston to the tank. And the brake is set to "ON".
4) ANTI-INVERSION VALVE
This anti-inversion valve absorbs shocks produced as swing motion stops and reduced oscillation
cause by swing motion.
3-22
8. TRAVEL FORWARD AND RE
REVERSE
VERSE O
OPERATION
PERATION
ARM BUCKET BOOM
Pn2 Pn1
PS PS
SWING MOTOR
CK1 Rs
Pcb
Pc6
B5
C5 A5
D5
Pc5 Pb5
Pa5
OPTION BUCKET
Dd5 CK2
DR5
P05
C4 P04
TRAVEL MOTOR
D4
B4
DR3
Pc41
Pc40 Pb4
Pd40
Pa4
Pc42
Pb3
Pc3
DR2
Pa21
ARM 2
BOOM 2 Pd41
TURNING
JOINT B2
C2 V3
A2
D2
Pc2 Pb21
Pd2 DR1
SWING Pb20
DR4 Pa20
BOOM 1 P02
P03
Patt
C1 B1
D1 A1
Pc1 Pb1
Pd1 Pa1
TRAVEL(LH)
TRAVEL(RH)
DR0 V1
P01
PS
Ptr
P1 P2 Pu T1
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
2609S3HC18
When the right and left travel levers are manually placed to the forward or reverse position, the oil
flows from pilot pump through the pilot valve to travel sections of the main control valve.
Here, spool position is moved to forward and reverse position. The oil flows from A2 pump through
the travel (RH) section of the main control valve and turning joint to the right travel motor and oil flows
from A1 pump through the travel (LH) section of the main control valve and turning joint to the left
travel motor and move the machine forward or reverse.
The return oil flows from both travel motor through the turning joint and travel (RH, LH) sections
returned to the tank.
3-23
TRAVEL CIRCUIT OPERATION
TRAVEL MOTOR DEVICE

RED RED
D1 D2 D2 D1
P1 P2 P2 P1
P5 P5
P P
OVERLOAD
RELIEF VALVE
P3 P4 P4 P3
A B B A
COUNTER BALANCE
TURNING JOINT VALVE
Dr
Pk
TO/FROM MAIN CONTROL VALVE
25093HC16A
Valves are provided on travel motors to offer the following functions.
1) COUNTER BALANCE VALVE

When stopping the motor of slope descending, this valve to prevent the motor over run.
2) OVERLOAD RELIEF VALVE
Relief valve limit the circuit pressure below 380 kgf/cm2 to prevent high pressure generated at a time
of stopping the machine. Stopping the motor, this valve sucks the oil from lower pressure passage
for preventing the negative pressure and the cavitation of the motor.
3-24
GROUP 5 COMBINED OPERATION
1. OUTLINE
ARM BUCKET BOOM
Pn2 Pn1
PS PS
SWING MOTOR
CK1 Rs
Pcb
B5
C5 A5
D5
Pc5 Pb5
Pa5
OPTION BUCKET
Dd5 CK2
DR5
P05
C4 P04
TRAVEL MOTOR
D4
B4
DR3
Pc41
Pc40 Pb4
Pd40
Pa4
Pc42
Pb3
Pc3
DR2
Pa21
ARM 2
BOOM 2 Pd41
TURNING
JOINT B2
C2 V3
A2
D2
Pc2 Pb21
Pd2 DR1
SWING Pb20
DR4 Pa20
BOOM 1 P02
P03
Patt
C1 B1
D1 A1
Pc1 Pb1
Pd1 Pa1
TRAVEL(LH)
TRAVEL(RH)
DR0 V1
P01
PS
Ptr
P1 P2 Pu T1
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
2609S3HC20
The oil from the A1 and A2 pump flows through the neutral oil passage, bypass oil passage and
confluence oil passage in the main control valve. Then the oil goes to each actuator and operates
them. Check valves and orifices are located on these oil passage in the main control valve. These
control the oil from the main pumps so as to correspond to the operation of each actuator and
smooth the combined operation.

This straight travel spool is provided in the main control valve.
If any actuator is operated when traveling, the straight travel spool is pushed to the right by the pilot
oil pressure from the pilot pump.
Consequently, the left and right travel oil supply passage are connected, and equivalent amount of
oil flows into the left and right travel motors. This keeps the straight travel.
3-25
2. COMBINED SWING AND BOOM UP OPERATION
ARM BUCKET BOOM
Pn2 Pn1
PS PS
SWING MOTOR
CK1 Rs
Pcb
B5
C5 A5
D5
Pc5 Pb5
Pa5
OPTION BUCKET
Dd5 CK2
DR5
P05
C4 P04
TRAVEL MOTOR
D4
B4
DR3
Pc41
Pc40 Pb4
Pd40
Pa4
Pc42
Pb3
Pc3
DR2
Pa21
ARM 2
BOOM 2 Pd41
TURNING
JOINT B2
C2 V3
A2
D2
Pc2 Pb21
Pd2 DR1
SWING Pb20
DR4 Pa20
BOOM 1 P02
P03
Patt
C1 B1
D1 A1
Pc1 Pb1
Pd1 Pa1
TRAVEL(LH)
TRAVEL(RH)
DR0 V1
P01
PS
Ptr
P1 P2 Pu T1
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
2609S3HC21
When the swing and boom up functions are operated, simultaneously the swing spool and boom
spools changed. The oil flows from the A2 pump through boom1 section of the main control valve to
boom cylinders and the boom functions.
The oil flows from A1 pump flow into swing motor through swing spool and the boom cylinder
through boom 2 spool.
The upper structure swing and the boom is up.
Refer to page 3-8 for the boom priority system.
3-26
3. COMBINED SWING AND ARM OPERATION
ARM BUCKET BOOM
Pn2 Pn1
PS PS
SWING MOTOR
CK1 Rs
Pcb
B5
C5 A5
D5
Pc5 Pb5
Pa5
ARM OPTION BUCKET

Dd5 CK2
DR5
HOLDING
P05
VALVE
C4 P04
TRAVEL MOTOR
D4
B4
DR3
Pc41
Pc40 Pb4
Pd40
Pa4
SWING Pc42
PRIORITY
SPOOL
Pb3
Pc3
DR2
Pa21
ARM 2
BOOM 2 Pd41
TURNING
JOINT B2
C2 V3
A2
D2
Pc2 Pb21
Pd2 DR1
SWING Pb20
DR4 Pa20
BOOM 1 P02
P03
Patt
C1 B1
D1 A1
Pc1 Pb1
Pd1 Pa1
TRAVEL(LH)
TRAVEL(RH)
DR0 V1
P01
PS
Ptr
P1 P2 Pu T1
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
2609S3HC22
When the swing and arm functions are operated, simultaneously the swing spool and arm spools in
the main control valve are moved to the functional position by the pilot oil pressure from the remote
control valve.
The oil from the A1 pump flows into the swing motor through swing spool and the arm cylinder
through arm 1 spool.
The oil from the A2 pump flows into the arm cylinder through the arm 2 spool of the right control
valve. The upper structure swings and the arm is operated.
3-27
4. COMBINED SWING AND BUCKET OPERATION
ARM BUCKET BOOM
Pn2 Pn1
PS PS
SWING MOTOR
CK1 Rs
Pcb
B5
C5 A5
D5
Pc5 Pb5
Pa5
OPTION BUCKET
Dd5 CK2
DR5
P05
C4 P04
TRAVEL MOTOR
D4
B4
DR3
Pc41
Pc40 Pb4
Pd40
Pa4
Pc42
Pb3
Pc3
DR2
Pa21
ARM 2
BOOM 2 Pd41
TURNING
JOINT B2
C2 V3
A2
D2
Pc2 Pb21
Pd2 DR1
SWING Pb20
DR4 Pa20
BOOM 1 P02
P03
Patt
C1 B1
D1 A1
Pc1 Pb1
Pd1 Pa1
TRAVEL(LH)
TRAVEL(RH)
DR0 V1
P01
PS
Ptr
P1 P2 Pu T1
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
2609S3HC23
When the swing and bucket functions are operated, the swing and bucket spools changed. The oil
flows from the A2 pump through the bucket section of the main control valve to the bucket cylinder
and the bucket functions. The oil flows from A1 pump through swing section of the main control
valve to the swing motor and swing the superstructure.
3-28
5. COMBINED SWING AND TRAVEL OPERATION
ARM BUCKET BOOM
Pn2 Pn1
PS PS
SWING MOTOR
CK1 Rs
Pcb
B5
C5 A5
D5
Pc5 Pb5
Pa5
OPTION BUCKET
Dd5 CK2
DR5
P05
C4 P04
TRAVEL MOTOR
D4
B4
DR3
Pc41
Pc40 Pb4
Pd40
Pa4
Pc42
Pb3
Pc3
DR2
Pa21
ARM 2
BOOM 2 Pd41
TURNING
JOINT B2
C2 V3
A2
D2
Pc2 Pb21
Pd2 DR1
SWING Pb20
DR4 Pa20
BOOM 1 P02
P03
Patt
C1 B1
D1 A1
Pc1 Pb1
Pd1 Pa1
TRAVEL(LH)
TRAVEL(RH)
DR0 V1
P01
PS
Ptr
P1 P2 Pu T1
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
2609S3HC24
When the swing and travel functions are operated, simultaneously the swing spool and travel spools
in the main control valve are moved to the functional position by the pilot oil pressure from the
remote control valve. At the same time, the straight travel spool is pushed to the right by the pilot oil
pressure from the pilot pump.
The oil from the A2 pump flows into the swing motor through the swing spool. The oil from the A1
pump flows into the travel motor through the RH travel spool of the right control valve and the LH
travel spool of the left control valve via the straight travel spool.
The superstructure swings and the machine travels straight.
3-29
6. COMBINED BOOM AND TRAVEL OPERATION
ARM BUCKET BOOM
Pn2 Pn1
PS PS
SWING MOTOR
CK1 Rs
Pcb
B5
C5 A5
D5
Pc5 Pb5
Pa5
OPTION BUCKET
Dd5 CK2
DR5
P05
C4 P04
TRAVEL MOTOR
D4
B4
DR3
Pc41
Pc40 Pb4
Pd40
Pa4
Pc42
Pb3
Pc3
DR2
Pa21
ARM 2
BOOM 2 Pd41
TURNING
JOINT B2
C2 V3
A2
D2
Pc2 Pb21
Pd2 DR1
SWING Pb20
DR4 Pa20
BOOM 1 P02
P03
Patt
C1 B1
D1 A1
Pc1 Pb1
Pd1 Pa1
TRAVEL(LH)
TRAVEL(RH)
DR0 V1
P01
PS
Ptr
P1 P2 Pu T1
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
2609S3HC25
When the boom and travel functions are operated, simultaneously the boom spools and travel spools
in the main control valve are moved to the functional position by the pilot oil pressure from the
pressure from the pilot pump. The oil from the A2 pump flows into the boom cylinders through the
boom 2 spool and boom 1 spool via the parallel and confluence passage in case boom up operation.
The oil from the A1 pump flows into the travel motors through the RH travel spool of the right control
valve and the LH travel spool of the left control valve via the straight travel spool.
3-30
7. COMBINED ARM AND TRAVEL OPERATION
ARM BUCKET BOOM
Pn2 Pn1
PS PS
SWING MOTOR
CK1 Rs
Pcb
B5
C5 A5
D5
Pc5 Pb5
Pa5
ARM OPTION BUCKET

Dd5 CK2
DR5
HOLDING
P05
VALVE
C4 P04
TRAVEL MOTOR
D4
B4
DR3
Pc41
Pc40 Pb4
Pd40
Pa4
Pc42
Pb3
Pc3
DR2
Pa21
ARM 2
BOOM 2 Pd41
TURNING
JOINT B2
C2 V3
A2
D2
Pc2 Pb21
Pd2 DR1
SWING Pb20
DR4 Pa20
BOOM 1 P02
P03
Patt
C1 B1
D1 A1
Pc1 Pb1
Pd1 Pa1
TRAVEL(LH)
TRAVEL(RH)
DR0 V1
P01
PS
Ptr
P1 P2 Pu T1
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
2609S3HC26
When the arm and travel functions are operated, simultaneously the arm spools and travel spools in
the main control valve are moved to the functional position by the pilot oil pressure from the remote
control valve. At the same time, the straight travel spool is pushed to the right by the pilot oil
pressure from the pilot pump. The oil from the A2 pump flows into the arm cylinders through the
arm 1 spool and arm 2 spool via the parallel and confluence oil passage. The oil from the A1 pump
flows into the travel motors through the RH travel spool of the right control valve and the LH travel
spool of the left control valve via the straight travel spool.
3-31
8. COMBINED BUCKET AND TRAVEL OPERATION
ARM BUCKET BOOM
Pn2 Pn1
PS PS
SWING MOTOR
CK1 Rs
Pcb
B5
C5 A5
D5
Pc5 Pb5
Pa5
OPTION BUCKET
Dd5 CK2
DR5
P05
C4 P04
TRAVEL MOTOR
D4
B4
DR3
Pc41
Pc40 Pb4
Pd40
Pa4
Pc42
Pb3
Pc3
DR2
Pa21
ARM 2
BOOM 2 Pd41
TURNING
JOINT B2
C2 V3
A2
D2
Pc2 Pb21
Pd2 DR1
SWING Pb20
DR4 Pa20
BOOM 1 P02
P03
Patt
C1 B1
D1 A1
Pc1 Pb1
Pd1 Pa1
TRAVEL(LH)
TRAVEL(RH)
DR0 V1
P01
PS
Ptr
P1 P2 Pu T1
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
2609S3HC27
When the bucket and travel functions are operated, simultaneously the bucket spool and travel
spools in the main control valve are moved to the functional position by the pilot oil pressure from the
pressure from the pilot pump. The oil from the A2 pump flows into the bucket cylinder through the
bucket spool via the confluence oil passage. The oil from the A1 pump flows into the travel motors
through the RH travel spool of the right control valve and the LH travel spool of the left control valve
via the straight travel spool of the control valve.
3-32
Group 1 Component Location ----------------------------------------------------------------------------------------- 4-1

Group 2 Electrical Circuit -------------------------------------------------------------------------------------------------- 4-3
Group 3 Electrical Component Specification ------------------------------------------------------------------ 4-38
Group 4 Connectors --------------------------------------------------------------------------------------------------------- 4-46
GROUP 1 COMPONENT LOCATION
1. LOCATION 1
26 25
27 24
28 23
29 22
30
Switch
panel
B
A
C
Membrane
switch
21
20
19
18
1
17
2
3
4
5
6
7 Electric box
8
9
15
14
13
12 CN-16&16A
CN-16B
11 16
10
3009SH4EL01
1 Cigar light 11 Power max switch 21 MCU

2 Aircon & heater switch panel 12 Emergency engine stop switch 22 USB socket
3 Accel dial switch 13 One touch decel switch 23 Overload switch
4 Horn switch 14 Fuse box 24 Beacon switch
5 Breaker operation switch 15 Master switch 25 Quick clamp switch
6 Air compressor switch 16 Emergency engine connector 26 Cab light switch
7 Starting switch 17 RS232 service socket 27 Travel alarm switch
8 Cluster 18 Radio & USB player 28 Washer switch
9 Service meter 19 Heated seat switch 29 Wiper switch
10 Safety lever 20 Speaker 30 Main light switch
4-1
2. LOCATION 2
4
24 19 1
1
1
1
21
CLUSTER TYPE 2 BOOM SOLENOID VALVE CAB
2 8 9 10 20
18
a4
22
a3
23
3 a2 11
a1
12
24
13
5
6
16
7 17
Patt
Ptr
14
H
F
D C 1
J A
G
E
B 15
SHUTTLE BLOCK MAIN CONTROL VALVE

2609S4EL02
1 Lamp 9 P2 pressure sensor 17 Travel pressure sensor

2 Fuel sender 10 P3 pressure sensor 18 EPPR Pressure sensor
3 Fuel filler pump 11 Alternator 19 Solenoid valve
4 Beacon lamp 12 Air cleaner switch 20 Pump EPPR valve
5 Battery 13 Travel alarm buzzer 21 Boom priority EPPR valve
6 Battery relay 14 Boom up pressure sensor 22 Start relay
7 Horn 15 Swing pressure sensor 23 Heater relay
8 P1 pressure sensor 16 Attach pressure sensor 24 MCU(machine control unit)
※ Cluster type 1 only : 10, 14, 15, 18
4-2
GROUP 2 ELECTRICAL CIRCUIT
CIRCUIT(1/2, CLUSTER TYPE 1)
AC
COMP RY
CS-74A
R/DRYER 5R 146 146 5R
CS-74
1
87a 87 85
30 86
WASHER P/P 145 5W 143 5R
2
Pa
POWER RY
M
CABIN LAMP RY MASTER SW 138 2WR
CN-22
CN-29
FUSE BOX
DO-5
CR-7
87a
CN-95
30
2
86
1
85
87
87a 87 85
1
30 86
MASTER SW
2
1
5W 145
87a 87 85
30 86
2
10
1
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
5W 144
1
30A
10A
30A
30A
20A
10A
10A
10A
20A
20A
10A
10A
10A
20A
30A
30A
10A
20A
30A
30A
10A
20A
10A
20A
20A
20A
20A
20A
10A
20A
10A
0.8GrW
0.8GrW
CR-35
0.8V
0.8L
0.8L
0.8V
FUSIBLE LINK
0.8
0.8
0.8V
87a
0.8
30
86
85
CR-9
87
87a
FUEL CUT-OFF SOL
CABIN LAMP(OPTION)
5R 143
30
ROOM LAMP/CASSETTE
86
85
87
2
OPTION(BEACON)
AIR CON/HEATER
5R
148A
148E
142 BATTERY
CN-11
149
150
NO. DESTINATION 1
39E
149
13A
39A
SWITCH PANEL
0.8WOr
60
13
FUEL HEATER
2B 129
CS-74B
FUEL HEATER RY
AC& HEATER
CONVERTER
2WR
1 AC GND 1 CN-60
START,STOP
0.8B
SAFETY SOL
TRAVEL SOL
WORK LAMP
0.8Gr
SOLENOIDE
MCU CONT.
HEAD LAMP
2W
60B
START KEY
60R
0.8R
MCU_EPPR
FUEL PUMP
CASSETTE
2
IG POWER
FUEL HEATER
PRE-HEAT
2 BLOWER SIG. 2
CLUSTER
2R
2V
CLUSTER
FUEL P/P
2L 148
OPTION
87a 87 85
30 86
3 AC 24V
138
3
WIPER
SPARE
WIPER
G3
CIGAR
M
24
34
HORN
CN-36
140
140A
21
30
MCU
4 REVERSE FAN 4 CR-1
CN-96
2W
2W
3Y 147
12V X 2
5 AC CONTROLLER B+ 5 G23 1.2B
2
1
CR-46
0.8 150
CN-61
87a
6 AC COMP 6 1.2G
30
141
86
85
87
TO:STARTER "B" TERM.
1
2
7 AC CONDENSOR FAN 7
2Br
0.8GrW
1.2ROr
2B
0.8RW
1.2RW
0.8RW
1.2R
0.8Y
0.8ROr 10E
0.8Gr
1.2Or
1.2Gr
1.2Or
1.2Br
1.2Br
2W
2W
8 ILLUMINATION 8
2RW
0.8R
1.2R
3Y
1.2V
2.0Y
0.8V
1.2V
0.8L
BATT RY
0.8
0.8
2R
2Y
2L
2L
0.8V
2B
2Y
0.8L
G31
AIR-CON
2Br
133
147
2L
DO-3
24
25
78
23
130
140
131
124
148
134
104
132
126
12
79
86
32
26
26
17
39
50
87
18
16
20
47
141E 0.8G
6
5
2
87A
133
122
0.8B 4
87
G24 0.8B
G21
1
126
CN-5 1
0.8Y
1 CLUSTER_TX 1
0.8L 2
2 CLUSTER_RX 2
SH 3G CD-43
3 SHIELD 3 1.2ROr 2A
PRESS
0.8B 4 SUPPLY A
4 CLUSTER_GND 4 SIG B
1.2L 1
0.8Gr 5
5 CLUSTER_IG 5 1.2BW 4A
P2
0.8RW 6 RETURN C
6 CLUSTER_BATT.24V 6 CD-42 CD-44
7 ECONO SW_COM 7 1.2ROr 2 80H 1.2ROr
PRESS
SUPPLY A A SUPPLY
8 ECONO SW_NO 8 1.2G 3 91 1.2LW
0.8BW 82 SIG B B SIG
9 P_DUMP(SERVICE CONN.) 9 1.2BW 4 81H 1.2BW
P1
0.8Br 7 RETURN C C RETURN
10 QUICK COUPLER SW_NO 10
0.8Br 7 A3
11 OVERLOAD SW_COM 11
0.8ROr 00
12 OVERLOAD SW_NO 12
0.8ROr 10A
13 ILLUMINATION 13 CD-18
0.8W 11
14 HOUR METER SIG. 14 1 1.2GrW
15
0.8G 74 Pa
RS232 RX(SERVICE CONN.) 15
0.8R 73
16 RS232 TX(SERVICE CONN.) 16
0.8B 3F ENG OIL PS
17 GND(SERVICE CONN) 17
0.8R 12
18 WIPER CONT_BATT.24V 18
0.8V 13
19 WIPER CONT_WASHER P/P DRIVE 19
20 CAN_Hi(SERVICE CONN) CN-28
20 2 1.2VW
1
21 CAN_Lo(SERVICE CONN) 21
22 CAN SHIELD 22
23 nc 23 AC COMP
24 WIPER IG 24
0.8GrW 39 CN-2 1.2GrW
1.2ROr 104 46 0.8Y 1
25 OPTION SW 25 1
1.2B 15 2 CN-79
26 HEAT SEAT_GND 26 60 0.8V 1.2VW 2 3 2B
1.2Gr 16 3 G
27 CIGAR LIGHTER_IG 27 00 0.8 1.2 00 4 2W
1.2V 17 F
28 DC-DC CONVERTER 24V 28 4
1.2Or 18 86E 0.8 1.2LW 5 5 1.2LW
29 SPARE SW_COM(IG) 29 5 H
1.2B 19A 00 0.8 1.2 00
30 GND 30 19 2B 6 FUEL CUT OFF SOL
1.2B 19E 00 0.8 1.2 00
31 GND 31 7
64 2W 2W 4
32 NC 32 8 CN-75
20 56 Or 1.2Or 6 6 1.2Or
1.2Br 9 2
33 BEACON SW_COM(IG) 33 75 Br 1.2Br 7 7 1.2Br
1.2V 21A 21 2V
34 CABIN LIGHT 34 10 1
0.8BOr 22 8 Y 1.2Y 8
35 START KEY SW_START 35 11 EPPR V/V
1.2W 23 9 L 1.2L 9
36 START KEY SW_COM 36 12
00 0.8
13
1.2 00 CD-17
37 CAMERA_3 37 8 1.2Y
0.8V 21E 68 2B 2B 3 2 m
38 CABIN LIGHT 38 14 9 1.2L rp
00 0.8 1.2 00 1
39 REVERSE FAN AUTO 39 15
TACHO SENSOR
40 REVERSE FAN MANUAL 40
41 RS232 RX2(GPS) 41
0.8BrW 77
ENG.HARNESS REAR
0.8GrW 76
42 RS232 TX2(GPS) 42 CR-23 CN-45
43 NC 43 CN-3
68A 0.8B 1.2 10 10 B M
44 NC 44
64E 0.8
1
1.2 11 11 Gr
1 M
45 NC 45 2 2
0.8Y 25 66 0.8W 1.2 12
46 CASSETTE RADIO_BATT.24V 46 3
0.8V 26 67 0.8Y 1.2 13 START RY B+
47 CASSETTE RADIO_IG 47 4 FROM BATT.RY
48 CASSETTE RADIO_GND 48
0.8B 27 81A 0.8
5
1.2 14 STARTER
0.8BrW 28 43 0.8 1.2 15
49 SWITCH PANEL_HEAD LIGHT 49 6
0.8VW 29
50 SWITCH PANEL_WORK LIGHT 50 7
15 R
51 CAMERA GND 51
0.8 84
8 RS-1 CN-74
0.8 84 43 0.8 0.8 15 16
52 CAMERA SIG. 52 9 2 B+
0.8 84 43 0.8 0.8 15 3W/300 12A
53 CAMERA SHIELD 53 10 1 G
0.8 84 43 0.8 0.8 15 1 P
54 SWITCH PANEL_PREHEAT 54 11 12 1.2W 3~
0.8Gr 30 43 SH SH 15 2 L
55 SWITCH PANEL_CABIN LAMP 55 12 3 FI
U
0.8RW 32
56 SWITCH PANEL_TRAVEL ALARM 56 4 NC
0.8RW 32
57 SWITCH PANEL_IG 57 CR-24
58 SWITCH PANEL_GND 58
0.8B 33
13 V
15R ALT.
0.8WOr 34 CN-249
59 START SW_ACC 59 1
0.8B 24
0.8GW 35 15R
60 START SW_BR 60 0.8L 22
2
0.8Y 23
3 PRE-HEAT RY Pre-heater
0.8Gr 21
CN-8 4
1 NC 1 CAMERA
2 NC 2 14
CD-8
B
3 NC 3 ENG.HARNESS FRONT 15 G
1 C
4 NC 4 2
0.8 18
5 GND 5 WATER TEMP SENDOR
6 NC 6
0.8 18
7 ILLUMINATION 7
8 NC 8
9 NC 9
10 NC 10 CR-36
55 0.8BOr
11 NC 1
11 132A 0.8L 4 5 1
12 NC 2
12 132 0.8L
3
CN-7 4
1 NC 1 67 0.8Y 3 2
5
2 NC 2 PRE-HEAT RY
3 NC 3
0.8 18 CR-5
4 SEAT HEAT 4 131 2.0Y
0.8Or 18 30
5 BREAKER SW 5 22 0.8BOr 87a 87 85
0.8BW 40 86
6 BREAKER SW 6 64 2W
0.8B G42 87
7 HORN 7 123 0.8Br
0.8GrW 41 85
8 HORN 8 30 86
87a
9 BUTTON 2 9
10 BUTTON 2
ANTI-RESTART RY
10
11 BUTTON 1 11 CR-13
50 1.2Br
12 BUTTON 1 12 30
50A 0.8Br 87a 87 85
13 NC 13 86
0.8Gr 42 10 1.2ROr
14 ACCEL DIAL SUPPLY 14 87
0.8W 99 28 0.8BrW
15 ACCEL DIAL SIGNAL 15 85
0.8B 37 30 86
16 ACCEL DIAL GND 16 87a
RH CONSOL HEAD LAMP RY
CN-4 CL-4
1 G22 1.2B
1 NC 2
2 NC 2 10 1.2ROr
1
3 NC 3 HEAD LAMP
4 NC 4 CR-62 CL-3
0.8GrW 00 1.2B
5 POWER MAX SW 5 G30 0.8Br
1
G22
2
0.8B 81R 5 1
6 POWER MAX SW 6 40 0.8BW 4 10 1.2ROr
0.8GrW 48 2 1
7 ONE TOUCH DECEL 7 18 0.8Or
0.8B 81R 3 HEAD LAMP
8 ONE TOUCH DECEL 8 4
9 BUTTON 2 9 136 0.8Br
5 3 2 CN-12 CL-5
G11 2B B 2 2 B
10 BUTTON 2 10 2 1
BREAKER RY 128 2RG
1
V 1 1 V
11 BUTTON 1 11 2
12 BUTTON 1 12 CR-4 WORK LAMP
2A B
13 NC 13 130 2RW
30 1
1.2B G41 V
14 SAFETY SW COM 14 130A 0.8RW
86
87a 87 85 1A
2
15 SAFETY SW NC 15 128 2RG
CL-6
1.2G 49 87
16 SAFETY SW NO 16 29 0.8VW
85
LH CONSOL 87a 30 86
CN-68 WORK LAMP RY

1.2G 49
1
1.2V 134
2 CR-2
41 0.8GrW
SAFETY SOL 1
124A 0.8V 4 5 1
CN-140 2
B 152 124 0.8V
1 3
0.8Br 7 CN-25
2 4 G12 0.8B
127 0.8G 3 2 2
QUICK COUPLER 5 127 0.8G
1
HORN RY HORN
CD-10 0.8B
1.2B 81S G13
2
Pa 1.2YOr 83 127 0.8G
1
AIR CLEANER SW CN-20
CD-2
0.8B 81R
1
0.8 100
2
FUEL LEVEL
CD-1
0.8B 81
C 1
0.8 101
2
HYD TEMP
G32
47E
120
121
158
136
80
98
81
0.8ROr
0.8GW
0.8LOr
0.8BW
0.8BW
0.8Or
0.8Br
0.8Br
0.8B
CN-15
10
11
12
2
6
7
8
9
1
4
3
5
2B 3
42A
37A
63
54
36
2B
1
2
3
4
5
6
7
4
5
101
118
118
118
118
118
118
118
118
118
123
118
118
118
118
118
118
118
82
76
76
76
77
55
00
90
00
91
00
00
0.8Gr
80E
81E
80A
81A
80A
81A
81H
80A
9
81J
3E
78
79
1.2ROr 80
81
42
37
54
53
11
51
73
74
94
96
80
90
91
1
3
W
8
G
V
0.8GrW
0.8GrW
0.8GrW
0.8OrW
0.8BrW
0.8BOr
1.2RW
1.2LOr
0.8LW
0.8Gr
0.8W
CN-76
0.8G
1.2R
0.8R
1.2B
0.8B
0.8V
1.2B
0.8Y
0.8V
0.8Y
0.8L
0.8L
0.8WOr
1.2
SH
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8OrW
0.8ROr
0.8ROr
0.8BOr
0.8ROr
0.8ROr
0.8ROr
6
5
4
3
2
0.8BW
0.8BW
1
0.8BW
0.8BW
0.8BW
0.8LW
0.8V
105
104
47H
47G
106
70
47A
118
CN-51
CN-52
6
7
119
SIG
47
M+
P+
NC
M-
P-
10
11
12
13
SPEED SENSOR+(HMC) 14
15
16
17
18
19
20
21
22
RS485+(TX)-CLUSTER 23
24
25
TRAVEL ALARM SELECT SIG 26
27
28
AIR CLEANER SW(NO) 29
30
31
32
RS485-(RX)-CLUSTER 33
34
35
PRE-HEAT SELECT SIG 36
37
38
39
40
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
WATER TEMP SENDOR 25
FUEL LEVEL SENSOR 26
27
28
29
30
31
PUMP EPPR2 SENSOR 32
ATT PILOT PRESSURE 33
34
35
36
37
38
39
40
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
CD-24
CD-32
CD-31
CD-6
CD-7
0.8V
0.8ROr
0.8RW
1
0.8Or
5
0.8BW
0.8BW
0.8GOr
0.8BrW
RETURN C
RETURN C
SUPPLY A
B
SUPPLY A
B
RETURN C
2
RETURN C
RETURN C
SUPPLY A
B
SUPPLY A
B
SUPPLY A
B
0.8Rw
0.8W
0.8Or
0.8Or
0.8Or
M
BOOM PRIORITY EPPR+
ARM IN_OUT BUCKET IN PRESS

PUMP POWER EPPR+
WORK PRESS SENSOR(A)

BOOM PRIORITY EPPR-
0.8
0.8
BOOM UP PRESS SENSOR
PUMP POWER EPPR-
SWING PRESS SENSOR

GOV. POTENTIO SIG.
TRAVEL PRESS SENSOR(A)
0.8LOr
0.8GW
HYD. TEMP SENDER
TRAVEL SPEED SOL
ATT_CONFLUX SOL.
ONE TOUCH DECEL
0.8Or
0.8Or
0.8Or
ENGINE OIL FILTER
POWER BOOST SW
0.8Br
P1 PRESS SENSOR
P2 PRESS SENSOR
RS232C1_RX-HRDT
RS232C1_TX-HRDT
0.8Br
6
CN-81
ENG PRE-HEAT RY
FUEL WARMER RY
0.8B
BATT POWER_24V
ANTI RESTART RY
RS232C2_RX-RCM
ATT_ SAFETY SOL

RS232C2_TX-RCM
TACHO SENSOR+
POWER MAX SOL

POWER_24V OUT
PROGRAM DUMP
ATT_PRESS SOL.
ARM REGEN SOL
TACHO SENSOR-
TRAVEL BUZZER
GOV. MOTOR
POWER IG EPPR
CN-133
CN-242
CN-70
CD-69
2
1
SIG
SIG
CN-88
POWER_5V OUT
SIG
ACCEL DIAL SIG

SIG
SIG
CN-135
OVERLOAD SIG
1
2
1
2
1
2
RETURN C
1
SUPPLY A
B
2
G/A MOTOR(+)
GND_RETURN
ENG STOP RY
G/A MOTOR(-)
HOUR METER
CN-236
CN-149
BLOWER SIG.
CN-237
CN-66
CAN_SHIELD
ATT. EPPR+
1
2
1
2
1
2
ATT. EPPR-
ENG OIL PS
BOOM
coolent level
OVER
ALT. LEVEL
SWING TRAVEL WORK

GND_MAIN
EPPR GND
POWER IG
LOAD UP
CAN1 Lo
GND_5V
CAN1 Hi
SIG
ATT BOOM ARM TRAVEL POWER
FLOW TRAVEL BZ PRIORITY REGEN HIGH MAX ATT. ATT.
nc
ATT.
nc
nc
nc
nc
nc
BREAKER SOL.
nc
nc
nc
nc
nc
nc
nc
ATT. PS
PRESS SAFETY CONFLUX
SOL.
MCU
2609S4EL03
4-3
·ELECTRICAL
ELECTRICAL CIRCUIT (2/2, CLUSTER TYPE 1)
2609S4EL04
4-4
■ ELECTRICAL CIRCUIT (1/2, CLUSTER TYPE 2)
AC
COMP RY
CS-74A
R/DRYER 5R 146 146 5R
CS-74
1
87a 87 85
30 86
WASHER P/P 145 5W 143 5R
2
Pa
POWER RY
M
138 2WR
MASTER SW CABIN LAMP RY
CN-22
CN-29
FUSE BOX
DO-5
CR-7
87a
CN-95
2
1
30
2
86
85
1
87
87a 87 85
30 86
2
MASTER SW
1
5W 145
87a 87 85
2
30 86
10
1
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
5W 144
1
30A
10A
30A
30A
20A
10A
10A
10A
20A
10A
10A
10A
30A
20A
30A
30A
10A
20A
30A
30A
10A
20A
10A
20A
20A
20A
20A
20A
10A
20A
10A
0.8GrW
0.8GrW
CR-35
0.8V
0.8L
0.8L
0.8V
0.8
0.8
FUSIBLE LINK
0.8V
0.8
87a
30
86
85
87
CR-9
ROOM LAMP/CASSETTE
87a
5R 143
CABIN LAMP(OPTION)
30
86
85
87
2
OPTION(BEACON)
AIR CON/HEATER
5R
148A
148E
142 BATTERY
CN-11
149
150
NO. DESTINATION 1
39E
149
13A
39A
0.8WOr
SWITCH PANEL
60
13
FUEL CUT OFF

CS-74B
2B 129
FUEL HEATER
AC GND FUEL HEATER RY
2WR
1 1 CN-60
AC& HEATER
0.8B
START,STOP
CONVERTER
SAFETY SOL
TRAVEL SOL
WORK LAMP
0.8Gr
2W
SOLENOIDE
60B
MCU CONT.
HEAD LAMP
60R
START KEY
0.8R
FUEL PUMP
1
2
CASSETTE
IG POWER
2 BLOWER SIG. 2 FUEL HEATER
PRE-HEAT
2R
2V
CLUSTER
FUEL P/P
2L 148
OPTION
CN-36
87a 87 85
3 AC 24V
30 86
138
SPARE
3
WIPER
SPARE
SPARE
G3
WIPER
M
CIGAR
24
34
HORN
140
140A
21
30
REVERSE FAN
MCU
4 4 CR-1
2W
12V X 2
2W
3Y 147
CN-96
5 AC CONTROLLER B+ 5 G23 1.2B
2
1
0.8 150
CR-46
AC COMP
87a
6 6
CN-61
141 1.2G
30
86
TO:STARTER "B" TERM.
85
87
1
AC CONDENSOR FAN
2
7 7
2Br
0.8GrW
1.2ROr
2B
0.8RW
1.2RW
0.8RW
1.2R
0.8Y
0.8ROr 10E
0.8Gr
1.2Or
1.2Gr
1.2Or
1.2Br
1.2Br
ILLUMINATION
2W
2W
8 8
2RW
0.8R
1.2R
3Y
1.2V
2.0Y
0.8V
1.2V
0.8L
BATT RY
0.8
2.0
2R
2Y
2L
2L
0.8V
2B
2Y
0.8L
G31
AIR-CON
2Br
133
147
2L
DO-3
24
25
78
23
130
140
131
124
148
134
104
132
126
12
79
86
32
26
26
17
39
50
87
18
16
20
47
141E 0.8G
6
5
2
87A
133
122
0.8B 4
87
G24 0.8B
G21
1
126
CN-5 0.8Y 1
1 CLUSTER_TX 1
0.8L 2
2 CLUSTER_RX 2
SH 3G
3 SHIELD 3
0.8B 4
4 CLUSTER_GND 4
0.8Gr 5
5 CLUSTER_IG 5
0.8RW 6
6 NC 6
7 NC 7 CD-43
1.2ROr 2A
PRESS
8 NC 8 SUPPLY A
0.8BW 82 1.2L 1
9 P_DUMP(SERVICE CONN.) 9 SIG B
0.8Br 7 1.2BW 4A
P2
10 QUICK COUPLER SW_NO 10
7
RETURN C CN-1
0.8Br 1 0.8L 85
11 OVERLOAD SW_COM 11 CD-42 1
0.8ROr 00 1.2ROr 2 2 1.2ROr 80P
PRESS
12 OVERLOAD SW_NO 12 SUPPLY A 2
0.8ROr 10A 1.2G 3 3 0.8G 84
13 ILLUMINATION 13 SIG B 3 CD-18
0.8W 11 1.2BW 4 81P
P1
4 0.8BW
14 HOUR METER SIG. 14 RETURN C 4 1
0.8G 74 1.2GrW Pa
15 RS232 RX(SERVICE CONN.) 15 4 0.8BW 81P
CD-44 5
0.8R 73
16 RS232 TX(SERVICE CONN.) 16 1.2ROr 2 6
PRESS
0.8B 3F SUPPLY A
17 GND(SERVICE CONN) 17 1.2G 3 ENG OIL PS
0.8R 12 SIG B
18 WIPER CONT_BATT.24V 1.2BW 4
P3
18 RETURN C
0.8V 13
19 WIPER CONT_WASHER P/P DRIVE 19
20 CAN_Hi(SERVICE CONN)
CN-28
20 2 1.2VW
1
21 CAN_Lo(SERVICE CONN) 21
22 CAN SHIELD 22
23 23 AC COMP
24 WIPER IG 24
0.8GrW 39 CN-2 1.2GrW
1.2ROr 104 46 0.8Y 1
25 OPTION SW 25 1
1.2B 15
26 GND 26 2 CN-79
1.2Gr 16 60 0.8V 1.2VW 2 3 2B
27 CIGAR LIGHTER_IG 27 3 G
1.2V 17 00 0.8 1.2 00 4 2W
28 DC-DC CONVERTER 24V 28 4 F
1.2Or 18 86E 0.8 1.2LW 5 5 1.2LW
29 SPARE SW_COM(IG) 29 5 H
1.2B 19A 00 0.8
30 GND 30 19 2B 6 FUEL CUT OFF SOL
1.2B 19E 00 0.8
31 GND 31 7
64 2W 2W 4
32 NC 32 8 CN-75
1.2Br 20 56 Or 1.2Or 6 6 1.2Or
33 BEACON SW_COM(IG) 33 9 2
1.2V 21A 21 2V 75 Br 1.2Br 7 7 1.2Br
34 CABIN LIGHT 34 10 1
0.8BOr 22 8 Y 1.2Y 8
35 START KEY SW_START 35 11 EPPR V/V
1.2W 23 9 L 1.2L 9
36 START KEY SW_COM 36 12
00 0.8
13
1.2 00 CD-17
37 NC 37 8 1.2Y
0.8V 21E 68 2B 2B 3 2 m
38 CABIN LIGHT 38 14 9 1.2L rp
00 0.8 1.2 00 1
39 NC 39 15
40 NC 40
TACHO SENSOR
ENG.HARNESS REAR ENG.HARNESS
41 NC 41
42 NC 42 CR-23 CN-45
43 NC 43 CN-3
68A 0.8B 1.2 10 10 B M
44 NC 44
64E 0.8
1
1.2 11 11 Gr
1
2
M
45 NC 45 2
0.8Y 25 66 0.8W 1.2 12
46 CASSETTE RADIO_BATT.24V 46 3
0.8V 26 67 0.8Y 1.2 13 START RY B+
47 CASSETTE RADIO_IG 47 4 FROM BATT.RY
48 CASSETTE RADIO_GND 48
0.8B 27 81A 0.8
5
1.2 14 STARTER
0.8BrW 28 43 0.8 1.2 15
49 SWITCH PANEL_HEAD LIGHT 49 6
0.8VW 29 0.8
50 SWITCH PANEL_WORK LIGHT 50 7
15 R
51 NC 51 8 RS-1 CN-74
16
52 NC 52 9 2 B+
0.8 84
3W/300 12A
53 BREAKER SW 53 10 1 G
0.8 84 1 P
54 SWITCH PANEL_PREHEAT 54 11 12 1.2W 3~
0.8Gr 30 2 L
55 SWITCH PANEL_CABIN LAMP 55 12 3 U
0.8RW 32 FI
56 SWITCH PANEL_TRAVEL ALARM 56 4 NC
0.8RW 32
57 SWITCH PANEL_IG 57 CR-24
0.8B 33 15R ALT.
58 SWITCH PANEL_GND 58 13 V
0.8WOr 34
59 START SW_ACC 59
0.8GW 35 15R
60 START SW_BR 60
PRE-HEAT RY Pre-heater
CN-8
1 NC 1
2 NC 2 CD-8
14 B
3 NC 3 1 C
15 G
4 NC 4 2
0.8 18
5 GND 5 WATER TEMP SENDOR
6 NC 6
0.8 18
7 ILLUMINATION 7
8 NC 8
9 NC 9
10 NC 10 CR-36
55 0.8BOr
11 NC 1
11 132A 0.8L 4 5 1
12 NC 2
12 132 0.8L
3
CN-7 4
1 NC 1 67 0.8Y 3 2
5
2 NC 2 PRE-HEAT RY
3 NC 3
0.8 18 CR-5
4 SEAT HEAT 4 131 2Y
0.8Or 18 30
5 BREAKER SW 5 22 0.8BOr 87a 87 85
0.8BW 40 86
6 BREAKER SW 6 64 2W
0.8B G42 87
7 HORN 7 123 0.8Br
0.8GrW 41 85
8 HORN 8 30 86
87a
9 BUTTON 2 9
ANTI-RESTART RY
10 BUTTON 2 10
11 BUTTON 1 11 CR-13
50 1.2Br
12 BUTTON 1 12 30
50A 0.8Br 87a 87 85
13 NC 13 86
0.8Gr 42 10 1.2ROr
14 ACCEL DIAL SUPPLY 14 87
0.8W 99 28 0.8BrW
15 ACCEL DIAL SIGNAL 15 85
0.8B 37 30 86
16 ACCEL DIAL GND 16 87a
HEAD LAMP RY
RH CONSOL CN-4 CL-4
G22 1.2B
1 NC 1 2
2 NC 2 10 1.2ROr
1
3 NC 3 HEAD LAMP
4 NC 4 CR-62 CL-3
0.8GrW 00 1.2B
5 POWER MAX SW 5 G30 0.8Br
1
G22
2
0.8B 81R 5 1
6 POWER MAX SW 6 40 0.8BW 4 10 1.2ROr
0.8GrW 48 2 1
7 ONE TOUCH DECEL 7 18 0.8Or
3 HEAD LAMP
0.8B 81R
8 ONE TOUCH DECEL 8 4
9 BUTTON 2 9 136 0.8Br
5 3 2 CN-12 CL-5
G11 2B B 2 2 B
10 BUTTON 2 10 2 1
BREAKER RY 128 2RG V 1 1 V
11 BUTTON 1 11 1 2
12 BUTTON 1 12 WORK LAMP
CR-4 2A B
13 NC 13 130 2RW
30 1
1.2B G41 V
14 SAFETY SW COM 14 130A 0.8RW
86
87a 87 85 1A
2
15 SAFETY SW NC 15 128 2RG
CL-6
1.2G 49 87
16 SAFETY SW NO 16 29 0.8VW
85
30 86
LH CONSOL 87a
CN-68 WORK LAMP RY

1.2G 49
1
1.2V 134
2 CR-2
41 0.8GrW
SAFETY SOL 1
124A 0.8V 4 5 1
CN-140 2
B 152 124 0.8V
1 3
0.8Br 7
4 G12
CN-25
2 0.8B
127 0.8G 3 2 2
QUICK COUPLER 5 127 0.8G
1
HORN RY
CD-10 HORN
1.2B 81S G13 0.8B
Pa 2
1.2YOr 83 127 0.8G
1
CN-20
0.8Br
AIR CLEANER SW
0.8B
CD-2
CN-66
0.8B 81R
1
1
2
0.8 100
2
FUEL LEVEL
CD-1 BREAKER SOL.
0.8B 81
C 1
0.8 101
2
HYD TEMP
3 2B
27
81H
80A
81J
81J
2B
117
80
90
91
80
90
8A
26
34
OR/W 28
GY/W 30
14
47
16
38
39
40
31
45
36
13
G/OR 11
29
25
B/OR 33
65
67
12
32
55
63
W/OR 61
62
62
50
57
37
54
64
51
44
46
46
66
23
68
69
71
72
73
48
42A
BR/OR
3
37A
G/W
R/W
Y/W
B/W
Y/W
Y/W
B/W
V/W
L/W
63
54
36
0.8OrW
OR
OR
0.8OrW
GY
GY
BR
BR
BR
0.8ROr
0.8ROr
0.8ROr
0.8BW
0.8BW
0.8BW
0.8LW
W
W
W
G
G
G
G
R
R
Y
B
Y
B
L
105
104
47G
0.8Gr
70
47A
118
119
CN-51
CN-50
47
W
G
V
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
10
11
12
TRAVEL SPEED SOL. 13
14
15
16
17
18
19
20
ENGINE OIL FILTER 21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
CD-6
CD-7
CD-31
0.8V
0.8RW
0.8Or
0.8GOr
0.8BrW
CN-76
C
C
SUPPLY A
RETURN B
SUPPLY A
RETURN B
C
SUPPLY A
RETURN B
0.8W
FUEL LEVEL SENSOR
0.8Or
0.8Or
GND(PRES.SENSOR)
WATER TEMP SENDOR

24V(PRES.SENSOR)
6
5
4
3
2
1
TRAVEL ALARM SW
BOOM PRIORITY SOL

HYD TEMP SENDOR
TACHO SENSOR(+)
TACHO SENSOR(-)
ANTI-RESTART RY
WATER LEVEL SW
POWER MAX SOL.

PUMP PROLIX SW
AIR CLEANER SW
ENG PREHEATER
CN-81
PROGRAM DUMP
TRAVEL BUZZER
POWER MAX SW
GND (POT&DIAL)
BATTERY 24V(+)
MAX FLOW SOL.
ACCEL DIAL SIG
OVERLOAD SIG
CN-133
CN-70
GND (SENSOR)
SIG
CN-88
2
1
P1 PRESS SIG.
P2 PRESS SIG.
P3 PRESS SIG.
O/T DECEL SW
PUMP EPPR(+)
M+
5V (POT&DIAL)
P+
NC
SIG
SIG
M-
PRE-HEAT SW
SIG
FUEL HEATER
PUMP EPPR(-)
ACCEL ACT(+)
P-
1
HOUR-METER
HOUR-METER
1
2
1
ACCEL ACT(-)
2
WORKING PS
RS232 (GND)
TRAVEL PS
ENG OIL PS
GND (MAIN)
1
5
SERIAL-RX
ALT LEVEL
SERIAL-TX
POWER IG
2
RS232 (+)
WORK
M
OVERLOAD PS TRAVEL
RS232 (-)
POT-SIG
6
GND
GOV. MOTOR BOOM TRAVEL POWER

NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
TRAVEL BZ PRIORITY HIGH MAX
MCU
2609S4EL05
4-5
·ELECTRICAL
ELECTRICAL CIRCUIT (2/2, CLUSTER TYPE 2)
Service Tool DC/DC CONVERTER CIGARLIGHT

OVERLOAD SW RELAY
INTAKE M/ACT MODE(D/FOOT) MODE(VENT)
RS232 P_DUMP
TEMP M/ACT BLOWER
24V
12V SOCKET HOUR METER
12
12
10
3
4
9
ECONO SWITCH
C 12V 12V
4 2 7 4 2 7
RS232_RX
h
RS232_TX
1 1 BLOWER
12
M M M M
12
3 3 7
CAN2_Lo
7
10
3
1
CAN2_Hi
3
4
9
CAN_Lo
CAN_Hi
B GND
CN-48
5
IG 24V
A 24V
5
CL-2
M
CN-139
GND
4
2
CN-138
5
6
7
5
6
7
5
6
7
1
2
3
4
5
6
7
1
2
3
4
1
2
3
4
1
2
3
4
3
2
1
11
CS-67
1
1
2
CS-50
8
1
1
2
1
10
4
2
3
11
12
CN-21
9
4
8
1
2
3
6
7
11
1 12
1.2Gr
7
8
CS-52
2
1.2B
ROr
0.8W
0.8B
0.8Y
3 1 WIPER CUT
G
H
B
00
C
E
A
10
0.8G
11
F
12
1.2Or
10
9
R 3
8
1
2
3
6
7
24M 1.2B
1.2Or
1.2V
24L 1.2B
0.8VOr
2 9 0.8Br
0.8Or
0.8Or
0.8Br
Gr 12 4
24Q
0.8V
24R 0.8B
12B
5 3
35E
24V
21
CS-53
13
R 4A 5
60
0.8BW
0.8Or
27F 0.8Br
4
60
22
0.8G
0.8G
0.8B
24T 0.8B
0.8G
0.8G
0.8G
0.8G
0.8G
0.8R
0.8V
0.8B
4 G 8 6
61
11
27
10
61
5 23F 0.8Or 3
L 9 7 7 HARNESS AIR-CON
B
2 6 9
6
6
6
6
5
4
3
2
1
6 M 23F 0.8Or
62
62
CN-126
Or
8
7
2A
4 CN-11 NO. DESTINATION
10
9 8
9
8
7
6
5
4
3
2
1
11
WIPER MOTOR 10 1 1 GND
10
9A 0.8Br
11
2 2 BLOWER SIG
0.8BW
24S 0.8B 11 12 3 3 FUSE(IG)
0.8G
0.8G
0.8R
0.8V
0.8B
12
4 4 REVERSE FAN
CN-141 QUICK COUPLING SW
G 8 5 5 FUSE(Battery)
59
73
72
71
70
69
FEED BACK 1
W 1 6 6 DPS(COMPRESSOR)
MOTOR DRIVE SIG 2 CN-17 CN-113
3
L 9 00 0.8B 7 7 CONDENSOR FAN
MOTOR DRIVE- 1
R 10 1 W 0.8W 48 1 8 8 ILLUMINATION
MOTOR DRIVE+ 4 2 00 0.8G
B 2 2 B 1.2B 24B 2
GND 5 3
GrW 3 3 GrW 0.8ROr 65 BUZZER
VCC 6 4
R 4 4 R 0.8R 14
CONTINUE 24V 7 5
V 5 5 V 0.8V 15
WASHER P/P 8 6
L 6 6 L 0.8L 49
WASHER SIG. 9 7
Br 7 7 Br 0.8Br 50
INT. SIG 10 8
Or 11
WIPER CUT SW 11
N.C 12
Gr 12 WIPER MOTOR HARNESS
FEED BACK 13
WIPER MOTOR CONT. CN-56

17 BR RR
1 POWER IG(24V)
10
11
12
13
14
15
16
17
18
10
11
12
13
14
B
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
18
2 GND
19 Y
TEMP MOTOR ACT(+)
DUCT SENSOR(GND)
TEMP MOTOR ACT(-)
3
DPS(COMPRESSOR)
RX
MODE M/ACT(FOOT)
BLOWER RELAY(Lo)
INLET MOTOR(REC)
INLET MOTOR(FRE)
20 L
0
MODE M/ACT(PBR)
0
0
MODE M/ACT(DEF)
AMBIENT SENSOR
TEMP M/ACT(PBR)
CONDENSOR FAN
MOTOR ACT(REF)
4
DUCT SENSOR(+)
W/TEMP SENSOR
MODE M/ACT(M+)
1
2
TX
POWER TR BASE
MODE M/ACT(M-)
FET(FEED BACK)
INCAR SENSOR
REVERSE FAN
CLUSTER
ILLUMINATION
ILLUMINATION
> > >
BATTERY(+)
CN-5
FET(GATE)
CS-82
POWER IG
0.8B 20E 1 0.8Y POWER TR AMBIENT INCAR W/TEMP
12 1 1 MCU_RX SENSOR SENSOR SENSOR
IG 24V
12 11 0.8LW 26A 2 0.8L DUCT
2 2 MCU_TX
GND
11
SENSOR
NC
NC
NC
3 SH
10 3 3 MCU_GND
10 4 0.8B
8 9 4 4 GND
4 1.2ROr 19A 5 0.8Gr
5 FUSE AC&HEATER CONTROLLER(auto)
8 5
9
7 7 6 6 NC
3 7 0.8B
6 7 7 NC CS-1 CN-24
8 Gr 11 0.8G 2
0.8Or 2
5 8 8 NC CN-10 NO. DESTINATION
1.2LW 26 59 0.8BW 0.8V 3
4 9 9 P_DUMP(MCU) 1
9 0.8Br CL-1 1 1 NC
3 10 10 QUICK COUPLING SOL DOOR S.W Gr 11 SPEAKER RH
10 0.8V 3 2 2 NC
2 11 11 OVERLOAD PS 0.8Y 1 1 0.8Y
12 1 11 0.8VOr 2 3 3 FUSE
1 12 12 MCU_OVERLOAD 0.8B 6 2 0.8G
12 0.8ROr 1 4 4 CASSETTE_RH-
SPARE 13 13 HEAD LAMP RY ROOM LAMP MG651032 3 0.8V
5 5 CASSETTE_RH+
13 0.8W CN-23
14 14 MCU_HOURMETER 0.8Y 4 4 0.8Y
69 0.8G 2 6 6 CASSETTE_LH-
15 15 RS232_RX(MCU) 0.8L 5 5 0.8L
70 0.8R 1 7 7 CASSETTE_LH+
16 16 RS232_TX(MCU) 6 2.0B
71 0.8B SPEAKER LH 8 8 GND
17 17 GND 7 2.0B
14 0.8R CL-7 9 9 GND
18 18 FUSE 1.2BrW 8 8 1.2BrW
15 0.8V 10 10 BEACON SW
19 19 WASHER P/P M 1.2B 6A 9 2.0V
72 0.8V 11 11 CABIN LIGHT RY
20 20 CAN_Hi 10 2.0V
73 0.8G BEACON LAMP 12 12 CABIN LIGHT RY
21 21 CAN_Lo
74 SH
22 22 Shieeld CL-8 CL-9
2
2.0V 9 10 2.0V
2
HARNESS CABIN
23 23 NC 1.2B
65 0.8ROr 1.2B 6B 7
24 24 WIPER FUSE 1 1
19 1.2ROr
25 25 FUSE CABIN LIGHT
26 26 GND
21 1.25Gr ACCEL DIAL LED
27 27 FUSE CS-83
CN-279
22 1.2V 0.8B 19G
CS-23 28 28 FUSE 12 CS-26A
1
2
0.8B 24J 23 1.2Or 12 11 0.8Or 18A 5E 0.8BW
12 29 29 FUSE 11 2
12 11 0.8BrW 58A 24A 1.2B 4E 0.8G
11 30 30 GND 10 1
24E 1.2B 10 0.8G 15
0.8ROr
10 24 2B 31 31 GND 8 9
BREAKER
0.8B
10 4 0.8V 16
8 9 32 32 NC 8
4 1.2Br 27E 27 1.2Br 9 0.8BrW 17
8 33 33 FUSE 7 7 CN-156
9 28 2V 28A 1.2V 3 19 1.2B
32
19F
7 7 34 34 CABIN LAMP RY 6 2
3 29 1.2BOr 31 1.2ROr
6 35 35 ANTI RESTART RY 5 1
30 1.2W 0.8Or 18
5 36 36 FUSE 4 AIR SEAT
1.2BrW 58 0.8Gr 20
4 37 37 NC 3 CN-8 NO. DESTINATION
28E 0.8V
CABIN LAMP RY 15 0.8G
3 38 38 12 1 2 1 1 NC
2 39 39 NC 1 16 0.8V
12 1 2 2 FUSE
1 40 40 NC SPARE 17 0.8BrW
3 3 CRAB COM
BEACON LAMP SW 41 41 NC 18 0.8Or
CS-99 4 4 NC
42 42 NC 0.8B 19A 19 1.2B
CS-27 12 5 5 NC
0.8B 24J 43 43 NC 12 11 0.8GW 21A 20 0.8Gr
12 11 6 6 CRAB SIG_MCU
12 11 0.8BrW 58A 44 44 NC 32 0.8ROr
11 10 7 7 ILLUMINATION
45 45 NC 10 22 0.8L
10 35 0.8Y 8 9 8 8 NC
10 46 46 FUSE 4 0.8L 22 23 0.8VW
8 9 36 0.8V 8 9 9 DPF REGEN
4 0.8 27E 47 47 FUSE 9 0.8L 22A 24 0.8R
8 37 0.8B 7 7 10 10 DPF COM
9 48 48 GND 3 25 0.8LW
7 7 38 0.8BrW 6 11 11 DPF INHIBIT
3 49 49 HEAD LAMP RY 26 0.8RW
6 39 0.8VW 5 12 12 AIR COMP RY
50 50 WORK LAMP RY 0.8GW 21
5 4
0.8 58 51 51 NC 0.8RW 26
4 3
3 40 0.8
52 52 NC
12 1 2
HARNESS RH,CONSOL
2
53 53 BREAKER SW(JOYSTICK) 1
12 1 40 0.8WOr
1
54 54 PRE-HEAT SPARE
41 0.8Gr
55 55 CABIN LAMP RY
BREAKER SW 42 0.8YW CS-100
56 56 MCU_TRAVEL ALARM SW
CN-10 43 0.8RW 1 CN-7 NO. DESTINATION
57 57 FUSE
1 NC 1 44 0.8B 2 1 1 NC
58 58 GND
2 NC 2 45 0.8WOr 3 2 2 NC
0
0.8Y 35A 59 59 POWER RY 0.8VW 23
3 ROOM LAMP 24V 3 46 0.8GW 4 3 3 NC
0,1
0.8G 51 60 60 BATT. RY 31 1.2ROr
4 SPEAKER RH- 4 5 4 4 FUSE
0.8V 53 0.8R 24 0.8G
5 SPEAKER RH+ 5 4 R 6 1
4 4 0.8G
5 5 BREAKER SW
0.8Y BREAK
52
6 B 0.8BW 5 5 0.8BW
6 SPEAKER LH- 6 7 2 6 6 BREAKER RY
0.8L 55 0.8R 24A CS-26 0.8B 6 6 0.8B
7 SPEAKER LH+ 7 8 1 7 7 GND
1.2B 24F 24 2B
30 1.2W
CS-2 HORN
R 0.8Grw 7 7 0.8Grw
9
H0 I
8 GND 8 10 I 2 8 8 HORN RY
1.2B 24G 1 0.8LW 25 CS-5 0.8L 8 8 0.8L
9 GND 9 46 0.8GW 8 10 9 9 NC
2
0, I
1.2BrW 58 2 L 0.8L 9 9 0.8L
10 BEACON LAMP 10 47 1.2R 11 10 10 NC
3 4
H
1.2V 28F 28 2V 12 11 0.8Br 30 0.8Gr 10 10 0.8Gr
11 CABIN LIGHT 11 12 11 11 NC
4
BR ACC
1.2V 28G 1 1 Gr
B
2 0.8Gr 11 11 0.8Gr
12 CABIN LIGHT 12
5 3 SPARE 12 12 NC
29 1.2BOr AIR COMP RY
HARNESS CABIN 6 CN-142 13 13
0.8Gr 12 12 0.8Gr
+ A 14 14 MCU_5V
ST C
5
6 0.8W 13 13 0.8W
S B 15 15 MCU_ACCEL SIG.
0.8B 14 14 0.8B
START KEY SW - C 16 16 MCU_SUPPLY GND
CN-116 ACCEL DIAL
12 NC
44 0.8B
11 GND
43 0.8RW
10 POWER 24V CS-33
9 NC 6 6
42 0.8YW
8 TRAVEL ALARM 5 5 HARNESS LH,CONSOL
41 0.8Gr
7 CABIN LIGHT OUT 4 4
40 0.8WOr
6 PRE-HEAT 3 3
49 0.8L
5 WASHER SIG 2 2 CN-4 NO. DESTINATION
48 0.8W
4 WIPER MOTOR DRIVE 1 1 1 1 NC
50 0.8Br
0.8VW
3 INT. SIG EM'CY STOP SW 2 2 NC
39
0.8BrW
2 WORK LIGHT OUT 3 3 NC
38
36E
36E
1 HEAD LIGHT OUT 4 4 NC

12F
25
68
18
63
31
0.8Y 4 4 0.8Y
51
17
35
12
53
16
37
37E
SWITCH PANEL 1 5 5 MCU_POWER MAX

36
power
max B 0.8B 5 5 0.8B
6 6 MCU_SIG.GND
0.5ROr
2
0.8ROr
0.8BOr
0.5BW
0.5GY
0.5YL
0.5LY
0.5Lg
0.8Or
cs-29 0.8Grw 6 6 0.8Grw

0.5V
0.5V
0.8G
0.8V
0.5B
0.8Y
0.8V
0.8B
1 7 7 MCU_DECEL
decel R 0.8B 7 7 0.8B
2 8 8 MCU_SIG.GND
cs-19 0.8L 8 8 0.8L
CN-246
CN-27
CN-27A
2 L 9 9 NC
9
1
4
5
10
11
12
13
14
15
16
2
4
5
0.8L
3
0.8L 9
10
1
2
3
4
5
6
7
9
8
10 10 NC
0.8Gr 10 10 0.8Gr
1 Gr 11 11 NC
0.8Gr 11 11 0.8Gr
REMOCON GND
12 12 NC
SPK FRT RH+
SPK FRT LH+

