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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.
SECTION 2 STRUCTURE AND FUNCTION
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.
SECTION 3 HYDRAULIC SYSTEM
This section explains the hydraulic circuit, single and combined operation.
SECTION 4 ELECTRICAL SYSTEM
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.
SECTION 5 MECHATRONICS SYSTEM
This section explains the computer aided power optimization system and each component.
SECTION 6 TROUBLESHOOTING
This section explains the troubleshooting charts correlating "problems" to "causes".
SECTION 7 MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
SECTION 8 DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling
each component, as well as precautions to be taken for these operations.
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Contact your HYUNDAI distributor for the latest information.

0-1
2. HOW TO READ THE SERVICE MANUAL
Distribution and updating Revised edition mark(‫ںڹڸ‬š)
Any additions, amendments or other changes When a manual is revised, an edition mark is
will be sent to HYUNDAI distributors. recorded on the bottom outside corner of the
Get the most up-to-date information before you pages.
start any work.
Revisions
Filing method Revised pages are shown at the list of revised
1. See the page number on the bottom of the pages on the between the contents page and
page. section 1 page.
File the pages in correct order.
2. Following examples shows how to read the Symbols
page number. So that the shop manual can be of ample
Example 1 practical use, important places for safety and
2-3 quality are marked with the following symbols.
Item number (2. Structure and
Function)
Consecutive page number for Symbol Item Remarks
each item.
Special safety precautions are
3. Additional pages : Additional pages are necessary when performing the
indicated by a hyphen(-) and number after the work.
Safety
page number. File as in the example.
Extra special safety precautions
10 - 4 are necessary when performing
10 - 4 - 1 the work because it is under
Added pages internal pressure.
10 - 4 - 2
10 - 5 Special technical precautions or

Ɠ Caution
other precautions for preserving
standards are necessary when
performing the work.

0-2
3. CONVERSION TABLE
Method of using the Conversion Table
The Conversion Table in this section is provided to enable simple conversion of figures. For details of
the method of using the Conversion Table, see the example given below.

Example
1. Method of using the Conversion Table to convert from millimeters to inches
Convert 55mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as ‫ڞ‬, then draw a
horizontal line from ‫ڞ‬.
(2) Locate the number 5 in the row across the top, take this as ‫ڟ‬, then draw a perpendicular line
down from ‫ڟ‬.
(3) Take the point where the two lines cross as ‫ڠ‬. This point ‫ ڠ‬gives the value when converting
from millimeters to inches. Therefore, 55mm = 2.165 inches.

2. Convert 550 mm into inches.


(1) The number 550 does not appear in the table, so divide by 10(move the decimal point one place
to the left) to convert it to 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 ‫ڟ‬ 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
‫ڠ‬
‫ڞ‬ 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 = 0.03937 in

0 1 2 3 4 5 6 7 8 9

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354


10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

Kilogram to Pound 1kg = 2.2046 lb

0 1 2 3 4 5 6 7 8 9

0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84


10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.5. 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03

50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26

0-4
Liter to U.S. Gallon
1ֻ = 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 1ֻ = 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
kgm to lb.ft 1kg.m = 7.233 lb.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
kg / cm2 to lb / in2 1kg / cm2 = 14.2233 lb /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.

Ɓ
C Ɓ
F Ɓ
C Ɓ
F Ɓ
C Ɓ
F Ɓ
C Ɓ
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
R290LC-3 Service Manual http://ce.hhi.co.kr/eng/parts/sm/R290lc-3/c_exca1.htm

CRAWLER TYPE EXCAVATOR [R290LC-3]


FOREWORD Group 2 Operation of CAPO System
SECTION 1 Group 3 System Diagram
Group 4 Engine Control System
GENERAL
Group 5 EPPR Valve
Group 1 Safety Hints
Group 6 Prolix Switch
Group 2 Specifications
Group 7 Function and Electrical Circuit
SECTION 2
SECTION 6
STRUCTURE AND FUNCTION
TROUBLESHOOTING
Group 1 Pump Device
Group 1 Hydraulic and Mechanical System
Group 2 Main Control Valve
Group 2 Electrical System
Group 3 Swing Device
Group 3 Mechatronics System
Group 4 Travel Device
SECTION 7
Group 5 RCV Lever
MAINTENANCE STANDARD
Group 6 RCV Pedal
Group 1 Operational Performance Test
SECTION 3
Group 2 Major Components
HYDRAULIC SYSTEM
Group 3 Track and Work Equipment
Group 1 Hydraulic Circuit
SECTION 8
Group 2 Main Circuit
DISASSEMBLY AND ASSEMBLY
Group 3 Pilot Circuit
Group 1 Precaution
Group 4 Single Operation
Group 2 Tightening Torque
Group 5 Combined Operation
Group 3 Pump Device
SECTION 4
Group 4 Main Control Valve
ELECTRICAL SYSTEM
Group 5 Swing Device
Group 1 Component Location
Group 6 Travel Device
Group 2 Electrical Circuit
Group 7 RCV Lever
Group 3 Monitoring System
Group 8 Turning Joint
Group 4 Electrical Component Specification
Group 9 Boom, Arm and Bucket Cylinder
Group 5 Connectors
Group 10 Undercarriage
SECTION 5
Group 11 Work Equipment
MECHATROMICS SYSTEM
Group 1 Outline

1 of 1 6/16/2011 10:53 AM
SECTION 1 GENERAL
GROUP 1 SAFETY

FOLLOW SAFE PROCEDURE


Unsafe work practices are dangerous. Understand
service procedure before doing work; do not attempt
shortcuts.

WEAR PROTECTIVE CLOTHING


Wear close fitting clothing and safety equipment
appropriate to the job.

WARN OTHERS OF SERVICE WORK


Unexpected machine movement can cause serious
injury.
Before performing any work on the excavator, attach a
ŜDo Not Operateŝtag on the right side control lever. WARN

DO
NOT
OPERATE

USE HANDHOLDS AND STEPS


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

1-1
PREPARE FOR EMERGENCIES
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance
service, hospital, and fire department near your
telephone.

PROTECT AGAINST FLYING DEBRIS


Guard against injury from flying pieces of metal or
debris; wear goggles or safety glasses.

PROTECT AGAINST NOISE


Prolonged exposure to loud noise can cause
impairment or loss of hearing.
Wear a suitable hearing protective device such as ear-
muffs or earplugs to protect against objectionable or
uncomfortable loud noises.

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.

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.

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
operating the machine in congested areas. Coordinate
hand signals before starting the excavator.

OPERATE ONLY FORM OPERATOR'S SEAT


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

PARK MACHINE SAFELY


Before working on the machine:
ňPark machine on a level surface.
ňLower bucket to the ground.
ňTurn auto idle switch off.
ňRun engine at 1/2 speed without load for 2 minutes.
ňTurn key switch to OFF to stop engine. Remove key
from switch.
ňMove pilot control shutoff lever to locked position.
ňAllow engine to cool.

1-3
SUPPORT MACHINE PROPERLY
Always lower the attachment or implement to the
ground before you work on the machine. If you must
work on a lifted machine or attachment, securely
support the machine or attachment.
Do not support the machine on cinder blocks, hollow
tiles, or props that may crumble under continuous load.
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.

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.

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.

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:
ň If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
ň 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.

1-5
SERVICE MACHINE SAFELY
Tie long hair behind your head. Do not wear a necktie,
scarf, loose clothing or necklace when you work near
machine tools or moving parts. If these items were to
get caught, severe injury could result.
Remove rings and other jewelry to prevent electrical
shorts and entanglement in moving parts.

STAY CLEAR OF MOVING PARTS


Entanglements in moving parts can cause serious
injury.
To prevent accidents, use care when working around
rotating parts.

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 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.

1-6
AVOID HEATING NEAR PRESSURIZED FLUID
LINES
Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to
yourself and bystanders. Do not heat by welding,
soldering, or using a torch near pressurized fluid lines or
other flammable materials.
Pressurized lines can be accidentally cut when heat
goes beyond the immediate flame area. 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 16Ƅ(60ŞF).

PREVENT ACID BURNS


Sulfuric acid in battery electrolyte is poisonous. It is
strong enough to burn skin, eat holes in clothing, and
cause blindness if splashed into eyes.
Avoid the hazard by:
1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is added.
4. Avoiding spilling of dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize the
acid.
3. Flush your eyes with water for 10-15 minutes. Get
medical attention immediately.
If acid is swallowed:
1. Drink large amounts of water or milk.
2. Then drink milk of magnesia, beaten eggs, or
vegetable oil.
3. Get medical attention immediately.

1-7
USE TOOLS PROPERLY
Use tools appropriate to the work. Makeshift tools,
parts, and procedures can create safety hazards.
Use power tools only to loosen threaded tools and
fasteners.
For loosening and tightening hardware, use the correct
size tools. DO NOT use U.S. measurement tools on
metric fasteners. Avoid bodily injury caused by slipping
wrenches.
Use only recommended replacement parts.(See Parts
catalogue.)

DISPOSE OF FLUIDS PROPERLY


Improperly disposing of fluids can harm the environment
and ecology. Before draining any fluids, find out the
proper way to dispose of waste from your local
environmental agency.
Use proper containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
DO NOT pour oil into the ground, down a drain, or into a
stream, pond, or lake. Observe 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.

LIVE WITH SAFETY


Before returning machine to customer, make sure
machine is functioning properly, especially the safety
systems. Install all guards and shields.

1-8
GROUP 2 SPECIFICATIONS

1. MAJOR COMPONENT

Battery Fuel tank Oil cooler Radiator

Engine

Main pump
Tooth Bucket Turning joint Swing motor
Hydraulic oil tank
Main control valve

Arm Arm cylinder Boom Boom cylinder Cab Muffler


Counterweight

Bucket cylinder Idler Carrier roller Travel motor

Side cutter Connecting rod Track roller Sprocket


Connecting link Track

1-9
2. SPECIFICATION
1) ROBEX 290-3

I(I') D
C

E
G
F

H
J M
K N
A B(L)

Description Unit Specification

Operating weight kg (lb) 27000 (59600)


Bucket capacity(CECE heaped), standard m 'yd (
3 3
1.1 (1.44)
Overall length A 10580 (34' 9")
Overall width, with 810mm shoe B 3410 (11' 2")
Overall height C 3320 (10' 11")
Superstructure width D 2900 (9' 6")
Cab height E 3040 (9' 12")
Ground clearance of counterweight F 1185 (3' 11")
Engine cover height G 2420 (7' 11")
Minimum ground clearance H mm (ft-in) 500 (1' 8")
Rear-end distance I 3100 (10' 2")
Rear-end swing radius I' 3100 (10' 2")
Distance between tumblers J 3710 (12' 2")
Undercarriage length K 4650 (15' 3")
Undercarriage width L 3410 (11' 2")
Track gauge M 2600 (8' 6")
Track shoe width, standard N 810 (32")
Travel speed (low/high) km/hr (mph) 3.0 / 4.6 (1.9 / 2.9)
Swing speed rpm 10.2
Gradeability degree ($) 35 (70)
Ground pressure(810mm shoe) kg/cm2 (psi) 0.43 (6.12)

1-10
2) ROBEX 290LC-3

I(I') D
C

E
G
F

H
J M
K N
A B(L)

Description Unit Specification

Operating weight kg (lb) 29100 (64200)


Bucket capacity(CECE heaped), standard m 'yd (
3 3
1.1 (1.44)
Overall length A 10580 (34' 9")
Overall width, with 810mm shoe B 3410 (11' 2")
Overall height C 3320 (10' 11")
Superstructure width D 2900 (9' 6")
Cab height E 3040 (9' 12")
Ground clearance of counterweight F 1185 (3' 11")
Engine cover height G 242 (7' 11")
Minimum ground clearance H mm (ft-in) 500 (1' 8")
Rear-end distance I 3100 (10' 2")
Rear-end swing radius I' 3150 (10' 4")
Distance between tumblers J 4020 (13' 2")
Undercarriage length K 4940 (16' 2")
Undercarriage width L 3410 (11' 2")
Track gauge M 2600 (8' 6")
Track shoe width, standard N 810 (32")
Travel speed (low/high) km/hr (mph) 3.0 / 4.6 (1.9 / 2.9)
Swing speed rpm 10.8
Gradeability degree ($) 35 (70)
Ground pressure(810mm shoe) kg/cm2 (psi) 0.41 (5.8)

1-11
3) ROBEX 290NLC-3

I(I') D
C

E
G
F

H
J M
K N
A B(L)

Description Unit Specification

Operating weight kg (lb) 27100 (59700)


Bucket capacity(CECE heaped), standard m 'yd (
3 3
1.1 (1.44)
Overall length A 10580 (34' 9")
Overall width, with 600mm shoe B 2990 (9' 9")
Overall height C 3320 (10' 11")
Superstructure width D 2900 (9' 6")
Cab height E 3040 (9' 12")
Ground clearance of counterweight F 1185 (3' 11")
Engine cover height G 2420 (7' 11")
Minimum ground clearance H mm (ft-in) 500 (1' 8")
Rear-end distance I 3100 (10' 2")
Rear-end swing radius I' 3100 (10' 2")
Distance between tumblers J 4020 (13' 2")
Undercarriage length K 4940 (16' 2")
Undercarriage width L 2990 (9' 9")
Track gauge M 2390 (7' 8")
Track shoe width, standard N 600 (24")
Travel speed (low/high) km/hr (mph) 3.0 / 4.6 (1.9 / 2.9)
Swing speed rpm 10.2
Gradeability degree ($) 35 (70)
Ground pressure(600mm shoe) kg/cm2 (psi) 0.52 (7.40)

1-12
3. WORKING RANGE

A
A'
F
D
E
B'
C
B

8ft

Description 2.10 m(6' 11")Arm 2.50 m(8' 2")Arm 3.05 m(10' 0")Arm 3.75 m(12' 4")Arm

Max. digging reach A 10020 mm (32' 9") 10360 mm (34' 0") 10800 mm (35' 5") 11400 mm (37' 5")
Max. digging reach on ground A' 9815 mm (32' 2") 10160 mm (33' 4") 10600 mm (34' 9") 11220 mm (36' 10")
Max. digging depth B 6440 mm (21' 10") 6950 mm (22' 10") 7500 mm (24' 7") 8200 mm (26' 11")
Max. digging depth (8ft level) B' 6240 mm (20' 5") 6740 mm (22' 1") 7300 mm (23' 11") 8010 mm (26' 3")
Max. vertical wall digging depth C 581 mm (19' 0") 6060 mm (19' 11") 6410 mm (21' 0") 7080 mm (23' 3")
Max. digging height D 10070 mm (33' 0") 10130 mm (33' 3") 10160 mm (33' 4") 10340 mm (33' 11")
Max. dumping height E 6930mm (22' 7") 7040 mm (23' 1") 7110 mm (23' 4") 7300 mm (23' 11")
Min. swing radius F 4380 mm (14' 4") 4260 mm (14' 0") 4230 mm (13' 11") 4140 mm (13' 7")
164KN 164KN 164KN 164KN
Bucket digging force 16700 kgf 16700 kgf 16700 kgf 16700 kgf
36817 lbf 36817 lbf 36817 lbf 36817 lbf
167 KN 140 KN 120 KN 108 KN
Arm crowd force 17000 kgf 14300 kgf 12200 kgf 11000 kgf
34700 lbf 31526 lbf 26896 lbf 24251 lbf

1-13
4. WEIGHT

R290-3 R290LC-3 R290NLC-3


Item
kg lb kg lb kg lb
Upperstructure assembly 12470 27500 12630 27800 12420 27400
Main frame weld assembly 2170 4780
Engine assembly 590 1300
Main pump assembly 160 350
Main control valve assembly 120 260
Swing motor assembly 320 700
Hydraulic oil tank assembly 280 620
Fuel tank assembly 160 350
Counterweight 4900 10800
Cab assembly 300 660
Undercarriage assembly 10600 23400 10930 24100 10700 23600
Track frame weld assembly 3390 7500 3740 8200 3660 8100
Swing bearing 410 900
Travel motor assembly 410 900
Turning joint 50 110
Track recoil spring and idler 230 510
Idler 210 460
Carrier roller 40 80
Track roller 50 110
Track-chain assembly (standard triple grouser shoe) 2130 4700 2260 4980 1900 4200
Front attachment assembly (6.25 m boom, 3.05
4030 8880
arm, 1.1 m3(CECE heaped) bucket)
6.25 m boom assembly 2140 4720
3.05 m arm assembly 930 2050
1.1 m (CECE heaped) bucket
3
960 2120
Boom cylinder assembly 260 570
Arm cylinder assembly 350 770
Bucket cylinder assembly 230 500
Bucket control rod assembly 110 240

1-14
5. LIFTING CAPACITIES
1) ROBEX 290LC-3
(1) 6.25m(20' 6") boom, 2.1m(6' 11") arm equipped with 1.1m3(CECE heaped) bucket and 810mm(32")
triple grouser shoe.

ş : Rating over-front ş : Rating over-side or 360 degree

Load radius At max. reach


Load point 3.0m(10' 0") 4.5m(15' 0") 6.0m(20' 0") 7.5m(25' 0") Capacity Reach
height
m(ft)
9.0m kg *5170 *5170 6.25
(30' 0") lb *11400 *11400 (21.4)
7.5m kg *5590 *5590 *5140 4410 7.99
(25' 0") lb *12320 *12320 *11330 9720 (26.2)
6.0m kg *5890 *5890 *5730 4750 *5220 3530 8.89
(20' 0") lb *12990 *12990 *12630 10470 *11510 7780 (29.2)
4.5m kg *8630 *8630 *6810 6790 *6020 4630 4660 3080 9.41
(15' 0") lb *19030 *19030 *15010 14970 *13270 10210 10270 6790 (30.9)
3.0m kg *11280 9780 *8010 6340 *6590 4430 4400 2870 9.64
(10' 0") lb *24870 21560 *17660 13980 *14539 9770 9700 6330 (31.6)
1.5m kg *13110 9100 *9080 5960 6440 4230 4380 2840 9.58
(5' 0") lb *28900 20060 *20020 13140 14200 9330 9660 6260 (31.4)
Ground kg *13650 8900 8920 5740 6300 4100 4620 3010 9.24
line lb *30090 19620 19670 12650 13890 9040 10190 6640 (30.3)
-1.5m kg *12900 *12900 *13380 8910 8850 5680 6270 4070 5230 3430 8.59
(-5' 0") lb *28440 *28440 *29500 19640 19510 12520 13820 8970 11530 7560 (28.2)
-3.0m kg *17110 *17110 *12370 9080 8950 5770 *6000 4390 7.50
(-10' 0") lb *37720 *37720 *27270 20020 19730 12720 *13230 9680 (24.6)
-4.5m kg *13840 *13840 *10100 9450
(-15' 0") lb *30510 *30510 *22270 20830

Note 1. Lifting capacity are based on SAE J1097


2. Lifting capacity of the ROBEX series does not exceed 75% of tipping load with the machine
on firm, level ground or 87% of full hydraulic capacity.
3. The load point is a hook located on the back of the bucket.
4. *indicates load limited by hydraulic capacity.

1-15
(2) 6.25m(20' 6") boom, 2.5m(8' 2") arm equipped with 1.1m3(CECE heaped) bucket and 810mm(32") triple
grouser shoe.

Load radius At max. reach


Load point 1.5m(5' 0") 3.0m(10' 0") 4.5m(15' 0") 6.0m(20' 0") 7.5m(25' 0") Capacity Reach
height
m(ft)
9.0m kg *4770 *4770 7.04
(30' 0") lb *10520 *10520 (23.1)
7.5m kg *4810 4100 8.40
(25' 0") lb *10600 9040 (27.6)
6.0m kg *5330 4870 *4920 3340 9.25
(20' 0") lb *11750 10740 *10850 7360 (30.3)
4.5m kg *7930 *7930 *6420 *6420 *5730 4730 4440 2930 9.75
(15' 0") lb *17480 *17480 *14150 *14150 *12630 10430 9790 6460 (32.0)
3.0m kg *10580 10060 *7670 6470 *6350 4500 4190 2740 9.97
(10' 0") lb *23320 22180 *16910 14260 *14000 9920 9240 6040 (32.7)
1.5m kg *12690 9290 *8840 6060 6500 4290 4170 2700 9.91
(5' 0") lb *27980 20480 *19490 13360 14330 9460 9190 5950 (32.5)
Ground kg *13600 8970 8980 5800 6330 4130 4370 2840 9.59
line lb *29980 19780 19800 12790 13960 9110 9630 6260 (31.5)
-1.5m kg *13070 *13070 *13590 8920 8870 5700 6270 4070 4880 3190 8.96
(-5' 0") lb *28810 *28810 *29960 19670 19550 12570 13820 8970 10760 7030 (29.4)
-3.0m kg *14990 *14990 *18270 *18270 *12810 9030 8920 5740 *5990 3970 7.94
(-10' 0") lb *33050 *33050 *40280 *40280 *28240 19910 19670 12650 *13210 8750 (26.0)
-4.5m kg *15310 *15310 *10950 9340 *5550 *5550 6.28
(-15' 0") lb *33750 *33750 *24140 20590 *12240 *12240 (20.6)

(3) 6.25m(20' 6") boom, 3.05m(10' 0") arm equipped with 1.1m3(CECE heaped) bucket and 810mm(32")
triple grouser shoe.

Load radius At max. reach


Load point 1.5m(5' 0") 3.0m(10' 0") 4.5m(15' 0") 6.0m(20' 0") 7.5m(25' 0") 9.0m(30' 0") Capacity Reach
height
m(ft)
9.0m kg *4230 *4230 7.68
(30' 0") lb *9330 *9330 (25.2)
7.5m kg *4320 3800 8.92
(25' 0") lb *9520 8380 (29.3)
6.0m kg *4770 *4770 *4460 3130 9.72
(20' 0") lb *10520 *10520 *9830 6900 (31.9)
4.5m kg *5760 *5760 *5220 4880 *4640 2770 10.20
(15' 0") lb *12700 *12700 *11510 10760 *10230 6110 (33.5)
3.0m kg *9920 *9920 *9490 *9490 *7050 6690 *5900 4630 *4520 3340 4480 2590 10.40
(10' 0") lb *21870 *21870 *20920 *20920 *15540 14750 *13010 10210 *9960 7360 9880 5710 (34.1)
1.5m kg *11860 9630 *8320 6230 *6620 4380 *5360 3220 4440 2540 10.35
(5' 0") lb *26150 21230 *18340 13730 *14590 9660 *11820 7100 9790 5600 (34.0)
Ground kg *9240 *9240 *13180 9160 *9260 5910 *7200 4190 *4780 3120 4620 2640 10.05
line lb *20370 *20370 *29060 20190 *20410 13030 *15870 9240 *10540 6880 10190 5820 (33.0)
-1.5m kg *10010 *10010 *12980 *12980 *13530 9000 *9710 5750 7140 4090 5090 2930 9.45
(-5' 0") lb *22070 *22070 *28620 *28620 *29830 19840 *21410 12680 15740 9020 11220 6460 (31.0)
-3.0m kg *13560 *13560 *17530 *17530 *13070 9050 *9560 5740 7160 4100 *5800 3550 8.50
(-10' 0") lb *29890 *29890 *38650 *38650 *28810 19950 *21080 12650 15790 9040 *12790 7830 (27.9)
-4.5m kg *17740 *17740 *16770 *16770 *11670 9280 *8530 5900 *5790 5000 7.01
(-15' 0") lb *39110 *39110 *36970 *36970 *25730 20460 *18810 13010 *12760 11020 (23.0)
-6.0m kg *8360 *8360
(-20' 0") lb *18430 *18430

1-16
(4) 6.25m(20' 6") boom, 3.75m(12' 4") arm equipped with 1.1m3(CECE heaped) bucket and 810mm(32")
triple grouser shoe.
Load radius At max. reach
Load point 1.5m(5' 0") 3.0m(10' 0") 4.5m(15' 0") 6.0m(20' 0") 7.5m(25' 0") 9.0m(30' 0") Capacity Reach
height
m(ft)
9.0m kg *3680 *3680 8.54
(30' 0") lb *8110 *8110 (28.0)
7.5m kg *3800 3270 9.65
(25' 0") lb *8380 7210 (31.7)
6.0m kg *4019 *4019 *2620 *2620 *3960 2740 10.39
(20' 0") lb *8860 *8860 *5780 *5780 *8730 6040 (34.1)
4.5m kg *4550 *4550 *4080 3500 *4130 2440 10.83
(15' 0") lb *10030 *10030 *8990 7720 *9110 5380 (35.5)
3.0m kg *12940 *12940 8010 *8010 *6190 *6190 *5290 4690 *4810 3360 4019 2280 11.02
(10' 0") lb *25830 *28530 *17660 *17660 *16350 *13650 *11660 10340 *10600 7410 8860 5030 (36.2)
1.5m kg *9740 *9740 *10670 9910 *7590 6330 *6090 4410 *5270 3200 3980 2230 10.97
(5' 0") lb *21470 *21470 *23520 21850 *16730 13960 *13430 9720 *11620 7050 8770 4920 (36.0)
Ground kg *9970 *9970 *12480 9240 *8730 5930 *6800 4170 5390 3070 4120 2300 10.69
line lb *21980 *21980 *27510 20370 *19250 13070 *14990 9190 11880 6770 9080 5070 (35.1)
-1.5m kg *8980 *8980 *12330 *12330 *13300 8940 *9430 5690 7080 4019 5300 2980 4480 2520 10.14
(-5' 0") lb *19800 *19800 *27180 *27180 *29320 19710 *20790 12540 15610 8860 11680 6570 9880 5560 (33.3)
-3.0m kg *11860 *11860 *15680 *15680 *13290 8880 *9590 5620 7020 3970 5200 2970 9.27
(-10' 0") lb *26150 *26150 *34570 *34570 *29300 19580 *21140 12390 15480 8750 11460 6550 (30.4)
-4.5m kg *15200 *15200 *18430 *18430 *12410 9020 *9050 5690 *5590 3940 7.95
(-15' 0") lb *33510 *33510 *40630 *40630 *27360 19890 *19950 12540 *12320 8690 (26.1)
-6.0m kg *14890 *14890 *10230 9380
(-20' 0") lb *32830 *32380 *22550 20680

(5) 6.25m(20' 6") boom, 3.05m(10' 0") arm equipped with 1.1m3(CECE heaped) bucket and 810mm(32")
triple grouser shoe.

Load radius At max. reach


Load point 1.5m(5' 0") 3.0m(10' 0") 4.5m(15' 0") 6.0m(20' 0") 7.5m(25' 0") 9.0m(30' 0") Capacity Reach
height
m(ft)
9.0m kg *4230 *4230 7.68
(30' 0") lb *9330 *9330 (25.2)
7.5m kg *4320 3700 8.92
(25' 0") lb *9520 8160 (29.3)
6.0m kg *4770 *4770 *4460 3040 9.72
(20' 0") lb *10520 *10520 *9830 6700 (31.9)
4.5m kg *5760 *5760 *5220 4760 4100 2680 10.20
(15' 0") lb *12700 *12700 *11510 10490 9040 5910 (33.5)
3.0m kg *9920 *9920 *9490 *9490 *7050 6520 *5900 4510 *4520 3240 3870 2500 10.40
(10' 0") lb *21870 *21870 *20920 *20920 *15540 14370 *13010 9940 *9960 7140 8530 5510 (34.1)
1.5m kg *11860 9630 *8320 6060 6480 4260 4800 3120 3840 2460 10.35
(5' 0") lb *26150 20680 *18340 13360 14290 9390 10580 6880 8470 5420 (34.0)
Ground kg *9240 *9240 *13180 8910 8930 5740 6270 4070 4700 3020 3990 2560 10.05
line lb *20370 *20370 *29060 19640 19690 12650 13820 8970 10360 6660 8800 5640 (33.0)
-1.5m kg *10010 *10010 *12980 *12980 *13530 8760 8750 5580 6160 3960 4400 2840 9.45
(-5' 0") lb *22070 *22070 *28620 *28620 *29830 19310 19290 12300 13580 8730 9700 6260 (31.0)
-3.0m kg *13560 *13560 *17530 *17530 *13070 8810 8750 5580 6170 3980 5270 3440 8.50
(-10' 0") lb *29890 *29890 *38650 *38650 *28810 19420 19290 12300 13600 8770 11620 7580 (27.9)
-4.5m kg *17740 *17740 *16770 *16770 *11670 9040 *8530 5740 *5790 4870 7.01
(-15' 0") lb *39110 *39110 *36970 *36970 *25730 19930 *18810 12650 *12760 10740 (23.0)
-6.0m kg *8360 *8360
(-20' 0") lb *18430 *18430

1-17
(6) 6.25m(20' 6") boom, 3.75m(12' 4") arm equipped with 1.1m3(CECE heaped) bucket and 810mm(32")
triple grouser shoe.
Load radius At max. reach
Load point 1.5m(5' 0") 3.0m(10' 0") 4.5m(15' 0") 6.0m(20' 0") 7.5m(25' 0") 9.0m(30' 0") Capacity Reach
height
m(ft)
9.0m kg *3680 *3680 8.54
(30' 0") lb *8110 *8110 (28.0)
7.5m kg *3800 3180 9.65
(25' 0") lb *8380 7010 (31.7)
6.0m kg *4019 *4019 *2620 *2620 *3960 2660 10.39
(20' 0") lb *8860 *8860 *5780 *5780 *8730 5860 (34.1)
4.5m kg *4550 *4550 *4080 3400 3660 2360 10.83
(15' 0") lb *10030 *10030 *8990 7500 8070 5200 (35.5)
3.0m kg *12940 *12940 8010 *8010 *6190 *6190 *5290 4570 *4810 3260 3470 2200 11.02
(10' 0") lb *28530 *28530 *17660 *17660 *13650 *13650 *11660 10080 *10600 7190 7650 4850 (36.2)
1.5m kg *9740 *9740 *10670 9670 *7590 6160 *6090 4280 4790 3100 3430 2150 10.97
(5' 0") lb *21470 *21470 *23520 21320 *16730 13580 *13430 9440 10560 6830 7560 4740 (36.0)
Ground kg *9970 *9970 *12480 9000 *8730 5760 6260 4050 4640 2970 3540 2220 10.69
line lb *21980 *21980 *27510 19840 *19250 12700 13800 8930 10230 6550 7800 4890 (35.1)
-1.5m kg *8980 *8980 *12330 *12330 *13300 8690 8710 5530 6090 3890 4560 2890 3850 2430 10.14
(-5' 0") lb *19800 *19800 *27180 *27180 *29320 19160 19200 12190 13430 8580 10050 6370 8490 5360 (33.3)
-3.0m kg *11860 *11860 *15680 *15680 *13290 8640 8620 5450 6040 3840 4490 2880 9.27
(-10' 0") lb *26150 *26150 *34570 *34570 *29300 19050 19000 12020 13320 8470 9900 6350 (30.4)
-4.5m kg *15200 *15200 *18430 18360 *12410 8780 8700 5520 *5590 3820 7.95
(-15' 0") lb *33510 *33510 *40630 40480 *27360 19360 19180 12170 *12320 8420 (26.1)
-6.0m kg *14890 *14890 *10230 9140
(-20' 0") lb *32830 *32830 *22550 20150

1-18
2) ROBEX 290LC-3
(1) 6.25m(20' 6") boom, 2.1m(6' 11") arm equipped with 1.1m3(CECE heaped) bucket and 810mm(32") triple
grouser shoe.

ş : Rating over-front ş : Rating over-side or 360 degree

Load radius At max. reach


Load point 3.0m(10' 0") 4.5m(15' 0") 6.0m(20' 0") 7.5m(25' 0") Capacity Reach
height
m(ft)
9.0m kg *5170 *5170 6.25
(30' 0") lb *11400 *11400 (21.4)
7.5m kg *5590 *5590 *5140 4530 7.99
(25' 0") lb *12320 *12320 *11330 9990 (26.2)
6.0m kg *5890 *5890 *5730 4880 *5220 3530 8.89
(20' 0") lb *12990 *12990 *12630 10760 *11510 8000 (29.2)
4.5m kg *8630 *8630 *6810 *6810 *6020 4760 *5360 3170 9.41
(15' 0") lb *19030 *19030 *15010 *15010 *13270 10490 *11820 6990 (30.9)
3.0m kg *11280 10020 *8010 6500 *6590 4550 5070 2960 9.64
(10' 0") lb *24870 22090 *17660 14330 *14530 10030 11180 6530 (31.6)
1.5m kg *13110 9350 *9080 6130 *7170 4360 5050 2940 9.58
(5' 0") lb *28900 20610 *20020 13510 *15810 9610 11130 6480 (31.4)
Ground kg *13650 9140 *9730 5910 7290 4220 5330 3100 9.24
line lb *30090 20150 *21450 13030 16070 9300 11750 6830 (30.3)
-1.5m kg *12900 *12900 *13380 9160 *9820 5840 7250 4190 6030 3540 8.59
(-5' 0") lb *28440 *28440 *29500 20190 *21650 12870 15980 9240 13290 7800 (28.2)
-3.0m kg *17110 *17110 *12370 9320 *9190 5940 *6000 4510 7.50
(-10' 0") lb *37720 *37720 *27270 20550 *20260 13100 *13230 9940 (24.6)
-4.5m kg *13840 *13840 *10100 9700
(-15' 0") lb *30510 *30510 *22270 21380

(2) 6.25m(20' 6") boom, 2.5m(8' 2") arm equipped with 1.1m3(CECE heaped) bucket and 810mm(32") triple
grouser shoe.
Load radius At max. reach
Load point 1.5m(5' 0") 3.0m(10' 0") 4.5m(15' 0") 6.0m(20' 0") 7.5m(25' 0") Capacity Reach
height
m(ft)
9.0m kg *4770 *4770 7.04
(30' 0") lb *10520 *10520 (23.1)
7.5m kg *4810 4210 8.40
(25' 0") lb *10600 9280 (27.6)
6.0m kg *5330 5000 *4920 3430 9.25
(20' 0") lb *11750 11020 *10850 7560 (30.3)
4.5m kg *7930 *7930 *6420 *6420 *5730 4850 *5080 3020 9.75
(15' 0") lb *17480 *17480 *14150 *14150 *12630 10690 *11200 6660 (32.0)
3.0m kg *10580 10310 *7670 6630 *6350 4630 4830 2830 9.97
(10' 0") lb *23320 22730 *16910 14620 *14000 10210 10650 6240 (32.7)
1.5m kg *12690 9530 *8840 6220 *7000 4410 4810 2790 9.91
(5' 0") lb *27980 21010 *19490 13710 *15430 9720 10600 6150 (32.5)
Ground kg *13600 9210 *9620 5960 7320 4260 5040 2930 9.59
line lb *29980 20300 *21210 13140 16140 9390 11110 6460 (31.5)
-1.5m kg *13070 *13070 *13590 9160 *9870 5860 7250 4190 5630 3290 8.96
(-5' 0") lb *28810 *28810 *29960 20190 *21760 12920 15980 9240 12410 7250 (29.4)
-3.0m kg *14990 *14990 *18270 *18270 *12810 9280 *9470 5910 *5990 4090 7.94
(-10' 0") lb *33050 *33050 *40280 *40280 *28240 20460 *20880 13030 *13210 9020 (26.0)
-4.5m kg *15310 *15310 *10950 9580 *5550 *5550 6.28
(-15' 0") lb *33750 *33750 *24140 21120 *12240 *12240 (20.6)

1-19
3) ROBEX 290NLC-3
(1) 6.25m(20' 6") boom, 2.1m(6' 11") arm equipped with 1.1m3(CECE heaped) bucket and 810mm(32") triple
grouser shoe.