SPK FRT RH-
SPK FRT LH-
REMOCON+
CS-4 13 13 NC
USB(GND)
BACK UP+
AUX GND
AUX GND
TEL MUTE
USB GND
USB(D+)
0.8B 12 12 0.8B
USB(D-)
ANT 12V
B C
USB D+
AUX S1
USB 5V
GND
AUX S2
USB D-
A 14 14
AUX R
AUX L
USB+
HARNESS RH SIDE 0.8V 13 13 0.8V

GND
15 NC
ACC
B 15
ILL+
NC
NC
NC
NC
ILL-
NC
NC
NC
0.8G 14 14 0.8G
A C 16 16 SAFETY SOL
USB&SOCKET ASS'Y REMOTE ASS'Y CASSETTE RADIO SAFETY SW
2609S4EL06
4-6
MEMORANDUM
HYUNDAI HEAVY INDUSTRIES CO., LTD

CONSTRUCTION EQUIPMENT DIV.
4-7
1. POWER CIRCUIT (CLUSTER TYPE 1)
The negative terminal of battery is grounded to the machine chassis through master switch.
When the start switch is in the OFF position, the current flows from the positive battery terminal as
shown below.
1) OPERATING FLOW
Battery Battery relay Fusible link [CN-60] Master switch [CS-74]
Fuse box [No.1] Power relay [CR-35 (30)]
Fuse box [No.2] I/conn [CN-5 (46)] I/conn [CN -10 (3)] Room lamp [CL-1 (2)]
Door switch [CS-1]
Cassette radio [CN-27 (8)]
Hour meter [CN-48 (1)]
Fuse box [No.3] MCU controller [CN-51 (1)]
Fuse box [No.4] l/conn [CN-5 (36)] Start switch [CS-2 (1)]
RMS [CN-125A(1)]
Fuse box [No.5] l/conn [CN-11 (5)] AC & Heater controller
Blower relay
Fuse box [No.6] I/conn [CN - 5 (18)] I/conn [CN -17 (5)] Wiper motor controller
[CN-141 (7)]
Wiper motor [CN-21 (4)]
Fuse box [No.7] I/conn [CN - 5 (6)] I/conn [CN -56 (1)] Cluster
※ I/conn : Intermediate connector
2) CHECK POINT
Engine Start switch Check point Voltage
① - GND (battery 1EA) 10~12.5V

② - GND (battery 2EA) 20~25V
OFF OFF
③ - GND (battery 2EA) 20~25V
④ - GND (fusible link) 20~25V
※ GND : Ground
4-8
CN-141
MASTER SW
R
CONTINUE 24V 7
2
1
WIPER MOTOR CONTROLLER
CS-74B
CN-17
CN-21 1 2W CR-35
2W
2W
1 2 30
3 0.8WOr 87a 87 85
2 86
3
2WR
3 87
5 4 0.8B
R R 85
4 5
30 86
POWER RY
4 87a
5 6
0.8Gr
0.8RW
6 M 2 6 7 CN-5
8 1 CN-36
8
7
6
5
4
3
2
1
2 30A
CN-56
WIPER MOTOR 2W IG POWER
3 1
L
Gr
Y
B
W
0.8Y ROOM LAMP/CASSETTE 10A
WL
WR
RW
4 2
CN-125A 0.8Gr 1.2R MCU 30A
0.8W 5 3
BATTERT POWER 1 0.8RW 2W START KEY 30A
1.2R
TX
RX
6 4
SIG_2
GND
KEY "IG" 2
SIG_3
IG 24V
3Y 20A
5R
AIR CON/HEATER
BATT.24V
7 5
RMS 0.8R 10A
CAMERA SIG
WIPER
CLUSTER
8 6
6 0.8RW CLUSTER 10A
5
9
C ST
CS-2 7
17 0.8Gr CLUSTER 10A
6 0.8R 0.8R 8
18 MCU CONT. 20A
3 5 9
138
2 19 MCU_EPPR 20A
B
1
ACC BR
4 10
1.2R 20 10A
SWITCH PANEL
H
4 3
21 11
10A
0, I
POWER CIRCUIT (CLUSTER TYPE 1)
2 CASSETTE
1.2W 22 12
START KEY SW
1 FUEL CUT OFF-SOL. 10A
I 0 H
23 13
CONVERTER 20A
24 14
WORK LAMP 30A
31 15
CABIN LAMP(OPTION) 30A
32 16
33 WIPER 10A
17
4-9
34 HEAD LAMP 20A
18
35 FUEL HEATER 30A
CN-27 1.2W 1.2W 19
36 START,STOP 30A
ACC 1 20
37 HORN 10A
145 5W
ILL- 2 38 21
AC& HEATER 20A
NC 3 CN-48 39 22
SAFETY SOL 10A
SPK FRT RH- 4 3 42 23
h 2 OPTION 20A
SPK FRT LH- 5 0.8Y 43 24
1 SOLENOIDE 20A
TEL MUTE 6 44 25
20A
HOUR METER
ANT 12V 7 45 CIGAR
0.8Y 0.8Y 0.8Y 26
OPTION(BEACON) 20A
BACK UP+ 8 46 27
ILL+ 9 47 TRAVEL SOL 20A
28
CR-1
3
48 PRE-HEAT 10A
0.8Y
NC 10
29
57 20A
BATT RY
SPK FRT RH+ 11 FUEL P/P
CASSETTE RADIO
30
5
4
1
9
8
7
6
3
58
12
11
10
REMOCON+ 12 SPARE 10A
0.8WOr 0.8WOr
CN-10
59 31
FUSE BOX
REMOCON GND 13
60
SPK FRT LH+ 14
2
NC 15 CS-74A
60R
Gr
5R
Gr
GND 16
0.8Y
1
1
2
1
2
5R
CN-60
CN-95
2
CS-74
1
2
FUSIBLE LINK
CL-1
CN-11
MASTER SW
(12VX2)
CS-1
5R
1
5R
5W
BATTERY
5W
DOOR SW
BATTERY(+) 3 2
ROOM LAMP
4
ILLUMINATION 4 3
60B
W/TEMP SENSOR 10
1
4
AC & HEATER CONTROLLER(AUTO) 3Y
5
6
1 2 1 7
8
2609S4EL07
2
3
4 4 CN-51
3 1.2
BLOWER RY
BATT POWER 24V 1
MCU
■ POWER CIRCUIT (CLUSTER TYPE 2)
The negative terminal of battery is grounded to the machine chassis through master switch.
When the start switch is in the OFF position, the current flows from the positive battery terminal as
shown below.
1) OPERATING FLOW
Battery Battery relay Fusible link [CN-60] Master switch [CS-74]
Fuse box [No.1] Power relay [CR-35 (30)]
Fuse box [No.2] I/conn [CN-5 (46)] I/conn [CN -10 (3)] Room lamp [CL-1 (2)]
Door switch [CS-1]
Cassette radio [CN-27 (8)]
Hour meter [CN-48 (1)]
Fuse box [No.3] MCU controller [CN-50 (7)]
Fuse box [No.4] l/conn [CN-5 (36)] Start switch [CS-2 (1)]
Fuse box [No.5] l/conn [CN-11 (5)] AC & Heater controller
Blower relay
Fuse box [No.6] I/conn [CN - 5 (18)] I/conn [CN -17 (5)] Wiper motor controller
[CN-141 (7)]
Wiper motor [CN-21 (4)]
※ I/conn : Intermediate connector
2) CHECK POINT
① - GND (battery 1EA) 10~12.5V

② - GND (battery 2EA) 20~25V
OFF OFF
③ - GND (battery 2EA) 20~25V
④ - GND (fusible link) 20~25V
※ GND : Ground
4-10
CN-141
MASTER SW
R
CONTINUE 24V 7
2
1
CS-74B
CN-17
CN-21 1 2W CR-35
2W
2W
1 2 30
3 0.8WOr 87a 87 85
2 86
3
2WR
3 87
5 4 0.8B
R R 85
4 5
30 86
POWER RY
4 87a
5 6
BR
6 M 2 6 7 CN-5
8 1 CN-36
4
3
2
1
WIPER MOTOR 2 2W IG POWER 30A
CN-56
3 1
0.8Y ROOM LAMP/CASSETTE 10A
RR
4 2
0.8Gr 1.2R MCU 30A
5 3
2W START KEY 30A
6 4
3Y 20A
5R
AIR CON/HEATER
TX
RX
7 5
GND
0.8R WIPER 10A
8 6
POWER IG(24V)
CLUSTER
9 SPARE 10A
0.8W 0.8W 7
14 0.8Gr CLUSTER 10A
8
6 15 MCU CONT. 20A
5 9
C ST
CS-2
138
16 FUEL CUT OFF 10A

6 10
17 SWITCH PANEL 10A
5 0.8R 0.8R 11
3 18
2 CASSETTE 10A
B
1
POWER CIRCUIT (CLUSTER TYPE 2)
ACC BR
4 19 12
1.2R SPARE 30A
H
4 3 20 13
CONVERTER 20A
0, I
2 21 14
1.2W 30A
WORK LAMP
START KEY SW
1 31 15
I 0 H
32 16
33 WIPER 10A
17
34 HEAD LAMP 20A
18
4-11
35 FUEL HEATER 30A
CN-27 1.2W 1.2W 19
36 START,STOP 30A
ACC 1 20
37 HORN 10A
145 5W
ILL- 2 38 21
AC& HEATER 20A
NC 3 CN-48 39 22
0.8W SAFETY SOL 10A
SPK FRT RH- 4 3 42 23
h 2 OPTION 20A
SPK FRT LH- 5 0.8Y 43 24
1 SOLENOIDE 20A
TEL MUTE 6 44 25
20A
HOUR METER
ANT 12V 7 45 CIGAR
0.8Y 0.8Y 0.8Y 26
OPTION(BEACON) 20A
BACK UP+ 8 46 27
ILL+ 9 47 TRAVEL SOL 20A
28
CR-1
3
NC 10 48 PRE-HEAT 10A
0.8Y
29
57 20A
BATT RY
SPK FRT RH+ 11 FUEL P/P
CASSETTE RADIO
30
5
4
1
9
8
7
6
3
58
12
11
10
REMOCON+ 12 SPARE 10A
0.8WOr 0.8WOr
CN-10
59 31
FUSE BOX
REMOCON GND 13
60
SPK FRT LH+ 14
2
NC 15 CS-74A
60R
Gr
5R
Gr
GND 16
0.8Y
1
1
2
1
2
5R
CN-60
CN-95
2
CS-74
1
2
FUSIBLE LINK
CL-1
CN-11
MASTER SW
(12VX2)
CS-1
5R
1
5R
5W
BATTERY
5W
DOOR SW
BATTERY(+) 3 2
ROOM LAMP
4
ILLUMINATION 4 3
60B
W/TEMP SENSOR 10
1
4
AC & HEATER CONTROLLER(AUTO) 3Y
5
6
1 2 1 7
2 8
3
2609S4EL08
4 4 CN-50
3 GY
BLOWER RY
BATTERY 24V(+) 7
HOUR METER 22
MCU
2. STARTING CIRCUIT (CLUSTER TYPE 1)
1) OPERATING FLOW
Battery(+) terminal Battery relay [CR-1] Fusible link [CN-60] Master switch [CS-74]
Fuse box [No.4] Master switch [CS-74B] I/conn [CN-5(36)] Start switch [CS-2(1)]
(1) When start key switch is in ON position
Start switch ON [CS-2 (2)] I/conn [CN-5 (60)] Battery relay [CR-1]
Battery relay operating (all power is supplied with the electric component)
Start switch ON [CS-2 (3)] I/conn [CN-5 (59)] Power relay [CR-35 (86) → (87)]
Fuse box [No.10]
GPS [CN-125A (2)]
(2) When start key switch is in START position
Start switch START [CS-2 (6)] I/conn [CN-5 (35)] Anti-restart relay [CR-5 (86) → (87)]
l/conn [CN-3 (2)] Start relay [CR-23]
l/conn [CN-2 (8)] Fuel cut off solenoid
2) CHECK POINT
① - GND (battery)
② - GND (start key)
③ - GND (battery relay M4)
OPERATING START ④ - GND (starter B+) 20~25V
⑤ - GND (starter M)
⑥ - GND (start relay)
⑦ - GND (battery relay M8)
※ GND : Ground
4-12
CN-5
1
MASTER SW
2
2
1
3
CS-74B
4
5 2W CR-35
2W
2W
30
6 0.8WOr 87a 87 85
86
7 2WR
87
8 0.8B
CN-125A 85
0.8W 9 30 86
POWER RY
BATTERT POWER 1 87a
1.2R 17
KEY "IG" 2
18
RMS
19 CN-36
20 2W IG POWER 30A
1
21 ROOM LAMP/CASSETTE 10A
22 2
MCU 30A
23 3
6 2W START KEY 30A
5
ST C
CS-2 1.2BOr 24 4
AIR CON/HEATER 20A
6 31 5
5 WIPER 10A
3 32 6
2
B
10A
BR ACC
1 CLUSTER
5R
4 33
1.2R 7
10A
H
4 3 34 CLUSTER
0.8GW 1.2BOr 0.8BOr 8
20A
0, I
2 35 MCU CONT.
1.2W 1.2W 1.2W 9
138
1 36 20A
START KEY SW
MCU_EPPR
H 0 I
10
37 SWITCH PANEL 10A
11
38 CASSETTE 10A
2
39 12
0.8 FUEL CUT OFF-SOL. 10A
57 CN-51 0.8V
13
CONVERTER 20A
ANTI-RESTART RY 20
STARTING CIRCUIT (CLUSTER TYPE 1)
58 14
0.8WOr 0.8WOr WORK LAMP 30A
59 MCU 15
0.8GW 0.8GW CABIN LAMP(OPTION) 30A
60 16
CN-52 WIPER 10A
ALT LEVEL 27 17
HEAD LAMP 20A
MCU 18
4-13
FUEL HEATER 30A
19
2Y
2W
2Y START,STOP 30A
0.8Br
0.8BOr
20
5W
HORN 10A
21
20A
87
AC& HEATER
145
85
86
30
87a
22
CR-5
0.8
2B
10A
0.8B
0.8
2W
SAFETY SOL
0.8W
23
OPTION 20A
30
87a 87
24
20A
86
3
3
2
2
9
8
7
6
5
4
9
8
7
6
5
4
1
1
85
12
11
10
15
14
13
12
11
10
SOLENOIDE
25
CN-3
CN-2
3
CIGAR 20A
1.2B
1.2G
26
0.8B
0.8G
ANTI-RESTART RY
OPTION(BEACON) 20A
2B
2W
27
1.2LW
20A
2
TRAVEL SOL
1
28
CR-1
DO-3
B
PRE-HEAT 10A
Gr
6
29
DIODE
20A
7
BATT RY
FUEL P/P
30
SPARE 10A
3W/300
1
2
31
FUSE BOX
2
1
RS-1
1
CS-74A
60R
CR-23
5R
1
START RY
1
2
1
2
5R
CN-60
CN-95
2
CS-74
5R
5R
5W
5W
MASTER SW
FUSIBLE LINK
(12VX2)
4
BATTERY
60B
1.2W
B+
2B
2W
CN-45
15 R
1.2LW
4
3
2
1
F
M
H
G
L
P
FI
STARTER
2609S4EL09
B+
NC
ALT
CN-79
CN-74
3
~
G
U
FUEL CUT OFF SOL
■ STARTING CIRCUIT (CLUSTER TYPE 2)
1) OPERATING FLOW
Battery(+) terminal Battery relay [CR-1] Fusible link [CN-60] Master switch [CS-74]
Fuse box [No.4] Master switch [CS-74B] I/conn [CN-5(36)] Start switch [CS-2(1)]
(1) When start key switch is in ON position
Start switch ON [CS-2 (2)] I/conn [CN-5 (60)] Battery relay [CR-1]
Battery relay operating (all power is supplied with the electric component)
Start switch ON [CS-2 (3)] I/conn [CN-5 (59)] Power relay [CR-35 (86) → (87)]
Fuse box [No.10]
(2) When start key switch is in START position
Start switch START [CS-2 (6)] I/conn [CN-5 (35)] Anti-restart relay [CR-5 (86) → (87)]
I/conn [CN-3 (2)] Start relay [CR-23]
l/conn [CN-2 (8)] Fuel cut off solenoid
2) CHECK POINT
① - GND (battery)
② - GND (start key)
③ - GND (battery relay M4)
OPERATING START ④ - GND (starter B+) 20~25V
⑤ - GND (starter M)
⑥ - GND (start relay)
⑦ - GND (battery relay M8)
※ GND : Ground
4-14
CN-5
1
MASTER SW
2
2
1
3
CS-74B
4
5 2W CR-35
2W
2W
30
6 0.8WOr 87a 87 85
86
7 2WR
87
8 0.8B
85
9 30 86
POWER RY
87a
17
18
19 CN-36
20 2W IG POWER 30A
1
21 ROOM LAMP/CASSETTE 10A
22 2
MCU 30A
23 3
6 2W START KEY 30A
5
ST C
CS-2 1.2BOr 24 4
AIR CON/HEATER 20A
6 31 5
5 WIPER 10A
3 32 6
2
B
10A
BR ACC
1 SPARE
5R
4 33
1.2R 7
10A
H
4 3 34 CLUSTER
0.8GW 1.2BOr 0.8BOr 8
20A
0, I
2 35 MCU CONT.
1.2W 1.2W 1.2W 9
138
1 10A
START KEY SW
36 1.2R FUEL CUT OFF
H 0 I
10
37 SWITCH PANEL 10A
11
38 CASSETTE 10A
2
39 12
SPARE 30A
57 CN-50 V/W
13
CONVERTER 20A
ANTI-RESTART RY 11
STARTING CIRCUIT (CLUSTER TYPE 2)
58 14
0.8WOr 0.8WOr WORK LAMP 30A
59 MCU 15
0.8GW 0.8GW CABIN LAMP(OPTION) 30A
60 16
CN-51 WIPER 10A
W
ALT LEVEL 9 17
HEAD LAMP 20A
MCU 18
4-15
FUEL HEATER 30A
19
2Y
2W
2.0Y START,STOP 30A

0.8Br
0.8BOr
20
5W
HORN 10A
21
20A
87
AC& HEATER
145
85
86
30
87a
22
CR-5
0.8
2B
10A
0.8B
0.8
2W
SAFETY SOL
0.8W
23
OPTION 20A
30
87a 87
24
20A
86
3
3
2
2
9
8
7
6
5
4
9
8
7
6
5
4
1
1
85
12
11
10
15
14
13
12
11
10
SOLENOIDE
25
CN-3
CN-2
3
CIGAR 20A
1.2B
1.2G
26
0.8B
0.8G
ANTI-RESTART RY
OPTION(BEACON) 20A
2B
2W
27
1.2LW
20A
2
TRAVEL SOL
1
28
CR-1
DO-3
B
PRE-HEAT 10A
Gr
6
29
DIODE
20A
7
BATT RY
FUEL P/P
30
SPARE 10A
3W/300
1
2
31
FUSE BOX
2
1
RS-1
1
CS-74A
60R
CR-23
5R
1
START RY
1
2
1
2
5R
CN-60
CN-95
2
CS-74
5R
5R
5W
5W
MASTER SW
FUSIBLE LINK
(12VX2)
4
BATTERY
60B
1.2W
B+
2B
2W
CN-45
15 R
1.2LW
4
3
2
1
F
M
H
G
L
P
FI
STARTER
2609S4EL10
B+
NC
ALT
CN-79
CN-74
3
~
G
U
FUEL CUT OFF SOL
3. CHARGING CIRCUIT (CLUSTER TYPE 1)
When the starter is activated and the engine is started, the operator releases the key switch to the
ON position.
Charging current generated by operating alternator flows into the battery through the battery relay
[CR-1].
The current also flows from alternator to each electrical component and controller through the fuse box.
1) OPERATING FLOW
(1) Warning flow
Alternator "I" terminal I/conn [CN-3 (3)] MCU alternator level [CN-52 (27)]
Cluster charging warning lamp(Via serial interface)
(2) Charging flow

Alternator "B+" terminal Battery relay(M8) Battery(+) terminal
Fusible link [CN-60] Master switch [CS-74]
Fuse box
2) CHECK POINT
① - GND (battery voltage)

② - GND (battery relay)
Run ON ③ - GND (alternator B+ terminal) 20~30V
④ - GND (alternator I terminal)
⑤ - GND (MCU)
※ GND : Ground
4-16
SH
0.8L
0.8Y
CN-51 CN-36
5
4
1
9
8
7
6
3
60
59
58
57
24
23
22
21
20
19
18
17
30A
0.8L
IG POWER
0.8Y
BATT POWER_24V 1
CN-5
1
POWER IG 2 ROOM LAMP/CASSETTE 10A
SH
2
8
7
6
5
4
3
2
1
POWER_24V OUT 3
0.8L
0.8Y
MCU 30A
CN-56
TACHO SENSOR+ 4 3
5 START KEY 30A
L
Gr
Y
B
W
WL
WR
RW
CAN1 Hi
4
21 20A
AIR CON/HEATER
nc 22 5
0.8L 10A
RS485+(TX)-CLUSTER 23 WIPER
6
TX
RX
RS232C1_TX-HRDT 24 10A
SIG_2
GND
CLUSTER
5R
SIG_3
IG 24V
RS232C2_TX-RCM 25 7
BATT.24V
CLUSTER 10A
CAMERA SIG
CLUSTER
8
ENG OIL PS 27 MCU CONT. 20A
coolent level 28 9
MCU_EPPR 20A
AIR CLEANER SW(NO) 29 10
BLOWER SIG. 30 SWITCH PANEL 10A
CAN1 Lo 31
11
CASSETTE 10A
nc 32 12
0.8Y
RS485-(RX)-CLUSTER 33 FUEL CUT-OFF SOL. 10A
13
CONVERTER 20A
ENGINE OIL FILTER 37 14
nc WORK LAMP 30A
38
15
nc 39 CABIN LAMP(OPTION) 30A
nc 40 16
WIPER 10A
17
CN-52 HEAD LAMP 20A
MCU
18
ARM REGEN SOL 1 30A
FUEL HEATER
POWER MAX SOL 2 19
CHARGING CIRCUIT (CLUSTER TYPE 1)
TRAVEL SPEED SOL 3 START,STOP 30A

20
5W
ATT_ SAFETY SOL 4 HORN 10A

ATT_PRESS SOL. 5 21
AC& HEATER 20A
145
ATT_CONFLUX SOL. 6 22
10A
0.8B
SAFETY SOL
0.8W
4-17
23
OPTION 20A
FUEL LEVEL SENSOR 26 24
20A
3
2
9
8
7
6
5
4
1
ALT. LEVEL
12
11
10
27 SOLENOIDE
25
CN-3
GOV. POTENTIO SIG. 28 20A
CIGAR
1.2B
P1 PRESS SENSOR 29 26
0.8B
4
P2 PRESS SENSOR 30 OPTION(BEACON) 20A
27
20A
2
TRAVEL SOL
1
SWING PRESS SENSOR 36 28
CR-1
DO-3
B
PRE-HEAT 10A
Gr
WORK PRESS SENSOR(A) 37 29
DIODE
TRAVEL PRESS SENSOR(A) 20A
2
38
OVERLOAD SIG 39
BATT RY FUEL P/P
30
SPARE 10A
3W/300
1
2
nc 40 31
FUSE BOX
2
1
RS-1
1
CS-74A
60R
CR-23
5R
1
START RY
1
2
1
2
5R
CN-60
CN-95
2
CS-74
5R
5R
5W
5W
MASTER SW
FUSIBLE LINK
(12VX2)
BATTERY
60B
1.2W
3
B+
CN-45
15 R
4
3
2
1
M
L
P
FI
B+
NC
ALT
STARTER
CN-74
3
~
G
2609S4EL11
■ CHARGING CIRCUIT (CLUSTER TYPE 2)
When the starter is activated and the engine is started, the operator releases the key switch to the
ON position.
Charging current generated by operating alternator flows into the battery through the battery relay
[CR-1].
The current also flows from alternator to each electrical component and controller through the fuse box.
1) OPERATING FLOW
(1) Warning flow
Alternator "I" terminal I/conn [CN-3 (3)] MCU alternator level [CN-51 (9)]
Cluster charging warning lamp(Via serial interface)
(2) Charging flow

Alternator "B+" terminal Battery relay(M8) Battery(+) terminal
Fusible link [CN-60] Master switch [CS-74]
Fuse box
2) CHECK POINT
① - GND (battery voltage)

② - GND (battery relay)
Run ON ③ - GND (alternator B+ terminal) 20~30V
④ - GND (alternator I terminal)
⑤ - GND (MCU)
※ GND : Ground
4-18
CN-51
SH
0.8L
0.8Y
WORKING PS 1
POWER MAX SW 2 CN-36
L
Y
5
4
1
9
8
7
6
3
TRAVEL ALARM SW 3
60
59
58
57
24
23
22
21
20
19
18
17
IG POWER 30A
CN-5
ENG OIL PS 4 1
NC 5
ROOM LAMP/CASSETTE 10A
SH
2
4
3
2
1
0.8L
0.8Y
NC 6 MCU 30A
CN-56
24V(PRES.SENSOR) 7 3
4
START KEY 30A
GND(PRES.SENSOR) 8 4
RR
W 20A
ALT LEVEL 9 AIR CON/HEATER
5
P1 PRESS SIG. 10 WIPER 10A
P2 PRESS SIG. 11 6
SPARE 10A
5R
P3 PRESS SIG. 12 7
TX
RX
GND
TRAVEL PS 13 CLUSTER 10A
O/T DECEL SW 14
8
20A
POWER IG(24V)
MCU CONT.
CLUSTER
WATER LEVEL SW 15 9
AIR CLEANER SW 16 FUEL CUT OFF 10A
10
NC 17 SWITCH PANEL 10A
NC 18 11
CASSETTE 10A
NC 19 12
GND (POT&DIAL) 20 SPARE 30A
5V (POT&DIAL)
13
21 20A
CONVERTER
22 14
WORK LAMP 30A
CN-50 15
MCU
BOOM PRIORITY SOL 1 16
MAX FLOW SOL. 2 WIPER 10A
17
POWER MAX SOL. 3 20A
HEAD LAMP
HOUR-METER 4 18
FUEL HEATER 30A
ENG PREHEATER 5 19
CHARGING CIRCUIT (CLUSTER TYPE 2)
FUEL HEATER 6 START,STOP 30A

20
5W
BATTERY 24V(+) 7
HORN 10A
PUMP EPPR(-) 8 21
AC& HEATER 20A
145
NC 9
22
10 10A
0.8B
SAFETY SOL
0.8W
4-19
NC 25 23
OPTION 20A
NC 26 24
20A
3
2
9
8
7
6
5
4
1
NC
12
11
10
27 SOLENOIDE
25
CN-3
GND (MAIN) 28 20A
Y 1.2B CIGAR
SERIAL-TX 29 26
0.8B
L OPTION(BEACON) 20A
SERIAL-RX 30
27
GND 31 20A
2
TRAVEL SOL
1
RS232 (+) 32 28
CR-1
DO-3
B
PRE-HEAT 10A
Gr
RS232 (-) 33 29
DIODE
20A
2
BATT RY
RS232 (GND) 34 FUEL P/P
NC
30
35 10A
SPARE
3W/300
1
2
PUMP EPPR(+) 36 31
FUSE BOX
2
1
RS-1
1
CS-74A
60R
CR-23
5R
1
START RY
1
2
1
2
5R
CN-60
CN-95
2
CS-74
5R
5R
5W
5W
MASTER SW
FUSIBLE LINK
(12VX2)
BATTERY
60B
1.2W
3
B+
CN-45
15 R
4
3
2
1
M
L
P
FI
B+
NC
ALT
STARTER
CN-74
3
~
G
2609S4EL12
4. HEAD AND WORK LIGHT CIRCUIT (CLUSTER TYPE 1)
1) OPERATING FLOW
Fuse box (No.15) Work light relay [CR-4 (30, 86)]
Fuse box (No.18) Head light relay [CR-13 (30, 86)]
(1) Head light switch ON
Head light switch ON [CN-116 (1)] l/conn [CN-5 (49)] Head light relay [CR-13 (85) → (87)]
Head light ON [CL-3 (1), CL-4 (1)]
l/conn [CN-11 (8)] AC & Heater controller illumination ON [4]
l/conn [CN-5 (13)] Cassette radio illumination ON [CN-27 (9)]
Cigar light [CL-2]
l/conn [CN-8 (7)] Accel dial LED ON
(2) Work light switch ON

Work light switch ON [CN-116 (2)] l/conn [CN-5 (50)] Work light relay [CR-4 (85) → (87)]
l/conn [CN-12 (1)] Work light ON [CL-5 (2), CL-6 (2)]
2) CHECK POINT
① - GND (fuse box)

② - GND (switch power output)
③ - GND (head light relay)
④ - GND (head light)
STOP ON 20~25V
⑤ - GND (fuse box)
⑥- GND (switch power output)
⑦ - GND (work light relay)
⑧ - GND (work light)
※ GND : Ground
4-20
ACCEL DIAL LED
NC
GND
2
1
IG 24V
CN-279
CN-36
POWER IG
BATTERY(+)
IG POWER 30A
ILLUMINATION
ILLUMINATION
REVERSE FAN
1
0.8B
INCAR SENSOR
POWER TR BASE
W/TEMP SENSOR
0.8ROr
DUCT SENSOR(+)
AMBIENT SENSOR
2
MCU 30A
DUCT SENSOR(GND)
3
START KEY 30A
4
20A
9
8
7
6
5
4
3
2
1
AIR CON/HEATER
14
13
12
11
10
5
WIPER 10A
6
CLUSTER 10A
7
CLUSTER 10A
CN-5 8
20A
AC & HEATER CONTROLLER(AUTO)

MCU CONT.
0.8ROr
1 9
MCU_EPPR 20A
2 10
2
2
5
5
7
6
4
1
4
1
8
7
6
3
3
12
11
10
SWITCH PANEL 10A
3
CN-8
11
CN-11
CASSETTE 10A
CN-27 4 12
0.8
1
ACC 1 FUEL CUT-OFF SOL. 10A
5
0.8ROr
13
ILL- 2 6 CONVERTER 20A
14
NC 3 7 2RW WORK LAMP 30A
15
SPK FRT RH- 4 8 CABIN LAMP(OPTION) 30A
16
SPK FRT LH- 5 9 10A
WIPER
TEL MUTE 6 10 17
1.2Br HEAD LAMP 20A
ANT 12V 7 11 18
FUEL HEATER 30A
BACK UP+ 8 12 19
0.8ROr 0.8ROr 0.8ROr START,STOP 30A
ILL+ 9 13 20
10A
5
HORN
NC 10 14 21
AC& HEATER 20A
SPK FRT RH+ 11 15
CASSETTE RADIO
22
4-21
REMOCON+ 12 16 SAFETY SOL 10A
23
REMOCON GND 13 17 OPTION 20A
24
SPK FRT LH+ 14 18 SOLENOIDE 20A
CL-2 25
NC 15 19 CIGAR 20A
26
GND 16 20 OPTION(BEACON) 20A
HEAD AND WORK LIGHT CIRCUIT (CLUSTER TYPE 1)
21 27
ROr TRAVEL SOL 20A
28
41 PRE-HEAT 10A
CIGAR LIGHT
42 29
FUEL P/P 20A
43 30
SPARE 10A
44 31
8
FUSE BOX
45
2B
2RG
2
46
47
1
2
CN-116 48
CN-12
0.8BrW 0.8BrW 0.8BrW

HEAD LIGHT OUT 1 49
0.8VW 0.8VW 0.8VW
WORK LIGHT OUT 2 50
INT. SIG 3 51
7
WIPER MOTOR DRIVE 4 52

WASHER SIG 5 53
6
0.8Br
0.8RW
3 4
3 4
PRE-HEAT 6 54
V
B
V
B
1.2ROr
2RG
0.8BrW
0.8VW
1.2B
1.2B
2RW
1.2Br
1.2ROr
1.2ROr
CABIN LIGHT OUT 7 55

TRAVEL ALARM 8 56
1
1
2
2
1
87
87
2
85
85
1
86
86
2
30
30
87a
87a
CL-4
CL-3
CL-6
57
CR-4
CL-5
NC 9
SWITCH PANEL
CR-13
POWER 24V 10 58
GND 11 59
HEAD LAMP
HEAD LAMP
30 86
30 86
87a 87 85
87a 87 85
NC 12 60
WORK LAMP
HEAD LAMP RY
WORK LAMP RY
2609S4EL13
■ HEAD AND WORK LIGHT CIRCUIT (CLUSTER TYPE 2)
1) OPERATING FLOW
Fuse box (No.15) Work light relay [CR-4 (30, 86)]
Fuse box (No.18) Head light relay [CR-13 (30, 86)]
(1) Head light switch ON
Head light switch ON [CN-116 (1)] l/conn [CN-5 (49)] Head light relay [CR-13 (85) → (87)]
Head light ON [CL-3 (1), CL-4 (1)]
l/conn [CN-11 (8)] AC & Heater controller illumination ON [4]
l/conn [CN-5 (13)] Cassette radio illumination ON [CN-27 (9)]
Cigar light [CL-2]
l/conn [CN-8 (7)] Accel dial LED ON
(2) Work light switch ON

Work light switch ON [CN-116 (2)] l/conn [CN-5 (50)] Work light relay [CR-4 (85) → (87)]
l/conn [CN-12 (1)] Work light ON [CL-5 (2), CL-6 (2)]
2) CHECK POINT

② - GND (switch power output)
③ - GND (head light relay)
④ - GND (head light)
STOP ON 20~25V
⑥- GND (switch power output)
⑦ - GND (work light relay)
⑧ - GND (work light)
※ GND : Ground
4-22
ACCEL DIAL LED
NC
GND
2
1
IG 24V
CN-279
CN-36
POWER IG
BATTERY(+)
IG POWER 30A
ILLUMINATION
ILLUMINATION
REVERSE FAN
1
0.8B
INCAR SENSOR
POWER TR BASE
W/TEMP SENSOR
0.8ROr
DUCT SENSOR(+)
AMBIENT SENSOR
2
MCU 30A
DUCT SENSOR(GND)
3
START KEY 30A
4
20A
9
8
7
6
5
4
3
2
1
AIR CON/HEATER
14
13
12
11
10
5
WIPER 10A
6
SPARE 10A
7
CLUSTER 10A
CN-5 8
20A
AC & HEATER CONTROLLER(AUTO)

MCU CONT.
0.8ROr
1 9
FUEL CUT OFF 10A
2 10
2
2
5
5
7
6
4
1
4
1
8
7
6
3
3
12
11
10
SWITCH PANEL 10A
3
CN-8
11
CN-11
CASSETTE 10A
CN-27 4 12
0.8
1
ACC 1 SPARE 30A
5
0.8ROr
13
ILL- 2 6 CONVERTER 20A
14
NC 3 7 2RW WORK LAMP 30A
15
SPK FRT RH- 4 8 CABIN LAMP(OPTION) 30A
16
SPK FRT LH- 5 9 10A
WIPER
TEL MUTE 6 10 17
1.2Br HEAD LAMP 20A
ANT 12V 7 11 18
FUEL HEATER 30A
BACK UP+ 8 12 19
0.8ROr 0.8ROr 0.8ROr START,STOP 30A
ILL+ 9 13 20
10A
5
HORN
NC 10 14 21
AC& HEATER 20A
SPK FRT RH+ 11 15
CASSETTE RADIO
22
10A
4-23
REMOCON+ 12 16 SAFETY SOL
23
REMOCON GND 13 17 OPTION 20A
24
SPK FRT LH+ 14 18 SOLENOIDE 20A
CL-2 25
NC 15 19 CIGAR 20A
26
GND 16 20 OPTION(BEACON) 20A
HEAD AND WORK LIGHT CIRCUIT (CLUSTER TYPE 2)
21 27
ROr TRAVEL SOL 20A
28
41 PRE-HEAT 10A
CIGAR LIGHT
42 29
FUEL P/P 20A
43 30
SPARE 10A
44 31
8
FUSE BOX
45
2B
2RG
2
46
47
1
2
CN-116 48
CN-12
0.8BrW 0.8BrW 0.8BrW

HEAD LIGHT OUT 1 49
0.8VW 0.8VW 0.8VW
WORK LIGHT OUT 2 50
INT. SIG 3 51
7

WASHER SIG 5 53
6
0.8Br
0.8RW
3 4
3 4
PRE-HEAT 6 54
V
B
V
B
1.2ROr
2RG
0.8BrW
0.8VW
1.2B
1.2B
2RW
1.2Br
1.2ROr
1.2ROr

TRAVEL ALARM 8 56
1
1
2
2
1
87
87
2
85
85
1
86
86
2
30
30
87a
87a
CL-3
CL-6
57
CL-4
CR-4
CL-5
NC 9
SWITCH PANEL
CR-13
POWER 24V 10 58
GND 11 59
HEAD LAMP
HEAD LAMP
30 86
30 86
87a 87 85
87a 87 85
NC 12 60
WORK LAMP
HEAD LAMP RY
WORK LAMP RY
2609S4EL14
5. BEACON LAMP AND CAB LIGHT CIRCUIT (CLUSTER TYPE 1)
1) OPERATING FLOW
Fuse box (No. 27) I/conn [CN-5 (33)] Beacon lamp switch [CN-23 (8)]
Fuse box (No.16) Cab light relay [CR-9 (30, 86)]
(1) Beacon lamp switch ON
Beacon lamp switch ON [CS-23 (4)] Switch indicator lamp ON [CS-23 (11)]
l/conn [CN-10 (10)] Beacon lamp ON [CL-7]
(2) Cab light switch ON
Cab light switch ON [CN-116 (7)] I/conn [CN-5 (55)] Cabin light relay [CR-9 (85) → (87)]
I/conn [CN-5 (34)] I/conn [CN-10 (11, 12)] Cab light ON [CL-8 (2), CL-9 (2)]
2) CHECK POINT

② - GND (switch power input)
③ - GND (switch power output)
④ - GND (beacon lamp)
STOP ON 20~25V
⑥ - GND (cab light relay)
⑦ - GND (switch power output)
⑧ - GND (cab light)
※ GND : Ground
4-24
CN-36
IG POWER 30A
1
2
MCU 30A
12
M
3
4
9
12
10
3
CL-7
CL-9
CL-8
START KEY 30A
4
AIR CON/HEATER 20A
2
2
1
1
5
WIPER 10A
CAB LIGHT-LH
7
8
CAB LIGHT-RH
2
11
6
BEACON LAMP
CLUSTER 10A
1.2B
7
1.2B
2.0V
2.0V
1.2B
10
11
5
9
12
4
8
4
1
2
3
6
7
1.2BrW
CLUSTER 10A
CS-23
8
BEACON LAMP SW
8
MCU CONT. 20A
9
0.8B
MCU_EPPR 20A
1.2BrW
1.2Br
0.8BrW
10
SWITCH PANEL 10A
11
10A
3
CASSETTE
12
2
FUEL CUT-OFF SOL. 10A
13
5
CONVERTER 20A
14
WORK LAMP 30A
15
5
4
1
9
8
7
6
3
12
11
10
2R CABIN LAMP(OPTION) 30A
16
CN-10
CN-5
WIPER 10A
1 17
HEAD LAMP 20A
2 18
FUEL HEATER 30A
3 19
4 START,STOP 30A
20
5 HORN 10A
21
6 AC& HEATER 20A
22
7 SAFETY SOL 10A
23
8 20A
4-25
1.2B 1.2B OPTION
30 24
1
1.2B 1.2B SOLENOIDE 20A

31 25
CIGAR 20A
32 26
1.2Br 1.2Br 1.2Br OPTION(BEACON) 20A
33 27
1.2V 1.2V TRAVEL SOL 20A
34 28
PRE-HEAT 10A
35 29
FUEL P/P 20A
36 30
37 SPARE 10A
CN-116 0.8V 0.8V 31
FUSE BOX
1 38
HEAD LIGHT OUT
BEACON LAMP AND CAB LIGHT CIRCUIT (CLUSTER TYPE 1)
2 39
WORK LIGHT OUT
INT. SIG 3 51
WIPER MOTOR DRIVE 52
7
4
WASHER SIG 5 53
PRE-HEAT 6 54
0.8Gr 0.8Gr 0.8Gr
6

TRAVEL ALARM 8 56
0.8R
NC 9 57
2V
SWITCH PANEL
0.8Gr
58
2R
POWER 24V 10
GND 11 59
87
85
86
30
NC 12 60
87a
CR-9
30 86
87a 87 85
CABIN LAMP RY
2609S4EL15
■ BEACON LAMP AND CAB LIGHT CIRCUIT (CLUSTER TYPE 2)
1) OPERATING FLOW
Fuse box (No. 27) I/conn [CN-5 (33)] Beacon lamp switch [CN-23 (8)]
Fuse box (No.16) Cab light relay [CR-9 (30, 86)]
(1) Beacon lamp switch ON
Beacon lamp switch ON [CS-23 (4)] Switch indicator lamp ON [CS-23 (11)]
l/conn [CN-10 (10)] Beacon lamp ON [CL-7]
(2) Cab light switch ON
Cab light switch ON [CN-116 (7)] I/conn [CN-5 (55)] Cabin light relay [CR-9 (85) → (87)]
I/conn [CN-5 (34)] I/conn [CN-10 (11, 12)] Cab light ON [CL-8 (2), CL-9 (2)]
2) CHECK POINT

④ - GND (beacon lamp)
STOP ON 20~25V
⑥ - GND (cab light relay)
⑦ - GND (switch power output)
⑧ - GND (cab light)
※ GND : Ground
4-26
CN-36
IG POWER 30A
1
2
MCU 30A
12
M
3
4
9
12
10
3
CL-7
CL-9
CL-8
START KEY 30A
4
AIR CON/HEATER 20A
2
2
1
1
5
WIPER 10A
CAB LIGHT-LH
7
8
CAB LIGHT-RH
2
11
6
BEACON LAMP
SPARE 10A
1.2B
7
1.2B
2.0V
2.0V
1.2B
10
11
5
9
12
4
8
4
1
2
3
6
7
1.2BrW
CLUSTER 10A
CS-23
8
BEACON LAMP SW
8
MCU CONT. 20A
9
0.8B
FUEL CUT OFF 10A
1.2BrW
1.2Br
0.8BrW
10
SWITCH PANEL 10A
11
10A
3
CASSETTE
12
2
SPARE 30A
13
5
CONVERTER 20A
14
WORK LAMP 30A
15
5
4
1
9
8
7
6
3
12
11
10
2R CABIN LAMP(OPTION) 30A
CN-5 16
CN-10
WIPER 10A
1 17
HEAD LAMP 20A
2 18
FUEL HEATER 30A
3 19
4 START,STOP 30A
20
5 HORN 10A
21
6 AC& HEATER 20A
22
7 SAFETY SOL 10A
23
8 20A
4-27
1.2B 1.2B OPTION
30 24
1
1.2B 1.2B SOLENOIDE 20A

31 25
CIGAR 20A
32 26
1.2Br 1.2Br 1.2Br OPTION(BEACON) 20A
33 27
1.2V 1.2V TRAVEL SOL 20A
34 28
PRE-HEAT 10A
35 29
FUEL P/P 20A
36 30
37 SPARE 10A
CN-116 0.8V 0.8V 31
FUSE BOX
1 38
HEAD LIGHT OUT
BEACON LAMP AND CAB LIGHT CIRCUIT (CLUSTER TYPE 2)
2 39
WORK LIGHT OUT
INT. SIG 3 51
WIPER MOTOR DRIVE 52
7
4
WASHER SIG 5 53
PRE-HEAT 6 54
0.8Gr 0.8Gr 0.8Gr
6

TRAVEL ALARM 8 56
0.8R
NC 9 57
2V
SWITCH PANEL
0.8Gr
58
2R
POWER 24V 10
GND 11 59
87
85
86
30
NC 12 60
87a
CR-9
30 86
87a 87 85
CABIN LAMP RY
2609S4EL16
6. WIPER AND WASHER CIRCUIT (CLUSTER TYPE 1)
1) OPERATING FLOW
(1) Key switch ON
Fuse box (No.11) I/conn [CN-5 (57)] Switch panel [CN-116 (10)]
Fuse box (No.6) I/conn [CN-5 (18)] I/conn [CN-17 (5)] Wiper motor controller [CN-141(7)]
Wiper motor [CN-21(4)]
Fuse box (No.17) I/conn [CN-5 (24)] l/conn [CN-17 (4)] Wiper motor controller [CN-141 (6)]
Washer pump [CN-22 (2)]
(2) Wiper switch ON : 1st step (Intermittent)
Wiper switch ON [CN-116 (3)] I/conn [CN-17 (8)] Wiper motor controller [CN-141 (10) → (3)]
Wiper motor intermittently operating [CN-21 (6)]
(3) Wiper switch ON : 2nd step (continual)
Wiper switch ON [CN-116(4)] I/conn[CN-17(2)] Wiper motor controller [CN-141(2) → (4)]
Wiper motor operating [CN-21(2)]
(4) Washer switch ON
Washer switch ON [CN-116 (5)] I/conn [CN-17 (7)] Wiper motor controller [CN-141 (9) → (8)]
I/conn [CN-17 (6)] I/conn [CN-5 (19)] Washer pump [CN-22 (1)] Washer operating
Wiper switch ON [CN-116 (4)] I/conn[CN-17 (2)] Wiper motor controller [CN-141 (2) → (4)]
Wiper motor operating [CN-21 (2)]
(5) Auto parking
parking(when switch OFF)
Switch OFF [CN-116 (4)] Wiper motor parking position by wiper motor controller
2) CHECK POINT

24V
STOP ON 0 ~ 5V
④ - GND (wiper power input)
⑤ - GND (wiper power output) 24V
⑥ - GND (wiper motor) 0 or 24V
※ GND : Ground
4-28
CN-5
1
2
3
4 CN-36
5 IG POWER 30A
6
CN-21 6 1
1 CS-53 7 2
3 Or
R MCU 30A
2 8 3
Gr START KEY 30A
5 3 9 4
R 20A
4 10 AIR CON/HEATER
4 G B
5
5 11 0.8R WIPER 10A
WIPER CUT SW
L 6
6 M 2 6 12 CLUSTER 10A
WIPER MOTOR
7
13 CLUSTER 10A
8
1
14 20A
MCU CONT.
15 9
MCU_EPPR 20A
16 10
4
0.8RW SWITCH PANEL 10A
17 11
0.8R 0.8R 10A
CN-141 18 CASSETTE
G 0.8V 0.8V 12
FEED BACK 1 19 FUEL CUT-OFF SOL. 10A
W 13
1
MOTOR DRIVE SIG 2 CN-17 20 CONVERTER 20A
L 14
MOTOR DRIVE- 3 1 21 WORK LAMP 30A
R W 0.8W
MOTOR DRIVE+ 4 2 22 15
B B 1.2B CABIN LAMP(OPTION) 30A
GND 5 3 23 16
GrW GrW 0.8ROr 0.8ROr 0.8GrW 0.8GrW WIPER 10A
VCC 6 4 24 17
R R 0.8R HEAD LAMP 20A
CONTINUE 24V 7 5 25 18
V V 0.8V 30A
WASHER P/P 8 6 26 FUEL HEATER
19
1
L L 0.8L
WASHER SIG. 9 7 27 START,STOP 30A
Br Br 0.8Br 20
INT. SIG 10 8 28 HORN 10A
Or 21
WIPER CUT SW 11 29 AC& HEATER 20A
1.2B 1.2B 22
N.C 12 30 10A
SAFETY SOL

Gr 1.2B 1.2B
FEED BACK 13 31 23
4-29
OPTION 20A
32 24
SOLENOIDE 20A
5
33 25
CIGAR 20A
34 26
WIPER AND WASHER CIRCUIT (CLUSTER TYPE 1)
35 OPTION(BEACON) 20A
27
36 TRAVEL SOL 20A
28
37 PRE-HEAT 10A
29
38 FUEL P/P 20A
39 30
SPARE 10A
40 31
FUSE BOX
41
42
0.8V
0.8V
0.8GrW
0.8GrW
43
2
1
44
2
1
DO-5
45
CN-22
M
DIODE
46
CN-116 47
HEAD LIGHT OUT 1
WASHER PUMP
48
WORK LIGHT OUT 2
0.8Br 49
INT. SIG 3 50
0.8W
0.8L
WASHER SIG 5 52
PRE-HEAT 6 53
3
TRAVEL ALARM 8 55
NC 9 56
SWITCH PANEL
0.8RW 0.8RW 0.8RW
POWER 24V 10 57
GND 11 58
NC 12 59
2609S4EL17
60
2
■ WIPER AND WASHER CIRCUIT (CLUSTER TYPE 2)
1) OPERATING FLOW
(1) Key switch ON
Fuse box (No.11) I/conn [CN-5 (57)] Switch panel [CN-116 (10)]
Fuse box (No.6) I/conn [CN-5 (18)] I/conn [CN-17 (5)] Wiper motor controller [CN-141(7)]
Wiper motor [CN-21(4)]
Fuse box (No.17) I/conn [CN-5 (24)] l/conn [CN-17 (4)] Wiper motor controller [CN-141 (6)]
Washer pump [CN-22 (2)]
(2) Wiper switch ON : 1st step (Intermittent)
Wiper switch ON [CN-116 (3)] I/conn [CN-17 (8)] Wiper motor controller [CN-141 (10) → (3)]
Wiper motor intermittently operating [CN-21 (6)]
(3) Wiper switch ON : 2nd step (continual)
Wiper switch ON [CN-116(4)] I/conn[CN-17(2)] Wiper motor controller [CN-141(2) → (4)]
Wiper motor operating [CN-21(2)]
(4) Washer switch ON
Washer switch ON [CN-116 (5)] I/conn [CN-17 (7)] Wiper motor controller [CN-141 (9) → (8)]
I/conn [CN-17 (6)] I/conn [CN-5 (19)] Washer pump [CN-22 (1)] Washer operating
Wiper switch ON [CN-116 (4)] I/conn[CN-17 (2)] Wiper motor controller [CN-141 (2) → (4)]
Wiper motor operating [CN-21 (2)]
(5) Auto parking
parking(when switch OFF)
Switch OFF [CN-116 (4)] Wiper motor parking position by wiper motor controller
2) CHECK POINT

24V
STOP ON 0 ~ 5V
④ - GND (wiper power input)
⑤ - GND (wiper power output) 24V
⑥ - GND (wiper motor) 0 or 24V
※ GND : Ground
4-30
CN-5
1
2
3
4 CN-36
5 IG POWER 30A
6
CN-21 6 1
3 1 CS-53 7 2
R Or MCU 30A
2 8 3
Gr START KEY 30A
5 3 9 4
R 20A
4 10 AIR CON/HEATER
4 G B
5
5 11 0.8R WIPER 10A
WIPER CUT SW
L 6
6 M 2 6 12 SPARE 10A
WIPER MOTOR
7
13 CLUSTER 10A
8
1
14 20A
MCU CONT.
15 9
FUEL CUT OFF 10A
16 10
4
0.8RW SWITCH PANEL 10A
17 11
0.8R 0.8R 10A
CN-141 18 CASSETTE
G 0.8V 0.8V 12
FEED BACK 1 19 SPARE 30A
W 13
1
MOTOR DRIVE SIG 2 CN-17 20 CONVERTER 20A
L 14
MOTOR DRIVE- 3 1 21 WORK LAMP 30A
R W 0.8W
MOTOR DRIVE+ 4 2 22 15
B B 1.2B CABIN LAMP(OPTION) 30A
GND 5 3 23 16
GrW GrW 0.8ROr 0.8ROr 0.8GrW 0.8GrW WIPER 10A
VCC 6 4 24 17
R R 0.8R HEAD LAMP 20A
CONTINUE 24V 7 5 25 18
V V 0.8V 30A
WASHER P/P 8 6 26 FUEL HEATER
19
1
L L 0.8L
WASHER SIG. 9 7 27 START,STOP 30A
Br Br 0.8Br 20
INT. SIG 10 8 28 HORN 10A
Or 21
WIPER CUT SW 11 29 AC& HEATER 20A
1.2B 1.2B 22
N.C 12 30 10A
SAFETY SOL

Gr 1.2B 1.2B
FEED BACK 13 31 23
4-31
OPTION 20A
32 24
SOLENOIDE 20A
5
33 25
CIGAR 20A
34 26
WIPER AND WASHER CIRCUIT (CLUSTER TYPE 2)
35 OPTION(BEACON) 20A
27
36 TRAVEL SOL 20A
28
37 PRE-HEAT 10A
29
38 FUEL P/P 20A
39 30
SPARE 10A
40 31
FUSE BOX
41
42
0.8V
0.8V
0.8GrW
0.8GrW
43
2
1
44
2
1
DO-5
45
CN-22
M
DIODE
46
CN-116 47
HEAD LIGHT OUT 1
WASHER PUMP
48
WORK LIGHT OUT 2
0.8Br 49
INT. SIG 3 50
0.8W
0.8L
WASHER SIG 5 52
PRE-HEAT 6 53
3
TRAVEL ALARM 8 55
NC 9 56
SWITCH PANEL
0.8RW 0.8RW 0.8RW
POWER 24V 10 57
GND 11 58
NC 12 59
2609S4EL18
60
2
CN-76
M- 6
6 5
M M+ 5
NC 4
2 B
P- 3
3 1
-
+
S
SIG 2
0.8Gr
GOV. MOTOR
P+ 1
ACCEL DIAL
B
A
C
CN-142
B
W
Gr
2
5
4
1
9
8
7
6
3
16
15
14
13
12
11
10
CN-51
CN-7
1.2
BATT POWER_24V 1
1.2R
RH CONSOLE
POWER IG 2
POWER_24V OUT 3
TACHO SENSOR+ 4
1.2B CN-36
GND_5V 5
0.8Gr 30A
POWER_5V OUT 6 IG POWER
1
G/A MOTOR(+) 7 ROOM LAMP/CASSETTE 10A
G/A MOTOR(-) 8 2
1.2R MCU 30A
nc 9 3
START KEY 30A
nc 10 4
GND_MAIN 11 AIR CON/HEATER 20A
5
CAN_SHIELD 12 WIPER 10A
GND_RETURN 13 6
CLUSTER 10A
SPEED SENSOR+(HMC) 14 7
TACHO SENSOR- CLUSTER 10A
15
8
PROGRAM DUMP 16 1.2RW MCU CONT. 20A
ONE TOUCH DECEL
9
17 1.2R 20A
MCU_EPPR
POWER BOOST SW 18 10
SWITCH PANEL 10A
HOUR METER 19 11
ANTI RESTART RY 20 CASSETTE 10A
12
CAN1 Hi 21 FUEL CUT-OFF SOL. 10A
nc 22
13
CONVERTER 20A
RS485+(TX)-CLUSTER 23 14
WORK LAMP 30A
24
CONTROLLER CIRCUIT (CLUSTER TYPE 1)
15
16
WIPER 10A
4-32
MCU
17
CN-52 HEAD LAMP 20A
18
ARM REGEN SOL 1 FUEL HEATER 30A
POWER MAX SOL
19
2 30A
START,STOP
TRAVEL SPEED SOL 3 20
HORN 10A
ATT_ SAFETY SOL 4 21
ATT_PRESS SOL. 5 AC& HEATER 20A
22
ATT_CONFLUX SOL. 6 SAFETY SOL 10A
BOOM PRIORITY EPPR+ 7 23
0.8 OPTION 20A
POWER IG EPPR 8 24
0.8 SOLENOIDE 20A
PUMP POWER EPPR+ 9 25
ATT. EPPR+ 10 CIGAR 20A
26
nc 11 OPTION(BEACON) 20A
FUEL WARMER RY 12 27
TRAVEL SOL 20A
TRAVEL BUZZER 13 28
ENG STOP RY PRE-HEAT 10A
14
29
ENG PRE-HEAT RY 15 FUEL P/P 20A
nc
30
16 SPARE 10A
BOOM PRIORITY EPPR- 17 31
FUSE BOX
EPPR GND 18
0.8
PUMP POWER EPPR- 19
ATT. EPPR- 20
nc 21
nc 22
0.8
Br
Or
ACCEL DIAL SIG 23
24
5
4
1
9
8
7
6
3
15
14
13
12
11
10
CN-2
Br
Or
2
1
2609S4EL19
CN-75
EPPR V/V
CN-76
M- 6
6 5
M M+ 5
NC 4
2 B
P- 3
3 1
SIG 2
0.8Gr
GOV. MOTOR
P+ 1
-
+
ACCEL DIAL
B
A
C
CN-142
CN-51
B
W
Gr
WORKING PS 1
POWER MAX SW 2
TRAVEL ALARM SW 3
ENG OIL PS
5
4
4
1
9
8
7
6
3
16
15
14
13
12
11
10
CN-7
NC 5
NC 6
RH CONSOLE
24V(PRES.SENSOR) 7
GND(PRES.SENSOR) 8
ALT LEVEL 9 CN-36
P1 PRESS SIG. 10 30A
IG POWER
P2 PRESS SIG. 11 1
P3 PRESS SIG. 12 2
TRAVEL PS 13 1.2R MCU 30A
3
O/T DECEL SW 14 START KEY 30A
WATER LEVEL SW 15 4
AIR CON/HEATER 20A
AIR CLEANER SW 16 5
WIPER 10A
NC 17 6
NC 18 SPARE 10A
7
NC 19 10A
B CLUSTER
GND (POT&DIAL) 20 8
G/OR 1.2RW MCU CONT. 20A
5V (POT&DIAL) 21 9
POT-SIG FUEL CUT OFF 10A
22
W 10
ACCEL DIAL SIG 23 SWITCH PANEL 10A
11
CASSETTE 10A
TACHO SENSOR(-) 25 12
SPARE 30A
26 13
CONVERTER 20A
CONTROLLER CIRCUIT (CLUSTER TYPE 2)
CN-50 14
MCU
WORK LAMP 30A
BOOM PRIORITY SOL 1 15
4-33
MAX FLOW SOL. 2 16
POWER MAX SOL. 3 WIPER 10A
17
HOUR-METER 4 20A
HEAD LAMP
ENG PREHEATER 5 18
FUEL HEATER 30A
FUEL HEATER 6 19
GY START,STOP 30A
BATTERY 24V(+) 7
BR 20
PUMP EPPR(-) 8 HORN 10A
NC
21
9 20A
AC& HEATER
PROGRAM DUMP 10 22
SAFETY SOL 10A
ANTI-RESTART RY 11 23
ACCEL ACT(+) 12 OPTION 20A
24
TRAVEL SPEED SOL. 13 SOLENOIDE 20A
NC 14
25
CIGAR 20A
NC 15 26
OPTION(BEACON) 20A
TRAVEL BUZZER 16 27
PRE-HEAT SW 17 TRAVEL SOL 20A
28
NC 18 PRE-HEAT 10A
NC 19 29
FUEL P/P 20A
OVERLOAD SIG 20 30
ENGINE OIL FILTER SPARE 10A
21
31
FUSE BOX
HOUR-METER 22
ACCEL ACT(-) 23
OR
POWER IG 24
NC 25
NC 26
Br
Or
NC 27
GND (MAIN) 28
SERIAL-TX 29
5
4
1
9
8
7
6
3
15
14
13
12
11
10
SERIAL-RX 30
CN-2
GND 31
RS232 (+) 32
RS232 (-) 33
RS232 (GND) 34
Br
Or
NC 35
OR
2609S4EL20
PUMP EPPR(+) 36
1
2
CN-75
EPPR V/V
CN-51
BATT POWER_24V 1
POWER IG 2
POWER_24V OUT 3
TACHO SENSOR+ 4
GND_5V 5
Pa
POWER_5V OUT 6
CD-10
C 1
2
G/A MOTOR(+) 7
2
1
CD-1
HYD TEMP
G/A MOTOR(-) 8
FUEL LEVER
CD-2
nc 9
1.2B
0.8
0.8
1.2YOr
AIR CLEANER SW
0.8B
0.8B
nc 10
GND_MAIN 11
CAN_SHIELD 12 CN-36
GND_RETURN 13 30A
IG POWER
SH
0.8Gr
0.8L
0.8Y
0.8RW
0.8L
0.8Y
0.8Gr
0.8RW
TACHO SENSOR- 15 2
MCU 30A
5
4
1
9
8
7
6
PROGRAM DUMP
3
16
60
59
58
57
24
23
22
21
20
19
18
17
3
CN-5
ONE TOUCH DECEL
8
7
6
5
4
3
2
1
17 START KEY 30A
4
CN-56
POWER BOOST SW 18 20A
SH
AIR CON/HEATER
0.8L
0.8Y
L
Gr
HOUR METER
Y
B
W
5
0.8Gr
19
WL
WR
RW
0.8RW
WIPER 10A
ANTI RESTART RY 20 6
CAN1 Hi 21 0.8RW CLUSTER 10A
7
nc 22 10A
TX
0.8Gr
RX
0.8L CLUSTER
SIG_2
GND
SIG_3
8
IG 24V
BATT.24V
MCU CONT. 20A
RS232C1_TX-HRDT 24 9
CAMERA SIG
CLUSTER
RS232C2_TX-RCM MCU_EPPR 20A
25 10
TRAVEL ALARM SELECT SIG 26 SWITCH PANEL 10A
ENG OIL PS
11
27 CASSETTE 10A
coolent level 28 12
0.8GrW FUEL CUT-OFF SOL. 10A
AIR CLEANER SW(NO) 29 13
BLOWER SIG. 30 CONVERTER 20A
14
CAN1 Lo 31 WORK LAMP 30A
nc
15
32 30A
0.8Y CABIN LAMP(OPTION)
RS485-(RX)-CLUSTER 16
MONITORING CIRCUIT (CLUSTER TYPE 1)
33
WIPER 10A
RS232C1_RX-HRDT 34 17
RS232C2_RX-RCM 35 HEAD LAMP 20A
18
4-34
PRE-HEAT SELECT SIG 36 FUEL HEATER 30A
ENGINE OIL FILTER 37
19
START,STOP 30A
nc 38 20
HORN 10A
nc 39 21
nc 40 AC& HEATER 20A
22
SAFETY SOL 10A
CN-52 23
MCU
OPTION 20A
ARM REGEN SOL 1 24
POWER MAX SOL 2 SOLENOIDE 20A
25
TRAVEL SPEED SOL 3 CIGAR 20A
OPTION(BEACON) 20A
ATT_PRESS SOL. 5 27
TRAVEL SOL 20A
ATT_CONFLUX SOL. 6 28
BOOM PRIORITY EPPR+ 7 PRE-HEAT 10A
29
POWER IG EPPR 8 FUEL P/P 20A
PUMP POWER EPPR+ 9 30
SPARE 10A
ATT. EPPR+ 10 31
FUSE BOX
nc 11
FUEL WARMER RY 12
TRAVEL BUZZER 13
ENG STOP RY 14
ENG PRE-HEAT RY 15
nc 16
BOOM PRIORITY EPPR- 17
EPPR GND 18
PUMP POWER EPPR- 19
ATT. EPPR- 20
nc 21
nc 22
ACCEL DIAL SIG 23
0.8
HYD. TEMP SENDER 24
0.8OrW
2609S4EL21
27
Pa
CD-10
C 1
2
2
1
CD-1
HYD TEMP
FUEL LEVER
CD-2
1.2B
0.8
0.8
1.2YOr
AIR CLEANER SW
0.8B
0.8B
CN-51 CN-36
SH
L
Y
B
WORKING PS 1 30A
Br
0.8L
0.8B
0.8Y
IG POWER
0.8Gr
POWER MAX SW 2 1
TRAVEL ALARM SW 3 2
MCU 30A
5
4
1
9
8
7
6
3
60
59
58
57
24
23
22
21
20
19
18
17
ENG OIL PS 4
3
4
3
2
1
CN-5
NC 5 START KEY 30A
CN-56
NC
4
6 20A
AIR CON/HEATER
SH
RR
5
0.8L
24V(PRES.SENSOR)
0.8B
0.8Y
7
0.8Gr
WIPER 10A
GND(PRES.SENSOR) 8 6
ALT LEVEL 9 SPARE 10A
7
P1 PRESS SIG. 10 0.8Gr CLUSTER 10A
8
TX
RX
P2 PRESS SIG. 11
GND
MCU CONT. 20A
P3 PRESS SIG. 12 9
10A
POWER IG(24V)
FUEL CUT OFF
CLUSTER
TRAVEL PS 13 10
O/T DECEL SW 14 SWITCH PANEL 10A
11
WATER LEVEL SW 15 CASSETTE 10A
L
AIR CLEANER SW 16 12
SPARE 30A
NC 17 13
NC CONVERTER 20A
18 14
NC 19 WORK LAMP 30A
GND (POT&DIAL)
15
20 CABIN LAMP(OPTION) 30A
5V (POT&DIAL) 21 16
WIPER 10A
POT-SIG 22 17
ACCEL DIAL SIG 23 HEAD LAMP 20A
B/OR 18
FUEL LEVEL SENSOR 24 FUEL HEATER 30A
MONITORING CIRCUIT (CLUSTER TYPE 2)
TACHO SENSOR(-) 25
19
START,STOP 30A
TACHO SENSOR(+) 26 20
HORN 10A
NC 27 21
4-35
NC 28 AC& HEATER 20A
22
NC 29 SAFETY SOL 10A
NC 30 23
OPTION 20A
GND (SENSOR) 31 24
PUMP PROLIX SW SOLENOIDE 20A
32
25
WATER TEMP SENDOR 33 CIGAR 20A
BR/OR 26
HYD TEMP SENDOR 34 20A
OPTION(BEACON)
NC 35 27
TRAVEL SOL 20A
NC 36 28
PRE-HEAT 10A
29
FUEL P/P 20A
CN-50 30
BOOM PRIORITY SOL SPARE 10A
1
31
FUSE BOX
MAX FLOW SOL. 2