ş : Rating over-front ş : Rating over-side or 360 degree

Load radius At max. reach


Load point 3.0m(10' 0") 4.5m(15' 0") 6.0m(20' 0") 7.5m(25' 0") Capacity Reach
height
m(ft)
9.0m kg *5170 *5170 6.52
(30' 0") lb *11400 *11400 (21.4)
7.5m kg *5590 *5590 *5140 4000 7.99
(25' 0") lb *12320 *12320 *11330 8820 (26.2)
6.0m kg *5890 *5890 *5730 4300 *5220 3180 8.89
(20' 0") lb *12990 *12990 *12630 9480 *11510 7010 (29.2)
4.5m kg *8630 *8630 *6810 6150 *6020 4180 5190 2760 9.41
(15' 0") lb *19030 *19030 *15010 13560 *13270 9220 11440 6080 (30.9)
3.0m kg *11280 9740 *8010 5710 *6590 39870 4900 2560 9.64
(10' 0") lb *24870 19270 *17660 12590 *14539 8770 10800 5640 (31.6)
1.5m kg *13110 8090 *9080 5340 *7170 3790 4890 2530 9.58
(5' 0") lb *28900 17840 *20020 11770 *15810 8360 10780 5580 (31.4)
Ground kg *13650 7890 *9730 5120 7050 3660 5160 2680 9.24
line lb *30090 17390 *21450 11290 15540 8070 11380 5910 (30.3)
-1.5m kg *12900 *12900 *13380 7900 *9820 5060 7020 3630 5840 3070 8.59
(-5' 0") lb *28440 *28440 *29500 17420 *21650 11160 15480 8000 12870 6770 (28.2)
-3.0m kg *17110 16490 *12370 8060 *9190 5150 *6000 3940 7.50
(-10' 0") lb *37720 36350 *27270 17770 *20260 11350 *13230 8690 (24.6)
-4.5m kg *13840 *13840 *10100 8420
(-15' 0") lb *30510 *30510 *22270 18560

(2) 6.25m(20' 6") boom, 2.5m(8' 2") arm equipped with 1.1m3(CECE heaped) bucket and 600mm(24") triple
grouser shoe.
Load radius At max. reach
Load point 1.5m(5' 0") 3.0m(10' 0") 4.5m(15' 0") 6.0m(20' 0") 7.5m(25' 0") Capacity Reach
height
m(ft)
9.0m kg *4770 *4770 7.04
(30' 0") lb *10520 *10520 (23.1)
7.5m kg *4810 3720 8.40
(25' 0") lb *10600 8200 (27.6)
6.0m kg *5330 4420 *4920 3000 9.25
(20' 0") lb *11750 9740 *10850 6610 (30.3)
4.5m kg *7930 *7930 *6420 6280 *5730 4270 4930 2620 9.75
(15' 0") lb *17480 *17480 *14150 13850 *12630 9410 10870 5780 (32.0)
3.0m kg *10580 9010 *7670 5830 *6350 4059 4670 2440 9.97
(10' 0") lb *23320 19860 *16910 12850 *14000 8950 10300 5380 (32.7)
1.5m kg *12690 8270 *8840 5430 *7000 3840 4650 2400 9.91
(5' 0") lb *27980 18230 *19490 11970 *15430 8470 10250 5290 (32.5)
Ground kg *13600 7960 *9620 5180 7090 3690 4870 2520 9.59
line lb *29980 17550 *21210 11420 15630 8140 10740 5560 (31.5)
-1.5m kg *13070 *13070 *13590 7910 *9870 5080 7020 3630 5450 2850 8.96
(-5' 0") lb *28810 *28810 *29960 17440 *21760 11200 15480 8000 12020 6280 (29.4)
-3.0m kg *14990 *14990 *18270 16330 *12810 8020 *9470 5120 *5990 3570 7.94
(-10' 0") lb *33050 *33050 *40280 36000 *28240 17680 *20880 11290 *13210 7870 (26.0)
-4.5m kg *15310 *15310 *10950 8310 *5550 *5420 6.28
(-15' 0") lb *33750 *33750 *24140 18320 *12240 *11950 (20.6)

1-20
(3) 6.25m(20' 6") boom, 3.05m(10' 0") arm equipped with 1.1m3(CECE heaped) bucket and 600mm(24")
triple grouser shoe.
Load radius At max. reach
Load point 1.5m(5' 0") 3.0m(10' 0") 4.5m(15' 0") 6.0m(20' 0") 7.5m(25' 0") 9.0m(30' 0") Capacity Reach
height
m(ft)
9.0m kg *4230 *4230 7.68
(30' 0") lb *9330 *9330 (25.2)
7.5m kg *4320 3340 8.92
(25' 0") lb *9520 7360 (29.3)
6.0m kg *4770 4490 *4460 2730 9.72
(20' 0") lb *10520 9900 *9830 6020 (31.9)
4.5m kg *5760 *5760 *5220 4310 4560 2390 10.20
(15' 0") lb *12700 *12700 *11510 9500 10050 5270 (33.5)
3.0m kg *9920 *9920 *9490 9240 *7050 5880 *5900 4059 *4520 2900 4320 2220 10.40
(10' 0") lb *21870 *21870 *20920 20370 *15540 12960 *13010 8950 *9960 6390 9520 4890 (34.1)
1.5m kg *11860 8360 *8320 5440 *6620 3820 5360 2770 4290 2170 10.35
(5' 0") lb *26150 18430 *18340 11990 *14590 8420 11820 6110 9460 4780 (34.0)
Ground kg *9240 *9240 *13180 7900 *9260 5120 7030 3630 *4780 2680 4460 2260 10.05
line lb *20370 *20370 *29060 17420 *20410 11290 15500 8000 *10540 5910 9830 4980 (33.0)
-1.5m kg *10010 *10010 *12980 *12980 *13530 7750 *9710 4970 6910 3520 4920 2520 9.45
(-5' 0") lb *22070 *22070 *28620 *28620 *29830 17090 *21410 10960 15230 7760 10850 5560 (31.0)
-3.0m kg *13560 *13560 *17530 15890 *13070 7800 *9560 4960 6930 3540 *5800 3070 8.50
(-10' 0") lb *29890 *29890 *38650 35030 *28810 17200 *21080 10930 15280 7800 *12790 6770 (27.9)
-4.5m kg *17740 *17740 *16770 16340 *11670 8020 *8530 5120 *5790 4370 7.01
(-15' 0") lb *39110 *39110 *36970 36020 *25730 17680 *18810 11290 *12760 9630 (23.0)
-6.0m kg *8360 *8360
(-20' 0") lb *18430 *18430

(4) 6.25m(20' 6") boom, 3.75m(12' 4") arm equipped with 1.1m3(CECE heaped) bucket and 600mm(24")
triple grouser shoe.

Load radius At max. reach


Load point 1.5m(5' 0") 3.0m(10' 0") 4.5m(15' 0") 6.0m(20' 0") 7.5m(25' 0") 9.0m(30' 0") Capacity Reach
height
m(ft)
9.0m kg *3680 *3680 8.54
(30' 0") lb *8110 *8110 (28.0)
7.5m kg *3800 2860 9.65
(25' 0") lb *8380 6310 (31.7)
6.0m kg *4019 *4019 *2620 *2620 *3960 2370 10.39
(20' 0") lb *8860 *8860 *5780 *5780 *8730 5220 (34.1)
4.5m kg *4550 4380 *4080 3050 4090 2090 10.83
(15' 0") lb *10030 9660 *8990 6720 9020 4610 (35.5)
3.0m kg *12940 *12940 *8010 *8010 *6190 6030 *5290 4110 *4810 2910 3880 1940 11.02
(10' 0") lb *28530 *28530 *17660 *17660 *13650 13290 *11660 9060 *10600 6420 8550 4280 (36.2)
1.5m kg *9740 *9740 *10670 8630 *7590 5530 *6090 3840 *5270 2760 3840 1890 10.97
(5' 0") lb *21470 *21470 *23520 19030 *16730 12190 *13430 8470 *11620 6080 8470 4170 (36.0)
Ground kg *9970 *9970 *12480 7980 *8730 5140 *6800 3600 5200 2620 3970 1950 10.69
line lb *21980 *21980 *27510 17590 *19250 11330 *14990 7940 11460 5780 8750 4300 (35.1)
-1.5m kg *8980 *8980 *12330 *12330 *13300 7690 *9430 4910 6840 3450 5120 2540 4320 2140 10.14
(-5' 0") lb *19800 *19800 *27180 *27180 *29320 16950 *20790 10820 15080 7610 11290 5600 9520 4720 (33.3)
-3.0m kg *11860 *11860 *15680 15520 *13290 7630 *9590 4840 6790 3400 5030 2550 9.27
(-10' 0") lb *26150 *26150 *34570 34220 *29300 16820 *21140 10670 14970 7500 11090 5620 (30.4)
-4.5m kg *15200 *15200 *18430 15870 *12410 7770 *9050 4910 *5590 3420 7.95
(-15' 0") lb *33510 *33510 *40630 34990 *27360 17130 *19950 10820 *12320 7540 (26.1)
-6.0m kg *14890 *14890 *10230 8109
(-20' 0") lb *32830 *32830 *22550 17880

1-21
6. BUCKET SELECTION GUIDE
1) ROBEX 290-3

0.7 m3 CECE 0.9 m3 CECE 1.1 m3 CECE 1.3 m3 CECE 1.5 m3 CECE 1.6 m3 CECE
heaped bucket heaped bucket heaped bucket heaped bucket heaped bucket heaped bucket

Capacity Width Recommendation

PCSA CECE Without With Weight 2.10 m Arm 2.50 m Arm 3.05 m Arm 3.75 m Arm
heaped heaped side cutter side cutter (6' 11") (8' 2") (10' 0") (12' 4")

0.79 m3 0.7 m3 890 mm 1010 mm 740 kg


(1.03 yd3) (0.92 yd3) (35") (40") (1631 lb)

1.03 m3 0.9 m3 1090 mm 1210 mm 850 kg


(1.35 yd3) (1.18 yd3) (43") (48") (1874 lb)

1.27 m3 1.1 m3 1290 mm 1410 mm 960 kg


(1.66 yd3) (1.44 yd3) (51") (56") (2116 lb)

1.5 m3 1.3 m3 1490 mm 1610 mm 1020 kg


(1.96 yd3) (1.70 yd3) (59") (63") (2249 lb)

1.73 m3 1.5 m3 1696 mm _ 1120 kg


(2.26 yd3) (1.96 yd3) (67") (2469 lb)

1.85 m3 1.6 m3 1800 mm _ 1160 kg


(2.24 yd3) (2.09 yd3) (71") (2557 lb)

Applicable for materials with density of 2000 kg/m3 (3370 lb/yd3) or less
Applicable for materials with density of 1600 kg/m3 (2700 lb/yd3) or less
Applicable for materials with density of 1100 kg/m3 (1850 lb/yd3) or less

1-22
2) ROBEX 290LC-3, ROBEX 290NLC-3

0.7 m3 CECE 0.9 m3 CECE 1.1 m3 CECE 1.3 m3 CECE 1.5 m3 CECE 1.6 m3 CECE
heaped bucket heaped bucket heaped bucket heaped bucket heaped bucket heaped bucket

Capacity Width Recommendation

PCSA CECE Without With Weight 2.10 m Arm 2.50 m Arm 3.05 m Arm 3.75 m Arm
heaped heaped side cutter side cutter (6' 11") (8' 2") (10' 0") (12' 4")

0.79 m3 0.7 m3 890 mm 1010 mm 740 kg


(1.03 yd3) (0.92 yd3) (35") (40") (1631 lb)

1.03 m3 0.9 m3 1090 mm 1210 mm 850 kg


(1.35 yd3) (1.18 yd3) (43") (48") (1874 lb)

1.27 m3 1.1 m3 1290 mm 1410 mm 960 kg


(1.66 yd3) (1.44 yd3) (51") (56") (2116 lb)

1.5 m3 1.3 m3 1490 mm 1610 mm 1020 kg


(1.96 yd3) (1.70 yd3) (59") (63") (2249 lb)

1.73 m3 1.5 m3 1696 mm _ 1120 kg


(2.26 yd3) (1.96 yd3) (67") (2469 lb)

1.85 m3 1.6 m3 1800 mm _ 1160 kg


(2.24 yd3) (2.09 yd3) (71") (2557 lb)

Applicable for materials with density of 2000 kg/m3 (3370 lb/yd3) or less
Applicable for materials with density of 1600 kg/m3 (2700 lb/yd3) or less
Applicable for materials with density of 1100 kg/m3 (1850 lb/yd3) or less

1-23
7. UNDERCARRIAGE
1) TRACKS
X-leg type center frame is integrally welded with reinforced box-section track frames. The design
includes dry tracks, lubricated rollers, idlers, sprockets, hydraulic track adjusters with shock
absorbing springs, and assembled track-type tractor shoes with triple grousers.

2) TYPES OF SHOES
Triple grouser

Model Shapes

Shoe width mm (in) 600(24) 710 (28) 810 (32) 900 (35)
Operating weight kg (lb) 27500 (60600) 28100 (61900) 28400 (62600) 28700 (63300)
R290-3
Ground pressure kg/cm2 (psi) 0.57 (8.11) 0.49 (6.97) 0.43 (6.12) 0.40 (5.69)
Overall width mm (ftin) 3200 (10' 6") 3310 (10' 10") 3410 (11' 2") 3500 (11' 6")
Shoe width mm (in) 600 (24) 710 (28) 810 (32) 900 (35)
Operating weight kg (lb) 28400 (62600) 28800 (63500) 29100 (64200) 29400 (64800)
R290LC-3
Ground pressure kg/cm2 (psi) 0.54 (7.68) 0.47 (6.68) 0.41 (5.83) 0.37 (5.26)
Overall width mm (ftin) 3200 (10' 6") 3310 (10' 10") 3410 (11' 2") 3500 (11' 6")
Shoe width mm (in) 600 (24) 710 (28) 810 (32) 900 (35)
Operating weight kg (lb) 28000 (61700) 28500 (62800) 28800 (63500) 29100 (64200)
R290NLC-3
Ground pressure kg/cm2 (psi) 0.52 (7.40) 0.44 (6.26) 0.39 (5.55) 0.35 (4.98)
Overall width mm (ftin) 2990 (9' 9") 3100 (10' 2") 3200 (10' 5") 3300 (10' 9")

3) NUMBER OF ROLLERS AND SHOES ON EACH SIDE

Quantity
Item
ROBEX 290LC-3, 290NLC-3 ROBEX 290-3
Carrier rollers 2 EA 2 EA
Track rollers 9 EA 8 EA
Track shoes 51 EA 48 EA

1-24
8. SPECIFICATIONS FOR MAJOR COMPONENTS
1) ENGINE

Item Specification

Model CUMMINS 6CT8.3-C


Type 4-cycle turbocharged, after cooled diesel engine
Cooling method Water cooling
Number of cylinders and arrangement 6 cylinders, in-line
Firing order 1-5-3-6-2-4
Combustion chamber type Direct injection type
Cylinder bore ź stroke 114ź135 mm (4.49"ź5.32")
Piston displacement 8270 cc (505 cu in)
Compression ratio 17.3 : 1
Rated gross horse power 198 Hp at 1900 rpm(148.8kw at 1900 rpm)
Maximum torque at 1500rpm 77.6 kgfşm (567 lbşft)
Engine oil quantity 22.4 ֻ (5.9 U.S. gal)
Dry weight 587 kg (1294 lb)
High idling speed 2050 * 50 rpm
Low idling speed 800 * 100 rpm
Rated fuel consumption 152.6 g/Hpşhr
Starting motor DELCO REMY 37MT(24V)
Alternator DAC HC60(24V-60AMP)
Battery 2ź12Vź160 Ah

2) MAIN PUMP

Item Specification

Type Variable displacement tandem axial piston pump


Capacity 2ź140 cc/rev
Maximum pressure 320 kg/cm2 (4550 psi)
Rated oil flow 2ź260ֻ/min (67.9 U.S. gpm/ 56.5 U.K. gpm)

1-25
3) PILOT PUMP

Item Specification

Type Fixed displacement gear pump single stage


Capacity 10 cc/rev
Maximum pressure 40 kg/cm2 (570 psi)
Rated oil flow 19.5ֻ/min (5.3 U.S. gpm/ 4.4 U.K. gpm)

4) MAIN CONTROL VALVE

Item Specification

Type 7 spool
Operating method Hydraulic pilot assist
Main relief valve pressure 320 kg/cm2 (4550 psi)
Overload relief valve pressure 350 kg/cm2 (4980 psi)

5) SWING MOTOR

Item Specification

Type Fixed displacement axial piston motor


Capacity 169.4 cc/rev
Relief pressure 240 kg/cm2 (3410 psi)
Braking system Automatic, spring applied hydraulic released
Braking torque 70 kgfşm (506 lbşft)
Brake release pressure 26 kg/cm2 (370 psi)
Reduction gear type 2 - stage planetary
Swing speed 10.8 rpm

6) TRAVEL MOTOR

Item Specification

Type Variable displacement axial piston motor


Operating pressure 320 kg/cm2 (4550 psi)
Reduction gear type 3 - stage planetary
Braking system Automatic, spring applied hydraulic released
Brake release pressure 9 kg/cm2 (128 psi)

1-26
7) REMOTE CONTROL VALVE

Item Specification

Type Pressure reducing type


minimum 5 kg /cm2 (71 psi)
Operating pressure
maximum 20 kg /cm2 (284 psi)
lever 61 mm (2.4 in)
Single operation stroke
pedal 123 mm (4.84 in)

8) CYLINDER

Item Specification

Bore diaźRod diaźStroke ‫ٻ‬140ź‫ٻ‬100ź1465 mm


Boom cylinder
Cushion Extend only
Bore diaźRod diaźStroke ‫ٻ‬150ź‫ٻ‬105ź1765 mm
Arm cylinder
Cushion Extend and retract
Bore diaźRod diaź Stroke ‫ٻ‬140ź‫ٻ‬95ź1185 mm
Bucket cylinder
Cushion Extend only

9) SHOE

Item Width Ground pressure Link quantity Overall width

Standard 810 mm (32") 0.43 kg/cm2 (6.12 psi) 48 3410 mm (11' 2")
600 mm (24") 0.57 kg/cm2 (8.11 psi) 48 3200 mm (10' 6")
R 290-3
Option 710 mm (28") 0.49 kg/cm (6.97 psi)
2
48 3310 mm (10' 10")
900 mm (35") 0.40 kg/cm (5.79 psi)
2
48 3500 mm (11' 6")
Standard 810 mm (32") 0.41 kg/cm (5.83 psi)
2
51 3410 mm (11' 2")
600 mm (24") 0.54 kg/cm2 (7.68 psi) 51 3200 mm (10' 6")
R 290LC-3
Option 710 mm (28") 0.47 kg/cm (6.68 psi)
2
51 3310 mm (10' 10")
900 mm (35") 0.37 kg/cm (5.26 psi)
2
51 3500 mm (11' 6")
Standard 600 mm (24") 0.52 kg/cm (7.40 psi)
2
51 2990 mm (9' 9")
710 mm (28") 0.44 kg/cm2 (6.26 psi) 51 3100 mm (10' 2")
R 290NLC-3
Option 810 mm (32") 0.39 kg/cm (5.55 psi)
2
51 3200 mm (10' 5")
900 mm (35") 0.35 kg/cm (4.98 psi)
2
51 3300 mm (10' 9")

1-27
10) BUCKET

Capacity Tooth Width


Item
PCSA heaped CECE heaped quantity Without side cutter With side cutter

Standard 1.27 m3 (1.66 yd3) 1.1 m3 (1.44 yd3) 5 1290 mm (51") 1410 mm (56")
0.79 m (1.03 yd )
3 3
0.7 m (0.92 yd )
3 3
3 890 mm (35") 1010 mm (40")
1.03 m (1.35 yd )
3 3
0.9 m (1.18 yd )
3 3
4 1090 mm (43") 1210 mm (48")
Option 1.50 m3 (1.96 yd3) 1.3 m3 (1.70 yd3) 5 1490 mm (59") 1610 mm (63")
1.73 m (2.26 yd )
3 3
1.5 m (1.96 yd )
3 3
6 1696 mm (67") ӧ
1.85 m (2.42 yd )
3 3
1.6 m (2.09 yd )
3 3
6 1800 mm (71") ӧ

1-28
10. RECOMMENDED OILS

Use only oils listed below or equivalent.


Do not mix different brand oil.

Ambient temperature Ƅ(ŞF)


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

Engine SAE 10W


Engine oil 22.4 (5.9)
oil pan
SAE 10W-30

SAE 15W-40

Swing drive 11 (2.9)


Gear oil SAE 85W-140
7ź2
Final drive (1.8ź2)

Tank; ISO VG 32
270 (71.3)
Hydraulic tank Hydraulic oil ISO VG 46
System;
380 (100.3)
ISO VG 68

ASTM D975 NO. 1


Fuel tank Diesel fuel 450 (118.8)
ASTM D975 NO. 2

NLGI NO. 1
Fitting 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.

1-29
SECTION 2 STRUCTURE AND FUNCTION
GROUP 1 PUMP DEVICE

1. STRUCTURE
The pump device consists of main pump, regulator and gear pump.

Pi1

A3

B3

Dr P1
a4 Pi2
Qmin adjusting screw Qmax adjusting screw Qmax adjusting screw

Regulator Regulator

Pi1 Pi2

Dr
Dr B3

B1
a3

a1 a2
Front pump Port block Rear pump Gear pump

a1 A1 P1 a4 A2 a2 Port Port name Port size

A1,2 Delivery port SAE6000psi 1"


B1 Suction port SAE2500psi 3"
Dr Drain port PF 3/4 - 20
Pi1 Pi2 Power shift port
P1 (For decreasing)
PF 1/4 - 15

Pi1,i2 Pilot port PF 1/4 - 15


M
Dr a3 a1,2,3,4 Gauge port PF 1/4 - 15

B1 B3 A3 A3 Gear pump delivery port PF 1/2 - 19


B3 Gear pump suction port PF 3/4 - 20

2-1
1) MAIN PUMP(1/2)
The main pump consists of two piston pump(front & rear) and valve block.

A
789 532 548 724 792 954
732 214 531 702 534 901 719
535
808
953
886
717
406
261
824

111
774
127
710

123 251 401 211 156 157 313 312 725 314 468 141 152 113
490 212 153 158 114 124 466 885 728 151 271

111 Drive shaft(F) 271 Pump casing 719 O-ring


113 Drive shaft(R) 312 Valve block 724 O-ring
114 Spline 313 Valve plate(R) 725 O-ring
123 Roller bearing 314 Valve plate(L) 726 O-ring
124 Needle bearing 325 Casing 728 O-ring
127 Bearing spacer 401 Hexagon socket bolt 732 O-ring
141 Cylinder block 406 Hexagon socket bolt 774 Oil seal
151 Piston 466 VP Plug 789 Back up ring
152 Shoe 468 VP Plug 792 Back up ring
153 Push plate 490 VP Plug 808 Hexagon head nut
156 Bushing 531 Tilting pin 824 Snap ring
157 Cylinder spring 532 Servo piston 885 Pin
158 Spacer 534 Stopper(L) 886 Spring pin
211 Shoe plate 535 Stopper(S) 901 Eye bolt
212 Swash plate 548 Pin 953 Hexagon socket screw
214 Bushing 702 O-ring 954 Set screw
251 Support plate 710 O-ring
261 Seal cover(F) 717 O-ring

2-2
MAIN PUMP(2/2)

544

542

543

545

541 (079)

725

466
725

325

407
VIEW A

325 Valve casing 542 Spacer 725 O-ring


407 Hexagon socket bolt 543 Stopper 1 (079) Proportional reducing valve
466 Plug 544 Stopper 2
541 Seat 545 Steel ball

2-3
2) REGULATOR(1/2)

412 875 874


755
A
897 858
B
614
612

615
613
A 611
B

A
KR3H-9N29
P2
438 Pf

801 Pi

924

641 730 643 708 644 645 646 728

SECTION B-B B

413 438

438

656
Port name port size
Pi
735 A Delivery port 1"
B Suction port 3"
Pi Pilot port PF 1/4-15
Pf Powershift port PF 1/4-15
P2 Companion delivery port -
496 724 725 436

2-4
REGULATOR(2/2)

734 653 654 836 651 652 601 624 629 630 628
655

641 801

814 925

898

631 627

732

733
732

622

621 623 625 626 887 763 756


SECTION A-A

412 Hexagon socket screw 630 Lock Nut 732 O-ring


413 Hexagon socket screw 631 Sleeve, pf 733 O-ring
436 Hexagon socket screw 641 Pilot cover 734 O-ring
438 Hexagon socket screw 643 Pilot piston 735 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 814 Snap ring
614 Fulcrum plug 653 Spring seat 836 Snap ring
615 Adjust plug 654 Return spring 858 Snap ring
621 Compensator piston 655 Set spring 874 Pin
622 Piston case 656 Block cover 875 Pin
623 Compensator rod 708 O-ring 887 Pin
624 Spring seat(C) 722 O-ring 897 Pin
625 Outer spring 724 O-ring 898 Pin
626 Inner spring 725 O-ring 924 Set screw
627 Adjust stem(C) 727 O-ring 925 Adjust screw(QI)
628 Adjust screw(C) 728 O-ring
629 Cover(C) 730 O-ring

2-5
3) GEAR PUMP

700 354 351 433

434

850
311
312
355
732
307

309
710 435 361 353 310 308 434 466
725

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

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
shoes(151,152), set plate(153), spherical 124
313
bush(156), spacer(158) and cylinder 141
spring(157). The drive shaft is supported 158
151 156
by bearing(123,124) at its both ends. 152 153
The shoe is caulked to the piston to form
111
a spherical coupling. It has a pocket to 157
relieve thrust force generated by loading 123
211
pressure and to 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 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.
531
(2) Swash plate group 548
The swash plate group consists of swash 214
plate(212), shoe plate(211), swash plate
support(251), tilting bush(214), tilting 212
pin(531) and servo piston(532). 251 211
The swash plate is a cylindrical part
formed on the opposite side of the sliding
surface of the shoe and is supported by
the swash support.
532 ҄
If the servo piston moves to the right and
left as hydraulic force controlled by the
regulator is admitted to hydraulic
chamber located on both sides of the ҄
servo piston, the swash plated slides over
the swash plate support via the spherical
part of the tilting pin to change the tilting
angle(ѭ ).

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
ports is fixed to the valve block and feeds 312
and collects oil to and from the cylinder
block. 313
885
The oil changed over by the valve plate is
connected to an external pipeline by way
of the valve block.
Now, if the drive shaft is driven by a prime
mover(electric motor, engine, etc), it
rotates the cylinder block via a spline
linkage at the same time. If the swash
plate is tilted as in Fig(previous page) the
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 press, Pi
uselessly.

2-9
‫ ڸ‬Flow reducing function

643 654 651 652 613 646

P1 CL
B(E)
874
897
C
A

875

611

Servo piston Small diameter


Large diameter D chamber
chamber 548
531

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
‫ ڹ‬Flow increasing function

643 654 651 652 613 646

P1 CL
B(E)
874
897
C

875
611

Small diameter
Servo piston D chamber
Large diameter 548
chamber
531

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
‫ ں‬Adjustment of flow control characteristic
The flow control characteristic can be
adjusted with the adjusting screw.
Adjust it by loosening the hexagon 801
924
nut(801) and by tightening(or loosening)
the hexagonal socket head screw(924).
Tightening the screw shifts the control
chart to the right as shown in the figure.
Ɠ Adjusting values are shown in table.

Adjustment of flow control


characteristic
Speed
Tightening Flow control Flow change
amount of control change

Delivery flow, Q
adjusting starting amount
screw(924) pressure
change
amount

(min -1) (Turn) (kgf/cm2) (֤/min)

1900 +1/4 +2 +16

Pilot press, 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

Delivery flow, Q
with a rise in the delivery pressure P1 of
the self pump and the delivery pressure
P2 of the companion pump.
(The input horsepower is constant when
the speed is constant.)
Since the regulator is of the simul
Delivery press, (P1+P2)
taneous 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 = P1ţq/2ॏ + P2ţq/2ॏ
= (P1+P2)ţq/2ॏ
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
‫ ڸ‬Overload preventive function

621 651 652 623 612 601 625 626

P1 CL
B(E)
897

P2 P1
875

611

Large diameter Servo piston


chamber Small diameter
D chamber

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
‫ ڹ‬Flow reset function

621 651 652 623 612 601 625 626

P1 CL
B(E)
897

P2 P1

875

Large diameter Small diameter


chamber Servo piston D chamber

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
‫ ں‬Low 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(٤4) protruding from the large hole(٤8), only the
lever lessening the tilting angle contacts the pin(897) ; the hole(٤8) 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.
‫ ڻ‬Adjustment of input horsepower
Since the regulator is of total cumulative horsepower type, adjust the adjusting screws of both
the front and rear pumps, when changing the horsepower set values. The pressure change
values by adjustment are based on two pumps pressurized at the same time, and the values will
be doubled when only one pump is loaded.

a. Adjustment of outer spring


Adjust it by loosening the hexagon 625 626 630 628
nut(630) and by tightening(or
loosening) the adjusting screw C(628).
Tightening the screw shifts the control 801
chart to the right and increases the
925
input horsepower as shown in the
figure. Since turning the adjusting
screw C by N turns changes the setting
of the inner spring(626), return the
adjusting screw QI(925) by NţA turns
at first.(A=2.2)
Ɠ Adjusting values are shown in table.

Adjustment of outer spring


Speed
Tightening Compens- Input torque
Delivery flow, Q

amount of ating control change


adjusting starting amount
screw(C) pressure
(924) change
amount

(min -1) (Turn) (kgf/cm2) (kgfňm)

1900 +1/4 +18 +6 Delivery press, (P1+P2)

2-16
b. Adjustment of inner spring
626
Adjust it by loosening the hexagon nut
(801) and by tightening(or loosening)
the adjusting screw QI(925).
801
Tightening the screw increases the flow
and then the input horsepower as
925
shown in the figure.
Ɠ Adjusting valves are shown in table.

Adjustment of outer spring


Speed
Tightening Compens- Input torque
amount of ating control change
adjusting starting amount
screw(QI) pressure
(925) change
amount

Delivery flow, Q
(min -1) (Turn) (kgf/cm2) (kgfňm)

1900 +1/4 +18 +4

Delivery press, (P1+P2)

2-17
(3) Power shift control

621 651 652 623 612 625 626

898 P1 CL
B(E)
897

Pf
P2 P1
875

611

Large diameter Small diameter


chamber Servo piston D chamber

The set horsepower valve is shifted by


varying the command current level of
the proportional pressure reducing valve
Delivery flow, Q

attached to the pump.


Only one proportional pressure reducing Pf=
valve is provided. MIN
Pf= .
However, the secondary pressure Pf MA
X.
(power shift pressure) is admitted to the
horsepower control section of each
pump regulator through the pump's Delivery press, (P1+P2)
internal path to shift it to the same set
horsepower level.
This function permits arbitrary setting of the pump output power, thereby providing the optimum
power level according to the operating condition.
The power shift pressure Pf controls the set horsepower of the pump to a desired level, as
shown in the figure.
As the power shift pressure Pf rises, the compensating rod(623) moves to the right via the
pin(898) and compensating piston(621).
This decreases the pump tilting angle and then the set horsepower in the same way as
explained in the overload preventive function of the hosepower control. On the contrary, the
set horsepower rises as the power shift pressure Pf falls.

2-18
(4) Adjustment of maximum and minimum flows
‫ ڸ‬Adjustment of maximum flow 808
Adjust it by loosening the hexagon
954
nut(808) and by tightening(or loosening)
the set screw(954).
The maximum flow only is adjusted
without changing other control
characteristics.

Adjustment of outer spring


Speed

Delivery flow, Q
Tightening amount Flow change
of adjusting screw amount
(953)

(min -1) (Turn) (֤/min)

1900 +1/4 -6 Delivery press, Pi

‫ ڹ‬Adjustment of minimum flow


Adjust it by loosening the hexagon
nut(808) and by tightening(or loosening)
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
much, the required horsepower during
the maximum delivery pressure(or during
relieving) may increase.

Adjustment of outer spring


Speed
Delivery flow, Q

Tightening amount Flow change


of adjusting screw amount
(953)

(min -1) (Turn) (֤/min)

1900 +1/4 +6 Delivery press, Pi

2-19
GROUP 2 MAIN CONTROL VALVE
9
1. STRUCTURE 2

8 7
6
1 Plunger
2 Logic check assy
3 Check assy
4 Load check assy Section J-J
5 Orifice assy Section B-B Section F-F
6 Check valve assy
7 Foot relief assy
8 Selector valve assy
9 Logic valve assy
1
10 Relief assy
TR
11 Option port
TL OPT

AM BKT

SW BM

2
Section A-A Section E-E

4 3 3 4
A E
10 10
11

F F
OPT
B B
Section H-H
C H

5 C H 5
10
10

D D

A E

Section D-D

2-20
STRUCTURE

42
39

39 80
52
6 53
2 39 41
17 3
7 46 9 57 13
2728 58 14
11 47
26 8 59
4 29
25 11 32
23 4 30
2728 25
33
31
51 30
23
5049
9
10

40
18 39
34
35
14
13
39 54 56
42
79

39
80

2 Back up ring 26 Check 47 Spring washer


3 O-ring 27 Back up ring 49 Cap
4 Spring 28 O-ring 50 O-ring
6 Cap 29 Cover 51 Cap
7 Spring 30 Spring guide 52 Cap
8 Poppet 31 Spring 53 O-ring
9 O-ring 32 Plunger cap 54 Plunger
10 Port relief valve 33 O-ring 56 Housing
11 Nylon chip 34 Retainer 57 Cap
13 Bolt 35 O-ring 58 Spring
14 Spring washer 39 O-ring 59 Spool
17 Cap 40 Cap 79 Plunger
18 Plunger 41 Main relief 80 Port relief
23 Cap 42 Port relief
25 Check 46 Bolt

2-21
STRUCTURE

64
49
50 55 62
60
55
48
47
60 55
50
49
61 55
55 60

75
74 63
73
61
55
78
65
66 47
76
68 48
69 77
67
71
70
39
72

39 O-ring 63 O-ring 72 Cap


47 Spring washer 64 Orifice 73 Plug
48 Bolt 65 Check 74 Spring
49 Cap 66 Spring 75 Check
50 O-ring 67 Spring 76 Back up ring
55 O-ring 68 O-ring 77 Spring
60 O-ring 69 Sleeve 78 Poppet
61 O-ring 70 O-ring
62 Manifold 71 Piston

2-22
STRUCTURE

13
1 29 14
2
3
47 81 32
46 11
30 1615
33 13
30 31 14
12
4 32 29
5 30
33
30 31
9 42 40
39 39
10 8 37 38
7 3 36
2
6
25
18 4 26
19 11
35 28
34 27 17
20 25
14 4 11
13 53 49 28
39 27
50 23 22
52
21 45 3
1516 40 39 44
42 43 2
38
39 24
40 36
37

39
41

1 Cap 19 Plunger 37 Back up ring


2 Back up ring 20 Plunger 38 Plug
3 O-ring 21 Plunger 39 O-ring
4 Spring 22 Plunger 40 Cap
5 Check 23 Cap 41 Main relief
6 Cap 24 Cap 42 Port relief
7 Spring 25 Check 43 Bolt
8 Poppet 26 Check 44 Plunger
9 O-ring 27 Back up ring 45 O-ring
10 Port relief 28 O-ring 46 Bolt
11 Nylon chip 29 Cover 47 Spring washer
12 Housing 30 Spring guide 49 Cap
13 Bolt 31 Spring 50 O-ring
14 Spring washer 32 Plunger cap 52 Cap
15 Cap 33 O-ring 53 O-ring
16 O-ring 34 Retainer 81 Check
17 Cap 35 O-ring
18 Plunger 36 O-ring

2-23
2. FUNCTION
1) HYDRAULIC CIRCUIT DIAGRAM

Pi P3 a fr

A7
B7
b7
a7
A6
B3 B6
A3
a3 b6
a6
b3
B2 A5
A2 B5
a2 a5
b5
b2 A4
B1
A1 B4
a1 b4
b1 a4
c

Rs c a R b P3

2-24
2) BASIC OPERATION
(1) Neutral circuit
Oil discharged from P1 flows in from
control valve's entrance port PL and
goes through center bypass passages
of each plunger to reach the end of the Logic valve assembly
stream.
Foot relief assembly
Logic valve assembly and foot relief
assembly are installed between the end
of the stream and the tank passage. FR
FL
In neutral, the logic valve assembly is in
unload status; the foot relief assembly
onloads and sends signal F L to the
pump, minimizing the flow of P1 pump.
Oil discharged from pump P2 flow as
above, minimizing the flow of the P2
TR
pump.
TL OPT

AM BKT

SW BM

PL P1 P2
PR
FR PP
FL

P1 P2

2-25
(2) Bucket operation circuit
Oil from pump P2 is fed into cylinder port
A R5 by adding pressure to bucket
plunger pilot port ar5 and the oil from
actuator flow tank through cylinder port
BR5.
At this time, center bypass passage is Foot relief assembly
closed, pressure signal FR from foot
relief valve become low, the actuator is
FR
operated at maximum output power by FL
maximum discharge of pump.
The P1 pump is in unload status.

TR

TL OPT

AM BKT

SW BM

AR5
BR5

br5 ar5
BKT
BKT

PL P1 P2
PR
FR PP

FL

P1 P2

2-26
(3) Arm flow summation circuit

Oil from pump P1 is feed into cylinder


port B L2 by adding pressure to arm
plunger pilot port bl2.
Logic valve assembly
Oil from pump P2 flow into the logic
valve assembly via center bypass Check
passage, but since the pilot passage of
logic valve assembly is blocked by the
shift of arm plunger, the logic valve is FR
FL
closed then the check is opened; oil flow
into the high pressure feed passage via
Manifold
manifold and joins to the flow from the
pump P1.

TR

TL OPT

AM BKT

SW BM

AL2 BL2

al2 bl2

AM AM

PL P1 P2 PR
FR PP
FL
P1 P2

2-27
(4) Boom up flow summation circuit

Oil from pump P2 is fed into cylinder port


BR4 by adding pressure to boom plunger
pilot port br4.
Oil from pump P1 flow into the logic Logic valve assembly
valve assembly via center bypass, but
since the pilot passage of logic valve
assembly is blocked by shift of boom
plunger, the logic valve is closed. FR
FL
At same time, boom up signal works on
the logic check assembly(C port), and
the logic check assembly is opened; oil Manifold
flow from the center bypass passage(the
swing section base) through logic check
assembly into the boom high pressure
feed passage and joins to the flow from TR
the pump P2.
TL OPT

AM BKT

SW BM

BR4 AR4

ar4
br4
SW Logic check assembly BM

BM

PL P1 P2 PR
FR PP
FL
P1 P2

2-28
(5) Boom down flow circuit

Oil from pump P2 is fed into cylinder port


AR4 by adding pressure to boom plunger
pilot port ar4.
Logic valve assembly
In case of boom down operation, high
pressure oil flow into parallel feed
passage, but the pilot pressure signal of
boom plunger is not applied, the logic
check assembly is closed, the passage FR
FL
is blocked.
Oil from pump P1 flow into logic check
assembly through center bypass Manifold
passage, the pilot passage of logic valve
assembly is closed by shift of boom
plunger, the P1 pump is in unload status.
TR

TL OPT

AM BKT

SW BM

BR4 AR4

br4
ar4
Logic check assembly BM

BM

PL P1 P2 PR
FR PP
FL
P1 P2

2-29
(6) Swing priority circuit

Oil from pump P1 is fed into cylinder port


AL1 by adding pressure to swing plunger
pilot port al1. Logic valve assembly

In case of simultaneous operation of


swing and arm, the delivery oil from P1 Check
for swing is also supplied to arm cylinder
port AL2 via the orifice and through the FR
parallel feed passage, FL
This orifice ensures swing drive pressure
in case of low arm load. Manifold

Oil from pump P2 flow into the logic valve


assembly via the center bypass
passage, but since the pilot passage of
logic valve assembly is blocked by shift TR
of arm plunger, the logic valve is closed;
TL OPT
oil flows into the high pressure feed
passage via manifold and joins to the AM BKT
flow from the pump P1.
SW BM
al1 bl1

AL2 BL2

AM al2 bl2

AM

SW

PL P1 P2 PR
FR
PP
Parallel FL
P1 P2 feed passage

Orifice

2-30
(7) Travel priority circuit

This circuit keeps straight travel in case of simultaneous


operation of other actuators(SW, AM, BKT, BM) during a straight
travel.
‫ ڸ‬During straight travel by operating left/right travel plunger(TL, Pi1
Selector valve assembly
TR): Oil from pump P1 is fed into cylinder port BL3 by the
operation of TL plunger.
Oil from pump P2 is fed into cylinder port BR7 by the
operation of TR plunger.
Thus, straight travel is performed separately with pump P1 FR
FL
driving rightward travel(TL) and pump P2 driving leftward
travel(TR)
‫ ڹ‬In case of a swing operation during straight travel for
instance: At the beginning of swing plunger stroke the pilot
signal line inside the control valve is blocked and the signal
pressure makes the connection between the feed passages
of right and left travel plungers(TL, TR) by switching selector TR
valve(Pi1 port). When the swing plunger is completely TL OPT
switched, oil discharged from pump P1 preferentially flows
into swing motor which is positioned upstream. AM BKT
Thus, simultaneous operation of swing and straight travel is
SW BM
made possible as oil from pump P1 is fed to swing and oil
al1 bl1
from pump P2 is fed to right travel(TR) and left travel(TL).
The orifice at the upstream of the parallel feed passage
sends surplus oil of swing to right and left travel(TL, TR) to
avoid abrupt change of the machine speed.
The basic operation is same with swing even in the case of other
actuators on upper frame of machine during straight travel.
Pilot pressure line
Pi1 AL3 BL3
BR7 AR7

TR

al3 bl3 ar7


br7
TL TL TR

PL P1 P2 PR
FR
PP
To pi1 port
SW Parallel FL
feed passage

Orifice

P1 P2

2-31
3) OPERATIONAL DESCRIPTION OF CONTROL VALVE
(1) Plunger operation
‫ ڸ‬Neutral position of plunger

Parallel feed passage


Load check valve
Cylinder port B Cylinder port A

Port relief valve


Port relief valve assy

C1 C2

Pilot port a

Pilot port b

Spring
Low pressure
passage Center bypass Low pressure
High pressure feed passage
passage

In neutral, spring sets the plunger at the neutral position; the high pressure feed passage is shut
off by the plunger; oil from the pump flows through the center bypass.

2-32
‫ ڹ‬Operation of plunger

Parallel feed passage


Load check valve Cylinder port A
Cylinder port B

Port relief valve assy


Port relief valve assy

C2
C1
Pilot port a

Pilot port b

Spring
Low pressure Center bypass
passage
High pressure Low pressure
feed passage passage

When actuated(pressure is applied to pilot port a), the plunger moves to the left; the center
bypass is shut off; oil from the center bypass pushes up the check valve C1 and flows into
cylinder port A via the high pressure feed passage. Meanwhile, oil from the parallel feed
passage pushes down check valve C2 and flows into cylinder port A via the high pressure feed
passage.
The return oil from cylinder port B flows into the tank via the low pressure feed passage.
Ɠ Reversed when pressure is applied to pilot port b.

2-33
(2) Foot relief valve operation
‫ ڸ‬fp is lower than spring force

C D E Spring

fp
From logic valve

A B
Pressure signal
To low pressure Cartridge sent out to the pump
passage

Oil from the logic valve flows into the tank via passage(A), orifice(B) of poppet.
Pressure fp generated by orifice(B) is led to the pump via hole(C), passage(D) and hole(E), to
control the pump delivery flow.

‫ ڹ‬fp is higher than spring force

C D E Spring

fp
From logic valve

A B
Pressure signal
To low pressure Cartridge sent out to the pump
passage

If a large amount flows due to delayed pump response, etc., and pressure fp reaches the preset
spring force, then the poppet is lifted and functions as a relief valve.

2-34
(3) Selector valve operation
‫ ڸ‬Straight travel signal : ON

B A From high pressure feed passage for


travel of the companion valve

To high pressure feed


Low pressure passage for travel Travel straight signal
passage passage

If any actuator is operated when traveling, travel straight signal pressure reaches a spring force,
the spool(A) moves to the left the high pressure passage for travel of the companion valve(TL)
and the high pressure passage for travel(TR) are connected, and equal amount of oil flows to TR
and TL.

‫ ڹ‬Straight travel signal : OFF

B A From high pressure feed passage for


travel of the companion valve

To high pressure feed


Low pressure passage for travel Travel straight signal
passage passage

The spring sets spool in position; which shuts off the high pressure feed passages of TR and TL.

2-35
(4) Logic check valve operation
‫ ڸ‬Boom down or neutral
when boom up pilot pressure is not supplied to Pi port

From center bypass passage


of 3 plunger side
1 A B
a

d2
d1

Pi
Manifold

Boom up
pilot signal

b
Orifice c
E D To boom high pressure feed
passage of 4 plunger side

Spring force sets piston (c) in the shown position;


Pressure in the passage a (Pa) enters chamber (1) via passage (A).
Pressure in the passage b (Pb) enters chamber (1) via orifice and passage (D).

If Pa > Pb
Poppet (E) is moved to left by the force of Pa(d2 - d1), because d1<d2 and passage from a to b is
blocked.

If Pa < Pb
Passage from b to a is blocked by the check valve (B). also, passage from b to a is blocked by
d1<d2 and Pa<Pb.

2-36
‫ ڹ‬Boom up
When boom up pilot pressure is supplied to Pi port
Piston (c) moves to left; passage (A) is shut off.
When Pa > Pb

From center bypass passage


of 3 plunger side
1 A B
a

d2
d1

Pi
Manifold

Boom up
pilot signal
b
Orifice c
E D To boom high pressure feed
passage of 4 plunger side

The pressure of chamber(1) is equal to pressure Pb; poppet (E) is lifted; oil flows through from a
to b.
When Pa < Pb

From center bypass passage


of 3 plunger side
1 A B
a

d2
d1

Pi
Manifold

Boom up
pilot signal
b
c
Orifice E D To boom high pressure feed
passage of 4 plunger side

Oil of chamber(1) is shut off; passage b to a is blocked.

2-37
(5) Overload relief valve operation
‫ ڸ‬Overload working operation

3
1 2 A B

d3 d1 K d2 d4

Cylinder port

J H G Low pressure E D C
passage tank F

Hydraulic oil from cylinder port enters chamber (2) via orifice (J) of piston (H). Because d1<d2
and d3 <d4, poppets (G) and (F) are securely seated.

3
1 2 A B

Cylinder port

J H G Low pressure F D C
passage tank E

When hydraulic pressure reaches the preset force of spring (B), poppet (A) opens; oil flows around
poppet (A) and into the low pressure passage via side hole (C) and passage (E).

2-38
3
1 2 A B

Cylinder port

Low pressure E D C
J H G passage tank F

Oil flow is formed; pressure drops before and behind orifice (J); piston (H) moves to right and
seats at the tip of poppet (A).

3
1 2
A B

Cylinder port

Low pressure E D C
J H G passage tank F

Hydraulic oil from chamber (1) enters chamber (2) via throttle (K) at the tip of poppet (A); it flows
around poppet (A) and into the low pressure passage via side hole (C) and passage (E).
Pressure drops before and behind throttle (K), making pressure of chamber (1) x area
d1 >pressure of chamber (2) x area d2; poppet (G) is lifted and hydraulic oil flows into the low
pressure passage.

2-39
‫ ڹ‬Make up operation

3
1 2 A B

d3 d1 K d2 d4

Cylinder port

J H G Low pressure E D C
passage tank F

Poppet (F) is securely seated because the cylinder port pressure is normally higher than the
tank pressure and d3 <d4.

3
1 2 A B

Cylinder port

J H G Low pressure F E D C
passage tank

When the cylinder port pressure drops(closer to negative pressure) until the cylinder port
pressure is lower than the tank pressure, poppet (F) opens receiving the tank pressure for the
difference in area between d3 and d4; oil flows from the tank passage to the cylinder port in order
to prevent cavitation.

2-40
(6) Logic valve
‫ ڸ‬Pilot port : Release
Oil from center by pass flow into pilot port via orifice of poppet(A).
Oil flow is formed;pressure drops before and behind orifice, making pressure of chamber(1)ó
pressure of chamber(2); poppet(A) is lifted and oil flows into foot relief valve.

Pilot port

To foot relief valve


Orifice

1
From center bypass

‫ ڹ‬Pilot port : Block


Oil flow of pilot port is blocked; making pressure of chamber(1) = chamber(2), but the poppet(A)
is return by spring force and oil flows into foot relief valve is blocked.

Pilot port

To foot relief valve

Orifice
1
From center bypass

2-41
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.

Relief valve
A B MU

A, B

P3
SH Dr
Reduction gear Swing motor Time delay valve

SH
Port Port name Port size

P3 A Main port SAE 3/4"


B Main port SAE 3/4"
Dr Drain port PF 1/2
MU Make up port PF 1
Dr
SH Brake release port PF 1/4
P3 Stand by port PF 1/4

A MU B

2-42
1) SWING MOTOR

993 117 121 118 114 706 707 702 712 472 488 355 351 469 051

106
438
432 444
106 A 303
443
471 A
304

101
491
437
124
468
487
433
401
301 994 122 123 113 116 111 742 743 031 131 451

464 485

Section A-A

101 Drive shaft 304 Front cover 485 O-ring


106 Spacer 351 Plunger 487 O-ring
111 Cylinder block 355 Spring 488 O-ring
113 Retainer 401 Hex socket screw 491 Oil seal
114 Cylinder spring 432 Snap ring 702 Brake piston
116 Push rod 433 Snap ring 706 O-ring
117 Spacer F 437 Snap ring 707 O-ring
118 Spacer R 438 Snap ring 712 Brake piston
121 Piston 443 Roller bearing 742 Friction plate
122 Shoe 444 Roller bearing 743 Separator plate
123 Return plate 451 Pin 993 Plug
124 Swash plate 468 VP plug 994 Plug
131 Balance plate 469 RO plug 051 Relief valve
301 Casing A 471 O-ring 031 Time delay valve
303 Valve casing A 472 O-ring

2-43
2) REDUCTION GEAR

351 202 103 402 915 209 802

102

401
231 312 311
801
911

201
288
211

287
912
286

204 285

403
284
210
282

283 901 910 702

902 203 701

102 Front casing 283 Thrust washer 403 Needle gauge


103 Middle casing 284 Thrust button 701 Hex socket bolt
201 Shaft 285 Pin1 702 Hex socket bolt
202 Ring gear 2 286 Side plate 801 Oil seal
203 Planetary gear 2 287 Side plate 802 O - ring
204 Sun gear 2 288 Side plate 901 Spring pin
209 Ring gear 1 311 Level bar 902 plug
210 Planetary gear 1 312 Pipe 910 Spring pin
211 Sun gear 1 351 Lock pin 911 Stop ring
231 Carrier 401 Roller bearing 912 Stop ring
282 Pin 402 Roller bearing 915 Stop ring

2-44
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 cylinder 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
direction of oil flow is reversed, rotational direction of cylinder is also reversed. Output torque is
given by the equation.
pźq F
T= , q=ZňAňPCDňtanѴ , F1= , F2=F tanҋ, S=PCDźtanҋ
2० COSѴ
Where p : Effective difference of pressure(kgf/cm2)
q : Displacement(cc/rev)
T : Output torque(kgfňcm)
Z : Piston number
A : Piston area(cm2)
ҋ: Tilting angle of swash plate(degree)
S : Piston stroke(cm)

Low High
pressure oil pressure oil

F1 F2

131

124 123 121 111

2-45
2) MAKE UP VALVE
In the system using this type of motor, there is no counter balance functioning valve and there
happens the case of revolution exceeding hydraulic supply of motor. To prevent the cavitation
caused by insufficient oil flow there is a make up valve to fill up the oil insufficiency.
A make up valve is provided immediately before the port leading to the hydraulic oil tank to secure
feed pressure required when the hydraulic motor makes a pumping action. The boost pressure
acts on the hydraulic motor's feed port via the make up valve.
Pressurized oil into the port B, the motor rotate counterclockwise.
If the plunger of MCV moves neutral position, the drain oil from Mu port run into motor via right
make up valve, which prevent the cavitation of motor.

A B

MU

2-46
3) RELIEF VALVE

1 Body
2 Seat
3 Plunger
1 4 Spring
5 Rod
8 6 Piston
8 Spring seat
9
9 Shim
6

4
3

(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=pressure, T=time
P
on the relief valve is related to its rising
process. Here is given the function,
PS
referring to the figure following page.
4
P2

3
P1

T
1

2-47
‫ ڸ‬Ports (P, R) at tank pressure.

g n h 5 3 m

6 A2 4 1 A1

‫ ڹ‬When hydraulic oil pressure(PźA1) reaches the preset force(FSP) of spring(4), the plunger(3)
moves to the left as shown. Also the oil flow chamber g via orifice m and n.
P1źA1=FSP+PgźA2
FSP+PgźA2
P1 =
A1

g n 4 m

P=P1

2-48
‫ ں‬When the pressure of chamber g reaches the preset force(FSP) of spring(4), the piston(6) moves
right and stop the piston(6) hits the end of body(1).

g n 4 m

P=P2

‫ ڻ‬When piston(6) hits the end of body(1), it stops moving to the right any further. As the result, the
pressure in chamber g equals PS .
PS źA1=FSP+PsźA2
FSP
PS =
A1-A2

P=PS

2-49
4) BRAKE SYSTEM
(1) Control valve swing brake system
This is the brake system to stop the swing motion of the excavator for during operation.
In this system, the hydraulic circuit is throttled by the swing control valve, and the resistance
created by this throttling works as a brake force to slow down the swing motion.

Work Deceleration Stop

A B A B A B

MCV MCV MCV

MCV A, B opened MCV A, B throttled MCV A, B closed

(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.
‫ ڸ‬Brake assembly
Circumferential rotation of separate
plate(743) is constrained by the groove
located at casing (301). When casing is
pressed down by brake spring(702)
through friction plate(742), separate
plate(743) and brake piston(702), friction 16
force occurs there.
12
Cylinder(111) is constrained by this
friction force and brake acts, while brake 11
releases when hydraulic force exceeds 10
spring force. 25 Groove
26

111 Cylinder 712 Brake spring


301 Casing 742 Disc
702 Brake piston 743 Separate plate

2-50
‫ ڹ‬Operating principle
a. When the swing control lever(1) is set to the swing position, the pilot oil go to the swing control
valve(2) and to SH of the time delay valve(3) via the shuttle valve(4), this pressure shift time
delay valve so, pilot pump charged oil(P3) go to the chamber G.
This pressure is applied to move the piston(6) to the upward against the force of the spring(9)
thus releasing the brake force.

712
G SH
702

1 Swing control lever


2 Swing control valve(MCV)
3 Time delay valve 5
4 Shuttle valve P3
5 Pilot pump
702 Brake piston
2 2
712 Brake spring
4

2-51
b. When the swing control(1) lever is set the neutral position, the time delay valve(3) shifts the
neutral position and the pilot oil blocked chamber G.
Then, the piston(6) is moved lower by spring force and the return oil from the chamber G is
drain.

712
G SH
702

1 Swing control lever


2 Swing control valve(MCV)
3 Time delay valve 12
4 Shuttle valve P3
12 Pilot pump
702 Brake piston
2 2
712 Brake spring
4

1 Swing control lever


2 Swing control valve(MCV)
3 Time delay valve
4 Shuttle valve

2-52
GROUP 4 TRAVEL DEVICE

1. CONSTRUCTION
Travel device consists travel motor and gear box.
Travel motor include counter balance valve, cross over relief valve.

Am A N B Bm

Dr Dr

Pi
Pi Pi

View A

Dr

Port Port name Port size


Pi
A Main port SAE 6000 psi
B Main port SAE 6000 psi
N Pi Gauge port PF 1/2
Am Bm
Dr Drain port PF 1
Negative brake
N release port PF 1/4
A B

2-53
1) TRAVEL MOTOR(1/2)

111 742 741 709 707 702 708 461 545 547 472 705 461 303
121
568
123
567
122
116
131
202
452 568
113 567
272
107 464
485
101

491 103
304 451
435 507
471
102 506
105 505
506 511
507
504
510
509 461 501 114 201 502 503 508 512 546 509 461 533 531 572 571

101 Drive shaft 304 Seal cover 510 Back up ring


102 Roller bearing 435 Snap ring 511 O-ring
103 Needle bearing 451 Pin 2 512 Back up ring
106 Bearing spacer 452 Pin 1 531 Tilting spool
107 Snap ring 461 Plug 533 Tilting spring
111 Cylinder block 471 O-ring 545 Orifice
113 Spherical bushing 472 O-ring 546 Orifice
114 Cylinder spring 491 Oil seal 547 O-ring
116 Spacer 501 Tilting piston 571 Plug
121 Piston 502 Tilting piston 1 572 O-ring
122 Shoe 503 Stopper 705 Brake piston
123 Set plate 504 Stopper S 707 Piston ring 252
131 Valve plate 505 Tilting rod 708 Piston ring 278
201 Swash plate 506 Hex socket screw 709 Center pin
202 Swash plate support 507 Nu 741 Separator plate
272 Casing A 508 O-ring 742 Friction plate
303 Valve casing 509 O-ring

2-54
TRAVEL MOTOR(2/2)

362 022 361 402

366
364

365
711 712

485 713
464
710

350
E
714

702
Section E- E
E

401
567
568

541 543 542 567 568

022 C/B Spool sub assy 402 Hex socket screw 568 O - ring
350 Relief valve 464 VP plug 702 Brake piston
361 Washer 485 O - ring 710 Spring guide
362 C/B spring 541 Seat 711 Spool
364 C/B cover 542 Stopper 712 Bushing
365 O - ring 543 Steel ball 713 Spring
366 Hex socket screw 567 VP plug 714 RO plug
401 Hex socket screw

2-55
2) REDUCTION GEAR

30 6 27 7 1 31

4
26
46
11
5
45
10
24
32

42
9
25
12
21
15
44
19
18
36
32
16

20 41 22 13 20 36 17 14 23 20 37 8 35 33 2 29 34

1 Ring gear 16 Pin 2 31 Hex screw


2 Housing 17 Pin 3 32 Plug
4 Side cover 18 Side plate 33 Angular bearing
5 Carrier 1 19 Side plate 34 Floating seal
6 Carrier 2 20 Side plate 35 Shim
7 Carrier 3 21 Needle case 36 Spring pin
8 Bearing retainer 22 Needle case 37 Spring pin
9 Sun gear 1 23 Needle case 41 Set screw
10 Sun gear 2 24 Thrust ring 42 Shim
11 Sun gear 3 25 Thrust ring 44 Snap ring
12 Planetary gear 1 26 Thrust ring 45 Clip
13 Planetary gear 2 27 Shim 46 W clip
14 Planetary gear 3 29 Hex socket screw
15 Pin 1 30 Hex socket screw

2-56
2. FUNCTION
1) ROTARY GROUP

Y
111 A 121

wi

ri F P
fi
wi
Ni

Shaft

Y
High pressure Low pressure

The high pressure oil sent by the hydraulic pump passes through the valve casing (303) and valve
plate(131) and is led into the cylinder block(111).
The motor has such construction that the above high pressure oil is led only to the cylinders on one
side in respect to the line Y-Y which connects the upper and lower dead points of the stroke of the
pistons(121).
The high pressure oil works on the piston(121) to push the swash plate with the force fi(fi = PźA,
where P : supply pressure, and A : pressure receiving area), and the force Fi is generated as its
reaction force. This Fi is divided by the swash plate(201) having a tilting angle ҋinto the thrust
component Ni and radial one Wi.
The Wi generates a torque Ti = Wi ź ri in respect to the line Y-Y.

The torque generated by each piston on the high pressure side is summed up into a resultant
torqueȐ(riźWi), which produces torque for rotation.
This torque gives a rotating force to the cylinder block(111) through the pistons.
Since the cylinder block is spline-coupled with the shaft, the rotating force is transmitted to the shaft
accordingly.

2-57
2) COUNTERBALANCE VALVE

Am P Bm

L K

H Cv Cm
Dv

2'
1'

Av Bv

F G' Dm D' C' G E 1 M

Port Bv is connected to the hydraulic pump and Port Av, to the tank. The oil supplied from the
hydraulic pump passes through Bv, Cv and C' in sequence, pushes up the poppet of the check
valve, passes through K to Port Bm, and is supplied to the hydraulic motor to turn it.
Therefore, the pump discharge oil pressure increases, and the pressure is led via passage G to
spring room E and via the ball check valve to dumping room M. When the pressure in rooms E
and M exceeds the value equivalent to the force of the spring which holds the spool at its neutral
position, the spool begins to move left. Since the working oil in room N flows into room F via orifice
1' or clearance 2' and that in room F is discharged via passage G' through port Av to the tank, the
spool moves left to have passage L-Dm-D'-Dv composed. In addition, passage Cv-H-P is also
composed, and the pump discharge pressure in port Bv is led to port P.
Because of the orifice or clearance provided for the working oil flow from room N, this changeover
motion of the spool is comparatively slow.
When the pump discharge pressure is higher, the spool movement is larger and the above opening
area of the spool is larger.
When the pump discharge pressure falls, pressures in rooms E and M fall and the spool will move
right due to the spring on the room F side.
Since working oil in room M flows to room E via orifice 1 and that in room E, to port Bv via passage
G, the spool moves right.
When the pressure at port Bv falls down to the tank pressure, the pressure in room E also falls to
the tank pressure and becomes equal to that in room F, and so the spool returns to its neutral
position.

2-58
3) DISPLACEMENT CHANGEOVER SECTION
As a supporting mechanism for the swash plate (201) on which the shoes (122) slide, the pillar
system is adopted to support the load with semi-cylindrical sliding bearings provided at both ends of
the mechanism.
The capacity is changed by changing the tilting angle of this swash plate.
This is a mechanism that has the tilting angle pistons arranged opposed to each other with the
swash plate inserted in between, and the tilting angle of the swash plate is decided in two positions
(Large and Small) by controlling the flows to and from these piston rooms with the displacement
changeover valve section.
(1) External pilot pressure : Pi = 0 Large displacement

Room B
Room A
External pilot pressure
Pi=0
Sb
B

A Sa

504 501 201 501 503 Drain P

531 571
533
High
pressure oil
High pressure
High pressure wotking oil
selector valve

By means of the built-in high pressure selector mechanism in the valve casing (303), the high
pressure oil working on the motor functions to port P of the displacement-changeover valve. This
pressure becomes the servo pressure. Since the spool (531) assembled in the displacement
changeover valve is pressed to plug (571) by thy spring (533), the high pressure oil at port P flows
to port Sa.
This high pressure oil flows from port Sa through the oil passage (passage A) in the valve casing
and casing (272) and works to room A.
The oil in room B flows through passage B and port Sb into the drain line.
With high pressure applied, the displacement-changeover piston (501) is pushed right and the
swash plate (201) moves in the arrowed direction around rotation center O. The swash plate
moves until it touches stopper L (503), and then is fixed there.

2-59
(2) External pilot pressure : Pi ն 20kgf/cm2 small displacement

Room B
Room A
External pilot pressure
Pi ն20kgf.cm2
B Sb

A Sa

504 501 201 501 503 Drain P

531 571
533
High
pressure oil
High pressure
wotking oil
High pressure
selector valve

The force working on the spool (531) of the displacement-changeover valve becomes higher than
that of the spring (533), and the spool moves left. The high pressure oil flows from port P of the
displacement-changeover valve through port Sb and passage B to room B where it works.
The oil in room A flows through passage A and port Sa into the drain line.
The displacement piston (501) is pushed left by the high pressure oil and the swash plate moves
in the arrowed direction. The swash plate moves until it touched stopper S (504), and then is
fixed there.

2-60
4) RELIEF VALVE
The relief valve mainly has the following two functions :
(1) To keep the starting pressure of the hydraulic motor at a constant value and bypass to the return
line excessive oil generated at the motor inlet depending upon the acceleration speed of the
driven inertia.
(2) To generate a brake pressure at the outlet during stopping of the driven inertia, and stop it
forcedly.

Port B

Port A

Poppet A

Seat A

Room A

The compartment A is always connected to port A of the motor.


When the pressure at port A increases and the force pushing poppet A is higher than the set
pressure of the spring, then poppet A is pushed up from the contact surface of seat A, and oil
flows from compartment A to port B.

2-61
5) NEGATIVE BRAKE
The negative brake is released applying to the brake piston (702) the pressure led through the built-
in counterbalance spool sub-assembly (022).
With no pressure working, the brake force is always ensured.

272 709 741 742 702 705

303

111

101

The brake force is the friction force generated on the surfaces of the friction plates (742) spline-
coupled with the cylinder block, when their rotation is restricted by the casing (272), separator plate
(741), and brake piston all connected with the pins (709).
Without pressure being applied to the brake piston, the brake piston is pushed by ten brake springs
(705), and the friction plate and separator plate are held between the brake piston and casing.
This holding force functions as the friction force. This friction force restrains the shaft (101) spline-
coupled with the cylinder block, and thus functions the brake.

2-62
6) PRESSURE RELEASE VALVE (flow control valve)

During running During stop

This brake is of a back pressure-insensitive type. In other words, since the counterbalance spool
used is overlapped at the neutral position, the pressure release valve prevents the circuit back
pressure from working into the brake room when the machine stops traveling and works, and so the
specified brake torque is available even on a slope.
During normal traveling, the pressure coming through the counterbalance valve is applied to the
brake room to release the break, and is also applied to the pressure release valve section.
This pressure release valve is of a constant differential pressure type, and irrespective of the
working pressure, the passing flow is constant and approximately 1 to 2 ֻ/ min.
When the condition changes from traveling to stop, the counterbalance spool returns to its neutral
position. With the counterbalance spool at its neutral position, the brake piston is pushed by the
brake spring, and the oil in the brake room flows to the motor drain line via the pressure release
valve. Then the brake torque is generated.

2-63
7) RELEASING METHOD OF NEGATIVE BRAKE
In releasing the negative brake without applying the brake releasing pressure, follow the procedures
shown below.

Details of work Tools

Remove two plugs (464) from the valve casing (303). Double (single)-ended wrench (27mm)

Tighten an M16 screw of 130mm in length into a tapped hole of Hexagon bar spanner (14mm)
the brake piston (702), and pull out the brake piston. Then the
condition having the brake release pressure is attained and the
brake is released.

Note : Even with the negative brake released, the hydraulic motor will not turn. When it is difficult to
generate the working pressure due to failure of the pump or so, and the whole machine is to
be pulled for transportation without removing the hydraulic motor, connect pressure
measurement ports AM and BM with a short hose or something. Then the machine can be
pulled slowly.

2-64
8) REDUCTION GEAR
The reduction gear is composed of a three-stage planetary gear mechanism shown in the following
figure. Since the sun gear is designed to have a floating mechanism, errors of the gears and
carrier pin hole pitches will not affect the gears' lives heavily.

R3 R2 R1

C3 C2 C1
P3 P2 P1

S3 S2
S1

The input rotation of the hydraulic motor is transmitted to No. 1 sun gear (S1) and this drives No. 1
planetary gears (P1). This No. 1 planetary gears (P1) drive No.1 ring gear (R1) with the same
force as the meshing tangential force with No. 1 sun gear (S1), and also No. 1 carrier (C1) with the
same force as the meshing reaction force. In other words, No. 1 planetary gears (P1) revolve
rotating. This rotation of No. 1 carrier (C1) becomes the output of the 1st stage, and is transmitted
directly to No. 2 sun gear (S2).
(No. 1 carrier is spline-coupled with No. 2 sun gear.) Similarly the revolution of No. 2 planetary gear
(P2) are transmitted via No.2 carrier (C2) to No. 3 sun gear (S3). Since No. 3 carrier (C3)
supporting No. 3 planetary gears (P3) are fixed, No. 3 planetary gears (P3) do not revolve, but
rotates to drive No. 3 ring gears (R3).
Therefore, the rotating case is driven by the overall driving torque of numbers.
1,2 and 3 ring gears. This reduction ratio is expressed as shown below:
(ZS1 + Zr1) (ZS2 + Zr2) (ZS3 + Zr3)
i= -1
ZS1ňZS2 ňZS3
where Z : Number of teeth of each gear
The direction of rotation is reverse to that of the input shaft.

2-65
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, 4 and 5 provided at the bottom face.
Port 5 is only RCV lever of LH.

19Ɓ

19Ɓ
25Ɓ
Single
Simultaneous operation
operation Handle bending direction
(NO.3 push rod direction)

33Ɓ 33Ɓ

3 2
45Ɓ

P T
5

4 1

A Port LH RH Port
size

P Pilot inlet port Pilot inlet port


T Pilot return port Pilot return port
1 Left swing port Bucket out port
2 Arm in port Boom down port PF-1/4
T 3 Right swing port Bucker in port
P
4 Arm out port Boom up port
5 Swing shuttle port 
1 5 32 4

2-66
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(201), spring(241) for setting secondary
pressure, return spring(221), washer 1(215), spring seat(216) and washer 2(217). The spring for
setting the secondary pressure has been generally so preset that the secondary pressure is 5 to 19 ָf/
ֲ (depending on the type). The spool is pushed against the push rod(212) 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.
In case of the two point type electric switch is fitted, as shown in the attached cross section drawing, the
roller(451), switch lever(452) and switch(455) are built in the inside of the handle(401). When the center
of the handle cap(402) provided at the handle head is pushed, the roller is come down, and the switch
lever contacted with the roller tilts to make the switch function. The cord(456), connected to the switch,
is led through the handle section and casing to the outside.

101 Casing 217 Washer 2 412 Nut


111 Port plate 221 Spring 413 Washer
121 Seal washer 241 Spring 421 Screw 2
122 O-ring 291 *Seat 422 Nut
125 Hex socket bolt 292 *Steel ball 431 Screw 3
126 Spring pin 293 *Plug 451 Roller
131 Bushing 294 *O-ring 452 Lever
151 Plate 301 Universal joint 453 Switch seat 1
201 Spool 302 Plate 454 Switch seat 2
211 Plug 312 Adjust nut 455 Switch
212 Push rod 315 Lock nut 456 Cord
213 Seal 323 Handle bar 457 Bushing
214 O-ring 401 Handle 458 Tube
215 Washer 1 402 Handle cap 459 Terminal
216 Spring seat 411 Screw 1 501 Bellows
*Mark : LH only item.

2-67
CROSS SECTION

451

402
421
422
453
454
452

401
455
431
458
411 456
457 412
413

501
323

301
459 315
302
312
213

212
211

151
214
215

216

241
121
217
125
221
201
126
101
122
292
293

294

111 291

2-68
2. FUNCTION
1) FUNDAMENTAL FUNCTIONS
The pilot valve is a valve that controls the spool stroke, direction, etc of a main control valve. This
function is carried out by providing the spring at one end of the main control valve spool and
applying the output pressure(=secondary pressure) of the pilot valve to the other end.
For this function to be carried out satisfactorily, the pilot valve is composed of the following
elements.
(1) Inlet port(P) where oil is supplied from hydraulic pump.
(2) Output ports(1,2,3 & 4) to apply pressure supplied from inlet port to ends of control valve spools.
(3) Tank port(T) necessary to control the above output pressure.
(4) Spool to connect output port to inlet port or tank port.
(5) Mechanical means to control output pressure, including springs that work on the above spools.

2) FUNCTIONS OF MAJOR SECTIONS


The functions of the spool(201) 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(241) works on this spool to determine the output pressure.
The change the deflection of this spring, the push rod(212) is inserted and can slide in the
plug(211).
For the purpose of changing the displacement of the push rod through the plate(302) and adjusting
nut(312) are provided the handle(401) that can be tilted in any direction around the fulcrum of the
universal joint(301) center.
The spring(221) works on the casing(101) and spring seat(216) and tries to return the push
rod(212) 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.

2-69
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

1 Pilot valve 3 Main pump 5 Hydraulic motor


2 Pilot pump 4 Main control valve 6 Hydraulic cylinder

2-70
(1) Case where handle is in neutral position

T
241

221

201
P

1 3

The force of the spring(241) that determines the output pressure of the pilot valve is not applied to
the spool(201). Therefore, the spool is pushed up by the spring(221) to the position of port 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.

2-71
(2) Case where handle is tilted

212

201

1 3

When the push rod(212) is stroked, the spool(201) moves downwards.


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

2-72
(3) Swing shuttle function(LH only)

212

201

1 5 3

When the push rod(212) is stroked, the spool(201) 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.
At the same time, the pressure of port P1 applied shuttle valve, the ball moves to the right, and port
P1 is connected with port P5.
In this manner, oil flow swing motor, than swing motor, than swing brake valve is released.

2-73
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.

Ɓ 12.4
12.4 Ɓ

1 2

3 4
Port Port name Port size

P Pilot oil inlet port


T Pilot oil return port
1 Travel (LH, Forward)
PF-1/4
T 2 Travel (LH, Backward)
P
3 Travel (RH, Forward)
4 Travel (RH, Backward)
1 23 4
Hydraulic circuit

2-74
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(11) for setting secondary pressure,
return spring (18), stopper 1 (13), spring seat (12) and shim(9). 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 (19) 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.

25
7 6 24
21 5
22 23
20 16 4
14 17
19 15
15 13
12 11
18
30
1
9, 10
8 26 27 28 29

1 Casing 11 Spring 21 Set screw


2 Pedal 12 Spring seat 22 Nut
3 Pedal cover 13 Stopper 23 Cam shaft
4 Cover 14 Plug 24 Set screw
5 Bushing 15 O-ring 25 Hexagon socket bolt
6 Cam 16 Dust seal 26 Plug
7 Bellows 17 Rod seal 27 Spacer
8 Spool 18 Spring 28 O-ring
9 Shim 19 Push rod 29 Hexagon socket bolt
10 Spring seat 20 Hexagon socket bolt 30 Plug

2-75
2. FUNCTION
1) FUNDAMENTAL FUNCTIONS
The pilot valve is a valve that controls the spool stroke, direction, etc of a main control valve. This
function is carried out by providing the spring at one end of the main control valve spool and
applying the output pressure(=secondary pressure) of the pilot valve to the other end.
For this function to be carried out satisfactorily, the pilot valve is composed of the following
elements.
(1) Inlet port(P) where oil is supplied from hydraulic pump.
(2) Output ports(1,2,3 & 4) to apply pressure supplied from inlet port to ends of control valve spools.
(3) Tank port(T) necessary to control the above output pressure.
(4) Spool to connect output port to inlet port or tank port.
(5) Mechanical means to control output pressure, including springs that work on the above spools.

2) FUNCTIONS OF MAJOR SECTIONS


The functions of the spool (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 port pressure oil to tank port T.
The spring (11) works on this spool to determine the output pressure.
The change the deflection of this spring, the push rod (19) is inserted and can slide in the plug (14).
For the purpose of changing the displacement of the push rod through the cam (6) and adjusting
nut (22) are provided the pedal (2) that can be tilted in any direction around the fulcrum of the cam
(6) center.
The spring (18) works on the casing (1) and spring seat (12) and tries to return the push rod (19) 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.

2-76
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
2

2 4

1 Pilot valve 3 Main pump 5 Hydraulic motor


2 Pilot pump 4 Main control valve 6 Hydraulic cylinder

2-77
(1) Case where pedal is in neutral position

11

8
T
18

1 2

The force of the spring (11) 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 (18) 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.

2-78
(2) Case where pedal is tilted

19

1 2

When the push rod(212) is stroked, the spool(201) moves downwards.


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

2-79
SECTION 3 HYDRAULIC SYSTEM
GROUP 1 HYDRAULIC CIRCUIT

1 PUMP
2 MCV
3 SWING MOTOR
4 TRACK MOTOR
5 RCV PEDAL
6 RCV LEVER
7 RCV LEVER
8 BOOM CYL
9 BUKT CYL
10 ARM CYL
11 TURNING JOINT
12 SOLENOID VALVE
13 CHECK VALVE
14 CHECK VALVE
15 CHECK VALVE
16 HYD TANK
17 OILCOOLER
18 BREATHER
19 BY PASS VALVE
20 RETURN FILTER
21 STRAINER
22 LINE FILTER
23 SPIN FILTER
24 ACCUMULATOR
25 PRESSURE SWITCH
26 PRESSURE SWITCH

3-1
GROUP 2 MAIN CIRCUIT

The main hydraulic circuit consists of suction circuit, delivery circuit, return circuit and drain circuit.
The hydraulic system consists of one main pump, one control valve, one swing motor, four cylinders
and two travel motors.
The swash plate type variable displacement 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

The pump 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.