POWER MAX SOL. 3
HOUR-METER 4
ENG PREHEATER 5
FUEL HEATER 6
BATTERY 24V(+) 7
PUMP EPPR(-) 8
NC 9
PROGRAM DUMP 10
ANTI-RESTART RY 11
12
NC 27
GND (MAIN) 28
Y
SERIAL-TX 29
L
SERIAL-RX 30
GND 31
RS232 (+) 32
RS232 (-) 33
RS232 (GND) 34
2609S4EL22
NC 35
PUMP EPPR(+) 36
B
max
C
Horn
2
2
1
1
Brea
Decel
A
Power
SIG
SIG
SIG
2
1
2
1
CS-26A
C
1
2
CS-5
CD-2
CD-1
CS-29
ker CS-26
CS-19
-
+
S
HYD TEMP
L
L
B
B
A3
SUPPLY
R
R
BREAKER
SUPPLY
SUPPLY
Gr
Gr
RETURN
RETURN
RETURN
FUEL LEVEL
CD-24
A
B
C
SAFETY SW
A
B
A
SUPPLY
B
A
C
C
B
A
B
A
C
C
1
1
1
1
2
2
2
2
ACCEL DIAL
PUMP1 PRESS
PUMP2 PRESS
CS-4
CN-142
CD-44
CD-43
CD-42
SIG B
SWING
RETURN C
CD-31
SUPPLY A
SIG B
LOAD
OVER
RETURN C
CD-32
SUPPLY A
UP
SIG B
BOOM
RETURN C
CD-6
SUPPLY A
9
8
7
5
2
4
1
6
3
2
2
5
5
4
1
4
1
9
8
7
6
9
8
7
6
3
3
15
14
13
12
11
10
SIG B
16
15
14
13
12
11
10
16
15
14
13
12
11
10
CN-4
CN-7
CN-2
TRAVEL
RETURN C
CD-7
SUPPLY A
SIG B
WORK
RETURN C
CS-50
1
CN-76 2 12
2
M- 6
6 5 3
M M+ 5
NC 4 4
2
P- 3 5
3 1
SIG 2 6
GOV. MOTOR
P+ 1 3
7 7
9
8
OVERLOAD SW
4
9 8
10
10
11
11 12
12
ELECTRIC CIRCUIT FOR HYDRAULIC (CLUSTER TYPE 1)
CS-67
1
2 12
2
CN-51
BATT POWER_24V 1
3
POWER IG 2 4
POWER_24V OUT 3 5
TACHO SENSOR+ 4 6
GND_5V 5 3
7 7
POWER_5V OUT 6 9
8
G/A MOTOR(+) 7 4
G/A MOTOR(-) 8 9 8
10
nc 9 10
QUICK COUPLING SW
nc 10 11
11 12
GND_MAIN 11 12
CAN_SHIELD 12
CN-113
GND_RETURN 13
TACHO SENSOR- 15 2
PROGRAM DUMP 16
BUZZER
6
9
8
7
ONE TOUCH DECEL 17

10
12
60
59
58
57
35
34
33
32
31
30
29
28
27
11
CN-5
POWER BOOST SW 18
HOUR METER 19
ANTI RESTART RY 20
CAN1 Hi 21
CN-140
nc 22
2
1
RS232C1_TX-HRDT 24
RS232C2_TX-RCM 25
QUICK COUPLER SOL
ENG OIL PS 27
coolent level 28
AIR CLEANER SW(NO) 29
BLOWER SIG. 30
4-36
CAN1 Lo 31
nc 32 CN-36
RS485-(RX)-CLUSTER 33 IG POWER 30A
RS232C1_RX-HRDT 34 1
RS232C2_RX-RCM 35 2
PRE-HEAT SELECT SIG 36 MCU 30A
3
ENGINE OIL FILTER 37 30A
START KEY
nc 38 4
AIR CON/HEATER 20A
nc 39 5
nc 40 WIPER 10A
6
CLUSTER 10A
CN-52 7
MCU
ARM REGEN SOL CLUSTER 10A
1
8
POWER MAX SOL 2 MCU CONT. 20A
TRAVEL SPEED SOL 3 9
MCU_EPPR 20A
ATT_PRESS SOL. 5 SWITCH PANEL 10A
11
ATT_CONFLUX SOL. 6 CASSETTE 10A
BOOM PRIORITY EPPR+ 7 12
FUEL CUT-OFF SOL. 10A
POWER IG EPPR 8 13
PUMP POWER EPPR+ 9 CONVERTER 20A
14
ATT. EPPR+ 10 WORK LAMP 30A
nc 11 15
FUEL WARMER RY 12 16
TRAVEL BUZZER 13 WIPER 10A
17
ENG STOP RY 14 20A
HEAD LAMP
ENG PRE-HEAT RY 15 18
FUEL HEATER 30A
nc 16 19
BOOM PRIORITY EPPR- 17 START,STOP 30A
20
EPPR GND 18 10A
HORN
PUMP POWER EPPR- 19 21
AC& HEATER 20A
ATT. EPPR- 20 22
nc 21 SAFETY SOL 10A
nc
23
22 20A
OPTION
ACCEL DIAL SIG 23 24
SOLENOIDE 20A
HYD. TEMP SENDER 24 25
WATER TEMP SENDOR 25 CIGAR 20A
26
OPTION(BEACON) 20A
ALT. LEVEL 27 27
GOV. POTENTIO SIG. TRAVEL SOL 20A
28
28
P1 PRESS SENSOR 29 PRE-HEAT 10A
P2 PRESS SENSOR 30
29
FUEL P/P 20A
nc 31 30
PUMP EPPR2 SENSOR SPARE 10A
32
31
ATT PILOT PRESSURE
FUSE BOX
33
ARM IN_OUT BUCKET IN PRESS 34
BOOM UP PRESS SENSOR 35
SWING PRESS SENSOR 36
WORK PRESS SENSOR(A) 37
TRAVEL PRESS SENSOR(A) 38
OVERLOAD SIG 39
nc
2
5
4
1
9
8
7
6
3
40
12
11
10
CN-15
4
2
3
5
1
CR-62
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
1
2
1
2
CD-69
CN-66
CN-88
CN-70
CN-68
3 2
4 5 1
CN-242
CN-237
CN-149
CN-236
CN-135
CN-133
B SIG
BREAKER RY
POWER MAX
CN-81
TRAVEL BZ
TRAVEL-HIGH
SAFETY SOL
A SUPPLY
C RETURN
ATT
BOOM PRIORITY
ATT
ATT
ARM REGENERATION
ATT FLOW
ATT PS
PRESS SOL
SAFETY SOL
BREAKER SOL
CONFLUX SOL
2609S4EL23
P3 P1 P2
PRESS PRESS PRESS
SIG
SIG
SIG
max
C
Horn
2
2
1
1
Brea
Decel
A
Power
SUPPLY
SUPPLY
SUPPLY
RETURN
RETURN
RETURN
2
1
2
1
CS-26A
C
1
2
CS-5
CD-2
1
CD-1
2
B
A
B
A
CS-29
ker CS-26
C
C
CS-19
B
A
C
-
+
S
HYD TEMP
L
L
B
B
R
R
BREAKER
Gr
Gr
CD-44
CD-42
CD-43
FUEL LEVEL
CN-156
A
B
C
SAFETY SW
B
A
1
1
1
1
2
2
2
2
AIR SEAT
CS-4
ACCEL DIAL
CN-142
CD-31
PS
SUPPLY A
RETURN B
SIG C
CD-6
SUPPLY A
RETURN B
SIG C
6
5
4
1
2
2
2
5
5
4
1
4
1
9
8
7
6
9
8
7
6
3
3
16
15
14
13
12
11
10
16
15
14
13
12
11
10
CN-4
CN-7
CD-7
CN-1
SUPPLY A
RETURN B
CS-27
SIG C
OVERLOAD TRAVEL WORK

1
2 12
2
CN-76
M- 6
3
6 5
4
9
8
7
5
2
4
1
6
3
M+ 5
15
14
13
12
11
10
M
CN-2
NC 4 5
2
P- 3 6
3 1
SIG 2 3
7 7
P+ 1 9
GOV. MOTOR
8
4
BREAKER SW
9 8
10
10
11
11 12
12
CS-50
1
2 12
2
3
4
5
ELECTRIC CIRCUIT FOR HYDRAULIC (CLUSTER TYPE 2)
6
3
7 7
9
8
4
OVERLOAD SW
9 8
10
10
11
11 12
12
CS-67
1
2 12
2
CN-51
WORKING PS 1
3
POWER MAX SW 2 4
TRAVEL ALARM SW 3 5
ENG OIL PS 4 6
NC 5 3
7 7
NC 6 9
8
24V(PRES.SENSOR) 7 4
GND(PRES.SENSOR) 8 9 8
10
ALT LEVEL 9 10
QUICK COUPLING SW
P1 PRESS SIG. 10 11
P2 PRESS SIG.
11 12
11 12
P3 PRESS SIG. 12
CN-113
TRAVEL PS 13
O/T DECEL SW 14 1
WATER LEVEL SW 15 2
AIR CLEANER SW 16
BUZZER
6
9
8
7
NC 17
10
12
60
59
54
53
35
34
33
32
31
30
29
28
27
11
CN-5
NC 18
NC 19
GND (POT&DIAL) 20
5V (POT&DIAL) 21
4-37
CN-140
POT-SIG 22
2
ACCEL DIAL SIG 23
1
TACHO SENSOR(-) 25
TACHO SENSOR(+) 26
QUICK COUPLER SOL
NC 27
NC 28
NC 29
NC 30
GND (SENSOR) 31
PUMP PROLIX SW 32 CN-36
WATER TEMP SENDOR 33 30A
IG POWER
HYD TEMP SENDOR 34 1
NC 35 2
NC 36 MCU 30A
3
START KEY 30A
CN-50 4
MCU
BOOM PRIORITY SOL 1 AIR CON/HEATER 20A
MAX FLOW SOL. 2
5
WIPER 10A
POWER MAX SOL. 3 6
HOUR-METER SPARE 10A
4
7
ENG PREHEATER 5 CLUSTER 10A
FUEL HEATER 6 8
MCU CONT. 20A
BATTERY 24V(+) 7 9
PUMP EPPR(-) 8 FUEL CUT OFF 10A
10
NC 9 SWITCH PANEL 10A
PROGRAM DUMP 10 11
CASSETTE 10A
ANTI-RESTART RY 11 12
ACCEL ACT(+) 12 SPARE 30A
13
TRAVEL SPEED SOL. 13 CONVERTER 20A
NC 14 14
WORK LAMP 30A
NC 15 15
TRAVEL BUZZER 16 CABIN LAMP(OPTION) 30A
16
PRE-HEAT SW 17 10A
WIPER
NC 18 17
HEAD LAMP 20A
NC 19 18
OVERLOAD SIG 20 FUEL HEATER 30A
ENGINE OIL FILTER
19
21 START,STOP 30A
HOUR-METER 22 20
HORN 10A
ACCEL ACT(-) 23 21
POWER IG 24 AC& HEATER 20A
NC
22
25 10A
SAFETY SOL
NC 26 23
OPTION 20A
NC 27 24
GND (MAIN) 28 SOLENOIDE 20A
SERIAL-TX 29
25
CIGAR 20A
SERIAL-RX 30 26
GND OPTION(BEACON) 20A
31
27
RS232 (+) 32 TRAVEL SOL 20A
RS232 (-) 33
28
PRE-HEAT 10A
RS232 (GND)
9
8
7
5
2
4
1
34
6
3
29
12
11
10
FUEL P/P 20A

CN-3
NC 35
30
PUMP EPPR(+) 36 SPARE 10A
31
FUSE BOX
4
2
3
5
1
CR-62
1
1
1
2
2
2
2
1
2
2
1
1
2
CD-8
CN-88
CN-70
CN-66
CN-68
C
3 2
4 5 1
CN-133
BREAKER RY
POWER MAX
CN-81
TRAVEL BZ
TRAVEL-HIGH
SAFETY SOL
BREAKER SOL
BOOM PRIORITY
WATER TEMP SENDOR
2609S4EL24
GROUP 3 ELECTRICAL COMPONENT SPECIFICATION
Part name Symbol Specifications Check
※ Check specific gravity

12V × 100Ah 1.280 over : Over charged
Battery
(2EA) 1.280 ~ 1.250 : Normal
1.250 below : Recharging
Rated load : ※ Check coil resistance(M4 to M4)

24V Normal : About 50Ω
Battery relay
100A (continuity) ※ Check contact
1000A (30seconds) Normal : ∞Ω
CR-1
※ Check contact
Pre-heat relay 24V 200A Normal : 0.942Ω
(For terminal 1-GND)
CR-24
5
4
1
6
2
3
B
※ Check contact
0, I
B-BR : 24V 1A OFF : ∞Ω(for each terminal)
1
Start key B-ACC : 24V 10A

ON : 0Ω(for terminal 1-3 and 1-2)
H0 I B-ST : 24V 40A
4
3
2
6
5
STC BR ACC H
START : 0Ω(for terminal 1-5)
CS-2
A SUPPLY
B SIG
Pressure
sensor C RETURN 8~30V ※ Check contact
(cluster type 1) CD-7 CD-7 CD-24 Normal : 0.1Ω
CD-6
CD-31 CD-32 CD-42
CD-43 CD-44 CD-69
A SUPPLY
B SIG
Pressure
C RETURN 8~30V ※ Check contact
sensor
(cluster type 2) CD-7 CD-7 CD-31 Normal : 0.1Ω
CD-6
CD-42 CD-43 CD-44
4-38
Pre-heat plug 24V 200A ※ Check resistance

0.25~0.12Ω
CN-80
C 1 ※ Check resistance
Temperature
- 50˚C : 804Ω
sensor
2 80˚C : 310Ω
(hydraulic,
coolant) CD-8 100˚C : 180Ω
CD-1 CD-8
※ Check contact
Air cleaner Pa High level : ∞Ω
pressure switch (N.O TYPE)
Low level : 0Ω
CD-10
※ Check resistance
Full : 50Ω 6/12 : 350Ω
2 11/12 : 100Ω 5/12 : 400Ω
10/12 : 150Ω 4/12 : 450Ω
Fuel sender 1 - 9/12 : 200Ω 3/12 : 500Ω
8/12 : 250Ω 2/12 : 550Ω
CD-2 7/12 : 300Ω 1/12 : 600Ω
Empty warning : 700Ω
3 4 4 ※ Check resistance
3 Normal : About 200Ω
Relay
(air con blower)
2 24V 20A (for terminal 1-3)
1 2 1 0Ω
(for terminal 2-4)
CR-46
1
2
4 5 1 ※ Check resistance
3 Normal : About 160 Ω
Relay (for terminal 1-2)
4 24V 16A
3 2
5 0Ω(for terminal 3-4)
CR-2
CR-2 CR-36
CR-5 CR-62
CR-36 ∞Ω(for terminal 3-5)
CR-45
Cluster CR-62
type 2 only (CR-52)
4-39
30
87a 87 85 ※ Check resistance
86
87
Normal : About 160 Ω
Relay 85 24V 16A (for terminal 85-86)
87a 30 86
0Ω(for terminal 30-87a)
CR-4
CR-4 CR-7CR-7
CR-5 CR-9CR-9
CR-13 CR-35 CR-46 ∞Ω(for terminal 30-87)
CR-13 CR-35 CR-46
1 ※ Check resistance
Solenoid valve
24V 1A Normal : 15~25Ω
(cluster type 1) 2
(for terminal 1-2)
CN-66 CN-68 CN-70
CN-88 CN-135 CN-140
CN-149 CN-236 CN-237
1
Solenoid valve
2 24V 1A Normal : 15~25Ω
(cluster type 2)
CN-66 CN-68 CN-70
CN-70 (for terminal 1-2)
CN-66 CN-68
CN-88 CN-135 CN-140
CN-88 CN-140 CN-133
CN-149 CN-236 CN-237
1 ※ Check resistance
EPPR valve Normal : 15~25Ω
2 700mA
(cluster type 1)
(for terminal 1-2)
CN-75
CN-75 CN-133
CN-133 CN-242
CN-238
CN-239 CN-240 CN-241
CN-242
1
Speaker 2
20W
Normal : A fewΩ
CN-23(LH)
CN-24(RH)
※ Check contact
7
6
3
2
1
8
4
12
5
11
10
11
2
8
Normal
Switch
24V 8A ON : 0 Ω(for terminal 3-7, 4-8)
(locking type)
∞Ω(for terminal 7-9, 8-10)
10
12
12
9
4
OFF : ∞Ω(for terminal 3-7, 4-8)

CS-23
CS-23 CS-50
CS-50CS-52
CS-67CS-67
CS-82 0 Ω(for terminal 7-9, 8-10)
CS-83 CS-83
CS-82 CS-99CS-99
CS-100
CS-100
※ Check resist
Normal : About 5kΩ
A + (for terminal A-C)
B S ※ Check voltage
Accel dial -
C - Normal : About 5V
(for terminal A-C)
CN-142 : 2~4.5V
(for terminal C-B)
4-40
3 ※ Check disconnection
Normal : 1.0Ω
2 ON : 0Ω(For terminal 1-2)
Room lamp 24V 10W ∞Ω(For terminal 1-3)
1
OFF : ∞Ω(For terminal 1-2)
CL-1 0Ω(For terminal 1-3)
2
Head lamp, 24V 65W ※ Check disconnection
Work lamp, 1
(H3 Type) Normal : 1.2Ω
Cab lamp CL-3 CL-4
CL-4 CL-5 CL-5
CL-6
CL-8 CL-9 CL-9
CL-6 CL-8
Beacon lamp 21V 70W ※Check disconnection

M (H1 Type) Normal : A fewΩ
CL
-
CL-7
1 M
24V 10A ※Check resistance
Fuel filler pump 2 35ℓ /min Normal : 1.0Ω
CN-61
3 ※Check operation
2
h Supply power(24V) to terminal
Hour meter 16~32V
1 No.2 and connect terminal No.1
CN-48 and ground
1 ※Check operation
Horn DC22~28V Supply power(24V) to each
2 2A terminal and connect ground.
CN-20 CN-25
4-41
※Check contact
2 3 1
Normal : 0Ω(for terminal 1-2)
24V 15A
Safety switch 2 ∞Ω(for terminal 1-3)
(N.C TYPE)
Operating : ∞Ω(for terminal 1-2)
3
1 0Ω(for terminal 1-3)
CS
-
CS-4
24V ※Check contact

Wiper cut switch (N.O TYPE) Normal : 0Ω(one pin to ground)
CS-53
1
Receiver dryer P ※Check contact
2 24V 2.5A Normal : ∞Ω
CN
2-
CN-29
10
11
12
13
14
15
16
1
2
3
4
5
6
7
9
8
Radio & ※Check voltage

REMOCON GND
SPK FRT RH+
SPK FRT LH+

SPK FRT RH-
24V 2A
SPK FRT LH-
REMOCON+
USB plalyer 20~25V

BACK UP+
TEL MUTE
ANT 12V
GND
GND
(for terminal 1-3, 3-8)

ACC
ILL+
ILL-
NC
NC
CN-27
Washer pump 24V 3.8A ※Check contact

Normal : 10.7Ω(for terminal 1-2)
CN-22
3 1
2
5 3
4 ※Check disconnection
Wiper motor 4
24V 2A
5
Normal : 7Ω(for terminal 2-6)
6 M 2 6
CN-21
4-42
3 12V 12V
DC/DC 2 24V 24V (1-2)
Converter 1 GND 24V 12V 3A
12V (1-3)
CN-138
※Check coil resistance

Normal : About 1MΩ
Cigar lighter 24V 5A 1.4W ※Check contact
Normal : ∞Ω
Operating time : 5~15sec
CL
-
CL-2
B+
G
1 P
3 ~
2 L
U Delco Remy ※Check contact
Normal : 0Ω (for terminal B+-I)
3 FI
Alternator 4 NC 24V 50A
CN-74 Normal : 24~27.5V
M
M
Starter Denso ※Check contact
24V 4.5kW Normal : 0.1Ω
B+
CN-45
Travel alarm ※Check contact

24V 0.5A
Normal : 5.2Ω
CN-81
1
Aircon ※Check contact
compressor 24V 79W Normal : 13.4Ω
CN-28
4-43
Start relay ※Check contact

24V 300A
Normal : 0.94Ω(for terminal 1-2)
CR-23
1 M ※Check resistance
Blower motor 24V 9.5A
2 Normal : 2.5Ω(for terminal 1-2)
※Check resistance
Duct sensor 2 1˚C OFF Normal : 0Ω(for terminal 1-2),
(switch) 4˚C ON the atmosphere temp :
1
Over 4˚C
Door switch 24V 2W ※Check resistance

Normal : About 5MΩ
CS-1
CS-1
Switch 1
(power max, ※Check resistance
24V 6A
one touch decel, 2 Normal : ∞Ω
horn, breaker)
CS-5 CS-19
CS-26 CS-26A CS-29
2 ※Check disconnection
normal : 0Ω
Fusible link 60A
1 (connect ring terminal and check
resist between terminal 1 and 2)
CN-60 CN-95
4-44
Master switch 6-36V ※Check disconnection

Normal : 0.1Ω
CS-74 CS-74B
2 ※Check resistance
m
rp
Speed sensor - Normal : 300Ω

1
(for terminal 1.2)
CD-17
Pressure ※Check resistance

Pa 0.5 kgf·m2
switch
(N.C TYPE) Normal : ∞Ω(CLOSE)
(engine oil)
CD-18
M- 6
6 5
M M+ 5 ※Check resistance
NC 4
2 Normal : 1~2Ω(for terminal 5-6)
Accel actuator 3 1
P- 3
-
SIG 2 0.8~1.2Ω
P+ 1
(for terminal 1-3)
CN-76
1
24V 200mA
Travel alarm 2 107 ± 4dB
-
CN-113
1
Socket 2
12V 10A -
CN-139
4-45
GROUP 4 CONNECTORS
1. CONNECTOR DESTINATION
Connector No. of Connector part No.
Type Destination
number pin Female Male
CN-1 AMP 6 I/conn (Frame harness-Pump PS harness cluster type 2) S816-006002 S816-106002
CN-2 AMP 15 I/conn (Frame harness-Engine harness) 2-85262-1 368301-1
CN-3 AMP 12 I/conn (Frame harness-Engine harness) S816-012002 S816-112002
CN-4 AMP 16 I/conn (Console harness LH-Frame harness) 368047-1 368050-1
CN-5 DEUTSCH 60 I/conn (Side harness RH-Frame harness) DRB16-60SAE-L018 DRB14-60PAE-L018
CN-7 AMP 16 I/conn (Console harness RH-Frame harness) 368047-1 368050-1
CN-8 AMP 12 I/conn (Console harness RH-Frame harness) S816-012002 S816-112002
CN-10 DEUTSCH 12 I/conn (Cab harness-Side harness RH) DT06-12S-EP06 DT04-12P-BE02
CN-11 DEUTSCH 8 I/conn (Frame harness-Aircon harness) DT06-8S-EP06 -
CN-12 DEUTSCH 2 I/conn (Frame harness-Boom wire harness) DT06-2S-EP06 DT04-2P-E005
CN-15 AMP 12 I/conn (Frame harness-Breaker solenoid) S816-012002 S816-112002
CN-17 AMP 8 I/conn (Wiper harness-Side harness RH) S816-008002 S816-108002
CN-20 MOLEX 2 Horn 36825-0211 -
CN-21 AMP 6 Wiper motor 925276-0 -
CN-22 KET 2 Washer pump MG640605 -
CN-23 KET 2 Speaker-LH MG610070 -
CN-24 KET 2 Speaker-RH MG610070 -
CN-25 MOLEX 2 Horn 36825-0211 -
CN-27 KUM 16 Radio & USB player PK145-16017 -
CN-28 KUM 1 Aircon compressor MWP-01F-B -
CN-29 KET 2 Receiver dryer MG640795 -
CN-36 - - Fuse & relay box 21Q7-10901 -
CN-45 RING-TERM - Starter motor B+ S820-308000 -
CN-48 KET 1 Hour meter 2-520193-2 -
CN-51 DEUTSCH 40 MCU (cluster type 1) DRC26-40SA -
CN-51 AMP 36 MCU (cluster type 2) 341111-1 -
CN-52 DEUTSCH 40 MCU (cluster type 1) DRC26-40SB -
CN-52 AMP 36 MCU (cluster type 2) 341111-1 -
CN-56 AMP 8 Cluster (type 1) - S816-108002
CN-56 DEUTSCH 4 Cluster (type 2) - DT04-4P
CN-60 AMP 2 Fusible link - S813-130201
CN-61 DEUTSCH 2 Fuel filler pump DT06-2S-EP06 -
CN-66 DEUTSCH 2 Breaker solenoid (cluster type 2) DT06-2S-EP06 DT04-2P-E005
CN-68 DEUTSCH 2 Safety solenoid DT06-2S-EP06 -
CN-70 DEUTSCH 2 Travel high solenoid DT06-2S-EP06 -
CN-74 AMP 4 Alternator "l" terminal 12186568 -
4-46
Type Destination
CN-75 AMP 2 Pump EPPR S816-002002 -
CN-76 DEUTSCH 6 Accel actuator DT06-6S-EP06 -
CN-79 AMP 3 Fuel cut off solenoid 12124685
CN-80 RING-TERM - Glow plug S820-306000 -
CN-81 DEUTSCH 2 Travel buzzer solenoid DT06-2S-EP06 -
CN-88 DEUTSCH 2 Power max solenoid DT06-2S-EP06 -
CN-95 AMP 2 Fusible link - S813-130201
CN-96 AMP 4 Fuel warmer 2-967325-3 -
CN-113 KET 2 Buzzer MG651205-5 -
CN-116 AMP 12 Switch panel 176116 -
CN-125A Econoseal J 4 GPS connector (cluster type 1) DT06-12S -
CN-126 AMP 8 Service tool S816-010002 -
CN-133 DEUTSCH 2 Boom priority solenoid DT06-2S-EP06 -
CN-135 DEUTSCH 2 Arm regeneration solenoid (cluster type 1) DT06-2S-EP06 -
CN-138 DEUTSCH 3 DC/DC Converter DT06-3S -
CN-139 FASTEN 2 12V socket 170434-2 -
CN-140 DEUTSCH 2 Quick clamp solenoid DT06-2S-EP06 DT04-2P-E005
CN-141 AMP 13 Wiper motor controller 172498-1 DT04-3P-EP10
CN-142 DEUTSCH 3 Accel dial DT06-3S-EP06 -
CN-147 AMP 2 Fuel-heater 15300029 -
CN-149 DEUTSCH 2 Attach safety solenoid (cluster type 1) DT06-2S-EP06 -
CN-156 DEUTSCH 2 Air seat DT04-2P-E005 -
CN-157 AMP 1 Antena power S822-014002 -
CN-170 AMP 2 Heated seat 12052641 12162000
CN-236 DEUTSCH 2 Attach pressure solenoid (cluster type 1) DT06-2S-EP06 -
CN-237 DEUTSCH 2 Attach conflux solenoid (cluster type 1) DT06-2S-EP06 -
CN-242 AMP 2 Attach flow solenoid (cluster type 1) S816-002002 S816-102002
CN-246 AMP 10 USB 316988-6 -
CN-249 AMP 4 Rear view camera (cluster type 1) S816-004002 S816-104002
·Relay
CR-1 RING-TERM - Battery relay ST710285-2 -
CR-2 - 5 Horn relay - -
CR-4 - 5 Working lamp relay - -
CR-5 - 5 Anti restart relay - -
CR-7 - 5 Aircon compressor relay - -
CR-9 - 5 Head lamp relay - -
CR-13 - 5 Cabin lamp relay - -
CR-23 AMP 2 Start relay - 814-102001
CR-24 RING TERM 1 Preheat relay S822-014000 -
4-47
Type Destination
CR-35 - 5 Power relay - -
CR-36 - 5 Preheat relay - -
CR-46 - 5 Fuel warmer relay - -
CR-62 - 5 Breaker relay - -
·Switch
CS-1 SHUR 1 Door switch S822-014002 S822-114002
CS-2 WP 6 Start key switch S814-006100 -
CS-4 DEUTSCH 3 Safety switch DT06-3S-EP06 -
CS-5 DEUTSCH 2 Horn switch - DT04-2P-E005
CS-19 DEUTSCH 2 One touch decel switch - DT04-2P-E005
CS-20 AMP 1 Safety switch S822-014002 -
CS-23 SWF 12 Beacon lamp switch SWF589790 -
CS-26 DEUTSCH 2 Breaker switch DT06-2S-EP06 -
CS-26A AMP 2 Breaker pedal switch S816-002002 S816-102002
CS-27 SWF 10 Breaker switch (cluster type 2) SWF 593757 -
CS-29 DEUTSCH 2 Power max switch DT06-2S-EP06 -
CS-50 SWF 12 Overload switch SWF589790 -
CS-53 AMP 1 Wiper cut switch S822-014002 -
CS-67 SWF 12 Quick clamp switch SWF 589790 -
CS-73 SWF 12 Spare switch SWF 589790 -
CS-74A AMP 2 Master switch S813-030201 -
CS-74B DEUTSCH 2 Master switch DT06-2S-EP06 -
CS-142 DEUTSCH 3 Accel dial LED DT06-3S-EP06 -
·Light
CL-1 KET 3 Room lamp MG651032 -
CL-2 AMP 1 Cigar light S822-014002 S822-114002
CL-3 DEUTSCH 2 Head lamp-LH DT06-2S-EP06 -
CL-4 DEUTSCH 2 Head lamp-RH DT06-2S-EP06 DT04-2P-E005
CL-5 DEUTSCH 2 Work lamp-LH - DT04-2P
CL-6 DEUTSCH 2 Work lamp-RH - DT04-2P
CL-7 SHUR 1 Beacon lamp S822-014002 S822-114002
CL-8 DEUTSCH 2 Cab light-LH DT06-2S-EP06 DT04-2P-E005
CL-9 DEUTSCH 2 Cab light-RH DT06-2S-EP06 DT04-2P-E005
4-48
Type Destination
·Sensor, sendor
CD-1 AMP 2 Hydraulic oil temp sender 85202-1 -
CD-2 DEUTSCH 2 Fuel sender DT06-2S-EP06 -
CD-6 DEUTSCH 3 Travel pressure switch DT06-3S-EP06 -
CD-7 DEUTSCH 3 Working pressure switch DT06-3S-EP06 -
CD-8 AMP 2 Coolant temp sender 85202-1 -
CD-10 RING TERM - Air cleaner switch ST730135-2 S820-104000
CD-17 AMP 2 Speed sensor - S818-120221
CD-18 RING TERM - Engine oil pressure switch S820-104000 -
CD-24 DEUTSCH 3 Swing sensor (cluster type 1) DT06-3S-EP06 -
CD-31 DEUTSCH 3 Overload sensor (cluster type 1) DT06-3S-EP06 -
CD-31 DEUTSCH 3 Overload sensor (cluster type 2) DT06-3S-EP06 DT04-3P
CD-32 DEUTSCH 3 Boom up sensor (cluster type 1) DT06-3S-EP06 -
CD-35 DEUTSCH 3 Air in sensor (cluster type 1) DT06-3S-EP06 -
CD-42 AMP 3 Pump pressure 1 S816-004002 -
CD-43 AMP 3 Pump pressure 2 S816-004002 -
CD-44 DEUTSCH 3 Pump pressure 3 DT06-3S-EP06 -
CD-69 DEUTSCH 3 Attach pressure sensor (cluster type 1) DT06-3S-EP06 -
DO-3 - - Diode 21EA-50550 -
DO-5 - - Diode 21EA-50570 -
4-49
2. CONNECTION TABLE FOR CONNECTORS
1) PA TYPE CONNECTOR
No. of
pin Receptacle connector (female) Plug connector (male)
2 5 1 3
1 3 2 5
S811-005002 S811-105002
3 7 1 4
1 4 3 7
S811-007002 S811-107002
4 9 1 5
1 5 4 9
S811-009002 3S811-109002
5 11 1 6
11
1 6 5 11
S811-011002 S811-111002
4 - 50
No. of
Receptacle connector (female) Plug connector (male)
pin
6 13 1 7
13
1 7 6 13
S811-013002 S811-113002
8 1 9
17
17
1 9 8 17
S811-017002 S811-117002
1 21
1 11
21
1 11 1 21
S811-021002 S811-121002
4 - 51
2) J TYPE CONNECTOR
No. of
pin
1 1
2
2 12
S816-002001 S816-102001
2 3 1
3 1 2
S816-003001 S816-103001
3 1 4 2
4 2 3 1
S816-004001 S816-104001
8 5 2
6 3 1
8 5 2 6 3 1
S816-008001 S816-108001
4 - 52
3) SWP TYPE CONNECTOR
No. of
pin
1 1
S814-001000 S814-101000
2 1
1 2
S814-002000 S814-102000
3 1
2 1 23
S814-003000 S814-103000
2 4
1 3
1 3 2 4
S814-004000 S814-104000
4 - 53
No. of
pin Receptacle connector (female) Plug connector (male)
3 6
1 4
1 4 3 6
S814-006000 S814-106000
4 8
1 5
1 5 4 8
S814-008000 S814-108000
4 12
1 9
12
4 12
1 9
S814-012000 S814-112000
3 14
1 11
14
1 11 3 14
S814-014000 S814-114000
4 - 54
4) CN TYPE CONNECTOR
No. of
pin
1 1
S810-001202 S810-101202
2 2
1 1
S810-002202 S810-102202
3 2
1 2 1 3
S810-003202 S810-103202
2 4 1 3
1 3 2 4
S810-004202 S810-104202
4 - 55
No. of
pin
3 6 1 4
1 4 3 6
S810-006202 S810-106202
4 8 1 5
1 5 4 8
S810-008202 S810-108202
4 - 56
5) 375 FASTEN TYPE CONNECTOR
No. of
pin
1 2 1 2
S810-002402 S810-102402
6) AMP ECONOSEAL CONNECTOR

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

No. of
pin
85202-1
4 - 57
8) AMP 040 MULTILOCK CONNECTOR
No. of
pin
12 1 6
7 12
174045-2
9) AMP 070 MULTILOCK CONNECTOR

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

No. of
pin
3 1
6
6 4
1
4 6 3
480003-9
925276-0
4 - 58
11) KET 090 CONNECTOR
No. of
pin
1
2
MG610070
12) KET 090 WP CONNECTORS

No. of
pin
1
2
MG640605
2 1
MG640795
4 - 59
13) KET SDL CONNECTOR
No. of
pin
14
7
6
14
MG610406
4 - 60
14) DEUTSCH DT CONNECTORS
DT 06 - 3S - ★★★★
Modifications (see below)

Number of contacts (P : Pin, S : Socket)
04 : Receptacle, 06 : Plug
Deutsch connectors
※ Modification
E003 : Standard end cap - gray
E004 : Color of connector to be black
E005 : Combination - E004 & E003
EP04 : End cap
EP06 : Combination P012 & EP04
P012 : Front seal enhancement - connectors color to black for 2, 3, 4 & 6pin
No. of
pin
1 2 2 1
2
DT06-2S DT04-2P
2 1 1 2
3 3
DT06-3S DT04-3P
4 1 1 4
3 2 2 3
DT06-4S DT04-4P
4 - 61
No. of
pin
6 1 1 6
4 3 3 4
DT06-6S DT04-6P
4 5 5 4
1 8
8 1
DT06-8S DT04-8P
7 6
6 7
12
1 12 12 1
DT06-12S DT04-12P
4 - 62
15) MOLEX 2CKTS CONNECTOR
No. of
pin
1 2
35215-0200
35215-0200
16) ITT SWF CONNECTOR

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

No. of
pin
1
1
NMWP01F-B
4 - 63
18) ECONOSEAL J TYPE CONNECTORS
No. of
pin
S816-001002 S816-101002
1 2 2 1
S816-002002 S816-102002
S816-003002 S816-103002
S816-004002 S816-104002
4 - 64
No. of
pin
S816-006002 S816-106002
S816-008002 S816-108002
10
S816-010002 S816-110002
12
S816-012002 S816-112002
4 - 65
No. of
pin
15
368301-1 2-85262-1
19) METRI-PACK TYPE CONNECTOR

No. of
pin
12040753
20) DEUTSCH HD30 CONNECTOR

No. of
pin
J K
K J
B
23 N T
A B
F
F Q N
Q A
HD36-24-23SN HD34-24-23PN
4 - 66
21) DEUTSCH MCU CONNECTOR
No. of
Receptacle connector (Female) Plug connector (Male)
pin
5
1 6
11 1
10
2
3
11 4
5
21
6
40 21 31
32
7
8
9
33 10
34
35
31 36
37
20
30
20
38
39
35 40
36
30
40
DRC26-40SA/B/C
22) DEUTSCH SERVICE TOOL CONNECTOR

No. of
pin
C
D
E
A
9
F
B
G
H J
HD10-9-96P
23) AMP FUEL WARMER CONNECTOR

No. of
pin
3 2
2-967325-3
4 - 67
24) DEUTSCH E
ENGINE
NGINE ECM CONNECTOR
No. of
pin
1 5
6
11
1
10
2
11 3
4
21 5
21 31
6
7
50 31 41
42
8
9
10 20
43
44
41 45
20
46
47
30
40
30
48
45 49
50
46
50 40
DRC26-50S-04
25) DEUTSCH INTERMEDIATE CONNECTOR

No. of
pin
1
13 12
25 24
31
30
60 37
36
49
48
60
DRB16-60SAE-L018
4 - 68
Group 1 Outline----------------------------------------------------------------------------------------------------------------- 5-1

Group 2 Mode Selection System ------------------------------------------------------------------------------------ 5-5
Group 3 Automatic Deceleration System ----------------------------------------------------------------------- 5-11
Group 4 Power Boost System ----------------------------------------------------------------------------------------- 5-13
Group 5 Travel Speed Control System --------------------------------------------------------------------------- 5-15
Group 6 Automatic Warming Up System ----------------------------------------------------------------------- 5-17
Group 7 Engine Overheat Prevention System --------------------------------------------------------------- 5-19
Group 8 Variable Power Control System ------------------------------------------------------------------------ 5-21
Group 9 Attachment Flow Control System --------------------------------------------------------------------- 5-22
Group 10 Anti-Restart System ------------------------------------------------------------------------------------------- 5-23
Group 11 Self-Diagnostic System ------------------------------------------------------------------------------------- 5-24
Group 12 Engine Control System ------------------------------------------------------------------------------------- 5-31
Group 13 EPPR Valve -------------------------------------------------------------------------------------------------------- 5-33
Group 14 Monitoring System --------------------------------------------------------------------------------------------- 5-39
Group 15 Fuel Warmer System ----------------------------------------------------------------------------------------- 5-71
GROUP 1 OUTLINE (CLUSTER TYPE 1)
The CAPO (Computer Aided Power Optimization) system controls engine and pump mutual power at
an optimum and less fuel consuming state for the selected work by mode selection, auto-deceleration,
power boost function, etc. It monitors machine conditions, for instance, engine speed, coolant
temperature, hydraulic oil temperature, and hydraulic oil pressure, etc.
It consists of a MCU, a cluster, an accel actuator, EPPR valves, and other components. The MCU and
the cluster protect themselves from over-current and high voltage input, and diagnose malfunctions
caused by short or open circuit in electric system, and display error codes on the cluster.
Power mode selection (P, S, E)

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

NEW CAPO
SYSTEM
Variable power control system
Attachment flow control system
Anti-restart system
MCU & cluster protection
Self-diagnostic system Open-short diagnosis & error code display
Machine error code display
Machine condition monitoring
Machine monitoring system
Electric signal monitoring
One touch deceleration system
5-1
SYSTEM DIAGRAM (CLUSTER TYPE 1)
Attachment pilot Work Travel

Work tool pressure pressure pressure
MCV
Option Bucket
SOLENOID VALVE Arm EPPR VALVE

Arm 1 regeneration
Travel speed Attachment Boom 2
pressure Arm 2
Swing priority
Power boost Attachment Boom 1 Boom priority

conflux Swing
EPPR
Arm regen Attachment Travel(LH) Travel(RH) Attachment

safety flow EPPR
Overload P1
pressure pressure
sensor
P2
pressure
Boom cylinder
Engine Main pump
Coolant
temp sensor P1 P2
P3
Pilot pump
Pump power
shift EPPR
Signal
Coolant temperature signal
Pressure signal
Pressure signal
Drive signal
MCU
Drive signal Pressure signal
Switch signal
Pressure signal Accel dial signal CN-16A CN-16
Power boost
button Normal
One touch
decel button Horn button CN-16B
Emergency
Option
button
LH control RH control Accel dial
lever lever
Serial communication(-)
Serial communication(+)
SL SR AO AI BI BU
Shuttle
block
Swing Boom up
pressure pressure Cluster
3009SH5MS01
5-2
■ OUTLINE (CLUSTER TYPE 2)
The NEW CAPO (Computer Aided Power Optimization) system controls engine and pump mutual
power at an optimum and less fuel consuming state for the selected work by mode selection, auto-
deceleration, power boost function, etc. It monitors machine conditions, for instance, engine speed,
coolant temperature, hydraulic oil temperature, and hydraulic oil pressure, etc.
It consists of a MCU, a cluster, an accel actuator, EPPR valves, and other components. The MCU and
the cluster protect themselves from over-current and high voltage input, and diagnose malfunctions
caused by short or open circuit in electric system, and display error codes on the cluster.
Engine control system

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

NEW CAPO
SYSTEM
Anti-restart system
MCU & cluster protection
Self-diagnostic system Open-short diagnosis & error code display
Machine error fault code display
Machine condition monitoring
Machine monitoring system
Electric signal monitoring
One touch deceleration system
5-3
SYSTEM DIAGRAM (CLUSTER TYPE 2)
Work Travel
pressure pressure
MCV
Option Bucket
SOLENOID VALVE Arm EPPR VALVE

Arm 1 regeneration
Travel speed Boom 2 Arm 2
Swing priority
Power boost Swing Boom 1
Arm regen Travel(LH) Travel(RH) Boom priority

EPPR
Overload P1
pressure pressure
sensor
P2
pressure
Boom cylinder
Engine Main pump
Coolant
temp sensor P1 P2
P3
Pilot pump
Pump power
shift EPPR
Signal
Pressure signal
Pressure signal
Drive signal
MCU
Drive signal Pressure signal
Signal
Accel dial signal CN-16A CN-16
Power boost
button Normal
One touch
decel button Horn button CN-16B
Emergency
Option
button
LH control RH control Accel dial
lever lever
Serial communication(-)
Serial communication(+)
Cluster
3009SH5MS20A
5-4
GROUP 2 MODE SELECTION SYSTEM (CLUSTER TYPE 1)
1. POWER MODE SELECTION SYSTEM
Main control valve
Engine
P1 P2
Main pump Pilot pump
Pump shift
EPPR
Cluster
Drive signal
MCU
Normal
CN-16B
Emergency
Power mode Accel dial

pilot lamp
Power mode switch signal
3009SH5MS02
Mode selection system (micro computer based electro-hydraulic pump and engine mutual control
system) optimizes the engine and pump performance.
The combination of 3 power modes (P, S, E) and accel dial position (10 set) makes it possible to use
the engine and pump power more effectively corresponding to the work conditions from a heavy and
great power requesting work to a light and precise work.
Engine rpm Power shift by EPPR valve
Power Standard Option Standard Option
Application
mode
Current Pressure Current Pressure
Unload Load Unload Load
(mA) (kgf/cm2) (mA) (kgf/cm2)
P Heavy duty power 2150±50 1950±50 2150±50 1950±50 420±30 16±3 290±30 8
S Standard power 2000±50 1800±50 2050±50 1850±50 420±30 16±3 400±30 15±3
E Economy operation 1850±50 1650±50 1900±50 1700±50 500±30 20±3 450±30 18±3
AUTO Engine
1150±100 - 1150±100 - 700±30 38±3 700±30 38±3
DECEL deceleration
One touch Engine quick
1000±100 - 1000±100 - 700±30 38±3 700±30 38±3
decel deceleration
KEY Key switch
1000±100 - 1000±100 - 700±30 38±3 700±30 38±3
START start position
※ Power shift (Standard/Option) can be changed by "Service menu" in "Management" on the cluster.
5-5
2. WORK MODE SELECTION SYSTEM
Work mode consists of the general operation (bucket) and the optional attachment (breaker,
crusher).
Attachment pilot
pressure sensor
Main control valve
Work tool
Option Bucket
SOLENOID VALVE
Arm
Arm 1 regeneration Attachment
pressure
Boom 2 Arm 2
Swing priority Attachment
conflux
Swing Boom 1
Attachment
Travel(LH) Travel(RH) safety
Engine

Pump power
shift EPPR
Cluster
Drive signal
Drive signal
MCU
Pressure signal
Normal
CN-16B
Emergency
Work mode
pilot lamp Work mode switch signal
Accel dial
3009SH5MS03
1) GENERAL WORK MODE (bucket)

This mode is used to general digging work.
2) ATT WORK MODE (breaker, crusher)
It controls the pump flow and system pressure according to the operation of breaker or crusher.
General mode Work tool

Description
Bucket Breaker Crusher
Attachment safety solenoid OFF ON ON
Attachment pressure solenoid OFF OFF ON
Attachment conflux solenoid OFF OFF ON/OFF
Attachment flow EPPR current 100 mA 100~700 mA 0~700 mA
5-6
3. USER MODE SELECTION SYSTEM
Main control valve
Engine

Pump power
shift EPPR
Drive signal
Cluster
MCU
Normal
CN-16B
Emergency
User mode Accel dial

pilot lamp
User mode switch signal
3009SH5MS04
1) High idle rpm, auto idle rpm and EPPR pressure can be adjusted and memorized in the U-mode.
2) LCD segment vs parameter setting
Step Engine speed Idle speed Power shift
( ) (rpm) (rpm) (bar)
1 1500 1000 (low idle) 0
2 1600 1050 3
3 1700 1100 6
4 1800 1150 (decel rpm) 9
5 1900 1200 12
6 1950 1250 16
7 2000 1300 20
8 2050 1350 26
9 2100 1400 32
10 2150 1450 38
5-7
■ MODE SELECTION SYSTEM (CLUSTER TYPE 2)
1. POWER MODE SELECTION SYSTEM
Main control valve
Engine
P1 P2
Pump shift
EPPR
Drive signal
Power mode
pilot lamp
MCU
Power mode switch signal Accel dial signal CN-16A CN-16
Work mode switch signal Normal
User mode switch signal
CN-16B
Emergency
Accel dial
Cluster
3009SH5MS21
Mode selection system (micro computer based electro-hydraulic pump and engine mutual control
system) optimizes the engine and pump performance.
The combination of 2 power modes (H, S) and accel dial position (10 set) makes it possible to use
the engine and pump power more effectively corresponding to the work conditions from a heavy and
great power requesting work to a light and precise work.
Engine rpm Power shift by EPPR valve
Power Standard Option Standard Option
Application
mode
Current Pressure Current Pressure
Unload Load Unload Load
(mA) (kgf/cm2) (mA) (kgf/cm2)
M Heavy duty power 2150±50 1950±50 2150±50 1950±50 350±30 11±3 290±30 8±3
H Standard power 2000±50 1800±50 2050±50 1850±50 350±30 11±3 330±30 10±3
S Economy operation 1850±50 1650±50 1900±50 1700±50 400±30 15±3 365±30 13±3
AUTO Engine
1150±100 - 1150±100 - 700±30 38±3 700±30 38±3
DECEL deceleration
One touch Engine quick
1000±100 - 1000±100 - 700±30 38±3 700±30 38±3
decel deceleration
KEY Key switch
1000±100 - 1000±100 - 700±30 38±3 700±30 38±3
START start position
5-8
2. WORK MODE SELECTION SYSTEM
2 Work modes can be selected for the optional work speed of the machine operation.
Main control valve
Option Bucket
Arm
Arm 1 regeneration
Boom 2 Arm 2
Swing priority
Swing Boom 1
Travel(LH) Travel(RH)
Engine
Pump shift
EPPR
Drive signal
Power mode
pilot lamp MCU
Work mode switch signal Normal
CN-16B
Emergency
Accel dial
Cluster
3009SH5MS22
1) HEAVY DUTY WORK MODE

Boom and arm operation speed faster than general work mode.
2) GENERAL WORK MODE
When key switch is turned ON, this mode is selected and swing operation speed is faster than
heavy duty work mode.
Work mode Heavy duty work solenoid Max flow cut-off solenoid
Heavy duty OFF OFF
General ON OFF
5-9
3. USER MODE SELECTION SYSTEM
An operator can change the engine and pump power and memorize it for his preference.
Mode Operation
High idle rpm, auto decel rpm
U
EPPR pressure can be modulated and memorized separately
HOW TO MPDULATE THE MEMORY SET

1) Each memory mode has a initial set which are
mid-range of max engine speed, auto decel
rpm, and EPPR valve input current. ACCEL
DECEL
2) High idle rpm, auto decel rpm, EPPR pressure
EPPR
can be modulated and memorized separately in
the U-mode. 2507A4OP08
※ Refer to the page 5-68 for set of use mode.

·LCD
LCD segment vs parameter setting
SYSTEM MENU
Segment ACCEL DECEL EPPR
( ) (rpm) (rpm) (mA)
Monitoring Diagnosis Management
1 1500 1000 (low idle) 150

2 1600 1050 200 Settings Display User Mode
3 1700 1100 250 User mode icon

4 1800 1150 (decel rpm) 300
5 1900 1200 350
ACCEL
6 1950 1250 400 DECEL
7 2000 1300 450 EPPR
8 2050 1350 500

9 2100 1400 550
10 2150 1450 600
3009SH4OP05
5-10
GROUP 3 AUTOMATIC DECELERATION SYSTEM (CLUSTER TYPE 1)
Work Travel
pressure pressure
Main control valve

Engine
Cluster
Pressure signal

MCU
Normal
Auto idle
pilot lamp CN-16B
Emergency
Accel dial
Auto idle switch signal
3009SH5MS05
1. WHEN AUTO IDLE PILOT LAMP ON

When all of the work equipment control levers including swing and travel levers are at neutral for 4
seconds, MCU drives the accel actuator to reduce the engine speed to 1150 rpm. If the control levers
are at neutral for 1 minute, MCU reduces the engine speed to 1000 rpm. As the result of reducing the
engine speed, fuel consumption and noise are effectively cut down during non-operation of the
control levers.
When the Auto idle pilot lamp is turned off by pressing the switch or any control lever is operated, the
reduced engine speed rises upto the speed before deceleration in a second.
Engine rpm
Accel dial
set rpm
Auto idle 1150 rpm

rpm
4 sec
Low idle 1000 rpm
rpm
60 sec 1sec
Lever Lever Time

neutral operation
3009SH5MS06
2. WHEN AUTO IDLE PILOT LAMP OFF

The engine speed can be set as desired using the accel dial switch, and even if the control levers are
neutral, the engine speed is not reduced.
※ Auto idle function can be activated when accel dial position is over 4.
5-11
■ AUTOMATIC DECELERATION SYSTEM (CLUSTER TYPE 2)
Work Travel
pressure pressure
Main control valve

Engine
P3
Pump power
shift EPPR
Signal
Pressure signal
MCU Accel dial signal CN-16A CN-16
Normal
CN-16B
Emergency
Auto decel
pilot lamp
Accel dial
Cluster
3009SH5MS23
1. WHEN AUTO IDLE PILOT LAMP ON

When all of the work equipment control levers including swing and travel levers are at neutral for 4
seconds, MCU drives the accel actuator to reduce the engine speed to 1150 rpm. If the control levers
are at neutral for 1 minute, MCU reduces the engine speed to 1000 rpm. As the result of reducing the
engine speed, fuel consumption and noise are effectively cut down during non-operation of the
control levers.
When the Auto idle pilot lamp is turned off by pressing the switch or any control lever is operated, the
reduced engine speed rises upto the speed before deceleration in a second.
Engine rpm
Accel dial
set rpm
Auto idle 1150 rpm

rpm
4 sec
Low idle 1000 rpm
rpm
60 sec 1sec
Lever Lever Time

neutral operation
3009SH5MS06
2. WHEN AUTO IDLE PILOT LAMP OFF

The engine speed can be set as desired using the accel dial switch, and even if the control levers are
neutral, the engine speed is not reduced.
※ Auto idle function can be activated when accel dial position is over 4.
5-12
GROUP 4 POWER BOOST SYSTEM (CLUSTER TYPE 1)
Main control valve
Option Bucket
Arm
Arm 1 regeneration
Boom 2 Arm 2
Swing priority
Swing Boom 1
Main relief
valve
P1 P2
pressure pressure
Power boost
solenoid valve
Engine

Pump power
Power boost shift EPPR
button
Signal
LH control
lever Drive signal
Power boost button signal
Pressure signal
MCU
Normal
CN-16B
Emergency
Accel dial
Power max Power mode sw signal
pilot lamp
Cluster 3009SH5MS07
· When the power boost switch on the left control lever knob is pushed ON, the power mode is set P
mode and maximum digging power is increased by 10 %.
· When the power boost function is activated, the power boost solenoid valve pilot pressure raises the
set pressure of the main relief valve to increase the digging power.
Description Condition Function

- Power mode : P
- Accel dial power : 9
Power boost switch : ON
Activated - Power boost solenoid : ON
Accel dial : over 8
- Power boost pilot lamp : ON
- Operating time : max 8 seconds
- Pre-set power mode
Canceled Power boost switch : OFF - Power boost solenoid : OFF
- Power boost pilot lamp : OFF
※ When the auto power boost is set to Enable and power mode is set to P mode on the cluster, the
digging power is automatically increased as working conditions by the MCU. It is operated max 8
seconds.
5-13
■ POWER BOOST SYSTEM (CLUSTER TYPE 2)
Main control valve
Option Bucket
Arm
Arm 1 regeneration
Boom 2 Arm 2
Swing priority
Swing Boom 1
Main relief
valve
P1 P2
pressure pressure
Power boost
solenoid valve
Engine Main pump
P1 P2
P3
Pilot pump
Pump power
shift EPPR
Power boost
button
Signal
Pressure signal
LH control
lever Drive signal
MCU
Power max button signal
Power mode switch signal Normal
CN-16B
Emergency
Cluster Accel dial
3009SH5MS24
· When the power boost switch on the left control lever knob is pushed ON, the maximum digging
power is increased by 10 %.
· When the power set is at M, H or S and the power boost function is activated, the power solenoid
valve pilot pressure raises the set pressure of the main relief valve to increase the digging power.
Power boost switch

Description
OFF ON
H or S H
Power set
M M
2
Main relief valve set pressure 350 kgf/cm 380 kgf/cm2
Even when pressed continuousty, it
Time of operation -
is canceled after 8 sec.
※ Default - Power boost solenoid valve : OFF
5-14
GROUP 5 TRAVEL SPEED CONTROL SYSTEM (CLUSTER TYPE 1)
Main control valve Travel motor
Option Bucket
Arm
Arm 1 regeneration
Boom 2 Regulator
Arm 2
Swing priority
Swing Boom 1
Travel speed
solenoid valve
Engine
Cluster
Drive signal
MCU
Travel speed
pilot lamp
Travel speed switch signal
29095MS06
Travel speed can be switched manually by pressing the travel speed switch on the cluster.
Travel speed Lamp

Speed Operation
solenoid valve on cluster
Low OFF Turtle Low speed, high driving torque in the travel motor
High ON Rabbit High speed, low driving torque in the travel motor
※ Default : Turtle (Low)
5-15
■ TRAVEL SPEED CONTROL SYSTEM (CLUSTER TYPE 2)
Main control valve Travel motor
Option Bucket
Arm
Arm 1 regeneration
Boom 2 Regulator
Arm 2
Swing priority
Swing Boom 1
Travel(LH) Travel(RH) Travel speed

solenoid valve
Engine
Drive signal
Travel speed pilot lamp MCU
Travel speed switch signal
Cluster
3009SH5MS25
Travel speed can be switched manually by pressing the travel speed switch on the cluster.
Travel speed Lamp

Speed Operation
solenoid valve on cluster
Low OFF Turtle Low speed, high driving torque in the travel motor
High ON Rabbit High speed, low driving torque in the travel motor
※ Default : Turtle (Low)
5-16
GROUP 6 AUTOMATIC WARMING UP SYSTEM (CLUSTER TYPE 1)
Main control valve

Engine
Coolant
temp sensor

Pump power
shift EPPR

Hydraulic temp signal
Cluster MCU Drive signal Hydraulic temp sensor
Normal
CN-16B
Emergency
Accel dial
Warming up pilot lamp signal
Warming up pilot lamp
3009SH5MS08
1. The MCU reads engine coolant temperature through the temperature sensor, and if the coolant
temperature is below 30˚C, it increases the engine speed from key start rpm to 1150rpm. At this
time the mode does not change. If the coolant temperature sensor has fault, the hydraulic oil
temperature signal is substituted.
2. In case of the coolant temperature increases up to 30˚C, the engine speed is decreased to key start
speed. And if an operator changes power mode set during the warming up function, the MCU
cancels the automatic warming up function.
3. LOGIC TABLE

- Coolant temperature : - Power mode : Default (E mode)
Actuated below 30˚C (after engine run) - Warming up time : 10 minutes (max)
- Warming up pilot lamp : ON
- Coolant temperature : Above 30˚C - Power mode : set mode

- Warming up time : Above 10 minutes - Warming up pilot lamp : OFF
- Changed power mode set by operator
Canceled - RCV lever or pedal operating
- Auto idle cancel
※ If any of the above conditions is
applicable, the automatic warming up
function is canceled
5-17
■ AUTOMATIC WARMING UP SYSTEM (CLUSTER TYPE 2)
Main control valve

Engine

Cluster Pump power
shift EPPR
Coolant temp signal

Warming up
pilot lamp MCU Coolant temp sensor
Drive signal
Warming up pilot lamp signal
Normal
CN-16B
Emergency
Accel dial
3009SH5MS26
1. The MCU reads engine coolant temperature through the temperature sensor, and if the coolant
temperature is below 30˚C, it increases the engine speed from key start rpm to 1150rpm. At this
time the mode does not change.
2. In case of the coolant temperature increases up to 30˚C, the engine speed is decreased to key start
speed. And if an operator changes mode set during the warming up function, the MCU cancels the
automatic warming up function.
3. LOGIC TABLE
- Coolant temperature : - Power mode : Default (S mode)
Actuated below 30˚C (after engine run) - Warming up time : 10 minutes (max)
- Accel dial poisition is under 30˚C - Warming up lamp : ON
- Coolant temperature : Above 30˚C - Power mode : set mode

- Warming up time : Above 10 minutes - Warming up pilot lamp : OFF
- Changed mode set by operator
Canceled - Increase engine speed by rotating accel
dial clockwise
※ If any of the above conditions is
applicable, the automatic warming up
function is canceled
Warming up lamp - Coolant temperature : Above 30˚C - Warming up lamp : OFF
5-18
GROUP 7 ENGINE OVERHEAT PREVENTION SYSTEM (CLUSTER TYPE 1)
Main control valve

Engine
Coolant
temp sensor

Pump power
shift EPPR

Emergency
warning lamp MCU Drive signal
Hydraulic temp sensor
Cluster
Normal
CN-16B
Emergency
Accel dial
Overheat warning signal
Coolant temperature Hydraulic temperature

warning lamp warning lamp
3009SH5MS09A
1. The engine coolant temperature or the hydraulic oil temperature is overheated over 100˚C, the
warning lamp is ON and the pump input torque or the engine speed is reduced as below logic table.
2. LOGIC TABLE
- Coolant or hydraulic oil temperature : - Warning lamp & buzzer : ON
Activated
First step Above 100˚C - Pump input torque is reduced.
warning - Coolant or hydraulic oil temperature : - Return to pre-set the pump input torque.
Canceled
Less than 95˚C
- Emergency warning lamp pops up on the
- Coolant or hydraulic oil temperature :
Activated center of LCD and the buzzer sounds.
Above 105˚C
Second step - Engine speed is reduced after 10 seconds.
warning - Return to pre-set the engine speed.
- Coolant or hydraulic oil temperature :
Canceled - Hold pump input torque on the first step
Less than 100˚C
warning.
5-19
■ ENGINE OVERHEAT PREVENTION SYSTEM (CLUSTER TYPE 2)
Main control valve