3-2
2. RETURN CIRCUIT

Full flow filter Check valve(2)


1.5kg/cm2

Main control valve Actuators

Check valve(1)
3.0kg/cm2

Bypass relief valve


1.5kg/cm2

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 1.5kg/cm2(21psi) and 3.0kg/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 3.0kg/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 is provided in the hydraulic tank.
The oil from right and left side of control valve is combined and filtered by the full-flow filter. A bypass
relief valve is provided in the full-flow filter.
When the filter element is clogged, the bypass relief valve opens at 1.5kg/cm2(21psi) differential pressure.

3-3
3. DRAIN CIRCUIT

Travel motor Swing motor

Main pump

Turning joint

Bypass valve
1.5kg/cm2

Drain filter
Hydraulic
oil tank

Besides internal leaks from the motors and main pump, the oil for lubrication circulates. These oil have
to be fed to the hydraulic tank passing through drain filter.
When the drain oil pressure exceed 1.5kg/cm2, the oil returns to the hydraulic tank directly.

1) TRAVEL MOTOR DRAIN CIRCUIT


Oil leaking from the right and left travel motors come 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 be filtered by drain filter.
2) SWING MOTOR DRAIN CIRCUIT
Oil leaking from the swing motor come out and further with drain oil from the travel circuit and return
to the hydraulic tank passing through a full-flow filter.
3) MAIN PUMP DRAIN CIRCUIT
Oil leaking from main pump come out and return to the hydraulic tank passing through drain filter.

3-4
GROUP 3 PILOT CIRCUIT

Remote control valve Remote control valve


RCV pedal
(LH lever) (RH lever)

Control valve Swing parking brake


Safety lock
solenoid valve

High speed solenoid valve

Pilot filter
Main pump
Relief valve
40kg/cm2

Pilot pump Suction filter

The pilot circuit consists of suction circuit, delivery circuit and return circuit.
The pilot pump is provide 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 pilot filter, EPPR
valve, high speed solenoid valve, swing parking brake, main control valve and safety lock solenoid
valve.

3-5
1. SUCTION DELIVERY AND RETURN CIRCUIT

SAFETY
SOLENOID VALVE
PEDAL RCV LEVER(LH) RCV LEVER(RH)

TRAVEL SWING ARM BOOM BUCKET

OIL TANK
PILOT PUMP

SUCTION
FILTER

PILOT FILTER RELIEF VALVE

The pilot pump receive oil from the hydraulic tank. The discharged oil from the pilot pump flows to
the safety solenoid valve through the pilot filter. The oil is filtered by the pilot filter. The pilot relief
valve is provided in the pilot pump for limiting the pilot circuit pressure.
The oil filtered by pilot filter flows remote control valve through safety solenoid valve.
The return oil returned to hydraulic tank through the remote control valve.

3-6
2. SAFETY VALVE (SAFETY LEVER)

LEVER DOWN
LEVER UP

OIL TANK
PILOT PUMP

When the lever of the safety solenoid valve moved downward, oil flow remote control valve through
solenoid valve and pilot filter.
When the lever of the safety solenoid valve moved upward, oil does not flow remote control valve,
because of blocked by the spool.

3-7
3. SWING PARKING BRAKE RELEASE

SWING MOTOR DEVICE


SH

P3

SWING

PILOT PUMP

When the swing control lever is tilted, the pilot oil go to SH port of shuttle valve, this pressure move
spool so, discharged oil from pilot pump go to P3 port.
This pressure is applied to swing motor disc cylinder, thus the brake released.
When the swing control lever is set neutral position, oil in the motor disc cylinder is drain, thus the
brake works.

3-8
4. SPEED CONTROL PRESSURE

SAFETY
TRAVEL MOTOR DEVICE SOLENOID VALVE
HI

PK

P3 LO
LO LO
HI HI

PK

PILOT PUMP

P3

When the travel speed solenoid valve was placed in the HI position, the pressure oil from pilot pump
flows to PK port of 2 speed change over valve, and the control piston is pushed up, thus minimizing
the displacement.
When the travel speed solenoid valve was placed in the LO position, the oil of PK port return to the
tank and the control piston is returned, thus maximizing the displacement.

3-9
GROUP 4 SINGLE OPERATION

1. BOOM RAISE CIRCUIT OPERATION


BOOM CYLINDER

RELIEF VALVE
MAKE UP VALVE

a4

OIL TANK
FRONT REAR PILOT
PUMP PUMP PUMP

When the right control lever is pulled to boom raise position. Then the oil from pilot pump through
the remote control valve to boom sections of the control valve.
Here, the spool positions are moved to the boom raise position, and the boom circuits are opened.
The oil flows from both main pumps through boom section of the control valve to the bottom end of
the boom cylinders, and to raise the boom.
The return oil flow from the rod end of the cylinders are directed to the tank through the boom section
of the control valve.
Cavitation and excessive pressure in the boom cylinder bottom end circuit is prevented by a overload
relief and make up valve in the control valve.

3 - 10
2. BOOM DOWN CIRCUIT OPERATION

BOOM CYLINDER

MAKE UP VALVE
RELIEF VALVE

b4

OIL TANK
FRONT PILOT
PUMP PUMP

When the right control lever is pushed forward to boom lower position. Then the oil from pilot pump
through the remote control valve to boom sections of the control valve. Here, the spool positions are
moved to the boom lower position, and the boom lower circuit is opened.
Oil flows from front pump through boom section of the control valve to the rod end of the boom
cylinders, and to lower the boom.
The return oil flows from the bottom end of the cylinders to the tank through the boom section of the
control valve.
Cavitation and excessive pressure in the boom cylinder rod end circuit is prevented by a overload
relief and make up valve in the control valve.

3 - 11
3. ARM ROLL IN CIRCUIT OPERATION

ARM CYLINDER

MAKE UP VALVE

RELIEF VALVE
a2

OIL TANK
FRONT REAR PILOT
PUMP PUMP PUMP

When the left control lever manually is placed in the arm roll in position.
Then the oil flows from pilot pump through the remote control valve to arm sections of the control
valve. Here, the spool positions are moved to arm roll in position.
The pilot pressure is not applied pilot port(a); the logic valve is blocked.
The oil flows from both main pump through arm section of the control valve to the bottom end of the
arm cylinder, and to roll in arm.
The return oil flows from the rod end of the cylinder through the arm section returned to the tank.
Then cavitation which will happen to the bottom of the arm cylinder is prevented by a make up valve,
on other hand. The excess pressure is also prevented by an overload relief valve in the control
valve.

3 - 12
4. ARM ROLL OUT CIRCUIT OPERATION

ARM CYLINDER
RELIEF VALVE
MAKE UP VALVE

b2

OIL TANK
FRONT REAR PILOT
PUMP PUMP PUMP

When the left control lever manually is placed in the arm roll out position.
Then the oil flows from pilot pump through the remote control valve to arm sections of the control
valve. Here, the spool positions are moved to arm roll out position.
The pilot pressure is not applied pilot port(a); the logic valve is blocked.
The oil flows from both pump through arm section of control valve to the bottom end of the arm
cylinder, and to roll out arm.
The return oil flows from the bottom end of the cylinder through the arm section returned to the tank.
The cavitation which will happen to the rod of the arm cylinder is prevented by a make up valve, on
other hand. The excess pressure is also prevented by an overload relief valve in the control valve.

3 - 13
5. BUCKET CIRCUIT OPERATION

BUCKET CYLINDER

RELIEF VALVE
MAKE UP VALVE
b5
a5

OIL TANK
FRONT REAR PILOT
PUMP PUMP PUMP

When the right control lever manually placed in the bucket roll in(roll out) position. Then the oil from
pilot pump through the pilot valve to bucket section of the control valve. Here the spool position is
moved to bucket roll in(roll out) position.

3 - 14
6. SWING CIRCUIT OPERATION

SWING MOTOR DEVICE


SH

a1
p3

b1

A B

SWING

OIL TANK
FRONT REAR PILOT
PUMP PUMP PUMP
b1 SH a1

P3

When the left control lever manually is placed in the swing position. Then the oil flows from pilot
pump through the pilot valve to the swing section of the control valve. Here, the spool position is
moved to right or left swing position.
The oil flows from rear pump through swing section of the control valve to the swing motor and
swings the superstructure.
The motor brake valve, make up valve and swing parking brake are provided in the swing motor.

3 - 15
SWING CIRCUIT OPERATION

PARKING BRAKE

SWING MOTOR DEVICE


BRAKE RELEASE VALVE

BRAKE OFF
SH

P3

BRAKE ON

MAKE UP VALVE
A B

MAKE UP MOTOR BRAKE VALVE


PORT(Mu)

TO / FROM MAIN CONTROL VALVE

1) MOTOR BRAKE VALVE


Motor brake valve for the swing motor limits to cushion the starting and stopping pressure of swing
operation.
2) MAKE UP VALVE
The make up valves prevent cavitation by supplying return oil to the vacuum side of the motor.
3) PARKING BRAKE
In case that the parking, of the machine at slope is required during operation, there is the danger of
involuntary swing caused by the self weight of the machine. The brake is connected to prevent this
involuntary swing.
PARKING BRAKE "OFF" OPERATION
The parking brake is released by the pilot pressure oil from the pilot pump.
When the left control lever placed in the swing position, the pilot pressure at the shuttle valve is
transferred to the brake release valve and the brake release valve is change over. Then the pilot
pressure lift the brake piston and release the parking brake.
PARKING BRAKE "ON" OPERATION
When the control lever placed in the neutral position, the pressure of the pilot oil passage down.
Then the brake release valve returned to the neutral position and the oil is returned from the brake
piston to the tank. And the brake is set to "ON".

3 - 16
7. SWING OPERATION

SWING MOTOR

a1
b1

LEVER DOWN

SWING

OIL TANK
REAR
PUMP PILOT PUMP
b1 SH a1

When the left control lever is manually placed in the left(right) swing position. Then the oil flows from
rear pump through the swing section of the control valve to swing motor to left(right) swing the
superstructure. The return oil flow from swing motor through the swing section of the 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"

3 - 17
8. TRAVEL CIRCUIT OPERATION

2 SPEED SOLENOID VALVE


TRAVEL MOTOR DEVICE Hi speed

PK

Low speed
P3

A B PK A B

b7
SELECT a7
VALVE
Pt

a3
b3

TRAVEL

OIL TANK
FRONT REAR
PUMP PUMP PILOT PUMP
b7 a7 a3 b3 Pt

P3

When the travel levers are manually placed to the forward or reverse position.
Then the oil flows from pilot pump through the pilot valve to travel sections of the control valve. Here,
spools position is moved to forward and reverse position. The oil flows from both main pumps
through the travel sections of the control valves to the travel motors, and move the machine forward
and reverse.
Brake valves are provided on travel motors to offer the following functions.

3 - 18
TRAVEL CIRCUIT OPERATION

TRAVEL MOTOR DEVICE

A B A B
CHECK VALVE
OVERLOAD COUNTER
RELIEF BALANCE
VALVE VALVE

TURNING JOINT

TO/FROM CONTROL VALVE

1) CHECK VALVE
Stopping the motor, this valve sucks the oil from lower pressure passage for preventing the
negative pressure and the cavitation of the motor.
2) COUNTER BALANCE VALVE
When stopping the motor or slope descending, this valve to prevent the motor over run.
3) OVERLOAD RELIEF VALVE
Relief valve limit the circuit pressure below 350kgf/cm2 to prevent high pressure generated at a time
of stopping the machine.

3 - 19
9. TRAVEL FORWARD AND REVERSE OPERATION

TRAVEL MOTOR

Pt

SELECT VALVE b7
a7

a3
b3

LEVER DOWN

TRAVEL

OIL TANK
FRONT REAR
PUMP PUMP PILOT PUMP
b7 a7 a3 b3 Pt

P3

When the right and left travel levers are manually placed to the forward or reverse position. Then the
oil flows from rear pump through the travel(R) section of the control valve and turning joint to the right
travel motor and oil flows from front pump through the travel(L) section of the control valve and
turning joint to the left travel motor and move the machine forward and reverse.
The return oil flows from both travel motor through the turning joint and travel(R), (L) sections
returned to the tank.

3 - 20
GROUP 5 COMBINED OPERATION
1. OUTLINE

BUCKET BOOM
CYLINDER CYLINDER
TRAVEL MOTOR

SELECT VALVE

ARM CYLINDER

SWING MOTOR

OIL TANK
FRONT REAR
PUMP PUMP PILOT PUMP

SUCTION
FILTER

In case operation, the oil flows from both main pumps through the neutral oil passage, bypass oil
passage and confluence oil passage. Then the oil is supplied to each actuator and function them.
Check valves and orifices are provided with on these flow passage. These control the oil flows from
the pump corresponding to the each actuator's state of functioning and smooth the combined
operation.
SELECT VALVE
This select valve is provided in the control valve.
When the spool except travel is moved, the pilot oil from the pilot pump is closed by its spool.
Consequently, the pilot pressure port of the select valve rised and its spool is moved. Then the left
and right travel oil supply passage is opened, and the machine straight travelling.

3 - 21
2. COMBINED SWING AND BOOM OPERATION

BOOM
CYLINDER

SWING MOTOR

a1 b4
b1 a4
c

CENTER
BYPASS VALVE

OIL TANK
FRONT REAR
PUMP PUMP PILOT PUMP

SUCTION
FILTER

When the swing and boom functions are operated, simultaneously the swing spool and boom spools
changed. The oil flows from the front pump through boom section of the control valve to boom
cylinders and the boom functions.
The oil flows from rear pump through swing section to swing motor. At the same time the pressure in
the boom circuits can be high while the swing pressure is low therefore the oil flows from rear pump
to boom cylinders through boom confluence passage.

3 - 22
3. COMBINED SWING AND ARM OPERATION

ARM CYLINDER
a2
b2
SWING MOTOR

a1
b1

OIL TANK
FRONT REAR
PUMP PUMP PILOT PUMP

SUCTION
FILTER

When the swing and arm functions are operated, simultaneously the swing and arm spools changed.
The oil flows from the rear pump through arm and swing section of the control valve to arm cylinder
and swing motor, and the arm and swing function.
At the same time, the center bypass valve is blocked, the oil flows from the front pump through the
arm confluence oil passage to arm cylinder.

3 - 23
4. COMBINED SWING AND BUCKET OPERATION

BUCKET
CYLINDER

a5
b5
SWING MOTOR

a1
b1

OIL TANK
FRONT REAR
PUMP PUMP PILOT PUMP

SUCTION
FILTER

When the swing and bucket functions are operated, the swing and bucket spools changed. The oil
flows front pump through the bucket section of the right control valve to the bucket cylinder and the
bucket function. The oil flows from rear pump through swing section of the left control valve to the
swing motor and swing the superstructure.

3 - 24
5. COMBINED SWING, BOOM, ARM AND BUCKET OPERATION

BUCKET BOOM
CYLINDER CYLINDER

LOGIC VALVE

ARM CYLINDER
a2 b5
a5
b2

SWING MOTOR

a1 b4
b1 a4

c a b
ORIFICE

CENTER ORIFICE
BYPASS VALVE
LOGIC VALVE

OIL TANK
FRONT REAR
PUMP PUMP PILOT PUMP

SUCTION
FILTER

When the swing, boom, arm and bucket functions are operated, the each spools of the control valve
changed.
The oil flows from front pump through boom and bucket section to boom and bucket cylinders. The
oil flows from rear pump through the parallel oil passage and the swing and arm section to swing
motor and arm cylinder. Then the functions to each actuators.
According to the state of each actuators functioning, center bypass valve is blocked, the oil flows from
rear pump through the confluence oil passage to right control valve and the oil flows from rear pump
through logic valve to boom cylinders.

3 - 25
6. COMBINED SWING AND TRAVEL OPERATION

TRAVEL MOTOR

Pt

SELECT VALVE b7
a7

a3
b3

SWING MOTOR

a1
b1

ORIFICE
CENTER
BYPASS VALVE

OIL TANK
FRONT REAR
PUMP PUMP PILOT PUMP

SUCTION
FILTER

When the swing and right and left travel functions are operated, the swing and travel(R),(L) spools
and the select valve changed. The oil flows from front pump through the travel (R),(L) section of the
control valve to the right and left travel motor.
And the oil flows from rear pump through swing section of the right control valve to the swing motor.
Because of check valve the pressure in the travel circuit can be high while the swing pressure is low.
When the travel circuit pressure drops lower than swing pressure, as when traveling downhill, swing
priority and smoothness are maintained because of the orifice. In either case, the machine will
continue to travel straight.

3 - 26
7. COMBINED BOOM AND TRAVEL OPERATION

BOOM
CYLINDER
TRAVEL MOTOR

Pt

SELECT VALVE
b7
a7

a3
b3

b4

a4
c

CENTER ORIFICE
BYPASS VALVE
LOGIC VALVE

OIL TANK
FRONT REAR
PUMP PUMP PILOT PUMP

SUCTION
FILTER

When the boom and travel (R) (L) functions are operated, the boom and travel (R),(L) spools and the
select valve changed. The oil flows from front pump through the travel (R),(L)section of the control
valve to the right and left travel motor.
And the oil flows from front pump through boom section of the left control valve to the boom cylinder.
Because of check valve the pressure in the travel circuit can be high while the boom pressure is low.
When the travel circuit pressure drops lower than boom pressure, as when travelling downhill, boom
priority and smoothness are maintained because of the orifice. In either case, the machine will
continue to travel straight.

3 - 27
8. COMBINED ARM AND TRAVEL OPERATION

TRAVEL MOTOR

Pt

SELECT VALVE
b7
a7

a3
b3

ARM CYLINDER a2

b2

ORIFICE
CENTER
BYPASS VALVE

OIL TANK
FRONT REAR
PUMP PUMP PILOT PUMP

SUCTION
FILTER

When the arm and travel (R) (L) functions are operated, the arm and travel (R),(L) spools and the
select valve changed. The oil flows from front pump through the travel (R),(L) section of the control
valve to the right and left travel motor.
And the oil flows from rear pump through arm section of the right control valve to the arm cylinder.
Because of check valve the pressure in the travel circuit can be high while the arm pressure is low.
When the travel circuit pressure drops lower than arm pressure, as when traveling downhill, arm
priority and smoothness are maintained because of the orifice. In either case, the machine will
continue to travel straight.

3 - 28
9. COMBINED BUCKET AND TRAVEL OPERATION

BUCKET CYLINDER

TRAVEL MOTOR

Pt

SELECT VALVE
b7
a7
CHECK
VALVE

a3
b3

b5
a5

CENTER ORIFICE
BYPASS VALVE

OIL TANK
FRONT REAR
PUMP PUMP PILOT PUMP

SUCTION
FILTER

When the bucket and travel (R),(L) functions are operated, the bucket and travel (R),(L) spools and
the select valve changed. The oil flows from rear pump through the travel (R),(L) section of the
control valve to right and left travel motor and the machine travelling.
The oil flows from front pump through bucket section of the control valve to the bucket cylinder and
the bucket functions.

3 - 29
SECTION 4 ELECTRICAL SYSTEM
GROUP 1 COMPONENT LOCATION

1. LOCATION 1

10
11
12
1 13
2 14
15
16
17
18

20
21
22

7
19
8

1 Horn switch 9 Relay board assembly 17 Cigar lighter switch


2 Cluster 10 Washer switch 18 Cold start switch
3 Safety lever 11 Wiper switch 19 Manual engine acceleration lever
4 Fuse box 12 Head light switch 20 Breaker switch(option)
5 Aircon & heater switch 13 Work light switch 21 Service meter
6 CPU controller 14 Room lamp switch 22 Cassette & Radio
7 Resister 15 Travel alarm switch
8 Prolix switch 16 Start switch

4-1
2. LOCATION 2

16
1
2 15
3 14
4 11
12
5 13

17
6

8
9
10
7

18

1 Hyd temperature sendor 7 Light 13 Temperature oil adapter


2 Fuel sendor 8 Engine speed sensor 14 Heater adapter
3 Connector plate 9 Governor motor 15 Heater valve
4 Battery relay 10 Press oil switch 16 Alternator
5 Fuel filler pump 11 Hydraulic temperature sendor 17 Air cleaner switch
6 Battery 12 Over heat switch 18 Connector plate

4-2
GROUP 2 ELECTRICAL CIRCUIT

4-3
CE REGULATION NOT APPLIED

4-4
1. POWER CIRCUIT
The negative terminal of battery is grounded to the machine chassis.
When the start key switch is in the OFF position, the current flows from the positive battery terminal as
shown here.
1) OPERATING FLOW
Battery Battery relay Fusible linkŭCN-60(1)Ů I/connŭCN-5(1)Ů Start key switch
ŭCS-2(1)Ů
I/connŭCN-40(1)Ů
Fuse boxŭNo.19Ů I/connŭCN-38(8)Ů I/connŭCN-6(4)Ů Room lampŭCL-1(2)Ů
Fuse boxŭNo.18Ů I/connŭCN-38(7)Ů ClusterŭCN-8(6)Ů
CPU controllerŭCN-50(10)Ů
Fuse boxŭNo.17Ů I/connŭCN-38(6)Ů Cassette radioŭCN-27(7)Ů

2) CHECK POINT

Engine Key switch Check point Voltage

‫ ڸ‬- GND (Battery 1 EA) 10 ~ 12.5V


‫ ڹ‬- GND (Battery 2 EA) 20 ~ 25V
OFF OFF
‫ ں‬- GND (Battery 2 EA) 20 ~ 25V
‫ ڻ‬- GND (Fusible link ) 20 ~ 25V

Ɠ GND : Ground

4-5
POWER CIRCUIT

4-6
2. STARTING CIRCUIT
1) OPERATING FLOW
Battery(+) terminal Battery relay(M8, B+ terminal) Fusible linkŭCN-60(1)Ů
I/connŭCN-5(1)Ů Start key switchŭCS-2(1)Ů

Ɠ When start key switch is in ON position


Start key switch ONŭCS-2(1),(3)Ů I/connŭCN-4(2)Ů Battery relayŭM4 terminalŮ
I/connŭCN-38(1)Ů Fuse box
I/connŭCN-40(1)Ů Fuse box(No. 18)

Ɠ When start key switch is in START position


Start key switch STARTŭCS-2(5)Ů I/connŭCN-1(1)Ů Start relayŭCR-23(1)Ů
Fuel cut-offŭCN-79(2)Ů

2) CHECK POINT

Engine Key switch Check point Voltage

‫ ڸ‬- GND (Battery)


‫ ڹ‬- GND (Start key)
‫ ں‬- GND (Battery relay M4)
Operating Start ‫ ڻ‬- GND (Start (B)) 20 ~ 25V
‫ ڼ‬- GND (Start (S))
‫ ڽ‬- GND (Start relay)
‫ ھ‬- GND (Battery relay M8)

Ɠ GND : Ground

4-7
STARTING CIRCUIT

4-8
3. CHARGING CIRCUIT
When the starter is activated and the engine is started, the operator releases the key switch to the ON
position.
Charging current generated by operating alternator flows into the battery through the Battery
relay(CR-1).
The current also flows from alternator to each electrical component and controller through the fuse
box.
1) OPERATING FLOW
AlternatorūIŬterminal I/connŭCN-1(2)Ů CPU Alternator power level
ŭCN-51(18)Ů,
Charging lampŭCN-53(7)Ů I/connŭCN-7(7)Ů cluster charging warning lamp
ŭCN-56(7)Ů

Alternator B+ terminal Battery relay (M8) Battery(+) terminal


Fusible linkŭCN-60(1)Ů
I/connŭCN-5(1)Ů I/connŭCN-40(1)Ů Fuse Box

2) CHECK POINT
Engine Key switch Check point Voltage

‫ ڸ‬- GND (Battery voltage)


‫ ڹ‬- GND (Battery relay)
‫ ں‬- GND (Alternator B terminal)
ON ON ‫ ڻ‬- GND (Alternator I terminal) 20 ~ 25V
‫ ڼ‬- GND CPU
‫ ڽ‬- GND CPU
‫ ھ‬- GND Cluster

Ɠ GND : Ground

4-9
CHARGING CIRCUIT

4 - 10
CHARGING CIRCUIT(CE Regulation not applied)
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
AlternatorūIŬterminal I/connŭCN-1(2)Ů CPU Alternator power level
ŭCN-51(18)Ů,
Charging lampŭCN-53(7)Ů I/connŭCN-7(7)Ů cluster charging warning lamp
ŭCN-56(7)Ů

Alternator B+ terminal Battery relay (M8) Battery(+) terminal


Fusible linkŭCN-60(2)Ů
I/connŭCN-5(2)Ů I/connŭCN-40(2)Ů Fuse Box

2) CHECK POINT
Engine Key switch Check point Voltage

‫ ڸ‬- GND (Battery voltage)


‫ ڹ‬- GND (Battery relay)
‫ ں‬- GND (Alternator B terminal)
ON ON ‫ ڻ‬- GND (Alternator I terminal) 20 ~ 25V
‫ ڼ‬- GND CPU
‫ ڽ‬- GND CPU
‫ ھ‬- GND Cluster

Ɠ GND : Ground

4 - 11
CHARGING CIRCUIT(CE Regulation not applied)

4 - 12
4. HEAD LIGHT CIRCUIT
1) OPERATING FLOW
Fuse box (No.8) I/connŭCN-37(1)Ů Head light switchŭCS-39(6)Ů
Head light relayŭCR-13(4)Ů
Ɠ When Light switch ON
Head light switch ONŭCS-39(2)Ů Head light relayŭCR-13(3) Ɗ (1)Ů Ground
ŭCR-13(4) Ɗ (2)Ů
Head light ONŭCL-3(2)Ů
I/connŭCN-4(7)Ů Head light ONŭCL-4(2)Ů
I/connŭCN-7(9)Ů Cluster illumination LampŭCN-56(9)Ů

2) CHECK POINT

Engine Key switch Check point Voltage

‫ ڸ‬- GND (Fuse box)


‫ ڹ‬- GND (Switch power input)
‫ ں‬- GND (Switch power output)
STOP ON ‫ ڻ‬- GND (Relay input) 20 ~ 25V
‫ ڼ‬- GND (Relay coil)
‫ ڽ‬- GND (Relay output)
‫ ھ‬- GND (Head light)

Ɠ GND : Ground

4 - 13
HEAD LIGHT CIRCUIT

4 - 14
HEAD LIGHT CIRCUIT(CE Regulation not applied)
1) OPERATING FLOW
Fuse box (No.8) I/connŭCN-37(1)Ů Head light switchŭCS-39(6)Ů
Head light relayŭCR-13(4)Ů
Ɠ When Light switch ON
Head light switch ONŭCS-39(2)Ů Head light relayŭCR-13(3) Ɗ (1)Ů Ground
ŭCR-13(4) Ɗ (2)Ů
Head light ONŭCL-3(3)Ů
I/connŭCN-4(7)Ů Head light ONŭCL-4(3)Ů
I/connŭCN-7(9)Ů Cluster illumination LampŭCN-56(9)Ů

2) CHECK POINT

Engine Key switch Check point Voltage

‫ ڸ‬- GND (Fuse box)


‫ ڹ‬- GND (Switch power input)
‫ ں‬- GND (Switch power output)
STOP ON ‫ ڻ‬- GND (Relay input) 20 ~ 25V
‫ ڼ‬- GND (Relay coil)
‫ ڽ‬- GND (Relay output)
‫ ھ‬- GND (Head light)

Ɠ GND : Ground

4 - 15
HEAD LIGHT CIRCUIT(CE Regulation not applied)

4 - 16
5. WORK LIGHT CIRCUIT
1) OPERATING FLOW
Fuse box (No.9) I/connŭCN-37(2)Ů Work light switchŭCS-36(6)Ů
Work light switchŭCR-3(4)Ů
Ɠ When Light switch ON
Work light switch ONŭCS-36(2)Ů Work light relayŭCR-3(3) (1)Ů Ground
ŭCR-3(4) (2)Ů
I/connŭCN-7(10)Ů Cluster Work light ONŭCN-56(10)Ů
I/connŭCN-4(4)Ů I/connŭCN-10(2)Ů Work light ONŭCL-6(2), CL-5(2)Ů

2) CHECK POINT

Engine Key switch Check point Voltage

‫ ڸ‬- GND (Fuse box)


‫ ڹ‬- GND (Switch power input)
‫ ں‬- GND (Switch power output)
STOP ON ‫ ڻ‬- GND (Relay input) 20 ~ 25V
‫ ڼ‬- GND (Relay coil)
‫ ڽ‬- GND (Relay output)
‫ ھ‬- GND (Work light)

Ɠ GND : Ground

4 - 17
WORK LIGHT CIRCUIT

4 - 18
WORK LIGHT CIRCUIT(CE Regulation not applied)
1) OPERATING FLOW
Fuse box (No.9) I/connŭCN-37(2)Ů Work light switchŭCS-36(6)Ů
Work light switchŭCR-3(4)Ů
Ɠ When Light switch ON
Work light switch ONŭCS-36(2)Ů Work light relayŭCR-3(3) (1)Ů Ground
ŭCR-3(4) (2)Ů
I/connŭCN-7(10)Ů Cluster Work light ONŭCN-56(10)Ů
I/connŭCN-4(4)Ů I/connŭCN-10(3)Ů Work light ONŭCL-6(3), CL-5(3)Ů

2) CHECK POINT

Engine Key switch Check point Voltage

‫ ڸ‬- GND (Fuse box)


‫ ڹ‬- GND (Switch power input)
‫ ں‬- GND (Switch power output)
STOP ON ‫ ڻ‬- GND (Relay input) 20 ~ 25V
‫ ڼ‬- GND (Relay coil)
‫ ڽ‬- GND (Relay output)
‫ ھ‬- GND (Work light)

Ɠ GND : Ground

4 - 19
WORK LIGHT CIRCUIT(CE Regulation not applied)

4 - 20
6. CAB LIGHT CIRCUIT
1) OPERATING FLOW
Fuse box (No.10) I/connŭCN-37(3)Ů Cab light switchŭCS-24(6)Ů
Cab light relayŭCR-9(4)Ů
Ɠ When Light switch ON
Cab light switch ONŭCS-24(2)Ů Cab light relayŭCR-9(3) (1)Ů Ground
ŭCR-9(4) (2)Ů
I/connŭCN-6(5)Ů I/connŭCN-14(4)Ů
Cab light ONŭCL-8(rear), CL-10(RH), CL-9(LH)Ů

2) CHECK POINT

Engine Key switch Check point Voltage

‫ ڸ‬- GND (Fuse box)


‫ ڹ‬- GND (Switch power input)
‫ ں‬- GND (Switch power output)
STOP ON ‫ ڻ‬- GND (Relay input) 20 ~ 25V
‫ ڼ‬- GND (Relay coil)
‫ ڽ‬- GND (Relay output)
‫ ھ‬- GND (Cab light)

Ɠ GND : Ground

4 - 21
CABIN LIGHT CIRCUIT

4 - 22
7. WIPER MOTOR CIRCUIT
1) OPERATING FLOW
(1) Wiper motor switch ON
Fuse box (No.1) I/connŭCN-36(6)Ů Wiper motor relayŭCR-4(2) ‫( ׿‬6)Ů
Wiper switchŭCS-3(6) ‫( ׿‬2)Ů Ground
Wiper motor relayŭCR-4(4) ‫( ׿‬1)Ů
I/connŭCN-6(1)Ů I/connŭCN-13(1)Ů
Wiper motor operatingŭCN-21(1)Ů

(2) Auto - parking (When switch OFF)


Wiper motorŭCN-21(1)Ů OFF Fuse box(No.1) I/connŭCN-36(6)Ů
I/connŭCN-6(2)Ů I/connŭCN-13(3)Ů Wiper motorŭCN-21(3) ‫( ׿‬4)Ů
Wiper motor stop

2) CHECK POINT

Engine Key switch Check point Voltage

‫ ڸ‬- GND (Fuse box)


‫ ڹ‬- GND (Switch input)
‫ ں‬- GND (Relay)
‫ ڻ‬- GND (Relay coil)
‫ ڼ‬- GND (Relay input)
OFF ON 20 ~ 25V
‫ ڽ‬- GND (Relay)
‫ ھ‬- GND (Wiper power input)
‫ ڿ‬- GND (Wiper power input)
‫ ۀ‬- GND (Wiper motor)
‫ ہ‬- GND (Switch output)

Ɠ GND : Ground

4 - 23
WIPER MOTOR CIRCUIT

4 - 24
WIPER MOTOR CIRCUIT(CE Regulation not applied)
1) OPERATING FLOW
(1) Wiper motor switch ON
Fuse box (No.1) I/connŭCN-36(6)Ů Wiper motor relayŭCR-4(2) ‫( ׿‬6)Ů
Wiper switchŭCS-3(6) ‫( ׿‬2)Ů Ground
Wiper motor relayŭCR-4(4) ‫( ׿‬1)Ů
I/connŭCN-6(1)Ů I/connŭCN-13(1)Ů
Wiper motor operatingŭCN-21(1)Ů

(2) Auto - parking (When switch OFF)


Wiper motorŭCN-21(1)Ů OFF Fuse box(No.1) I/connŭCN-36(6)Ů
I/connŭCN-6(2)Ů I/connŭCN-13(3)Ů Wiper motorŭCN-21(3) ‫( ׿‬4)Ů
Wiper motor stop

2) CHECK POINT

Engine Key switch Check point Voltage

‫ ڸ‬- GND (Fuse box)


‫ ڹ‬- GND (Switch input)
‫ ں‬- GND (Relay)
‫ ڻ‬- GND (Relay coil)
‫ ڼ‬- GND (Relay input)
OFF ON 20 ~ 25V
‫ ڽ‬- GND (Relay)
‫ ھ‬- GND (Wiper power input)
‫ ڿ‬- GND (Wiper power input)
‫ ۀ‬- GND (Wiper motor)
‫ ہ‬- GND (Switch output)

Ɠ GND : Ground

4 - 25
WIPER MOTOR CIRCUIT(CE Regulation not applied)

4 - 26
CONTROLLER CIRCUIT

4 - 27
ELECTRICAL CIRCUIT FOR HYDRAULIC

4-28
MONITORING CIRCUIT

4-29
GROUP 3 MONITORING SYSTEM

1. OUTLINE
Monitoring system consists of the monitor part and switch part.
The monitor part gives warnings when any abnormality occurs in the machine and informs the
condition of the machine.
Various select switches built into the monitor panel, and it acts as the control portion of the machine
control system.

Input Output
Alternator level signal Charge warning lamp
Engine oil pressure switch Engine oil warning lamp
Engine tacho signal Tachometer (or clock)
Work light Work light lamp
Air cleaner switch Air cleaner warning lamp
Coolant overheat sensor Coolant overheat warning lamp
Hydraulic oil temp. sensor Hydraulic oil temp warning lamp
Monitor
Coolant level sensor Coolant level lamp
Fuel sendor Fuel gauge
Coolant temp. sensor Fuel low level lamp
Coolant temperature gauge
Warming up lamp

Switch
Mode selection signal 1
ňMode selection switch Mode selection signal 2
Mode selection lamp 1 ňAuto idle selection switch Travel speed signal
Mode selection lamp 2 ňTravel speed switch Auto idle selection signal
Engine speedŜupŝsignal
Engine speedŜdownŝsignal

Battery(B+) Signal ground


Battery relay Power ground

4 - 30
2. CLUSTER
1) Monitor panel

Fuel gauge Clock and


tachometer

Battery charging TIME bar Engine coolant


lamp rpm temperature
gauge
F
Overheat warning Engine oil
lamp pressure lamp
E C H
Coolant Warming up
level lamp lamp

Air cleaner Working light


warning lamp pilot lamp
POWER MODE

Hyd oil temp H S L F Fuel low


warning lamp level lamp
AUTO SELECT
DECEL
Power mode H M
switch Select switch
Automatic TRAVEL SPEED ENGINE SPEED
deceleration
switch Buzzer stop
switch
Travel speed
switch Engine speed
control switch

4 - 31
1) CLUSTER CHECK PROCEDURE
(1) Start key : ON
‫ ڸ‬Check monitor initial 3 seconds
a. All lamps light up.
b. Buzzer sound.

‫ ڹ‬Check monitor after 3 seconds : indicate machine condition


a. Tachometer : 0 rpm
b. Fuel gauge : All light up below appropriate level
c. Engine coolant temperature gauge : All light up below appropriate level
d. Warning lamp
Ɠ In case, the engine oil pressure lamp and battery charging lamp go on, but it is not abnormal.
Ɠ When engine coolant temperature below 30Ƅ, the warming up lamp light up.

‫ ں‬Switch portion
a. Mode selection : S mode
b. Auto decel LED : ON
c. Travel speed switch : Low(turtle)

(2) Start of engine


‫ ڸ‬Check machine condition
a. Tachometer indicate at present rpm
b. Gauge and warning lamp : indicate at present condition.
Ɠ When normal condition : All warning lamp OFF
c. Mode selection : S mode
d. Auto decel : ON(about 1200rpm)
d- Travel speed : Low(turtle)

‫ ڹ‬When warming up operation


a. Warming up lamp : ON
b. 10 seconds after engine started, mode selection changes from S to F mode and engine speed
increases from auto decel speed to F mode speed (Auto decel LED : ON)
Ɠ Others same as above ‫ڸ‬

‫ ں‬When abnormal condition


a. The lamp lights up and the buzzer sounds.