Engine
Coolant
temp sensor

Pump power
shift EPPR

Hydraulic temperature Coolant temperature MCU Drive signal Hydraulic temp sensor
warning lamp warning lamp
Normal
CN-16B
Emergency
Accel dial
Overheat warning signal
Cluster 3009SH5MS27
1. MCU receives engine coolant temperature through the temperature sensor and when the engine
coolant boils up to 110˚C, it sends overheat warning signal to the cluster and decrease the engine
speed same as accel dial 7 position.
2. If the coolant temperature drops less than 100˚C, the MCU returns the mode to the mode set before.
And if mode set is changed during the function, the MCU cancels the function.
Even if the overheat prevention function is canceled by mode change, the overheat warning lamp
turns OFF only when the coolant temperature is less than 100˚C.
3. LOGIC TABLE
- Coolant temperature : Above 110˚C - Engine rpm drop to accel dial 7 position
Actuated
- Accel dial set : Above 8 - Overheat warning lamp & buzzer : ON
- Coolant temperature : Less than 100˚C - Return to the mode and accel dial set before
- Changed mode set by operator - Hold on the changed set
Canceled ※ If any of the above conditions is
applicable, engine overheat
prevention function is canceled
Overheat warning lamp - Coolant temperature : Less than 100˚C - Overheat warning lamp : OFF
5-20
GROUP 8 VARIABLE POWER CONTROL SYSTEM (CLUSTER TYPE 1)
Work Travel
pressure pressure
Main control valve
P1 P2
pressure pressure
Engine

Pump power
shift EPPR
Signal
Pressure signal
MCU Pressure signal

Switch signal
Pressure signal Accel dial signal CN-16A CN-16
LH control RH control
lever lever Normal
CN-16B
Emergency
AO AI BI BU
Accel dial
Shuttle
block
Boom up
pressure
E mode power
Cluster
3009SH5MS10
· The variable power control system controls the engine and pump mutual power according to RCV
lever stroke and pump load.
It makes fuel saving and smooth control at precise work.
Description Working condition
Power mode E
Work mode General (bucket)
Pressure sensor Normal
※ The variable power control function can be activated when the power mode is set to E mode.
5-21
GROUP 9 ATTACHMENT FLOW CONTROL SYSTEM (CLUSTER TYPE 1)
Attachment pilot
pressure sensor
Main control valve
Work tool
Option Bucket SOLENOID VALVE
Arm
Arm 1 regeneration Attachment
pressure
Boom 2 Arm 2
Swing priority Attachment
conflux
Swing Boom 1
Attachment
safety
Engine

Attachment
flow EPPR
Cluster Drive signal
Drive signal
MCU
Pressure signal
Normal
CN-16B
Emergency
Accel dial
Work mode
pilot lamp Work mode switch signal
3009SH5MS11
· The system is used to control the pump delivery flow according to set of the work tool on the
cluster by the attachment flow EPPR valve.
Work tool
Description
Breaker Crusher
Max 7 step, Max 4 step,
Flow level reduced 10 lpm each step reduced 20 lpm each step
Attach safety solenoid ON ON
Attach pressure solenoid OFF ON
Attach conflux solenoid OFF ON/OFF
※ Refer to the page 5-51 for the attachment kinds and max flow.
5-22
GROUP 10 ANTI-RESTART SYSTEM
Engine
Starter
Start safety relay
Drive signal
MCU
Normal
CN-16B
Emergency
Accel dial
3009SH5MS12
1. ANTI-RESTART FUNCTION
After a few seconds from the engine starts to run, MCU turns off the start safety relay to protect the
starter from inadvertent restarting.
2. When a replacement or taking-off of the MCU is needed, connect CN-16 and CN-16B to ensure the
engine start without the MCU.
5-23
GROUP 11 SELF-DIAGNOSTIC SYSTEM (CLUSTER TYPE 1)
1. OUTLINE
When any abnormality occurs in the ADVENCED CAPO system caused by electric parts
malfunction and by open or short circuit, the MCU diagnoses the problem and sends the error codes
to the cluster and also stores them in the memory.
2. MONITORING
1) Active fault
21093CD66
21093CD66A-1 21093CD66B
· The active faults of the MCU can be checked by this menu.
2) Logged fault
21093CD66C
21093CD66D-1 21093CD66E
· The logged faults of the MCU can be checked by this menu.
3) Delete fault
21093CD66F
21093CD66G 21093CD66H
· The logged faults of the MCU can be deleted by this menu.
5-24
3. MACHINE ERROR CODES TABLE
Error code
Description
HCESPN FMI
3 Hydraulic oil temperature sensor circuit - Voltage above normal, or shorted to high source.
101
4 Hydraulic oil temperature circuit - Voltage below normal, or shorted to low source.
0 Working pressure sensor data above normal range.
1 Working pressure sensor data below normal range.
105
2 Working pressure sensor data error.
4 Working pressure sensor circuit - Voltage below normal, or shorted to Low source.
0 Travel oil pressure sensor data above normal range.
1 Travel oil pressure sensor data below normal range.
108
2 Travel oil pressure sensor data error.
4 Travel oil pressure sensor circuit - Voltage below normal, or shorted to low source.
0 Main pump 1 (P1) pressure sensor data above normal range.
1 Main pump 1 (P1) pressure sensor data below normal range.
120 2 Main pump 1 (P1) pressure sensor data error.
Main pump 1 (P1) pressure sensor circuit - Voltage below normal, or shorted to low
4
source.
0 Main pump 2 (P2) pressure sensor data above normal range.
1 Main pump 2 (P2) pressure sensor data below normal range.
121 2 Main pump 2 (P2) pressure sensor data error.
Main pump 2 (P2) pressure sensor circuit - Voltage below normal, or shorted to low
4
source.
0 Overhead pressure sensor data above normal range.
1 Overhead pressure sensor data below normal range.
122
2 Overhead pressure sensor data error.
4 Overhead pressure sensor circuit - Voltage below normal, or shorted to low source.
0 Negative 1 pressure sensor data above normal range.
1 Negative 1 pressure sensor data below normal range.
123
2 Negative 1 pressure sensor data error.
4 Negative 1 pressure sensor circuit - Voltage below normal, or shorted to low source.
0 Negative 2 Pressure sensor data above normal range.
1 Negative 2 Pressure sensor data below normal range.
124
2 Negative 2 Pressure sensor data error.
4 Negative 2 Pressure sensor circuit - Voltage below normal, or shorted to low source.
0 Pilot pump (P3) pressure sensor data above normal range.
1 Pilot pump (P3) pressure sensor data below normal range.
125
2 Pilot pump (P3) pressure sensor data error.
4 Pilot pump (P3) pressure sensor circuit - Voltage below normal, or shorted to low source.
0 Boom up pilot pressure sensor data above normal range.
1 Boom up pilot pressure sensor data below normal range.
127
2 Boom up pilot pressure sensor data error.
4 Boom up pilot pressure sensor circuit - Voltage below normal, or shorted to low source.
0 Swing pilot pressure sensor data above normal range.
1 Swing pilot pressure sensor data below normal range.
135
2 Swing pilot pressure sensor data error.
4 Swing pilot pressure sensor circuit - Voltage below normal, or shorted to low source.
※ Some error codes are not applied to this model.
5-25
Error code
Description
HCESPN FMI
0 Attachment pilot pressure sensor data above normal range.
1 Attachment pilot pressure sensor data below normal range.
138
2 Attachment pilot pressure sensor data error.
4 Attachment pilot pressure sensor circuit - Voltage below normal, or shorted to low source.
5 Pump EPPR valve circuit - Current below normal, or open circuit.
140
6 Pump EPPR valve circuit - Current above normal.
5 Boom priority EPPR valve circuit - Current below normal, or open circuit.
141
6 Boom priority EPPR valve circuit - Current above normal.
5 Travel EPPR valve circuit - Current below normal, or open circuit.
143
6 Travel EPPR valve circuit - Current above normal.
5 Attachment flow EPPR valve circuit - Current below normal, or open circuit.
144
6 Attachment flow EPPR valve circuit - Current above normal.
5 Remote cooling fan EPPR valve circuit - Current below normal, or open circuit.
145
6 Remote cooling fan EPPR valve circuit - Current above normal.
5 Left rotate EPPR valve circuit - Current below normal, or open circuit.
150
6 Left rotate EPPR valve circuit - Current above normal.
5 Right rotate EPPR valve circuit - Current below normal, or open circuit.
151
6 Right rotate EPPR valve circuit - Current above normal.
5 Left tilt EPPR valve circuit - Current below normal, or open circuit.
152
6 Left tilt EPPR valve circuit - Current above normal.
5 Right tilt EPPR valve circuit - Current below normal, or open circuit.
153
6 Right tilt EPPR valve circuit - Current above normal.
5 Power max solenoid circuit - Current below normal, or open circuit.
166
6 Power max solenoid circuit - Current above normal.
5 Travel speed solenoid circuit - Current below normal, or open circuit.
167
6 Travel speed solenoid circuit - Current above normal.
5 Attachment pressure solenoid circuit - Current below normal, or open circuit.
168
6 Attachment pressure solenoid circuit - Current above normal.
5 Attachment conflux solenoid circuit - Current below normal, or open circuit.
169
6 Attachment conflux solenoid circuit - Current above normal.
5 Arm regeneration solenoid circuit - Current below normal, or open circuit.
170
6 Arm regeneration solenoid circuit - Current above normal.
5 Attachment safety solenoid circuit - Current below normal, or open circuit.
171
6 Attachment safety solenoid circuit - Current above normal.
5 Remote cooling fan reverse solenoid circuit - Current below normal, or open circuit.
181
6 Remote cooling fan reverse solenoid circuit - Current above normal.
0 Pump EPPR 2nd pressure sensor data above normal range.
1 Pump EPPR 2nd pressure sensor data below normal range.
200
2 Pump EPPR 2nd pressure sensor data error.
4 Pump EPPR 2nd pressure sensor circuit - Voltage below normal, or shorted to low source.
5 Fuel level sensor circuit - Voltage above normal, or shorted to high source.
301
6 Fuel level sensor circuit - Voltage below normal, or shorted to low source.
Engine coolant temperature sensor circuit - Voltage above normal, or shorted to high
3
source.
304
Engine coolant temperature sensor circuit - Voltage below normal, or shorted to low
4
source.
310 8 Engine speed signal error - Abnormal frequency or pulse width.
3 Engine preheat relay circuit - Voltage above normal, or shorted to high source.
322
4 Engine preheat relay circuit - Voltage below normal, or shorted to low source.
3 Fuel warmer relay circuit - Voltage above normal, or shorted to high source.
325
4 Fuel warmer relay circuit - Voltage below normal, or shorted to low source.
5-26
Error code
Description
HCESPN FMI
3 Potentiometer (G/A) circuit - Voltage above normal, or shorted to high source.
340
4 Potentiometer (G/A) circuit - Voltage below normal, or shorted to low source.
5 Governor actuator circuit - Current below normal, or open circuit.
341
6 Governor actuator circuit - Current above normal.
0 Transmission oil pressure sensor data above normal range.
1 Transmission oil pressure sensor data below normal range.
501
2 Transmission oil pressure sensor data error.
4 Transmission oil pressure sensor circuit - Voltage below normal, or shorted to low source.
0 Brake pressure sensor data above normal range.
1 Brake pressure sensor data below normal range.
503
2 Brake pressure sensor data error.
4 Brake pressure sensor circuit - Voltage below normal, or shorted to low source.
0 Working brake pressure sensor data above normal range.
1 Working brake pressure sensor data below normal range.
505
2 Working brake pressure sensor data error.
4 Working brake pressure sensor circuit - Voltage below normal, or shorted to low source.
3 Working brake lamp circuit - Voltage above normal, or shorted to high source.
506
4 Working brake lamp circuit - Voltage below normal, or shorted to low source.
3 Ram lock lamp circuit - Voltage above normal, or shorted to high source.
520
4 Ram lock lamp circuit - Voltage below normal, or shorted to low source.
5 Ram lock solenoid circuit - Current below normal, or open circuit.
525
6 Ram lock solenoid circuit - Current above normal.
0 Travel F pilot pressure sensor data above normal range.
1 Travel F pilot pressure sensor data below normal range.
530
2 Travel F pilot pressure sensor data error.
4 Travel F pilot pressure sensor circuit - Voltage below normal, or shorted to low source.
0 Travel R pilot pressure sensor data above normal range.
1 Travel R pilot pressure sensor data below normal range.
531
2 Travel R pilot pressure sensor data error.
4 Travel R pilot pressure sensor circuit - Voltage below normal, or shorted to low source.
3 Hourmeter circuit - Voltage above normal, or shorted to high source.
701
4 Hourmeter circuit - Voltage below normal, or shorted to low source.
0 MCU input voltage high.
705
1 MCU input voltage low.
707 1 Alternator node I voltage low.
3 Acc. dial circuit - Voltage above normal, or shorted to high source.
714
4 Acc. dial circuit - Voltage below normal, or shorted to low source.
3 Rotate signal input circuit - Voltage above normal, or shorted to high source.
715
4 Rotate signal input circuit - Voltage below normal, or shorted to low source.
3 Tilt signal input circuit - Voltage above normal, or shorted to high source.
716
4 Tilt signal input circuit - Voltage below normal, or shorted to low source.
3 Travel alarm (buzzer) circuit - Voltage above normal, or shorted to high source.
722
4 Travel alarm (buzzer) circuit - Voltage below normal, or shorted to low source.
830 12 MCU internal memory error.
840 2 Cluster communication data error.
843 2 Option #1 (CAN 2) communication data error.
850 2 RCM communication data error.
5-27
■ SELF-DIAGNOSTIC SYSTEM (CLUSTER TYPE 2)
1. OUTLINE
When any abnormality occurs in the NEW CAPO system caused by electric parts malfunction and
by open or short circuit, the MCU diagnoses the problem and sends the error codes to the cluster
and also stores them in the memory.
2. CURRENT
URRENT ERROR DISPLAY
(Error display)
(Recorded error delete)
5-28
3. ERROR CODES TABLE
Error code No. Description
1 Short circuit in accel actuator system
2 Potentiometer circuit is shorted to Vcc (5V) or battery +
3 Short circuit in pump EPPR valve system
4 Short circuit in boom down EPPR valve system
5 Short circuit in travel speed solenoid system
6 Short circuit in power boost solenoid system
7 Short circuit in max flow solenoid system
10 Short circuit in hour-meter system
11 Accel dial circuit is shorted to Vcc (5 V) or battery +
12 P1 pressure sensor circuit is shorted to power supply (24V) line
15 Boom down pressure circuit is shorted to power supply (24V) line
16 Accel actuator circuit is open or shorted to ground
17 Potentiometer circuit is open or shorted to ground
18 Pump EPPR valve circuit is open or shorted to ground
19 Boom down EPPR valve circuit is open or shorted to ground
20 Travel speed solenoid circuit is open or shorted to ground
21 Power boost solenoid circuit is open or shorted to ground
22 Max flow solenoid circuit is open or shorted to ground
25 Hour-meter circuit is open or shorted to ground
26 Accel dial circuit is open or shorted to ground
27 P1 pressure sensor circuit is open or shorted to ground
30 Boom down pressure sensor circuit is open or shorted to ground
31 Engine preheater circuit is open or shorted to ground
32 Travel alarm buzzer circuit is open or shorted to ground
33 Altemator circuit is open or shorted to ground
34 Controller input voltage is below 18V
5-29
Error code No. Description
35 Controller input voltage is below 38V
36 Communication error with cluster
37 Engine speed sensor circuit is open or shorted to ground
38 Aati-restart relay circuit is open or shorted to ground
39 Accel actuator does not stop at a target position
40 There is more than 500 rpm difference between target speed and actual speed
41 Hydraulic oil temperature sensor circuit is shorted to ground
42 Fuel level sensor circuit is shorted to ground
43 Coolant temperature sensor circuit is shorted to ground
44 Boom up pressure sensor circuit is shorted to power supply (24V) line
45 Hydraulic oil temperature sensor circuit is open or shorted to battery +
46 Fuel level sensor circuit is open or shorted to battery +
47 Coolant temperature sensor circuit is open or shorted to battery +
48 Boom up pressure sensor circuit is open or shorted to ground
49 Engine preheater circuit is shorted to battery +
51 Heavy duty work solenoid circuit is open or shorted to battery +
56 Travel alarm buzzer circuit is shorted to battery +
58 Heavy duty work solenoid circuit is shorted to battery +
5-30
GROUP 12 ENGINE CONTROL SYSTEM
1. MCU (Machine Control Unit)
HY
UN
MO DA
DE I
L:
R3
20
-9
FUEL TANK
TOOL BOX
Fuel tank
LED
HY
1 MCU
UN
MO DA
DE I
L:
R2
10
-9
CN
2 Bolt (M8)
-51
1
2 CN
-52
3009SH5MS13
2. MCU ASSEMBLY
1) To match the pump absorption torque with the engine torque, MCU varies EPPR valve output
pressure, which control pump discharge amount whenever feedbacked engine speed drops under
the reference rpm of each mode set.
2) Three LED lamps on the MCU display as below.
LED lamp Trouble Service
G is turned ON Normal -
G and R are turned ON Trouble on MCU · Change the MCU

G and Y are turned ON Trouble on serial · Check if serial communication
communication line lines between controller and cluster are
disconnected
Three LED are turned OFF Trouble on MCU power · Check if the input power wire (24 V, GND) of
controller is disconnected
· Check the fuse
G : green, R : red, Y : yellow
5-31
3. EXCHANGE METHOD OF THE ROM IN
2
THE CLUSTER (TYPE 2)
1) Disassemble screws (2) and wiper motor 4
cover (1).
3
2) Disassemble hexgon socket bolts (3) and 1
cluster (4).
3009SH5MS28
4) Loosen the screws (6EA) located back of

the cluster. Screw
5) Then you can open the upper case of the

Cluster
cluster easily.
Upper case
3009SH5MS29
6) Install the new ROM. (Be careful of

direction and assemlbe the cluster in the
reverse order to removal).
Same
direction
21075MS14
5-32
GROUP 13 EPPR VALVE (CLUSTER TYPE 1)
1. PUMP EPPR VALVE

1) COMPOSITION
EPPR (Electro Proportional Pressure Reducing) valve consists of electro magnet and spool valve
installed at main pump.
(1) Electro magnet valve
Receive electric current from MCU and move the spool proportionally according to the specific
amount of electric current value.
(2) Spool valve
Is the two way direction control valve for pilot pressure to reduce main pump flow.
When the electro magnet valve is activated, pilot pressure enters into flow regulator of main pump.
(3) Pressure and electric current value for each mode
Pressure Electric current Engine rpm
Mode
kgf/cm
2 psi (mA) (at accel dial 10)
P 16 ± 3 228 ± 40 420 ± 30 2150 ± 50
Standard
S 16 ± 3 228 ± 40 420 ± 30 2000 ± 50
(Stage : 1.0)
E 20 ± 3 284 ± 40 500 ± 30 1850 ± 50
P 8±3 114 ± 40 290 ± 30 2150 ± 50
Option
S 15 ± 3 213 ± 40 400 ± 30 2050 ± 50
(Stage : 2.0)
E 18 ± 3 256 ± 40 450 ± 30 1900 ± 50
2) HOW TO SWITCH THE STAGE (1.0 ↔ 2.0) ON THE CLUSTER

You can switch the EPPR valve pressure set by selecting the stage (1.0 ↔ 2.0).
- Management
·Service menu
21093CD67M
21093CD67N 21093CD67P
Enter the password
21093CD67ZZ
· Power shift (standard/option) : Power shift pressure can be set by option menu.
5-33
■ EPPR VALVE (CLUSTER TYPE 2)
1. PUMP EPPR VALVE

1) COMPOSITION
EPPR (Electro Proportional Pressure Reducing) valve consists of electro magnet and spool valve
installed at main pump.
(1) Electro magnet valve
Receive electric current from MCU and move the spool proportionally according to the specific
amount of electric current value.
(2) Spool valve
Is the two way direction control valve for pilot pressure to reduce hydraulic pump flow.
When the electro magnet valve is activated, pilot pressure enters into flow regulator of hydraulic
pump.
So, pump flow decreases to prevent engine stall.
(3) Pressure and electric current value for each mode
Pressure Electric current Engine rpm
Mode
kgf/cm
2 psi (mA) (at accel dial 10)
M 11 ± 3 156 ± 40 350 ± 30 2150 ± 50
Standard
H 11 ± 3 156 ± 40 350 ± 30 2000 ± 50
(Stage : 1.0)
S 15 ± 3 213 ± 40 400 ± 30 1850 ± 50
M 8±3 114 ± 40 290 ± 30 2150 ± 50
Option
H 10 ± 3 142 ± 40 330 ± 30 2050 ± 50
(Stage : 2.0)
S 13 ± 3 185 ± 40 365 ± 30 1900 ± 50
2) HOW TO SWITCH VERSION (3.1 ↔ 4.1) ON THE CLUSTER

You can switch the EPPR valve pressure set by selecting the version (3.1 ↔ 4.1).
- Dual mode
·Changing the MCU mode
5-34
3) OPERATING PRINCIPLE (pump EPPR valve, cluster type 1,2)
(1) Structure
6 7
2 3 4 5
5-22(1)
1 Sleeve 4 O-ring 6 Solenoid valve

2 Spring 5 O-ring 7 Connector
3 Spool
A
P Pilot oil supply line (pilot pressure)
P
T Return to tank
T
A Secondary pressure to flow regulator at main pump
(2) Neutral
eutral
Pressure line is blocked and A oil returns
to tank.
P A
P T
T
A
(3) Operating
perating
Secondary pressure enters into A.
P A
T
P T
A
5-22(2)
5-35
4) EPPR VALVE CHECK PROCEDURE Spec : 100~700 mA
(Cluster type 1,2)
Adapter(P/no.:21Q6-50410)
(1) Check electric current value at EPPR valve
CN-75
① Disconnect connector CN-75 from Multimeter
EPPR valve.
② Insert the adapter to CN-75 and install
multimeter as figure. EPPR valve
③ Start engine.
④ Set power-mode and cancel auto decel
mode.
Main pump
: cluster type 1 : S mode
cluster type 2 : H mode
⑤ Position the accel dial at 10.
21095MS21
⑥ If tachometer show approx 2000±50
rpm disconnect one wire harness from
EPPR valve.
⑦ Check electric current at bucket circuit
relief position.
(2) Check pressure at EPPR valve Spec : 4~20 kgf/cm2 (60~280 psi)
① Remove plug and connect pressure
gauge as figure. Pressure adjusting
screw locknut
·Gauge capacity : 0 to 50 kgf/cm2 Supply line,
pilot pressure CN-75
(0 to 725 psi)
② Start engine.
③ Set power-mode and cancel auto decel
EPPR valve
mode.
: cluster type 1 : S mode
cluster type 2 : H mode
④ Position the accel dial at 10.
⑤ If tachometer show approx 2000±50
rpm check pressure at relief position of
bucket circuit by operating bucket control
29095MS10
lever.
⑥ If pressure is not correct, adjust it.
⑦ After adjust, test the machine.
5-36
2. BOOM PRIORITY EPPR VALVE (Cluster type 1,2)
1) COMPOSITION
The boom priority EPPR valve is built in a manifold and mainly consisting of valve body and coil.
This EPPR valve installed under the solenoid valve.
2) CONTROL
The boom priority EPPR valve has to be controlled by a specific electronic amplifier card, which is
supplying the coil with a current 580 mA at 30Ω and 24 V.
3) OPERATING PRINCIPLE
(1) Structure
1 5 4 6
P T
2 Control spool 3
21095MS14
P : Pilot supply line

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

2 Support ring 4 Coil 6 Cover cap
(2) Operation
In de-energized mode the inlet port (P) is closed and the outlet port (A) is connected to tank port
(T).
In energized mode the solenoid armature presses onto the control spool with a force
corresponding to the amount of current. This will set a reduced pressure at port A. The setting is
proportional to the amount of current applied.
(3) Maximum pressure relief
If a pressure from outside is applied on port A the valve may directly switch to tank port (T) and
protect the system before overload.
5-37
2) EPPR VALVE CHECK PROCEDURE Spec : 400~600 mA
(combined boom up and swing operation)
(1) Check electric current value at EPPR
valve
① Disconnect connector CN-133 from Solenoid valve
EPPR valve.
② Insert the adapter to CN-133 and install Boom priority
multimeter as figure. EPPR valve
③ Start engine.
④ If rpm display approx 2000±50 rpm CN-133
disconnect one wire harness from EPPR
valve.
⑤ Check electric current in case of Adapter
Multimeter (P/no.:21Q6-50410)
combined boom up and swing operation.
21095MS15
(2) Check pressure at EPPR valve Spec : 12~37 kgf/cm2 (170~530 psi)
① Remove hose from A5 port and connect (bucket relief operation)
pressure gauge as figure.
·Gauge capacity : 0 to 50 kgf/cm2 Pressure
gauge
(0 to 725 psi)
A5
② Start engine.
③ If rpm display approx 2000±50 rpm
check pressure at relief position of Solenoid valve
bucket circuit by operating bucket control
lever. Boom priority
EPPR valve
④ If pressure is not correct, adjust it.
⑤ After adjust, test the machine.
21095MS16
5-38
GROUP 14 MONITORING SYSTEM (CLUSTER TYPE 1)
1. OUTLINE
Monitoring system consists of the monitor part and switch part.
The monitor part gives warnings when any abnormality occurs in the machine and informs the
condition of the machine.
Various select switches are built into the monitor panel, which act as the control portion of the machine
control system.
2. CLUSTER
1) MONITOR PANEL
Time display
Warning lamps
(See page 5-43)
Gauge(See page 5-42)

Main menu(See page 5-50)
Engine rpm/Tripmeter
(See page 5-42)
Pilot lamps
(See page 5-46)
Switches
(See page 5-48)
3009SH5MS31
5-39
2) CLUSTER CHECK PROCEDURE
(1) Start key : ON
① Check monitor
a. Buzzer sounding for 4 seconds with HYUNDAI logo on cluster.
※ If the ESL mode is set to the enable, enter the password to start engine.
② After initialization of cluster, the operating screen is displayed on the LCD.
Also, self diagnostic function is carried out.
a. Engine rpm display : 0 rpm
b. Engine coolant temperature gauge : White range
c. Hydraulic oil temperature gauge : White range
d. Fuel level gauge : White range
※ When engine coolant temperature below 30˚C, the warming up pilot lamp lights up.
③ Indicating lamp state
a. Power mode pilot lamp : E mode or U mode
b. Work mode pilot lamp : General operation mode (bucket)
c. Travel speed pilot lamp : Low (turtle)
(2) Start of engine

① Check machine condition
a. RPM display indicates at present rpm
b. Gauge and warning lamp : Indicate at present condition.
※ When normal condition : All warning lamp OFF
c. Work mode selection : General work
d. Power mode selection : E mode or U mode
e. Travel speed pilot lamp : Low (turtle)
② When warming up operation
a. Warming up pilot lamp : ON
b. After engine started, engine speed increases to 1200rpm.
※ Others same as above.
③ When abnormal condition
a. The warning lamp lights up and the buzzer sounds.
b. If BUZZER STOP switch is pressed, buzzer sound is canceled but the lamp warning lights up
until normal condition.
※ The pop-up warning lamp moves to the original position and blink when the select switch is
pushed. Also the buzzer stops.
5-40
3. CLUSTER CONNECTOR
No. Name Signal
1 Battery 24V 20~32V
2 Signal 3 NTSC Cluster
3 GND -
4 Serial + (TX) 0~5V
5 Power IG (24V) 20~32V
6 Signal 2 NTSC 1 4
7 Camera signal NTSC
8 Serial - (RX) 0~5V CN-56
5 8
21095MS17
5-41
2) GAUGE
(1) Operation screen
Default Option 1 Engine coolant temperature gauge
2 Hydraulic oil temperature gauge
3 3 3 Fuel level gauge
1 2
1 4 RPM / Tripmeter display
2
4 4
21093CD07A
※ Operation screen type can be set by the screen type menu of the display.
Refer to page 5-60 for details.
(2) Engine coolant temperature gauge

① This gauge indicates the temperature of coolant.
·White range : 40-105˚C (104-221˚F)
·Red range : Above 105˚C (221˚F)
② If the indicator is in the red range or lamp blinks in red,
turn OFF the engine and check the engine cooling system.
※ If the gauge indicates the red range or lamp blinks in
21093CD07G
red even though the machine is on the normal condition,
check the electric device as that can be caused by the poor
connection of electricity or sensor.
(3) Hydraulic oil temperature gauge

① This gauge indicates the temperature of hydraulic oil.
·White range : 40-105˚C(104-221˚F)
·Red range : Above 105˚C(221˚F)
② If the indicator is in the red range or lamp blinks is red,
reduce the load on the system. If the gauge stays in the red
range, stop the machine and check the cause of the problem.
21093CD07E ※ If the gauge indicates the red range or lamp blinks in
(4) Fuel level gauge

① This gauge indicates the amount of fuel in the fuel tank.
② Fill the fuel when the red range, or lamp blinks in red.
※ If the gauge indicates the red range or lamp blinks in
21093CD07F
(5) RPM / Tripmeter display

① This displays the engine rpm or the tripmeter.
※ Refer to page 5-60 for details.
21093CD02D
5-42
3) WARNING LAMPS
Battery charging warning lamp Air cleaner warning lamp

Engine oil pressure warning lamp Overload warning lamp
Emergency warning lamp
Fuel level warning lamp

Engine coolant
temperature warning lamp Hydraulic oil temperature
warning lamp
4
3009SH3CD10
※ Each warning lamp on the top of the LCD pops up on the center of LCD and the buzzer sounds
when the each warning is happened. The pop-up warning lamp moves to the original position and
blinks when the select switch is pushed. And the buzzer stops.
Refer to page 5-49 for the select switch.
(1) Engine coolant temperature

① Engine coolant temperature warning is indicated two steps.
- 100˚C over : The lamp blinks and the buzzer sounds.
- 105˚C over : The lamp pops up on the center of LCD and
the buzzer sounds.
② The pop-up lamp moves to the original position and blinks
21093CD08A
when the select switch is pushed. Also, the buzzer stops and
lamp keeps blink.
③ Check the cooling system when the lamp keeps ON.
(2) Hydraulic oil temperature

① Hydraulic oil temperature warning is indicated two steps.
- 100˚C over : The lamp blinks and the buzzer sounds.
- 105˚C over : The lamp pops up on the center of LCD and
the buzzer sounds.
② The pop-up lamp moves to the original position and blinks
when the select switch is pushed. Also, the buzzer stops and
21093CD08C
lamp keeps blink.
③ Check the hydraulic oil level and hydraulic oil cooling system.
(3) Fuel level

① This warning lamp blinks and the buzzer sounds when the level
of fuel is below 55ℓ(14.53 U.S. gal).
② Fill the fuel immediately when the lamp blinks.
21093CD08B
5-43
(4) Emergency warning lamp
① This lamp pops up and the buzzer sounds when each of the
below warnings is happened.
- Engine coolant overheating (over 105˚C)
- Hydraulic oil overheating (over 105˚C)
- Pump EPPR circuit abnormal or open
21093CD30
- Attachment flow EPPR circuit abnormal or open
- MCU input voltage abnormal
- Accel dial circuit abnormal or open
- Cluster communication data error
※ The pop-up warning lamp moves to the original position and
blinks when the select switch is pushed. Also the buzzer stops.
This is same as following warning lamps.
② When this warning lamp blinks, machine must be checked and
serviced immediately.
(5) Engine oil pressure warning lamp

① This lamp blinks when the engine oil pressure is low.
② If the lamp blinks, shut OFF the engine immediately. Check oil
level.
21093CD32
(6) Battery charging warning lamp

① This lamp blinks when the battery charging voltage is low.
② Check the battery charging circuit when this lamp blinks.
21093CD34
(7) Air cleaner warning lamp

① This lamp blinks when the filter of air cleaner is clogged.
② Check the filter and clean or replace it.
21093CD35
5-44
(8) Overload warning lamp (opt)
① When the machine is overload, the overload warning lamp
blinks during the overload switch is ON. (if equipped)
② Reduce the machine load.
21093CD36
5-45
4) PILOT LAMPS
Work tool mode pilot lamp Message display

Work mode pilot lamp Travel speed pilot lamp
Power/User mode pilot lamp 4
Auto idle pilot lamp
Power max pilot lamp Maintenance pilot lamp
Preheat pilot lamp Fuel warmer pilot lamp
Warming up pilot lamp Decel
Decel pilot
pilotlamp
lamp
21093CD09
(1) Mode pilot lamps

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

4 Travel mode
High speed traveling
5 Auto idle mode Auto idle
4
6 Work tool mode Oil flow level of breaker or crusher mode
7 Message display "Setting is completed" display after selection
(2) Power max pilot lamp

① The lamp will be ON when pushing power max switch on the
LH RCV lever.
② The power max function is operated maximum 8 seconds.
※ Refer to the operator's manual page 3-38 for power max
function.
21093CD38
5-46
(3) Preheat pilot lamp
① Turning the start key switch ON position starts preheating in
cold weather.
② Start the engine after this lamp is OFF.
21093CD39
(4) Warming up pilot lamp

① This lamp is turned ON when the coolant temperature is below
30˚C (86˚F ).
② The automatic warming up is cancelled when the engine
coolant temperature is above 30˚C, or when 10 minutes have
passed since starting the engine.
21093CD40
(5) Decel pilot lamp

① Operating one touch decel switch on the RCV lever makes the
lamp ON.
② Also, the lamp will be ON and engine speed will be lowered
automatically to save fuel consumption when all levers and
pedals are at neutral position, and the auto idle function is
21093CD41
selected.
※ One touch decel is not available when the auto idle pilot lamp
is turned ON.
※ Refer to the operator's manual page 3-38.
(6) Fuel warmer pilot lamp

10˚C (50˚F ) or the hydraulic oil temperature 20˚C (68˚F ).
② The automatic fuel warming is cancelled when the engine
coolant temperature is above 60˚C, or the hydraulic oil temper-
ature is above 45˚C since the start switch was ON position.
21093CD43
(7) Maintenance pilot lamp

① This lamp will be ON when the consuming parts are needed to
change or replace. It means that the change or replacement
interval of the consuming parts remains below 30 hours.
② Check the message in maintenance information of main menu.
Also, this lamp lights ON for 3 minutes when the start switch is
21093CD44
ON position.
5-47
5) SWITCHES
Power/User mode Auto idle pilot lamp

pilot lamp
Work mode Travel speed pilot lamp
pilot lamp
Power mode switch Escape(previous or parent menu)

Rear camera(option)
Work mode switch Auto idle/Buzzer stop switch
User mode switch Travel speed switch
Select switch
21093CD45
※ When the switches are selected, the pilot lamps are displayed on the LCD. Refer to the page
5-46 for details.
(1) Power mode switch

① This switch is to select the machine power mode and selected
power mode pilot lamp is displayed on the pilot lamp position.
·P : Heavy duty power work.
·S : Standard power work.
·E : Economy power work.
21093CD45A
② The pilot lamp changes E → S → P → E in order.
(2) Work mode switch

① This switch is to select the machine work mode, which shifts
from general operation mode to optional attachment operation
mode.
· : General operation mode
· : Breaker operation mode (if equipped)
21093CD45C
· : Crusher operation mode (if equipped)
·Not installed : Breaker or crusher is not installed.
※ Refer to the operator's manual page 4-6 for details.
5-48
(3) User mode switch
① This switch is used to memorize the current machine operating
status in the MCU and activate the memorized user mode.
·Memory : Push more than 2 seconds.
·Action : Push within 2 seconds.
·Cancel : Push this switch once more within 2 seconds.
21093CD45D
② Refer to the page 5-51 for another set of user mode.
(4) Select switch

① This switch is used to select or change the menu and input
value.
② Knob push
·Long (over 2 sec) : Return to the operation screen
·Medium (0.5~2 sec) : Return to the previous screen
21093CD45E
·Short (below 0.5 sec) : Select menu
③ Knob rotation
This knob changes menu and input value.
·Right turning : Down direction / Increase input value
·Left turning : Up direction / Decreased input value
(5) Auto idle/ buzzer stop switch

① This switch is used to activate or cancel the auto idle function.
·Pilot lamp ON : Auto idle function is activated.
·Pilot lamp OFF : Auto idle function is cancelled.
② The buzzer sounds when the machine has a problem.
In this case, push this switch and buzzer stops, but the
21093CD45F
warning lamp blinks until the problem is cleared.
(6) Travel speed control switch

① This switch is used to select the travel speed alternatively.
· : High speed
· : Low speed
21093CD45G
(7) Escape/Camera switch

① This switch is used to return to the previous menu or parent
menu.
② In the operation screen, pushing this switch will display the
view of the camera on the machine (if equipped).
Please refer to page 5-61 for the camera.
21093CD45H
③ If the camera is not installed, this switch is used only ESC
function.
5-49
6) MAIN MENU
Press
21093CD64
21093CD64B
21093CD64A
※ Please refer to select switch, page 5-49 for selection and change of menu and input value.
(1) Structure
No Main menu Sub menu Description
Work tool Breaker, Crusher, Not installed
U mode power User mode only
Boom/Arm speed Boom speed, Arm speed
1
Auto power boost Enable, Disable
Mode Initial mode Default, U mode
21093CD64D Cluster switch (back up) Switch function
Active fault MCU
Logged fault MCU
Delete logged fault All logged fault delete, Initialization canceled
2
Monitoring (analog) Machine information
Monitoring
Monitoring Monitoring (digital) Switch status, Output status
21093CD64E Operating hours Operating hours for each mode
Maintenance information Replacement, Change interval oils and filters
Machine security ESL mode setting, Password change
Machine Information Cluster, MCU, Engine, Machine
3
A/S phone number A/S phone number, A/S phone number change
Management Service menu
Management Power shift, Hourmeter start, Replacement history,
21093CD64F Update
Display item Engine speed, Tripmeter A, Tripmeter B, Tripmeter C
Clock Clock
Brightness Manual, Auto
4 Unit Temperature, Pressure, Flow, Date format
Language Korean, English, Chinese
Display
Display
Screen type A type, B type
21093CD64G
Tripmeter 3 kinds (A, B, C)

DMB DMB select, DAB select, Channel scan, Exit
Entertainment Play MP4, codec.
5
Camera setting Basic direction, Display switching, Full screen
Utilities Message box Record for fault, attachment etc.
21093CD64H
5-50
(2) Mode setup
① Work tool
21093CD65
21093CD65A 21093CD65B
A B
· A : Select one installed optional attachment.

· B : Max flow - Set the maximum flow for the attachment.
Flow level - Reduce the operating flow from maximum flow.
Breaker - Max 7 steps, Reduced 10 lpm each step.
Crusher - Max 4 steps, Reduced 20 lpm each step.
※ The flow level is displayed with the work mode pilot lamp.
② U mode power
Power
Step Engine Idle speed
speed shift
( ) (rpm) (rpm)
(bar)
1 1500 1000 (low idle) 0
2 1600 1050 3
21093CD65D 3 1700 1100 6
4 1800 1150 (decel rpm) 9
21093CD65E
5 1900 1200 12
· Engine high idle rpm, auto idle rpm and pump torque 6 1950 1250 16
(power shift) can be modulated and memorized 7 2000 1300 20
separately in U-mode. 8 2050 1350 26
· U-mode can be activated by user mode switch. 9 2100 1400 32
10 2150 1450 38
③ Boom/Arm speed
21093CD65F
21093CD65G
· Boom speed
- Control type
Manual - Boom up speed is fixed as set steps.
Auto - Boom up speed is automatically adjusted as working conditions by the MCU.
- Speed setting - Boom up speed is increased as much as activated steps.
· Arm speed
- Regeneration - Arm regeneration function can be activated or cancelled.
Enable - Arm in speed is up.
Disable - Fine operation.
5-51
④ Auto power boost
21093CD65L
21093CD65M
· The power boost function can be activated or cancelled.

· Enable - The digging power is automatically increased as working conditions by the MCU.
It is operated max 8 seconds.
· Disable - Not operated.
⑤ Initial mode
21093CD65P
21093CD65Q
· Default - The initial power mode is set E mode when the engine is started.
· U mode - The initial power mode is set U mode when the engine is started.
⑥ Cluster switch (back up)
21093CD65S
21093CD65T
- The cluster switch can be selected and changed by this menu when the switches are
abnormal on the cluster.
- In order to exit "Cluster switch" mode, please put the cursor on the ESC/CAM switch by
turning the select switch and push the select switch.
- In "Cluster switch", other switches except "Select switch" do not work.
5-52
(3) Monitoring
① Active fault
21093CD66
21093CD66A-1 21093CD66B
· The active faults of the MCU can be checked by this menu.
② Logged fault
21093CD66C
21093CD66D-1 21093CD66E
· The logged faults of the MCU can be checked by this menu.
③ Delete logged fault
21093CD66F
21093CD66G 21093CD66H
· The logged faults of the MCU can be deleted by this menu.
④ Monitoring
Monitoring(Analog)
21093CD66J
21093CD66K 21093CD66L
· The machine status such as the engine rpm, oil temperature, voltage and pressure etc. can
be checked by this menu.
5-53
⑤ Monitoring (digital)
21093CD66M
21093CD66N 21093CD66P
· The switch status or output status can be confirmed by this menu.

· The activated switch or output pilot lamps are light ON.
⑥ Operating hours
21093CD66Q
21093CD66R
· The operating hour of each mode can be confirmed by this menu.
5-54
(4) Management
① Maintenance information
21093CD67
21093CD67A
21093CD67Q 21093CD67R
21093CD67S 21093CD67T
· Alarm( ) : Gray - Normal

Yellow - First warning
Red - Second warning
· Replacement : The elapsed time will be reset to zero (0).
· Change interval : The change or replace interval can be changed in the unit of 50 hours.
· OK : Return to the item list screen.
· Change or relpace interval
No Item Interval
1 Engine oil 250
2 Final gear oil 1000
3 Swing gear oil 1000
4 Hydraulic oil 5000
5 Pilot line filter 1000
6 Drain filter 1000
7 Hydraulic oil return filter 1000
8 Engine oil filter 250
9 Fuel filter 500
10 Pre-filter 500
11 Hydraulic tank breather 250
12 Air cleaner (inner) 500
13 Radiator coolant 2000
14 Swing gear pinion grease 1000
5-55
② Machine security
21093CD67C
21093CD67D 21093CD67E
· ESL mode
- ESL : Engine Starting Limit
- ESL mode is desingned to be a theft deterrent or will
prevent the unauthorized operation of the machine.
- If the ESL mode was selected Enable, the password will
be required when the start switch is turned ON.
21093CD67EE
- Disable : Not used ESL function
Enable (always) : The password is required whenever the
operator start engine.
Enable (interval) : The password is required when the oper-
ator start engine first. But the operator
restarts the engine within the interval
time, the password is not required.
The interval time can be set maximum 4 21093CD67H
hours.
21093CD67U Enter the current password 21093CD67V
· Password change
- The password is 5~10 digits.
Enter the new password 21093CD67VV
21093CD67X 21093CD67XX
The new password is stored in the MCU. Enter the new password again
5-56
③ Machine Information
21093CD67F
21093CD67G
· This can confirm the identification of the cluster, MCU, engine and machine.
④ A/S phone number
21093CD67J
21093CD67K 21093CD67L
21093CD67Z 21093CD67Y
⑤ Service menu
21093CD67M
21093CD67N 21093CD67P
Enter the password
21093CD67ZZ
· Power shift (standard/option) : Power shift pressure can be set by option menu.
· Hourmeter start : Operating hours since the machine line out can be checked by this menu.
· Replacement history : Replacement history of the MCU and cluster can be checked by this
menu.
· Update : Firm ware can be upgraded by this menu. (the USB port is located under the
cluster)
5-57
(5) Display
① Display item
21093CD68
21093CD68A 21093CD68W
21093CD68B 21093CD68E
Center display
Center display
· The center display type of the LCD can be selected by this menu.
· The engine speed or each of the tripmeter (A,B,C) is displayed on the center display.
② Clock
21093CD68C
21093CD68D
· The first line's three spots "**/**/****" represent Month/Day/Year each.

· The second line shows the current time. (0:00~23:59)
5-58
③ Brightness
21093CD68F
21093CD68G 21093CD68H
Manual (1st~10th step)
21093CD68J 21093CD68K
Auto (day/night)
※ If "Auto" is chosen, brightness for day and night can be differently set up. Also by using the
bar in lower side, users can define which time interval belongs to day and night.
(in bar figure, gray area represents night time while white shows day time)
④ Unit
21093CD68L
21093CD68M 21093CD68N
· Temperature : ˚C ↔ ˚F
· Pressure : bar ↔ MPa ↔ kgf/cm2
· Flow : lpm ↔ gpm
· Date format : yy/mm/dd ↔ mm/dd/yy ↔ dd-Mar-yy
⑤ Language
21093CD68R
21093CD68S 21093CD68T
· User can select preferable language and all displays are changed the selected language.
5-59
⑥ Screen type
21093CD68U
21093CD68V 21093CD68W
A Type Standard
21093CD68Y
B Type 21093CD68X Option
(6) Utilities
① Tripmeter
21093CD69
21093CD69A 21093CD69B
· Maximum 3 kinds of tripmeters can be used at the same time.

· Each tripmeter can be turned on by choosing "Start" while it also can be turned off by
choosing "Stop".
· If the tripmeter icon is activated in the operation screen, it can be controlled directly there.
② DMB
21093CD69C
21093CD69D 21093CD69E
· DMB select : TV channel can be selected by this menu.

· DAB select : Audio channel can be selected by this menu.
· Channel scan : This menu can be used other region for TV/Audio.
· Exit : Exit DMB menu
5-60
③ Entertainment
· Play MP4 or codec file of external hard disk through USB port.
· The USB port is located under the cluster.
21093CD69F
21093CD69G
④ Camera setting
21093CD69J
21093CD69K 21093CD69L
· Three cameras can be installed on the machine.

· The display order can be set by this menu.
21093CD69M 21093CD69N
· If the camera was not equipped, this menu is not useful.

· In the operation screen, if the ESC/CAM switch is pushed, the first ordered display camera
will be viewed.
· Turnning the select switch in clockwise direction, the next ordered will be shown and in
counter-clockwise direction, the previously ordered will be shown.
· Push the select switch, the displayed screen will be enlargement.
⑤ Message box
· The history of the machine operating status can be checked by this menu.
21093CD69Q
21093CD69R
5-61
■ MONITORING SYSTEM (CLUSTER TYPE 2)
1. OUTLINE
Monitoring system consists of the monitor part and switch part.
The monitor part gives warnings when any abnormality occurs in the machine and
informs the condition of the machine.
Various select switches are built into the monitor panel, which act as the control portion of
the machine control system.
2. CLUSTER
1) MONITOR PANEL
LCD main operation display

(See page 5-63)
Warning lamp Pilot lamp

(See page 5-69) (See page 5-69)
3009SH5MS30
5-62
2) LCD main operation display
Default screen
screen screen
Option screen 1 Time display
2 2
1 1 2 RPM display
4
4
5
3 Hydraulic oil temperature gauge
3 3
5 4 Fuel level gauge
1607A3CD02A 1607A3CD02B 5 Engine coolant temperature gauge
(1) Time display

① This displays the current time.
※ Refer to the page 5-67 to set time for details.
1607A3CD02C
(2) RPM display

① This displays the engine rpm.
1607A3CD02C
(3) Hydraulic oil temperature gauge
12th step
① This gauge indicates the temperature of hydraulic oil in 12 step
gauge.
·1st step : Below 30˚C (86˚F)
·2nd~10th step : 30-105˚C (86-221˚F)
1st step ·11th~12th step : Above 105˚C (221˚F)
1607A3CD02D
② The gauge between 2nd and 10th steps illuminates when
operating.
③ Keep idling engine at low speed until the gauge between 2nd
and 10th steps illuminates, before operation of machine.
④ When the gauge of 11th and 12th steps illuminates, reduce
the load on the system. If the gauge stays in the 11th~12th
steps, stop the machine and check the cause of the problem.
(4) Fuel level gauge
1st step ① This gauge indicates the amount of fuel in the fuel tank.
② Fill the fuel when the 1st step or fuel icon blinks in red.
※ If the gauge illuminates the 1st step or fuel icon blinks in
1607A3CD02E
(5) Engine coolant temperature gauge
12th step
① This gauge indicates the temperature of coolant in 12 step
gauge.
·1st step : Below 30˚C (86˚F)
·2nd~10th step : 30-105˚C (86-221˚F)
1st step
·11th~12th step : Above 105˚C (221˚F)
1607A3CD02F ② The gauge between 2nd and 10th steps illuminates when
operating.
③ Keep idling engine at low speed until the gauge between 2nd
and 10th steps illuminates, before operation of machine.
④ When the gauge of 11th and 12th steps illuminates, turn OFF
the engine, check the radiator and engine.
5-63
3) Warning
arning of main operation screen
(1) Warning display
① Engine coolant temperature
- This lamp blinks and the buzzer sounds
when the temperature of coolant is over
the normal temperature 105˚C (221˚F).
- Check the cooling system when the lamp
blinks.
② Fuel level
when the level of fuel is below 69ℓ (18.2
U.S. gal).
- Fill the fuel immediately when the lamp
blinks.
③ Hydraulic oil temperature
- This warning lamp operates and the
buzzer sounds when the temperature of
hydraulic oil is over 105˚C (221˚F).
- Check the hydraulic oil level when the
lamp blinks.
- Check for debris between oil cooler and
radiator.
④ All gauge
when the all gauge is abnormal.
- Check the each system when the lamp
blinks.
⑤ Communication error
- Communication problem between MCU
and cluster makes the lamp blinks and
the buzzer sounds.
- Check if any fuse for MCU burnt off.
If not check the communication line
between them.
(2) Pop-up icon display
No Switch Selected mode Interval No Switch Selected mode Interval
1 Work mode General work 3 Auto Light ON

switch mode deceleration
switch
Heavy duty Light OFF
work mode
2 Power mode High power 4 Travel speed Low speed

switch work mode control
switch
Standard power High speed
work mode
5-64
4) LCD
1 : LCD
SYSTEM MENU
: Escape,
1
Monitoring Diagnosis Management
2
Settings Display User Mode
Return to the previous menu
3 : Down / Left Direction
4 : Up/Right Direction
: Select (enter)
5
2 Activate the currently chosen item
4
3 5
2209S3CD05
(1) Main menu

1 2 3 4
1 : Menu information
: Monitoring
2
- Equipment, Switch, Output
: Diagnosis
3
- Current error, Recorded error
5 6 7 4 : Maintenance
2507A4OP94
: Settings
5 - Time set, Dual mode
- System lock (reserved)
: Display
6
- Operation skin, Brightness, Language
7 : User mode
5-65
(2) Display map
① Monitoring
② Diagnosis
a. Protocol type 1
(Error display)
(Recorded error delete)
5-66
b. Protocol type 2
- If there are more than 2 error codes, each one can be displayed by pressing or switch
respectively.
- 3 error codes (①SPN200200, ②FMI06, ③SPN6789, ④FMI04, ⑤345) display.
① ② ⑤ No change
① ③ ④
① ③ ③
③ Maintenance
④ Setting
a. Time set
: Adjusting
: Setting
b. System lock - Reserved
5-67
c. Dual mode
- Changing the MCU mode
⑤ Display
a. Operation skin
b. Brightness
c. Language
⑥ User mode
Usermode(U) is not selected.
: Adjusting : Adjusting : Adjusting

: Setting : Setting : Setting
5-68
5) Warning
arning and pilot lamp
(1) Engine oil pressure warning lamp
① This lamp blinks and the buzzer sounds after starting the
engine because of the low oil pressure.
② If the lamp blinks during engine operation, shut OFF engine
immediately. Check oil level.
21073CD07
(2) Air cleaner warning lamp

① This lamp blinks and the buzzer sounds when the filter of air
cleaner is clogged.
② Check the filter and clean or replace it.
21073CD08
(3) CPU controller check warning lamp

① If any fault code is received from MCU, this lamp blinks and the
buzzer sounds.
② Check the communication line between MCU and cluster.
21073CD10
(4) Battery charging warning lamp

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

① When the machine is overload, the overload warning lamp
blinks during the overload switch is ON.
21073CD15
5-69
(6) Power max pilot lamp
① The lamp will be ON when pushing power max switch on the LH
RCV lever.
21073CD11
(7) Decel pilot lamp

① Operating auto decel or one touch decel makes the lamp ON.
② The lamp will be ON when pushing one touch decel switch on
the LH RCV lever.
21073CD17
(8) Warming up pilot lamp

30˚C (86˚F).
② The automatic warming up is cancelled when the engine cool-
ant temperature is above 30˚C, or when 10 minutes have
passed since starting.
21073CD18
(9) Preheat pilot lamp

Turning the start key switch ON position starts preheating in cold
weather.
Start the engine as this lamp is OFF.
21073CD12
5-70
3. E
1. S
2. O
CN-5
1 CR-35
2W
2 30
0.8WOr 87a 87 85
86
3
minutes.
2WR
87
4
ELECTRIC
0.8B
85
5
30 86
mechanism.
87a
OPERATION
PERATION
POWER RY
6 6
3) Current : 15 A
5
ST C
CS-2 7
GROUP 15 F
6
8 2W
SPECIFICATION
PECIFICATION
3 5 1 CN-36
9
2 2W
BR ACC
1 4
2) Power : 350±50 W
17 2 30A
2W IG POWER
138
1
FUEL
H
4 3 18 CS-74B 10A
LECTRIC CIRCUIT
ROOM LAMP/CASSETTE
MASTER SW
2
1.2R
0, I
2 19 30A
1.2R MCU
2WR
1 3
START KEY SW
20 30A
H 0 I
2W START KEY 4
21 20A
AIR CON/HEATER
22 5
1) Operating voltage : 24±4 V
WIPER 10A
5R 146
23 6
CLUSTER 10A
according to fuel temperature.

24 7
CLUSTER 10A
31 8
MCU CONT. 20A
32 9
MCU EPPR 20A
reduce the current as low as 1.5 A.