4 - 32
3. CLUSTER CONNECTOR
1) CN-57 CONNECTOR

No. Signal Input/ CN-57


output
1 Engine speedŜ downŝ output 6 5 4 3 2 1
2 Engine speedŜupŝ output
12 11 10 9 8 7
3 Engine coolant gauge input
4 Fuel gauge input
5 Power source(24v) -
6 Power source(B+) -
7 Travel speed selection output
8 Mode selection 2 output
9 Mode selection 1 output
10 Engine rpm input
11 Power ground -
12 Signal ground -

2) CN-56 CONNECTOR
Input/
No. Signal
output
1 Mode LED 1 input
2 Mode LED 2 input
3 Null -
4 Null -
5 Null -
6 Coolant level sensor input
Cluster
7 Battery charging warning input
8 Auto decel selection output
9 Head light input
10 Work light input
11 Null -
12 Hyd. oil overheat warning input CN-56
13 Engine oil pressure warning input
8 7 6 5 4 3 2 1
14 Air cleaner clog warning input
15 Coolant overheat warning input 16 15 14 13 12 11 10 9

16 Warming up output

4 - 33
4. CLUSTER FUNCTION
1) TACHOMETER
‫ ڸ‬Tachometer displays the number of engine revolutions.
‫ ڹ‬Refer select switch for the selection and adjustment.

rpm

2) CLOCK
‫ ڸ‬Clock displays the current time by electric digital timer(LCD).
‫ ڹ‬Refer select switch for the selection and adjustment.

TIME

3) FUEL GAUGE
Green D E ‫ ڸ‬This gauge indicates the amount of fuel in the fuel tank.
F
şSegment A : Approximately 33ֻ(Warning lamp display)
C F
şSegment B : Approximately 103ֻ
B şSegment C : Approximately 173ֻ
Red şSegment D : Approximately 246ֻ
A E şSegment E : Approximately 319ֻ
şSegment F : Approximately 392ֻ
şQuantity of fuel tank : Approximately 450ֻ.

4) ENGINE COOLANT TEMPERATURE GAUGE


Green D E ‫ ڸ‬This gauge indicates the temperature of coolant.
F
şSegment A : Approximately 40~60Ƅ(White)
C G
Red şSegment B : Approximately 60~67Ƅ(Green)
B H şSegment C : Approximately 67~74Ƅ(Green)
şSegment D : Approximately 74~81Ƅ(Green)
A
C H HI şSegment E : Approximately 81~88Ƅ(Green)
White
şSegment F : Approximately 88~95Ƅ(Green)
şSegment G : Approximately 95~102Ƅ(Green)
şSegment H : Approximately 102~110Ƅ(Red)
şSegment I : Approximately 110~ (Red)

4 - 34
5) COOLANT LEVEL WARNING LAMP
‫ ڸ‬This lamp is turned ON when the coolant is below LOW in the
reservoir tank of radiator.
‫ ڹ‬Check if the coolant level is between FULL and LOW in the reservoir
tank locating the side of radiator after opening the engine cover, and
check if there is mixture of oil and coolant.

6) BATTERY CHARGING LAMP


‫ ڸ‬Check if the charging lamp is OFF during engine operation. If the
lamp is turned ON, it is not charged.
‫ ڹ‬This lamp is ON before starting the engine, it is turned OFF after
starting the engine. Check the battery charging circuit when this
lamp comes ON.

7) WORKING LIGHT LAMP


‫ ڸ‬When the working light switch is turned ON, the working light
mounted on boom and the working light indicator lamp light ON.

8) HYDRAULIC OIL OVERHEAT WARNING LAMP


‫ ڸ‬This warning lamp operates and the buzzer sounds when the
temperature of hydraulic oil is over 105Ƅ.
‫ ڹ‬Check the coolant when the lamp is turned ON.

9) ENGINE OIL PRESSURE WARNING LAMP


‫ ڸ‬This lamp is turned ON before starting the engine but turned OFF
after starting the engine as the pressure caused from the engine oil
pump lubricates each part.

4 - 35
10) AIR CLEANER WARNING LAMP
‫ ڸ‬This lamp operates by the vacuum caused inside when the filter of
air cleaner is clogged which supply air to the engine.
‫ ڹ‬Check the filter and wash or replace it when the lamp operates.

11) OVERHEAT WARNING LAMP


‫ ڸ‬This lamp is turned ON when the temperature of coolant is over the
normal temperature(110Ƅ)and lose the cooling function.
‫ ڹ‬Check the coolant when the lamp is ON.

12) WARMING UP LAMP


‫ ڸ‬This lamp is turned ON when the coolant temperature is below
30Ƅ.
‫ ڹ‬The automatic warming up is cancelled when the engine coolant
temperature is above 30Ƅ, or when 10 minutes have passed since
starting.

13) MODE SELECTION SWITCH


‫ ڸ‬The lamp of selected mode is turned ON by pressing the right
switch( , ), when selecting the mode to use.
POWER MODE ňH : This is used for heavy-duty work.
H S L F ňS : This is used for ordinary work.
ňL : This is used for light-duty work.
ňF : This is used for light-duty work, especially for finishing
work.

14) AUTO DECELERATION SWITCH


‫ ڸ‬This switch is used to actuate the auto-deceleration function.
AUTO ‫ ڹ‬The engine speed is lowered by touching the switch when
DECEL
temporary stop or stand-by for dump is required.

4 - 36
15) ENGINE SPEED CONTROL SWITCH
‫ ڸ‬This switch is to control the engine speed which is increased by
ENGINE SPEED pressing switch and decreased the engine speed by pressing
switch.

16) SELECTION SWITCH(tachometer and clock)


‫ ڸ‬This switch is used to select the tachometer or clock.
SELECT ‫ ڹ‬The switch is pressed, each function is selected by turns.
‫ ں‬The switch is pressed for 3 seconds, it is selected time adjusting
function.
şHour : Auto decel switch
şMinute : Buzzer stop switch
‫ ڻ‬After time set, the switch is pressed, it is returned clock.

17) BUZZER
‫ ڸ‬The buzzer sounds when the warning lamp lights ON.

4 - 37
GROUP 4 ELECTRICAL COMPONENT SPECIFICATION
Part name Symbol Specifications Check

Ɠ Check specific gravity


12V ź 100Ah 1.280 over : over charged
Battery
(2EA) 1.280 ~ 1.250 : normal
1.250 below : recharging

Rated load 9 Ɠ Check coil resist


24V Normal : about 50ѻ
Battery relay Ɠ Check contact
100A(continuity)
1000A(30seconds) Normal : ſѻ

Ɠ Check disconnection
Normal : 0ѻ
Fusible link 60A (connect ring terminal and
check resist between terminal
1 and 2)

1 2 3 4 5 6 CS-2 Ɠ Check contact


OFF : ſѻ(for each terminal)
1.25BR
1.25W
1.25R
1.25R
1.25Y
1.25L

 ON : 0ѻ(for terminal 1-3


Start key
ST and 1-5)
ACC
OFF START : 0ѻ(for terminal 1-3
HT
OFF B BR IG R1 R2 C and 1-5)

Pressure switch Ɠ Check contact


4 ~ 6‫׏‬/‫׉‬
(for travel alarm) Normal : ſ(OPEN)
(N. O TYPE)
CD-11~CD-14

Pressure switch 0.5‫׏‬/‫׉‬ Ɠ Check contact


(for engine oil) (N. C TYPE) Normal 90ѻ(CLOSE)
CD-18

4 - 38
Part name Symbol Specifications Check

Ɠ Check resist
Coolant 50Ƅ : 153.9ѻ
temperature  80Ƅ : 51.9ѻ
sensor 100Ƅ : 27.4ѻ
CD-8

Coolant Ɠ Check resist


overheat sensor  Normal 9ſѻ
Start key CD-9 105Ƅ over 90ѻ

Air cleaner pressure:635‫ׅ‬ Ɠ Check contact


pressure switch H2O Normal 9ſѻ
CD-10 (N.O TYPE)

Coolant level Ɠ Check contact


2
sensor  High level : ſѻ
1 Low level : 0ѻ
CD-16

Ɠ Check resist
Full : 3ѻ
5/6 : 25ѻ
2 4/6 : 35ѻ
Fuel sender
1  3/6 : 68ѻ
CD-2 2/6 : 95ѻ
1/6 : 110ѻ
Empty warning :180ѻ

1 N Ɠ Check resist
Tacho sensor  Normal 9300ѻ
2 S
CD-17

4 - 39
Part name Symbol Specifications Check

4
Ɠ Check resist
3
Normal - About 200ѻ
Relay  (for terminal 1-3)
2

1
- ſѻ
CR-2
(for terminal 2-4)

Ɠ Check resist
C 1 Normal - About 160ѻ
B 2 (for terminal 2-6)
Relay 
E 4 - 0ѻ
D 6
(for terminal 1-3)
A 3
- ſѻ
CR-4
(for terminal 1-4)

Ɠ Check resist
3
R
POTEN GND
Normal - About 5‫ױ‬
Potentiometer W
(for terminal 1-3)
2 POTEN SIG 
Y
1 POTEN 5V - 0.6‫~ױ‬5‫ױ‬
CN-77 (for terminal 2-3)

B
Ɠ Check resist
1 MOTOR A
G Normal - 5~6ѻ
Governor motor 2 MOTOR A'

3
R
MOTOR B (for terminal 1-2)
Y
4 MOTOR B' - 5~6ѻ
CN-76 (for terminal 3-4)

Ɠ Check resist
Solenoid valve 2
24V 1A Normal - 15~25ѻ
1
(for terminal 1-2)
CN-88

Ɠ Check resist
EPPR valve 24V Normal - 18~25ѻ
(for terminal 1-2)

CN-75

4 - 40
Part name Symbol Specifications Check

1 Ɠ Check resist
Resister 50ѻ 20W
2 Normal - 50ѻ

CN-47

Speaker Ɠ Check resist


4ѻ 20W
Normal - 50ѻ
CN-23(LH)
CN-24(RH) 2 1

Ɠ Check contact
10 9 8 7 6 5 4 3 2 1 Normal
Switch 10 6 5 ON - 0ѻ (for terminal 1-5,2-6)
24V 8A
(Looking type) - ſѻ (for terminal 5-7,6-8)
OFF - ſѻ (for terminal 1-5,2-6)
9 8 2 7 1
- 0ѻ (for terminal 5-7,6-8)

Ɠ Check contact
10 9 8 7 6 5 4 3 2 1 Normal
Switch 10 6 5 ON - 0ѻ (for terminal 1-5,2-6)
24V 8A
(Non-looking type) - ſѻ (for terminal 5-7,6-8)
OFF - ſѻ (for terminal 1-5,2-6)
9 2 1
- 0ѻ (for terminal 5-7,6-8)

24V 75W/70W Ɠ Check disconnection


Head lamp
(H4 TYPE) Normal : a few ѻ

Ɠ Check disconnection
Work lamp 24V 75W/70W Normal : a few ѻ
(H4 TYPE)

4 - 41
Part name Symbol Specifications Check

1
24V 10W Ɠ Check disconnection
Room light
Normal : a few ѻ

2
CL-1

Ɠ Check operation
ňSupply power(24V) to
P
Fuel filler pump terminal 1 pin
24V 35 ֻ/min
ňConnect ring terminal with
CN-61 ground and switch turn ON.

Ɠ Check operation
ňSupply power(24V) to
2

Hour meter terminal NO. 2 and connect



1

terminal NO. 1 and ground.


CN-48

Ɠ Check operation
ňSupply power(24V) to each
Horn
24V 8A terminal and connect ground.
CN-20

Ɠ Check contact
Normal - 0ѻ (for terminal 1-3)
- ſѻ (for terminal 1-2)
Safety switch 24V Operating - ſѻ
(N.C TYPE) (for terminal 1-3)
- 0ѻ
(for terminal 1-2)

4 - 42
GROUP 5 CONNECTORS

1. CONNECTOR DESTINATION
Connector No. of Connector part No.
Type Destination
number pin Female Male
CN-1 SWP 12 I/conn(Engine harness-main harness) S814-012000 S814-112000
CN-2 SWP 12 I/conn(Engine harness-main harness) S814-012000 S814-112000
CN-3 SWP 12 I/conn(solenoid harness-main harness) S814-012000 S814-112000
CN-4 SWP 12 I/conn(R.H harness-main harness) S814-012000 S814-112000
CN-5 370FASTON 2 I/conn(R.H harness-main harness) S813-030200 S813-130200
CN-6 SWP 8 I/conn(Cabin harness-main harness) S814-008000 S814-108000
CN-7 SWP 12 I/conn(Cabin harness-main harness) S814-012000 S814-112000
CN-8 SWP 12 I/conn(Cabin harness-main harness) S814-012000 S814-112000
CN-9 SWP 4 I/conn(Cabin harness-main harness) S814-004000 S814-104000
CN-10 BS 3 I/conn(Boom harness-main harness) S812-003011 -
CN-13 CN 4 I/conn(Wiper harness-main harness) S810-004204 S810-104204
CN-14 CN 4 I/conn(Cabin harness-main harness) S810-004204 -
CN-20 MARK-н 1 Horn S819-010122 -
CN-21 CN 4 Wiper motor S810-004204 -
CN-22 CN 2 Washer tank S810-002202 -
CN-23 - 2 Speaker (LH) S819-020222 S819-120222
CN-24 - 2 Speaker (RH) S819-020222 S819-120222
CN-27 PA 9 Cassette & radio S811-009003 -
CN-28 CN 2 Compressor S810-002202 -
CN-29 - 4 R/dryer S812-002001 -
CN-30 CN 6 Fan speed switch S810-006202 -
CN-31 CN 4 Blower S810-004202 -
CN-32 PA 3 Air-con switch S811-003001 -
CN-36 SWP 12 Fuse box S814-012000 -
CN-37 AMP 3 Fuse box S810-003202 -
CN-38 SWP 8 Fuse box S814-008000 -
CN-40 58-L 2 Fuse box S813-030200 -
CN-45 RING-TERM - Start motor B+ S820-310000 -
CN-47 CN 2 Resistor S810-002202 -
CN-48 CN 2 Hour motor S810-002202 -
CN-50 LC 10 CPU & controller S815-010000 -
CN-51 LC 18 CPU & controller S815-018000 -
CN-52 LC 24 CPU & controller S815-024000 -
CN-53 PA 13 CPU & controller AMP,172498-1 -
CN-56 ML 16 Cluster AMP,174046-2 -
CN-57 ML 12 Cluster AMP,174045-2 -
CN-60 58-L 2 Fusible link - S813-130200
CN-61 - 1 Fuel filler pump S822-015000 -

4 - 43
Connector No. of Connector part No.
Type Destination
number pin Female Male
CN-65 - 1 Travel alarm S822-014000 -
CN-66 J 2 Breaker solenoid S816-002001 -
CN-68 J 2 Safety solenoid S816-002001 -
CN-70 J 2 Travel solenoid S-816-002001 -
CN-74 RING-TERM - Alternator "I" term S820-106000 -
CN-75 - 1 Eppr valve S822-014000 -
CN-76 58-X 4 Governor motor S813-060400 -
CN-77 58-X 3 Potentiometer S813-060300 -
CN-78 - 1 Cold start aid S822-014004 S822-114004
CN-79 - 3 Fuel cut-off solenoid S818-020311 -
ňRelay
CR-1 RING-TERM - Battery relay S820-104000 -
CR-2 CN 4 Horn relay S810-004202 -
CR-3 CN 4 Work lamp relay S810-004202 -
CR-4 CN 6 Wiper relay S810-006202 -
CR-7 CN 4 Air-con relay S810-004202 -
CR-9 CN 4 Cabin light relay S810-004202 -
CR-13 CN 4 Head lamp relay S810-004202 -
CR-23 CN 2 Start relay S816-002003 -
ňSwitch
CS-1 - 1 Door switch S810-014004 -
CS-2 SWP 6 Start key switch S814-006000 -
CS-3 SWF 10 Wiper switch SWF,593757 -
CS-4 CN 3 Safety switch S810-003202 -
CS-5 - 1 Horn switch S822-014000 S822-114000
CS-7 CN 6 Prolix switch S810-006202 -
CS-16 SWF 10 Travel alarm switch SWF,593757 -
CS-22 SWF 10 Cold start switch SWF,593757 -
CS-24 SWF 10 Cabin light switch SWF,593757 -
CS-26 - 1 Pedal switch S822-014000 S822-114000
CS-27 SWF 10 Breaker switch SWF,593757 -
CS-30 SWF 10 Washer switch SWF,593757 -
CS-36 SWF 10 Work lamp switch SWF,593757 -
CS-39 SWF 10 Head lamp switch SWF,593757 -

4 - 44
Connector No. of Connector part No.
Type Destination
number pin Female Male
ňLight
CL-1 CN 2 Room lamp YAZAKI,7123-8326 -
CL-2 - 1 Cigar lighter S822-014004 S822-114004
CL-4 BS 3 Head lamp S812-003011 -
CL-5 BS 3 Work lamp S812-003011 -
CL-6 BS 3 Work lamp S812-003011 -
CL-7 - 1 Beacon lamp S822-014000 S822-114000
CL-8 - 1 Cabin light (rear) S822-014000 S822-114000
CL-9 - 1 Cabin light (LH) S822-014000 S822-114000
CL-10 - 1 Cabin light (RH) S822-014000 S822-114000
ňSensor,sendor
CD-1 MARK-н 1 Hydraulic oil temp sendor S819-010112 -
CD-2 CN 3 Fuel sendor KET,MG 610320 -
CD-8 MARK-н 1 Water temp sendor S819-010122 -
CD-9 - 1 Over heat sensor S822-014000 -
CD-10 - 1 Air cleaner switch S822-014000 S822-114000
CD-11 - 1 Travel alarm press switch S822-014000 -
CD-12 - 1 Travel alarm press switch S822-014000 -
CD-13 - 1 Travel alarm press switch S822-014000 -
CD-14 - 1 Travel alarm press switch S822-014000 -
CD-16 CN 2 Water level sensor S810-002202 -
CD-17 TWP 2 Speed sensor - S818-120221
CD-18 CN 1 Engine oil press switch S810-001202 -

4 - 45
2. CONNECTION TABLE FOR CONNECTORS
1) 58-L TYPE CONNECTOR

No. of Receptacle connector(Female) Plug connector(Male)


pin

1 1

S813-030100 S813-130100

1 2 1 2

S813-030200 S813-130200

4 - 46
2) MULTILOCK TYPE CONNECTOR

No. of Receptacle connector(Female) Plug connector(Male)


pin

20 1 10

11 20
S817-020105

4 - 47
3) PA TYPE CONNECTOR

No. of Receptacle connector(Female) Plug connector(Male)


pin

1 3
2 5

2 5
1 3
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 S811-109002

5 11 1 6

11

1 6 5 11
S811-011002 S811-111002

4 - 48
No. of Receptacle connector(Female) Plug connector(Male)
pin

6 1 7
13

13

1 7 6 13

S811-013002 S811-013002

1 9
8 17

17

1 9 8 17
S811-017002 S811-117002

10 21 1 11

21

1 10 21
11
S811-021002 S811-121002

4 - 49
4) 58-X TYPE CONNECTOR

No. of Receptacle connector(Female) Plug connector(Male)


pin

1 1

S813-060100 S813-160100

2 1

1 2

S813-060200 S813-160200

2 1 3

1 3 2

S813-060200 S813-060200

2 4 1 3

1 3 2 4

S813-060200 S813-060200

4 - 50
5) J TYPE CONNECTOR

No. of Receptacle connector(Female) Plug connector(Male)


pin

1 1

2 2
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

6 3 1 8 5 2

8 5 2 6 3 1
S816-008001 S816-108001

4 - 51
6) SWP TYPE CONNECTOR

No. of Receptacle connector(Female) Plug connector(Male)


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 - 52
No. of Receptacle connector(Female) Plug connector(Male)
pin

3 6
1 4

4 3 6
1
S814-006000 S814-106000

4 8 1 5

4 8
1 5
S814-008000 S814-108000

4 12 1 9

12

1 9 4 12

S814-012000 S814-112000

3 14 1 11

14

3 14
1 11
S814-014000 S814-114000

4 - 53
7) CN TYPE CONNECTOR

No. of Receptacle connector(Female) Plug connector(Male)


pin

1 1

S810-00120 S810-10120

2 2

1 1

S810-002202 S810-102202

3 2

1 2 1 3
S810-003202 S810-103202

2 4 1 4

1 3 2 3
S810-004202 S810-104202

4 - 54
No. of Receptacle connector(Female) Plug connector(Male)
pin

3 6 1 4

1 4 3 6
S810-006202 S810-106202

1 5
4 8

1 5 4 8
S810-008203 S810-108203

4 - 55
8) BS TYPE CONNECTOR

No. of Receptacle connector(Female) Plug connector(Male)


pin

2 1

1 2

S812-002001 S812-102001

1 3 1 2

2 3

S812-003001 S812-103001

2 4 1 3

1 3 2 4

S812-004001 S812-104001

3 6 1 4

1 4 3 6
S812-006001 S812-106001

4 - 56
9) LC TYPE CONNECTOR

No. of Receptacle connector(Female) Plug connector(Male)


pin

5 10

1 6
S815-010000

6 12

12

1 7
S815-012000

8 16

16

1 9
S815-016000

9 18

18

1 10
S815-018000

4 - 57
No. of Receptacle connector(Female) Plug connector(Male)
pin

12 24

24

1 13
S815-024000

4 - 58
10) 375 FASTEN TYPE CONNECTOR

No. of Receptacle connector(Female) Plug connector(Male)


pin

2
1 2
1 2

S810-002402 S810-102402

4 - 59
SECTION 5 MECHATRONICS SYSTEM
GROUP 1 OUTLINE

This micro computer based electro-hydraulic


pump and engine mutual control system(mode
selection system) optimizes engine and pump
performance. 4 power modes(H, S, L, F) make
it possible to use the engine more effectively
corresponding to the work conditions from a
heavy and great power requesting work to a
light and precise work.

PUMP CONTROL BY ENGINE SPEED SENSING


To match the engine torque with the pump
absorption torque, CPU controller varies
EPPR(electro proportional pressure
reducing)valve output pressure, which controls
pump discharge amount whenever feedbacked
engine speed drops under the reference rpm of
each mode set.

1. MAXIMUM POWER MODE : "H" MODE


When "H" mode is set, CPU controller moves
the engine governor motor lever to the full
position and it also sends out current into the
EPPR valve to set the pump absorption torque
high.
So, it is possible to maximize the work
performance by using 100% of the engine flow G'0//$(
power at this mode. 'ֻ.min( R'74$(

K'6/$(
2. GENERAL STANDARD MODE : "S' MODE
When "S" mode is set, CPU controller moves E'4/$(
the engine governor motor lever to the full pressure'kgf.cm2(
position.
And it also sends out more currents into the
EPPR valve than those of "H" mode, which
reduces the discharge amount. So, it is
possible to work swift and soft controllability.

5-1
3. ENERGY(FUEL) SAVING AND FINISHING WORK : "L", "F" MODE
1) When "L" mode is set, CPU controller
moves the engine governor motor lever to Pump input torque
(kg/HPňhr)
the partial position and it also sends out Pump input torque
much more currents into the EPPR valve
than those of "S" mode, which reduces the
pump absorption power largely. So, at this
mode it is useful for light work and for Engine fuel
energy saving. consumption

F L H,S Engine
speed(rpm)

2) When "F" mode is set, CPU controller


moves the engine governor motor lever to
the partial position and it also sends out
maximum currents into the EPPR valve to
reduce the pump absorption power to the
least amount. So, at this mode it is useful
for light work, especially for finishing work.

5-2
GROUP 2 OPERATION OF CAPO SYSTEM

CAPO : Computer Aided power optimization system, is the name of mode selection system, developed
by HYUNDAI

Engine rpm
Item Mode Application
Idle rpm Rated rpm
H Heavy duty operation 2050+50 1900
POWER S General operation 2050+50 1900
MODE L Light duty operation 1850+50 1700
F Finishing operation 1550+50 1400
TRAVEL LO Low speed travelling ӧ ӧ
MODE HI High speed travelling ӧ ӧ
KEY STARTING ӧ Key switch start position 1000Ţ100 ӧ
ONE TOUCH
ӧ Engine deceleration 1000Ţ100 ӧ
DECEL MODE

When engine start, S mode, One Touch Decel and Travel Lo(Turtle) mode are selected automatically.

POWER MODE

H S L F
AUTO SELECT
DECEL
H M

TRAVEL SPEED ENGINE SPEED

5-3
GROUP 3 SYSTEM DIAGRAM

This system is combined system of electronics, hydraulics and mechanics designed with four power
modes to have maximum performance and economical operation.

MCV

Engine

Coolant
temp. Sensor
Hydraulic
Throttle lever
EPPR valve
Governr
motor Speed sensor

CPU
Controller
(Micro computer)

Resistor Battery

Emergency switch
Electric Line
Hydraulic Line

5-4
GROUP 4 ENGINE CONTROL SYSTEM

1. CPU CONTROLLER MOUNTING


4
1

1 CPU controller 2 Controller mounting bracket 3 Rubber


4 Bolt

2. CPU CONTROLLER ASSEMBLY


1) Remove four pieces of bolt(4) of controller
mounting bracket.
2) Pull out bracket(2). CN53

3) Disconnect 4 connectors from CPU CN52


controller.
4) Remove 4 pieces of screw and cover of CN51
CPU controller CN50
5) Inspection : Check PCB(Printed Circuit
Board)
(1) If any damage is found, replace CPU
controller assembly.
(2) If not, but CAPO system does not work
then replace "A" only.(A : EPROM)
Ɠ Removal : Insert small screwdriver or
knife to bottom of EPROM
and lift up carefully.
Ɠ Assembly : Assemble EPROM to mach
with semicircle mark.

5-5
3. ENGINE GOVERNOR MOTOR AND EMERGENCY CABLE MOUNTING

1 Governor motor(step motor)


2 Connecting rod
3 Throttle cable for manual control(Emergency cable)

1) ENGINE THROTTLE LEVER

Lever, Injection pump

SL : Stopper, low idle


SL SH SH : Stopper, high idle
Connecting rod C : As required

Governor motor

2) EMERGENCY CABLE (push-pull cable)


It controls engine speed by connecting onto the lever of the injection pump when the malfunction of
the CPU controller or the governor motor happen.

5-6
3) ENGINE THROTTLE LEVER

4 5

9
Section A-A

1 Potentiometer
2 Cover
3 Shaft for connecting rod
4 Dust seal
5 Bearing
6 Motor
7 Gear
8 Connector(3 P)
8
9 Connector(4 P)

2 1 2 1

Connector 3 4 3

Type 3P, female 4P, female


1 Red Black
Line 2 White Green
Color
3 Yellow Red
4 ӧ Yellow
ňCheck resistance value ňCheck resistance value
Inspection of between No. 1-2 between No. 1-2 and 3-4.
governor motor
ňSpec : 0.6 ~ 5‫ױ‬ ňSpec : 5 ~ 6ѻ

5-7
4. ENGINE SPEED SENSOR
1) DETECT ACTUAL ENGINE RPM AND SEND SIGNAL TO TACHOMETER

3 2

2 Gear teeth, flywheel


3 Lock nut, speed sensor
Flywheel housing
A Clearance

2) INSTALLATION
(1) Clean contacting point of sensor.
(2) Loosen lock nut.
(3) Screw in speed sensor to flywheel housing.
(4) Turn it back 135Ňwhen it contact gear teeth.
(5) Tight lock nut and connect wiring.

5-8
GROUP 5 EPPR(Electro Proportional Pressure Reducing) VALVE

1. CONSIST OF EPPR VALVE


EPPR valve is consists of electro magnet and spool valve installed at main hydraulic pump.
1) ELECTRO MAGNET VALVE
Receive electric current from CPU controller and move the spool proportionally depend on the
specific amount of electric current value.
2) SPOOL VALVE
Is the two way direction control valve for pilot pressure to reducing hydraulic pump flow.
When electro magnet valve activate, pilot pressure enter to flow regulator at hydraulic pump.
So, pump flow decrease to prevent engine stall.
3) PRESSURE AND ELECTRIC CURRENT VALUE FOR EACH MODE

Pressure
Mode Electric current (mA) Engine rpm
kg/cm 2
psi
H 11 Ţ 3 160 Ţ 40 (350 Ţ 30) 2050 + 50
S 15 Ţ 3 220 Ţ 40 (400 Ţ 30) 2050 + 50
L 20 Ţ 3 290 Ţ 40 (450Ţ 30) 1850 + 50
F 33 Ţ 3 480 Ţ 40 (600 Ţ 30) 1550 + 50
ƕ 13 Ţ 3 190 Ţ 40 (375 Ţ 30) 
ƕ Manually operated condition when prolix switch is selected emergency position.

5-9
2. OPERATING PRINCIPLE
1) STRUCTURE

1 Sleeve
2 Spool
3 Piston
4 Bushing
5 Spring
6 9 2 8 10 6 Ball
7 Spring
8 O-ring
9 O-ring
A 10 O-ring
11 Solenoid valve
12 Lock nut
13 Adjusting screw
11 4 3 1 7 5

P Pilot oil supply line(Pilot pressure)


P A
T Return to tank
T A Secondary pressure to flow regulator at hydraulic pump.

2) AT H MODE
Pressure line blocked so, A oil return to tank.

A
P A
T

3) AT S, L, F MODE
Secondary pressure enter to A.

P A

5 - 10
3. EPPR VALVE CHECK PROCEDURE Spec : 270~450mA
1) CHECK ELECTRIC VALUE AT EPPR VALVE
(1) Start engine.
(2) Set S-mode and cancel quick decel
mode. CN-75

(3) If tachometer show approx 2050+50rpm,


disconnect one wire harness from EPPR
valve.
EPPR VALVE
(4) Install multimeter as below. Multimeter

(5) Check electric current value at bucket


circuit relief position.

2) CHECK PRESSURE AT EPPR VALVE Spec : 4~20kg/cm2 (58~290psi)


(1) Remove plug and connect pressure
gauge as Fig.
Gauge capacity : 0 to 40-50 kg / cm2
(0 to 580-730 psi)
(2) Start engine.
(3) Set S-mode and cancel quick decel Supply line, pilot press

mode.
CN-75
(4) If tachometer show approx 2050+50rpm. Pressure adjusting
screw
locknut
(5) Check pressure at relief position of bucket
circuit by operating bucket control lever.
(6) If pressure is not correct, adjust it.
(7) After adjust, test the machine.

5 - 11
GROUP 6 PROLIX SWITCH

Is the conversion switch to manual control temporarily when the electronic control system get out of
order, until repair work be done.

EMERGENCY

NORMAL

Never place this switch in EMERGENCY


position when the CPU is in normal operation.

1. OPERATING PRINCIPLE WIRING DIAGRAM

Ɠ Normal :
Emergency :
2
1
CN-47

6 PROLIX S.W
5
4
9 3
8 2
6 1
CN-50 CS-7

11 1
2 EPPR V/V

CN-75
CN-51 CN-2

1) NORMAL POSITION
- EPPR valve supply specified amount of pilot pressure to flow regulator at hydraulic pump and
regulate hydraulic pump delivery amount depend upon the signal of CPU controller by selected
mode.
2) EMERGENCY POSITION
- If prolix switch set emergency position when any abnormality occurs in CAPO system, constant
electric current of prolix resistor from battery flow to EPPR valve so that EPPR valve fixed
predetermined position.
- In this case excavator can be operated equivalent to S mode.

5 - 12
GROUP 7 FUNCTION AND ELECTRICAL CIRCUIT

1. ONE TOUCH DECELERATION FUNCTION


1) When one touch deceleration function is ňCircuit diagram
selected by touching the switch on, the one
touch-deceleration lamp on the cluster turns
on, at the same time the CPU controller
receives and one touch-deceleration signal CPU
Cluster controller
from the cluster.
2) When one touch deceleration function is Governor
motor
selected by touching the switch ON, the
CPU controller receives the signal, it moves
the engine governor motor lever to the low
idle position in order to cut down engine
speed to one touch deceleration speed
(1000 rpm). Thereby fuel consumption
and noise are reduced.
3) When the one touch-deceleration switch is
touched again and the lamp turns OFF, the
CPU controller moves the governor motor
lever quickly back to the position set before.
So it is possible to restart the work quickly
by returning engine speed to the high rpm
in a few seconds.
4) Logic table
Auto deceleration lamp
ON OFF
Signal Low(GND) High
Function Actuated Canceled
Ɠ Default : One touch deceleration lamp ON
The cluster turns ON.

5 - 13
2. TRAVEL SPEED HI/LO FUNCTION ňCircuit diagram
1) When the travel speed switch is switched
ON/OFF, the lamp on the cluster changes
from rabbit(HI)to turtle(Lo) and the CPU
controller receives the signal.
CPU
2) When the CPU controller receives the Cluster controller
switch signal of ON(rabbit), it activates the Travel solenoid
valve
travel speed solenoid valve to change the
travel speed onto high.
3) Logic table
Travel speed switch
ON OFF
Signal Low High
Voltage(V) 0(GND) 5
Lamp Rabbit Turtle
Ɠ Default : Travel speed lamp lights at Lo(turtle)
on the cluster.

3. ENGINE SPEED UP/DOWN FUNCTION ňCircuit diagram


1) Increasing(speed up) or decreasing(speed
down) is possible by touching the engine
speed up switch or the engine speed down
switch on the cluster.
When one of them is touched, CPU Cluster
CPU
controller
controller receives the signal and moves
the engine governor motor lever to high or Governor
motor
low position a little bit.
2) Logic table
Engine speed UP/DOWN switch
ON OFF
Signal Low High
Voltage(V) 0 (GND) 5

5 - 14
4. ENGINE SPEED SENSING FUNCTION ňCircuit diagram
1) Engine speed sensor mounted on the
engine sends AC voltage signals to CPU Engine speed
CPU
controller, after being rectified into Cluster
controller
rectangular pulse signals by the CPU
controller, they are displayed as engine rpm
counter on the 7-segment displays of the
cluster.
EPPR valve
2) When the engine speed drops below the ş Engine speed signal
reference rpm of each mode, the CPU 5V
controller reduces the pump discharge 0V
amount through engine speed feedback to
match engine output power with pump Ɠ Vpp = 5V
absorption power in the optimal condition.

5. BATTERY CHARGE WARNING FUNCTION ňCircuit diagram


1) When alternator generated voltage drops
below 26V DC after engine starts, the CPU
controller sends battery charge warning CPU
Cluster
buzzer drive signal and lamp drive signal to controller
Alternator
cluster and the warning buzzer and work in
condition of that the generated voltage by
alternator is less than 26V DC.
2) Logic table

Condition ž26V < 26V Description

Signal High(5V) Low(0V) CPU


Controller
Lamp & OFF ON Cluster
buzzer

5 - 15
6. HYDRAULIC OIL TEMP WARNING FUNCTION ňCircuit diagram
1) When the CPU controller receives hydraulic
oil temperature signals(analog voltage
signal) from the hydraulic oil temperature
Hydraulic oil temp sensor
sensor, it converts them into digital signals. Cluster
CPU
controller
If the temperature increases above 100Ƅ,
the CPU controller sends hydraulic oil
temperature warning buzzer signal and
lamp signal to cluster.
So the warning buzzer and lamp ON the
cluster work in condition of that the
temperature is above 100Ƅ
2) Logic table

Condition ž100Ƅ < 100Ƅ Description

Signal Low(GND) High(5V) CPU


Controller
Lamp & OFF ON Cluster
buzzer

7. AUTOMATIC WARMING UP FUNCTION ňCircuit diagram


1) Cluster reads engine coolant temperature
through the temperature sensor, and if the
coolant temperature is less than 30Ƅ, it Water temp. sensor

turns the warming-up lamp ON and sends


warming-up control signal to the CPU
controller. CPU
Cluster controller
2) When the CPU controller receives the
warming-up control signal from the cluster, Governor motor

it changes mode set to "F" mode and


engine speed also increases from one
touch deceleration speed to "F" mode
speed.
3) If the coolant temperature increases upto
30Ƅ, or an operator changes mode set
among the warming up function, the CPU
controller cancels the automatic warming
up function.

5 - 16
4) Logic table(1)

Condition Function

- Mode : "F" after 10 seconds of low idling


- Coolant temperature :
Actuated - Warming up time : at least 10 minutes
less than 30Ƅ(after engine run)
- Warming-up lamp : ON

- Coolant temperature : above 30Ƅ - Default mode


- Warming up time : above 10 minute - Default mode
- Changed mode set by operator - Changed mode
Canceled
ƕ If any of the above conditions is
applicable, the automatic warming-up
function is canceled

Warming-up
lamp Coolant temperature : above 30Ƅ Warming-up lamp : OFF

5) Logic table(2)

Coolant temp. Ž30Ƅ Coolant temp. >30Ƅ Description


Signal Low(0V) High(5V)
Warming-up ON OFF Cluster
lamp
Mode F Default CPU controller

5 - 17
8. ENGINE OVERHEAT PREVENTION FUNCTION ňCircuit diagram
1) When the engine coolant boils upto 110Ƅ,
the overheat switch is ON. and if the
Overheat switch
temperature drops to 100Ƅ, the switch is
OFF.
2) When the overheat switch is ON, engine CPU
Cluster controller
overheat warning buzzer and lamp work
and mode set is changed to "F" mode
Governor motor
automatically on the cluster.
3) If the coolant temperature drops to 100Ƅ or
mode set is changed among the function,
the cluster sends the overheat prevention
cancel signal to the CPU controller.
Thereby the CPU controller returns the
mode to the mode set before.
Ɠ Even if the overheat prevention function is
canceled by mode change, the overheat
warning lamp turns OFF only when the
overheat switch is OFF, that is, the coolant
temperature is less than 100Ƅ
4) Logic table(1)

Description Condition Function

Actuated - Coolant temperature : above 110Ƅ - Mode : "H", "S", "L" Ɗ "F"
- Overheat warning lamp & buzzer : ON
- Coolant temperature : less than 100Ƅ - Return to the mode set before
- Changed mode by operator - Hold on the changed mode
Canceled Ɠ If any of the above conditions is
applicable, engine overheat prevention
function is canceled
Overheat - Coolant temperature : less than 100Ƅ - Lamp OFF
warning lamp

5) Logic table(2)

Overheat switch
ON OFF
Condition Coolant temp : above 110Ƅ Coolant temp : less than 100Ƅ
Signal Low(GND) High(5V)
Lamp & buzzer ON OFF
(cluster)
Mode set F Default
(CPU controller)

5 - 18
SECTION 6 TROUBLESHOOTING
GROUP 1 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 cummings 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.
‫ ڸ‬Was the any strange thing about machine before failure occurred?
‫ ڹ‬Under what conditions did the failure occur?
‫ ں‬Have any repairs been carried out before the failure?
(5) Check before troubleshooting.
‫ ڸ‬Check oil and fuel level.
‫ ڹ‬Check for any external leakage of oil from components.
‫ ں‬Check for loose or damage of wiring and connections.

6-1
2. DRIVE SYSTEM
1) UNUSUAL NOISE COMES OUT OF PUMP CONNECTION

Cause Remedy
YES
Coupling element Disassemble and
is broken. repair.
Remove dust plug
under engine
flywheel and check YES
if rubber pieces or Replace hub or
particles are not retighten
present. Coupling hub setscrew.
spline is worn or
NO hub fastening
setscrew is slack.
If hydraulic pump or engine is suspected as
NO
a culprit refer also to shop manuals
"hydraulic components" and"engine"

6-2
2) ENGINE STARTS BUT MACHINE DOES NOT OPERATE AT ALL

Cause Remedy
NO
Replenish
specified oil to the
Is oil level in Abnormal noise standard level.
YES YES
hydraulic oil tank comes out of Hydraulic pump is Disassemble and
within standard hydraulic pump broken. repair.
level?
Do not hydraulic
Abnormal noise
pump and pump YES YES
comes out of See item 1).
YES connections make
pump connection
abnormal noise?

Is primary pilot
pressure within ‫ڞ‬
NO standard level?

YES
Clean pilot piping
Is not pilot piping interior or repair
YES clogged or is not
piping.
oil leakage present
on pilot piping?
Pilot valve is faulty. Disassemble and
NO
‫ڞ‬ repair.

YES
Pilot relief valve is Repair of replace.
Is gear pump faulty.
NO delivering oil?
Gear pump is Disassemble and
NO
broken. repair.

6-3
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
foams come up. replace hydraulic
oil.
Air is intruded. Check suction
NO
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 level.
Is hydraulic oil
volume proper? YES
Clean oil cooler.
In not oil cooler Secure air
clogged and is circulation route.
YES anything blocking YES ‫ڞ‬
air circulation?
Is fan belt tension
NO proper?
Adjust belt
NO
tension or
replace belt.

Is not the set YES Readjust set


pressure of main
relief,port relief and pressure.
‫ڞ‬
travel relief valve
lower than the Is main relief valve YES Reduce load.
standard level? NO used very often?

6-4
3) CAVITATION OCCURS WITH PUMP

Cause Remedy
NO
Replenish
specified oil to the
standard level.
Is hydraulic oil
YES
volume proper? Replace oil with
one of proper
Is not viscosity of viscosity.
YES hydraulic oil too YES
high? Clean suction
strainer.
Is not suction
NO Is not air intruding
strainer clogged?
Check for air
NO from pump suction
line? intrusion in
suction line and
retighten or
replace parts.

4) HYDRAULIC OIL IS CONTAMINATED

Cause Remedy
YES
Replace
Has not hydraulic hydraulic oil to be
oil passed specified.
specified replace-
ment hours? Has return filter
NO
been replaced at Flush with
NO
proper intervals? hydraulic oil and
replace return
filter.

6-5
4. SWING SYSTEM
1) BOTH LH AND RH SWING ACTIONS ARE IMPOSSIBLE

Cause Remedy
NO
Replenish
YES
‫ڞ‬ specified oil to the
Is safety valve standard level.
YES
pressure within
Gear is gear pump standard?
pressure within Safety valve faulty Repair or replace.
NO
Is oil in hydraulic standard level?
YES
tank within Gear pump faulty Repair or replace.
standard level? NO
YES
Are broken pieces Pump connection Disassemble and
of coupling present coupling is broken. repair.
‫ڞ‬ when dust plug
under engine fly Is not main relief
NO Hydraulic pump is Disassemble and
Are attachment wheel is removed? valve faulty?
NO
and travel motions out of order. repair.
impossible at all?
NO
Swing control valve Disassemble and
YES Does swing control
valve spool move spool is stuck. repair.
Is MCV pilot ‫ڟ‬
YES YES
pressure within
standard level?
Is RH travel NO
‫ڠ‬
NO function? Does not symptom
change when front
and rear pump Hydraulic pump is Disassemble and
NO
discharge hoses broken. repair.
are exchanged?
YES
Swing brake Disassemble and
release valve is repair.
Is swing brake broken.
‫ڟ‬ release valve
faulty? YES Swing reduction Disassemble and
Does swing motor unit is broken. repair.
NO rotate?
Swing motor is Disassemble and
NO
broken. repair.

YES
Pilot relief valve is Disassemble and
NO Is gear pump faulty. repair or replace.
delivering oil?
Gear pump is out Disassemble and
Is gear pump pilot NO
of order. repair.
‫ڠ‬ pressure within
standard level? YES
Is not there oil Clean pilot piping
leakage from pilot interior or repair
YES piping or is not it piping.
clogged?
Pilot valve is Disassemble and
NO
broken. repair.

6-6
2) SWING SPEED IS LOW

Cause Remedy
YES
Swing port relief Disassemble and
Does swing control
YES valve is faulty. repair or replace.
valve spool move
smoothly by hand?
Swing control valve Disassemble and
NO
Is secondary pilot spool is stuck. repair.
pressure same on
LH and RH sides? YES
Clogged or oil leak. Clean pilot piping
Is not pilot piping
interior or repair
Single direction clogged or is not it
NO piping.
leaking oil?
Is the trouble in NO Pilot valve or Disassemble and
one direction or in shuttle valve is repair.
both direction? faulty.
YES ‫ڞ‬

YES Does swing control


Both directions valve spool move
Is MCV pilot
YES pressure within Swing control valve Disassemble and
NO
Is Arm speed standard level? spool is stuck. repair.
within standard ‫ڟ‬
NO
‫ڠ‬
NO
Is swing motor's
‫ڞ‬ NO Swing motor is Disassemble and
drain rate within
standard value? broken. repair.
Check that pilot
YES piping is not NO
Pilot valve or Disassemble and
clogged or oil is not
leaking from it? shuttle valve is repair.
faulty.
Is gear pump pilot Clogged or oil leak. Clean pilot piping
‫ڟ‬ pressure within interior or repair
standard level?
piping.

YES
Pilot relief valve is Disassemble and
Is gear pump
defective. repair or replace.
NO delivering oil?
NO
Gear pump is Disassemble and
broken. repair.
NO
Main relief valve Main relief valve
faulty. pressure
resetting or repair.
Is main relief valve Does the symptom YES Hydraulic pump is Disassemble and
‫ڠ‬ setting pressure change when front
YES broken. repair.
normal and rear pump
discharge hoses
Is safety valve pilot are exchanged? Shuttle valve faulty. Repair or replace.
NO
pressure within
YES YES
standard level? Pilot relief faulty. Repair or replace.
Is gear pump
output pressure
NO within standard
level Gear pump faulty. Repair or replace.
NO

6-7
3) SWING MOTION IS IMPOSSIBLE IN ONE DIRECTION

Cause Remedy
YES
Does symptom Swing port relief Disassemble and
change when LH valve is faulty. repair.
YES
and RH port relief
Does swing valves are
exchanged Shuttle valve is Disassemble and
YES control valve spool NO
move smoothly by faulty repair.
hand?
Is MCV pilot Swing control valve Disassemble and
pressure same for NO
spool is stuck. repair.
LH and RH? Check if pilot piping
is not clogged or YES
Pilot valve is Disassemble and
NO does not have oil
leakage. broken. repair.

Clogged or oil
Clean pilot piping
leak.
interior or repair
piping.

4) MACHINE SWINGS BUT DOES NOT STOP

Cause Remedy
YES
Pilot relief valve is Disassemble and
Is MCV pilot Is gear pump pilot
YES YES faulty. repair or replace.
pressure within pressure within
standard value? standard level?
NO
Gear pump is Disassemble and
broken. repair.
YES Does swing
control valve spool
move smoothly by Pilot valve is faulty. Disassemble and
NO
hand? repair.
Is swing control
valve's return
Swing control valve Disassemble and
spring normal? NO
spool is stuck. repair.

Return spring is Disassemble and


NO
faulty. replace.

6-8
5) THE SWING UNIT DRIFTS WHEN THE MACHINE IS AT REST ON A SLOPE

Cause Remedy
YES
Shuttle valve is Disassemble and
YES Is brake spring faulty. replace.
normal?
YES Is brake spring
‫ڞ‬
NO
normal?
Is return spring of
swing control Brake spring is Disassemble and
valve normal? NO
faulty replace.
Return spring of Disassemble and
NO
swing control valve replace.
is faulty.

YES
Swing relief valve Disassemble and
YES Is drain rate of is faulty. repair or replace.
swing motor within
standard value?
Is swing relief Swing motor is Disassemble and
NO
‫ڞ‬ pressure within broken. repair.
standard level?
Adjust swing relief
NO
valve pressure or
replace swing
relief valve.

6-9
5. TRAVEL SYSTEM
1) TRAVEL DOES NOT FUNCTION AT ALL ON ONE SIDE

Cause Remedy
YES ‫ڇ‬
Does counterbalance
YES spool in travel brake
valve move lightly by
Is travel brake hand?
YES valve pressure Counter spool in
NO
Disassemble and
within standard Does the symptom travel brake valve repair or replace.
Has travel control level? change when relief is stuck.
YES valve spool valves in travel YES
Relief valve built in Disassemble and
changed over NO motor are
exchanged? travel motor is repair.
positively?
faulty.
YES
Does spool move Control system is Disassemble
lightly when hand defective. inspect and
NO is let free from repair.
control cable?
Is bucket or arm NO
Travel control valve Disassemble and
operation spool is stuck. repair.
possible?
YES
Travel reduction Disassemble and
Do not metallic
particles come out unit is faulty. repair.
‫ڞ‬ of drain port in
travel reduction
unit?
NO Travel motor is out Disassemble and
of order. repair.
Does the symptom
change when front
and rear pump YES
Hydraulic pump is Disassemble and
NO discharge hoses
broken. repair.
are exchanged?

6 - 10
2) SPEED ON ONE SIDE FALLS AND THE MACHINE CURVES

Cause Remedy
YES
Brake valve is Disassemble and
Do LH and RH defective. repair or replace.
travel speeds
YES change when LH
YES
and RH travel Does the symptom Relief valve built in Disassemble and
brake valves are change when relief travel motor is repair.
valves in LH and
NO faulty.
Has control valve RH travel motors
YES ‫ڇ‬
spool changed are exchanged? NO
over positively?
YES
Control system is Disassemble,
Does spool move faulty . inspect and
lightly when it is cut repair.
Is the lower speed
NO off from control
(bucket or arm) spool?
within standard Control valve spool Disassemble and
level? NO
is stuck. repair.

YES
Travel relief valve is Disassemble and
Do LH and RH
faulty. repair or replace.
travel speeds Does the symptom
change over when YES
change when front YES
NO travel relief valves and rear pump Hydraulic pump is Disassemble and
are exchanged? Is external pilot discharge hoses broken. repair.
pressure within are exchanged?
NO
standard level?
NO External pilot piping Disassemble and
is clogged or oil is clean.
leaking from it.
Does travel speed
change when
YES parking brake YES Travel motor's Disassemble and
Is leak rate of spring in the slower parking brake is not clean pilot piping.
‫ڞ‬ travel motor within travel motor is
released properly.
standard level?
Travel motor is Disassemble and
NO
faulty. repair.

6 - 11
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 is Disassemble and
Check if parking friction plate worn?
YES faulty. repair.
brake pilot line is
not clogged.
clogged Disassemble and
Is travel brake clean pilot piping.
pressure within Is drain rate of NO
standard level? travel motor within Travel motor is Disassemble and
standard value? defective. repair.

Brake valve is Disassemble and


NO
faulty. repair or replace.

4) LH AND RH TRAVEL MOTIONS ARE IMPOSSIBLE

Cause Remedy
YES
Inspect according
to the procedure
"Travel does not
function at all on
one side."
However, a case
where both LH
and RH travel
motions are
disabled is
extremely
seldom
Is bucket or arm
statistically.
operation
possible? OK Hydraulic pump is Disassemble and
Disassemble both
travel relief valves faulty. repair.
OK and inspect for
Remove dust plug any fault.
under engine
OK flywheel and Travel relief valve is Disassemble and
Faulty
check that there is faulty. repair or replace.
no coupling
Check oil volume element particles.
Particles present. Coupling at pump Disassemble and
in hydraulic oil
NO connection is repair.
tank.
broken.
Short Replenish
hydraulic oil.

6 - 12
5) TRAVEL ACTION IS POWERLESS(travel only)

Cause Remedy
YES
‫ڇ‬
YES Is travel motor's
drain rate within
standard level?
YES Is travel brake NO
Travel motor is Disassemble and
pressure within faulty. repair.
standard level?
Is travel relief valve Travel brake valve Disassemble and
pressure within NO
is defective. repair or replace.
standard level?

Travel relief valve is Disassemble and


NO
faulty. repair or replace.

YES
Hydraulic circuit Disassemble and
Does parking that releases travel clean.
Remove parking Increases brake piston move parking brake is
brake spring in lightly by hand? clogged with dirt.
travel motor, draw
out piston Parking brake Disassemble and
‫ڞ‬ NO
completely, refit piston in travel repair.
cover and check if motor is stuck.
travel power Remains
Travel reduction Disassemble and
changes. unchanged
unit is defective. repair.

6) MACHINE RUNS RECKLESSLY ON A SLOPE

Cause Remedy
Travel brake valve
(counterbalance Disassemble and
valve) is faulty. repair or replace.

6 - 13
7) MACHINE MAKES A CURVED TRAVEL OR DOES NOT TRAVEL AT ALL WHEN TRAVEL AND
ATTACHMENT OPERATIONS ARE EXECUTED AT THE SAME TIME

Does logic valve


function normally Cause Remedy
YES when boom is NO Is logic valve NO
Replace spring.
executed at the spring normal?
YES Is select valve same time?
normal?
Select valve is Repair or replace
NO
Is pilot pressure for faulty
travel select valve
within standard YES
level? Remove dirt on
Is filter in pilot pilot line filter
piping between
NO gear pump and YES Is pilot relief valve NO Pilot relief valve is
control valve not Disassemble and
normal?
clogged? Is gear pump defective. repair or replace.
NO delivering oil?
Gear pump is Disassemble and
NO
broken. repair.

6 - 14
6. ATTACHMENT SYSTEM
1) BOOM OR ARM ACTION IS IMPOSSIBLE AT ALL

Cause Remedy
Does the symptom YES Port relief valve is Disassemble and
change when port faulty. repair or replace.
YES
relief valve is
replaced with other
Is MCV pilot valve? ‫ڇ‬
YES NO
pressure within
standard level? Inspect if pilot
piping is not OK
YES Are other clogged or oil is not Pilot valve is faulty. Disassemble and
attachments NO
leaking from the repair.
operable? piping.
YES
Pilot relief valve is Disassemble and
Is gear pump pilot NO
Is gear pump faulty. repair or replace.
pressure within
NO delivering oil?
standard level?
Gear pump is Disassemble and
NO
Are LH/RH broken. repair.
operations
possible? OK Hydraulic pump is Disassemble and
Disassemble main broken. repair.
YES relief valve and
Remove dust plug check if it is not
under engine irregular.
OK flywheel and check Main relief valve is Disassemble and
Faulty
if coupling element defective. repair or replace.
particles are not
Inspect oil volume present. Particles present
NO
in hydraulic oil Coupling at pump Disassemble and
tank. connection is repair.
broken.
Short
Replenish
hydraulic oil
YES
Does control valve Cylinder interior is Disassemble and
‫ڞ‬ spool move lightly broken. repair.
by hand?
NO Control valve spool Disassemble and
is stuck. repair.

6 - 15
2) BOOM, ARM OR BUCKET SPEED IS LOW
Cause Remedy
YES
Normal
YES ‫ڞ‬
Are other
YES attachment speeds
Is speed low only Is combination of within standard
oil streams normal levels? ‫ڟ‬
in composite YES NO
operation? at boom hoisting YES Logic valve is faulty
and at arm Repair or replace.
extrusion? Logic valve
Are LH/RH travel NO normal.
speeds within Replace spring.
NO NO
standard levels?
YES
Hydraulic pump is Disassemble and
Are both LH/RH faulty. repair.
YES ‫ڠ‬
NO travel speeds low?
Is MCV pilot
pressure within
NO
standard?
NO
‫ڡ‬
Does the symptom OK Port relief valve is Disassemble and
YES change when port faulty. repair or replace.
relief valve is
replaced with other
Does control valve valve? Cylinder is faulty. Disassemble and
YES spool move lightly NO
repair.
by hand?

NO
Control valve spool Disassemble and
Is MCV pilot
‫ڞ‬ pressure within is stuck. repair.
standard level?
YES
Is not secondary Clean pilot piping
pilot pressure interior or repair
piping clogged or
NO piping.
is not there oil
leakage? Pilot valve is Disassemble and
NO
defective. repair.
YES
Pilot relief valve is Disassemble and
Is primary pilot
NO Is gear pump faulty. repair or replace.
‫ڟ‬ pressure within
delivering oil?
standard level?
Gear pump is Disassemble and
NO
broken. repair.
Is engine
NO
‫ڠ‬ revolution within Adjust engine
standard level? revolution.

YES
Clean orifice in
control valve.
Is not orifice in
‫ڡ‬ control valve YES
clogged? Is pilot piping not Clean pilot piping
clogged or is oil not interior or repair
NO leaking from the piping
piping? Is pilot valve
Pilot valve is faulty. Disassemble and
NO normal? NO
repair.

6 - 16
3) BOOM, ARM OR BUCKET CYLINDER EXTENDS OR CONTRACTS ITSELF AND ATTACHMENT FALLS

Cause Remedy
YES
Port relief valve is Disassemble and
Does the
faulty repair or replace.
symptom change
Normal
when port relief
valve is replaced YES ‫ڇ‬
with normal valve? Is control valve
YES Is not hydraulic oil NO return spring
normal?
temperature high? Control valves Disassemble and
NO
return spring is replace.
faulty.
Is genuine Abnormally high. Locate the cause
hydraulic oil or of hydraulic oil
equivalent being
used? temperature rise
and lower it to
proper level.

NO Replace with
genuine hydraulic
oil or equivalent.
OK
Disassemble and Pressure tightness Disassemble and
inspect check between control repair.
YES
valve in hydraulic valve casing and
circuit and check spool is poor.
Is cylinder internal for any fault.
Abnormal Contact surface Disassemble and
‫ڞ‬ leakage within
between poppet repair.
standard level?
and seat is poor.
NO
Cylinder is faulty. Disassemble and
repair.

4) BOOM, ARM OR BUCKET POWER IS WEAK

Cause Remedy
YES
Check according
Is cylinder internal to the procedure
YES leakage within in Item "Speed is
standard level? low"
Is relief pressure in
YES port relief valve Cylinder is faulty. Disassemble and
NO
within standard repair.
level?
Is relief pressure in
main relief valve Port relief valve is Adjust pressure,
within standard NO
faulty. repair or replace.
level?

Main relief valve is Adjust pressure,


NO
defective. repair or replace.

6 - 17
5) ONLY BUCKET OPERATION IS TOTALLY IMPOSSIBLE

Cause Remedy
YES
Port relief valve is Disassemble and
Does the
defective. repair or replace.
symptom change
YES when port relief
valve is replaced YES
Cylinder interior is Disassemble and
with other valve? Does control valve broken. repair.
Is secondary pilot NO spool move
YES smoothly by hand?
pressure within Control valve spool Disassemble and
standard level? NO
is stuck. repair.

Is RH travel Pilot valve is faulty. Disassemble and


NO
possible? repair.

YES
Does the Main relief valve is Adjust pressure,
symptom change faulty. repair or replace.
when LH/RH main Does the symptom
NO
relief valves are change when YES
exchanged? Hydraulic pump is Disassemble and
NO hydraulic pump's
discharge hoses broken. repair.
are exchanged?

6 - 18
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 seal
and boom
Is boom foot pin
greased proper.
sufficiently? Ɠ Frictional
noise will
disappear if
they are kept
used.

Boom foot pin has Supply grease to


NO
run out of grease. it.
Ɠ 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 - 19
Ɠ 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.

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

3. Raise bucket OFF the ground by retracting


the arm cylinder rod.

If off 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.

6 - 20
GROUP 2 ELECTRICAL SYSTEM

1. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR
ňBefore disconnecting the connector, always turn the starting switch OFF.
ňBefore carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No. 14.
ňAfter checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Defective cluster Replace
Check voltage
YES
between CN-57
(5) and chassis
Short circuit or poor Repair or replace
NO
Check voltage connection (after clean)
YES
between CN-8(5) between CN-57 (5)
and chassis
and chassis

Short circuit or poor Repair or replace


Check voltage NO
between CN-50 connection (after clean)
(7) and chassis between CN-8(5)
and chassis
Voltage : 20~30V
Starting switch : ON
YES
Check voltage Defective controller Replace
between CN-50
NO (9) and chassis
Short circuit or poor Repair or replace
NO
connection (after clean)
between CN-8(5)
and chassis

FUSE
3
NO.14
CN-38

CLUSTER
9
5 5 7
11 11
CN-50
12 12
CPU CONTROLLER
CN-57 CN-8
11

CN-51

check voltage value


XDR 1/}2/U
MN /U

6 - 21
2. BATTERY CHARGING LAMP LIGHTS UP(Starting switch : ON)

ňBefore disconnecting the connector, always turn the starting switch OFF.
ňBefore carrying out below procedure, check all the related connectors are properly inserted.
ňAfter checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
‫ڞ‬
Check voltage
YES
between CN-53
(7) and chassis
Check voltage Defective controller Replace
YES NO
between CN-51
(18) and chassis
Short circuit or poor Repair or replace
YES Check voltage NO
between CN-1 (2) connection (after clean)
and chassis between CN-51
(18) and chassis
Check voltage Short circuit or poor Repair or replace
between alternator NO
connection (after clean)
terminal "I" and
chassis between CN-1(2)
Voltage : 20~30V and alternator
Starting switch : ON terminal "I"
Defective alternator Replace
NO
YES
Defective cluster Replace
Check voltage
‫ڞ‬ between CN-
7(7) and chassis
Short circuit or poor Repair or replace
NO
connection (after clean)
between
CN-7(7) and
chassis

CLUSTER CPU CONTROLLER

7 7 7

CN-56 CN-7 CN-53

18

CN-51

ALTERNATOR
2
check voltage value "I" TERMINAL
XDR 1/}2/U CN-1
MN /U

6 - 22
3. WHEN COOLANT OVERHEAT LAMP LIGHTS UP(Engine is started)

ňBefore disconnecting the connector, always turn the starting switch OFF.
ňBefore carrying out below procedure, check all the related connectors are properly inserted.
ňAfter checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Coolant overheat Check engine
(110ƄŹ2Ƅ) system

YES
Check resistance ‫ڞ‬
YES between CN-1(3) -
Does display go chassis and CN-
off when 51 (1) -chassis Short circuit or Repair or replace
disconnect CD-9 NO
and connector?
Starting switch : OFF poor connection (after clean)
Check resistance
YES
Starting switch : ON between CN-9(3)
Engine : start and chassis
Starting switch : OFF
Check resistance Short circuit or Repair or replace
NO
between CN-56 (after clean)
NO poor connection
(15) and chassis

Starting switch : OFF


Before checking,
disconnect CN-9 Defective cluster Replace
NO

YES
Defective sensor Replace
Check resistance
between CD-9 -
‫ڞ‬ chassis and
sensor-chassis
Starting switch : OFF NO Short circuit or Repair or replace
poor connection (after clean)

CLUSTER CPU CONTROLLER

15 3 1

CN-56 CN-9 CN-51 OVER HEAT SWITCH

3
check resistance value CN-1 CD-9
XDR L@W0‫װ‬
MN LHM0‫ײ‬

6 - 23
4. WHEN AIR CLEANER LAMP LIGHTS UP(Engine is started)

ňBefore disconnecting the connector, always turn the starting switch OFF.
ňBefore carrying out below procedure, check all the related connectors are properly inserted.
ňAfter checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Check air filter Repair or replace
(after clean)

YES
Short circuit or Repair or replace
Check resistance poor connection (after clean)
Does display go off YES between CN-1(9)
when disconnect
CD-10 and and chassis
connector? Short circuit or Repair or replace
Check resistance Starting switch : OFF NO
Starting switch : ON YES between CN-9(2) poor connection (after clean)
Engine : start
and chassis
Starting switch : OFF
Check resistance NO
Short circuit or Repair or replace
between CN-56 poor connection (after clean)
NO
(14) and chassis
Starting switch : OFF
Before checking,
disconnect CD-10 Defective cluster Replace
NO

CLUSTER AIR CLEANER SWITCH

14 2 9

CN-56 CN-9 CN-1 CD-10

check resistance value


XDR L@W0‫װ‬
MN LHM0‫ײ‬

6 - 24
5. WHEN ENGINE OIL PRESSURE LAMP LIGHTS UP(Engine is started)

ňBefore disconnecting the connector, always turn the starting switch OFF.
ňBefore carrying out below procedure, check all the related connectors are properly inserted.
ňAfter checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Engine oil leakage, Check engine oil
or defective switch level or replace
switch

YES
Short circuit or Repair or replace
Does display go off Check resistance
when disconnect YES between CN-1 (5) poor connection (after clean)
CD-18 and
and chassis
connector?
Short circuit or Repair or replace
Starting switch : ON Check resistance NO
Engine : start YES between CN-9 (1) poor connection (after clean)
and chassis
Starting switch : OFF
Check resistance NO Short circuit or Repair or replace
between CN-56 poor connection (after clean)
NO
(13) and chassis
Starting switch : OFF
Before checking,
disconnect CD-18
NO
Defective cluster Replace

ENGINE OIL PRESS SWITCH


CLUSTER

13 1 5

CN-56 CN-9 CN-1 CD-18

check resistance value


XDR L@W0‫װ‬
MN LHM0‫ײ‬

6 - 25
6. WHEN HYDRAULIC OIL TEMPERATURE LAMP LIGHTS UP(Engine is started)

ňBefore disconnecting the connector, always turn the starting switch OFF.
ňBefore carrying out below procedure, check all the related connectors are properly inserted.
ňAfter checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Defective switch Check hydraulic
oil temperature
(105ƄŹ2Ƅ) ,
YES
‫ڞ‬ Replace
Check resistance
Does display go YES
between CN-53 (8)
off when
disconnect CD-1 and chassis
and connector? Short circuit or Repair or replace
Check resistance Starting switch : OFF
Starting switch : ON YES between CN-7 (12) poor connection (after clean)
Engine : start
and chassis
Starting switch : OFF
Check resistance NO
Short circuit or Repair or replace
between CN-56 poor connection (after clean)
NO
(13) and chassis
Starting switch : OFF
Before checking,
disconnect CD-1 Defective cluster Replace
NO

YES Repair or replace


Short circuit or
Check poor connection (after clean)
resistance
‫ڞ‬ between CN-
52(21) and
chassis
Short circuit or Repair or replace
Start switch : OFF NO
poor connection (after clean)

HYDRAULIC
check resistance value OIL TEMPERATURE SENDER
XDR L@W0‫װ‬
MN LHM0‫ײ‬
CD-1

21

CN-52
CLUSTER CPU CONTROLLER

13 12 8

CN-56 CN-7 CN-53

6 - 26
7. WHEN COOLANT LEVEL LAMP LIGHTS UP(Engine is started)

ňBefore disconnecting the connector, always turn the starting switch OFF.
ňBefore carrying out below procedure, check all the related connectors are properly inserted.
ňAfter checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Insufficient Refill coolant
coolant or
Defective switch Replace

YES
Short circuit or Repair or replace
Does display go Check resistance poor connection (after clean)
off when YES between CN-1 (11)
disconnect CD-16 and chassis
and connector?
Starting switch : ON Check resistance Starting switch : OFF NO Short circuit or Repair or replace
Engine : start YES between CN-7 (6) poor connection (after clean)
and chassis
Starting switch : OFF
Check resistance
NO Short circuit or Repair or replace
between CN-56
NO poor connection (after clean)
(6) and chassis
Starting switch : OFF
Before checking,
disconnect CD-16
NO Defective cluster Replace

WATER LEVEL
CLUSTER

6 6 11 2

CN-56 CN-7 CN-1 1

CD-16

check resistance value


XDR L@W0‫װ‬
MN LHM0‫ײ‬

6 - 27
8. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE
(Check coolant temperature lamp ON/OFF)
ňBefore disconnecting the connector, always turn the starting switch OFF.
ňBefore carrying out below procedure, check all the related connectors are properly inserted, and
short of fuse N0. 14.
ňAfter checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Coolant overheat Check coolant
or Defective switch temperature or
replace

YES
Short circuit or Repair or replace

Does display go off poor connection (after clean)


Check resistance
when disconnect YES between CN-1(6)
CD-8 and and chassis
connector?
Starting switch : ON Starting switch : OFF NO Short circuit or Repair or replace
Check resistance
Engine : start YES poor connection (after clean)
between CN-8(3)
and chassis
Starting switch : OFF
Check resistance Short circuit or Repair or replace
NO
between CN-57
NO poor connection (after clean)
(3) and chassis
Starting switch : OFF
Before checking,
disconnect CD-8
Defective cluster Replace
NO

Check Resistance Value


XDR L@W0‫װ‬
MN LHM0‫ײ‬
Check Table
C H Sdlodq`stqd
'4/Ƅ( 7/Ƅ 0//Ƅ '01/Ƅ(
Hsdl
TmhsQdrhrs`mbd'‫(װ‬ '042-8( 40-8 16-3 '05-0(
Snkdq`mbd *14+,1/ *3-8+,0-1 *0-8+,0-1 Ź0-1

CLUSTER WATER TEMPERATURE SENDER

3 3 6

CN-57 CN-8 CN-1 CD-8

6 - 28
9. WHEN FUEL GAUGE DOES NOT OPERATE(Check warning lamp ON/OFF)

ňBefore disconnecting the connector, always turn the starting switch OFF.
ňBefore carrying out below procedure, check all the related connectors are properly inserted.
ňAfter checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Defective cluster Replace

Check resistance
value between YES
CN-57(4) and Short circuit Repair or replace
chassis between CN-57 (after clean)
Starting switch : OFF Check resistance
(4) and CN-8(4)
See : TABLE value between
YES Repair or replace
NO CN-8(4) and Short circuit
chassis between CN-8(4) (after clean)
See : TABLE Check resistance and CN-4(6)
value between
YES Short circuit Repair or replace
NO CN-4(6) and
chassis Check resistance between CN-4(6) (after clean)
See : TABLE value between
NO CD-2(2) and and CD-2(2)
chassis ‫ڞ‬
See : TABLE NO

YES Check circuit Repair or replace


Check resistance between CD-2(1) (after clean)
value between
‫ڞ‬ and chassis
CD-2(2) and
CD-2(1) Defective sensor Replace
See : TABLE
NO

Check Table
F
Kdudk Dlosx '0.1( Etkk
Hsdl
TmhsQdrhrs`mbd'‫(װ‬ 00/ '21-4( 2
E Snkdq`mbd Ź2 Ź1

FUEL SENDER
CLUSTER

4 4 6 2

CN-57 CN-8 CN-4 1

CD-2

6 - 29
10. WHEN SAFETY SOLENOID DOES NOT OPERATE

ňBefore disconnecting the connector, always turn the starting switch OFF.
ňBefore carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No. 4.
ňAfter checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES Check hydraulic
YES Check operation system
of solenoid
Defective solenoid Replace
Safety lever : ON-OFF NO
Check resistance
value between
CN-68(1)-(2) with YES
chassis Check chassis Replace
Starting switch : ON contact
Voltage : 20~30v Check resistance
Safety state
value between YES
NO CN-68(1) with Short circuit Repair or replace
chassis between CN-3(6)
Safety lever : ON Check resistance
value between and CN-68(1)
NO CN-3(6) and YES Repair or replace
Short circuit
chassis
between CS-4(1)
Starting switch : ON Check operation
Voltage : 20~30v NO of safety switch and fuse
Defective switch Replace
Voltage : 20~30v NO
Connector(male)

SAFETY SWITCH
FUSE
1 COM.
NO.4 2
NC
3
NO
CS-4 SAFETY SOLENOID

1
3 6 2

CN-36 CN-3 CN-68

6 - 30
11. WHEN TRAVEL SPEED 1,2 DOES NOT OPERATE

ňBefore disconnecting the connector, always turn the starting switch OFF.
ňBefore carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No. 2.
ňAfter checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES Short circuit Repair or replace

Check voltage between CN-36(7)


NO between CN-36 and CN-3(8)
(7) and chassis

Starting switch : ON Recheck fuse Replace


NO
(Short circuit)
Check voltage
YES
between CN-3(8) Check hydraulic
and chassis system
YES Check operation
Starting switch : ON of solenoid
Voltage : 20~30v
Defective solenoid Replace
Check voltage NO
between CN-70
YES YES ‫ڞ‬
(1)-(2)and chassis YES Check voltage

Starting switch : ON between CN-51


Check voltage (5) and chassis Defective controller Replace
between CN-3(8) NO
NO
and chassis
Short circuit Repair or replace
NO
between CN-52
(13) and CN-3(9)
YES Defective cluster Repair or replace
Check voltage
‫ڞ‬ between CN-57
(7) and chassis
Short circuit Replace
NO
between CN-57(7)
and CN-8(7)
FUSE
7
NO.2
CN-36

CONTROLLER TRAVEL SOLENOID

13 9 1
8 2
CN-52
CN-3 CN-70
5

CN-51 CLUSTER

7 7

CN-8 CN-57

6 - 31
12. WHEN ENGINE DOES NOT START

ňCheck supply of the power at engine stop solenoid while starting switch is ON.
ňBefore disconnecting the connector, always turn the starting switch OFF.
ňBefore carrying out below procedure, check all the related connectors are properly inserted.
ňAfter checking, connect the disconnected connectors again immediately unless otherwise specified. START KEY S.W
1 B+
3 IG
Cause Remedy
5 START
YES
Check engine
CS-2
system
Defective battery Charge(after
checking specific 24V
1
gravity of battery)
or replace CN-38
Check operation YES
Defective magnet Replace
Check voltage 24V
of start motor 1
YES between starter
of start motor
magnet coil CN-40
Starting switch : start
and chassis Replace
Defective start
Starting switch : start NO
relay FUEL CUT-OFF
10
Check operation YES Defective start Repair or replace 1
NO of start relay Check voltage switch CN-1
YES between CS-2
CN-79
Starting switch : start (1) and chassis
Short circuit Repair or replace
Starting switch : ON NO ENGINE STOP SOLENOID
between CS-2(1)
Check voltage and CN-40(1)
1 STARTER
between CR-23
NO 2
(1)-(2) YES
Short circuit Repair or replace
Starting switch : start CR-23
between CN-1(1) M
Check voltage and CR-23
between CN-1
NO (start relay)
(1) and chassis
Starting switch : OFF
‫ڞ‬
NO

YES Short circuit Replace


Check voltage between CN-1(1)
‫ڞ‬ between CS-2 and CS-2(5)
(5) and chassis
Starting switch : start
Voltage :20~30V
Defective start Repair or replace
NO
switch