33 10
SWITCH PANEL 10A
34 11
CASSETTE 10A
CN-125A 35 12
0.8W SPARE 10A
BATTERY POWER 1 36 13
1.2R 20A
KEY "IG" 2 37 CONVERTER
14
NC 3 CN-51 WORK LAMP 30A
38
RX232(1)-TX 4 1.2B 15
39 BATTERY POWER 24V(+) 1 CABIN LAMP(OPTION) 30A
RX232(1)-GND 5 16
UEL WARMER SYSTEM
42 MCU(CLUSTER TYPE 1) WIPER 10A

RX232(2)-RX 6 17
RX232(2)-TX 7 43 HEAD LAMP 20A
RMS
CN-50 18
1.2B
5-71
RX232(2)-GND 8 44 BATTERY POWER 24V(+) 7 FUEL HEATER 30A
warmer and engine may be started in 1~2
automatically controlled without thermostat
So, fuel is protected from overheating by this

warmer heater senses the fuel temperature to
3) If the fuel starts to flow, ceramic-disk in the fuel
2) At the first state, the 15 A current flows to the fuel
1) T h e c u r r e n t o f f u e l w a r m e r s y s t e m i s
2L
RX232(1)-RX 9 19
45 MCU(CLUSTER TYPE 2) START,STOP 30A
NC 10 20
46 HORN 10A
MAIN GND 11
145 5W
21
47 20A
MAIN GND 12 AC& HEATER
48 22
SAFETY SOL 10A
57 23
OPTION 20A
58 24
SOLENOIDE 20A
59 25
CN-52 CIGAR 20A
60 26
FUEL WARMER RY 12 OPTION(BEACON) 20A
27
MCU(CLUSTER TYPE 1) TRAVEL SOL 20A
28
CN-50 PRE-HEAT 10A
29
FUEL WARMER RY 6 FUEL P/P 20A
CR-1
30
MCU(CLUSTER TYPE 2) ALT 10A
31
BATT RY
CR-46
FUSE BOX
30
85 87 87a
86
CS-74A
60R
87
5R
85 1
86 30
1
2
1
2
87a 5R
CN-60
CN-95
2
CS-74
FUEL WARMER RY
MASTER SW
CN-96
(12VX2)
FUSIBLE LINK
5R
5R
5W
BATTERY
5W
1
2
60B
3
Prefilter
FUEL WARMER
Fuel warmer
2507A5MS12
2609S5MS32
Group 1 Before Troubleshooting -------------------------------------------------------------------------------------- 6-1

Group 2 Hydraulic and Mechanical System ------------------------------------------------------------------- 6-4
Group 3 Electrical System ----------------------------------------------------------------------------------------------- 6-24
Group 4 Mechatronics System ---------------------------------------------------------------------------------------- 6-56
GROUP 1 BEFORE TROUBLESHOOTING
1. INTRODUCTION
When a trouble is occurred in the machine, this section will help an operator to maintain the machine
with easy.
The trouble of machine is parted Hydraulic & Mechanical system, Electrical system and
Mechatronics system. At each system part, an operator can check the machine according to the
troubleshooting process diagram.
※ Before carring out troubleshooting procedure, check monitoring menu in the cluster.
Hydraulic &
Mechanical part GROUP 2
Electrical part GROUP 3
Mechatronics
Troubles occur part GROUP 4
Fault codes HCESPN 3digit

displayed on See page
+ FMI 1 digit 5-25
monitor display (machine)
(Cluster type 1)
Fault codes 2 digit See page
displayed on
monitor display (machine) 5-29
(Cluster type 2)
6-1
2. DIAGNOSING PROCEDURE
To carry out troubleshooting efficiently, the following steps must be observed.
STEP 1. Study the machine system

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

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

Before starting troubleshooting, check the
machine for the daily maintenance points as
shown in the operator's manual.
And also check the electrical system including
batteries, as the troubles in the electrical system ON THE
INSPECTION
such as low battery voltage, loose connections
and blown out fuses will result in malfunction of
(210-7) 6-2(3)
the controllers causing total operational failures
of the machine.
6-2
STEP 4. Inspect the trouble actually on the
machine
In case that some trouble cannot be confirmed,
obtain the details of the malfunction from the
operator.
Also, check if there are any in complete
connections of the wire harnesses are or not.
(210-7) 6-3(1)
STEP 5. Perform troubleshooting

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

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

procedure to avoid consequential malfunctions.
(210-7) 6-3(3)
6-3
GROUP 2 HYDRAULIC AND MECHANICAL SYSTEM
1. INTRODUCTION
1) MACHINE IN GENERAL
(1) If even a minor fault is left intact and operation is continued, a fatal failure may be caused,
entailing a large sum of expenses and long hours of restoration.
Therefore when even a small trouble occurs, do not rely on your intuition and experience, but look
for the cause based on the troubleshooting principle and perform maintenance and adjustment to
prevent major failure from occurring. Keep in mind that a fault results from a combination of
different causes.
(2) The following lists up commonly occurring faults and possible causes with this machine. For the
troubleshooting of the engine, refer to the coming troubleshooting and repair.
(3) When carrying out troubleshooting, do not hurry to disassemble the components.
It will become impossible to find the cause of the problem.
(4) Ask user or operator the following.
① Was there any strange thing about machine before failure occurred?
② Under what conditions did the failure occur?
③ Have any repairs been carried out before the failure?
(5) Check before troubleshooting.
① Check oil and fuel level.
② Check for any external leakage of oil from components.
③ Check for loose or damage of wiring and connections.
2) MACHINE STATUS MONITORING ON THE CLUSTER (CLUSTER TYPE 1)
(1) The machine status such as the engine rpm, oil temperature, voltage and pressure etc. can be
checked by this menu.
Note 6
Note 3
Note 4
Note 5
Note 2
Note 1
Analog 1
Analog 1 Analog22
Analog 3009SH6HS01
(2) Specification
No. Description Specification
Note 1 Pilot pump pressure 40+20 bar
Note 2 Swing pilot pressure 0~40 bar
Note 3 Boom up pilot pressure 0~40 bar
Note 4 P1 pump control pressure 0~25 bar
Note 5 P2 pump control pressure 0~25 bar
Note 6 Pump 1 pressure 350 bar
6-4
2. DRIVE SYSTEM
1) UNUSUAL NOISE COMES OUT OF PUMP CONNECTION
Cause Remedy
YES
Coupling element Disassemble
is broken. and repair.
Remove dust
plug under engine
flywheel and
YES
check if rubber Replace hub or
pieces or particles retighten
are not present. Coupling hub setscrew.
spline is worn or
NO hub fastening
setscrew is slack.
If hydraulic pump or engine is
suspected as a culprit refer to this
NO
manual "Structure and function".
6-5
2) ENGINE STARTS BUT MACHINE DOES NOT OPERATE AT ALL
Cause Remedy
NO
Replenish
specified oil to
the standard
Is oil level in Abnormal noise level.
hydraulic oil YES comes out of YES
Hydraulic pump is Disassemble
tank within hydraulic pump
standard level? broken. and repair.
Do not hydraulic Abnormal noise

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

NO
broken. and repair.
6-6
3. HYDRAULIC SYSTEM
1) HYDRAULIC OIL IS CLOUDY
Cause Remedy
YES
Water is mixed. Put hydraulic oil
still, separate
Drop hydraulic oil water and
sample on hot dispose it or
plate and check if replace hydraulic
foams come up. oil.
NO
Air is intruded. Check suction
line and return
line and eliminate
the air intruding
source.
2) HYDRAULIC OIL TEMPERATURE HAS RISEN ABNORMALLY
Cause Remedy
NO
Replenish
specified oil to
the standard
Is hydraulic oil level.
volume proper? YES
Oil cooler clogged. Clean oil cooler.
Bypass check Replace
Is oil cooler clogged
and is bypass check valve is defective.
YES valve always open? YES ⓐ
Is fan belt
NO tension proper?
Adjust belt
NO tension or
replace belt.
Is not the set
pressure of main YES Readjust set
relief, port relief pressure.
ⓐ and travel relief
Is main relief
valve lower than
valve used very YES Reduce load.
the standard NO often?
level?
6-7
3) CAVITATION OCCURS WITH PUMP
Cause Remedy
NO Replenish
specified oil to
the standard
Is hydraulic oil level.
volume proper? YES
Replace oil with
one of proper
Is not viscosity viscosity.
of hydraulic oil
YES YES
too high? Clean suction
Is not suction strainer.
NO strainer clogged? Is not air intruding
from pump Check for air
NO intrusion in
suction line?
suction line and
retighten or
replace parts.
4) HYDRAULIC OIL IS CONTAMINATED
Cause Remedy
YES Replace
Has not hydraulic hydraulic oil to be
oil passed specified.
specified replace-
ment hours? Has return filter
NO
been replaced at Flush with
NO proper intervals?
hydraulic oil and
replace return
filter.
6-8
4. SWING SYSTEM
1) BOTH LH AND RH SWING ACTIONS ARE IMPOSSIBLE
Cause Remedy
NO
Replenish
Does safety YES
ⓐ specified oil to the
YES solenoid valve
standard level.
operation
Is gear pump pilot normal? Safety solenoid Repair or replace.
NO
pressure within valve faulty or not
YES standard level?
Is oil in hydraulic operated.
YES tank within
See Note 1 Gear pump faulty. Repair or replace.
standard level? NO
YES
Are broken pieces Pump connection Disassemble and
of coupling present coupling is broken. repair.
ⓐ when dust plug
under engine fly NO
Are attachment wheel is removed? Is main relief Hydraulic pump is Disassemble and
NO valve faulty?
and travel out of order. repair.
motions
impossible at all? NO
Does swing Swing control valve Disassemble and
YES
control valve spool is stuck. repair.
Is MCV swing spool move?
YES pilot pressure YES
ⓑ
within standard See Note 5
level?
ⓒ
Is LH travel See Note 2 NO
NO function normal?
Does not symptom
change when front YES
and rear pump Hydraulic pump is Disassemble and
NO
discharge hoses broken. repair.
are exchanged?
YES
Swing parking Disassemble and
brake release valve repair.
Is swing parking is broken.
ⓑ brake release
valve faulty? YES
Swing reduction Disassemble and
Does swing unit is broken. repair.
NO motor rotate?
Swing motor is Disassemble and
NO
broken. repair.
YES
Pilot relief valve in Disassemble and
NO Is gear pump gear pump is faulty. repair or replace.
delivering oil?
Gear pump is out of Disassemble and
NO
Is gear pump pilot order. repair.
ⓒ pressure within
standard level? YES
Is there oil Clean pilot piping
See Note 1 interior or repair
leakage from
YES pilot piping or is it piping.
clogged? RCV is broken. Disassemble and
NO
repair.
6-9
2) SWING SPEED IS LOW
Cause Remedy
YES
Swing port relief Disassemble and
YES Does swing spool valve is faulty. repair or replace.
move?
Swing control valve Disassemble
Is MCV pilot NO
spool is stuck. and repair.
pressure same
on LH and RH YES Clogged or oil
sides? Clean pilot piping
leak. interior or repair
See Note 2 Is pilot piping
Single direction clogged or is it piping.
NO leaking oil?
Is the trouble in RCV or shuttle Disassemble
one direction or NO
valve is faulty. and repair.
in both direction? YES
ⓐ
YES Does swing spool
Both directions move?
YES Is MCV pilot Swing spool is Disassemble
pressure within NO
Is Arm speed See Note 5 stuck. and repair.
standard level?
within standard ⓑ
value? See Note 2 NO
ⓒ
NO
Is swing motor's NO
ⓐ drain rate within Swing motor is Disassemble
standard value? broken. and repair.
Check that pilot
YES piping is clogged NO
or oil is leaking RCV or shuttle Disassemble
from it? valve is faulty. and repair.
Clogged or oil leak. Clean pilot piping

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

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

NO
faulty. and replace.
6-11
5) THE SWING UNIT DRIFTS WHEN THE MACHINE IS AT REST ON A SLOPE
Cause Remedy
YES
ⓐ
YES Is swing shuttle
valve normal?
Shuttle valve is Disassemble
NO
faulty. and replace.
YES Is brake spring
normal?
Is return spring
of swing spool Brake spring is Disassemble
NO
normal? faulty. and replace.
Return spring of Disassemble

NO
swing control and replace.
valve is faulty.
YES
Is drain rate of Swing port relief Disassemble
YES swing motor valve is faulty. and repair or
within standard replace.
Is swing relief value? Swing motor is Disassemble
pressure within NO
ⓐ broken. and repair.
standard level?
SPEC : 300±10kgf/cm2 Adjust swing
NO
relief valve
pressure or
replace swing
relief valve.
6-12
5. TRAVEL SYSTEM
1) TRAVEL DOES NOT FUNCTION AT ALL ON ONE SIDE
Cause Remedy
YES
Does ⓐ
YES counterbalance
spool move lightly
by hand? Counter spool is
Is travel brake Disassemble
NO
YES valve pressure stuck. and repair or
within standard replace.
level? Does the symptom
change when
relief valves in YES
Relief valve built Disassemble
NO travel motor are
Has travel spool exchanged? in travel motor is and repair.
YES
changed over faulty.
positively?
YES Control system is Disassemble
defective. inspect and
Does travel spool
repair.
NO move?
NO
Travel spool is Disassemble
stuck. and repair.
Is bucket or arm
operation YES Travel reduction Disassemble
possible? Do not metallic
unit is faulty. and repair.
particles come
ⓐ out of drain port
in travel
reduction unit? Travel motor is Disassemble
NO
out of order. and repair.
Does the symptom
NO
change when front YES
and rear pump Hydraulic pump is Disassemble
Does the discharge hoses
symptom change broken. and repair.
are exchanged?
when LH/RH
NO
travel relief valves
are exchanged?
YES
Travel relief Disassemble
valves are faulty. and repair or
replace.
6-13
2) SPEED ON ONE SIDE FALLS AND THE MACHINE CURVES
Cause Remedy
YES
Brake valve is Disassemble
Do LH and RH
travel speeds defective. and repair or
YES change when LH replace.
YES
and RH travel Does the symptom Relief valve built Disassemble
brake valves are change when in travel motor is and repair.
exchanged? relief valves in
faulty.
NO LH and RH
YES Has travel spool travel motors are
changed over exchanged? ⓐ
positively? NO
YES
Control system is Disassemble,
faulty . inspect and
Does spool move? repair.
Is the lower NO
speed (bucket or
arm) within See Note 5, 6 Control valve Disassemble
NO
standard level? spool is stuck. and repair.
YES
Travel relief valve Disassemble
Do LH and RH is faulty. and repair or
travel speeds Does the symptom replace.
change over when change when
NO travel relief valves YES front and rear YES
pump discharge Hydraulic pump is Disassemble
are exchanged?
Is external pilot hoses are broken. and repair.
pressure within exchanged?
NO
standard level?
External pilot Disassemble
NO
piping is clogged and clean.
or oil is leaking
Does travel speed from it.
change when
YES parking brake YES
spring in the Travel motor's Disassemble
travel motor is parking brake is and clean pilot
Is drain rate of removed? not released piping.
ⓐ travel motor within
standard level? properly.
Travel motor is Disassemble

NO
faulty. and repair.
6-14
3) MACHINE DOES NOT STOP ON A SLOPE
Machine is pulled forward as sprocket rotates during digging operation.
Cause Remedy
None Is parking brake YES
friction plate Friction plate is Disassemble
YES Check if parking worn? faulty. and repair.
brake pilot line is
clogged.
Clogged Disassemble
and clean pilot
Is drain rate of piping.
Is travel brake YES NO
travel motor
pressure within Travel motor is Disassemble
within standard
standard level? defective. and repair.
value?
SPEC : 15.7kgf/cm2
Brake valve is Disassemble

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

normal?
Straight spool is Repair or

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

NO
broken. and repair.
6-17
6. ATTACHMENT SYSTEM
1) BOOM OR ARM ACTION IS IMPOSSIBLE AT ALL
Cause Remedy
YES
Does the Port relief valve is Disassemble
YES symptom change faulty. and repair or
when port relief replace.
valve is replaced
with other valve? NO ⓐ
YES Is MCV pilot
pressure within
standard level?
Inspect if pilot
See Note 3 piping is clogged OK
RCV is faulty. Disassemble
NO or oil is leaking
YES Are other from the piping. and repair.
attachments
operatable?
YES
Is gear pump
pilot pressure YES Is gear pump faulty. and repair or
NO within standard delivering oil? replace.
level? Gear pump is Disassemble
See Note 1 NO
broken. and repair.
Are LH/RH travel
operations OK
possible? Hydraulic pump is Disassemble
Disassemble broken. and repair.
YES main relief valve
Remove dust plug and check if it is
under engine not irregular.
OK flywheel and
Main relief valveDisassemble
Faulty
check if coupling is defective. and repair or
element particles replace.
Inspect oil are not present. Coupling at pump Disassemble
Particles present
NO
volume in
hydraulic oil tank. connection is and repair.
broken.
Short Replenish
hydraulic oil.
YES
Cylinder interior is Disassemble
Does control broken. and repair.
ⓐ valve spool
move?
MCV spool is Disassemble
See Note 5, 6 NO
stuck. and repair.
6-18
2) BOOM, ARM OR BUCKET SPEED IS LOW
Cause Remedy
YES
Normal.
YES
Are other ⓐ
YES attachment
Is combination speeds within
Is speed low only of oil streams standard levels? NO ⓑ
in composite YES
normal at boom YES
operation? up and at arm Does spool of flow Flow summation Disassemble
extrusion? summation check check valve is and repair.
NO valve move lightly stuck.
Are LH/RH travel by hand?
NO speeds within NO
standard levels?
YES
Are both LH/RH faulty. and repair.
travel speeds YES ⓒ
NO
low? Is MCV pilot
pressure within
NO
standard? ⓓ
NO
See Note 3
OK
Does the Port relief valve is Disassemble
symptom change faulty. and repair or
YES
when port relief
valve is replaced replace.
Does control with other valve? Cylinder is faulty. Disassemble
YES valve spool NO
and repair.
move ?
See Note 7
NO MCV spool is Disassemble
Is MCV pilot
ⓐ pressure within stuck. and repair.
standard level?
Is not MCV pilot YES
Clean pilot
See Note 3
pressure piping piping interior or
clogged or is not
NO
there oil repair piping.
leakage? RCV is defective. Disassemble
NO
and repair.
YES
Is pilot pressure NO faulty. and repair or
ⓑ Is gear pump
within standard
delivering oil? replace.
level?
NO
See Note 1
broken. and repair.
AIs engine NO
ⓒ revolution within Adjust engine
standard level? revolution.
YES
Clean orifice in
control valve.
Is not orifice in
ⓓ main control YES
valve clogged? Is pilot piping Clean pilot
clogged or is oil piping interior or
NO leaking from the repair piping.
piping? Is RCV normal? RCV is faulty. Disassemble
NO NO
and repair.
6-19
3) BOOM, ARM OR BUCKET CYLINDER EXTENDS OR CONTRACTS ITSELF AND ATTACHMENT FALLS
Cause Remedy
YES
Port relief valve is Disassemble
Does the symptom faulty. and repair or
change when port
Normal
relief valve is replace.
YES
replaced with ⓐ
normal value? Is control valve
return spring
YES
Is not hydraulic NO
normal?
oil temperature Control valve's Disassemble
high? NO
return spring is and replace.
faulty.
Is genuine Abnormally high. Locate the
hydraulic oil or cause of
equivalent being hydraulic oil
used?
temperature rise
and lower it to
proper level.
Replace with
NO
genuine
hydraulic oil or
equivalent.
OK
Pressure Disassemble
Disassemble and tightness and repair.
inspect load between control
YES
check valve in
MCV and check valve casing and
for any fault. spool is poor.
Is cylinder Contact surface Disassemble
internal leakage Abnormal
ⓐ within standard between poppet and repair.
level? and seat is poor.
Cylinder is faulty. Disassemble

NO
and repair.
6-20
4) BOOM, ARM OR BUCKET POWER IS WEAK
Cause Remedy
YES
Check according
Is cylinder to the procedure
YES internal leakage in Item "Speed is
within standard low".
level?
Is relief pressure
YES in port relief Cylinder is faulty. Disassemble
valve within NO
and repair.
standard level?
Is relief pressure
in main relief Port relief valve is Adjust pressure,
valve within NO
standard level? faulty. repair or replace.
See Note 7
Main relief valve Adjust pressure,
NO
is defective. repair or replace.
5) ONLY BUCKET OPERATION IS TOTALLY IMPOSSIBLE
Cause Remedy
YES
Port relief valve is Disassemble
Does the defective. and repair or
YES
symptom change
when port relief replace.
YES
valve is replaced Cylinder interior is Disassemble
with other valve? Does control broken. and repair.
valve spool
Is MCV pilot NO move?
YES
pressure within MCV spool is Disassemble
standard level? See Note 5 NO
stuck. and repair.
Is RH travel RCV is faulty. Disassemble

NO
possible? and repair.
Does the YES

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

NO
has run out of to it.
grease. ※ If seizure is
in an initial
stage, supply
sufficient
grease.
If seizure is
in a grown
state, correct
it by paper
lapping or
with an oil
stone.
6-22
※ HOW TO CHECK INTERNAL BOOM CYLINDER LEAKAGE
1. Lower the bucket teeth to the ground with
bucket cylinder fully retracted and arm
cylinder rod retracted almost in full.
29076TS01
2. Disconnect hose (A) from rod side of boom

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

the arm cylinder rod.
If oil leaks from piping side and boom
cylinder rod is retracted there is an internal
leak in the cylinder.
If no oil leaks from piping side and boom
cylinder rod is retracted, there is an internal
leak in the control valve.
29076TS01
6-23
GROUP 3 ELECTRICAL SYSTEM (CLUSTER TYPE 1)
1. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR
·Before disconnecting the connector, always turn the starting switch OFF.
·Before carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No.7, 8.
·After checking, insert the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
Defective cluster Replace
Check voltage YES

Disconnection in Repair or replace
between CN-56
(3) and (5) wiring harness or (after clean)
Check voltage poor contact
Starting switch : ON between
Voltage : 20~32V between
NO CN- 5 (4) and (5)
CN-5-CN-56
Starting switch : ON
Voltage : 20~32V Disconnection in Repair or replace
NO
wiring harness or (after clean)
poor contact
between CN-5 (4)
-GND or fuse
No.7, 8
Check voltage
YES 20~32V
NO 0V
FUSE
CLUSTER NO.7
POWER(24V) 1 6
FUSE
POWER IG(24V) 5 5
NO.8
GND 3 4
CN-56 CN-5
3009SH6ES01
6-24
2. COMMUNICATION ERROR FLASHES ON THE CLUSTER (HCESPN 840, FMI 2)
·Before carrying out below procedure, check all the related connectors are properly inserted.
Cause Remedy
YES
YES Check voltage

between CN-56
(4, 8) and (3) Disconnection in Repair or replace
NO wiring harness or (after clean)
Check voltage Voltage : 2V poor contact
between between CN-56
CN-5 (1) and (2) (4, 8)-CN-5 (1, 2)
Voltage : 2V Defective MCU Replace
NO Disconnection in Repair or replace
poor contact
between CN-5 (1,
2)- CN-51(23, 33)
Check voltage
YES 2V
NO 0V
CLUSTER
GND 3 4 MCU
RS485 RX 8 2 23 RS485 TX
RS485 TX 4 1 33 RS485 RX
CN-51
CN-56 CN-5
3309S6ES02
6-25
3. BATTERY CHARGING WARNING LAMP LIGHTS UP
UP(Starting switch : ON)
Cause Remedy
YES
Defective MCU Replace
YES Check voltage
between CN-52
(27) and chassis Disconnection in Repair or replace
NO
Check voltage wiring harness or (after clean)
YES Voltage : 20~32V
between CN-3 poor contact
(3) and chassis between CN-52
(27)-CN-3 (3)
Voltage : 20~32V
Check voltage NO wiring harness or (after clean)
(2) and chassis between CN-3 (3)-
CN-74 (1)
Engine : Running
Voltage : 20~32V
Defective alternator Replace

NO
Check voltage
YES 20~32V
NO 0V
ALTERNATOR
B+
MCU
G
1 P
27 3 2 L
3 ~
U
3 FI
4 NC
CN-74
CN-52 CN-3
3009S6ES01
6-26
4. WHEN COOLANT OVERHEAT WARNING LAMP LIGHTS UP (engine is started)
Cause Remedy
YES
Coolant overheat Check engine
Resistance (110˚C±2˚C) cooling system
YES between CD-8
(1, 2) is in range
of 120~150Ω?
Defective temp Replace
Disconnect CD-8 NO
sensor
Does display go
off when
disconnect
CD-8?
Engine : Start YES
Short circuit in Repair or replace
Resistance wiring harness (after clean)
between CN-51
NO (13) and CN-52
(25) 0~1Ω?
Disconnect CN-51 NO
KEY OFF
Check Table
Temperature (˚C ) 0 25 50 80 95
Resistance (kΩ) 30~37 9.3~10.7 3.2~3.8 1.0~1.3 0.7~0.8
MCU
13
WATER TEMP SENDER
5 1 C
CN-51
6 2
CN-3 CD-8
25
CN-52
3009SH6ES04
6-27
5. WHEN AIR CLEANER WARNING LAMP LIGHTS UP (engine is started)
Cause Remedy
YES
Clogged air filter or Check filter or
defective switch replace switch
Does display go
off when
disconnect YES
CD-10? Short circuit in Repair or replace
Starting switch : ON wiring harness (after clean)
Engine : Start Check resistance
between CD-10-
between CN-51
NO CN-51(29)
(29) and chassis
Starting switch : OFF
Disconnect CN-51
NO
Check resistance
YES MAX 1Ω
NO MIN 1MΩ
MCU AIR CLEANER SWITCH
Pa
29
CD-10
CN-51
3009SH6ES05
6-28
6. WHEN ENGINE OIL PRESSURE WARNING LAMP LIGHTS UP (engine is started)
Cause Remedy
YES
Engine oil leakage, Check engine oil
or defective switch level or replace
switch
Does display go
off when
disconnect YES
CD-18? Defective controller Replace
Engine : Start Check resistance
between CN-51
NO
(27) and chassis
Disconnect CN-51
NO
poor contact
between
CN-51(27)-CD-18
MCU ENGINE OIL PRESSURE SWITCH
27 1 Pa
CN-51 CN-2 CD-18
3009SH6ES06
6-29
7. WHEN HYDRAULIC OIL TEMPERATURE WARNING LAMP LIGHTS UP (engine is started)
Cause Remedy
YES
High temperature Check hydraulic
Resistance oil temperature
YES between CD-1 (105˚C±2˚C),
(1, 2) is in range
of 164~151Ω?
Does display go Starting switch : ON Defective temp Replace
Disconnect CD-1 NO
off when sensor
disconnect
CD-1? YES
Short circuit Repair or replace
Starting switch : ON Resistance between temp
Engine : Start between CN-51
sensor and MCU
NO (13) and CN-52
(24) 0~1Ω?
Starting switch : OFF NO
Disconnect CN-51
Check Table
Temperature (˚C ) ~ -30 ~ -10 ~0 ~ 40 ~ 70 ~ 80 ~ 90 ~ 100 105~
22.22 8.16 5.18 1.06 0.39 0.322 0.243 0.185 0.164
Resistance (kΩ)
~31.78 ~10.74 ~ 6.6 ~1.28 ~0.476 ~0.298 ~0.219 ~0.167 0.151
MCU
13
CN-51
HYDRAULIC OIL
TEMPERATURE SENDER
1 C
24 2
CD-1
CN-52 3009SH6ES07
6-30
8. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE (HCESPN 304,
FMI 3 or 4)
Cause Remedy
YES
poor contact
Is resistance between
YES between CN-51 CN-52-CD-8
(13) and CN-52
(25) over 2kΩ?
Starting switch : OFF YES
Does the gauge Disconnect CN-50 Defective MCU Replace
light up and Check resistance
down at lamp between CN-3
NO
check? (5) and (6)
Starting switch : ON Defective temp Replace
See Table NO
sensor
NO
Disconnection Replace
cluster
Check Table
Temperature (˚C ) 0 25 50 80 95
Resistance (kΩ) 30~37 9.3~10.7 3.2~3.8 1.0~1.3 0.7~0.8
MCU
13
WATER TEMP SENDER
5 1 C
CN-51
6 2
CN-3 CD-8
25
CN-52
3009SH6ES04
6-31
9. WHEN FUEL GAUGE DOES NOT OPERATE
OPERATE(HCESPN 301, FMI 3 or 4)
Cause Remedy
YES
Defective MCU or Replace
Check resistance cluster
YES between CN-51
(13) and CN-52
(26)
Starting switch : OFF Disconnection in Repair or replace
Check resistance Disconnect CN-51 NO
between fuel Spec : 50~600Ω wiring harness or
sender (1) and poor contact
(2) between fuel
Starting switch : OFF sender-MCU
Spec : 50~600Ω
See table
Defective fuel Replace
NO
sender
Check Table
Range Resistance (Ω) Range Resistance (Ω)
Full 50 5/12 400
11/12 100 4/12 450
10/12 150 3/12 500
9/12 200 2/12 550
8/12 250 1/12 600
7/12 300 Empty warning 700
6/12 350 - -
MCU
13
FUEL LEVEL SENDER

1
CN-51
2
CD-2
26
CN-52
3009SH6ES08
6-32
10. WHEN SAFETY SOLENOID DOES NOT OPERATE
short of fuse No.23.
Cause Remedy
YES
Hydraulic system Check hydraulic
YES Check operation malfunction system
of solenoid
Defective solenoid Replace
NO
Safety lever : ON-OFF
YES
Disconnect in Repair or replace
Check resistance
(1) - (2) YES between CN-4 between
(16) and chassis CN-4-CN-68
Voltage : 20~30V YES
Safety state Starting switch : OFF Disconnect in Repair or replace
Safety state
Spec : 0Ω
Disconnect CN-4 Check resistance poor contact
Check voltage
between CS-4 between
between CN-68 NO
NO (A)-(C) CN-4-CS-4
(2) and chassis
Safety lever : OFF Defective safety Replace
Safety switch : ON-0Ω
Starting switch : ON NO
Voltage : 20~30V
OFF-∞ switch

NO
wiring harness
between
CN-68 (2)-fuse
FUSE
NO.23
SAFETY SWITCH
B C A 14 SAFETY SOLENOID
B 15 2
A C 16 1
CS-4 CN-68
CN-4
21096ES10
6-33
11. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE (HCESPN 167, FMI 5 or 6)
Cause Remedy
YES
wiring harness or
Check resistance poor contact
YES
between CN-70 between CN-70-
(1) and (2) CN-52
Starting switch : OFF Defective solenoid Replace
Spec : 30Ω NO
YES Check fault code Disconnect CN-70
167 active?
YES
Defective hydraulic Check hydraulic
system system
Check voltage
Check if travel between CN-70
speed lamps( , NO (1) and (2)
) change when
pressing the travel Starting switch : ON Disconnection in Repair or replace
Spec : 20~30 V NO
speed switch on wiring harness or
Disconnect CN-70
the cluster poor contact
between CN-70-
fuse No. 25
YES
Check MCU
Y R G
NO
NO
FUSE
NO.25
MCU TRAVEL SOLENOID
3 1
CN-70
CN-52
3009SH6ES09
6-34
12. WHEN ENGINE DOES NOT START ( lights up condition)
short of fuse No. 1, 4, 20.
Cause Remedy
YES START KEY SW
Delective battery Replace CN-5
CS-2
H0 I
35 1
0, I
36 2
59 3 4
H
60
BR ACC
4 1
B
2
5 3
6
Check operation YES
ST C
5
Check voltage Defective magnet Replace 6
start motor
YES between starter of start motor
magnet coil and CR-35
Starting switch : START NO.1
chassis Defective start relay Replace
NO
Starting switch : START
Check operation Spec : 20~30V YES
YES Check voltage ⓐ
of start relay between CN-3
NO
CR-23 (2) and chassis
NO.4
POWER RY
NO
Starting switch : START wiring harness or
Starting switch : START poor contact
Check operation Spec : 20~30V between CN-3 (2) CS-74
of anti-restart -CR-5 (87) 1
NO relay CR-5 2
CN-95
NO.20
YES 2
Check voltage Defective anti- Replace 1 MASTER SW
between CR-5 restart relay FUSIBLE LINK

NO 2
(85, 86)
NO
ⓑ 1
CN-60
Spec : 20~30V
CR-1 BATTERY
YES
Check voltage Defective start relay Replace
ⓐ between CR-23 BATT RY
and chassis Disconnection in Repair or replace DO-3
NO
wiring harness or 2
Starting switch : START CN-51
poor contact ANTI-RESTART RY 20
1
Spec : 20~30V DIODE
between CN-3- MCU
CR-5
CR-5 CN-3 CR-23 START MOTOR
YES
Disconnection in Repair or replace 1 1
wiring harness or 2 2
Check voltage poor contact START RY
ⓑ between CR-5 between CN-51 CN-45
(86) and chassis ANTI-RESTART RY
(20)-CR-5 (85)
Starting switch : START NO Disconnection in Repair or replace
Spec : 20~30V wiring harness or
poor contact
between CS-2 (6)-
CR-5 (86)
3009SH6ES10
6-35
13. WHEN STARTING SWITCH ON DOES NOT OPERATE
·Before carrying out below procedure, check all the related connectors are properly inserted, master
switch ON and check open circuit of fusible link (CN-60).
START KEY SW
CN-5
CS-2
H0 I
35 1
Cause Remedy
0, I
36 2
59 3 4
H
YES 60
BR ACC
4 1
B
Disconnection in Repair or replace 5
2
3
wiring harness or (after clean) 6
poor contact
ST C
5
YES Check voltage

6
between DO-3 (1)-
between DO-3 CR-1 or defective
(1) and chassis battery relay CR-35
NO.1
Voltage : 20~30V
YES Check voltage NO wiring harness or (after clean)
between CS-2
poor contact
(2) and chassis NO.4
between CS-2 (2)- POWER RY
Voltage : 20~30V CN-5(60)- DO-3 (1)
Defective start Replace CS-74
NO
YES Check voltage switch 1
between CS-2 2
(1) and chassis YES CN-95
Disconnection in Replace NO.20 2
wiring harness or 1 MASTER SW
Voltage : 20~30V
poor contact FUSIBLE LINK
between CS-2 (1)-
Check voltage 2
CN-5 (36) 1
between CN-5
NO CN-60
Check voltage (36) and chassis YES
Disconnection in Charge or replace
and specific wiring harness or (after clean) CR-1 BATTERY
gravity of battery Voltage : 20~30V
Specific gravity : MIN 1.28 between CS-74 between CS-74 (1)
Voltage : MIN 24V NO -CN-5 (36)
(1) and chassis BATT RY
Voltage : 20~30V ⓐ DO-3
NO CN-51
2
1
ANTI-RESTART RY 20
DIODE
MCU
Battery capacity Charge or replace
NO too low (after clean) CR-5 CN-3 CR-23 START MOTOR
YES 1 1
Defective master Replace 2 2
Check voltage
ⓐ switch START RY
between CS-74
CN-45
(2)- chassis ANTI-RESTART RY
NO
Voltage : 20~30V wiring harness or (after clean)
poor contact
between CS-74 (2)
-CR-1
3009SH6ES11
6-36
14. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE
·Before carrying out below procedure, check all the related connectors are properly inserted and the fuse
No. 6, 11 and 17 is not blown out.
·After checking, insert the disconnected connectors again immediately unless otherwise specified. CN-21
3 1
Cause Remedy 2
5 3 CN-5
NO
Defective wiper Replace 4 4
cut switch 5
NO 6 M 2 6
Check operation wiring harness or (after clean)
wiper cut switch WIPER MOTOR FUSE
poor contact 18
between CN-141 NO.6
Front sliding door (11)- CS-53 CN-141 19
open-close
Check valtage
FEED BACK 1
between CN-141 YES
YES (11) and chassis Defective switch Replace MOTOR DRIVE SIG 2 CN-17
panel
NO Check voltage
MOTOR DRIVE- 3 1
Front sliding door-close between CN-116 MOTOR DRIVE+ 4 2
Voltage : 4~5V (10) and chassis GND 5 3
Check operation 1)Recheck fuse Replace FUSE
NO VCC 6 4 24
Starting switch : ON No.11
YES of switch panel Vottage : 20~30V CONTINUE 24V 7 5 NO.17
LED ON. 2)Disconnection in Repair or replace CN-22
wiring harness or (after clean) WASHER P/P 8 6
Starting switch : ON ⓐ 2 M
Push wiper switch button YES
poor contact WASHER SIG. 9 7
between INT. SIG 10 8 1
CN-116(6)-Fuse WIPER CUT SW 11 WASHER PUMP
between N.C 12
CN-116 (13)-Chassis FEED BACK 13
Check voltage between NO
Defective switch Replace WIPER MOTOR CONTROLLER
CN-116 (4) and chassis panel
Intermittent
NO CS-53
1) Recheck fuse Replace
Check voltage CN-116 No.6
ⓐ
(5) and chassis 2) Disconnection Repair or replace
Washing Check operation in wiring harness (after clean)
of wiper motor or poor contact
Check voltage CN-116 and controller between WIPER CUT SW
(3) and chassis check voltage CN-141(7)-Fuse,
YES CN-141 (7) and
Sarting switch : ON CN-21(4)-Fuse CN-116
Voltage : 0~1V
chassis, CN-21 HEAD LIGHT OUT 1
(4) and chassis NO
1) Recheck fuse Replace WORK LIGHT OUT 2
Starting switch : OFF No.17 INT. SIG 3
Voltage : 20~30V Check voltage WIPER MOTOR DRIVE 4
2) Disconnection Repair or replace
CN-141 (6) and WASHER SIG 5
YES chassis CN-141(6)-Fuse (after clean)
PRE-HEAT 6
CABIN LIGHT OUT 7
Starting switch : ON ⓑ
Check continuity YES TRAVEL ALARM 8
Voltage : 20~30V
NO NC 9 FUSE
between Disconnection in Repair or replace POWER 24V 10 57
CN-141 (2)-CN-116 (4), wiring harness or (after clean) GND 11 NO.11
CN-141 (9)-CN-116 (5), poor contact NC 12
CN-141 (10)-CN-116 (3),
ⓑ NO SWITCH PANEL
CN-141 (5)-Chassis , Check wiper Defective wiper Replace
CN-141 (1)-CN-21 (5), motor resistance motor
CN-141 (3)-CN-21 (6),
YES between CN-21
CN-141 (4)-CN-21 (2), (2)-CN-21 (6) Defective wiper Replace
CN-141 (13)-CN-21 (3) YES motor controller
Resistance : 3~4Ω
21096ES14
6-37
15. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP
CN-5
Cause Remedy FUSE
YES NO.18
Check voltage Defective bulb Replace
YES between CL-4 CN-116
(1) and chassis, HEAD LIGHT OUT 1
CL-3(1) and WORK LIGHT OUT 2
chassis Disconnection in Repair or replace INT. SIG 3
NO CR-13
Voltage : 20~30V wiring harness or (after clean) WIPER MOTOR DRIVE 4
30 30 86
poor contact WASHER SIG 5
Check voltage between CR-13 PRE-HEAT 6 86
YES
between CR-13 (87)-CL-4 (1) or CABIN LIGHT OUT 7 87
(87) and chassis CR-13 (87)-CL-3 TRAVEL ALARM 8 49 85
87a 87 85
(1) NC 9 87a
Starting switch : ON POWER 24V 10 HEAD LAMP RY
Head lamp switch : ON GND 11
Voltage : 20~30V YES NC 12
Defective switch Replace CL-4
panel SWITCH PANEL
Check voltage Check voltage 2
between CR-13 between CN-116 1
(30) and chassis, NO
(1) and chassis
CR-13 (86) and Repair or replace HEAD LAMP
Disconnection in
chassis Starting switch : ON NO (after clean)
Head lamp switch : ON wiring harness or
Voltage : 20~30V Voltage : 20~30V poor contact CL-3
between CN-116
(1)-CR-13 (87) 2
1
Disconnection in Repair or replace HEAD LAMP

poor contact
between CR-13
(30) and chassis
or CR-13 (86) -
chassis
Recheck fuse Replace

No. 18
3009SH6ES12
6-38
16. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP
Cause Remedy
YES
Defective bulb Replace
YES
Check voltage
between CL-5 (1)
and chassis CN-5
FUSE
NO wiring harness or (after clean) NO.15
poor contact
CN-116
between CR-4
YES Check voltage HEAD LIGHT OUT 1
between CR-4 (87)-CL-5 (2) WORK LIGHT OUT 2
(87) and chassis INT. SIG 3 CR-4
WIPER MOTOR DRIVE 4
Starting switch : ON 30 30 86
WASHER SIG 5
Work lamp switch : ON PRE-HEAT 6 86
Defective switch Replace CABIN LIGHT OUT 7 87
panel TRAVEL ALARM 8 50 85

87a 87 85
Check voltage Check voltage NC 9 87a
between CR-4 between CN-116 POWER 24V 10 WORK LAMP RY
(30) and chassis, NO GND 11
(2) and chassis
CR-4(86) chassis NC 12 CL-5
CN-12
Starting switch : ON Starting switch : ON Disconnection in Repair or replace SWITCH PANEL
Work lamp switch : ON NO 2 1
Voltage : 20~30V poor contact 1 2
between CR-4
(87)-CN-116 (2) WORK LAMP
1
NO
poor contact CL-6
between CR-4
(30) and chassis
or CR-4 (86) and
chassis

No.15
21096ES16
6-39
GROUP 3 ELECTRICAL SYSTEM (CLUSTER TYPE 2)
1. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT
APPEAR
short of fuse No.8.
Cause Remedy
YES
YES Check voltage
between CN-56
(1) and chassis Disconnection in Repair or
NO
wiring harness or replace
Check voltage
between CN-5(5) poor contact (after clean)
and chassis between CN-5(5)-
CN-56(1)
Voltage : 20~32V
NO Disconnection in Repair or
wiring harness or replace
poor contact (after clean)
between CN-5(5)-
and fuse No.8
CLUSTER
FUSE
POWER IG(24V) 1 5
NO.8
GND 2 4
RX
TX
CN-56 CN-5
Check voltage
YES 20 ~ 32V
NO 0V
3009SH6ES20
6-40
2. COMMUNICATION ERROR FLASHES ON THE CLUSTER
Cause Remedy
YES
Defective controller Replace
YES Check voltage

between CN-56
(3,4) and chassis
between CN-5 between CN-56
(1,2)and chassis (3,4) CN-5(1,2)
KEY ON
NO
poor contact
between CN-5
(1,2)-CN-50
(29,30)
Check voltage
YES *4V *12V
NO 0V 0V
CLUSTER MCU
POWER IG(24V)
GND 2 4
*12V
RX 3 2 29
*4V
TX 4 1 30
CN-56 CN-5 CN-50
3009SH6ES21
6-41
3. BATTERY CHARGING WARNING LAMP LIGHTS UP(Starting switch : ON)
Cause Remedy
YES
Defective controller Replace
YES Check voltage
between CN-51
(9) and chassis Disconnection in Repair or replace
NO
YES poor contact
between CN-3(3)
and chassis between CN-51(9)
-CN-3(3)

Check voltage NO wiring harness or (after clean)
between CN-74(2) poor contact
and chassis between CN-3(3)-
CN-74(1)
Voltage : 20~32V
Engine : Running
NO
Defective alternator Replace
Check voltage
YES 20 ~ 32V
NO 0V
ALTERNATOR
B+
MCU
G
1 P
27 3 2 L
3 ~
U
3 FI
4 NC
CN-74
CN-52 CN-3
3009S6ES01
6-42
4. WHEN COOLANT OVERHEAT WARNING LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
Coolant overheat Check engine
(110。C±2。C) cooling system
YES Resistance
between CD-8
(1,2) is in range
of 120~150Ω?
Disconnect : CD-8 Replace
NO Defective temp
Does display go
sensor
off when
disconnect
CD-8?
Starting switch : ON YES
Engine : Start Shot circuit in Repair or replace
Resistance
between CN-51 wiring harness (after clean)
NO (31,33) is
0~1Ω? Defective MCU Replace
NO
Disconnect : CD-51
KEY OFF
12th step
Check Table
Range 1st step 2nd~10th step 11th~12th step
Temperature ~29。C 30~105。C 105。C ~
1 st step
MCU
WATER TEMP SENDER
31 5 1 C
33 6 2
CN-3 CD-8
CN-51
3009SH6ES23
6-43
5. WHEN AIR CLEANER WARNING LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
Clogged air filter or Check filter or
defective switch replace switch
Does display go off
when disconnect YES
CD-10? Short circuit in Repair or replace
Starting switch : ON Check resistance wiring harness (after clean)
Engine : Start between CN-51
NO
(16) and chassis
NO
Disconnect CN-51
Check resistance
YES MAX 1Ω
NO MIN 1MΩ
MCU AIR CLEANER SWITCH
Pa
16
CD-10
CN-51
3009SH6ES24
6-44
6. WHEN ENGINE OIL PRESSURE WARNING LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
Does display go
off when Engine oil leakage Check engine oil
disconnect
CD-18? of defective switch level or replace
Starting switch : ON switch
Does the gauge
light up and
down at lamp
check? YES Defective controller
Starting switch : ON Check resistance Replace
Engine : Start between
NO CN-51(4) and
chassis Disconnection in Repair or replace
NO
Disconnect : CN-51
poor contact
between CN-51(4)
-CD-18
Check resistance
YES MAX 1Ω
NO MIN 1MΩ
MCU ENGINE OIL PRESSURE SWITCH
4 1 Pa
CN-51 CN-2 CD-18
3009SH6ES25
6-45
7. WHEN HYDRAULIC OIL TEMPERATURE WARNING LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
High temperature Check hydraulic
Resistance oil temperature
YES between CD-1 (100˚C±2˚C)
(1,2) is in range
of 130~150Ω?
Starting switch : ON Defective temp Replace
Does display go Disconnect CD-1 NO
sensor
off when
disconnect CD-1? YES
Short circuit Check and repair
Engine : Start
Resistance
between CN-51
NO (31,34) is 0~1Ω?

Disconnect CN-51
MCU HYDRAULIC OIL

TEMPERATURE SENDER
31 1 C
34 2
CD-1
CN-51
3009SH6ES26
6-46
8. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE
Cause Remedy
YES
Is resistance poor contact
YES between
between
CN-51(31) and
(33) over 2kΩ? CN-51-CD-8
Starting switch : ON YES
Does the gauge Check resistance
light up and down between CN-2(5)
NO
at lamp check? and (6)
NO Defective temp Replace
Starting switch : ON Spec : 120Ω
See table sensor
NO
12th step Check Table

Range 1st step 2nd~10th step 11th~12th step
Temperature ~29。C 30~105。C 105。C ~
1 st step
MCU
WATER TEMP SENDER
31 5 1 C
33 6 2
CN-3 CD-8
CN-51
3009SH6ES23
6-47
9. WHEN FUEL GAUGE DOES NOT OPERATE(Check warning lamp ON/OFF)
Cause Remedy
YES
Disconnection in Check and repair
wiring harness
Is resistance
YES between CN-51
(24) and (31)
over 1kΩ? YES
Disconnect CN-51
Check resistance
Does the gauge between CD-2(1)
light up and NO and (2)
down at lamp Defective fuel Replace
Disconnect CD-2 NO
check? sensor
See Table

NO
2nd~10th step
Check Table
1 st step 11th~12th
step Range
Item 1st step 2nd~10th step 11th~12th step
Unit Resistance(Ω) 700~601 600~101 ~100

Tolerance(%) ±5 ±5 ±5
MCU
FUEL LEVEL SENDER
24 2
31 1
CD-2
CN-51
3009SH6ES27
6-48
10. WHEN SAFETY SOLENOID DOES NOT OPERATE
Cause Remedy
YES
Hydraulic system Check hydraulic
YES Check operation malfunction system
of solenoid
Defective solenoid Replace
Safety lever : ON-OFF NO
YES
Defective switch Replace
YES Check voltage
between CS-4(C)
Check voltage and chassis
between Disconnection in Repair or replace
CN-68(1) - (2) Start switch : ON NO
YES Check voltage Voltage : 20~30V
Starting switch : ON between CN-4(16) Disconnect CN-4 poor contact
Voltage : 20~30V and chassis between
Safety state
Starting switch : ON CS-4(C)-CN-68(1)
Voltage : 20~30V
Disconnect CN-4
Check voltage Disconnect in Repair or replace
NO
between CN-68(2) wiring harness or (after clean)
NO
with chassis poor contact
between
Safety lever : OFF
Starting switch : ON CN-4(16)-CN-68(1)
Voltage : 20~30V
Disconnection in Replace
NO
fuse No. 23
FUSE
NO.23
SAFETY SWITCH
B C A 14 SAFETY SOLENOID
B 15 2
A C 16 1
CS-4 CN-68
CN-4
21096ES10
6-49
11. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE
short of fuse No.28 .
Cause Remedy
YES
Defective hydraulic Check hydraulic
system system
YES Check voltage YES Check operation
between CN-50 YES
of solenoid Defective MCU Replace
(13) and chassis
Check resistance
Check if travel Starting switch : ON Starting switch : ON between CN-70
Voltage : 20~30V : OFF NO Defective solenoid
speed lamps( , (1) and (2)
Disconnect CN-50 : ON
) change when Replace
pressing the travel
SPEC : 15~25Ω
speed switch on Disconnect CN-70
the cluster Defective cluster
YES
Starting switch : ON Replace
Check controller
Y R G
NO Defective MCU
Replace
NO
FUSE
MCU NO.28
TRAVEL SOLENOID
13 1
CN-70
CN-50
3009SH6ES28
6-50
12. WHEN ENGINE DOES NOT START ( lights up condition)
short of fuse No. 1, 4, 20.
Cause Remedy
YES START KEY SW
Delective battery Replace CN-5
CS-2
H0 I
35 1
0, I
36 2
59 3 4
H
60
BR ACC
4 1
B
2
5 3
6
Check operation YES
ST C
5
Check voltage Defective magnet Replace 6
start motor
YES between starter of start motor
magnet coil and CR-35
Starting switch : START NO.1
chassis Defective start relay Replace
NO
Check operation Spec : 20~30V YES
YES Check voltage ⓐ
of start relay between CN-3
NO
CR-23 (2) and chassis
NO.4
POWER RY
NO
Starting switch : START wiring harness or
Starting switch : START poor contact
Check operation Spec : 20~30V between CN-3 (2) CS-74
of anti-restart -CR-5 (87) 1
NO relay CR-5 2
CN-95
NO.20
YES 2
Check voltage Defective anti- Replace 1 MASTER SW
between CR-5 restart relay FUSIBLE LINK

NO 2
(85, 86)
NO
ⓑ 1
CN-60
Spec : 20~30V
CR-1 BATTERY
YES
Check voltage Defective start relay Replace
ⓐ between CR-23 BATT RY
and chassis Disconnection in Repair or replace DO-3
NO
wiring harness or 2
Starting switch : START CN-50
poor contact ANTI-RESTART RY 11
1
Spec : 20~30V DIODE
between CN-3- MCU
CR-5
CR-5 CN-3 CR-23 START MOTOR
YES
Disconnection in Repair or replace 1 1
wiring harness or 2 2
Check voltage poor contact START RY
ⓑ between CR-5 between CN-50 CN-45
(86) and chassis ANTI-RESTART RY
(11)-CR-5 (85)
Starting switch : START NO Disconnection in Repair or replace
Spec : 20~30V wiring harness or
poor contact
between CS-2 (6)-
CR-5 (86)
3009SH6ES29
6-51
13. WHEN STARTING SWITCH ON DOES NOT OPERATE
·Before carrying out below procedure, check all the related connectors are properly inserted, master
switch ON and check open circuit of fusible link (CN-60).
START KEY SW
CN-5
CS-2
H0 I
35 1
Cause Remedy
0, I
36 2
59 3 4
H
YES 60
BR ACC
4 1
B
2
3
wiring harness or (after clean) 6
poor contact
ST C
5
YES Check voltage

6
between DO-3 (1)-
between DO-3 CR-1 or defective
(1) and chassis battery relay CR-35
NO.1
Voltage : 20~30V
YES Check voltage NO wiring harness or (after clean)
between CS-2
poor contact
(2) and chassis NO.4
between CS-2 (2)- POWER RY
Voltage : 20~30V CN-5(60)- DO-3 (1)
Defective start Replace CS-74
NO
YES Check voltage switch 1
between CS-2 2
(1) and chassis YES CN-95
Disconnection in Replace NO.20 2
wiring harness or 1 MASTER SW
Voltage : 20~30V
poor contact FUSIBLE LINK
between CS-2 (1)-
Check voltage 2
CN-5 (36) 1
between CN-5
NO CN-60
Check voltage (36) and chassis YES
and specific wiring harness or (after clean) CR-1 BATTERY
gravity of battery Voltage : 20~30V
Specific gravity : MIN 1.28 between CS-74 between CS-74 (1)
Voltage : MIN 24V NO -CN-5 (36)
(1) and chassis BATT RY
Voltage : 20~30V ⓐ DO-3
NO CN-50
2
1
ANTI-RESTART RY 11
DIODE
MCU
Battery capacity too Charge or replace
NO low (after clean) CR-5 CN-3 CR-23 START MOTOR
YES 1 1
Defective master Replace 2 2
Check voltage
ⓐ switch START RY
between CS-74
CN-45
(2)- chassis ANTI-RESTART RY
NO
poor contact
between CS-74 (2)
-CR-1
3009SH6ES30
6-52
14. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE
·Before carrying out below procedure, check all the related connectors are properly inserted and the fuse
No. 6, 11 and 17 is not blown out.
·After checking, insert the disconnected connectors again immediately unless otherwise specified. CN-21
3 1
Cause Remedy 2
5 3 CN-5
NO
Defective wiper Replace 4 4
cut switch 5
NO 6 M 2 6
Check operation wiring harness or (after clean)
wiper cut switch WIPER MOTOR FUSE
poor contact 18
between CN-141 NO.6
Front sliding door (11)- CS-53 CN-141 19
open-close
Check valtage
FEED BACK 1
between CN-141 YES
YES (11) and chassis Defective switch Replace MOTOR DRIVE SIG 2 CN-17
panel
NO Check voltage
MOTOR DRIVE- 3 1
Front sliding door-close between CN-116 MOTOR DRIVE+ 4 2
Voltage : 4~5V (10) and chassis GND 5 3
Check operation 1)Recheck fuse Replace FUSE
NO VCC 6 4 24
Starting switch : ON No.11
YES of switch panel Vottage : 20~30V CONTINUE 24V 7 5 NO.17
LED ON. 2)Disconnection in Repair or replace CN-22
wiring harness or (after clean) WASHER P/P 8 6
Starting switch : ON ⓐ 2 M
Push wiper switch button YES
poor contact WASHER SIG. 9 7
between INT. SIG 10 8 1
CN-116(6)-Fuse WIPER CUT SW 11 WASHER PUMP
between N.C 12
CN-116 (13)-Chassis FEED BACK 13
Check voltage between NO
Defective switch Replace WIPER MOTOR CONTROLLER
CN-116 (4) and chassis panel
Intermittent
NO CS-53
1) Recheck fuse Replace
Check voltage CN-116 No.6
ⓐ
(5) and chassis 2) Disconnection Repair or replace
Washing Check operation in wiring harness (after clean)
of wiper motor or poor contact
Check voltage CN-116 and controller between WIPER CUT SW
(3) and chassis check voltage CN-141(7)-Fuse,
YES CN-141 (7) and
Sarting switch : ON CN-21(4)-Fuse CN-116
Voltage : 0~1V
chassis, CN-21 HEAD LIGHT OUT 1
(4) and chassis NO
1) Recheck fuse Replace WORK LIGHT OUT 2
Starting switch : OFF No.17 INT. SIG 3
Voltage : 20~30V Check voltage WIPER MOTOR DRIVE 4
2) Disconnection Repair or replace
CN-141 (6) and WASHER SIG 5
YES chassis CN-141(6)-Fuse (after clean)
PRE-HEAT 6
CABIN LIGHT OUT 7
Starting switch : ON ⓑ
Check continuity YES TRAVEL ALARM 8
Voltage : 20~30V
NO NC 9 FUSE
between Disconnection in Repair or replace POWER 24V 10 57
CN-141 (2)-CN-116 (4), wiring harness or (after clean) GND 11 NO.11
CN-141 (9)-CN-116 (5), poor contact NC 12
CN-141 (10)-CN-116 (3),
ⓑ NO SWITCH PANEL
CN-141 (5)-Chassis , Check wiper Defective wiper Replace
CN-141 (1)-CN-21 (5), motor resistance motor
CN-141 (3)-CN-21 (6),
YES between CN-21
CN-141 (4)-CN-21 (2), (2)-CN-21 (6) Defective wiper Replace
CN-141 (13)-CN-21 (3) YES motor controller
Resistance : 3~4Ω
21096ES14
6-53
15. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP
CN-5
Cause Remedy FUSE
YES NO.18
Check voltage Defective bulb Replace
YES between CL-4 CN-116
(1) and chassis, HEAD LIGHT OUT 1
CL-3(1) and WORK LIGHT OUT 2
chassis Disconnection in Repair or replace INT. SIG 3
NO CR-13
Voltage : 20~30V wiring harness or (after clean) WIPER MOTOR DRIVE 4
30 30 86
poor contact WASHER SIG 5
Check voltage between CR-13 PRE-HEAT 6 86
YES
between CR-13 (87)-CL-4 (1) or CABIN LIGHT OUT 7 87
(87) and chassis CR-13 (87)-CL-3 TRAVEL ALARM 8 49 85
87a 87 85
(1) NC 9 87a
Starting switch : ON POWER 24V 10 HEAD LAMP RY
Head lamp switch : ON GND 11
Voltage : 20~30V YES NC 12
Defective switch Replace CL-4
panel SWITCH PANEL
Check voltage Check voltage 2
between CR-13 between CN-116 1
(30) and chassis, NO
(1) and chassis
CR-13 (86) and Repair or replace HEAD LAMP
Disconnection in
chassis Starting switch : ON NO (after clean)
Head lamp switch : ON wiring harness or
Voltage : 20~30V Voltage : 20~30V poor contact CL-3
between CN-116
(1)-CR-13 (87) 2
1
Disconnection in Repair or replace HEAD LAMP

poor contact
between CR-13
(30) and chassis
or CR-13 (86) -
chassis

No. 18
3009SH6ES12
6-54
16. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP
Cause Remedy
YES
Defective bulb Replace
YES
Check voltage
between CL-5 (1)
and chassis CN-5
FUSE
NO wiring harness or (after clean) NO.15
poor contact
CN-116
between CR-4
YES Check voltage HEAD LIGHT OUT 1
between CR-4 (87)-CL-5 (2) WORK LIGHT OUT 2
(87) and chassis INT. SIG 3 CR-4
WIPER MOTOR DRIVE 4
Starting switch : ON 30 30 86
WASHER SIG 5
Work lamp switch : ON PRE-HEAT 6 86
Defective switch Replace CABIN LIGHT OUT 7 87
panel TRAVEL ALARM 8 50 85

87a 87 85
Check voltage Check voltage NC 9 87a
between CR-4 between CN-116 POWER 24V 10 WORK LAMP RY
(30) and chassis, NO GND 11
(2) and chassis
CR-4(86) chassis NC 12 CL-5
CN-12
Starting switch : ON Starting switch : ON Disconnection in Repair or replace SWITCH PANEL
Work lamp switch : ON NO 2 1
Voltage : 20~30V poor contact 1 2
between CR-4
(87)-CN-116 (2) WORK LAMP
1
NO
poor contact CL-6
between CR-4
(30) and chassis
or CR-4 (86) and
chassis

No.15
21096ES16
6-55
GROUP 4 MECHATRONICS SYSTEM (CLUSTER TYPE 1)
1. ALL ACTUATORS SPEED ARE SLOW

※ Boom, Arm, Bucket, Swing and travel speed are slow, but engine speed is good.
※ Spec : P-mode 2150 ± 50 rpm S -mode 2000 ± 50 rpm E-mode 1850± 50 rpm
※ Before carrying out below procedure, check all the related connectors are properly inserted and
fault code on the cluster.
1) INSPECTION PROCEDURE
Cause Remedy
YES
Defective
YES Check pressure hydraulic system
at EPPR valve
NO Check electric Defective Replace
current at EPPR SPEC : 5~20 kgf/cm2
NO
EPPR valve
valve See TEST 3
SPEC : 100~700 mA
See TEST 2
Check if HCESPN NO
140 active fault
display on the LCD YES
Short circuit or Check & repair
poor connection wire harness or
Check resistance
YES at EPPR valve -CN-75 -CN-75
SPEC : 15~25Ω(20。C) Defective EPPR Replace

See TEST 1 NO
valve
Wiring diagram
MCU
FUSE
8
NO.10
9
PUMP EPPR VALVE
9 2
19 10 1
CN-52 CN-2 CN-75
3309S6MS01
6-56
2) TEST PROCEDURE SPEC : 15~25Ω(20˚C)
(1) Test 1 : Check resistance at connector
CN-75
CN-75.
Multimeter
① Starting key OFF.
② Disconnect connector CN-75 from EPPR
valve at main hydraulic pump.
③ Check resistance between 2 lines as
figure. EPPR valve
29096MS01
(2) Test 2 : Check electric current at EPPR SPEC : 160~460 mA (S mode)

valve.
① Install multimeter as figure.
② Start engine. CN-75
Multimeter
③ Set the accel dial at "10" (MAX)
④ Set S-mode and cancel auto decel
mode.
⑤ If tachometer show approx 2000±50 rpm,
EPPR valve
check electric current.
Main pump
21095MS21
(3) Test 3 : Check pressure at EPPR valve. SPEC : 4~20 kgf/cm2 (60~280 psi)
Pressure adjusting
gauge as figure. Supply line,
screw locknut
·Gauge capacity : 0 to 50 kgf/cm2 pilot pressure CN-75
(0 to 710 psi)
② Start engine.
③ Set the accel dial at "10" (Max).
④ Set S-mode and cancel auto decel EPPR valve
mode.
check pressure.
29095MS10
6-57
2. ENGINE STALL
※ Before carrying out below procedure, check all the related connectors are properly inserted.
Cause Remedy
YES
Not enough Check engine
engine power fault
YES Check pressure Contact cummins
at EPPR valve
SPEC:5~20 kgf/cm2 Defective EPPR Replace

See TEST 5 NO
Check electric valve
current at EPPR
valve
YES
Short circuit or Check and repair
SPEC : 100~700 mA poor connection wire harness
See TEST 4
Check resistance between
between CN-52 - CN-75
NO at EPPR valve
SPEC : 15~25Ω(20˚C)
See TEST 1
NO
Defective EPPR Replace
valve
Wiring diagram
MCU
FUSE
8
NO.10
9
PUMP EPPR VALVE
9 2
19 10 1
CN-52 CN-2 CN-75
3309S6MS01
6-58
2) TEST PROCEDURE SPEC : 100~700 mA
(1) Test 4 : Check electric current at EPPR Adapter(P/no.:21Q6-50410)
valve at S-mode
CN-75
① Install multimeter as figure. Multimeter
② Start engine.
③ Set the accel dial at "10" (max)
④ Set S-mode with 2000±50 rpm.
⑤ Check electric current. EPPR valve
Main pump
21095MS21
(2) Test 5 : Check pressure at EPPR valve at SPEC : 4~20 kgf/cm2 (60~280 psi)
S-mode
① Connect pressure gauge at EPPR valve. Pressure adjusting
screw locknut
② Start engine. Supply line,
④ Set S-mode with 2000±50 rpm.
⑤ Operate bucket lever completely push or
pull. EPPR valve
⑥ Hold arm lever at the end of stroke.
⑦ Check pressure at relief position.
29095MS10
6-59
3. MALFUNCTION OF CLUSTER OR MODE SELECTION SYSTEM
Cause Remedy
YES
No power supply to Check fuse No.3
See if all lamps the MCU
YES off in the MCU
case YES
Y R G MCU failure Replace
Y R G
See if HCESPN
840 active fault NO
display on the LCD
NO Y R G
ⓐ
NO
OK
Check connection Cluster failure Replace
between CN-51
ⓐ (33) - CN-56(4) or
CN-51(23) -
CN-56(8) No connection Check and repair
NO
KEY OFF
Wiring diagram
CLUSTER MCU
BATT.24V
SIG 3
GND
TX 4 1 33
IG 24V 8 2 23
SIG 2
CN-56 CN-5 1
CAMERA SIG
RX CN-51
FUSE
NO.3
3009SH6MS02
6-60
4. MALFUNCTION OF ACCEL DIAL
Cause Remedy
YES
YES
Open circuit or Replace or repair
poor connection
between CN-7
Check voltage YES Check voltage
between (15)-CN-52 (23)
between
CN-52(23)-GND CN-7(15)-GND YES
Check resistance Defective accel Replace
Spec : actuator operating
Spec : actuator operating between dial
1~5V
1~5V
NO CN-142(B)-
See TEST 6 CN-7(15) Open circuit or Replace or repair
Check voltage NO
Spec : 0Ω poor connection
NO
CN142(A)-(C) (B)-CN-7 (15)
Spec : 5V YES CN-52
poor connection
between CN-142 23
Check voltage (A)-CN-7 (14) or
between CN-142 (C )-
NO CN-7(14)-(16)
CN-7 (16)
MCU
Spec : 5V
NO poor connection ACCEL DIAL
between CN-7 + A 14 5
(16)-CN-51 (5) or
S B 15 6
CN-7 (14 )-
CN-51 (6) - C 16
CN-142
CN-7 CN-51
3009SH6MS03
6-61
2) TEST PROCEDURE SPEC : Actuator operating : 1~5 V
(1) Test 6 : Check voltage at CN-52(23) and
ground.
① Prepare 1 piece of thin sharp pin, steel or
MCU
copper.
PIN
② Insert prepared pin to rear side of CN-51 CN-52
connectors : One pin to (23) of CN-52.
③ Starting key ON.
④ Check voltage as figure.
CN-52 Female
10 9 8 7 6 5 4 3 2 1
20 11
23
30
40 39 38 37 36 35 34 33 32 31
GROUND
Multimeter
3009SH6MS04
6-62
5. AUTO DECEL SYSTEM DOES NOT WORK
· Fault code : HCESPN 105, FMI 0~4 (work pressure sensor)
HCESPN 108, FMI 0~4 (travel oil pressure sensor)
Cause Remedy
YES
YES
Defective travel Replace
Check voltage
NO pressure switch
between CD-6(A)
and (C)
Short circuit or poor Replace or repair
NO
Check voltage SPEC : connection
between CN-52 Key ON : 24±2V between CN-51(3)-
(38)-GND and CD-6(A) and / or
CN-52(37)-GND CN-51(13)-CD-
6(C) (fault code 108
SPEC :
Actuator operating : 1~5V
displayed)
See TEST 7, 8 YES
Defective work Replace
Check voltage
pressure sensor
between CD-7(A)
NO and (C)
NO
SPEC : connection
Key ON : 24±2V between CN-51(3)-
CD-7(A) and / or
CN-51(13)-CD-
7(C) (fault code 105
displayed)
Wiring diagram
CN-51
CD-6
3 A SUPPLY
B SIG
13 C RETURN
TRAVEL PRESSURE SENSOR
MCU
38 CD-7
A SUPPLY
37 B SIG
C RETURN
CN-52 WORK PRESSURE SENSOR
3009SH6MS05
6-63
ground.
① Prepare 1 piece of thin sharp pin, steel or MCU
PIN
copper.
CN-51 CN-52
② Insert prepared pin to rear side of
(2) Test 8 : Check voltage at CN-52(37)and
ground.
10 9 8 7 6 5 4 3 2 1
20 11 CN-52
copper 30
38
21
Female
② Insert prepared pin to rear side of 40 39 38 37 36 34 33 32 31

GROUND
Multimeter
10 9 8 7 6 5 4 3 2 1
20 11 CN-52
30
37
21 Female
40 39 38 37 36 35 34 33 32 31
GROUND
Multimeter
3009SH6MS06
6-64
6. MALFUNCTION OF PUMP 1 PRESSURE SENSOR
· Fault code : HCESPN 120, FMI 0~4
Cause Remedy
YES
YES
Short circuit or Replace or repair
poor connection
YES Check voltage between CN-52-
between
CN-2(6)-GND (29)-CN-2(6)
Check voltage SPEC : Detective P1 Replace or repair
between CN-52 Actuator operating: 1~5V NO
Check voltage pressure sensor
(29) - GND YES between short circuit or poor
SPEC : CD-42(A)-(C) connection
Actuator operating: 1~5V between CN-2(6)-
See TEST 9 SPEC :
Key ON : 24±2V CD-42(B)
Check voltage Short circuit or Replace or repair

NO
between poor connection
NO CN-2(13)-(15) between CD-42(A)-
CN-2(13) or
SPEC :
Key ON : 24±2V
CD-42(C)-
CN-2(15)

NO poor connection
between CN-2(13)-
CN-51(3) or CN-2
(15) - CN-51(13)
Wiring diagram
CN-51
CD-42
3 13 A SUPPLY
6 B SIG
13 15 C RETURN
PUMP 1 PRESSURE SENSOR
CN-2
MCU
29
CN-52
3009SH6MS07
6-65
ground.
copper. PIN

CN-52 Female
10 9 8 7 6 5 4 3 2 1
20 11
29
30
40 39 38 37 36 35 34 33 32 31
GROUND
Multimeter
3009SH6MS08
6-66
Cause Remedy
YES
YES
poor connection
between
CN-2(7)-GND (30)-CN-2(7)
(30) - GND YES between short circuit or
SPEC : CD-43(A)-(C) poor connection
See TEST 10 SPEC :
Key ON : 24±2V CD-43(B)

NO
NO CN-2(13)-(15) between D-43(A)-
CN-2(13) or
SPEC :
Key ON : 24±2V
CD-43(C)-
CN-2(15)

NO poor connection
between
CN-2(13)-
CN-51(3) or CN-2
(15)-CN-51(13)
Wiring diagram
CN-51
CD-43
3 13 A SUPPLY
7 B SIG
13 15 C RETURN
CN-2
MCU
30
CN-52
3009SH6MS09
6-67
ground.
copper. PIN

CN-52 Female
10 9 8 7 6 5 4 3 2 1
20 11
30
30
40 39 38 37 36 35 34 33 32 31
GROUND
Multimeter
3009SH6MS10
6-68
Cause Remedy
YES
YES
poor connection
between
CN-2(4)-GND (32)-CN-2(4)
See TEST 11 SPEC :
Key ON : 24±2V CD-44(B)

NO
NO CN-2(13)-(15) between D-44(A)-
CN-2(13) or
SPEC :
Key ON : 24±2V
CD-44(C)-
CN-2(15)

NO poor connection
between
CN-2(13)-
CN-51(4) or CN-2
(15) - CN-51(5)
Wiring diagram
CN-51
CD-44
3 13 A SUPPLY
4 B SIG
13 15 C RETURN
CN-2
MCU
32
CN-52
3009SH6MS11
6-69
ground.
copper. PIN