6 - 32
13. WHEN STARTING SWITCH "ON" DOES NOT OPERATE

ňBefore disconnecting the connector, always turn the starting switch OFF.
ňBefore carrying out below procedure, check all the related connectors are properly inserted.
START KEY SWITCH
ňAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
1 B+
3 IG
Cause Remedy 5 START
YES CS-2
Defective cable Repair or replace
Check voltage assembly (after clean)
YES between
CN-60(1)-(2)
Check voltage Short circuit or Replace
YES Voltage : 20~30V NO
between defective of
CN-4(2)-(9) fusible link 1
Check voltage
YES Voltage : 20~30V Short circuit or Replace CN-39
between NO
CS-2(1)-(3) defective of
battery relay IG POWER
Check voltage Voltage : 20~30V 1
CONTINUOUS POWER 24V
and specific Short circuit or Replace 2
NO
gravity of battery defective of start CN-40
Specific gravity : MIN 1.28 switch
Voltage : MIN 24V BATTERY(12VX2)
Battery capacity Charge or replace
NO
too low (after clean)

FUSIBLE LINK
2 2
1 1
CN-5 CN-60
M4 M8
2
9 CR-1
CN-4 M4 M8

BATTERY RELAY
1
2
TO STARTER

6 - 33
14. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE
ňBefore disconnecting the connector, always turn the starting switch OFF.
ňBefore carrying out below procedure, check all the related connectors are properly inserted and
short of fuse NO.14.
WIPER MOTOR
ňAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
S1
3 4 4
Cause Remedy B
2 3 3
YES
‫ڞ‬ 7 2 2 E M
Check voltage 1 1 S2
YES 1
between CN-13
(1) and chassis CN-6 CN-13 CN-21
Voltage : 20~30V NO Short circuit or poor Repair or replace
Check voltage
YES between CN-6 (1) Starting switch : ON connection between (after clean)
Wiper switch : ON
and chassis CN-13(1) - CN-6
Voltage : 20~30V (1) with chassis
Starting switch : ON Short circuit or poor Repair or replace
Wiper switch : ON NO
Check voltage connection between (after clean)
YES WIPER RELAY
between CR-4 (1)
CR-4(1) - CN-6(1) WIPER SWITCH
and chassis 1
with chassis LAMP
Voltage : 20~30V YES 2 9
Starting switch : ON Defective relay Replace
Wiper switch : ON 4 10
Check voltage YES Short circuit or poor Repair or replace
6 2
NO between CR-4 (4) connection between (after clean)
and chassis Check voltage 3 6
SWITCH
Voltage : 20~30V between CN-36 CR-4(4) - CN-36(6)
NO CR-4 CS-3
Starting switch : ON (6) and chassis with chassis
Replace WASHER SWITCH
NO Short circuit of
Voltage : 20~30V
Check operation Starting switch : ON LAMP
of wiper relay fuse 10
YES Defective relay Replace 9
Starting switch : ON 2
Wiper switch : ON-OFF Check connection
YES
between CR-4(6) 6
and chassis 5
Short circuit or Repair or replace
Check connection Wiper switch : OFF NO 1
YES poor connection (after clean) SWITCH
between CS-3(2) CS-30
and chassis between CR-4(6)
Check voltage and chassis 1
between CR-4 (2)
Wiper switch : OFF
Defective wiper Replace switch 2
W WASHER TANK
and chassis NO
switch CN-22
Voltage : 20~30V
Starting switch : ON Short circuit of Replace
NO FUSE
fuse 6

CN-36 NO.1
YES Defective wiper Replace
Check voltage motor
‫ڞ‬ between CN-21(1)
and chassis
Short circuit or Repair or replace
NO
Starting switch : ON
Wiper switch : ON-OFF
poor connection (after clean)
between CN-13
(1) and CN-21(1)

6 - 34
15. WHEN STARTING SWITCH IS TURNED ON, CAB LAMP DOES NOT LIGHT UP

ňBefore disconnecting the connector, always turn the starting switch OFF.
ňBefore carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No.10
ňAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
CN-10
Cause Remedy
YES
Short circuit or Repair or replace
poor connection (after clean)
Check voltage
YES between lamps CL-9
between CN-14
(4) and chassis
Voltage : 20~30V Short circuit or Repair or replace 5 4
Check voltage Starting switch : ON NO
YES between CN-6 (5) (after clean) 7 1
cab lamp switch : ON poor connection
and chassis CL-8
between CN-6(5) CN-6 CN-14
CABIN LIGHT
Voltage : 20~30V and CN-14(4)
Starting switch : ON
cab lamp switch : ON Short circuit or Repair or replace
NO
Check voltage poor connection (after clean)
YES
between CR-9 (2) between CR-9(2)
and chassis
and CN-6(5)
Voltage : 20~30V YES
Defective relay Replace
Starting switch : ON
cab lamp switch : ON CABIN LIGHT
Check voltage CABIN LIGHT SWITCH
4
between CR-9(4) YES LAMP
NO Short circuit or Repair or replace 3 10
and chassis
poor connection (after clean) 1 9
Voltage : 20~30V Check voltage 2 2
Starting switch : ON between CN-37 between CR-9(4)
NO 6
(3) and chassis and CN-37(3) CR-9 SWITCH
Voltage : 20~30V Replace CS-24
Starting switch : ON NO Short circuit of fuse

YES Repair or replace


Short circuit or FUSE
Check operation
of cab lamp relay Check voltage poor connection (after clean)
YES
between CS-24 between CR-9(3) NO.9
Starting switch : ON CN-37
cab lamp switch: ON-OFF
(2) and chassis and CS-24(2)
Cab lamp switch : ON Replace switch
NO
Defective cab
Check connection
lamp switch
NO between CS-24 (6)
and chassis
YES
Voltage : 20~30V Short circuit or Repair or replace
Starting switch : ON
Check voltage poor connection (after clean)
between CN-37 between CS-24(6)
NO
(3) and chassis
and CN-37(3)

NO Short circuit of fuse Replace

Check the bulb of YES


NO cab lamp
Replace

6 - 35
16. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP
ňBefore disconnecting the connector, always turn the starting switch OFF.
ňBefore carrying out below procedure, check all the related connectors are properly inserted and
HEAD LIGHT
short of fuse No.8
ňAfter checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause Remedy
YES
Defective bulb Replace
Check voltage
YES between CL-4(3)
and chassis
NO Short circuit or Repair or replace
Check voltage Voltage : 20~30V 1 2
YES between CN-4 (7) Starting switch : ON poor connection (after clean) CL-3
Head lamp switch : ON
and chassis between CL-4(3)
and chassis
Voltage : 20~30V 7 2
Starting switch : ON
NO Short circuit or Repair or replace
Head lamp switch : ON 9 1
Check voltage poor connection (after clean)
YES CN-4 CL-4
between CR-13 between CL-4(3) HEAD LIGHT
(2) and chassis
and CN-4(7)
Voltage : 20~30V YES
Defective relay Replace
Starting switch : ON
Head lamp switch : ON

Check voltage 9 9
YES
NO between CR-13 Short circuit or Repair or replace CN-7 CN-56
(4) and chassis
poor connection (after clean)
Voltage : 20~30V Check voltage HEAD LIGHT RELAY
Starting switch : ON between CR-13(4)
NO between CN-37 HEAD LIGHT SWITCH
(1) and chassis and CN-37(1) 4
LAMP
3 10
Voltage : 20~30V
NO Short circuit of
Replace
Starting switch : ON 1 9
fuse 2
2
YES
Short circuit or Repair or replace 6
CR-13 SWITCH
Check voltage poor connection (after clean)
Check operation CS-39
YES
of head lamp relay between CS-39 between CR-13(3)
(2) and chassis CS-39(2)
Starting switch : ON Head lamp switch : ON
Head lamp switch : Defective head Replace switch FUSE
NO
ON-OFF Check voltage lamp switch
NO between CS-39 (6) NO.8
and chassis CN-37
YES
Short circuit or Repair or replace
Voltage : 20~30V
Starting switch : ON
Check voltage poor connection (after clean)
between CN-37 between CN-37(1)
NO
(1) and chassis and CS-39(6)
Short circuit of Replace
NO
fuse

Check the bulb of YES


Replace
NO head lamp

6 - 36
17. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP
ňBefore disconnecting the connector, always turn the starting switch OFF.
ňBefore carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No.9. WORK LIGHT
ňAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
1
Cause Remedy 2
YES CL-6
Short circuit or Repair or replace
poor connection (after clean)
Check voltage berweenCL-5(3) 9 1 1
YES 4 2 2
between CN-10
(2) and chassis and CL-6(3)
CN-4 CN-10 CL-5
Voltage : 20~30V
Check voltage Starting switch : ON Short circuit or Repair or replace
YES Work lamp switch : ON NO
between CN-4(4) poor connection (after clean)
and chassis CLUSTER
between CN-4(4)
Voltage : 20~30V and CN-10(2)
Starting switch : ON
10 10
Work lamp switch : ON Short circuit or Repair or replace CN-7 CN-56
NO
Check voltage poor connection (after clean)
YES
between CR-3 (2) WORK LIGHT
between CR-3(2)
and chassis WORK LIGHT SWITCH
and CN-4(4) 4
Voltage : 20~30V YES
LAMP
Starting switch : ON Defective relay Replace 3 10
Work lamp switch : ON 1 9
2 2
Check voltage
between CR-3(4) 6
NO YES Short circuit or CR-3 SWITCH
and chassis Repair or replace
CS-36
poor connection (after clean)
Voltage : 20~30V Check voltage
Starting switch : ON between CN-37 between CR-3(4)
NO
(2) and chassis and CN-37(2) FUSE
Voltage : 20~30V Short circuit of Replace 2
Starting switch : ON NO
fuse CN-37 NO.9

Check operation YES


of work lamp relay Short circuit or Repair or replace
Check voltage poor connection (after clean)
YES
Starting switch : ON between CS-36 between CR-3(3)
Work lamp switch : (2) and chassis
ON-OFF and CS-36(2)
Work lamp switch :
ON-OFF NO Defective work Replace switch
Check voltage
NO between CS-36 lamp switch
(6) and chassis
YES
Voltage : 20~30V Short circuit or Repair or replace
Starting switch : ON
Check voltage poor connection (after clean)
between CN-37 between CS-36
NO
(2) and chassis
(6) and CN-37(2)
Short circuit of fuse Replace
NO

Check the bulb of


Replace
NO work lamp

6 - 37
GROUP 3 MECHATRONICS SYSTEM

1. ALL SPEED ARE SLOW


Ɠ Boom, Arm, Bucket, Swing and travel but engine speed is good.
Ɠ Spec : H-mode 2050 +50rpm S-mode 2050 +50rpm
L-mode 1850 +50rpm F-mode 1550 +50rpm
Ɠ Before carrying out below procedure, check all the related connectors are properly inserted.

1) INSPECTION PROCEDURE

Cause Remedy
YES
Defective
YES Check pressure hydraulic system.
at EPPR valve

YES Check electric NO


Defective Replace.
current value SPEC : 4~20 kg/cm2
SEE : TEST 4 EPPR valve.
at EPPR valve
SPEC:270~450 mA
NO Defective CPU Replace.
Check resistance SEE:TEST 3
controller.
value between
CN-50(6) - (8) YES
Short circuit or Check & repair
SPEC:24Ţ1‫(י‬20Ƅ) poor connection wire harness or
SEE : TEST 1 Check resistance between CN-50 - between CN-50 -
value at EPPR
NO CN-75. CN-75.
valve
SPEC:24Ţ1‫(י‬20Ƅ) Defective EPPR Replace
SEE : TEST 2 NO
valve.

Wiring diagram

2 Ɠ Normal :
1
CN-47 Emergency :

PROLIX S.W
6
5
4
9 3
8 2
6 1
CN-50 CS-7

11 1
EPPR V/V
2
CN-75
CN-51 CN-2

6 - 38
2) TEST PROCEDURE
SPEC : 24 Ţ 1ѻ(20Ƅ)
(1) Test 1 : Check resistance value (6)-(8) at
connector CN-50.
‫ ڸ‬Starting key OFF. CN-50
‫ ڹ‬Remove CPU controller and disconnect CPU 1 2 3 4 5
connector CN-50. CONTROLLER 6 7 8 9 10
‫ ں‬Check resistance value between pin No. CN53 CN52 CN51 CN-50

6 and No. 8 at connector CN-50.

Multimeter

(2) Test 2 : Check resistance value at


connector CN-75. SPEC : 24 Ţ 1ѻ(20Ƅ)
‫ ڸ‬Starting key OFF.
‫ ڹ‬Disconnect connector CN-75 from
EPPR valve at main hydraulic pump. CN-75
‫ ں‬Check resistance value between 2 lines
as below.

Multimeter

(3) Test 3 : Check electric current value at


EPPR valve. SPEC : 270~450mA
‫ ڸ‬Start engine.
‫ ڹ‬Set S-mode and cancel auto decel
mode.
‫ ں‬If tachometer show approx 2050+50rpm,
CN-75
disconnect one wire harness from EPPR
valve.
‫ ڻ‬Install multimeter as Fig.
‫ ڼ‬Check electric current value at bucket
circuit relief position. EPPR VALVE

Multimeter

6 - 39
(2) Test 4 : Check pressure at EPPR valve.
‫ ڸ‬Remove plug and connect pressure SPEC : 4~20 kg/cm2(58~290 psi)
gauge as Fig.
Gauge capacity : 0 to 40~50 kg/cm2
(0 to 580~730 psi)
‫ ڹ‬Start engine.
‫ ں‬Set S-mode and cancel auto decel Supply line, pilot press

mode.
CN-75
‫ ڻ‬If tachometer show approx. 2350+50rpm,
Pressure adjusting
check pressure at relief position of screw
locknut
bucket circuit by operating bucket control
lever.
‫ ڼ‬If pressure is not correct, adjust it.
‫ ڽ‬After adjust, test the machine.

6 - 40
2. ENGINE SPEED IS SLOW AT ALL MODE
Ɠ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE
Cause Remedy
YES
If test 7 is good
Check tachometer Check TEST 1~4
YES work properly or
YES
not by changing Check resistance Misalignment Clean speed
the mode. value between between speed sensor and adjust.
Check resistance
SEE : TEST 6 CN-52(14) - CN- sensor and fly SEE: 5-8page
YES value between NO 51(12)
CN-50(2) - (3) and wheel
(4) - (5) SPEC:0.2~0.4‫ױ‬ ‫ڞ‬
SEE : TEST 7 NO
SPEC:5~6‫י‬
Replace governor
Check linkage SEE : TEST 5 Defective governor motor or harness.
NO
between governor motor or short circuit assembly.
motor - injection or poor connection
pump. between CN-50 -
CN-2 and CN-2 -
CN-76 Adjust or repair.
Improper operation
NO
by loosening or
interference of Check and repair.
linkage.
YES
Short circuit or poor
Check resistance connection between
‫ڞ‬ value between CN-51(12) - CD- Replace.
CD-17(1) - (2) 17(2) or CN-52(14) -
CD-17(1)
SPEC:0.2~0.4‫ױ‬ NO
SEE : TEST 8 Defective
speed sensor.
Wiring diagram

2 Ɠ Mnql`k9
1
CN-47 Dldqfdmbx9
5 PROLIX S.W
4 6
3 5
2 4
9 3
8 2
6 1
CN-50 CS-7
11 1
12
2 EPPR V/V
10
CN-51 CN-2 CN-75 SPEED SENSOR
24 2
23 1
14 CD-17
CN-52 5 1
4 2 POT(POTENTIOMETER)
3 3
7
6 CN-77
9
10 1 A
11 2 A-
12 3 B
4 B-
CN-2
CN-76 GOVERNOR MOTOR

6 - 41
2) TEST PROCEDURE
(1) Test 5 : Check resistance value between CPU
(2)-(3) and (4)-(5) at connector CONTROLLER
CN-50. CN53 CN52 CN51 CN-50
‫ ڸ‬Starting key OFF.
‫ ڹ‬Remove CPU controller and disconnect
connector CN-50 from CPU controller.
‫ ں‬Check resistance value as below.

CN-50 CN-50

1 2 3 4 5 1 2 3 4 5
6 7 8 9 10 6 7 8 9 10

Multimeter Multimeter

unit : rpm
(2) Test 6 : Check tachometer
Spec Remark
(Work properly or not.)
‫ ڸ‬Start engine. H-mode 2050+50rpm
‫ ڹ‬Check tachometer reading. S-mode 2050+50rpm Check rpm after
cancel the one touch
L-mode 1850+50rpm decel mode.
F-mode 1550+50rpm

(2) Test 7 : Check resistance value between


SPEC : 0.2 ~ 0.4 ‫ױ‬
(14) of CN-52 and (12) of CN-51.
‫ ڸ‬Starting key OFF.
‫ ڹ‬Remove CPU controller and disconnect CPU
connector CN-51 and CN-52 from CPU CONTROLLER
controller. CN53 CN52 CN51 CN-50
‫ ں‬Check resistance value as below.

CN-52 CN-51
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9
13 14 1516 17 18 19 20 2122 23 24 10 11 12 13 14 1516 17 18

Multimeter

6 - 42
(4) Test 8 : Check resistance value at speed
SPEC : 0.2 - 0.4‫ױ‬
sensor.
‫ ڸ‬Starting key OFF.
‫ ڹ‬Disconnect connector CD-17 of speed Speed sensor

sensor at engine flywheel housing.


‫ ں‬Check resistance value as Fig.
CD-17 CD-17
1 2

Engine flywheel

Multimeter

6 - 43
3. ENGINE STALL
Ɠ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE
Cause Remedy
YES
Not enough engine Contact cummins
YES Check pressure at power. engine dealer.
EPPR valve.

NO
Defective EPPR Replace.
SPEC:30~33 kg/cm2 valve.
Check electric SEE:TEST 10
current value at YES
EPPR valve. Defective CPU Replace.
controller.
SPEC:570~600 mA
SEE:TEST 9 Check resistance
value between YES
Short circuit or poor Check and
NO CN-50(6) - (8)
connection repair.
SPEC:24Ţ1Ѥ(20Ƅ) Check resistance between
SEE : TEST 1 value at EPPR CN-50 - CN-2 or
NO
valve. CN-50 - CN-75
SPEC:24Ţ1Ѥ(20Ƅ)
SEE : TEST 2 Defective EPPR Replace.
NO
valve.

Wiring diagram

Ɠ Mnql`k9
Dldqfdmbx9
2
1
CN-47

PROLIX S.W
6
5
4
9 3
8 2
6 1
CN-50 CS-7

11 1
EPPR V/V
2
CN-75
CN-51 CN-2

6 - 44
2) TEST PROCEDURE
SPEC : 570~600mA
(1) Test 9 : Check electric current value at
EPPR valve at F-mode
‫ ڸ‬Start engine. CN-75
‫ ڹ‬Set F-mode with 1550 +50rpm
‫ ں‬Install multimeter as below.
‫ ڻ‬Check electric current value at bucket
circuit relief position.
EPPR VALVE

Multimeter

(2) Test 10 : Check pressure at EPPR valve


SPEC : 30~33 kg/cm2(440~480 psi)
at F-mode
‫ ڸ‬Connect pressure gauge at EPPR valve.
‫ ڹ‬Start engine.
‫ ں‬Set F-mode with 1550 +50rpm
‫ ڻ‬Operate bucket lever completely push or Supply line, pilot press

pull. CN-75
‫ ڼ‬Hold arm lever at the end of stroke. Pressure adjusting
screw
‫ ڽ‬Check pressure at relief position. locknut

6 - 45
4. CLUSTER LAMPS ARE OFF IMMEDIATELY AFTER KEY SWITCH OFF
Ɠ Before carrying out below procedure, check all the related connector are properly inserted.
Normal condition : Lamps "ON" approx. 3-12 second after key switch OFF.
1) INSPECTION PROCEDURE

Cause Remedy
YES
Defective Replace.
CPU controller.

Check voltage at YES


CN-50(10) Poor connection Check and
or short circuit repair.
SPEC:24Ţ1 VOLT between
SEE : TEST 11
Check CN-50(10) - CN-
NO Fuse No. 17 60(2)

SEE : TEST 12
Defective fuse. Replace.
NO

Wiring diagram

FUSE BOX

BATTERY
10 1 17 2 2 2
CN-40 CN-5 CN-60
CN-39
CN-50

6 - 46
2) TEST PROCEDURE
SPEC : 24 Ţ 1Volt
(1) Test 11 : Check voltage at (10) of CN-50.
‫ ڸ‬Starting key OFF. CN-50

‫ ڹ‬Disconnect connector CN-50 from CPU CPU 1 2 3 4 5


CONTROLLER 6 7 8 9
controller. 10
CN53 CN52 CN51 CN-50

Ground

Multimeter

(2) Test 12 : Check fuse at (17) of fuse Box.


‫ ڸ‬Starting key OFF. Fuse box
CPU WIPER &

20A
10A
12

1
CONTROLLER WASHER

‫ ڹ‬Selecting the fuse at (17) of fuse Box.

20A
20A
CLUSTER

2
13
SOL. B+

‫ ں‬Check if the fuse is defective or not.


CASSETTE &

20A
20A

3
WORK LAMP

14
RADIO

CIGAR &

20A
20A
15
SPARE

4
ETHER SOL.

CASSETTE & HORN &

20A
10A
16

5
CLOCK B+ SAFETY

MONITOR &

20A
20A
17

6
HEAD LAMP
CPU B+

F/PUMP &

10A

10A
18
ROOM LAMP

7
T/ALARM

AIR-CON

30A

20A
SPARE

8
BREAKER

30A

30A
SPARE

9
CABIN LIGHT

10A
30A

10
SPARE SPARE

10A
SPARE

11
FUSE

20A
12
PULLER SPARE

SPEC : 20A

Fuse No. 17 for CPU B+

6 - 47
5. CLUSTER LAMPS ARE STILL ON AFTER STARTING KEY OFF
Ɠ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE
Cause Remedy
YES
Improper Check and
operation of repair.
governor motor.
Check interference So, governor
YES of connecting rod motor supply
when governor
signal to
motor move to low
rpm side. cluster panel
continuously.
Replace.
Check voltage at Defective
CN-50(9). NO
CPU controller. Replace.
SPEC : YES
Key ON : 24Ţ1 VOLT Defective battery
Key OFF : 0 VOLT
SEE : TEST 13 Is the voltage 24V relay.
Replace.
NO between CN-50(4)
and GND?
NO
Defective CPU
TEST :
Repeat key switch controller
ON and OFF
SEE : TEST 14

Wiring diagram

FUSE BOX

9 3 3 START
14
1 IGNITION

CN-38 CS-2
CN-50 START KEY SWITCH

6 - 48
2) TEST PROCEDURE
SPEC :
(1) Test 13 : Check voltage at(9) of CN-50. Key ON : 24Ţ1 Volt
‫ ڸ‬Starting key "ON". Key OFF : 0 Volt
‫ ڹ‬Disconnect connector CN-50 from CPU
CN-50
controller. CPU 1 2 3 4 5
‫ ں‬Check voltage as below. CONTROLLER 6 7 8 9 10
CN53 CN52 CN51 CN-50

Ground

Multimeter

(2) Test 14 : Check operating status of main


SPEC :
power supply at (9) of CN-50.
Key OFF : 0 Volt
‫ ڸ‬Starting key "ON".
‫ ڹ‬Disconnect CN-50 from CPU controller. CN-50
‫ ں‬Check if the voltage remains at 24Ţ CPU 1 2 3 4 5
1volt inspire of operating key switch on CONTROLLER 6 7 8 9 10
and off. CN53 CN52 CN51 CN-50

Ɠ If there is certain amount of voltage,


replace CPU controller. Ground

Multimeter

6 - 49
6. CLUSTER LAMPS ARE ON WHEN ENGINE RUN OR MALFUNCTION OF MODE SELECTION
SYSTEM
Ɠ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE

Cause Remedy
YES
Defective lamps or Repair or Replace
Check voltage for cluster
YES
between CN-50(7)
- CN-57(5).

SPEC : 24Ţ1V NO
Defective CPU Replace.
Check resistance SEE : TEST 16 controller.
value for switches. Poor connection Check and repair.
between CN-50 -
SPEC :
Switch ON : 0‫י‬ CN-57.
Switch OFF : Ũ‫י‬
SEE : TEST 15 NO
Defective switch at Replace.
cluster.

Wiring diagram

8 8

4
CN-56 CN-7
5
6
7
8
9

7 7
CN-51
1 1
2 2
9 9
8 8
5 5 7
CN-57 CN-8

CN-50

6 - 50
2) TEST PROCEDURE
(1) Test 15 : Check resistance value for CPU
switches. CONTROLLER
‫ ڸ‬Starting key OFF. CN53 CN52 CN51 CN-50
‫ ڹ‬Disconnect connector CN-51 from CPU
controller.
‫ ں‬Check resistance value as below.

CN-51

1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18

Ground

Multimeter

(2) Test 16 : Check voltage for CN-50, CN-57


ňCN-50:output power(24Ţ1volt) SPEC : 24Ţ1 Volt
ňCN-57:input power(24Ţ1volt)
‫ ڸ‬Starting key ON.
CN-50
‫ ڹ‬Remove cluster from panel. CPU 1 2 3 4 5
Ɠ Don't disconnect connector CN-50 from CONTROLLER 6 7 8 9 10
CPU controller. CN53 CN52 CN51 CN-50
‫ ں‬Disconnect connector CN-57 from
cluster. Ground

‫ ڻ‬Check voltage CN-50,CN-57 with


ground as Fig. Multimeter

CN-57
1 2 3 4 5 6
7 8 9 10 11 12

Ground

Multimeter

6 - 51
7. SLOW ACTION OF ENGINE SPEED CHANGE WHEN CHANGE THE MODE
Ɠ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE

Cause Remedy
YES
Slow action of Check and repair.
engine speed
control due to
interference.
Check interference Replace.
Check voltage YES
between between CN- Defective CPU
connecting rod 52(24) - CN-51(10) controller.
and governor YES
and check
resistance value Replace.
Check resistance between CN- Defective governor
value between CN- 52(23) - CN-51(10). NO
motor.
NO 50(2) - (3) and CN- SPEC : (24)-(10) : 5Ţ1 volt
50(4) - (5) (23)-(10) : 0-5‫ױ‬
SEE : TEST 18 Replace.
SPEC : 5~6‫י‬
SEE : TEST 17 Defective governor
NO
motor.

Wiring diagram

2
3
4
5

CN-50
5 1
4 2 POT(POTENTIOMETER)
10 3 3

CN-77
CN-51
12 4 B-
11 3 B
10 2 A-
24 9 1 A
23
CN-2 CN-76 GOVERNOR MOTOR

CN-52

6 - 52
2) TEST PROCEDURE
Test - a
(1) Test 17 : Check resistance value
‫ ڸ‬Starting key OFF.
‫ ڹ‬Disconnect connector CN-50 from CPU CN-50
CPU
controller. 1 2 3 4 5
CONTROLLER
‫ ں‬Check resistance value between (2) and 6 7 8 9 10
CN53 CN52 CN51 CN-50
(3), (4) and (5) of CN-50 as below.

Multimeter

Test - b

CN-50
CPU
1 2 3 4 5
CONTROLLER
6 7 8 9 10
CN53 CN52 CN51 CN-50

Multimeter

6 - 53
(2) Test 18 : Check voltage and resistance
SPEC : 0 ~ 5 ‫ױ‬
value.
‫ ڸ‬Check resistance value between (23) of
CN-52 and (10) of CN-51. CPU
CONTROLLER
Ť Starting key OFF.
CN53 CN52 CN51 CN-50
Ť Disconnect connector CN-52 and CN-51
from CPU controller.
Ť Check resistance value with multimeter
as below.

CN-52 CN-51
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9
13 14 1516 17 18 19 20 2122 23 24 10 11 12 13 14 1516 17 18

Multimeter

‫ ڹ‬Check voltage between (24) of CN-52


SPEC : 5 Ţ 1Volt
and (10) of CN-51.
CPU
Ť Prepare 2 pieces of thin sharp pin, steel
CONTROLLER
or copper. Pin Pin
Ť Starting key ON.
Ť Insert prepared pins to rear side of
connectors :
One pin to (24) of CN-52
Other pin to (10) of CN-51
Ť Check voltage.
CN-52 CN-51
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9
13 14 1516 17 18 19 20 2122 23 24 10 11 12 13 14 1516 17 18

Multimeter

6 - 54
8. ONE TOUCH DECEL SYSTEM DOES NOT WORK
Ɠ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE
Cause Remedy
YES
Defective CPU Replace.
controller.
Short circuit or poor Replace or repair.
connection
Check resistance
between CN-51(3)
value between
CN-51(4) - GND. - (4)

SPEC :
Switch ON : 0‫װ‬
Switch OFF : ſ‫װ‬
SEE : TEST 19
NO
Defective cluster. Replace.

Wiring diagram

11 11 2
CS-29
8 8 CN-36

3
4
CN-56 CN-7 5
6
7
8
9
7 7
1 1 CN-51
2 2
9 9
8 8
5 5 7
CN-57 CN-8

CN-50

6 - 55
2) TEST PROCEDURE
SPEC :
(1) Test 19 : Check resistance value at One touch decel switch ON(Light ON) : 0‫װ‬
CN-51(4) and ground. One touch decel switch OFF(Light OFF) : ſ‫װ‬
‫ ڸ‬Starting key OFF.
‫ ڹ‬Disconnect connector CN-51 from CPU
CPU controller. CONTROLLER
‫ ں‬Turn start key ON. CN53 CN52 CN51 CN-50
Check resistance value as Fig.

CN-51

1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18

Ground

Multimeter

6 - 56
9. MALFUNCTION OF WARMING UP
Ɠ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE

Cause Remedy
YES
Defective cluster or Repair or
Check resistance CPU controller or Replace.
YES
value between CN- CD8(sensor)
57(3) - CD-8
Check resistance SPEC : 0ѻ Poor connection Repair.
NO
value between CN SEE : TEST 21 between CN-57(3)
-51(20) - CN-56(16) - CD-8.
SPEC : 0ѻ
SEE : TEST 20
Poor connection Repair.
NO
between CN-
52(20) - CN-56(16).

Wiring diagram

WATER TEMP SENSOR


20 4 16
CD-8
CN-52 CN-9

CN-56

3 6

CN-1
CN-57

6 - 57
2) TEST PROCEDURE
SPEC : 0ѻ
(1) Test 20 : Check resistance value between
connector (20) of CN-52- (16) of
CN-56. CPU
‫ ڸ‬Starting key OFF. CONTROLLER
‫ ڹ‬Remove CPU controller and disconnect CN53 CN52 CN51 CN50

CN-52 from CPU controller.


‫ ں‬Remove cluster and disconnect CN-56 Cluster

from cluster.
‫ ڻ‬Check resistance value as Fig.
CN-56

9 10 1112 1314 15 16

1 2 3 4 5 6 7 8
CN-52
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24

Multimeter

(2) Test 21 : Check resistance value between


connector (3) of CN-57 - CD-8. SPEC : 0ѻ
‫ ڸ‬Starting key OFF.
CN-57
‫ ڹ‬Remove cluster and disconnect CN-57 12 11 10 9 8 7

from cluster. 6 5 4 3 2 1
‫ ں‬Disconnect connector CD-8 of water
temp sensor at engine head.
‫ ڻ‬Check resistance value as Fig.

Cluster
CD-8 Water temp sensor

Multimeter

6 - 58
10. MALFUNCTION OF OVERHEAT
Ɠ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE

Cause Remedy
YES
Defective overheat Replace
switch
Check resistance
value between YES
CD-9 - GND. Defective CPU Replace
SPEC : Check resistance controller
Region мƊſѻ value between CN-
(Fig.) нƊſѻ NO
51(1) - CD-9
оƊſѻ
SEE : TEST 22 Short circuit or poor Check or Repair
SPEC : 0ѻ NO
SEE : TEST 23 connection between
CN-51(1) - CD-9.

coolant
temperature

110Ƅ

Ɠ Overheat switch ON coolant temperature 110Ƅ 110Ƅ


Ɠ Overheat switch OFF coolant temperature 100Ƅ

Time
Region ѓ Region є Region ѕ
Temperature curve
Wiring diagram
Overheat switch

1 3

CD-9
CN-51 CN-1

15 3

CN-59

CN-56

6 - 59
2) TEST PROCEDURE
SPEC : 0ѻ
(1) Test 22 : Check resistance value between
connector CD-9 - GND. CD-9 Overtheat switch
‫ ڸ‬Starting key OFF.
‫ ڹ‬Disconnect connector CD-9 of overheat
switch at engine head.
‫ ں‬Check resistance value as Fig.

Ground
Multimeter

(2) Test 23 : Check resistance value between


SPEC : 0ѻ
connector (1) of CN-51 - CD-9.
CPU
‫ ڸ‬Starting key OFF.
CONTROLLER
‫ ڹ‬Remove CPU controller and disconnect
connector CN-51 from CPU controller. CN53 CN52 CN51 CN-50

‫ ں‬Disconnect connector CD-9 of overheat


switch at engine head.
‫ ڻ‬Check resistance value as Fig.

CN-51
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18

CD-9
Overtheat switch

Multimeter

6 - 60
SECTION 7 MAINTENANCE
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 site, condition
it must be tested to confirm that the
operational performance of the machine Maintenance
meets HYUNDAI SPEC. record

2) OPERATIONAL PERFORMANCE OF A
WORKING MACHINE
With the passage of time, the machine's
operational performance deteriorates, so
that the machine needs to be serviced
periodically to restore it to its original Operating
time
performance level.
Before servicing the machine, conduct
performance tests to check the extent of
deterioration, and to decide what kind of
service needs to be done(by referring to the
"Service Limits" in this manual).
3) OPERATIONAL PERFORMANCE OF A
REPAIRED MACHINE
After the machine is repaired or serviced, it
must be tested to confirm that its
operational performance was restored by
the repair and/or service work done.

7-2
2. TERMINOLOGY
1) STANDARD
Specifications applied to the brand-new
machine, components and parts.

2) SERVICE LIMIT
The lowest acceptable performance level.
When the performance level of the machine
falls below this level, the machine must be
removed from work and repaired.
Necessary parts and components must be
replaced.

7-3
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
‫ ڸ‬Select a hard, flat surface.
Secure enough space to allow the
‫ ڹ‬machine to run straight more than 20m,
and to make a full swing with the front
attachment extended.
‫ ں‬If required, rope off the test area and
provide signboards to keep unauthorized
personnel away.
(3) Precautions
‫ ڸ‬Before 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 without fail.
‫ ڹ‬Operate the machine carefully and
always give first priority to safety.
‫ ں‬While 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.
‫ ڻ‬Avoid 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.

7-4
(4) Make precise measurements
‫ ڸ‬Accurately calibrate test instruments in
advance to obtain correct data.
‫ ڹ‬Carry out tests under the exact test
conditions prescribed for each test item.
‫ ں‬Repeat the same test and confirm that
the test data obtained can be procured
repeatedly. Use mean values of
measurements if necessary.

7-5
2) ENGINE SPEED
(1) Measure the engine speed at each power
mode
Ɠ 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
‫ ڸ‬Warm up the machine, until the engine
coolant temperature reaches 50Ƅor
Ź5Ƅ.
more, and the hydraulic oil is 50Ň
‫ ڹ‬Push the H-mode switch and confirm
that the fuel injection pump governor
lever comes into contact with the high-
idle stopper.
‫ ں‬To measure engine RPM:

(3) Measurement
‫ ڸ‬Start the engine. The engine will run at
start idle speed. Measure engine speed
with a tachometer.
‫ ڹ‬Measure and record the engine speed at
each mode(H.S.L.F)
‫ ں‬Select the H-mode.
‫ ڻ‬Lightly 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 4seconds.
‫ ڼ‬Measure and record the one touch
deceleration speed.