CN-52 Female
10 9 8 7 6 5 4 3 2 1
20 11
30
32
40 39 38 37 36 35 34 33 32 31
GROUND
Multimeter
3009SH6MS12
6-70
9. MALFUNCTION OF SWING PRESSURE SENSOR
Cause Remedy
YES
Check voltage YES

between CN-52 Detective swing Replace or repair
(36) - GND pressure sensor
SPEC : short circuit or
Actuator operating: 1~5V Check voltage poor connection
See TEST 14 between CD-24 between CN-52
NO (A)-(C) (36)-CD-24 (B)
SPEC :
Key ON : 24±2V
NO
poor connection
between CD-24
(A)-CN-51(3) or
CD-24(C)- CN-51
(13)
Wiring diagram
CN-51
CD-24
3 A SUPPLY
B SIG
13 C RETURN
SWING PRESSURE SENSOR
MCU
36
CN-52
3009SH6MS13
6-71
ground.
MCU
copper. PIN

CN-52 Female
10 9 8 7 6 5 4 3 2 1
20 11
30
36
40 39 38 37 36 35 34 33 32 31
GROUND
Multimeter
3009SH6MS14
6-72
10. MALFUNCTION OF BOOM UP PRESSURE SENSOR
Cause Remedy
YES
Check voltage YES

between CN-52 Detective boom up Replace or repair
(35) - GND pressure sensor
SPEC : short circuit or
Actuator operating: 1~5V Check voltage poor connection
See TEST 16 between CD-32 between CN-52
NO (A)-(C) (35)-CD-32 (B)
SPEC :
Key ON : 24±2V
NO
poor connection
between CD-32
(A)-CN-51(3) or
CD-32(C)- CN-51
(13)
Wiring diagram
CN-51
CD-32
3 A SUPPLY
B SIG
13 C RETURN
BOOM UP PRESSURE SENSOR
MCU
35
CN-52
3009SH6MS15
6-73
ground.
copper. PIN

CN-52 Female
10 9 8 7 6 5 4 3 2 1
20 11
30
35
40 39 38 37 36 35 34 33 32 31
GROUND
Multimeter
3009SH6MS16
6-74
11. MALFUNCTION OF POWER MAX
· Fault code : HCESPN 166, FMI 4 or 6
Cause Remedy
YES
Short circuit or poor Repair or replace
connection between
YES Check resistance CN-88(1)-CN-52 (2)
between CN-88
(1)-(2)
Defective power
NO
YES Check resistance SPEC: 15-35Ω max. solenoid valve Repair or replace
between CN-53 See TEST 18 Check hydraulic
(18)-GND
system
Is voltage between Short circuit or poor Repair or replace

NO
CN-88(2)-GND connection between
SPEC : Power max button pressed ON : 0Ω
normal? Power max button released OFF : ∞ Ω CN-51(18)-CS-29
SPEC
KEY ON : 24±1V
KEY OFF : 0V Short circuit or poor Repair or replace
See TEST 17 NO
connection between
CN-88(2)-
Fuse No. 25
Wiring diagram
MCU
CN-88
2 1
2
CN-52
POWER MAX SOLENOID
18 5
FUSE
6
NO.25
CN-51 CN-4
CS-29
1
2
POWER MAX SWITCH
3009SH6MS17
6-75
2) TEST PROCEDURE SPEC : Key ON : 24±1V
Key OFF : 0V
(1) Test 17:
17 Check voltage between connector
CN-88(2) - GND.
① Disconnect connector CN-88 from power
max solenoid valve. Power max switch
② Start key ON.
③ Check voltage as figure.
LH RCV-lever
CN-88
Power max
solenoid valve
2 1
1 2
GROUND
Multimeter
21096MS14A
(2) Test 18:

18 Check resistance of the solenoid SPEC : 15~35Ω
valve between CN-88(1)-(2).
Power max switch
② Disconnect connector CN-88 from power
max solenoid valve.
③ Check resistance as figure.
LH RCV-lever
CN-88
Power max 2 1
solenoid valve
1 2
Multimeter
21096MS14B
6-76
12. MALFUNCTION OF BOOM PRIORITY EPPR VALVE
Cause Remedy
YES
connection between
CN-52(17)-CN-133
Check resistance (1) or CN-52(7)-
between CN-133(2)
CN-133(1)-(2)
SPEC : 15~35V
KEY : ON
Defective EPPR Repair or replace
NO
valve
Wiring diagram
MCU
17
CN-133
7 2
BOOM PRIORITY
EPPR VALVE
CN-52
3009SH6MS18
6-77
13. MALFUNCTION OF ARM REGENERATION SOLENOID
Cause Remedy
YES
YES Check voltage

YES
between CN-52 Short circuit or Replace or repair
(1)-GND
poor connection
Check resistance between CN-52
SPEC :
KEY ON 24±2V between arm
Check voltage NO (1)-CN-135 (1)
See TEST 19 regen solenoid
between CN-135(2)
- GND SPEC : 15~35Ω Defective Replace
NO
SPEC : solenoid valve
KEY ON : 20~30V
Open circuit Replace or repair

NO
between CN-135
(2)-Fuse No. 25
Wiring diagram
MCU
CN-135
1 1
ARM REGENERATION SOLENOID
FUSE
NO.25
CN-52
3009SH6MS19
6-78
2) TEST PROCEDURE SPEC : Key ON : 24±2 V
ground.
copper. MCU
② Insert prepared pin to rear side of PIN
CN-51 CN-52 CN-53
CN-52 Female
10 9 8 7 6 5 4 3 2 1
20 11
30 21
40 39 38 37 36 35 34 33 32 31
GROUND
Multimeter
21096MS16A
6-79
■ MECHATRONICS SYSTEM (CLUSTER TYPE 2)
1. ALL ACTUATORS SPEED ARE SLOW

※ Boom, Arm, Bucket, Swing and travel speed are slow, but engine speed is good.
※ Spec : P-mode 2150 ± 50 rpm S -mode 2000 ± 50 rpm E-mode 1850 ± 50 rpm
※ Before carrying out below procedure, check all the related connectors are properly inserted and
fault code on the cluster.
Cause Remedy
YES
Defective
YES Check pressure hydraulic system
at EPPR valve
NO Check electric Defective Replace
current at EPPR SPEC : 5~20 kgf/cm2
NO
EPPR valve
valve See TEST 3
SPEC : 100~700 mA
See TEST 2
Check if HCESPN NO
140 active fault
display on the LCD YES
Short circuit or Check & repair
poor connection wire harness or
Check resistance
YES at EPPR valve -CN-75 -CN-75
SPEC : 15~25Ω(20。C) Defective EPPR Replace

See TEST 1 NO
valve
Wiring diagram
MCU
FUSE
24
NO.9
36
28 PUMP EPPR VALVE
9 2
8 10 1
CN-50 CN-2 CN-75
3009SH6MS30
6-80
2) TEST PROCEDURE SPEC : 15~25Ω(20˚C)
(1) Test 1 : Check resistance at connector
CN-75
CN-75.
Multimeter
② Disconnect connector CN-75 from EPPR
valve at main hydraulic pump.
③ Check resistance between 2 lines as
figure. EPPR valve
29096MS01
(2) Test 2 : Check electric current at EPPR SPEC : 160~460 mA (S mode)

valve.
① Install multimeter as figure.
② Start engine. CN-75
Multimeter
③ Set the accel dial at "10" (MAX)
④ Set H-mode and cancel auto decel
mode.
EPPR valve
check electric current.
Main pump
21095MS21
(3) Test 3 : Check pressure at EPPR valve. SPEC : 4~20 kgf/cm2 (60~280 psi)
Pressure adjusting
gauge as figure. Supply line,
screw locknut
·Gauge capacity : 0 to 50 kgf/cm2 pilot pressure CN-75
(0 to 710 psi)
② Start engine.
③ Set the accel dial at "10" (Max).
④ Set H-mode and cancel auto decel EPPR valve
mode.
check pressure.
29095MS10
6-81
2. ENGINE STALL
Cause Remedy
YES
Not enough Check engine
engine power fault
YES Check pressure Contact cummins
at EPPR valve
SPEC:5~20 kgf/cm2 Defective EPPR Replace

See TEST 5 NO
Check electric valve
current at EPPR
valve
YES
Short circuit or Check and repair
SPEC : 100~700 mA poor connection wire harness
See TEST 4
Check resistance between
between CN-50 - CN-75
NO at EPPR valve
SPEC : 15~25Ω(20˚C)
See TEST 1
NO
Defective EPPR Replace
valve
Wiring diagram
MCU
FUSE
24
NO.9
36
28 PUMP EPPR VALVE
9 2
8 10 1
CN-50 CN-2 CN-75
3009SH6MS30
6-82
2) TEST PROCEDURE SPEC : 100~700 mA
(1) Test 4 : Check electric current at EPPR Adapter(P/no.:21Q6-50410)
valve at S-mode
CN-75
① Install multimeter as figure. Multimeter
② Start engine.
④ Set H-mode with 2000±50 rpm.
⑤ Check electric current. EPPR valve
Main pump
21095MS21
(2) Test 5 : Check pressure at EPPR valve at SPEC : 4~20 kgf/cm2 (60~280 psi)
S-mode
① Connect pressure gauge at EPPR valve. Pressure adjusting
screw locknut
② Start engine. Supply line,
④ Set H-mode with 2000±50 rpm.
⑤ Operate bucket lever completely push or
pull. EPPR valve
⑥ Hold arm lever at the end of stroke.
⑦ Check pressure at relief position.
29095MS10
6-83
3. MALFUNCTION OF CLUSTER OR MODE SELECTION SYSTEM
Cause Remedy
YES
No power supply to Check fuse No.3
See if all lamps the MCU
YES off in the MCU
case YES
Y R G MCU failure Replace
Y R G
See if Co : Er
current error NO
display on the LCD
NO Y R G
ⓐ
NO
OK
Check connection Cluster failure Replace
between CN-50
ⓐ (29) - CN-56(3) or
CN-50(30) -
CN-56(4) No connection Check and repair
NO
KEY OFF
Wiring diagram
MCU
POWER IG(24V)
GND
RX 3 2 29
TX 4 1 30
CLUSTER
CN-56 CN-5 7
CN-50
FUSE
NO.3
3009SH6MS31
6-84
4. MALFUNCTION OF ACCEL DIAL
Cause Remedy
YES
YES
poor connection
between CN-7
Check voltage YES Check voltage
between (15)-CN-51 (23)
between
CN-51(23)-GND CN-7(15)-GND YES
Check resistance Defective accel Replace
Spec : actuator operating
Spec : actuator operating between dial
1~5V
1~5V
NO CN-142(B)-
See TEST 6 CN-7(15) Open circuit or Replace or repair
Check voltage NO
Spec : 0Ω poor connection
NO
CN142(A)-(C) (B)-CN-7 (15)
Spec : 5V YES
poor connection
between CN-142
Check voltage (A)-CN-7 (14) or MCU
between CN-142 (C )-
NO CN-7(14)-(16) ACCEL DIAL 20
CN-7 (16)
+ A 14 21
Spec : 5V
Open circuit or Replace or repair S B 15
NO poor connection - C 16 23
between CN-7
(14)-CN-52 (21) CN-142
CN-7 CN-51
or CN-7 (16 )-
CN-51 (20)
3009SH6MS32
6-85
ground.
copper. PIN

CN-51 Female
12 1
24 23 13
36 25
GROUND
Multimeter
3009SH6MS33
6-86
5. AUTO DECEL SYSTEM DOES NOT WORK
Cause Remedy
YES
YES
Defective travel Replace
Check voltage
NO pressure switch
between CD-6(A)
and (C)
NO
SPEC : connection
Check voltage between
Key ON : 24±2V
between CN-51 CN-51(7)-CD-6(A)
(8)-GND
and / or CN-51(13)-
CD-6(C)
SPEC :
Actuator operating : 1~5V
See TEST 7 YES
Defective work Replace
Check voltage
pressure sensor
between CD-7(A)
NO and (C)
NO
SPEC : connection
Key ON : 24±2V between
CN-51(7)-CD-7(A)
and / or CN-51(1)-
CD-7(C)
Wiring diagram
MCU
1 CD-6
7 A SUPPLY
8 B SIG
13 C RETURN
TRAVEL PRESSURE SENSOR
CN-51
CD-7
A SUPPLY
B SIG
C RETURN
WORK PRESSURE SENSOR
3009SH6MS34
6-87
ground.
copper. MCU
② Insert prepared pin to rear side of PIN
connectors : One pin to (8) of CN-51. CN-50 CN-51

CN-51 Female
12 8 1
24 13
36 25
GROUND
Multimeter
3009SH6MS35
6-88
Cause Remedy
YES
YES
poor connection
between
CN-1(3)-GND (10)-CN-1(3)
See TEST 8 SPEC :
Key ON : 24±2V CD-42(B)

NO
NO CN-1(2)-(4) between
CD-42(A)-CN-1(2)
SPEC :
Key ON : 24±2V
or CD-42(C)-
CN-1(4)

NO poor connection
between CN-1(2)-
CN-51(7) or CN-1
(4) - CN-51(8)
Wiring diagram
MCU
CD-42
7 13 2 A SUPPLY
10 6 3 B SIG
8 15 4 C RETURN
CN-2 CN-1
CN-51
3009SH6MS36
6-89
ground.
copper. PIN

CN-51 Female
12 10 1
24 13
36 25
GROUND
Multimeter
3009SH6MS37
6-90
Cause Remedy
YES
YES
poor connection
between
CN-1(1)-GND (11)-CN-1(1)
See TEST 9 SPEC :
Key ON : 24±2V CD-43(B)

NO
CD-43(A)-CN-1(2)
SPEC :
Key ON : 24±2V
or CD-43(C)-
CN-1(4)

NO poor connection
between CN-1(2)-
CN-51(7) or CN-1
(4) - CN-51(8)
Wiring diagram
MCU
CD-43
7 13 2 A SUPPLY
11 7 1 B SIG
8 15 4 C RETURN
CN-2 CN-1
CN-51
3009SH6MS38
6-91
ground.
copper. PIN

CN-51 Female
12 11 1
24 13
36 25
GROUND
Multimeter
3009SH6MS39
6-92
Cause Remedy
YES
YES
poor connection
between
CN-1(5)-GND (12)-CN-1(5)
See TEST 10 SPEC :
Key ON : 24±2V CD-44(B)

NO
CD-44(A)-CN-1(2)
SPEC :
Key ON : 24±2V
or CD-44(C)-
CN-1(4)

NO poor connection
between CN-1(2)-
CN-51(7) or CN-1
(4) - CN-7(8)
Wiring diagram
MCU
CD-44
7 13 2 A SUPPLY
12 4 5 B SIG
8 15 4 C RETURN
CN-2 CN-1
CN-51
3009SH6MS40
6-93
ground.
copper. PIN

CN-51 Female
12 11 1
24 13
36 25
GROUND
Multimeter
3009SH6MS41
6-94
9. MALFUNCTION OF POWER MAX
Cause Remedy
YES
connection between
YES Check resistance CN-88(1)-CN-50 (3)
between CN-88
(1)-(2)
Defective power
NO
YES Check resistance SPEC: 15-35Ω max. solenoid valve Repair or replace
between CN-51 See TEST 12 Check hydraulic
(2)-GND
system
Is voltage between Short circuit or poor Repair or replace

NO
CN-88(2)-GND connection between
SPEC : Power max button pressed ON : 0Ω
normal? Power max button released OFF : ∞ Ω CN-51(2)-CS-29
SPEC
KEY ON : 24±1V
KEY OFF : 0V Short circuit or poor Repair or replace
See TEST 11 NO
connection between
CN-88(2)-
Fuse No. 25
Wiring diagram
MCU
CN-88
3 1
2
CN-50
POWER MAX SOLENOID
2 5
FUSE
6
NO.25
CN-51 CN-4
CS-29
1
2
POWER MAX SWITCH
3009SH6MS42
6-95
2) TEST PROCEDURE SPEC : Key ON : 24±1V
Key OFF : 0V
(1) Test 11:
11 Check voltage between connector
CN-88(2) - GND.
① Disconnect connector CN-88 from power
max solenoid valve. Power max switch
② Start key ON.
③ Check voltage as figure.
LH RCV-lever
CN-88
Power max
solenoid valve
2 1
1 2
GROUND
Multimeter
21096MS14A
(2) Test 12:

12 Check resistance of the solenoid SPEC : 15~35Ω
valve between CN-88(1)-(2).
Power max switch
② Disconnect connector CN-88 from power
max solenoid valve.
③ Check resistance as figure.
LH RCV-lever
CN-88
Power max 2 1
solenoid valve
1 2
Multimeter
21096MS14B
6-96
10. MALFUNCTION OF BOOM PRIORITY EPPR VALVE
Cause Remedy
YES
connection between
CN-50(1)-CN-133
Check resistance (1) or Fuse No. 25
between CN-133(2)
CN-133(1)-(2)
SPEC : 15~35V
KEY : ON
Defective EPPR Repair or replace
NO
valve
Wiring diagram
MCU
CN-133
1 1
BOOM PRIORITY
EPPR VALVE
FUSE
NO.25
CN-50
3009SH6MS43
6-97
Group 1 Operational Performance Test ------------------------------------------------------------------------- 7-1

Group 2 Major Components ------------------------------------------------------------------------------------------- 7-23
Group 3 Track and Work Equipment ------------------------------------------------------------------------------ 7-31
GROUP 1 OPERATIONAL PERFORMANCE TEST
1. PURPOSE
Performance tests are used to check:
1) OPERATIONAL PERFORMANCE OF A
NEW MACHINE
Whenever a new machine is delivered in
Working
parts and reassembled at a customer's condition
site, it must be tested to confirm that the
operational performance of the machine
meets Hyundai spec.
2) OPERATIONAL PERFORMANCE OF A Maintenance
WORKING MACHINE record
With the passage of time, the machine's
operational performance deteriorates, so
that the machine needs to be serviced
periodically to restore it to its original
performance level. Operating
Before servicing the machine, conduct
performance tests to check the extent of
deterioration, and to decide what kind of
service needs to be done (by referring to
the "Service Limits" in this manual).
21077MS01
3) OPERATIONAL PERFORMANCE OF A
REPAIRED MACHINE
After the machine is repaired or serviced, it
must be tested to confir m that its
operational performance was restored by
the repair and/or service work done.
7-1
2. TERMINOLOGY
1) STANDARD
Specifications applied to the brand-new
machine, components and parts.
21077MS02
2) SERVICE LIMIT
The lowest acceptable performance level.
When the perfor mance level of the
machine falls below this level, the machine
must be removed from work and repaired.
Necessary parts and components must be
replaced.
21077MS03
7-2
3. OPERATION FOR PERFORMANCE TESTS
1) Observe the following rules in order to carry
out performance tests accurately and safely.
(1) The machine

Repair any defects and damage found, such
as oil or water leaks, loose bolts, cracks and
so on, before starting to test.
(2) Test area
① Select a hard, flat surface.
② Secure enough space to allow the machine
to run straight more than 20 m, and to make
a full swing with the front attachment
extended.
③ If required, rope off the test area and
provide signboards to keep unauthorized
personnel away.
(3) Precautions
① Before starting to test, agree upon the
signals to be employed for communication
among coworkers. Once the test is started,
be sure to communicate with each other
using these signals, and to follow them
7-3
without fail.
② Operate the machine carefully and always
give first priority to safety.
③ While testing, always take care to avoid
accidents due to landslides or contact with
high voltage power lines. Always confirm
that there is sufficient space for full swings.
④ Avoid polluting the machine and the ground
with leaking oil. Use oil pans to catch
escaping oil. Pay special attention to this
when removing hydraulic pipings.
(4) Make precise measurements

① Accurately calibrate test instruments in
advance to obtain correct data.
② Carry out tests under the exact test
conditions prescribed for each test item.
③ Repeat the same test and confirm that the
test data obtained can be procured
r e p e a t e d l y. U s e m e a n va l u e s o f
measurements if necessary.
7-3
2) ENGINE SPEED (CLUSTER TYPE 1)
(1) Measure the engine speed at each power
mode
※ The engine speed at each power mode
must meet standard RPM; if not, all other
CLUSTER
operational performance data will be
unreliable. It is essential to perform this
test first.
(2) Preparation
① Warm up the machine, until the engine
coolant temperature reaches 50˚C or
more, and the hydraulic oil is 50±5˚C.
② Set the accel dial at 10 (max) position.
③ Push the H-mode switch and confirm
that the fuel injection pump governor Engine RPM display
lever comes into contact with the high- Power mode switch
idle stopper. Pilot lamp(P, S, E)
④ Measure the engine RPM.

(3) Measurement
① Start the engine. The engine will run at
start idle speed. Measure engine speed
with a engine rpm display.
② Measure and record the engine speed at
each mode (P, S, E).
③ Select the P-mode.
④ Lightly operate the bucket control lever a
few times, then return the control lever to
neutral; The engine will automatically
enter the auto-idle speed after 4
seconds. 3009S7MS01
⑤ Measure and record the auto deceleration

speed.
(4) Evaluation
The measured speeds should meet the following specifications.
Unit : rpm
Model Engine speed Standard Remarks
Start idle 1000±100
P mode 2150±50
S mode 2000±50
R260LC-9S
E mode 1850±50
Auto decel 1150±100
One touch decel 1000±100
Condition : Set the accel dial at 10 (max) position.
7-4
■ ENGINE SPEED (CLUSTER TYPE 2)
(1) Measure the engine speed at each power
mode CLUSTER
※ The engine speed at each power mode
must meet standard RPM; if not, all other
operational performance data will be
unreliable. It is essential to perform this
test first.
(2) Preparation
① Warm up the machine, until the engine
coolant temperature reaches 50˚C or
more, and the hydraulic oil is 50±5˚C.
② Set the accel dial at 10 (max) position.
③ Push the H-mode switch and confirm
that the fuel injection pump governor
lever comes into contact with the high-
idle stopper. Power mode switch
④ Measure the engine RPM. Pilot lamp(H, S)
Engine RPM display
(3) Measurement
① Start the engine. The engine will run at
start idle speed. Measure engine speed
with a engine rpm display.
② Measure and record the engine speed at
each mode (M, H, S).
③ Select the M-mode.
④ Lightly operate the bucket control lever a
few times, then return the control lever to
neutral; The engine will automatically
enter the auto-idle speed after 4
seconds. 3009S7MS02
⑤ Measure and record the auto deceleration

speed.
(4) Evaluation
The measured speeds should meet the following specifications.
Unit : rpm
Model Engine speed Standard Remarks
Start idle 1000±100
M mode 2150±50
H mode 2000±50
R260LC-9S
S mode 1850±50
Auto decel 1150±50
One touch decel 1000±50
Condition : Set the accel dial at 10 (max) position.
7-5
3) TRAVEL SPEED
(1) Measure the time required for the
excavator to travel a 20 m test track.
(2) Preparation
① Adjust the tension of both tracks to be
equal.
② Prepare a flat and solid test track 20 m in
length, with extra length of 3 to 5 m on
0.3~0.5m
both ends for machine acceleration and
deceleration.
③ Hold the bucket 0.3 to 0.5 m above the
ground with the arm and bucket rolled in.
④ Keep the hydraulic oil temperature at
290LC7MS01
50±5˚C.
(3) Measurement
① Measure both the low and high speeds
of the machine.
② Before starting either the low or high
speed tests, adjust the travel mode
switch to the speed to be tested, then
select the following switch positions.
· Power mode switch :
P mode(Cluster type 1)
M mode(Cluster type 2) 3 ~ 5m 20m 3 ~ 5m
③ Star t traveling the machine in the
acceleration zone with the travel levers at
full stroke.
④ Measure the time required to travel 20 m.
⑤ After measuring the forward travel
290LC7MS02
speed, turn the upperstructure 180。and
measure the reverse travel speed.
⑥ Repeat steps ④ and ⑤ three times in
each direction and calculate the average
values.
(4) Evaluation
The average measured time should meet the following specifications.
Unit : Seconds / 20 m
Model Travel speed Standard Maximum allowable Remarks
1 Speed 21.2±2.0 28.2
R260LC-9S
2 Speed 13.1±1.0 18.0
7-6
4) TRACK REVOLUTION SPEED
(1) Measure the track revolution cycle time
with the track raised off ground.
(2) Preparation
① Adjust the tension of both side tracks to
be equal.
② On the track to be measured, mark one 90~110
shoe with chalk.
③ Swing the upperstructure 90˚ and lower
the bucket to raise the track off ground.
Keep the boom-arm angle between 90 to Mark
110˚ as shown. Place blocks under
machine frame.
50±5˚C.
21077MS06
(3) Measurement
① Select the following switch positions.
· Travel mode switch : 1 or 2 speed
M mode(Cluster type 2)
· Auto decel switch : OFF
② Operate the travel control lever of the
raised track in full forward and reverse.
③ Rotate 1 turn, then measure time taken
for next 3 revolutions.
④ Raise the other side of machine and
repeat the procedure.
⑤ Repeat steps ③ and ④ three times and
calculate the average values.
(4) Evaluation
The revolution cycle time of each track should meet the following specifications.
Unit : Seconds / 3 revolutions
Model Travel speed Standard Maximum allowable
1 Speed 29.3±2.0 36.6
R260LC-9S
2 Speed 17.6±2.0 22.0
7-7
5) TRAVEL DEVIATION
(1) Measure the deviation by the tracks from
a 20m straight line.
(2) Preparation
① Adjust the tension of both tracks to be
equal.
② Provide a flat, solid test yard 20 m in
length, with extra length of 3 to 5 m on 0.3~0.5m
both ends for machine acceleration and
deceleration.
③ Hold the bucket 0.3 to 0.5 m above the
ground with the arm and bucket rolled in.
290LC7MS01
50±5˚C.
(3) Measurement
① Measure the amount of mistracking at
high and low travel speeds.
② Before beginning each test, select the
following switch positions. 3~5 m extra length
· Power mode switch : a
M
20
M mode(Cluster type2)
③ Star t traveling the machine in the 3~5 m extra length
acceleration zone with the travel levers at
full stroke.
④ Measure the distance between a straight
20m line and the track made by the 7-7(2)
machine. (dimension a)
⑤ After measuring the tracking in forward
travel, turn the upperstructure 180。 and
measure that in reverse travel.
⑥ Repeat steps ④ and ⑤ three times and
(4) Evaluation
Mistrack should be within the following specifications.
Unit : mm / 20 m
Model Standard Maximum allowable Remarks
R260LC-9S 200 below 240
7-8
6) SWING SPEED
(1) Measure the time required to swing three
complete turns.
(2) Preparation
① Check the lubrication of the swing gear
and swing bearing.
② Place the machine on flat, solid ground
with ample space for swinging. Do not
conduct this test on slopes.
③ With the arm rolled out and bucket rolled
in, hold the bucket so that the height of
the bucket pin is the same as the boom
foot pin. The bucket must be empty.
50±5˚C.
290LC7MS03
(3) Measurement
· Power mode switch : Each mode
② Operate swing control lever fully.
③ Swing 1 turn and measure time taken to
swing next 3 revolutions.
④ Repeat steps ② and ③ three time and
(4) Evaluation
The time required for 3 swings should meet the following specifications.
Unit : Seconds / 3 revolutions
Model Power mode switch Standard Maximum allowable
P mode (Cluster type 1)
R260LC-9S 15±1.5 18
M mode (Cluster type 2)
7-9
7) SWING FUNCTION DRIFT CHECK
(1) Measure the swing drift on the bearing
outer circumference when stopping after
a 360˚ full speed swing.
(2) Preparation
① Check the lubrication of the swing gear
and swing bearing.
② Place the machine on flat, solid ground
with ample space for swinging. Do not
conduct this test on slopes.
③ With the arm rolled out and bucket rolled
the bucket pin is the same as the boom 290LC7MS03
foot pin. The bucket must be empty.
④ Make two chalk marks: one on the swing
bearing and one directly below it on the
track frame.
⑤ Swing the upperstructure 360˚.
⑥ Keep the hydraulic oil temperature at
50±5˚C.
(3) Measurement
① Conduct this test in the P mode.(M mode)
② Select the following switch positions.
③ Operate the swing control lever fully and
return it to the neutral position when the
mark on the upperstructure aligns with
that on track frame after swinging 360˚. Drift angle
④ Measure the distance between the two
360 swing
marks.
Swing start & stop
⑤ Align the marks again, swing 360˚, then
test the opposite direction.
21077MS08
⑥ Repeat steps ④ and ⑤ three times each
and calculate the average values.
(4) Evaluation
The measured drift angle should be within the following specifications.
Unit : Degree
Model Power mode switch Standard Maximum allowable Remarks
P mode
R260LC-9S 90 below 157.5
M mode
7-10
8) SWING BEARING PLAY
(1) Measure the swing bearing play using a
dial gauge to check the wear of bearing
races and balls.
(2) Preparation
① Check swing bearing mounting cap
screws for loosening.
② Check the lubrication of the swing
bearing. Confirm that bearing rotation is
smooth and without noise.
③ Install a dial gauge on the track frame as
shown, using a magnetic base.
④ Position the upperstructure so that the
7-10(1)
boom aligns with the tracks facing
towards the front idlers.
⑤ Position the dial gauge so that its needle
point comes into contact with the bottom
face of the bearing outer race.
⑥ Bucket should be empty.
(3) Measurement Measurement : (h1)
① With the arm rolled out and bucket rolled
in, hold the bottom face of the bucket to
the same height of the boom foot pin.
Record the dial gauge reading (h1).
② Lower the bucket to the ground and use
it to raise the front idler 50cm.
Measurement : (h2)
Record the dial gauge reading (h2).
③ Calculate bearing play(H) from this data
(h1 and h2) as follows.
H=h2-h1
(4) Evaluation 290LC7MS04
The measured drift should be within the following specifications.
Unit : mm
Model Standard Maximum allowable Remarks
R260LC-9S 0.5 ~ 1.5 3.0
7-11
9) HYDRAULIC CYLINDER CYCLE TIME
(1) Measure the cycle time of the boom,
standard arm, and standard bucket
cylinders.
(2) Preparation Boom cylinder
① To measure the cycle time of the boom Raise
cylinders:
With the arm rolled out and the empty
bucket rolled out, lower the bucket to the
ground, as shown. Lower
② To measure the cycle time of the arm
cylinder.
With the empty bucket rolled in, position
Arm cylinder
the arm so that it is vertical to the ground.
Lower the boom until the bucket is 0.5 m
above the ground. Roll out Roll in
③ To measure the cycle time of the bucket
cylinder.
90
The empty bucket should be positioned 0.5m
at midstroke between roll-in and roll-out,
so that the sideplate edges are vertical to
the ground. Bucket cylinder
50±5˚C.
(3) Measurement
· Power mode switch : Roll out Roll in
P mode(Cluster type 1) 0.5m
② To measure cylinder cycle times.
21077MS10
- Boom cylinders.
Measure the time it takes to raise the
boom, and the time it takes to lower the
boom. To do so, position the boom at
one stroke end then move the control
lever to the other stroke end as quickly
as possible.
- Arm cylinder.
Measure the time it takes to roll in the
arm, and the time it takes to roll out the
arm. To do so, position the bucket at
one stroke end, then move the control
as possible.
7-12
- Bucket cylinders
Measure the time it takes to roll in the
bucket, and the time it takes to roll out
the bucket. To do so, position the bucket
at one stroke end, then move the control
as possible.
- Repeat each measurement 3 times and
(4) Evaluation
The average measured time should meet the following specifications.
Unit : Seconds
Model Function Standard Maximum allowable Remarks
Boom raise 3.8±0.4 4.75
Boom lower 2.5±0.4 3.2
Regen ON 3.1±0.4 4.0
Arm in
R260LC-9S Regen OFF 3.5±0.4 4.6
Arm out 3.0±0.3 3.8
Bucket load 2.7±0.4 3.3
Bucket dump 2.3±0.3 2.7
7-13
10) DIG FUNCTION DRIFT CHECK
(1) Measure dig function drift, which can be
caused by oil leakage in the control valve
and boom, standard arm, and standard
bucket cylinders, with the loaded bucket.
When testing the dig function drift just
after cylinder replacement, slowly operate
each cylinder to its stroke end to purge air.
(2) Preparation
① Load bucket fully. Instead of loading the
bucket, weight (W) of the following
specification can be used.
· W=M3×1.5
Where :
M3 = Bucket heaped capacity (m3)
1.5= Soil specific gravity
② Position the arm cylinder with the rod 20
to 30 mm extended from the fully retracted
position.
③ Position the bucket cylinder with the rod
20 to 30 mm retracted from the fully
extended position.
290LC7MS05
④ With the arm rolled out and bucket rolled
the bucket pin is the same as the boom
foot pin.
⑤ Keep the hydraulic oil temperature at
50±5˚C.
(3) Measurement
① Stop the engine.
② Five minutes after the engine has been
stopped, measure the changes in the
positions of the boom, arm and bucket
cylinders.
③ Repeat step ② three times and calculate
the average values.
(4) The measured drift should be within the following specifications.
Unit : mm / 5 min
Model Drift to be measured Standard Maximum allowable Remarks

Boom cylinder 10 below 20
R260LC-9S Arm cylinder 10 below 20
Bucket cylinder 40 below 50
7-14
11) CONTROL LEVER OPERATING FORCE
(1) Use a spring scale to measure the
maximum resistance of each control lever
at the middle of the grip.
(2) Preparation
① Keep the hydraulic oil temperature at
50±5˚C.
(3) Measurement
① Start the engine.
② Select the following switch positions.
③ Operate each boom, arm, bucket and
swing lever at full stroke and measure the
maximum operating force for each.
④ Lower the bucket to the ground to raise
one track off the ground. Operate the
travel lever at full stroke and measure the
maximum operating force required.
When finished, lower the track and then
jack-up the other track.
⑤ Repeat steps ③ and ④ three times and
(4) Evaluation
The measured operating force should be within the following specifications.
Unit : kgf
Model Kind of lever Standard Maximum allowable Remarks
Boom lever 1.7 or below 2.0
Arm lever 1.7 or below 2.0
R260LC-9S Bucket lever 1.4 or below 2.0
Swing lever 1.4 or below 2.0
Travel lever 2.1 or below 3.15
7-15
12) CONTROL LEVER STROKE
(1) Measure each lever stroke at the lever top
using a ruler.
※ When the lever has play, take a half of this
value and add it to the measured stroke.
(2) Preparation
Keep the hydraulic oil temperature at
50±5˚C.
(3) Measurement
② Measure each lever stroke at the lever
top from neutral to the stroke end using a
ruler.
③ Repeat step ② three times and calculate
the average values.
(4) Evaluation
The measured drift should be within the following specifications.
Unit : mm
Model Kind of lever Standard Maximum allowable Remarks

Boom lever 112±10 140
Arm lever 112±10 140
R260LC-9S Bucket lever 90±10 113
Swing lever 90±10 113
Travel lever 139±10 174
7-16
13) PILOT PRIMARY PRESSURE (CLUSTER TYPE 1)
(1) Preparation a3
Main pump

50±5˚C.
Pressure sensor
(2) Measurement
· Power mode switch : P mode
Cluster
② Measure the primary pilot pressure by
the monitoring menu of the cluster.
29097MS13
(3) Evaluation
The average measured pressure should meet the following specifications:
Unit : kgf / cm2
Model Engine speed Standard Allowable limits Remarks
R260LC-9S P mode 40 +20 -
■ PILOT PRIMARY PRESSURE (CLUSTER TYPE 2)

(1) Preparation
② Push the pressure release button to
bleed air.
a3
③ Loosen and remove plug on the pilot
pump delivery port and connect pressure
gauge.
④ Star t the engine and check for oil
leakage from the port.
50±5˚C.
2507A7MS02A
(2) Measurement
· Power mode switch : M mode
② Measure the primary pilot pressure in the
M mode.
(3) Evaluation
Unit : kgf / cm2
R260LC-9S M mode 40 +20 -
7-17
14) FOR TRAVEL SPEED SELECTING PRESSURE
(1) Preparation
② Remove the top cover of the hydraulic
tank oil supply port with a wrench.
③ Push the pressure release button to
bleed air.
④ To measure the speed selecting pressure:
Install a connector and pressure gauge
assembly to turning joint P port as shown.
⑤ Star t the engine and check for on
leakage from the adapter.
50±5˚C.
(2) Measurement
Travel mode switch : 1 speed, 2 speed
· Mode selector :
② Measure the travel speed selecting
pressure in the Hi or Lo mode.
③ Lower the bucket to the ground to raise
the track off the ground. Operate the
travel lever at full stroke and measure the
fast speed pressure.
④ Repeat steps ② and ③ three times and
(3) Evaluation
The average measured pressure should be within the following specifications.
Unit : kgf / cm 2
Model Travel speed Standard Maximum allowable Remarks
1 Speed 0 -
R260LC-9S
2 Speed 40±5 -
7-18
15) SWING PARKING BRAKE RELEASING PRESSURE
(1) Preparation
② Remove the top cover of the hydraulic
tank oil supply port with a wrench.
③ The pressure release L wrench to bleed
air.
④ Install a connector and pressure gauge
assembly to swing motor SH port, as
SH
shown.
⑤ Star t the engine and check for oil
leakage from the adapter.
50±5˚C.
(2) Measurement
② Operate the swing function or arm roll in
function and measure the swing brake
21077MS14
c o n t r o l p r e s s u r e w i t h t h e b ra ke
disengaged. Release the control lever to
return to neutral and measure the control
pressure when the brake is applied.
Repeat step ② three times and calculate
the average values.
(3) Evaluation
Unit : kgf / cm2
Model Description Standard Allowable limits Remarks
Brake disengaged 40 Over 9
R260LC-9S
Brake applied 0 -
7-19
16) MAIN PUMP DELIVERY PRESSURE (CLUSTER TYPE 1)
(1) Preparation Main pump
50±5˚C.
Pressure sensor a1
(2) Measurement a2

· Power mode switch : P mode
② Measure the main pump deliver y
pressure by the monitoring menu of the
cluster. Cluster
(3) Evaluation 29097MS14
The average measured pressure should meet the following specifications.

Unit : kgf / cm2
R260LC-9S High ilde 40±10 -
■ MAIN PUMP DELIVERY PRESSURE (CLUSTER TYPE 2)

(1) Preparation
bleed air.
③ Loosen and remove pump pressure.
assembly main pump gauge port as
shown.
290LC7MS07
50±5˚C.
(2) Measurement
· Mode selector : M mode
② Measure the main pump deliver y
pressure in the M mode (high idle).
(3) Evaluation
Unit : kgf / cm2
R260LC-9S High idle 40±10 -
7-20
17) SYSTEM PRESSURE REGULATOR RELIEF SETTING (CLUSTER TYPE 1)
(1) Preparation
50±5˚C. Main pump
(2) Measurement
① Select the following switch positions. Pressure sensor a1
· Power mode switch : P mode a2
② Slowly operate each control lever of

boom, arm and bucket functions at full
stroke over relief and measure the
pressure.
Cluster
③ In the swing function, place bucket
against an immovable object and
measure the relief pressure.
④ In the travel function, lock undercarriage
with an immovable object and measure 29097MS14
the relief pressure.

(3) Evaluation
Unit : kgf / cm2
Model Function to be tested Standard Remark

Boom, Arm, Bucket 350(380)±10 400±10 (Port relief)
R260LC-9S Travel 350±10 -
Swing 300±10 -
( ) : Power boost
7-21
■ SYSTEM PRESSURE REGULATOR RELIEF SETTING (CLUSTER TYPE 2)
(1) Preparation
bleed air.
③ To measure the system relief pressure.
assembly main pump gauge port, as
shown.
50±5˚C.
(2) Measurement
· Mode selector : M mode 2507A7MS03A
② Slowly operate each control lever of

boom, arm and bucket functions at full
stroke over relief and measure the
pressure.
③ In the swing function, place bucket
against an immovable object and
measure the relief pressure.
④ In the travel function, lock undercarriage
with an immovable object and measure
the relief pressure.
(3) Evaluation
Unit : kgf / cm2
Model Function to be tested Standard Remark

Boom, Arm, Bucket 350(380)±10 400±10 (Port relief)
R260LC-9S Travel 350±10 -
Swing 300±10 -
( ) : Power boost
7-22
GROUP 2 MAJOR COMPONENT
1. MAIN PUMP
3 1 2
9 5 6 4 7 8 2209S7MP01
Standard Recommended
Part name & inspection item replacement Counter measures
dimension value
Clearance
between piston (1) & Replace piston
d D 0.039 0.067
cylinder bore (2) or cylinder.
(D-d)
Play between
piston (1) & shoe caulking
0-0.1 0.3
section (3)
(ɺ) Replace
assembly of
Thickness of shoe ɺ piston & shoe.
(t) t 4.9 4.7
Free height of cylinder

spring (4) Replace
41.1 40.3
(L) cylinder spring.
L
Combined height of set

h H
plate (5) & spherical Replace retainer
23.0 22.0
bushing (6) or set plate.
(H-h)
Surface roughness for valve Surface roughness

plate (sliding face) (7,8), necessary to be corrected 3z
swash plate (shoe plate Lapping
area) (9), & cylinder (2) Standard surface roughness 0.4z or lower
(sliding face) (corrected value)
7-23
2. MAIN CONTROL VALVE
Part name Inspection item Criteria & measure
Casing · Existence of scratch, rusting or corrosion. · In case of damage in following section,

replace part
- Sliding sections of casing fore and spool,
especially land sections applied with
holding pressure
- Seal pocket section where spool is
inserted
- Seal section of por t where O-ring
contacts
- Seal section of each relief valve for main,
travel, and port
- Other damages that may damage
normal functions
Spool · Existence of scratch, gnawing, rusting or · Replacement when its outside sliding
corrosion. section has scratch (especially on seals
contacting section)
· Insert spool in casing hole, rotate and · Correction or replacement when O-ring is
reciprocate it. damaged or when spool does not move
smoothly
Load check valve · Damage of load check valve or spring · Repair or replace of improper seat contact
Around spring · Rusting, corrosion, deformation or · Replacement for significant damage

breaking of spring, spring seat, plug or
cover.
Around seal · External oil leakage. · Replacement

for spool
Main relief valve, · External rusting or damage. · Replacement

Over relief valve · Contacting face of valve seat. · Replacement when damaged
7-24
3. SWING DEVICE
1) WEARING PARTS
Standard Recommended
Inspection item replacement Counter measures
dimension value
Replace piston or
Clearance between piston and cylinder block bore 0.028 0.058
cylinder block
Replace assembly
Play between piston and shoe caulking section (ɺ) 0 0.3
of piston and shoe
Replace assembly
Thickness of shoe (t) 5.5 5.3
of piston and shoe
Replace set of
Combined height of retainer plate and spherical
6.5 6.0 retainer plate and
bushing (H)
sperical bushing
Thickness of friction plate (h) 4.0 3.6 Replace
h H
t
ɺ
2507A7MS04 2507A7MS05
2) SLIDING PARTS
Part name Standard roughness Allowable roughness Remark
0.8-Z (Ra=0.2)
Shoe 3-Z (Ra=0.8)
(LAPPING)
0.4-Z (Ra=0.1)
Shoe plate 3-Z (Ra=0.8)
(LAPPING)
1.6-Z (Ra=0.4)
Cylinder 12.5-Z (Ra=3.2)
(LAPPING)
0.8-Z (Ra=0.2)
Valve plate 6.3-Z (Ra=1.6)
(LAPPING)
7-25
4. TRAVEL MOTOR
Problem Cause Remedy
Does not Pressure is not · Pump failure · Check if action other than traveling is
start developed available. If faulty, repair.
· Control valve malfunction · Check if spool moves correctly. Repair if
necessary.
Pressure in · Brake valve failure · Replace brake valve
developed -Sleeve stick
-Check valve stick
· Motor failure · Replace
-Valve seat seizure -Check hydraulic oil for contamination
· Gear broken and fragment locked · Replace reduction gear
· Overloaded · Reduce load
Oil leakage Leakage from · Scratch on engaging surfaces · Correct surfaces by oilstone or sandpa-
engaging sur- per or replace
faces · Loosening by poor bolt tightening · Check after retightening
Leakage from · Plug loosened · Retighten

casing · Crack formed by stone · Replace reduction gear
Leakage from · Sliding surfaces worn · Replace reduction gear
floating seal · Creep on O-ring · Replace floating seal
Leakage from · Bolt loosened · Tighten properly

hydraulic motor · O-ring damaged · Replace O-ring
· Sealing surface scratched · Correct by oilstone or sandpaper
Coasts on slope excessively · Poor volumetric efficiency of hydraulic · Replace hydraulic motor
motor
· Increase of internal leakage of brake · Replace brake valve
valve
· Parking brake not actuated
-Spring breakage · Replace spring
-Wear of friction plate · Replace parking brake
Excessive temperature on · Pitting on bearing · Replace reduction gear

reduction gear case · Lack of gear oil · Supply gear oil properly
· Hydraulic oil introduced to gear case · Check motor and replace oil seal
Meanders Meanders at · Delivery rate is different between · Repair pump

low pressure right and left
· Motor drain rate is different between · Replace motor
right and left
Meanders at · Delivery rate is different between · Repair regulator or pump
high pressure right and left
· Motor drain rate is different between · Replace motor
right and left
Meanders at · Relief pressure dropped at right and · Replace brake valve
high pressure left brake valve
· Main relief pressure dropped at right · Replace main relief valve
or left of control valve
Pump delivery is poor · Regulator operation poor · Repair regulator
· External leakage of pump is exces- · Repair pump
sive
External leakage of motor is · Replace motor
-
excessive
7-26
5. RCV LEVER
Maintenance
Criteria Remark
check item
Leakage The valve is to be replaced when the leakage Conditions :

becomes more than 1000 cc/m at neutral handle Primary pressure : 30 kgf/cm2
position, or more than 2000 cc/m during operation. Oil viscosity : 23 cSt
Spool This is to be replaced when the sliding surface has The leakage at the left condition is
worn more than 10μm, compared with the non- estimated to be nearly equal to the
sliding surface. above leakage.
Push rod
Ø7
1 mm
This is to be replaced when the top end has worn

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

drop, etc. are generated during operation, and
these cannot be remedied, referring to section 6.
Troubleshooting, replace the related parts.
Notes 1. It is desirable to replace seal materials, such as O-rings, every disassembling. However,
they may be reused, after being confirmed to be free of damage.
2. When loosening the hexagon socket head cap screw (125), replace the seal washers (121)
without fail.
7-27
6. RCV PEDAL
Maintenance
Criteria Remark
check item
Leakage The valve is to be replaced when the leakage effect Conditions :

to the system. For example, the primary pressure Primary pressure : 30 kgf/cm2
drop. Oil viscosity : 23 cSt
Spool This is to be replaced when the sliding surface has The leakage at the left condition is
worn more than 10μm, compared with the non- estimated to be nearly equal to the
sliding surface. above leakage.
Push rod
Ø7
1 mm
This is to be replaced when the top end has worn

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

drop, etc. are generated during operation, and
these cannot be remedied, referring to section 6.
Troubleshooting, replace the related parts.
Notes 1. It is desirable to replace seal materials, such as O-rings, every disassembling.

However, they may be reused, after being confirmed to be free of damage.
7-28
7. TURNING JOINT
Part name Maintenance standards Remedy
Sliding surface Plating worn or peeled due to seizure or contamination. Replace

with sealing
sections.
Sliding surface ·Worn abnormality or damaged more than 0.1 mm Replace

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

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

within wear limit (0.5 mm) (0.02 in).
·Extruded excessively from seal groove square ring. Replace
- Extrusion
Square ring
·Slipper ring 1.5 mm (0.059 in) narrower than seal Replace

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

(0.059 in)
-
7-29
8. CYLINDER
Part name Inspecting section Inspection item Remedy
Piston rod ·Neck of rod pin ·Presence of crack ·Replace

·Weld on rod hub ·Presence of crack ·Replace
·Stepped part to which piston ·Presence of crack ·Replace
is attached.
·Threads ·Presence of crack ·Recondition or replace
·Plated surface ·Plating is not worn off to ·Replace or replate
base metal.
·Rust is not present on plating. ·Replace or replate
·Scratches are not present. ·Recondition, replate or replace
·Rod ·Wear of O.D. ·Recondition, replate or replace
·Bushing at mounting part ·Wear of I.D. ·Replace
Cylinder tube ·Weld on bottom ·Presence of crack ·Replace
·Weld on head ·Presence of crack ·Replace
·Weld on hub ·Presence of crack ·Replace
·Tube interior ·Presence of faults ·Replace if oil leak is seen
·Bushing at mounting part ·Wear on inner surface ·Replace
Gland ·Bushing ·Flaw on inner surface ·Replace if flaw is deeper
than coating
7-30
GROUP 3 TRACK AND WORK EQUIPMENT
1. TRACK
1) TRACK ROLLER
2
1
3 4
21037MS01
Unit : mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Outside diameter of flange
͚200
Rebuild or
2 Outside diameter of tread ͚160 ͚148
replace
3 Width of tread 48 54
4 Width of flange 21.5 15.5
Standard size & tolerance Standard Clearance
Clearance between shaft Shaft Hole clearance limit Replace
5
and bushing bushing
-0.29 +0.046 0.39
͚70 -0.33 ͚70.1 2.0
0 to 0.476
Side clearance of roller Standard clearance Clearance limit
6 Replace
(both side) 0.2 to 1.2 2.0
7-31
2) CARRIER ROLLER
4 3
5
21037MS02
Unit : mm

1 Outside diameter of flange
͚169
Rebuild or
2 Outside diameter of tread ͚144 ͚134
replace
4 Width of flange 17 -
tolerance Standard Clearance
Standard size
5
and bushing bushing
- 0.05 + 0.3 0.15
͚55 - 0.1 + 0.1 ~ 0.40 2.0
7-32
3) IDLER
8
1
2
7
3 5
4
21037MS03
Unit : mm
1 Outside diameter of protrusion
͚560
2 Outside diameter of tread ͚520 ͚510 Rebuild or
3 Width of protrusion 84 replace
4 Total width 160

Standard size & tolerance Standard Clearance
6
and bushing bushing
0 +0.05
͚75 -0.03 ͚75.35 0 0.35 to 0.43 2.0
Clearance between shaft 0

7 ͚75 -0.03 ͚75 +0.07 0.03 to 0.1 1.2 Replace
and support +0.03
Side clearance of idler Standard clearance Clearance limit Replace
8
(both side) 0.25 to 1.2 2.0 bushing
7-33
4) TRACK
2 1
4
3
21037MS04
Unit : mm
Standard size Repair limit Turn or
1 Link pitch
190 199 replace
2 Outside diameter of bushing ͚59 ͚51

Rebuild or
3 Height of grouser 26 16 replace
4 Height of link 105 97
5 Tightening torque Initial tightening torque : 78Ü8 kgfÂm Retighten
7-34
5) TRACK FRAME AND RECOIL SPRING
2
3
1
21037MS05
Unit : mm
Standard size Tolerance Repair limit

+2
Track frame 113 0
117
1 Vertical width of idler guide
0
Idler support 110 106 Rebuild or
- 1.5
replace
+2
Track frame 272 0
276
2 Horizontal width of idler guide
Idler support 270 - 267

Free Installation Installation Free Installation
3 Recoil spring length length load length load Replace
͚235Ý627 508 16315kg 13052kg
7-35
2. WORK EQUIPMENT
A C D E F
B K J I H G
21077MS20
Unit : mm
Pin Bushing
Remedy
Measuring point Normal Recomm. Recomm.
Mark Limit Limit &
(Pin and Bushing) value service service
of use of use Remark
limit limit
A Boom Rear 100 99 98.5 100.5 101 Replace
B Boom Cylinder Head 90 89 88.5 90.5 91 Æ
C Boom Cylinder Rod 100 99 98.5 100.5 101 Æ
D Arm Cylinder Head 90 89 88.5 90.5 91 Æ
E Boom Front 100 99 98.5 100.5 101 Æ
F Arm Cylinder Rod 90 89 88.5 90.5 91 Æ
G Bucket Cylinder Head 90 89 88.5 90.5 91 Æ
H Arm Link 80 79 78.5 80.5 81 Æ
I Bucket and Arm Link 90 89 88.5 90.5 91 Æ
J Bucket Cylinder Rod 80 79 78.5 80.5 81 Æ
K Bucket Link 90 89 88.5 90.5 91 Æ
7-36
Group 1 Precaution --------------------------------------------------------------------------------------------------------- 8-1

Group 2 Tightening Torque --------------------------------------------------------------------------------------------- 8-4
Group 3 Pump Device ----------------------------------------------------------------------------------------------------- 8-7
Group 4 Main Control Valve -------------------------------------------------------------------------------------------- 8-30
Group 7 RCV Lever --------------------------------------------------------------------------------------------------------- 8-111
Group 8 Turning Joint ------------------------------------------------------------------------------------------------------ 8-125
Group 9 Boom, Arm and Bucket Cylinder --------------------------------------------------------------------- 8-130
Group 11 Work Equipment ----------------------------------------------------------------------------------------------- 8-159
GROUP 1 PRECAUTIONS
1. REMOVAL WORK
1) Lower the work equipment completely to the ground.
If the coolant contains antifreeze, dispose of it correctly.
2) After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
3) When draining oil, prepare a container of adequate size to catch the oil.
4) Confirm the match marks showing the installation position, and make match marks in the
necessary places before removal to prevent any mistake when assembling.
5) To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors.
6) Fit wires and hoses with tags to show their installation position to prevent any mistake when
installing.
7) Check the number and thickness of the shims, and keep in a safe place.
8) When raising components, be sure to use lifting equipment of ample strength.
9) When using forcing screws to remove any components, tighten the forcing screws alternately.
10) Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
11) When removing hydraulic equipment, first release the remaining pressure inside the hydraulic tank
and the hydraulic piping.
12) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
number D d L
06 6 5 8
08 8 6.5 11
10 10 8.5 12
12 12 10 15
14 14 11.5 18 Taper 1/8
ØD Ød
16 16 13.5 20
18 18 15 22
20 20 17 25
L
22 22 18.5 28
24 24 20 30
27 27 22.5 34
8-1
2. INSTALL WORK
1) Tighten all bolts and nuts (sleeve nuts) to the specified torque.
2) Install the hoses without twisting or interference.
3) Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
4) Bend the cotter pin or lock plate securely.
5) When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded
portion with 2-3 drops of adhesive.
6) When coating with gasket sealant, clean the surface and remove all oil and grease, check that
there is no dirt or damage, then coat uniformly with gasket sealant.
7) Clean all parts, and correct any damage, dents, burrs, or rust.
8) Coat rotating parts and sliding parts with engine oil.
9) When press fitting parts, coat the surface with antifriction compound (LM-P).
10) After installing snap rings, check that the snap ring is fitted securely in the ring groove (check that
the snap ring moves in the direction of rotation).
11) When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then
connect securely.
12) When using eyebolts, check that there is no deformation or deterioration, and screw them in fully.
13) When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
14) When operating the hydraulic cylinders for the first time after repairing and reassembling the
hydraulic cylinders, pumps, or other hydraulic equipment or piping, always bleed the air from the
hydraulic cylinders as follows:
(1) Start the engine and run at low idling.
(2) Operate the control lever and actuate the hydraulic cylinder 4-5 times, stopping 100mm before the
end of the stroke.
(3) Next, operate the piston rod to the end of its stroke to relieve the circuit. (The air bleed valve is
actuated to bleed the air.)
(4) After completing this operation, raise the engine speed to the normal operating condition.
※ If the hydraulic cylinder has been replaced, carry out this procedure before assembling the rod to
※ the work equipment.
Carry out the same operation on machines that have been in storage for a long time after
completion of repairs.
8-2
3. COMPLETING WORK
1) If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run
the engine to circulate the water through the system. Then check the water level again.
2) If the hydraulic equipment has been removed and installed again, add engine oil to the specified
level. Run the engine to circulate the oil through the system. Then check the oil level again.
3) If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been
removed for repair, always bleed the air from the system after reassembling the parts.
4) Add the specified amount of grease (molybdenum disulphied grease) to the work equipment
related parts.
8-3
GROUP 2 TIGHTENING TORQUE
1. MAJOR COMPONENTS
Torque
No. Descriptions Bolt size
kgfÂm lbfÂft
1 Engine mounting bolt (engine-bracket) M12 Ý 1.75 12.8 Ü 3.0 92.6 Ü 21.7
2 Engine mounting bolt (bracket-frame, FR) M20 Ý 2.5 55 Ü 3.5 398 Ü 25
3 Engine mounting bolt (bracket-frame, RR) M24 Ý 3.0 97 Ü 7.0 702 Ü 51
Engine
4 Radiator mounting bolt M16 Ý 2.0 29.7 Ü 4.5 215 Ü 32.5
5 Coupling mounting socket bolt M18 Ý 2.5 32 Ü1.0 231 Ü7.2
6 Fuel tank mounting bolt M20 Ý 2.5 57.9 Ü 8.7 419 Ü 62.9
7 Main pump housing mounting bolt M10 Ý 1.5 4.8 Ü 0.3 34.7 Ü 2.2
8 Main pump mounting socket bolt M20 Ý 2.5 42 Ü 4.5 304 Ü 32.5
Hydraulic
9 Main control valve mounting nut M12 Ý 1.75 12.3 Ü 1.3 89.0 Ü 9.4
system
10 Hydraulic oil tank mounting bolt M20 Ý 2.5 57.9 Ü 8.7 419 Ü 62.9
11 Turning joint mounting bolt, nut M12 Ý 1.75 12.3 Ü 1.3 89.0 Ü 9.4
12 Swing motor mounting bolt M24 Ý 3.0 97.8 Ü 10 707 Ü 72
13 Swing bearing upper part mounting bolt M20 Ý 2.5 57.9 Ü 6.0 419 Ü 43.4
Power
14 train Swing bearing lower part mounting bolt M20 Ý 2.5 57.9 Ü 6.0 419 Ü 43.4
system
15 Travel motor mounting bolt M16 Ý 2.0 23 Ü 2.5 166 Ü 18.1
16 Sprocket mounting bolt M16 Ý 2.0 26 Ü 3.0 188 Ü 21.7
17 Carrier roller mounting bolt, nut M16 Ý 2.0 29.7Ü 3.0 215 Ü 21.7
18 Track roller mounting bolt M16 Ý 2.0 29.7 Ü 3.0 215 Ü 21.7
Under
19 Track tension cylinder mounting bolt M16 Ý 2.0 29.7 Ü 4.5 215 Ü 32.5
carriage
20 Track shoe mounting bolt, nut M20 Ý 1.5 78 Ü 8.0 564 Ü 57.9
21 Track guard mounting bolt M20 Ý 2.5 57.9 Ü 8.7 419 Ü 62.9
22 Counterweight mounting bolt M36 Ý 3.0 340 Ü 10 2460 Ü 72.3
23 Others Cab mounting bolt M12 Ý 1.75 12.8 Ü 3.0 92.6 Ü 21.7
24 Operator's seat mounting bolt M 8 Ý 1.25 4.05 Ü 0.8 29.3 Ü 5.8
※ For tightening torque of engine and hydraulic components, see engine maintenance guide and
service manual.
8-4
2. TORQUE CHART
Use following table for unspecified torque.
1) BOLT AND NUT
(1) Coarse thread
8T 10T
Bolt size
kgf·m lbf·ft kgf·m lbf·ft
M 6×1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6
M 8×1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.7 ~ 4.1 19.5 ~ 29.7
M10×1.5 4.0 ~ 6.0 28.9 ~ 43.4 5.5 ~ 8.3 39.8 ~ 60.0
M12×1.75 7.4 ~ 11.2 53.5 ~ 81.0 9.8 ~ 15.8 70.9 ~ 114
M14×2.0 12.2 ~ 16.6 88.2 ~ 120 16.7 ~ 22.5 121 ~ 163
M16×2.0 18.6 ~ 25.2 135 ~ 182 25.2 ~ 34.2 182 ~ 247
M18×2.0 25.8 ~ 35.0 187 ~ 253 35.1 ~ 47.5 254 ~ 344
M20×2.5 36.2 ~ 49.0 262 ~ 354 49.2 ~ 66.6 356 ~ 482
M22×2.5 48.3 ~ 63.3 349 ~ 458 65.8 ~ 98.0 476 ~ 709
M24×3.0 62.5 ~ 84.5 452 ~ 611 85.0 ~ 115 615 ~ 832
M30×3.0 124 ~ 168 898 ~ 1214 169 ~ 229 1223 ~ 1656
M36×4.0 174 ~ 236 1261 ~ 1704 250 ~ 310 1808 ~ 2242
(2) Fine thread

8T 10T
Bolt size
kgf·m lbf·ft kgf·m lbf·ft
M 8×1.0 2.2 ~ 3.4 15.9 ~ 24.6 3.0 ~ 4.4 21.7 ~ 31.8
M10×1.2 4.5 ~ 6.7 32.5 ~ 48.5 5.9 ~ 8.9 42.7 ~ 64.4
M12×1.25 7.8 ~ 11.6 56.4 ~ 83.9 10.6 ~ 16.0 76.7 ~ 116
M14×1.5 13.3 ~ 18.1 96.2 ~ 131 17.9 ~ 24.1 130 ~ 174
M16×1.5 19.9 ~ 26.9 144 ~ 195 26.6 ~ 36.0 192 ~ 260
M18×1.5 28.6 ~ 43.6 207 ~ 315 38.4 ~ 52.0 278 ~ 376
M20×1.5 40.0 ~ 54.0 289 ~ 391 53.4 ~ 72.2 386 ~ 522
M22×1.5 52.7 ~ 71.3 381 ~ 516 70.7 ~ 95.7 511 ~ 692
M24×2.0 67.9 ~ 91.9 491 ~ 665 90.9 ~ 123 658 ~ 890
M30×2.0 137 ~ 185 990 ~ 1339 182 ~ 248 1314 ~ 1796
M36×3.0 192 ~ 260 1390 ~ 1880 262 ~ 354 1894 ~ 2562
8-5
2) PIPE AND HOSE (FLARE TYPE)
Thread size (PF) Width across flat (mm) kgf·m lbf·ft
1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 9.5 68.7
3/4" 36 18 130.2
1" 41 21 151.9
1-1/4" 50 35 253.2
3) PIPE AND HOSE (ORFS TYPE)

Thread size (UNF) Width across flat (mm) kgf·m lbf·ft
9/16-18 19 4 28.9
11/16-16 22 5 36.2
13/16-16 27 9.5 68.7
1-3/16-12 36 18 130.2
1-7/16-12 41 21 151.9
1-11/16-12 50 35 253.2
4) FITTING
Thread size Width across flat (mm) kgf·m lbf·ft
1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 9.5 68.7
3/4" 36 18 130.2
1" 41 21 151.9
1-1/4" 50 35 253.2
8-6
GROUP 3 PUMP DEVICE
1. REMOVAL AND INSTALL

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

Escaping fluid under pressure can
penetrate the skin causing serious injury.
(4) Remove the wirings for the pressure 13
1
sensors and so on.
(5) Loosen the drain plug under the hydraulic 2
tank and drain the oil from the hydraulic

tank. 12
·Hydraulic tank quantity : 160ℓ 3
(6) Remove bolts (13) and disconnect pipe 2609S8MP01
(1,2).
(7) Disconnect pilot line hoses (4, 5, 6, 7, 8,
9, 10).
4
(8) Remove bolts(12) and disconnect pump 5
10
suction tube (3).
※ When pump suction tube is disconnected,
the oil inside the piping will flow out, so
9
catch it in oil pan.
(9) Sling the pump assembly and remove the
7 8
pump mounting bolts. 2609S8MP02
·Weight : 140 kg (310 lb)
※ Pull out the pump assembly from housing.
When removing the pump assembly,
check that all the hoses have been
disconnected.
8-7
2) INSTALL
(1) Carry out installation in the reverse order
to removal
(2) Remove the suction strainer and clean it.
(3) Replace the return filter with a new one.
(4) Remove breather and clean it.
(5) After adding oil to the hydraulic tank to
the specified level.
(6) Bleed the air from the hydraulic pump.
① Remove the air vent plug (2EA)
② Tighten plug lightly
③ Start the engine, run at low idling, and
check oil come out from plug.
④ Tighten plug.
(7) Start the engine, run at low idling (3~5

minutes) to circulate the oil through the
system.
(8) Confirmed the hydraulic oil level and
check the hydraulic oil leaks or not.
8-8
2. MAIN PUMP (1/2)
The main pump consists of two piston pumps (front & rear) and valve block.
535 789 732 532 214 548 531 724 702 792 534 808 901 954 717 151 152 211 113
953 A
806
886
717
406
261 04
774
111
127
123
710
824
251 490 212 153 156 468 157
728 313 124 312 114 885 314 141 271 401
466
725
2209S2MP02
04 Gear pump 261 Seal cover (F) 717 O-ring

111 Drive shaft (F) 271 Pump casing 724 O-ring
113 Drive shaft (R) 312 Valve block 725 O-ring
114 Spline coupling 313 Valve plate (R) 728 O-ring
123 Roller bearing 314 Valve plate (L) 732 O-ring
124 Needle bearing 401 Hexagon socket bolt 774 Oil seal
127 Bearing spacer 406 Hexagon socket bolt 789 Back up ring
141 Cylinder block 466 VP Plug 792 Back up ring
151 Piston 468 VP Plug 806 Hexagon head nut
152 Shoe 490 Plug 808 Hexagon head nut
153 Set plate 531 Tilting pin 824 Snap ring
156 Bushing 532 Servo piston 885 Pin
157 Cylinder spring 534 Stopper (L) 886 Spring pin
211 Shoe plate 535 Stopper (S) 901 Eye bolt
212 Swash plate 548 Pin 953 Set screw
214 Bushing 702 O-ring 954 Set screw
251 Support 710 O-ring
8-9
MAIN PUMP (2/2)
544
543
545
541
079
VIEW A
21092MP08
541 Seat 544 Stopper 2 079 Proportional reducing valve

543 Stopper 1 545 Steel ball
8-10
2) TOOLS AND TIGHTENING TORQUE
(1) Tools
The tools necessary to disassemble/reassemble the pump are shown in the follow list.
Tool name & size Part name
Hexagon socket PT plug PO plug Hexagon socket
Name B
head bolt (PT thread) (PF thread) head setscrew
Allen wrench 4 M 5 BP-1/16 - M 8

5 M 6 BP-1/8 - M10
6 M 8 BP-1/4 PO-1/4 M12, M14
B
8 M10 BP-3/8 PO-3/8 M16, M18
17 M20, M22 BP-1 PO-1, 1 1/4, 1 1/2 -
Double ring spanner, Hexagon socket VP plug
- Hexagon nut
socket wrench, double (single) head bolt (PF thread)
open end spanner 19 M12 M12 VP-1/4
24 M16 M16 -
B
27 M18 M18 VP-1/2
30 M20 M20 -
36 - - VP-3/4
Adjustable angle wrench Medium size, 1 set
Screw driver Minus type screw driver, Medium size, 2 sets
Hammer Plastic hammer, 1 set
Pliers For snap ring, TSR-160
Steel bar Steel bar of key material approx. 10Ý8Ý200
Torque wrench Capable of tightening with the specified torques
8-11
(2) Tightening torque
Torque Wrench size
Part name Bolt size
kgfÂm lbfÂft in mm
Hexagon socket head bolt M 5 0.7 5.1 0.16 4

(Material : SCM435) M 6 1.2 8.7 0.20 5
M 8 3.0 21.7 0.24 6
M10 5.8 42.0 0.31 8
M12 10.0 72.3 0.39 10
M14 16.0 116 0.47 12
M16 24.0 174 0.55 14
M18 34.0 246 0.55 14
M20 44.0 318 0.67 17
PT Plug (Material : S45C) PT1/16 0.7 5.1 0.16 4
öWind a seal tape 1 1/2 to PT 1/8 1.05 7.59 0.20 5
2 turns round the plug PT 1/4 1.75 12.7 0.24 6
PT 3/8 3.5 25.3 0.31 8
PT 1/2 5.0 36.2 0.39 10
PF Plug (Material : S45C) PF 1/4 3.0 21.7 0.24 6
PF 1/2 10.0 72.3 0.39 10
PF 3/4 15.0 109 0.55 14
PF 1 19.0 137 0.67 17
PF 1 1/4 27.0 195 0.67 17
PF 1 1/2 28.0 203 0.67 17
8-12
3) DISASSEMBLY
(1) Select place suitable to disassembling.
ö Select clean place.
ö Spread rubber sheet, cloth or so on on
overhaul workbench top to prevent parts
from being damaged.
(2) Remove dust, rust, etc, from pump
surfaces with cleaning oil or so on.
(3) Remove drain port plug (468) and let oil
out of pump casing (front and rear pump).
(4) Remove hexagon socket head bolts (412,

413) and remove regulator.
(210-7) MP01
(5) Loosen hexagon socket head bolts (401)

which tighten swash plate support (251),
pump casing (271) and valve block (312).
ö If gear pump and so on are fitted to rear
face of pump, remove them before
starting this work.
(6) Place pump horizontally on workbench

with its regulator-fitting surface down and
separate pump casing (271) from valve
block (312).
ö Before bringing this surface down, spread
rubber sheet on workbench without fail to
prevent this surface from being damaged.
(210-7) MP02
8-13
(7) Pull cylinder block (141) out of pump
casing (271) straightly over drive shaft
(111). Pull out also pistons (151), set
plate (153), spherical bush (156) and
cylinder springs (157) simultaneously.
ö Take care not to damage sliding surfaces
of cylinder, spherical bushing, shoes,
swash plate, etc.
(210-7) MP03
(8) Remove hexagon socket head bolts (406)

and then seal cover (F, 261).
ö Fit bolt into pulling out tapped hole of seal
cover (F), and cover can be removed
easily.
ö Since oil seal is fitted on seal cover (F),
take care not to damage it in removing
cover.
(9) Remove hexagon socket head bolts (408) (210-7) MP04
and then seal cover (R, 262).

In case fitting a gear pump, first, remove
gear pump.
(10) Tapping lightly fitting flange section of
swash plate support (251) on its pump
casing side, separate swash plate support
from pump casing.
(210-7) MP05
(11) Remove shoe plate (211)and swash plate

(212) from pump casing (271).
(210-7) MP06
8-14
(12) Tapping lightly shaft ends of drive shafts
(111, 113) with plastic hammer, take out
drive shafts from swash plate supports.
(210-7) MP07
(13) Remove valve plates (313, 314) from

valve block (312).
ö These may be removed in work (6).
(210-7) MP08
(14) If necessary, remove stopper (L, 534),

stopper (S, 535), servo piston (532) and
tilting pin (531) from pump casing (271),
and needle bearing (124) and splined
coupling (114) from valve block (312).
ö In removing tilting pin, use a protector to
prevent pin head from being damaged.
ö Since loctite is applied to fitting areas of
tilting pin and servo piston, take care not
to damage servo piston.
ö Do not remove needle bearing as far as
possible, except when it is considered to
be out of its life span.
ö Do not loosen hexagon nuts of valve
block and swash plate support.
If loosened, flow setting will be changed.
8-15
4) ASSEMBLY
(1) F o r r e a s s e m b l i n g r e v e r s e t h e
disassembling procedures, paying
attention to the following items.
Η Do not fail to repair the parts damaged
during disassembling, and prepare
replacement parts in advance.
Θ Clean each part fully with cleaning oil
and dry it with compressed air.
Ι Do not fail to apply clean working oil to
sliding sections, bearings, etc. before
assembling them.
Κ In principle, replace seal parts, such as
O-rings, oil seals, etc.
Λ For fitting bolts, plug, etc., prepare a
torque wrench or so on, and tighten them
with torques shown in page 8-11, 12.
Μ For the double-pump, take care not to
mix up parts of the front pump with those
of the rear pump.
(2) Fit swash plate support (251) to pump

casing (271), tapping the former lightly
with a hammer.
ö After servo piston, tilting pin, stopper (L)
and stopper (S) are removed, fit them
soon to pump casing in advance for
reassembling.
ö In tightening servo piston and tilting pin,
use a protector to prevent tilting pin head
(210-7) MP09
and feedback pin from being damaged.
In addition, apply loctite (Medium
strength) to their threaded sections.
8-16
(3) Place pump casing with its regulator fitting
surface down, fit tilting bush of swash
plate to tilting pin (531) and fit swash plate
(212) to swash plate suppor t (251)
correctly.
ö Confirm with fingers of both hands that
swash plate can be removed smoothly.
ö Apply grease to sliding sections of swash
plate and swash plate support, and drive
(210-7) MP10
shaft can be fitted easily.
(4) To swash plate support (251), fit drive

shaft (111) set with bearing (123), bearing
spacer (127) and snap ring (824).
ö Do not tap drive shaft with hammer or so
on.
ö Assemble them into support, tapping
outer race of bearing lightly with plastic
hammer.
Fit them fully, using steel bar or so on.
(210-7) MP11
(5) Assemble seal cover (F, 261) to pump

casing (271) and fix it with hexagon
socket head bolts (406).
ö Apply grease lightly to oil seal in seal
cover (F).
ö Assemble oil seal, taking full care not to
damage it.
ö For tandem type pump, fit rear cover
(263) and seal cover (262) similarly.
(210-7) MP12
(6) Assemble piston cylinder subassembly

Ðc y l i n d e r bl o ck ( 1 4 1 ) , p i s t o n
subassembly (151, 152), set plate (153),
spherical bush (156), spacer (158) and
cylinder spring (157)Ñ.
Fit spline phases of retainer and cylinder.
Then, insert piston cylinder subassembly
into pump casing.
(210-7) MP13
8-17
(7) Fit valve plate (313) to valve block (312),
entering pin into pin hole.
ö Take care not to mistake suction / delivery
directions of valve plate.
(210-7) MP14
(8) Fit valve block (312) to pump casing (271)

and tighten hexagon socket head bolts
(401).
ö At first assemble this at rear pump side,
and this work will be easy.
ö Take care not to mistake direction of valve
block.
ö Clockwise rotation (Viewed from input
shaft side) - Fit block with regulator up
(210-7) MP16
and with delivery flange left, viewed from
front side.
ö Counter clockwise rotation (Viewed from
input shaft side) - Fit block with delivery
flange right, viewed from front side.
(9) Putting feedback pin of tilting pin into

feedback lever of regulator, fit regulator
and tighten hexagon socket head bolts
(412, 413).
ö Take care not to mistake regulator of front
pump for that of rear pump.
(210-7) MP17
(10) Fit drain port plug (468).

This is the end of reassembling procedures.
8-18
3. REGULATOR (1/2)
412 876 874 755 858

A
897 B
612
614
615
613
A
875
A 611
P2
B Pf
Pi
438
C
B
641 730 643 708 644 645 646 728 924 801
SECTION B-B
2209S2MP03
438 656 413 438

A Delivery port 3/4"
B Suction port 2 1/2"
735
Pi Pilot port PF 1/4-15
722
Pf Power shift port -
P2 Companion delivery port -
496 724 725 436
VIEW C
8-19
REGULATOR (2/2)
655 734 653 654 836 651 652 601 624 629 630 628 802
641
814
898
631
732
733
622
621 623 625 626 887 763 756 753 627

SECTION A-A
21092MP04
412 Hexagon socket screw 630 Lock nut 733 O-ring

413 Hexagon socket screw 631 Sleeve, pf 734 O-ring
436 Hexagon socket screw 641 Pilot cover 735 O-ring
438 Hexagon socket screw 643 Pilot piston 753 O-ring
496 Plug 644 Spring seat (Q) 755 O-ring
601 Casing 645 Adjust stem (Q) 756 O-ring
611 Feed back lever 646 Pilot spring 763 O-ring
612 Lever (1) 651 Sleeve 801 Nut
613 Lever (2) 652 Spool 802 Nut
614 Fulcrum plug 653 Spring seat 814 Snap ring
615 Adjust plug 654 Return spring 836 Snap ring
621 Compensator piston 655 Set spring 858 Snap ring
622 Piston case 656 Block cover 874 Pin
623 Compensator rod 708 O-ring 875 Pin
624 Spring seat (C) 722 O-ring 876 Pin
625 Outer spring 724 O-ring 887 Pin
626 Inner spring 725 O-ring 897 Pin
627 Adjust stem (C) 728 O-ring 898 Pin
628 Adjust screw (C) 730 O-ring 924 Set screw
629 Cover (C) 732 O-ring
8-20
(1) Tools
The tools necessary to disassemble/reassemble the pump are shown in the follow list.
Tool name & size Part name
Hexagon socket PT plug PO plug Hexagon socket
Name B head bolt (PT thread) (PF thread) head setscrew
Allen wrench 4 M 5 BP-1/16 - M 8
B
5 M 6 BP-1/8 - M10
6 M 8 BP-1/4 PO-1/4 M12, M14
Double ring spanner,
socket wrench, double (single) Hexagon head VP plug
- Hexagon nut
open end spanner bolt (PF thread)
B
6 M 8 M 8 -
Adjustable angle wrench Small size, Max 36mm
Screw driver Minus type screw driver, Medium size, 2 sets
Hammer Plastic hammer, 1 set
Pliers For snap ring, TSR-160
Steel bar 4Ý100 mm
Pincers -
Bolt M4, Length : 50 mm
8-21
Torque Wrench size
Part name Bolt size
kgfÂm lbfÂft in mm
Hexagon socket head bolt M 5 0.7 5.1 0.16 4
(Material : SCM435) M 6 1.2 8.7 0.20 5
M 8 3.0 21.7 0.24 6
M10 5.8 42.0 0.31 8
M12 10.0 72.3 0.39 10
M14 16.0 116 0.47 12
M16 24.0 174 0.55 14
M18 34.0 246 0.55 14
M20 44.0 318 0.67 17
PT Plug (Material : S45C) PT1/16 0.7 5.1 0.16 4
öWind a seal tape 1 1/2 to PT 1/8 1.05 7.59 0.20 5
2 turns round the plug PT 1/4 1.75 12.7 0.24 6
PT 3/8 3.5 25.3 0.31 8
PT 1/2 5.0 36.2 0.39 10
PF Plug (Material : S35C) PF 1/4 3.0 21.7 0.24 6
PF 1/2 10.0 72.3 0.39 10
PF 3/4 15.0 109 0.55 14
PF 1 19.0 137 0.67 17
PF 1 1/4 27.0 195 0.67 17
PF 1 1/2 28.0 203 0.67 17
8-22
3) DISASSEMBLY
Since the regulator consists of small
precision finished parts, disassembly and
assembly are rather complicated.
For this reason, replacement of a regulator
assembly is recommended, unless there is
a special reason, but in case disassembly is
necessary for an unavoidable reason, read
through this manual to the end before
starting disassembly.
(1) Choose a place for disassembly.
ö Choose a clean place.
ö Spread rubber sheet, cloth, or so on on
top of work-bench to prevent parts from
being damaged.
(2) Remove dust, rust, etc. from surfaces of
regulator with clean oil.
(3) Remove hexagon socket head screw

(412, 413) and remove regulator main
body from pump main body.
ö Take care not to lose O-ring.
(210-7) REG01
(4) Remove hexagon socket head screw

(438) and remove cover (C,629)
ö Cover (C) is fitted with adjusting screw
(C, 628), adjusting ring (C, 627), lock nut
(630), hexagon nut (801) and adjusting
screw (924).
ö Do not loosen these screws and nuts.
If they are loosened, adjusted pressure-
flow setting will vary.
(210-7) REG02
8-23
(5) After removing cover (C, 629) subassembly,
take out outer spring (625), inner spring
(626) and spring seat (C, 624) from
compensating section.
Then draw out adjusting ring (Q, 645),
pilot spring (646) and spring seat (644)
from pilot section.
ö Adjusting ring (Q,645) can easily be
drawn out with M4 bolt.
(210-7) REG03
(6) Remove hexagon socket head screws

(436, 438) and remove pilot cover (641).
After removing pilot cover, take out set
spring (655) from pilot section.
(210-7) REG04
(7) Remove snap ring (814) and take out

spring seat (653), return spring (654) and
sleeve (651).
ö Sleeve (651) is fitted with snap ring (836).
ö When removing snap ring (814), return
spring (654) may pop out.
Take care not to lose it.
(210-7) REG05
(8) Remove locking ring (858) and take out

fulcrum plug (614) and adjusting plug
(615).
ö Fulcrum plug (614) and adjusting plug
(615) can easily be taken out with M6 bolt.
(210-7) REG06
8-24
(210-7) REG07
(9) Remove lever (2, 613). Do not draw out

pin (875).
ö Work will be promoted by using pincers or
so on.
(210-7) REG08
(10) Draw out pin (874) and remove feedback

lever (611).
Push out pin (874, 4 mm in dia.) from
above with slender steel bar so that it may
not interfere with lever (1, 612).
(210-7) REG09
(210-7) REG10
8-25
(11) Remove lever (1, 612). Do not draw out
pin (875).
(12) Draw out pilot piston (643) and spool
(652).
(13) D r a w o u t p i s t o n c a s e ( 6 2 2 ) ,
compensating piston (621) and
compensating rod (623).
ö Piston case (622) can be taken out by
pushing compensating rod (623) at
opposite side of piston case.
This completes disassembly.
8-26
4) ASSEMBLY
(1) For assembly, reverse disassembly
procedures, but pay attention to the
following items.
Η Always repair parts that were scored at
disassembly.
Θ Get replacement parts ready beforehand.
Mixing of foreign matter will cause
malfunction.
Therefore, wash parts well with cleaning
oil, let them dry with jet air and handle
them in clean place.
Ι Always tighten bolts, plugs, etc. to their
specified torques.
Κ Do not fail to coat sliding surfaces with
clean hydraulic oil before assembly.
Λ Replace seals such as O-ring with new
ones as a rule.
(2) Put compensating rod (623) into

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

in spool of casing.
ö Confirm that spool and sleeve slide
smoothly in casing without binding.
ö Pay attention to orientation of spool.
Spool
Feedback lever
(210-7) 8-27
8-27
(5) Fit feedback lever (611), matching its pin
hole with pin hole in spool.
Then insert pin (874).
ö Insert pin in feedback lever a little to ease
Lever (1) side Lever (2) side
operation.
ö Take care not to mistake direction of (fulcrum plug of
adjusting plug side)
feedback lever.
(210-7) 8-28
(6) Put pilot piston (643) into pilot hole of

casing.
ö Confirm that pilot piston slides smoothly
without binding.
(7) Put pin force-fitted in lever (2, 613) into
groove of pilot piston.
Then fix lever (2).
(210-7) REG11
(8) Fit fulcrum plug (614) so that pin force-

fitted in fulcrum plug (614) can be put into
pin hole of lever (2).
Then fix locking ring (858).
(9) Insert adjusting plug (615) and fit locking
ring.
ö Take care not to mistake inserting holes
for fulcrum plug and adjusting plug.
At this point in time move feedback lever
to confirm that it has no large play and is
free from binding. (210-7) REG12
(10) Fit return spring (654) and spring seat

(653) into spool hole and attach snap ring
(814).
(210-7) REG13
8-28
(11) Fit set spring (655) to spool hole and put
compensating piston (621) and piston
case (622) into compensating hole.
Fit pilot cover (641) and tighten it with
hexagonal socket head screws (436,
438).
(210-7) REG14
(12) Put spring seat (644), pilot spring (646)

and adjusting ring (Q, 645) into pilot hole.
Then fix spring seat (624), inner spring
(626) and outer spr ing (625) into
compensating hole.
ö When fitting spring seat, take care not to
mistake direction of spring seat.
(210-7) REG15
(13) Install cover (C, 629) fitted with adjusting

screws (628), adjusting ring (C, 627), lock
nut (630), hexagon nut (801) and
adjusting screw (924).
Then tighten them with hexagonal socket
head screws (438).
(210-7) REG16
This completes assembly.
8-29
GROUP 4 MAIN CONTROL VALVE
1. REMOVAL AND INSTALL OF MOTOR

1) REMOVAL

penetrate the skin causing serious
injury.
※ When pipes and hoses are disconnected,
(4) Remove the wirings for the pressure
sensor and so on.
(5) Remove bolts and disconnect pipe.
2609S8MCV01
(6) Disconnect pilot line hoses.

(7) Disconnect pilot piping.
(8) Sling the control valve assembly and
remove the control valve mounting bolt.
·Weight : 200 kg (441lb)
(9) Remove the control valve assembly.
When removing the control valve
assembly, check that all the piping have
been disconnected.
2) INSTALL
2609S8MCV02
to removal.
(2) Bleed the air from below items.
① Cylinder (boom, arm, bucket)
② Swing motor
③ Travel motor
※ See each item removal and install.
(3) Confirm the hydraulic oil level and
recheck the hydraulic oil leak or not.
2609S8MCV03
8-30
2. STRUCTURE
59 52 81,78 1
A A'
B B'
C C1 C1' C'
D D'
E E'
F F'
G G'
59 52 65 24 76

43 88
50
87
44
86
SECTION C1-C1'
59 52 59 52 59 52
1 Housing (P1)
A A'
2 Housing (P2)
24 Plug
B B' 43 Orifice-signal
44 Coin type filter
C C' 50 O-ring
52 Plug
D D'
59 O-ring
64 O-ring
E E'
65 O-ring
F F' 76 Socket bolt
G G' 78 Hex socket head bolt
81 Spring washer
86 Poppet
81,77 2
64,24 87 Spring check
P2 BLOCK SPOOL SECTION 88 Plug
300H2MC10
8-31
59 52 67 20 23 21
82
3 Spool-straight
4 Spool-travel
61 15 Cover-pilot A
64
3 18 Cover-pilot A1
52,59 20 Plug
16
24 Plug
40 Sleeve
41 Piston
15 73 ,79 68 71 58 6046 60 56 44 43 68 73 ,79
43 Orifice-signal
44 Coin type filter
A-A' (STRAIGHT-TRAVEL & SUPPLY)
46 Plug
47 Plug
52 Plug
54 Plug
56 Plug
57 O-ring
15 73,79 68 4 61 67 20 61 57 47
58 O-ring
59 O-ring
60 O-ring
61 O-ring
62 O-ring
64 O-ring
65 O-ring
67 O-ring
68 O-ring
71 Back-up ring
72 Back-up ring
79 Washer
82 Main relief valve
54 67 72 62 65 24 67 20 23 21 72 62 67 54 68 73,79 16
B-B' (TRAVEL RIGHT & LEFT)
300H2MC11
8-32
27
27-7 27-2 27-3

21 23 20 67 27-1 27-6 27-4 27-9
88,50 83 6 27-5 C
27-10
27-8 D
34
16
C' D'
15 73,79 68 5 36 68 73,79
C-C' (SWING & BOOM1)
34-6 34-13 34-2 34-3 34-4 34-1 34-7

H
34-5
34-8
H'
34-15 ,34-16 SECTION H-H'
300H2MC12
5 Spool-swing 27-7 Restrictor-lock valve 34-15 Socket bolt

6 Spool-boom 27-8 O-ring 34-16 Spring washer
15 Cover-pilot A 27-9 O-ring 36 Logic valve
16 Cover-pilot B1 27-10 Back up ring 50 O-ring
20 Plug 34 Holding kit-A1 56 O-ring
21 Poppet 1-check valve 34-1 Block-H/D P1 66 O-ring
23 Spring 1-check valve 34-2 Piston 1-holding 67 O-ring
27 Holding kit-B 34-3 Guide piston-holding 68 O-ring
27-1 Poppet 34-4 Spring 1-lock valve 70 Back-up ring
27-2 Spring 34-5 Piston 2-holding 73 Hex socket head bolt
27-3 Poppet guide 34-6 Plug 79 Washer
27-4 Pilot poppet 34-7 Plug 83 Overload relief valve
27-5 Poppet seat 34-8 Plug 88 Plug
27-6 C-ring 34-13 Plug
8-33
57 45 11 94 21 23 20 67 75 53 85 65 2426 25 61 74 68
19 19-6
19-9 19-5
19-4
73,79
19-3
19-2
19-1 16
19-7,19-8
35
68
27-8
15 27-10
73 27-5
27-3
27-9
61 10 21 23 20 67 25 26 24 65 27-1 27-7 27-6 27-2 27-4
27
E-E' (ARM & ARM REGENRATION)
35-6 35-13 35-2 35-3 35-4 35-1

H
35-8
35-5
H'
35-7 35-15 ,35-16 SECTION H-H'

300H2MC13
10 Spool-arm 27 Poppet-lock valve 35-13 Plug

11 Spool-arm regeneration 27-1 Poppet 35-15 Socket bolt
15 Cover-pilot A 27-2 Spring 35-16 Spring washer
16 Cover-pilot B1 27-3 Poppet guide 45 Orifice-plug
19 Arm-regeneration 27-4 Pilot poppet 53 Flange
19-1 Block-regeneration 27-5 Poppet seat 56 O-ring
19-2 Piston-cut off 27-6 C-ring 57 O-ring
19-3 Stopper-regeneration 27-7 Restrictor-lock valve 61 O-ring
19-4 Spool-regeneration 27-8 O-ring 65 O-ring
19-5 Spring-regeneration 27-9 O-ring 66 O-ring
19-6 Plug 27-10 Back up ring 67 O-ring
19-7 Socket bolt 35 Holding kit-A2 68 O-ring
19-8 Spring wahser 35-1 Block-H/D P2 70 Back-up ring
19-9 Pin-regeneration 35-2 Piston 1-holding 73 Hex socket head bolt
20 Plug 35-3 Guide piston-holding 74 O-ring
21 Poppet 1-check valve 35-4 Spring 1-lock valve 75 Socket bolt
23 Spring 1-check valve 35-5 Piston 2-holding 79 Washer
24 Plug 35-6 Plug 85 O-ring
25 Poppet 2-check valve 35-7 Plug 94 Plug
26 Spring 2-check valve 35-8 Plug
8-34
84 61 69 65 24 26 25 9 83
7 Spool-swing priority
61
8 Spool-boom 2
9 Spool-arm 2
15 12 Spool-bucket
13 Spool-option
79 ,73
14 BC spool
68
15 Cover-pilot A
17 Cover-pilot B2
7
20 Plug
84 58 71 60 46 63 55 8 84 68
22 Poppet L/C-bucket
65,24
24 Plug
D-D' (SWING PRIORITY-BOOM2 & ARM2)
83 12 22 23 67 42 65 24 61 84 57 68 73,79 16 37 Bucket para orifice assy
26
90 25 38 Load check valve assy
67 42 Check valve
89 46 Plug
91 48 Spring-BC spool
15
49 Plug-BC spool
79, 73
51 Negative control valve
68 52 Plug
61 53 Flange
39 33,66 55 Plug
13 57 O-ring
58 O-ring
59 O-ring
83 53 75 21 23 20 67 38 75 53 85 80
60 O-ring
F-F' (OPTION & BUCKET) 61 O-ring
63 O-ring
51 65 O-ring
67 O-ring
68 O-ring
69 O-ring
51
71 Back-up ring
52 73 Hex socket head bolt
59 75 Socket bolt
79 Washer
61 14 48 63 49 85 O-ring
G-G' (CENTER BYPASS CUT-OFF
& NEGATIVE CONTROL)
300H2MC14
8-35
3. DISASSEMBLY AND ASSEMBLY
1) GENERAL PRECAUTIONS
(1) As hydraulic equipments, not only this valve are constructed precisely with very small clearances,
disassembling and assembling must be carefully done in a clean place with preventing dusts and
contaminants from entering.
(2) Prepare the section drawing and study the structure of MCV and then start disassembly work.
(3) When removing the control valve from the machine, install caps on every ports, and wash the
outside of the assembly with confirming the existence of caps before disassembling.
Prepare a suitable table and some clean papers or rubber mat on the table for disassembling.
(4) If the components are left disassembled, they may get rust. Make sure to measure the greasing
and sealing.
(5) For carrying the control valve, never hold with pilot cover or relief valve and overload relief valve
and carefully treat the valves.
(6) Do not tap the valve even if the spool movement is not smooth.
(7) Several tests for such as relief characteristics, leakage, overload relief valve setting and flow
resistance are required after re-assembling, and the hydraulic test equipments for those tests are
needed.
Therefore, do not disassemble what cannot perform test adjustment, even if it can disassemble.
※ Be sure to observe the mark (※) description in the disassembly and assembly procedures.
2) TOOLS
Before disassembling the control valve, prepare the following tools beforehand.
Name of tool Quantity Size (mm)
Vice mounted on bench (soft jaws) 1 unit

Hexagon wrench Each 1 piece 5, 6, 10, 12 and 14
Socket wrench Each 1 piece 27 and 32
Spanner Each 1 piece 26 and 32 (main relief valve)
8-36
3) DISASSEMBLY
(1) Removing spool
① The case of the section without holding valve
Instruction for removing the travel spool (for instance) is follows :
Remove two hex socket bolts by 5 mm allen key wrench, then remove pilot cover.
※ Pay attention not to lose the O-ring under the pilot cover.
As the return spring portion of travel spool comes out, pull the spring straight slowly, by which
spool assembly is removed.
※ The spools have to remove from the spring side.
Other spools (no lock valve type) can be removed in the same manner but the swing priority
spool is reversed.
※ When spool replace, do not disassemble of a spool by any cases. Please replace by spool
assembly.
※ Please attach using a tag etc. in the case of two or more kinds of spool replace, and understand
a position.
RETURN SPRING
PILOT COVER
O-RING
HEX SOCKET BOLT
29098MC01
8-37
② The case of the section with holding valve
Instruction for removing the boom spool (for instance) is follows :
Remove five hex socket bolts with washer by 5 mm allen key wrench. Then remove pilot cover
with internal parts below figure.
※ Be careful not to separate O-ring and poppet under pilot cover.
※ Pay attention not to damage the exposed piston A under pilot cover.
As the return spring portion of boom 1 spool comes out, pull the spring straight slowly, by which
spool assembly is removed.
※ The spools have to remove form the spring side.
※ When spool replace, do not disassemble of a spool by any cases, please replace by spool
assembly.
BOOM 1 SPOOL
PILOT COVER HEX SOCKET BOLT
POPPET POPPET SEAT O-RING PISTON "A"
29098MC02
8-38
(2) Removing holding valve
Remove the pilot cover with the holding valve as described on previous page.
※ Do not disassembled internal parts of the pilot cover.
Loosen the poppet seat by 26 mm spanner and remove the poppet, the spring seat, the spring
and the check in order.
※ Pay attention not to lose the poppet.
※ Do not disassembled internal parts of the check because the plug, functioning orifice, can
damage easily.
BOOM 1 SPOOL
SPRING
POPPET SEAT
CHECK POPPET
SPRING SEAT
29098MC03
8-39
(3) Removing load check valve and negative relief valve
① The load check valve

- Fix the body to suitable work bench. Loosen the plug by 10 mm allen key wrench.
- Remove the spring and the load check valve with pincers or magnet.
PLUG
SPRING
LOAD CHECK VALVE
29098MC04
② The negative relief valve

Loosen the socket by 12 mm allen key wrench.
Remove the spring, the spring holder, the piston and the negative control poppet.
BODY COIN FILTER POPPET SPRING PLUG

29098MC05
※ Do not disassemble the coin filter inside the negative control poppet because of forced fit.
8-40
(4) Removing main relief valve and overload relief valve
Fix the valve body to suitable work bench. Remove the main relief valve by 32 mm spanner and
remove the overload relief valve 32 mm spanner (standard) or 36 mm spanner (optional).
※ When disassembled, tag the relief valve for identification so that they can be reassembled
correctly.
※ Pay attention not to damage seat face of disassembled main relief and overload relief valve.
※ Main relief and overload relief valve are very critical parts for performance and safety of the
machine. Also, the pressure set is very difficult. Therefore, any abnormal parts are found, replace
it with completely new relief valve assembly.
MAIN RELIEF VALVE
32mm HEX
29098MC06
OVERLOAD RELIEF VALVE(STD) OVERLOAD RELIEF VALVE(OPT)

32mm HEX 36mm HEX
29098MC07
8-41
(5) Removing the swing logic valve and bucket logic valve
- Fix the valve body to suitable work bench.
- Loosen the body 2 by 32 mm spanner (swing logic valve) or 24 mm spanner (bucket logic valve)
and remove it.
- Remove the banjo plate.
- Loosen the body 1 as the same spanner of body 2 and remove it.
- Remove the check poppet and spring.
※ Pay attention not to damage seat face of removed check poppet.
※ Do not disassemble the check poppet and replace it with a assembly in case any abnormal
parts are found.
※ Pay attention not to lose and separation while disassembling and assembling.
BODY 2
PLATE
BODY 1
PISTON ROD
SPRING
CHECK POPPET
29098MC08
8-42
(6) Removing the option ON/OFF valve
- Fix the valve body to suitable work bench.
- Loosen the body 2 by 24 mm spanner and remove it.
- Remove the banjo plate.
- Loosen the body 1 as the same spanner of body 2 and remove it.
- Remove the pilot poppet, spring and seat.
- Remove the check poppet.
BODY 2
PILOT SPRING
PLATE
PISTON
BODY 1
PILOT POPPET
SPRING & SEAT
CHECK POPPET
29098MC09
8-43
4) ASSEMBLY
(1) Precaution
① When you assemble, please wash all parts by pure cleaning liquid.
② For re-assembling, basically use only bland new seals for all portions.
③ Apply grease or hydraulic oil to the seals and seal fitting section to make the sliding smooth,
unless otherwise specified.
④ Pay attention not to roll the O-ring when fitting and it may cause oil leakage.
⑤ Do not tap the valve even if the spool movement is not smooth.
⑥ Prepare the section drawing and study the structure of MCV and then start disassembly work.
⑦ Tighten bolt and parts with thread for all section by torque wrench to the respective tightening
torque.
8-44
(2) Assembly
Explanation only is shown for the assembly, refer to the figures shown in the previous
disassembly section.
① Main relief and overload relief valve
Fix the valve body to suitable work bench.
Install main relief valve and overload relief valve into the body and tighten to the specified torque
by 32 mm torque wrench.
·Tightening torque : 8~9 kgf·m (57.8~65.1 lbf·ft)
MAIN RELIEF VALVE
32mm HEX
29098MC06
OVERLOAD RELIEF VALVE(STD) OVERLOAD RELIEF VALVE(OPT)

32mm HEX 36mm HEX
29098MC07
8-45
② Load check valve
Assemble the load check valve and spring.
Put O-rings on to plug and tighten plug to the specified torque by 10 mm torque wrench.
PLUG
SPRING
LOAD CHECK VALVE
29098MC04
③ Negative control relief valve

Assemble the nega-con poppet, piston, spring holder and spring into body in order and tighten
the socket to the specified torque by 12 mm torque wrench.
BODY COIN FILTER POPPET SPRING PLUG

29098MC05
8-46
④ Holding valves
Assemble the check, spring seat and poppet into the hole of valve body in order.
Tighten the poppet seat to the specified torque by 25 mm torque wrench.
Fit the "piston A" under pilot cover with internal parts into hole on the poppet seat.
Tighten hexagon socket head bolt to specified torque by 5 mm torque wrench.
·Tightening torque : 1~1.1 kgf·m (7.2~7.9 lbf·ft)
※ Pay attention poppet not to separation.
※ Confirm that O-rings have been well fitted on the groove of body. (Apply grease on O-ring)
BOOM 1 SPOOL
SPRING
POPPET SEAT
CHECK POPPET
SPRING SEAT
29098MC03
8-47
⑤ Main spool
Put the spool position upward and fix it to the vise. Carefully insert the previously assembled
spool assemblies into their respective bores within of body.
Fit spool assemblies into body carefully and slowly. Do not under any circumstances push them
forcibly in.
Fit the pilot cover to the groove of the valve body.
Confirm that O-rings have been fitted on the groove of body. (Apply grease on O-ring)
Tighten the two socket bolt to the specified torque by 5 mm torque wrench.
·Tightening torque : 1~1.1 kgf·m (7.2~7.9 lbf·ft)
RETURN SPRING
PILOT COVER
O-RING
HEX SOCKET BOLT
29098MC01
8-48
⑥ The swing logic valve and bucket logic valve
- Assemble the piston rod, spring and check poppet into the body 1 in order.
- Install the body 1 assembly into valve body and tighten to the specified torque.
·Tightening torque : 2.9 kgf·m (21.0 lbf·ft)
- Assemble the banjo plate.
※ Confirm O-ring has been seated on the groove of banjo plate.
- Tighten the body 2 to the specified torque.
BODY 2
PLATE
BODY 1
PISTON ROD
SPRING
CHECK POPPET
29098MC08
8-49
⑦ Option ON/OFF valve
- Assemble the check poppet into the valve body.
※ Push the check poppet about half of hole.
- Assemble the pilot poppet, spring and seat into check poppet.
※ As it can not be fixed, hang it diagonally.
- Insert the end of pilot poppet into the machined center hole of body 1 and push it complete
- slowly. Then tighten to the specified torque.
※ Tighten socket piston.
- When push the piston to the end, confirm the repulsive spring force.
- Assemble the banjo plate.
- Put the pilot spring into body 2 and assemble it into body 1 and then tighten to the specified
torque.
BODY 2
PILOT SPRING
PLATE
PISTON
BODY 1
PILOT POPPET
SPRING & SEAT
CHECK POPPET
29098MC09
8-50
GROUP 5 SWING DEVICE
1. REMOVAL AND INSTALL OF MOTOR

1) REMOVAL
(2) Loosen the breather slowly to release the
Escaping fluid under pressure can pen-
etrate the skin causing serious in injury.
13031GE18
(3) Disconnect pipe assy (2, 3). 3 2 4
(4) Disconnect pilot line hoses (4, 5, 6, 7, 8,

9).
(5) Sling the swing motor assembly (1)and 10
remove the swing motor mounting bolts 1
(10).
ÂMotor device weight : 66 kg (146 lb)
ÂTightening torque : 57.9 kgfÂm
2609S8SM02
(419.0 lbfÂft)
(6) Remove the swing motor assembly.
※ When removing the swing motor assem-
bly, check that all the piping have been 5
disconnected.
6
2) INSTALL 7
to removal. 9
(2) Bleed the air from the swing motor.

8
① Remove the air vent plug.
② Pour in hydraulic oil until it over flows 2609S8SM01
from the port.

③ Tighten plug lightly.
④ Start the engine, run at low idling, and
⑤ Tighten plug fully.
(3) Confirmed the hydraulic oil level and
check the hydraulic oil leak or not.
8-51
2. DISASSEMBLY AND ASSEMBLY OF SWING MOTOR
1) STRUCTURE
2507A2SM02
031 Time delay valve 303 Valve casing 485 O-ring

051 Relief valve 304 Front cover 487 O-ring
052 Shockless valve assy 351 Plunger 488 O-ring
101 Drive shaft 355 Spring 491 Oil seal
106 Spacer 401 Socket bolt 702 Brake piston
111 Cylinder block 432 Snap ring 706 O-ring
113 Spherical bush 433 Snap ring 707 O-ring
114 Spring 437 Snap ring 712 Brake spring
116 Push rod 438 Snap ring 742 Friction plate
117 Spacer 443 Roller bearing 743 Separate plate
118 Spacer 444 Roller bearing 744 Dust plug
121 Piston 451 Spring pin 745 Dust plug
122 Shoe 464 Plug 746 Dust plug
123 Retainer 468 Plug 747 Name plate
124 Shoe plate 469 Plug 748 Rivet screw
131 Valve plate 471 O-ring 993 Level gauge
301 Casing 472 O-ring 994 Plug
8-52
3) DISASSEMBLY
(1) Wind the wire rope at motor outside, lift
up the motor, and clean the motor with
cleaning oil.
After cleaning, dry with compress air.
ö Polish the dirts blocking each ports with
tape, couldn't enter the dirts into the
motor.
(2) Draw the oil out the casing (301).
25098SM04
(3) Mount on a suitable table for the driven-

axis (101) below.
Before disassembling make a match
mark on motor casing (301) and valve
casing (303).
ö Select a clean place.
Put a rubber sheet on the work bench to
prevent parts from being damaged.
2507A8SM03
(4) Remove time delay valve (031).
2507A8SM05
8-53
(5) Remove relief valve (751) from valve
casing (303).
2507A8SM06
(6) Remove Ro plug (469) and take out

spring (355) and plunger (351) from valve
casing.
ö Be careful not to damage the plunger
seat.
2507A8SM07
(7) Remove hex socket bolts (401) and

disassemble valve casing (303) from
casing (301) (When loosening bolts, the
valve casing will be raised by brake spring
(712)). Remove valve plate (131) from the
valve casing.
ö Be careful not to drop the valve plate from
the valve casing.
(Sometimes valve plate is adhered to the
2507A8SM09
cylinder)
When open the combined plane, be
careful not to damage.
8-54
(8) Remove brake springs (712) from the
brake piston.
2507A8SM10
(9) Disassemble brake piston (702) from

casing (301) by using the special tool for
removing the brake piston.
ö Lit it up straight by using the bolt hole in
the brake piston.
2507A8SM11
(10) After placing the motor horizontally, take

out cylinder (111) from casing(301).
Remove piston (121), retainer (123)
spherical bush (113), spacer (117) and
shoe plate (124).
ö When taking out the cylinder, be careful
not to pull out push rod (116).
Be careful not to damage the sliding parts
of the cylinder, spherical bush and shoe.
2507A8SM12
If difficult to remove the swash plate,
disassemble it later as described in (14).
8-55
(11) Pull out fr iction plates (742) and
separation plate (743) from casing.
2507A8SM13
(12) Remove snap ring (437) and remove front

cover (304) from casing (301).
ö Be careful not to damage the front cover.
(The front cover can be removed with the
drive shaft.)
2507A8SM14
(13) Remove drive shaft (101) from casing

(301) while tapping the end of the drive
shaft with a plastic hammer.
ö Be careful not to damage the oil seal
contact surface.
2507A8SM15
(14) Remove shoe plate (124) from the casing

(301) by engaging a steel bar through the
casing and the side of the housing and
tapping it lightly.
2507A8SM16
8-56
(15) Do next step if required. Press
Η Remove snap ring (432) and spacer
Main shaft
(106) from drive shaft (101) and remove
roller bearing (443) with a press.
ö Strike the rod lightly and do not reuse
disassembling the bearing. Roller bearing
Press table hangs

in the inner ring
2507A8SM37
Θ Take out oil seal (304) from cover (304).

Press
ö Do not reuse the oil seal.
Rod
Front cover
Oil seal
2507A8SM38
Ι Pull out roller bearing (444) from valve

casing (303) with a sliding hammer and
a bearing puller.
ö Do not reuse the bearing.
8-57
4) ASSEMBLY
Followings are caution to be specially borne in mind.
- Rework damaged parts and before assembling, prepare all parts to be replaced.
- Clean all parts and dry with compressed air.
- Coat the sliding parts and bearing with clean hydraulic oil.
- Replace O-ring and oil seal.
- For the mounting of bolts to install the various parts, please use a torque wrench,
etc. and tighten the bolts with the torque shown at page 8-45.
(1) Place casing (301) on the work table with

the valve casing side downward.
(2) Assembly of roller bearing ;

Mount snap ring (432) and spacer (106)
to drive shaft (101) and collar of roller
bearing (443) and press-fit by the heat.
2507A8SM17
ö Pay attention to the direction of the collar. Output

Roundering part
of the collar
toward spacer
Spacer
2507A8SM39
(3) Insert the drive shaft complete with

bearing into casing (301). Using a brass
drift tap the bearing is fully seated.
ö Impact the outside surface outer loop
uniformly till stop at casing section.
2507A8SM18
8-58
(4) In case of the oil seal disassembling
press-fit oil seal (491) to front cover (304)
by using a jig.
ö Be careful to note the direction of the oil
seal.
Press-fit until fully seated.
2507A8SM19
(5) Mount O-ring (471) to casing (301).
2507A8SM20
(6) Assemble front cover (304) to casing

(301) while tapping it lightly with a plastic
hammer.
ö Coat the lip of the oil seal with grease and
tape the shaft spline.
Tap evenly.
2507A8SM21
(7) Mount locking snap ring (437) to casing

(301) by using the plier.
2507A8SM22
8-59
(8) Insert shoe plate (124)
ö Insert it with the larger chambered side of

the shoe plate toward the casing.
Coat lightly with grease.
2507A8SM23
(9) Insert push rods (116) and spacer (117)

to cylinder (111) and place spherical bush
(113) to the cylinder.
ö Be careful not to damage the sliding
surface of the cylinder insert 2 push rods
into each hole.
2507A8SM24
(10) Fit piston sub assembly unit (121, 122) to

retainer.
2507A8SM25
(11) Assemble the retainer with the piston sub

assembly (120, 222) unit to the cylinder
block (111).
ö Insert it to drive shaft (101) aligning the
spline.
2507A8SM26
8-60
(12) Place casing (301) with front cover (304)
downward and assemble separation plate
3 EA (743) and friction plate 2 EA (742) in
sequence.
2507A8SM27
ö Align 4 tangs to the notches as shown.

Cut the jaw and assemble that plate like
right picture.
Mounting side for

the brake releasing valve
2507A8SM40
(13) Mount O-ring (706, 707) to casing (301).

ö Coat the O-ring with grease.
2507A8SM28
(14) Assemble brake piston (702) to casing

(301).
ö Place 4 notches of the brake piston as
shown next page.
2507A8SM29
8-61
ö The piston is difficult to assemble because 2-M8 Brake piston
of the restriction of the O-ring; screw in two

M8 bolts on the brake piston and tap them
gently.
Slot(opposite side)
Mounting side for

the brake releasing valve
2507A8SM41
(15) Assemble brake springs (712) into brake

piston (702).
ö Confirm the springs are fitted to the brake
piston completely.
2507A8SM30
(16) Assemble of roller bearing (444).

Insert it to valve casing (303) while
tapping it lightly.
ö Tap evenly on the outer diameter of the
outer race with a brass drift until it
completely stops.
Do not use a steel punch or bar on the
bearing since it can chip or crack the race.
(17) Assemble valve plate (131) to valve

casing(303) and fit O-ring (472).
2507A8SM31
8-62
ö Be careful to note the direction of the Flange surface
valve plate.
Mount the valve plate with its round part
toward the opposite side of the flange.
Coat lightly with grease.
5
2507A8SM42
(18) Mount valve casing (303) to casing (301)

and tighten hex socket bolts (401) to
specification.
ö Be careful to note the mounting direction
of the valve plate (Refer to the drawing).
Be careful not to drop the valve plate or
let the brake springs pop out tighten the
bolts evenly.
2507A8SM32
(19) Install plunger (351) and spring (355) to

valve casing and tighten Ro plug (469)
with O-ring (488)
ö Confirm the smooth movement of the
plunger before installing the plug.
2507A8SM33
(20) Assemble relief valve with back-up ring

(162) and O-ring (161) to valve casing
(303)
2507A8SM34
8-63
(21) Tighten plug (468) with O-ring (487) to
valve casing (303).
Tighten plug (464) with O-ring (485) to
casing (301)
2507A8SM35
(22) Assemble time delay valve (761) to

casing (301) and tightening the hex
socket bolts to specified torque.
2507A8SM36
8-64
3. REMOVAL AND INSTALL OF REDUCTION GEAR
1) REMOVAL
(1) Remove the swing motor assembly.
For details, see removal of swing motor
assembly.
(2) Sling reduction gear assembly (1) and
remove mounting bolts (2).
(3) Remove the reduction gear assembly.
·Reduction gear device weight :
13031GE18
279 kg(615 lb)
2) INSTALL
to removal.
·Tightening torque : 97.8Ü10 kgf·m
(707Ü72.3 lbf·ft)
25098SM03
8-65
4. DISASSEMBLY AND ASSEMBLY OF REDUCTION GEAR
1) REDUCTION GEAR
27 26 25 3 29 30 9 10 22 33 21 20 19 18 24
31
32
17
(B)
28
6 5 4 1 7 8 14 15 23 11 13 12 34 16
36 35 37
2507A2SM03
1 Casing 14 Spring pin 27 Lock washer

2 Drive shaft 15 Thrust washer 28 Hexagon bolt
3 Spacer 16 Carrier 1 29 Plug
4 Roller bearing 17 Sun gear 1 30 Plug
5 Cover plate 18 Planet gear 1 31 Side plate 2
6 Hexagon bolt 19 Pin 1 32 Stop ring
7 Oil seal 20 Needle cage 33 Spring pin
8 Roller bearing 21 Side plate 1 34 Spring pin
9 Carrier 2 22 Ring gear 35 Gage bar
10 Sun gear 2 23 Knock pin 36 Gage pipe
11 Planet gear 2 24 Socket bolt 37 Air breather assy
12 Pin 2 25 Pinion gear
13 Bushing 2 26 Lock plate
8-66
2) DISASSEMBLY
(1) SWING REDUCTION GEAR
ΗRemove plug (29, 30) and drain out gear
oil.
25078SR29
ΘLoosen the socket bolts (24) to separate

swing motor from reduction gear.
25078SR28
ΙMove out No.1 sun gear (17) and No.1

carrier sub assy by using jig.
25078SR34
ΚFull out No.2 sun gear (10).
25078SR32
8-67
Λ Full out No.2 carrier sub assy by using jig
and crane.
ö Pay attention to ensure gear is not
damaged during disassembling.
25078SR31
ΜMoue out ring gear by the removal

groove between ring gear (22) and
casing (1) by using removal jig.
25078SR27
ΝFull out knock pin (23).

öDo not need to remove the knock pin if it
is not worn or damaged.
25078SR27
ΞPut it on the working table with drive

shaft up.
8-68
ΟRemove lock washer (27) by removal jig
and loosen hex bolt (28) with fixing
pinion gear (25) and thereafter plate lock
(26) & pinion gear (25).
25078SR21
ΠLoosen hex bolt (6) and remove spacer

(3) and cover plate by screwing a
removal bolt into tap hole on the cover
plate (5).
25078SR17
ΡDismantle drive shaft by using jig

öRemoved oil seal should not be reused.
Replace new oil seal when assembling.
25078SR16
8-69
(2) NO.1 CARRIER SUB ASSY
ΗRemove stop ring (32) and dismantle
No.2 side plate (31) and No.1 planet
gear (18).
25078SR03
ΘDismantle needle cage (20) and No.1

side plate (21).
ö Do not need to dismantle No.1 pin, No.1
carrier and spring pin, when they have
no problems.
ö Be sure to make a marking on the pin of
each planet gear to ensure them to be
placed in the same locations when
assembling. 25078SR02
When need to dismantle pin. Hammer
the section end of pin to pull out.

ΗRemove spring pin (14) by hammering in
a key to the opposite side of the No.2 pin.
25078SR10
8-70
ΘFull out No.2 pin assy
öDo not reuse both the No.2 pin assy and
spring pin.
25078SR07
(4) SHAFT ASSY

ΗPress drive shaft (2) by using jig to
remove roller bearing.
öDo not need to disassemble if it has no
special problems.
25078SR14
3) ASSEMBLY
ΗPlace the No.1 carrier (16) horizontally
on the work table. Fit the No.1 pin (19)
into the hole of No.1 carrier (16) by
hydraulic pressing machine.
öBe careful to direct the pin (19)
perpendicularly to the carrier (16) when
pressing.
25078SR01
ΘInstall the No.1 side plate (21) and

needle cage (20) thereafter.
25078SR02
8-71
ΙPut No.1 planet gear (18) and No.2 side
plate (31) together and install a stop ring
(32) by using assembling.
25078SR03
ΚInsert spring pin (33) into the carrier sub-

assembly by using jig and hammer.
öTake care of planet gear1 (18) when
assembling spring pin (33).
25078SR04
Locate the long

groove as
directed
Punch 2
points
Prevention of spring pin removal
25078SR05
(2) ASSEMBLY-NO.2 CARRIER

ΗPlace the thrust washer (15) on the No.2
carrier (9), meeting it with pin hole
location. Be sure to check that the
carrier (9) is not turned up side down
when putting the washer (15).
25078SR06
8-72
ΘPlace No.2 planet gear (11) onto the
right location of the carrier (9).
25078SR07
ΙAssemble the planet gears (11) and

carrier (9) by inserting the pin assembly
(12) using rubber hammer. Pay special
attention to locate the spring pin hole to
meet with the hole of the carrier (9).
25078SR08
ΚInsert spring pin (14) by using fixture and

hammer.
öTake care of planet gears (11) when
hammering the pin (12).
25078SR09
25078SR10
8-73
ΛAfter complete assembly, check if it
revolves without problem when rotate the
planet gears (11) by hand.
öWhen problems found in revolution,
disassemble it in reverse course and
assemble again. Be sure to use new
spring pin (14) when re-assembling.
25078SR11
(3) SHAFT ASSY

ΗHeat roller bearing (4) with bearing
heater up to about 80~100˚C.
öBe sure to keep the suggested heating
temperature. Over heating may cause
deformation.
25078SR12
ΘDemagnetize roller bearing (4) using

demagnetizing machine.
öUse special care to handle the bearing
as it is very hot.
25078SR13
ΙPlace drive shaft (2) with positioning 2

tap holes upside.
ΚPut bearing into drive shaft (2).
öBe sure to prevent any contamination on
the assembling surface during the install.
Be sure to check by eye the surface of
roller bearing (4) is completely contacting
to the mating surface of the drive shaft
25078SR14
(2).
8-74
ΛTurn the drive shaft (2) to have the 2 tap
hole side down and inject grease oil into
roller bearing (4).
Recommended amount of grease is 1.4
kg (3.1pound).
25078SR15
(4) CASE SUB ASSY

ΗPlace the case (1) on the reversing
machine, having the flange side of the
case up.
ΘTighten lifting bolts into the 2 Tap holes
(M16) of shaft (2) and install shaft
assembly (2) into case using crane.
öBe sure to clean the case before install,
using washing machine with the
temperature of 80 ˚C (176 ˚F).
Do not install shaft assembly by force. 25078SR16
ΙAssemble cover plate (5) and thereafter

spacer (3).
öUse jig when assembling spacer to be
seated completely on surface.
Spread grease on the inner part of
spacer.
25078SR17
ΚAssemble cover plate (5) with case (1)

after spreading loctite 262 and tighten
hex bolt(M10) (6).
25078SR18
8-75
ΛInstall pinion gear (25).
Be careful to check right direction of
pinion gear when installing.
25078SR19
ΜPut lock plate (26) and lock washer (27),

matching tap holes and tighten hex bolt
(28).
ÂTightening torque : 24 kgfÂm
(173 lbfÂft)
öWhen installing hex bolt (28), be sure to
spread loctite 262.
25078SR20
ΝTo lock the bolts (28), bend the lock

washer (27) to cover over the bolt head
using jig.
25078SR21
ΞReverse case (1) and press to insert oil

seal (7) by using jig after spreading
grease oil on the outside ring of the seal.
Coat grease oil slightly on the lip surface
of the oil seal to prevent any scratch
when installing.
25078SR22
8-76
öBe sure to check by eye the oil seal (7) is
seated completely after being installed.
25078SR23
ΟSpread loctite 609 on the outside ring of

roller bearing (8) and insert the bearing
(8) by using a pressing jig.
25078SR24
25078SR25
ΠClean the assembling surface of case

and spread packing liquid (TH1105).
25078SR26
8-77
ΡPlace ring gear (22) on the case by
matching knock pin hole.
΢Insert 4 knock pins (23) by using jig.
öBe sure to check the hole location of oil
gage before inserting.
25078SR27
ΣAssemble ring gear with case by

screwing socket bolt (M16) (24).
Spread loctite 262 on socket bolt (24)
when installing.
25078SR28
ΤInstall drain plug (29,30) after winding

sealing tape.
25078SR29
öLeak test
The successful assembly should have
no air leakage when applied by 2 kgf/cm2
of compressed air for about 3 minutes
after being air sealed.
25078SR30
8-78
(5) SWING REDUCTION GEAR
ΗMount No.2 carrier assembly in the case
sub assembly and install bolts into 2 tap
holes (M8).
öTurn the carrier slowly by hand to adjust
the matching holes when assembling.
25078SR31
ΘInstall No.2 sun gear (10).

öBe sure to check the direction of sun
gear (10) when assembling.
25078SR32
ΙMount No.1 carrier assembly in the case

sub assembly and install bolts into 2 tap
holes (M8).
öTurn the carrier slowly by hand to adjust
the catching holes when assembling.
25078SR33
ΚAssemble No.1 sun gear (17).
25078SR34
8-79
GROUP 6 TRAVEL DEVICE

1) REMOVAL
(1) Swing the work equipment 90Áand lower

it completely to the ground.

injury.
1
(4) Remove the track shoe assembly. 2
For details, see removal of track shoe
assembly.
2609S8TM01
(5) Remove the cover.

(6) Remove the hose.
※ Fit blind plugs to the disconnected hoses.
(7) Remove the bolts and the sprocket.
(8) Sling travel device assembly (1).
(9) Remove the mounting bolts (2), then
remove the travel device assembly.
ÂWeight : 276 kg (608 lb)
2) INSTALL
to removal.
(2) Bleed the air from the travel motor.
① Remove the air vent plug.
② Pour in hydraulic oil until it overflows from
the port.
③ Tighten plug lightly.
④ Start the engine, run at low idling, and
⑤ Tighten plug fully.
(3) Confirm the hydraulic oil level and check
the hydraulic oil leak or not.
8-80
2. SPECIFICATION
1) TRAVEL MOTOR
89-4 89-3 89-2 89-9 89-6 88-6 88-4 88-2 93 88-3 88-5 86 85 87 83 13 14 15 16 25 24 6 28 30 31 4 40 39 43 38 37 71 42 41 47 50
89-5 29
89-6 35
89-9
90-2 32
90-3 33
90-4 A 27
97 21
92 49
90-5
101 75,76
98 48
100 36
11 46
102
73 34
74 44
12
45
91
96
56
89-8 67
89-7
62
90-1 A
99
88-8
63
89-1
65
88-7 103 95 94 88-1 5 72 9 8 7 10 84 23 22 82 17 18 19 1 20 26 3 69 2 68 61 64 60 66 57 58,59 70 55 54 53 52 51
SECTION A-A
29092TM30
1 Casing 16 Plate 31 Ring 46 Back up ring 61 O-ring 83 Housing 89-1 Carrier No.2 91 Sun gear No.1
2 Plug 17 Piston 32 Spring 47 Cap 62 Lock screw 84 Bearing 89-2 Planetary gear No.2 92 Plug
3 Screw 18 Stopper 33 Valve casing 48 Cap 63 Nut 85 Shim 89-3 Needle No.2 93 Lock pin
4 Screw 19 O-ring 34 Needle bearing 49 Bolt 64 Spool 86 Retainer 89-4 Thrust washer No.2 94 Ring gear
5 Pin 20 Back up ring 35 O-ring 50 Socket bolt 65 Plug 87 Bolt 89-5 Pin No.2 95 Bolt
6 Pin 21 Cylinder block 36 Pin 51 Seat 66 O-ring 88 Carrier No.3 89-6 Spring pin No.2 96 Thrust ring No.1
7 Stopper 22 Cylinder spring 37 Spool 52 Steel ball 67 Valve plate 88-1 Carrier No.3 89-7 Sun gear No.2 97 Cover
8 O-ring 23 Spacer 38 Screw 53 Stopper 68 Spring 88-2 Planetary gear No.3 89-8 Snap ring No.2 98 Thrust ring No.2
9 Back up ring 24 Guide 39 Damping check 54 Plug 69 O-ring 88-3 Needle No.3 89-9 Spring pin No.2 99 Bolt
10 Piston 25 Plate 40 Spring 55 O-ring 70 Socket bolt 88-4 Thrust washer No.3 90 Carrier No.1 100 Motor ring
11 Shaft 26 Piston & Shoe assy 41 O-ring 56 Plug 71 Socket bolt 88-5 Pin No.3 90-1 Carrier No.1 101 Thrust ring No.3
12 Spacer 27 Plate 42 Plunger 57 Relief valve 72 Lock screw 88-6 Spring pin No.3 90-2 Planetary gear No.1 102 Pad
13 Roller bearing 28 Plate 43 Spring 58 O-ring 73 Oil seal 88-7 Sun gear No.3 90-3 Needle bearing No.1 103 Coupling
14 Stop ring 29 Brake 44 Stopper 59 Back up ring 74 Lock ring 88-8 Snap ring No.3 90-4 Thrust washer No.1
15 Support 30 Ring 45 O-ring 60 Rod 82 Floating Seal 89 Carrier No.2 90-5 Pin No.1
8-<#>
8-81
2) TOOLS
(1) Standard tools
No. Name Description/Size Qty

6 (M8) (PT1/4), 8 (M10) each 1
Hexagon wrench
1 10 (M12) (PF1/2) each 1
(JIS B 4648)
14 (M16), 4 (M6) 1
2 Socket wrench - 1
Nominal 30 kgfÂm dial type 1
3 Torque wrench
Nominal 90 kgfÂm dial type 1
Socket 22, 30, 32, 41, 40 each 1
4 Adapter for torque wrench
Bar 5, 6, 8, 10, 14 each 1
5 Extension bar (JIS B 4637) 150 mm 1
6 Hammer 12 1
7 Plastic hammer L=300 1
8 ( - ) driver 150 mm 1
9 Snap ring plier For shaft, For hole 1
Weight : over 300 kgf 1
Eye bolt (M16) 2
10 Hanger Eye bolt (M10) 2
Eye bolt (PF 1/2) 2
Wire 1
11 Press Press capacity above 200 kgf 1
2
12 Compressed air 3~5 kgf/cm , nozzle 1
13 Vessel General vessel : W450 × D300 × H120 2
Heating capacity : over 100 ˚C

14 Heating vessel 1
Volume : 500 Ý 500 Ý 500
15 Depth micro-meter Measuring range : 0.04 ~ 0.3 mm 1
16 Air hammer BRH-8 (compressed air 5~6 kgf/cm2) 1
17 Sealant Silicone rubber (780-RTV) 1
8-82
(2) Special tools
Η Inversion working bench
25098TM101
Θ Retainer (II)
25098TM102
Ι Steel bar
25098TM103
Κ Pressurize jig
25098TM104
8-83
Λ Floating sealing
25098TM105
Μ Caulking jig
25098TM106
3) TIGHTENING TORQUE
Tightening torque
Item No. Parts name Size Qty
kgfÂm lbfÂft
24 Plug M36Ý1.5 2 45 Ü 9 325 Ü65.1
26 Plug M26Ý1.5 2 26 Ü 4 188 Ü28.9
43 Socket bolt M16Ý2.0 12 25.7 Ü 4 186 Ü28.9
52 Plug PF 1/4 2 3.0 Ü 0.5 21.7 Ü3.6
54 Plug NPTF 1/16 7 1.0 Ü 0.25 7.2 Ü1.8
55 Plug PT 1/4 2 3.0 Ü 0.5 21.7 Ü3.6
63,128 Plug PF 1/2 7 10 Ü 2 72.3 Ü14.5
124 Socket bolt M10Ý1.5 16 5.9 Ü 1 42.7 Ü7.2
412 Adjust plug M8 2 12 Ü 1.5 86.8 Ü10.8
8-84
3. DISASSEMBLY
3.1 GENERAL PRECAUTIONS
1) Spread rubber or vinyl cover on the work bench.
2) When disassembling the travel motor, provide a match mark on the mating face or each part.
3) Arrange the detached parts to prevent them from being damaged or lost.
4) The disassembled seals must be replaced with new ones as a rule even if they are free from dam-
age. For disassembly, therefore, prepare new seals in advance.
3.2 DISASSEMBLY PROCEDURE

1) When inspecting or repairing the travel motors, use the disassembling procedures described below.
2) Numerals in brackets ( ) following the part name denote the item numbers used in the structure
drawing at page 8-84.
3) Prior to disassembly, install the travel motor on a inversion working bench.
3.3 DISASSEMBLING ORDER

1) DISASSEMBLING THE REDUCTION GEAR
PART
(1) Remove plugs (128, 3EA) and drain the reduction
gear oil.
(2) Loosen socket bolts (124, 16EA) and remove the
cover (123).
ö Remove the cover (123), after hook it, fit the
eye bolt in a screw hole for use of the plug (128). If 25098TM10
it’s impossible, please remove the cover using the
rod.
ö You can have difficulty removing it because loctite
is spread in the socket bolt (124).
ö Tools
·Hexagon wrench 8, 10
(3) Remove drive gear (121).
25098TM10
8-85
(4) Remove carrier No.1 assembly.
ö Carrier no.1 assembly consists of planetary gear
(117), needle bearing (118), shaft bearing (107),
carrier (134), thrust washer (131) and spring pin
(122).
25098TM12
(5) Disassembling the carrier No.1 assembly.

Η Drive spring pins (122) into shaft bearing (R)
(107).
ö Please don’t remove if repair isn’t necessary.
ö Do not reuse the spring pin (122).
25098TM13
② Remove shaft bearing (R) (107), planetary gears

(R) (117), thrust washer (R) (131), needle bear-
ings (118) and thrust washer (R) (131).
25098TM14
(6) Remove sun gear ((114).

114).
ö Snap ring (115) is assembled in sun gear (114).
Don’t remove it if not necessary.
25098TM16
8-86
(7) Remove the carrier No.2 assembly.
ö Remove it using a crane after M10 eye bolt is as-
sembled.
25098TM16
(8) Drive spring pins (110) into shaft bearing ( F) (113)

ö Do not reuse the spring pin (110).
25098TM17/17-1
(9) Remove shaft bearing (113, 4EA).
25098TM18
(10) Remove the thrust washer (F) (109), planetary

gears (F) (108), needle bearings (111) and float-
ing bushing (112) from carrier No.2 (103).
ö Each part consists of the 1st.
25098TM19
8-87
(11) Take off lock shim plate (136) by hammering on
chisel or on similar tool placed at parting surface.
25098TM20
(12) Remove the hub (105) from the spindle (101).

ö Remove it using a crane after M16 eye bolt is as-
sembled at the hub (105).
25098TM21
(13) Remove the distance piece (106) from the spindle

(101).
25098TM22
(14) Remove the floating seal (102) from the hub (105)
and the spindle (101).
ö User can remove easily if using ( - ) driver.
25098TM23
8-88
(15) The sealing (129), the angular bearing (125, 2EA),
the O-ring (130) are assembled on the hub (105)
with the floating seal (102).
ö Don’t remove if not necessary.
In case of the removal, be careful not to scratch
using aluminum rod or hammer.
25098TM24
2) DISASSEMBLING
ISASSEMBLING THE HYDRAULIC MOTOR
PART
(1) Remove the relief valve (2EA) from rear flange (1).
ö Tools
·Hexagon socket 32
·Torque wrench
25098TM25
(2) Remove hexagon socket head bolts (43) from the

rear flange (1).
ö Tools
·Hexagon wrench 14
25098TM26
(3) Remove the rear flange (1) from the spindle (101).
(4) Remove the spring (213, 10EA) form the rear
flange [1].
ö Remove the rear flange (1) carefully after
taken using hands. Be careful not to detach the
timing plate (209) and the spring (213) if twisted or
beated by constraint.
25098TM27
8-89
(5) Remove the parallel pin (42) from the spindle (101).
25098TM28
(6) Remove the O-ring (126) from the spindle (101).

ö Do not reuse the O-ring (126).
25098TM29
(7) Disassembling the rear flange (1) part

Η Remove the timing plate (9) from the rear flange
(1).
ö When removing the timing plate, user can have
difficulty of the removal due to the close adhesion
of rear flange (1) and oil. Remove it after fitting
a rod through the hole which is used when a
casting is detached.
ö Be careful of the leakage due to both surface 25098TM30
scratch if using a sharp tool.
Θ Remove the paralell pin (41) from the rear flange

(1).
25098TM31
8-90
Ι Remove the ball bearing (250) from the rear
flange (1).
25098TM32
Disassembling the spool

Η Remove two plugs (24) from the rear flange (1).
ö User can work easily if sub-disassembly was
done on the reversal table.
ö Tools
·Hexagon socket 41
·Torque wrench
25098TM33
Θ Take out two springs (31), two stopper (25, 26)

from the rear flange (1).
Ι Remove the spool (23) from the rear flange (1).
ö Be careful not to damage the outer surface of
the spool (23) and the sliding surface of the rear
flange (1).
ö Since the rear flange (1) and the spool (23) are of
the selective fitting type, replace them together as
a kit even if only one of the two parts is damaged. 25098TM34
Disassembling the check valve

Η Remove two plugs (29) from the rear flange (1).
ö Tools
·Hexagon wrench 14
25098TM35
8-91
Θ Remove the spring (32, 2EA), valve (30, 2EA)
from rear flange (1).
25098TM36
Disassembling the two speed valve

Η Remove the plug (63) from the rear flange (1).
ö Tools
·Hexagon wrench 10
25098TM37
Θ Remove the spool (65) and spring (66) from rear

flange (1).
25098TM38
(8) Disassembling the parking brake

Η Remove the piston (212) by injecting compressed
air from the parking brake access hole in the
spindle (101).
ö Use the protection cover on the upper part of
spindle (101) when users put the pressed air into
suddenly. Otherwise part damage and accident
might go on because the piston (212) is rushed
out of the spindle (101). 25098TM39
8-92
Θ Remove the O-rings (235, 239) and backup rings
(247 , 248) from the piston (212).
ö Do not reuse O-rings (235, 239) and backup
rings (247, 248) after removal.
25098TM40
(9) Disassembling the hydraulic motor part

Η Lay the travel motor body on the side.
Θ Drain out the oil from the travel motor.
ö Place an oil receptacle under the travel motor to
receive the oil flowing out as the motor is being
laid on the side.
25098TM41
Ι Hold the cylinder block (204) with both hands,

and remove it from the shaft (202).
Κ Remove the mating plates (216) and friction
plates (215) from the cylinder block (204).
ö Before removal, hold the cylinder block (204)
with both hands and turn it two to three times
in a clockwise and a counterclockwise direction
alternately to detach the shoe (206) from the
swash plate (203). 25098TM42
ö Be careful that if an attempt is made to remove
the cylinder block (204) without detaching the
shoe (206) from the swash plate (203), then the
piston, shoe and other parts that are connected
to the cylinder block may come the cylinder loose
and fall into the spindle.
8-93
Disassembling the cylinder block kit
Η Piston assembly [piston (205), shoe (206])] from
the removed cylinder block (204).
25098TM43
Θ Piston (205) and shoe (206) from the removed

retainer plate (207).
25098TM44
Ι Thrust ball (208) from the removed cylinder block

(204).
25098TM45
Κ Spring (214, 9EA) from the removed cylinder

block (204).
25098TM46
8-94
(10) Remove swash plate (203) from the shaft (202).
(11) Remove shaft (202) from the spindle (101).
ö When separating the swash plate, separate and

turn it by using hands to free from intervention of
the stopper.
25098TM47/48
(12) Remove speed selector piston assembly [piston

(261) and shoe (262)] form the spindle [101] by
feeding compressed air from the access hole in
spindle (101).
(13) Remove parallel pin (242) and pivot (267) from the
spindle (101).
(14) Remove ball bearing (249) from the spindle (101).
ö Piston assembly ; Piston (261), Shoe (262)
ö Compressed air ; 3~5 kgf/cm2 (43~71 psi)
ö When piston (261) or shoe (262) is damaged, 25098TM49
if exchange is necessary, they have to be ex-

changed together because the separation is im-
possible. Use the protection cover on the upper
part spindle when users put the pressed air into
suddenly. Otherwise part damage and accident
might go on because the piston is rushed out of
the spindle.
(15) Remove oil seal (232) from the spindle (101).

Hammer
ö Remove the oil seal (232) by hammering using
( - ) driver. (-)Driver
ö Do not reuse the oil seal (232).
Spindle(101) Oil seal(232)
25098TM50
8-95
4. REASSEMBLY
4.1 GENERAL PRECAUTIONS
1) Reassemble in a work area that is clean and free from dust and dirt.
2) Handle parts with bare hands to keep them free of linty contaminants.
3) Repair or replace the damaged parts.
Each parts must be free of burrs its corners.
4) Do not reuse O-ring, oil seal and floating seal that were removed in disassembly. Provide the new
parts.
5) Wash all parts thoroughly in a suitable solvent. Dry thoroughly with compressed air.
Do not use the cloths.
6) When reassembling oil motor components of travel motor, be sure to coat the sliding parts of the
motor and valve with fresh hydraulic oil. (NAS class 9 or above)
7) Use a torque wrench to tighten bolts and plugs, to the torque specified as follows.
4.2 REASSEMBLY PROCEDURE

1) REASSEMBLE
EASSEMBLE THE HYDRAULIC MOTOR PART
(1) Install oil seal (232) into the oil seal hole of spindle
(101).
ö Apply lithium grease to the lip portion of oil seal
(232) position the squarely over the bore of spindle
(101).
25098TM51
(2) Install parallel pin (242, 2EA) and two speed

piston assembly (261, 262) into the spindle (101).
25098TM52
8-96
(3) Install shaft (202) into the spindle (101).
ö Assemble after applying grease on oil seal lip
(232).
25098TM53
(4) Install pivot (267, 2EA) into the spindle (101).
25098TM54
(5) Install swash plate (303) to the spindle (101).

ö The swash plate (203) and the 2 speed stopper
of the spindle are interferenced. Install the swash
plate (203) after rotating. And then install it as the
regular position.
25098TM55
(6) Reassembe the cylinder block kit

Η Install spring (214, 9EA) to the cylinder block
(204).
25098TM56
8-97
Θ Install thrust ball (208) to the cylinder block (204).
25098TM57
Ι Insert piston assembly [piston (205) and shoe

(206)] into retainer plate (207).
Κ Mount the piston assembly into the cylinder block
(204).
ö After mounting, immerse the entire them in a
working fluid.
25098TM58
(7) Install cylinder block (204) assembly to the shaft

(202).
ö After fitting splines of both cylinder block (204) and
shaft (202), assemble them.
ö After installing the cylinder (204), confirm whether
it revolves or not by turning using both hands.
ö Motor is malfunction when it isn’t revolve.
25098TM59
(8) Reassembe the parking brake

Η Install mating plate (216) first and then a friction
plate (215), one by one, into the grooves of the
outer surface of the cylinder block (204).
ö Immerse the friction plates (215) in a working
fluid before fitting them into the grooves.
25098TM60
8-98
Θ Install O-ring (275, 2EA) into the spindle (101).
25098TM61
Ι Install two O-rings (235, 239) and two back up

ring (247, 248) in then O-ring grooves.
Κ Mount a piston (212) in the spindle (101).
ö Apply a thin coat of grease to the O-rings (235,
239).
ö If the piston (212) does not fit into the spindle (101)
because of the resistance of the O-ring, tap the
edge of the piston (212) lightly and equally with a
plastic hammer.
ö Be careful not to damage the O-ring and back up
ring at this time. 25098TM62
Λ Insert a O-ring (126) into spindle (101).

Μ Insert a paralell pin (42, 2EA) into spindle (101).
25098TM63
8-99
1) REASSEMBLE THE REAR FLANGE PART [1]
(1) Reassemble the check valve
Η Install O-ring (37, 2EA) on the plug (29, 2EA).
ö Apply grease to the O-ring (37).
Θ Install spring (32) and a valve (30) into the plug

(29).
Ι Install plug (29) into the rear flange (1).
ö Install a spring (32) and a valve (30) into the plug
(29), and then grease the spring (32) and the
valve (32) and hand-lock the former.
Κ Install plug (29) in conjunction with the spring (32)

and the valve (30) into the rear flange (1), and
tighten the plug to the required torque.
ö Tightening torque : 26Ü4.0 kgfÂm (188Ü28.9 lbfÂft)
ö Tools
·Adapter for hexagon wrench 14
·Torque wrench
25098TM64
(2) Reassembe the spool

Η Install spool (23) into the rear flange (1).
ö Before installing the spool (23), apply hydraulic oil
to the spool. Be careful not to damage the spool’s
surface and the inner of rear flange (1).
25098TM65
8-100
Θ Install O-ring (36) on the plug (24).
Ι Install spring (31) and a stopper (25, 26) into the
plug (24).
Κ Install plug (24) into the rear flange (1).
Λ Tighten the plug (24) to the required torque.
ö Tightening torque : 45Ü9 kgfÂm (325Ü65.1 lbfÂft)
ö Exchange it as the rear flange kit if the exchange
is necessary, because the rear flange (301), the 25098TM66
spool (323) insist of the rear flange kit.
ö Sochet (#41)/Torque for hexagon wrench.
ö Tools
ÂHexagon socket 41
ÂTorque wrench
(3) Reassembe the two speed valve

Η Install O-rings (46) on plugs (63).
Θ Insert a spool (65) and spring (66) into the rear
flange (1).
ö Apply hydraulic oil to the spool (65), while the
spool (65) is installed into the rear flange (1).
ö Be careful not to damage the hole’s inner of the
rear flange (1) and the spool (65) outer. It brings 25098TM67
on low efficiency of the travel motor because of
the leakage increase after reassembling.
ö The shaft center should align with the hole
center because of little gap.
ö It is in order to protect the damage and smooth
assembling of the rear flange (1) and the spool
(65).
Ι Insert a plug (63) into the rear flange (1).

ö Tightening torque : 10Ü2 kgfÂm (72.3Ü14.5 lbfÂft)
ö Tools
ÂAdapter for hexagon wrench 10
ÂTorque wrench
25098TM68
8-101
(4) Assembling of the rear flange’s inner parts
Η After installing the O-ring (74) on the plug (52),
install the steel ball (68) and the plug (52) into the
rear flange (1).
ö Do not disassemble and assemble if not
necessary.
25098TM69
Θ Install orifice (71), filter (79) into the rear flange (1).
Caulk it after assembling certainly.
ö Do not disassemble and assemble if not neces-
sary.
25098TM70
(5) Insert a ball bearing (250), timing plate (209),

parallel pin (41, 1EA) and spring (213, 12EA) into
the rear flange (1).
ö Be careful not so that the spring (213) and the
timing plate (209) should not separate from the
rear flange (1).
ö Apply hydraulic oil to the ball bearing (250).
25098TM71
25098TM72
8-102
(6) Reassemble the rear flange (1) and spindle
(101).
Η Mount the rear flange (1) on the spindle (101).
ö When the rear flange (1) is mounted on the spin-
dle (101), fix the spring (13) applied grease to not
drop.
25098TM73
Θ Tighten the socket bolt (43) into the spindle (101)

to the required torque.
ö Tightening torque : 5.9Ü1.0 kgfÂm (42.7Ü7.2 lbfÂft)
ö Tools
ÂTorque wrench
25098TM74
(7) Tighten the relief valve into the rear flange (1) to
the required torque.
ö Tightening torque : 25Ü5kgfÂm (181Ü36.2 lbfÂft)
ö Tools
ÂHexagon socket 32
ÂTorque wrench
25098TM75
3) THE REDUCTION GEAR ASSEMBLY

(1) Rotate the travel motor through 180 degrees to
make the spindle side face upward.
25098TM76
8-103
(2) Install floating seal (102) on the spindle (101).
ö Apply grease to the floating seal (102).
25098TM77
(3) Hub assembly

Η Install angular bearing (125) into the hub (105).
ö Be careful for the insert direction.
25098TM78
Θ Insert the O-ring (130), the sealing (129) in the

hub (105).
ö Apply grease to the O-ring (130) thinly.
25098TM79
Ι Install floating seal (102) on the hub (105).
25098TM80
8-104
ö Apply grease to the floating seal (102).
25098TM81
Κ Install distance piece (106) into the spindle.
25098TM82
Λ Install the hub assembly into the spindle.
25098TM83
8-105
Μ Use a press, and press inner lace of bearing
(125) into its full depth.
Ν While pressing flange of spindle (101), install
shim plate (136) into groove.
25098TM84
Ξ Install thrust washer (F) (109), planetary gears (F)

(108), needle bearings (111) and floating bushing
(112) from carrier No.2 (103).
25098TM85
Ο Install shaft bearing (113) into the carrier No.2

(103).
25098TM86
Π Install spring pin (110) into the carrier No.2 (103).
25098TM87
8-106
Ρ Place carrier No.2 assembly into hub (105).
25098TM88
΢ Fit the snap ring (115) on the sun gear (114).

ö Tools
·Snap ring plier (C-75(S))
25098TM89
Σ Install sun gear (114).
25098TM90
Τ Install thrust washer (R) (131), planetary gears (R)

(117), needle bearings (118) and shaft bearing (R)
(107) from carrier No.1 (134).
25098TM91
8-107
Υ Install the spring pin (122) into the carrier No.1
(134).
25098TM92
16 Place carrier No.1 assembly into hub (105).
25098TM93
17 Install drive gear (121) in the carrier No.1 assem-

bly.
25098TM94
18 Install thrust plate (133) in the cover (123).
ö Apply grease to the thrust plate (133).
25098TM95
8-108
19 Install thrust washer (M) (132) in the cover (123).
25098TM96
20 Apply sealant to the cover (123) after intalling with

the hub (105).
ö Tools
·Sealant : Silicone rubber (780-RTV)
25098TM97
21 Mount the cover (123) on the hub (105).
25098TM98
22 Tighten the socket bolt (124, 16EA) to the

specified torque.
ö Tightening torque : 5.9Ü1.0 kgfÂm (42.7Ü7.2 lbfÂft)
ö Tools
ÂTorque wrench
ö Apply loctite to the socket bolt (124) and then
install it.
25098TM99
8-109
23 Install O-ring (38) in the plug (128).
24 Tighten the plug (128) to the specified torque
into the cover (123).
ö Tightening torque : 10Ü2.0 kgfÂm
(72.3Ü14.5 lbfÂft)
ö Tools
ÂTorque wrench 25098TM100
3.3 CHECKING FACTS AFTER ASSEMBLY

1) AIR
IR TEST OF REDUCTION GEAR
Disassemble plug (032) of reduction gear part. When compressed air (0.3 kgf/cm2) is inserted that in
water during the 2 minutes, it should be not happened air bubble.
Fill the gear oil.
·Oil amount : 3.3 liter (0.87 U.S.gallon)
2) AIR TEST OF HYDRAULIC MOTOR
One port should be opened, the others port should be closed. When compressed air (3 kgf/cm2) is
inserted opened port in water during the 2 minutes, it should be not happened air bubble.
Fill the hydraulic oil.
·Oil amount : 1.0 liter (0.26 U.S.gallon)
8-110
GROUP 7 RCV LEVER

1) REMOVAL

penetrate the skin causing serious injury.
(4) Loosen the socket bolt (1). 1
2
(5) Remove the cover of the console box.
(6) Disconnect pilot line hoses (3). 3
(7) Remove the pilot valve assembly (2).

※ When removing the pilot valve assembly,
check that all the hoses have been
21098RL01
disconnected.
2) INSTALL
to removal.
(2) Confirm the hydraulic oil level and check
8-111
1) STRUCTURE
23
25
26
24
22
21
9
19
20 16
17,27
18
14
11 15
8
7
28 10
6
13
5
12
4
3
1
2
Port 1,3 Port 2,4 300E2RL02
1 Case 8 Stopper 15 O-ring 22 Lock nut

2 Plug 9 Push rod 16 Rod seal 23 Handle assembly
3 Bushing 10 Spring 17 Plate 24 Handle bar
4 Spool 11 Push rod 18 Boot 25 Nut
5 Shim 12 Spring 19 Joint assembly 26 Boot
6 Spring 13 Spring seat 20 Swash plate 27 Spring pin
7 Spring seat 14 Plug 21 Adjusting nut 28 Bushing
8-112
(1) Tools
Tool name Remark
Allen wrench 6 B
22
Spanner
27
(+) Driver Length 150
(-) Driver Width 4~5

Torque
Part name Item Size
kgf·m lbf·ft
Plug 2 PT 1/8 3.0 21.7
Joint 19 M14 3.5 25.3
Swash plate 20 M14 5.0±0.35 36.2±2.5
Adjusting nut 21 M14 5.0±0.35 36.2±2.5
Lock nut 22 M14 5.0±0.35 36.2±2.5
8-113
3) DISASSEMBLY
(1) Clean pilot valve with kerosene.
※ Put blind plugs into all ports
(2) Fix pilot valve in a vise with copper (or
lead) sheets.
(3) Remove end of boot (26) from case (1)
and take it out upwards.
300E8RL01
※ For valve with switch, remove cord also

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

(21) with spanners on them respectively,
and take out handle section as one body.
300E8RL03
(5) Remove the boot (18).
1408DA61
8-114
(6) Loosen adjusting nut (21) and swash
plate (20) with spanners on them
respectively, and remove them.
36078RL01
36078RL02
(7) Turn joint anticlockwise to loosen it,

utilizing jig (Special tool).
※ When return spring (10) is strong in force,
plate (17), plug (14) and push rod (11) will
come up on loosening joint.
Pay attention to this.
36078RL03
36078RL04
8-115
(8) Remove plate (17).
36078RL05
(9) When return spring (10) is weak in force,

plug (14) stays in casing because of
sliding resistance of O-ring.
※ Take it out with minus screwdriver.
Take it out, utilizing external periphery
groove of plug and paying attention not to
damage it by partial loading.
※ During taking out, plug may jump up due
to return spring (10) force.
36078RL06
Pay attention to this.
(10) Remove reducing valve subassembly

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

hexagon socket screw key.
36078RL08
8-116
(12) For disassembling reducing valve section,
stand it vertically with spool (4) bottom
placed on flat workbench. Push down
spring seat (7) and remove two pieces of
semicircular stopper (8) with tip of small
minus screwdriver.
※ Pay attention not to damage spool
surface.
※ Record original position of spring seat (7).
36078RL09
※ Do not push down spring seat more than
6mm.
(13) Separate spool (4), spring seat (7), spring

(6) and shim (5) individually.
※ Until being assembled, they should be
handled as one subassembly group.
36078RL10
(14) Take push rod (11) out of plug (14).
36078RL11
(15) Remove O-ring (15) and seal (16) from

plug (14).
Use small minus screwdriver or so on to
remove this seal.
36078RL12
8-117
36078RL13
(16) Remove lock nut (22) and then boot (26).
36078RL14
2507ARL10
8-118
(16) Cleaning of parts
① Put all parts in rough cleaning vessel
filled with kerosene and clean them
(rough cleaning).
※ If dirty part is cleaned with kerosene just
after putting it in vessel, it may be
damaged. Leave it in kerosene for a
while to loosen dust and dirty oil.
※ If this kerosene is polluted, parts will be
damaged and functions of reassembled
valve will be degraded.
Therefore, control cleanliness of
kerosene fully.
② Put parts in final cleaning vessel filled
with kerosene, turning it slowly to clean
them even to their insides (finish
cleaning).
※ Do not dry parts with compressed air,
since they will be damaged and/or rusted
by dust and moisture in air.
(17) Rust prevention of parts
Apply rust-preventives to all parts.
※ If left as they after being cleaned, they will
be rusted and will not display their
functions fully after being reassembled.
8-119
4) ASSEMBLY
(1) Tighten hexagon socket head plug (2) to
the specified torque.
※ Tighten two bolts alternately and slowly.
36078RL15
(2) Put shim (5), springs (6) and spring seat

(7) onto spool (4) in this order.
36078RL16
(3) Stand spool vertically with its bottom

placed on flat workbench, and with spring
seat pushed down, put two pieces of
semicircular stopper (8) on spring seat
without piling them on.
※ Assemble stopper (8) so that its sharp
edge side will be caught by head of spool.
Do not push down spring seat more than
6mm.
36078RL17
(4) Assemble spring (10) into casing (1).

Assemble reducing valve subassembly
into casing.
※ Assemble them to their original positions.
36078RL18
8-120
(5) Assemble O-ring (15) onto plug (14).
36078RL19
(6) Assemble seal (16) to plug (14).

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

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

※ When return spring is weak in force,
subassembly stops due to resistance of
O-ring.
36078RL22
8-121
(9) When return spring is strong in force,
assemble 4 sets at the same time,
utilizing plate (17), and tighten joint (19)
temporarily.
36078RL23
(10) Fit plate (17).
(11) Tighten joint (19) with the specified torque

to casing, utilizing jig.
36078RL24
(12) Assemble swash plate (20) to joint (19).

※ Screw it to position that it contacts with 4
push rods evenly.
※ Do not screw it over.
36078RL25
(13) Assemble adjusting nut (21), apply

spanner to width across flat of plate (20)
to fix it, and tighten adjusting nut to the
specified torque.
※ During tightening, do not change position
of disk.
36078RL26
8-122
(14) Fit boot (18) to plate.
1408DA61
(15) Fit boot (26) and lock nut (22), and handle
subassembly is assembled completely.
2507ARL10
36078RL27
(16) Pull out cord and tube through adjusting

nut hole provided in direction 60。to
120。from casing hole.
1408DA66
8-123
(17) Assemble bushing (27) to plate and pass
cord and tube through it.
※ Provide margin necessary to operation.
300E8RL04
(18) Determine handle direction, tighten lock

nut (22) to specified torque to fix handle.
300E8RL05
(19) Apply grease to rotating section of joint

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

(21) Inject volatile rust-preventives through all
ports and then put blind plugs in ports.
300E8RL07
8-124
GROUP 8 TURNING JOINT

1) REMOVAL

injury.
(4) Disconnect all hoses.
1
(5) Sling the turning joint assembly (1) and
remove the mounting bolt (2).
21078DA07
Weight : 55 kg (120 lb)
Tightening torque : 12.31.3 kgfm
(899.4 lbfft)
(6) Remove the turning joint assembly.
※ When removing the turning joint, check
that all the hoses have been disconnected.
2) INSTALL
to removal. 1
Take care of turning joint direction.
Assemble hoses to their original positions.
Confirm the hydraulic oil level and check
2
21078DA08
8-125
1) STRUCTURE
14 3
15 6
10
12 4
11 5
11
9
8
21098TJ01
1 Hub 6 Shim 11 Wear ring

2 Shaft 7 Slipper seal 12 Retainer ring
3 Cover 8 O-ring 13 Plug
4 Spacer 9 O-ring 14 Hexagon bolt
5 Shim 10 O-ring 15 Spring washer
8-126
2) DISASSEMBLY 14
Before the disassembly, clean the turning 15
joint.
3
(1) Remove bolts (14), washer (15) and cover
(3).
21078DA10
(2) Remove shim (6) and O-ring (10). 6

10
(3) Remove retainer ring (12), spacer (4) and
12
shim (5).
4
5
21078DA11
(4) Place hub (1) on a V-block and by using a Secure with hand
wood buffer at the shaft end, hit out shaft Wooden block
(2) to about 1/2 from the body with a
hammer.
※ Take care not to damage the shaft (2)
when remove hub (1) or rest it sideway.
V block
※ Put a fitting mark on hub (1) and shaft (2).
Work bench
8-14(3) (360-7)
(5) Remove six slipper seals (7) and O-ring 11

(9), two wear ring (11) from hub (1).
7
11
9
21078DA12
8-127
3) ASSEMBLY
※ Clean all parts.
※ As a general rule, replace oil seals and
O-ring.
※ Coat the sliding surfaces of all parts with
engine oil or grease before installing.
(1) Fix seven slipper seal (7) and O-ring (9), 11

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

plastic hammer to install. 2
21078DA13
(4) Fit shim (5), spacer (4) and retainer ring 6

(12) to shaft (2). 10
12
(5) Fit O-ring (10) to hub (1).
4
(6) Fit shim (6) to shaft (2).
5
21078DA11
8-128
(7) Install cover (3) to body (1) and tighten
14
bolts (14).
15
Torque : 10~12.5 kgfm
(72.3~90.4 lbfft) 3
21078DA10
8-129
GROUP 9 BOOM, ARM AND BUCKET CYLINDER

1) BUCKET CYLINDER
(1) Removal
ö Expand the arm and bucket fully, lower
the work equipment to the ground and
stop the engine.
ö Operate the control levers and pedals
13031GE18
ö Loosen the breather slowly to release the
Escaping fluid under pressure can Bucket Cylinder
injury.
ö Fit blind plugs in the hoses after
disconnecting them, to prevent dirt or dust
from entering. Arm
Η Set block between bucket cylinder and
Wooden block
arm.
29078CY001
Θ Remove bolt (2), nut (3) and pull out pin 2

(1).
ö Tie the rod with wire to prevent it from 3
coming out.
29078CY002
Ι Disconnect bucket cylinder hoses (4)

and put plugs (5) on cylinder pipe. 5
29078CY003
8-130
Κ Sling bucket cylinder assembly (8) and
remove bolt (6) then pull out pin (5). 8
Λ Remove bucket cylinder assembly (8).
6
29078CY004
(2) Install
Η Carry out installation in the reverse order
to removal.
When aligning the mounting position of
the pin, do not insert your fingers in the
pin hole.
ö Bleed the air from the bucket cylinder.
ö Confirm the hydraulic oil level and check
8-131
2) ARM CYLINDER
(1) Removal
stop the engine.
ö Loosen the breather slowly to release the 13031GE18

injury. Arm cylinder
ö Fit blind plugs in the hoses after
disconnecting them, to prevent dirt or
dust from entering. Block
Η Set block between arm cylinder and
boom.
21098CY18
Θ Remove bolt (2) and pull out pin (1).

ö Tie the rod with wire to prevent it from
coming out.
21098CY19
Ι Disconnect arm cylinder hoses (4) and

5
put plugs on cylinder pipe.
Κ Disconnect greasing pipings (5). 4
Plug
21098CY20
8-132
Λ Sling arm cylinder assembly(8) and
remove bolt (7) then pull out pin (6).
Μ Remove arm cylinder assembly (8). 8
6
7
21098CY21
(2) Install
to removal.
When aligning the mounting position
of the pin, do not insert your fingers in
the pin hole.
ö Bleed the air from the arm cylinder.
ö Confirm the hydraulic oil level and check
8-133
3) BOOM CYLINDER
(1) Removal
stop the engine.
ö Loosen the breather slowly to release the 13031GE18

injury.
ö Fit blind plugs in the hoses after 1
disconnecting them, to prevent dirt or dust
from entering.
Η Disconnect greasing hoses (1).
Θ Sling boom cylinder assembly.
21078DA22
Ι Remove bolt (4), stopper (5) and pull out 4

pin (2). 2
5
coming out.
2107A8DA23
Κ Lower the boom cylinder assembly (6)

on a stand.
21078DA24
8-134
Λ Disconnect boom cylinder hoses (7) and
put plugs on cylinder pipe.
21078DA25
Μ Remove bolt (9) and pull out pin (8).

Ν Remove boom cylinder assembly (6).
6
8
9
21078DA26
(2) Install
to removal.
When aligning the mounting position
of the pin, do not insert your fingers in
the pin hole.
ö Bleed the air from the boom cylinder.
ö Conformed the hydraulic oil level and
check the hydraulic oil leak or not.
8-135
1) STRUCTURE
(1) Bucket cylinder
9,10 6,7 8 4,5 23 32 31 3 22 11,12 1 2 13 14 17 16 15 18,19 20 21
Internal detail
24,26 29 28 30 25,27
25098CY01
1 Tube assembly 12 Back up ring 23 Hexagon socket head bolt

2 Rod assembly 13 Cushion ring 24 Pin bushing
3 Gland 14 Piston 25 Pin bushing
4 DD2 bushing 15 Piston seal 26 Dust seal
5 Snap ring 16 Wear ring 27 Dust seal
6 Rod seal 17 Dust ring 28 Band assembly
7 Back up ring 18 O-ring 29 Pipe assembly-R
8 Buffer ring 19 Back up ring 30 Pipe assembly-B
9 Dust wiper 20 Lock nut 31 O-ring
10 Snap ring 21 Hexagon socket set screw 32 Hexagon socket head bolt
11 O-ring 22 O-ring
8-136
(2) Arm cylinder
9,10 6,7 8 4,5 23 34 33 3 22 11,12 1 2 13 14 17 16 15 18,19 20 21
Internal detail
24, 25 30 32 31 24, 25
26,27,28,29
25098CY02
1 Tube assembly 13 Cushion ring 25 Dust seal

2 Rod assembly 14 Piston 26 Check valve
3 Gland 15 Piston seal 27 Coil spring
4 DD2 bushing 16 Wear ring 28 O-ring
5 Snap ring 17 Dust ring 29 Plug
6 Rod seal 18 O-ring 30 Band assembly-R
7 Back up ring 19 Back up ring 31 Band assembly-B
8 Buffer ring 20 Lock nut 32 Pipe assembly-R
9 Dust wiper 21 Hexagon socket set screw 33 O-ring
10 Snap ring 22 O-ring 34 Hexagon socket head bolt
11 O-ring 23 Hexagon socket head bolt
12 Back up ring 24 Pin bushing
8-137
(3) Boom cylinder
9,10 6,7 8 4,5 23 32 31 3 22 11,12 1 2 13 14 17 16 15 18,19 20 21
Internal detail
24,26 29 28 30 25,27
25098CY03
1 Tube assembly 12 Back up ring 23 Hexagon socket head bolt

2 Rod assembly 13 Cushion ring 24 Pin bushing
3 Gland 14 Piston 25 Pin bushing
4 DD2 bushing 15 Piston seal 26 Dust seal
5 Snap ring 16 Wear ring 27 Dust seal
6 Rod seal 17 Dust ring 28 Band assembly
7 Back up ring 18 O-ring 29 Pipe assembly-R, LH/RH
8 Buffer ring 19 Back up ring 30 Pipe assembly-B, LH/RH
9 Dust wiper 20 Lock nut 31 O-ring
10 Snap ring 21 Hexagon socket set screw 32 Hexagon socket head bolt
11 O-ring 22 O-ring
8-138
(1) Tools
Tools Remark
6
B
8
Allen wrench
14
17
7
Spanner
8
(-) Driver Small and large sizes

Torque
Part name Item Size
kgfÂm lbfÂft
23 M18 32Ü3.0 231Ü22
Bucket cylinder
32 M12 9.4Ü1.0 68Ü7.2
23 M18 32Ü3.0 231Ü22
Socket head bolt Boom cylinder
32 M12 9.4Ü1.0 68Ü7.2
23 M20 46Ü5.0 333Ü36
Arm cylinder
34 M12 9.4Ü1.0 68Ü7.2
Bucket cylinder 20 - 100Ü10 723Ü72.5
Lock nut Boom cylinder 20 - 100Ü10 723Ü72.5
Arm cylinder 20 - 150Ü15 1085Ü108
Bucket cylinder 14 - 150Ü15 1085Ü108
Piston Boom cylinder 14 - 150Ü15 1085Ü108
Arm cylinder 14 - 200Ü20 1447Ü145
8-139
3) DISASSEMBLY
(1) Remove cylinder head and piston rod
ö Procedures are based on the bucket
cylinder.
Η Hold the clevis section of the tube in a
vise.
ö Use mouth pieces so as not to damage
the machined surface of the cylinder
tube. Do not make use of the outside
piping as a locking means.
Θ Pull out rod assembly (2) about

200mm (7.1in). Because the rod
assembly is rather heavy, finish
extending it with air pressure after the oil
m
0m
20
draining operation.
21078DA30
Ι Loosen and remove socket bolts (23) of

Hexagon
the gland in sequence. socket wrench 23
ö Cover the extracted rod assembly (2)
with rag to prevent it from being
Turn counter
accidentally damaged during operation. clockwise
Cover here
with rag
2
25098DA31
Κ Draw out cylinder head and rod assembly

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

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

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

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

Η Remove back up ring (12) and O-ring 10 9 6 7 8 4 5 12 11
(11).
Θ Remove snap ring (10), dust wiper (9).
Ι Remove back up ring (7), rod seal (6)
and buffer ring (8).
ö Exercise care in this operation not to
damage the grooves.
ö Do not remove seal and ring, if does not
21078DA36
damaged.
ö Do not remove bushing (4).
8-142
3) ASSEMBLY
(1) Assemble cylinder head assembly
ö Check for scratches or rough surfaces if
found smooth with an oil stone.
Η Coat the inner face of gland (3) with
hydraulic oil.
21078DA37
Θ Coat dust wiper (9) with grease and fit Press here
dust wiper (9) to the bottom of the hole of (Straight down)
dust seal.
Metal
At this time, press a pad metal to the 9
metal ring of dust seal.
Ι Fit snap ring (10) to the stop face.
8-157(2)
Κ Fit back up ring (7), rod seal (6) and

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

Push bar
Therefore, confirm it before fitting them.
ö Fitting rod seal (6) upside down may
damage its lip. Therefore check the
correct direction that is shown in fig.
21078DA38
8-143
Λ Fit back up ring (12) to gland (3).
ö Put the backup ring in the warm water of
11
30~50˚C .
Μ Fit O-ring (11) to gland (3). 12
21078DA39
(2) Assemble piston assembly

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

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

17 16 15 16 17
piston (14).
14
2907A8CY05
8-144
(3) Install piston and cylinder head
Η Fix the rod assembly to the work bench. Cylinder head assembly
Θ Apply hydraulic oil to the outer surface of Rod assembly
rod assembly (2), the inner surface of
piston and cylinder head.
Ι Insert cylinder head assembly to rod
assembly.
21078DA40
Κ Insert cushion ring (13) to rod assembly.

ö Note that cushion ring (13) has a 13
direction in which it should be fitted.
Insert
8-159(2)
Λ Fit piston assembly (14) to rod assembly.

ÂTightening torque :
Item kgfÂm lbfÂft
Bucket 150Ü15 1085Ü108
14 Boom 150Ü15 1085Ü108
Arm 200Ü20 1447Ü145
25098CY09
Μ Fit lock nut (20) and tighten the screw

20 21
(21).
ÂTightening torque :
Item kgfÂm lbfÂft
Bucket 100Ü10 723Ü72.3
20 Boom 100Ü20 723Ü72.3
Arm 150Ü15 1085Ü108
21 2.7Ü0.3 19.6Ü2.2
50078CY10
8-145
(3) Overall assemble Fix with a bar
Η Place a V-block on a rigid work bench.
Mount the tube assembly (1) on it and Lift
fix the assembly by passing a bar
through the clevis pin hole to lock the
assembly. Straight
Θ Insert the rod assembly in to the tube
assembly, while lifting and moving the
rod assembly with a crane. Appply liquid packing
21078DA41
ö Be careful not to damage piston seal by
thread of tube assembly.
Ι Match the bolt holes in the cylinder head
flange to the tapped holes in the tube Turn clockwise
assembly and tighten socket bolts to a Apply loctite
specified torque.
ö Refer to the table of tightening torque.
Place rag
21078DA42
8-146
GROUP 10 UNDERCARRIAGE
1. TRACK LINK
1) REMOVAL
(1) Move track link until master pin is over
front idler in the position put wooden
Master pin
block as shown.
(2) Loosen tension of the track link.
ö If track tension is not relieved when the
grease valve is loosened, move the
machine backwards and forwards.
(3) Push out master pin by using a suitable
tool.
Block
8-161(1)
(4) Move the machine slowly in reverse, and

lay out track link assembly (1).
ö Jack up the machine and put wooden
block under the machine.
ö Don't get close to the sprocket side as the
track shoe plate may fall down on your
feet.
1
8-161(2)
2) INSTALL
to removal.
ö Adjust the tension of the track link. 90 ~ 110
21074OP14
8-147
2. CARRIER ROLLER Frame
1) REMOVAL
(1) Loosen tension of the track link. Grease
valve
8-162(1)
(2) Jack up the track link height enough to

permit carrier roller removal.
Jack Carrier roller

8-162(2)
(3) Loosen the lock nut (1).

1 Carrier
(4) Open bracket(2) with a screwdriver, push roller
2
out from inside, and remove carrier roller
assembly.
8-162(3)
2) INSTALL
to removal.
8-148
8-148
3. TRACK ROLLER Frame
1) REMOVAL
Grease
(1) Loosen tension of the track link. valve
8-163(1)
(2) Using the work equipment, push up track

frame on side which is to be removed.
ö After jack up the machine, set a block
under the unit.
90-110ä
8-163(2)
(3) Remove the mounting bolt (1) and draw

out the track roller (2). 1 2
8-163(3)
2) INSTALL
to removal.
8-149
4. IDLER AND RECOIL SPRING
1) REMOVAL
(1) Remove the track link.
For detail, see removal of track link.
8-164(1)
(2) Sling the recoil spring (1) and pull out idler
and recoil spring assembly from track
frame, using a pry. 1
8-164(2)
(3) Remove the bolts (2), washers (3) and

separate ilder from recoil spring.
2, 3
8-164(3)
2) INSTALL
to removal.
ö Make sure that the boss on the end face
of the recoil cylinder rod is in the hole of
the track frame.
8-164(4)
8-150
3) DISASSEMBLY AND ASSEMBLY OF IDLER
(1) Structure
36078UC01
1 Shell 4 O-ring 7 Spring pin

2 Bushing 5 Seal assembly 8 Plug
3 Shaft 6 Bracket
8-151
(2) Disassembly Press
Η Remove plug and drain oil.
Θ Draw out the spring pin (7), using a
press.
7 45078UC24
Ι Pull out the shaft (2) with a press.

Press
Κ Remove seal (5) from shell (1) and
bracket (6).
Λ Remove O-ring (4) from shaft.
3
45078UC23
Μ Remove the bushing (2) from idler, using

a special tool.
ö Only remove bushing if replacement is
necessity.
2
45078UC22
8-152
(3) Assembly
ö Before assembly, clean the parts.
ö Coat the sliding surfaces of all parts with 1 2 Press
oil.
Η Cool up bushing (2) fully by some dry ice
and press it into shell (1).
Do not press it at the normal
temperature, or not knock in with a
hammer even after the cooling.
45078UC28
Θ Coat O-ring (4) with grease thinly, and

install it to shaft (3). 4
Ι Insert shaft (3) into bracket (6) and drive 3
in the spring pin (7).
6
45078UC27
Κ Install seal (5) to shell (1) and bracket (6).

5
45078UC26
Λ Install shaft (3) to shell (1). 3 1
45078UC25
8-153
Μ Install bracket (6) attached with seal (5).
6
45078UC31
Ν Knock in the spring pin (7) with a

6 7 1
hammer.
45078UC30
Ξ Lay bracket (6) on its side.

6
Supply engine oil to the specified level,
and tighten plug.
45078UC29
8-154
4) DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING
(1) Structure
4 7, 8 3 6 5 2 1 9 10 11 12
13
R210UCG01
1 Body 6 Lock plate 11 Dust seal

2 Tie bar 7 Bolt 12 Rod assembly
3 Spring 8 Spring washer 13 Grease valve
4 Bracket 9 Rod seal
5 Lock nut 10 Back up ring
8-155
(2) Disassembly
Η Apply pressure on spring (3) with a
press.
ö The spring is under a large installed load.
This is dangerous, so be sure to set
properly. 4
ÂSpring set load : 16315 kg (35968 lb) 7, 8
Θ Remove bolt (7), spring washer (8) and 3
lock plate (6). 6
Ι Remove lock nut (5). 5
Take enough notice so that the press
which pushes down the spring, should
not be slipped out in its operation.
Κ Lighten the press load slowly and
remove bracket (4) and spring (3).
R210UCG2(1)
Λ Remove rod (12) from body (1).

1 12
Μ Remove grease valve (13) from rod (12).
13
R210UCG2(2)
Ν Remove rod seal (9), back up ring (10)

and dust seal (11). 1 9 10 11
R210UCG2(3)
8-156
(3) Assembly
Install dust seal (11), back up ring (10) 1 9 10 11
and rod seal (9) to body (1).
ö When installing dust seal (11) and rod
seal (9), take full care so as not to
damage the lip.
R210UCG2(3)
Θ Pour grease into body (1), then push in

1 12
rod (12) by hand.
After take grease out of grease valve
mounting hole, let air out.
ö If air letting is not sufficient, it may be
difficult to adjust the tension of crawler.
Ι Fit grease valve (13) to rod (12).
ÂTightening torque : 10Ü0.5 kgfÂm
(72.3Ü3.6 lbfÂft) 13
R210UCG2(4)
Κ Install spring (3) and bracket (4) to body

(1). Press
Λ Apply pressure to spring (3) with a press
and tighten lock nut (5).
ö Apply sealant before assembling.
ö During the operation, pay attention
specially to prevent the press from 4
slipping out.
3
R210UCG2(5)
8-157
Μ Lighten the press load and confirm the
set length of spring (3). Press
Ν After the setting of spring (3), install lock
plate (6), spring washer (8) and bolt (7).
7,8
6
5
3
_ 1.5
508 +
2507A8UC07
8-158
GROUP 11 WORK EQUIPMENT
1. STRUCTURE
A
A
SECTION A SECTION B SECTION C
29078WE01
8-159
1) BUCKET ASSEMBLY
(1) Removal
Η Lower the work equipment completely to
A
ground with back of bucket facing down.
B
36078AT04
Θ Remove nut (1), bolt (2) and draw out the

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

pin (B).
A
36078AT02
(2) Install
to removal.
When aligning the mounting position of
the pin, do not insert your fingers in the
pin hole.
ö Adjust the bucket clearance.
For detail, see operation manual.
36078AT05
8-160
2) ARM ASSEMBLY
(1) Removal
ö Loosen the breather slowly to release
the pressure inside the hydraulic tank.
penetrated the skin causing serious
injury.
Η Remove bucket assembly.
For details, see removal of bucket 8-175(1)
assembly.
Θ Disconnect bucket cylinder hose (1).
Fit blind plugs (5) in the piping at the
chassis end securely to prevent oil from 5
spurting out when the engine is started.
4
Ι Sling arm cylinder assembly, remove
spring, pin stopper and pull out pin.
coming out. 4
Κ For details, see removal of arm cylinder
assembly.
21078DA16
Place a wooden block under the cylinder
and bring the cylinder down to it.
Λ Remove bolt (2), plate (3) and pull out
the pin (4) then remove the ar m
assembly.
ö ÂWeight : 1000 kg (2200 lb) Crane
When lifting the arm assembly, always lift
the center of gravity.
2, 3, 4
8-175(3)
(2) Install
Η Carry out installation in the reverse
order to removal.
When lifting the arm assembly, always lift
the center of gravity.
ö Bleed the air from the cylinder.
8-161
3) BOOM CYLINDER
(1) Removal
Η Remove arm and bucket assembly.
For details, see removal of arm and
bucket assembly.
Θ Remove boom cylinder assembly from
boom.
For details, see removal of arm cylinder
assembly. 8-176(1)
Ι Disconnect head lamp wiring.

1
Κ Disconnect bucket cylinder hose (2) 2
and arm cylinder hose (1).
ö When the hose are disconnected, oil
may spurt out.
Λ Sling boom assembly (3). 1
21078DA45)
Μ Remove bolt (4), plate (5) and pull out

Crane
the pin (6) then remove boom assembly.
ÂWeight :1970 kg (4340 lb)
ö When lifting the boom assembly always
lift the center of gravity.
4, 5, 6
3
8-176(3)
(2) Install
to removal.
When lifting the arm assembly, always
lift the center of gravity.
ö Bleed the air from the cylinder.
21078DA46
8-162
Group 1 Introduction guide --------------------------------------------------------------------------------------------- 9-1

Group 2 Engine system -------------------------------------------------------------------------------------------------- 9-2
Group 3 Electric system ------------------------------------------------------------------------------------------------- 9-4
Group 4 Hydraulic system ---------------------------------------------------------------------------------------------- 9-6
Group 6 Structure ------------------------------------------------------------------------------------------------------------ 9-11
Group 7 Work equipment ------------------------------------------------------------------------------------------------ 9-15
GROUP 1 INTRODUCTION GUIDE
1. This section shows bolt specifications and

standard torque values needed when
mounting components to the machine.
2. Use genuine Hyundai spare parts.
We expressly point out that Hyundai will not
accept any responsibility for defects resulted
from non-genuine parts.
In such cases Hyundai cannot assume
liability for any damage.
※ Only metric fasteners can be used and
incorrect fasteners may result in machine
damage or malfunction.
※ Before installation, clean all the
components with a non-corrosive cleaner.
Bolts and threads must not be worn or 29079CM00
damaged.
9-1
GROUP 2 ENGINE SYSTEM
ENGINE AND ACCESSORIES MOUNTING
Muffler 00
3 A
2
6
3
2
7 Engine 3
4 4
Fan
3
6
1 00 2
4
4
A
00
1
00 3 1
Air cleaner
Accel actuator
2609S9CM01
·Tightening torque
Item Size kgf·m lbf·ft Item Size kgf·m lbf·ft

1 M 6×1.0 1.05±0.2 7.6±1.4 4 M12×1.75 12.8±3.0 92.6±21.7
2 M 8×1.25 2.5±0.5 18.1±3.6 5 M14×2.0 9.8±0.9 70.8±6.5
3 M10×1.5 6.9±1.4 49.9±10.1 6 M20×2.5 55±3.5 398±25
7 M24×3.0 90±7.0 651±51
9-2
COOLING SYSTEM AND FUEL TANK MOUNTING
4
Pre filter
Hyd tank
5
Air compressor 2
Fuel tank
Air con
idle pully 6
7
9
9
6 3
Y Condenser
6 Screen
10
2
1
2
Radiator
K 7
6 Oil cooler Y
Resevoir tank
Shroud
7
6
8
2609S9CM02
·Tightening torque

1 M 6×1.0 0.5±0.2 3.6±1.45 6 M10×1.5 6.9±1.4 49.9±10.1
2 M 8×1.25 2.5±0.5 18.1±3.6 7 M12×1.75 12.8±3.0 92.6±21.7
3 M 8×1.25 1.3±0.2 9.4±1.45 8 M16×2.0 29.7±4.5 215±32.5
4 M 8×1.25 4.3±0.2 31.1±1.45 9 M20×2.5 57.9±8.7 419±62.9
5 M10×1.25 5.0±0.2 36.1±1.45 10 - 1.8±0.1 13.0±0.7
9-3
GROUP 3 ELECTRIC SYSTEM
ELECTRIC COMPONENTS MOUNTING 1 (CLUSTER TYPE 1)
Work lamp
4
1 3 Alternator
1
2
2 2
DETAIL A DETAIL B
2 3
B
A Travel alarm
buzzer
Fuel filler
pump 3
3
3 2
1
2
Washer tank
Horn
2
Battery
Battery relay
2609S9CM03
·Tightening torque
1 M 6×1.0 1.05±0.2 7.6±1.45 3 M10×1.5 6.9±1.4 49.9±10.1

2 M 8×1.25 2.5±0.5 18.1±3.6 4 M12×1.75 12.8±3.0 92.6±21.7
9-4
ELECTRIC COMPONENTS MOUNTING 2
ELECTRIC COMPONENTS MOUNTING 2
VIEW A
Beacon lamp Electric box
3
1 Fuse box
Wiper
motor
TO FRAME HARNESS
Cluster
1
Cluster
B 1
DC-DC converter Radio & USB player
2
2
2
DETAIL B(TYPE 1) DETAIL B(TYPE 2)
3309S9CM04
·Tightening torque
1 M 6×1.0 1.05±0.2 7.6±1.45 3 M10×1.5 6.9±1.4 49.9±10.1

2 M 8×1.25 2.5±0.5 18.1±3.6
9-5
GROUP 4 HYDRAULIC SYSTEM
HYDRAULIC COMPONENTS MOUNTING 1
Gauge level
4 Solenoid valve
Air breather 4
3 3
Drain filter
Main control valve
5
Main pump
Hydraulic tank
A
5
Bracket-MCV mtg Swing motor

10
7 9
RCV-RH
4
1 3
Terminal assy
3
VIEW A
3 10 6
RCV-LH
3
Cross 3
1
8
2609S9CM05
·Tightening torque
1 M 6×1.0 1.05±0.2 7.6±1.45 6 M20×2.5 42±4.5 304±32.5
2 M10×1.5 4.8±0.3 34.7±2.2 7 M20×2.5 46±5.1 333±36.9
3 M10×1.5 6.9±1.4 49.9±10.1 8 M20×2.5 46.5±2.5 336±18.1
4 M12×1.75 12.3±1.3 88.9±9.4 9 M20×2.5 58.4±6.4 422±46.2
5 M12×1.75 12.8±3.0 92.5±21.6 10 M20×2.5 57.9±8.7 419±62.9
9-6
Double acting attachment piping Travel motor(RH)
5
4
Stop
valve
Travel motor(LH)
Turning joint
3
D/acting
1 3 way joint
3
4
D/acting
hose joint Solenoid valve
4
Accumulator 6
7
Check valve
D/acting single pedal
2 7
2
Check valve
Filter line Eppr valve

7
RCV-pedal
Cartridge
2609S9CM06
·Tightening torque
1 M 8×1.25 4.05±0.8 29.3±5.8 4 M12×1.75 12.8±3.0 92.6±21.7

2 M10×1.5 6.9±1.4 49.9±10.1 5 M14×2.0 19.6±2.9 142±20.9
3 M12×1.75 12.3±1.3 88.9±9.4 6 M24×3.0 84±8.0 723±72.3
9-7
1
1
3
BOOM CYLINDER
1
2 1
2
1 3
1
5 4
ARM CYLINDER BUCKET CYLINDER
2609S9CM07
·Tightening torque
1 M10×1.5 3.2±0.3 23.1±2.2 4 M18×2.5 32±3.0 232±21.7
2 M12×1.75 5.5±0.6 39.8±4.3 5 M20×2.5 46±5.0 333±36.2
3 M12×1.75 9.4±1.0 68.0±7.2
9-8
GROUP 5 UNDERCARRIAGE
UNDERCARRIAGE MOUNTING
ADJUST COMPONENT 1
Swing bearing
1
9
3 5 9
9
Cover
7 Idler
1 Cover
2 Carrier roller
8
Track chain
2
2 Adjust
component
Track roller
Track guard
6
Travel motor
Sprocket
2609S9CM08
·Tightening torque
1 M10×1.5 6.9±1.4 49.9±10.1 5 M16×2.0 29.7±4.5 215±32.5
2 M12×1.75 12.8±3.0 92.6±21.7 6 M20×2.5 57.9±6.0 419±43.4
3 M12×1.75 15±0.5 108±3.6 7 M22×1.5 115±5.0 831±36
4 M16×2.0 29.7±3.0 215±21.7 8 M24×3.0 100±10 723±72.3
9-9
UNDERCARRIAGE MOUNTING (HIGH WALKER)
Idler
1 2
Roller
4
Track guard
1
5
Full track guard type
2609S9CM09
·Tightening torque
1 M10×1.5 6.9±1.4 49.9±10.1 4 M20×2.5 57.9±8.6 419±62.2

2 M12×1.75 12.2±1.3 88.2±9.4 5 M24×3.0 100±15 723±108
3 M20×2.5 51±4.0 369±28.9 6 - - -
9-10
GROUP 6 STRUCTURE
CAB AND ACCESSORIES MOUNTING
Sun roof assy
2
4
1
Cab
4 5
4
2
1
Sliding
door wa Bracket latch assy
5
Plate
non slip
3
2
Side door Striker
Latch assy
3009SH9CM10
·Tightening torque
1 M 6×1.0 0.49±0.1 3.5±0.7 4 M10×1.5 6.9±1.4 49.9±10.1

2 M 8×1.25 2.5±0.5 18.1±3.6 5 M12×1.75 12.8±3.0 92.6±21.7
3 M10×1.5 4.7±0.9 34±6.5
9-11
CAB INTERIOR MOUNTING
Seat 1
1
Storage box
1
3
3
Console
box(RH)
1
3
Trim-rear mid
K 4 Plate
3 3
Seat base
Console
K box(LH)
1
5
Safety lever 3
3
4 Slide rail
Pedal 1
Pedal bracket 6
4
4
Travel Aircon cover-Low

lever
Viscous
Foot rest mount
Foot rest
bracket Bottom plate
4
4 3009SH9CM11
·Tightening torque
1 M 6×1.0 0.49±0.1 3.5±0.7 4 M10×1.5 6.9±1.4 49.9±10.1

2 M 8×1.25 4.05±0.8 29.3±5.8 5 M10×1.5 8.27±1.7 59.8±12.3
3 M 8×1.25 2.5±0.5 18.1±3.6 6 M16×2.0 29.7±4.5 215±32.5
9-12
COWLING MOUNTING
Engine hood
1
3
3 1
2
K
Pump screen
Screen
Tank cover
3
1
Air cleaner hood 3
3
3 3
3
3
3 MCV hood
Engine hood
3 support
3 3 HYU
ND
AI
K FU
LO
LL
3 2
1
2
3
1 1
3
Side cover(RH)
1
3 Side cover(LH)
2609S9CM12
·Tightening torque
Item Size kgf·m lbf·ft
1 M8×1.25 2.5±0.5 18.1±3.6
2 M10×1.5 6.9±1.4 49.9±10.1
3 M12×1.75 12.8±3.0 92.6±21.7
9-13
COUNTERWEIGHT AND COVERS MOUNTING
2
Counterweight
3
2
3
Handle
3
2
2
2
Hyd tank
3 Upper frame
Fuel tank Fuel tank
cover
3
3
1
4
Tool box 2
Pump under cover Engine under cover
1 Hyd tank under cover
1 Fuel tank under cover
Rad under cover
2 2
2
2
MCV under cover

Cab under cover
2609S9CM13
·Tightening torque
1 M 8×1.25 2.5±0.5 18.1±3.6 3 M12×1.75 12.8±3.0 92.6±21.7
2 M10×1.5 6.9±1.4 49.9±10.1 4 M36×3.0 308±46 2228±333
9-14
GROUP 7 WORK EQUIPMENT
Arm cylinder
rod pin
2
Arm cylinder
Bucket cylinder
head pin
1
2 Boom cylinder
rod pin
1
Bucket cylinder
1 Arm pin 2
Boom
Bucket
control link
2 Arm cylinder Boom cylinder
Bucket cylinder head pin Boom pin
rod pin head pin
Boom 1
2 2 cylinder
Bucket
2
Bucket control 3
rod pin
Side cutter(RH)
2 1
Cover plate
Side cutter(LH)
3009SH9CM14
·Tightening torque
1 M16×2.0 29.7±4.5 215±32.5 3 M22×2.5 81.9±16.1 592±116
2 M20×2.5 57.9±8.7 419±62.9
9-15

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Hyundai r260lc 9s Manual de Taller

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CONTENTS

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

SECTION 2 STRUCTURE AND FUNCTION

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

SECTION 3 HYDRAULIC SYSTEM

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

SECTION 4 ELECTRICAL SYSTEM

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

SECTION 5 MECHATRONICS SYSTEM

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

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

SECTION 7 MAINTENANCE STANDARD

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

SECTION 8 DISASSEMBLY AND ASSEMBLY

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

Group 1 Introduction guide --------------------------------------------------------------------------------------------- 9-1

2. Convert 550mm into inches.

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

Kilogram to Pound 1kg = 2.2046lb

0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

Liter to U.K. Gallon 1ℓ = 0.21997 U.K.Gal

0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

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

FOLLOW SAFE PROCEDURE

WEAR PROTECTIVE CLOTHING

WARN OTHERS OF SERVICE WORK

USE HANDHOLDS AND STEPS

Be careful of slippery conditions on platforms,

PROTECT AGAINST FLYING DEBRIS

PROTECT AGAINST NOISE

AVOID POWER LINES

MOVE AND OPERATE MACHINE SAFELY

OPERATE ONLY FORM OPERATOR'S SEAT

PARK MACHINE SAFELY

SERVICE COOLING SYSTEM SAFELY

HANDLE FLUIDS SAFELY-AVOID FIRES

Store flammable fluids away from fire hazards.

ILLUMINATE WORK AREA SAFELY

STAY CLEAR OF MOVING PARTS

AVOID HIGH PRESSURE FLUIDS

PREVENT BATTERY EXPLOSIONS

USE TOOLS PROPERLY

Use only recommended replacement parts.

REPLACE SAFETY SIGNS

LIVE WITH SAFETY

Battery box Fuel tank Hydraulic tank Main pump

Arm Arm cylinder Boom Boom cylinder Cab Muffler Counterweight

Bucket cylinder Connecting link Idler Carrier roller Sprocket

Side cutter Connecting rod

Description Unit Specification

Description Unit Specification

Operating weight kg (lb) 25100 (55300)

Description Unit Specification

6.0 m kg 3700 3700 4400 2660 9.22

6.0 m kg 4140 4140 *4510 3190 9.37

ľ1.15 m3 1.00 m3 1210 mm

ľ1.27 m3 1.10 m3 1310 mm

ľ1.46 m3 1.28 m3 1460 mm

Ľ1.16 m3 1.00 m3 1340 mm