7-6
(4) Evaluation
The measured speeds should meet the following specifications.
Unit : rpm
Model Engine speed Standard Remarks
Start idle 1000 Ź100
H mode 2050 + 50
S mode 2050 + 50
R290LC-3
L mode 1850 + 50
F mode 1550 + 50
One touch decel 1000Ź 100

7-7
1) TRAVEL-SPEED
(1) Measure the time required for the
excavator to travel a 20m test track.
(2) Preparation
‫ ڸ‬Adjust the tension of both tracks to be
equal.
‫ ڹ‬Prepare a flat and solid test track 20m in
length, with extra length of 3 to 5m on
both ends for machine acceleration and 0.3~0.5m
deceleration.
‫ ں‬Hold the bucket 0.3 to 0.5m above the
ground with the arm and bucket rolled in.
‫ ڻ‬Keep the hydraulic oil temperature at 50Ň
Ź5Ƅ.
(3) Measurement
‫ ڸ‬Measure both the medium and fast
speeds of the machine.
‫ ڹ‬Before starting either the medium or fast
speed tests, adjust the travel mode
switch to the speed to be tested, then
select the following switch positions: 20m 3~5m
3~5m
ş Mode selector : H mode
‫ ں‬Start traveling the machine in the
acceleration zone with the travel levers
at full stroke.
‫ ڻ‬Measure the time required to travel 20m.
‫ ڼ‬After measuring the forward travel
speed, turn the upperstructure 180Ňand
measure the reverse travel speed.
‫ ڽ‬Repeat 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/20m
Model Travel speed Standard Maximum allowable Remarks
1 speed 21.9Ź2.0 28.5
R290LC-3
2 speed 14.8Ź1.0 18.5

7-8
4) TRACK REVOLUTION SPEED
(1) Measure the track revolution cycle time
with the track raised off ground.
(2) Preparation
‫ ڸ‬Adjust the tension of both side tracks to
be equal.
‫ ڹ‬On the track to be measured, mark one
90~110Ň
shoe with chalk.
‫ ں‬Swing the upperstructure 90Ňand lower
the bucket to raise the track off ground. Mark
Keep the boom-arm angle between 90
to 110Ňas shown. Place blocks under
machine frame.
‫ ڻ‬Keep the hydraulic oil temperature at
50Ň Ź5Ƅ.
(3) Measurement
‫ ڸ‬Select the following switch positions:
ş Travel mode switch : 2 speed
ş Mode selector : H mode
ş Auto idle switch : OFF
‫ ڹ‬Operate the travel control lever of the
raised track in full forward and reverse.
‫ ں‬Rotate 1 turn, then measure time taken
for next 3 revolutions.
‫ ڻ‬Raise the other side of machine and
repeat the procedure.
‫ ڼ‬Repeat steps‫ ں‬and ‫ ڻ‬three 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
R290LC-3 2 speed 23.0Ź2.0 30

7-9
5) TRAVEL DEVIATION
(1) Measure the deviation by the tracks from
a 20m straight line.
(2) Preparation
‫ ڸ‬Adjust the tension of both tracks to be
equal.
‫ ڹ‬Provide a flat, solid test yard 20m in
0.3~0.5m
length, with extra length of 3 to 5m on
both ends for machine acceleration and
deceleration.
‫ ں‬Hold the bucket 0.3 to 0.5m above the
ground with the arm and bucket rolled in.
‫ ڻ‬Keep the hydraulic oil temperature at 50Ň
Ź5Ƅ.
(3) Measurement
‫ ڸ‬Measure the amount of mistracking at
fast, medium and slow travel speeds.
‫ ڹ‬Before beginning each test, select the
following switch positions: 3~5m extra length

ş MODE selector : H mode a

M
20
‫ ں‬Start traveling the machine in the
acceleration zone with the travel levers
at full stroke. 3~5m extra length
‫ ڻ‬Measure the distance between a straight
20m line and the track made by the
machine.(dimension a)
‫ ڼ‬After measuring the tracking in forward
travel, turn the upperstructure 180Ňand
measure that in reverse travel.
‫ ڽ‬Repeat steps ‫ ڻ‬and ‫ ڼ‬three times and
calculate the average values.
(4) Evaluation
Mistrack should be within the following specifications:
Unit : mm/20m
Model Standard Maximum allowable Remarks
R290LC-3 200 240

7 - 10
6) SWING SPEED
(1) Measure the time required to swing three
complete turns.
(2) Preparation
‫ ڸ‬Check the lubrication of the swing gear
and swing bearing.
‫ ڹ‬Place the machine of flat, solid ground
with ample space for swinging. Do not 1m
conduct this test on slopes.
‫ ں‬With 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.
‫ ڻ‬Keep the hydraulic oil temperature at
50Ň Ź5Ƅ.
(3) Measurement
‫ ڸ‬Select the following switch positions:
ş MODE selector : H mode
‫ ڹ‬Operate swing control lever fully.
‫ ں‬Swing 1 turn, and measure time taken to
swing next 3 revolutions.
‫ ڻ‬Repeat steps(3) and (4) three time and
calculate the average values.
(4) Evaluation
The time required for 5 swings should meet the following specifications:

Unit : Seconds / 3 revolutions

Model Power selector switch Standard Maximum allowable


H mode 16.8Ź2.0 17.2
S mode 13.9Ź2.0 -
R290LC-3
L mode 17.4Ź3.0 -
F mode 18.6Ź3.0 -

7 - 11
7) SWING FUNCTION DRIFT CHECK
(1) Measure the swing drift on the bearing
outer circumference when stopping after
a 90Ňfull speed swing.
(2) Preparation
‫ ڸ‬Check the lubrication of the swing gear
and swing bearing.
‫ ڹ‬Place the machine on flat, solid ground
with ample space for swinging. Do not 1.5m
conduct this test on slopes.
‫ ں‬With 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.
‫ ڻ‬Make two chalk marks: one on the swing
bearing and one directly below it on the
track frame.
‫ ڼ‬Swing the upperstructure 90Ş
‫ ڽ‬Keep the hydraulic oil temperature at
50Ş Ź5Ƅ.
(3) Measurement
‫ ڸ‬Conduct this test in the H mode.
‫ ڹ‬Select the following switch positions:
ş MODE selector : H mode
‫ ں‬Operate the swing control lever fully and Drift angle
return it to the neutral position when the Swing stop
mark on the upperstructure aligns with
that on track frame after swinging 90Ň
‫ ڻ‬Measure the distance between the two 90Ňswing

marks.
‫ ڼ‬Align the marks again, swing 90Ň, then Swing start

test the opposite direction.


‫ ڽ‬Repeat steps(4) and (5) three times
each and calculate the average values.
(4) Evaluation
The measured drift should be within the following specifications:
Unit :degree
Model Mode select switch Standard Maximum allowable Remarks
R290LC-3 H mode 50 below 70

7 - 12
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
‫ ڸ‬Check swing bearing mounting cap
screws for loosening.
‫ ڹ‬Check the lubrication of the swing
bearing. Confirm that bearing rotation is
smooth and without noise.
‫ ں‬Install a dial gauge on the track frame as
shown, using a magnetic base.
‫ ڻ‬Position the upperstructure so that the
boom aligns with the tracks facing
towards the front idlers.
‫ ڼ‬Position the dial gauge so that its needle
point comes into contact with the bottom
face of the bearing outer race.
‫ ڽ‬Bucket should be empty.
(3) Measurement Measurement :(h1)
‫ ڸ‬With 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. Record the dial gauge
reading(h1)
‫ ڹ‬Lower the bucket to the ground and use Measurement :(h2)
it to raise the front idler 50 cm. Record
the dial gauge reading(h2)
‫ ں‬Calculate bearing play(H) from this
data(h1 and h2) as follows:
H=h2-h1
(4) Evaluation
The measured drift should be within the following specifications:
1. PURPOSE Unit : mm
Model Standard Maximum allowable Remarks
R290LC-3 0.5}1.5 3.0

7 - 13
9) HYDRAULIC CYLINDER CYCLE TIME
(1) Measure the cycle time of the boom,
(standard) arm, and(standard) bucket
cylinders.
(2) Preparation şBoom cylinder
Raise
‫ ڸ‬To measure the cycle time of the boom
cylinders:
With the arm rolled out and the empty
bucket rolled in, lower the bucket to the Lower
ground, as shown.
‫ ڹ‬To measure the cycle time of the arm
cylinder: şArm cylinder
With the empty bucket rolled in, position Roll out
Roll in
the arm so that it is vertical to the ground.

Ň
Lower the boom until the bucket is 0.5m

90
above the ground. 0.5m
‫ ں‬To measure the cycle time of the bucket
cylinder:
The empty bucket should be positioned şBucket cylinder
at midstroke between roll-in and roll-out,
so that the sideplate edges are vertical to
the ground.
‫ ڻ‬Keep the hydraulic oil temperature at Roll in Roll out

50Ň Ź5Ƅ. 0.5m


(3) Measurement
‫ ڸ‬Select the following switch positions:
ň MODE selector : H mode
‫ ڹ‬To measure cylinder cycle times:
-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
lever to the other stroke end as quickly
as possible.

7 - 14
- 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 lever to the other stroke end as
quickly as possible.
- Repeat each measurement 3 times and
calculate the average values.
(4) Evaluation
The average measured time should meet the following specifications:
1) 1. PURPOSE Unit : seconds
Model Function Standard Maximum allowable Remarks
Boom raise 3.6Ź0.4 4.7
Boom lower 2.5Ź0.3 3.3
R290LC-3 Arm in 4.0Ź0.4 5.2
Arm out 3.4Ź0.3 4.4
Bucket load 4.4Ź0.4 5.7
Bucket dump 2.6Ź0.3 3.4

7 - 15
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
‫ ڸ‬Load bucket fully. In lieu of loading the
bucket, weight(W) of the following
specification can be used.
şW=M3ź1.5
1.5m
Where :
M3 =Bucket heaped capacity (m3)
1.5=Soil specific gravity
‫ ڹ‬Position the arm cylinder with the rod 20
to 30mm extended from the fully retracted
position.
‫ ں‬Position the bucket cylinder with the rod
20 to 30mm retracted from the fully
extended position.
‫ ڻ‬With 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.
‫ ڼ‬Keep the hydraulic oil temperature at
50Ş Ź5Ƅ
(3) Measurement
‫ ڸ‬Stop the engine.
‫ ڹ‬Five minutes after the engine has been
stopped, measure the changes in the
positions of the bottom of the bucket, as
well as the boom, arm and bucket
cylinders.
‫ ں‬Repeat step(2) three times and calculate
the average values.

7 - 16
(4) The measured drift should be within the following specifications:
Unit : mm/5min
Model Drift to be measured Standard Maximum allowable Remarks
Boom cylinder 40Ź7 55
R290LC-3 Arm cylinder 60Ź7 75
Bucket cylinder 60

7 - 17
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
‫ ڸ‬Keep the hydraulic oil temperature at
50ŞŹ5Ƅ
(3) Measurement
‫ ڸ‬Start the engine.
‫ ڹ‬Select the following switch positions:
şMODE H mode
‫ ں‬Operate each boom, arm, bucket and
swing lever at full stroke and measure
the maximum operating force for each.
‫ ڻ‬Lower 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.
‫ ڼ‬Repeat steps(3) and (4) three times and
calculate the average values.
(4) Evaluation
The measured operating should be within the following specifications
Unit : kgf
Model Kind of lever Standard Maximum allowable Remarks
Boom lever 1 or below 1.2
Arm lever 1 or below 1.2
R290LC-3 Bucket lever 1 or below 1.2
Swing lever 1 or below 1.2
Travel lever 1.8 or below 2.5

7 - 18
12) CONTROL LEVER STROKE
(1) Measure each lever stroke at the lever
top using a ruler.
Ɠ 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
50ŇŹ5Ƅ.
(3) Measurement
‫ ڸ‬Stop the engine.
‫ ڹ‬Measure each lever stroke at the lever
top from neutral to the stroke end using
a ruler.
‫ ں‬Repeat 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 60Ź10 78
Arm lever 60Ź10 78
R290LC-3 Bucket lever 60Ź10 78
Swing lever 60Ź10 78
Travel lever 150Ź10 195

7 - 19
13) PILOT PRIMARY PRESSURE
(1) Preparation
‫ ڸ‬Stop the engine.
‫ ڹ‬Remove the top cover of the hydraulic
tank oil supply port with a wrench.
Loosen and remove plug on the pilot
‫ ں‬pump delivery port and connect pressure
gauge.
‫ ڻ‬Start the engine and check for oil
leakage from the port.
‫ ڼ‬Keep the hydraulic oil temperature at
50Ş Ź5Ƅ.
(2) Measurement
‫ ڸ‬Select the following switch positions:
şMODE selector : H mode
şAuto-idle switch : OFF
‫ ڹ‬Measure the primary pilot pressure in the
H mode.
(3) Evaluation
The average measured pressure should meet the following specifications:
Unit : kgf / ֲ
Model Engine speed Standard Allowable limits Remarks
R290LC-3 H mode 40Ź5 -

7 - 20
14) FOR TRAVEL SPEED SELECTING PRESSURE:
(1) Preparation
‫ ڸ‬Stop the engine.
‫ ڹ‬Remove the top cover of the hydraulic
tank oil supply port with a wrench.
‫ ں‬Push the pressure release button to
bleed air.
‫ ڻ‬To measure the speed selecting pressure:
Install a connector and pressure gauge
assembly to turning joint E port as shown.
‫ ڼ‬Start the engine and check for on
leakage from the adapter.
‫ ڽ‬Keep the hydraulic oil temperature at
50Ş Ź5Ƅ.
(2) Measurement
‫ ڸ‬Select the following switch positions:
Travel mode switch : 1 speed
2 speed
ş MODE selector : H mode
‫ ڹ‬Measure the travel speed selecting
pressure in the Hi or Low mode.
‫ ں‬Lower 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.
‫ ڻ‬Repeat steps(2) and (3) three times and
calculate the average values.
(3) Evaluation
The measured drift should be within the following specifications:
Unit : kgf / ֲ
Model Travel speed mode Standard Allowable limits Remarks
1 speed 0 -
R290LC-3
2 speed 40 Ţ5 -

7 - 21
15) SWING PARKING BRAKE RELEASING PRESSURE
(1) Preparation
‫ ڸ‬Stop the engine.
‫ ڹ‬Remove the top cover of the hydraulic
tank oil supply port with a wrench.
‫ ں‬The pressure release L wrench to bleed
air.
‫ ڻ‬Install a connector and pressure gauge
assembly to swing motor SH port, as
shown.
‫ ڼ‬Start the engine and check for oil
leakage from the adapter.
‫ ڽ‬Keep the hydraulic oil temperature at
50Ş Ź5Ƅ.
(2) Measurement
‫ ڸ‬Select the following switch positions:
şMODE selector : H mode
‫ ڹ‬Operate the swing function or arm roll in
function and measure the swing brake
control pressure with the brake
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
The measured drift should be within the following specifications:
Unit : kgf / ֲ
Model Standard Allowable limits Remarks
Brake disengaged 26 -
R290LC-3
Brake applied Less than 2 -

7 - 22
16) MAIN PUMP DELIVERY PRESSURE
(1) Preparation
‫ ڸ‬Stop the engine.
‫ ڹ‬Remove the top cover of the hydraulic
tank oil supply port with a (+) driver.
‫ ں‬Push the pressure release button to
bleed air.
‫ ڻ‬To measure the main pump pressure :
Install a connector and pressure gauge
assembly main pump gauge port as
shown.
‫ ڼ‬Start the engine and check for oil
leakage from the port.
‫ ڽ‬Keep the hydraulic oil temperature at
50Ň Ź5Ƅ.
(2) Measurement
‫ ڸ‬Select the following switch positions:
ş MODE selector : H mode
‫ ڹ‬Measure the main pump delivery
pressure in the H mode(fast idle).
(3) Evaluation
The average measured pressure should meet the following specifications:
Unit : kgf / ֲ
Model Engine speed Standard Allowable limits Remarks
R290LC-3 fast idle 30Ź5 -

7 - 23
17) SYSTEM PRESSURE REGULATOR RELIEF SETTING
(1) Preparation
‫ ڸ‬Stop the engine.
‫ ڹ‬Remove the top cover of the hydraulic
tank oil supply port with a wrench.
‫ ں‬Push the pressure release button to
bleed air.
‫ ڻ‬To measure the system relief pressure :
Install a connector and pressure gauge
assembly main pump gauge port, as
shown.
‫ ڼ‬Start the engine and check for oil
leakage from the port.
‫ ڽ‬Keep the hydraulic oil temperature at
50Ň Ź5Ƅ.
(2) Measurement
‫ ڸ‬Select the following switch positions:
şMODE selector : H mode
‫ ڹ‬Slowly operate each control lever of
boom, arm and bucket functions at full
stroke over relief and measure the
pressure.
‫ ں‬In the swing function, place bucket
against an immovable object and
measure the relief pressure.
‫ ڻ‬In the travel function, lock undercarriage
with an immovable object and measure
the relief pressure.
(3) Evaluation
The measured drift should be within the following specifications:
Unit : kgf / ֲ
Model Function to be tested Normal Over load
Boom, Arm, Bucket 320+5 350
R290LC-3 Travel 320+5 -
Swing 270 -

7 - 24
GROUP 2 MAJOR COMPONENT

1. MAIN PUMP
3 1 2

9 6 5 4 7

Standard Recommended
Part name & inspection item replacement Countermeasures
dimension value
Clearance
between piston(1) & Replace
d D 0.043 0.070 piston or
cylinder bore(2)
(D-d) cylinder.

Play between
piston(1) & shoe caulking 0-0.1 0.3
section(3)
(҇) Replace
assembly of
Thickness of shoe ҇ piston & shoe.
(t) t 5.4 5.0

Free height of cylinder Replace


spring(t) cylinder
(L) 47.9 47.1
L spring.

Combined height of set


h H Replace
plate(H) & spherical
13.5 12.5 retainer or set
bushing(h)
plate.
(H-h)

Surface roughness for Surface roughness necessary


valve plate(sliding to be correcited 3z
face)(7,8), swash plate Lapping
(shoe plate area)(9), & Standard surface roughness 0.4z or lower
cylinder(2)(sliding face) (correcited value)

7 - 24
2. MAIN CONTROL VALVE

Part name Inspection item Remedy

Casing ňScratch, rust and corrosion ňReplace parts that have damage on
the following areas:
- Sliding surface between casing hole
and spool, particularly the land area.
- Seal pocket section into which spool
enters.
- Sealing area to which O-ring contact.
- Sealing area of main, travel and port
relief valves.
- Other areas which may be deemed
to mar normal functions.

Spool ňScratch, binding, rust and corrosion ňReplace a spool with a scratch that
may be caught by your nail
(particularly on an area in contact with
seals).
ňO-ring seals on both ends ňReplace such a spool having a
scratch on its sliding surface.
ňInsert spool into casing hole, rotate ňCorrect or replace such a spool that
and stroke it. may damage O-rings or that does it
operate smoothly.

Poppet ňDamage of poppet and spring ňCorrect or replace such a poppet that
gives incomplete sealing effect.
ňInsert poppet into casing and function ňPoppet is normal if it functions lightly
it. without binding.

Spring and ňInspect that spring, spring seat, plugs ňReplace those showing excessive
associated parts and covers are not rusted, corroded, damage.
deformed and broken.

Spool seal and ňOil leakage to outside ňCorrect or replace.


related areas ňRusting, corrosion and deformation of ňCorrect or replace.
seal plate

Relief valve ňExternal rusting and damage ňReplace.


ňContact surface of valve seat ňReplace one that is damaged.
ňContact surface of poppet ňReplace one that is damaged.
ňFault on springs ňReplace.
ňO-rings, backup rings and seals ňReplace all as a rule.

7 - 25
3. SWING MOTOR

Standard Recommended
Part name & inspection item replacement Countermeasures
dimension value
Clearance
between piston & Replace
d D 0.028 0.058 piston or
cylinder bore
(D-d) cylinder.

Play between
piston & shoe caulking 0 0.3
section
(҇) Replace
assembly of
Thickness of shoe ҇ piston & shoe.
(t) t 5.5 5.3

Combined height of set h H


plate(H) & spherical Replace
bushing(h) 6.5 6.0 retainer or set
(H-h) plate.

Friction plate
 4.0 3.6 Replace

SURFACE ROUGHNESS

Standard Surface Surface roughness Counter


Item roughness to be corrected measures
(correct value)
Shoe 0.8z 3z Lapping
Shoe plate 0.4z 3z Lapping
Cylinder 1.6z 12.5z Lapping
Valve plate 0.8z 6.3z Lapping

7 - 26
4. TRAVEL MOTOR
Replace parts in accordance with the following standards. However, if a part is damaged
significantly in terms of its appearance, replace it irrespective of the standards.
1) Hydraulic Motor

Standard Recommended
Part name ˕ inspection item dimension value for Remedy
replacement
Clearance between piston ˕
0.044 mm 0.065 mm Replacement
cylinder bore

Clearance caulked part


0.1mm 0.3 mm Replacement
between piston and shoe

Thickness of shoe 5.5 mm 5.3 mm Replacement

Assembled height of spherical


bush and set plate 13.5 mm 13.0 mm Replacement as a set

Free length of cylinder spring 47.9 mm 47.3 mm Replacement

Shaft over pin dia. Replacement if either one


Output spline 43.91(ܵ4.5) 43.31 mm reaches replacement
Cylinder spline 49.06(ܵ4.5) 48.46 mm value.

Spline over dia.


Spline in cylinder 35.25(ܵ5) 35.75 mm Replacement
Spline in spherical bush

Thickness of separator plate 2.3 mm 2.1 mm


Replacement
Thickness of friction plate 3.2 mm 3.0 mm

Free length of brake spring 46.6 mm 45.9 mm Replacement

Displacement over teeth


49.97(7teeth) 49.37 mm Replacement
Over pin dia. of friction
145.89(ܵ4.5) 146.49 mm Replacement
plate internal teeth

Roughness of sliding surfaces


Swash plate/shoe 0.4 z 3z Each independent lapping
Cylinder block/valve plate 0.4 z 3z Mutual lapping
Swash plate/its supporter 6.3 z 12.5 z Mutual lapping
Set plate/spherical bus 1.6 z 6.3 z Mutual lapping

Roller bearing Replacement if flaking is


- -
Needle bearing found on rolling surface

O-ring Replacement at every


- -
Oil seal disassembly, in principle

7 - 27
Standard Recommended
Part name ˕ inspection item dimension vaue for Remedy
replacement
Replacement if elongation
Screw  
is found.

Replacement if such
Piston ring   abnormality as seizure,
deformation, etc, is found.

d D
҇

clearance between piston Play at caulking between piston and shoe : ˕


and cylinder bore : D-d

h H
t

Thickness of shoe : t Assembled height of set plate


and spherical bush : H-h

7 - 28
2) Reduction Gear

Standard Recommended
Part name ˕ inspection item dimension value for Remedy
replacement
Pitting area Replacement pitting
Pitting or crack of gear -
rate : 10$ or crack is found

Motor driving gear external Overpin


43.31 mm (Z=14)
spline 43.91(ܵ4.5)

Overpin
No. 1 sun gar internal spline 30.85 mm Replacement (Z=14)
30.25(ܵ5)

Displacement
No. 1 sun gear 42.60 mm Do. (Z=28)
42.90(4teeth)
Reduction
Displacement
ratio No. 1 planetary gear 43.28 m Do. (Z=24)
43.58(4teeth)
i = 67.57
Overpin
Ring gear(1st stage) 302.44 mm Do. (Z=77)
301.84(ܵ7)

No. 1 carrier internal spline Overpin


92.73 mm Do. (Z=21)
92.13(ܵ10)

Displacement
No. 2 sun gear 39.57 mm Do. (Z=21)
39.87(3teeth)
Displacement
No. 2 planetary gear 54.71 mm Do. (Z=26)
55.01(4teeth)

Overpin
No. 2 carrier internal spline 112.84 mm Do. (Z=25)
112.24(ܵ10)

Displacement
No. 3 sun gear 39.86 mm Do. (Z=25)
40.16(3teeth)

Displacement
No. 3 planetary gear 39.76 mm Do. (Z=24)
40.09(3teeth)

Overpin
No. 3 carrier internal spline 158.13 mm Do. (Z=52)
157.53(ܵ5.486)

Overpin
Casing external spline 173.88 mm Replacement. (Z=52)
174.48(ܵ6.096)

Overpin
Ring gears (2nd ˕ 3rd stages) 373.19 mm Do. (Z=75)
372.59(ܵ7.2)

Crack and flaking of bearing Replacement if crack or


- -
inner/outer races and rollers flaking is found.

Crack and flaking of 1st/2nd/3rd


- - Do.
planetary and pins

7 - 29
Standard Recommended
Part name ˕ inspection item dimension value for Remedy
replacement
Radial clearance of needle Replacement of abnormal
0.01-0.04 mm 0.07 mm
bearing parts as a set.

Replacement if such
Crack of spline coupling area - - damage as crack, crevice
of chipping is found.

Dimension check and


Backlash of spline coupling 0.1-0.3 mm 0.5 mm replacement according to
following standards.
Thrust ring(024) 7 mm thick 6.6 mm Replacement if severe
Thrust ring(025) 5.8 mm thick 5.4 mm wear or seizure is found
Thrust ring(026) 7.8 mm thick 7.4 mm on sliding surface.

Replacement of scratch
or rust is found in sliding
Floating seal - - surface.
Replacement if O-ring is
deformed of damaged.

Shall Spirax 1st time : 500hr


90EP or 2nd time and later :
Gear oil equivalent to Every 2000hr After
SAE # 90 API - disassembling, fill with
Service new oil without fail.
Classification The above time are
GL-4 measured with engine
hour meter.

7 - 30
5. RCV LEVER

Maintenance Criteria Remark


check item
Leakage The valve is to be replaced when the leakage Conditions :
becomes more than 1000֦/m at neutral handle Primary pressure : 30kgf/cm2
position, or more than 2000֦/m during Oil viscosity : 23cSt
operation.

Spool This is to be replaced when the sliding surface The leakage at the left condition
has worn more than 10֭compared with the is estimated to be nearly equal
non-sliding surface. to the above leakage.

Push rod

‫ٻ‬7
1‫ׅ‬

This is to be replaced when the top end has


worn more than 1mm.

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

Operation stability When abnormal noises, hunting, primary


pressure drop, etc. are generated during
operation, and these cannot be remedied,
referring to section 6. Troubleshooting,
replace the related parts.

Notes 1. It is desirable to replace seal materials, such as O-rings, every disassembling. However,
they may be reused, after being confirmed to be free of damage.
2. When loosening the hexagon socket head cap screw(125), replace the seal washers(121)
without fail.

7 - 31
6. RCV PEDAL

Maintenance Criteria Remark


check item
Leakage The valve is to be replaced when the leakage Conditions :
effect to the system. For example, the primary Primary pressure : 30kgf/cm2
pressure drop. Oil viscosity : 23cSt

Spool This is to be replaced when the sliding surface The leakage at the left condition
has worn more than 10֭, compared with the is estimated to be nearly equal
non-sliding surface. to the above leakage.

Push rod

‫ٻ‬7
1‫ׅ‬

This is to be replaced when th top end has


worn more than 1mm.

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

Operation stability When abnormal noises, hunting, primary


pressure drop, etc. are generated during
operation, and these cannot be remedied,
referring to section 6 troubleshooting, replace
the related parts.

Notes 1. It is desirable to replace seal materials, such as O-rings, every disassembling. However,
they may be reused, after being confirmed to be free of damage.

7 - 32
7. TURNING JOINT

Part name Maintenance standards Remedy

Sliding surface Plating worn or peeled due to seizure or Replace


with sealing contamination.
sections.
Sliding surface ňWorn abnormality or damaged more than 0.1mm Replace
Body, between body and
stem other than (0.0039in) in depth due to seizure contamination.
Stem
sealing section. ňDamaged more than 0.1mm(0.0039in) in depth. Smooth with oilstone.
Sliding surface ňWorn more than 0.5mm(0.02in) or abnormality. Replace
with thrust plate. ňWorn less than 0.5mm(0.02in). Smooth
ňDamage due to seizure or contamination Smooth
remediable within wear limit (0.5mm(0.02in).

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

ňExtruded excessively from seal groove square Replace


ring.

- Extrusion
Square ring

ňSlipper ring 1.5mm(0.059in) narrower than seal Replace


groove, or narrower than back ring.

Seal set -

1.5mm(max.)
(0.059in)

ňWorn more than 0.5mm(0.02in) ~ 1.5mm(MAX.) Replace


(0.059in)

7 - 33
8. CYLINDER

Part name Inspecting section Inspection item Remedy

Piston rod ňNeck of rod pin ňPresence of crack ňReplace.


ňWeld on rod hub ňPresence of crack ňReplace.
ňStepped part to which ňPresence of crack ňReplace.
piston is attached.
ňThreads ňPresence of crack ňRecondition or replace.
ňBend ňMeasure degree of bend ňRefer to Table 4.
(See Fig. 39.)
ňPlated surface ňPlating is not worn off to ňReplace or replate.
base metal
ňRust is not present on ňReplace or replate.
plating.
ňScratches are not present. ňRecondition, replate or
replace.
ňRod ňWear of O.D. ňRecondition, replate or
replace.
ňBushing at mounting part ňWear of I.D. ňReplace.
Cylinder tube ňWeld on bottom ňPresence of crack ňReplace.
ňWeld on head ňPresence of crack ňReplace.
ňWeld on hub ňPresence of crack ňReplace.
ňTube interior ňPresence of faults ňReplace if oil leak is seen.
ňBushing at mounting part ňWear on inner surface ňReplace.
Cylinder head ňBushing ňWear on inner surface ňSee para. 4.2.
ňFlaw on inner surface ňReplace if flaw is deeper
than coating.

7 - 34
GROUP 3 TRACK AND WORK EQUIPMENT

1. TRACK
1) TRACK ROLLER

2
6

1
3 4

Unit :mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Outside diameter of flange
‫ٻ‬216 
Rebuild or
2 Outside diameter of tread ‫ٻ‬180 ‫ٻ‬168
replace
3 Width of tread 49 55
4 Width of flange 27 -
Standard Tolerance Standard Clearance
Clearance between shaft size Shaft Hole clearance limit
5
and bushing -0.215 +0.127 0.140
‫ٻ‬65 1.5 Replace
-0.315 +0.075 to 0.442
Standard Tolerance Standard Interference bushing
Interference between roller size Shaft Hole Interference limit
6
and bushing +0.108 +0.006 0.014
‫ٻ‬72 -
+0.008 -0.036 to 0.144
Standard clearance Clearance limit
7 Side clearance of roller Replace
0.2 to 0.6 1.5

7 - 35
2) CARRIER ROLLER

4 3

5
6
1
2

Unit :mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Outside diameter of flange
‫ٻ‬200 
Rebuild or
2 Outside diameter of tread ‫ٻ‬168 ‫ٻ‬158
replace
3 Width of tread 54 62
4 Width of flange 18.25 -
Standard size &Tolerance Standard Clearance
Clearance between shaft Shaft Hole clearance limit Replace
5
and support +0.085 +0.370 +0.396 bushing
‫ٻ‬55 +0.066
‫ٻ‬55 +0.330
1.5
to +0.455
Interference between shaft +0.125 +0.03 0.06
6 ‫ٻ‬65 ‫ٻ‬65 - Replace
and seal guard +0.090 0 to 0.155

7 - 36
3) IDLER

7
1
2

3 5
4

Unit :mm
No. Check item Criteria Remedy
Outside diameter of Standard size Repair limit
1
protrusion ‫ٻ‬646 
2 Outside diameter of tread ‫ٻ‬594 ‫ٻ‬575 Rebuild or
3 Width of protrusion 104 - replace
4 Total width 203 -
5 Width of tread 50.5 55.5
Standard size &Tolerance Standard Clearance
Clearance between shaft Shaft Hole clearance limit Replace
6
and bushing 0 +0.35 0.35 bushing
‫ٻ‬85 ‫ٻ‬85 1.5
-0.035 0.40 to 0.435
Clearance between shaft 0 +0.090 0.036
7 ‫ٻ‬85 -0.035
‫ٻ‬85 +0.036 to 0.125
0.15 Replace
and support
Side clearance of idler Standard clearance Clearance limit
8 Replace
(both side) 0.4 to 1.0 2.0

7 - 37
4) TRACK

2 1 6

5
4
3

Unit :mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Link pitch Turn or
203.2 207.2
replace
2 Outside diameter of bushing 66.9 61.65
3 Height of grouser 26 19 Rebuild or
4 Height of link 116.4 108.4 replace
Standard size &Tolerance Standard Interference
Interference between Shaft Hole interference limit
5
bushing and link +0.05 +0.07 0.020
‫ٻ‬66.65 -0 ‫ٻ‬66.27 -0 to
0.015
0.120
Replace
Interference between +0.1 +0.03 0.070 0.05
6 ‫ٻ‬44.45 ‫ٻ‬44.13
regular pin and link 0 0 to 0.130

Tightening angle method Initial tightening torque : 86+5 kgşm


7 Replace
(Tightening angle method) Additional tightening angle : 120Ź10Ş

7 - 38
5) TRACK FRAME AND RECOIL SPRING
2
1

Unit :mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
+2
1 Vertical width of idler guide Track frame 123 -1 127
0
Idler support 120 -1.5 116 Rebuild or
replace
+3
Track frame 292 -1 297
2 Horizontal width of idler guide
Idler support 290 - 288
Standard size Repair limit

3 Recoil spring Free Installation Installation Free Installation Replace


length length load length load
‫ٻ‬251ź732 615 18230kg  14580kg

7 - 39
2. WORK EQUIPMENT

A C D E F

B K J I H G

Unit :mm
Criteria Criteria
Remedy
Measuring point Normal Recomm. Limit Recomm. Limit &
Mark value service
(Pin and Bushing) of service of Remark
limit use limit use
A Boom Rear 100 99 98.5 100.5 101 Replace
B Boom Cylinder Head 90 89 88.5 90.5 91 ţ
C Boom Cylinder Rod 100 99 98.5 100.5 101 ţ
D Arm Cylinder Head 90 89 88.5 90.5 91 ţ
E Boom Front 100 99 98.5 100.5 101 ţ
F Arm Cylinder Rod 90 89 88.5 90.5 91 ţ
G Bucket Cylinder Head 90 89 88.5 90.5 91 ţ
H Arm Link 80 79 78.5 80.5 81 ţ
I Bucket and Arm Link 80 79 78.5 80.5 81 ţ
J Bucket Cylinder Rod 80 79 78.5 80.5 81 ţ
K Bucket Link 80 79 78.5 80.5 81 ţ

7 - 40
SECTION 8 DISASSEMBLY AND ASSEMBLY
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 A 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
ܵD ܵd
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
(3) before the end of the stroke.
(4) 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.)
After completing this operation, raise the engine speed to the normal operating condition.
Ɠ If the hydraulic cylinder has been replaced, carry out this procedure before assembling the rod to
the work equipment.
Ɠ 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 COMPONENT
Torque
No. Descriptions Bolt size

1 Engine mounting bolt, nut M22 ź 2.5 48Ţ2.0 347Ţ14


2 Radiator mounting bolt, nut M12 ź 1.75 12.2Ţ1.3 88.2Ţ9.4
Engine
3 Coupling mounting socket bolt M10 ź 1.5 6.9Ţ1.4 50Ţ10
4 Main pump housing mounting bolt M10 ź 1.5 2.8Ţ0.3 20.3Ţ2.2
5 Main pump mounting socket bolt M20 ź 2.5 42.0Ţ4.5 303.8Ţ32.5
6 Main control valve mounting bolt M16 ź 2.0 11.7Ţ1.6 84.6Ţ11.6
7 Hydraulic Fuel tank mounting bolt M20 ź 2.5 46.0Ţ5.1 332.7Ţ36.9
system
8 Hydraulic oil tank mounting bolt M20 ź 2.5 46.0Ţ5.1 332.7Ţ36.9
9 Turning joint mounting bolt, nut M16 ź 2.0 29.6Ţ3.2 214.1Ţ23.1
10 Swing motor mounting bolt M20 ź 2.5 58.4Ţ6.4 422.4Ţ46.3
11 Swing bearing upper part mounting bolt M24 ź 3.0 97.8Ţ10 707.4Ţ72.3
12 P/Train Swing bearing lower part mounting bolt M24 ź 3.0 97.8Ţ10 707.4Ţ72.3
system
13 Travel motor mounting bolt M20 ź 2.5 44Ţ4 318.3Ţ28.9
14 Sprocket mounting bolt M20 ź 2.5 51Ţ4 368.9Ţ28.9
15 Carrier roller mounting bolt M16 ź 2.0 21.0Ţ2.3 151.9Ţ16.6
16 Track roller mounting bolt M20 ź 2.5 54.7Ţ6.0 395.6Ţ43.4
17 Under Track tension cylinder mounting bolt M16 ź 2.0 29.6Ţ3.2 214.1Ţ23.1
carriage
18 Track shoe mounting bolt, nut M20 ź 1.5 79Ţ4.0 571Ţ29
19 Track guard mounting bolt M20 ź 2.5 54.7Ţ6 395.6Ţ43.4
20 Counter weight mounting bolt M36 ź 3.0 308Ţ46 2227Ţ334
Others
21 Cab mounting bolt, nut M12 ź 1.75 12.2Ţ1.3 88.2Ţ9.4

Ɠ For tightening torque of engine and hydraulic components, see each components disassembly and
assembly.

8-4
2. TORQUE CHART
The torques given are standard figures. Any figures specifically described in this manual has priority.
1) METRIC BOLT-coarse thread
8T 10T
Bolt size
kgfşm lbfşft kgfşm lbfşft
M 6 ź 1.0 0.9 ~ 1.3 6.5 ~ 9.4 1.1 ~ 1.7 A8.0 ~ 12.3
M 8 ź 1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.7 ~ 4.1 19.5 ~ 29.7
M10 ź 1.5 4.0 ~ 6.0 28.9 ~ 43.4 5.5 ~ 8.3 39.8 ~ 60.0
M12 ź 1.75 7.4 ~ 11.2 53.5 ~ 81.0 9.8 ~ 15.8 70.9 ~ 114.3
M14 ź 2.0 12.2 ~ 16.6 88.2 ~ 120.0 16.7 ~ 22.5 120.8 ~ 162.7
M16 ź 2.0 18.6 ~ 25.2 134.5 ~ 182.3 25.2 ~ 34.2 182.3 ~ 247.4
M18 ź 2.0 25.8 ~ 35.0 186.6 ~ 253.2 35.1 ~ 47.5 253.9 ~ 343.6
M20 ź 2.5 36.2 ~ 49.0 261.8 ~ 354.4 49.2 ~ 66.6 355.9 ~ 481.7
M22 ź 2.5 48.3 ~ 63.3 349.4 ~ 457.8 65.8 ~ 98.0 475.9 ~ 708.8
M24 ź 3.0 62.5 ~ 84.5 452.1 ~ 611.2 85.0 ~ 115.0 614.8 ~ 831.8
M30 ź 3.0 124.1 ~ 167.9 897.6 ~ 1214.4 169.1 ~ 228.9 1223.1 ~ 1655.6
M36 ź 4.0 174.3 ~ 235.6 1260.7 ~ 1704.0 250.0 ~ 310.0 1808.3 ~ 2242.2

2) METRIC BOLT-fine thread

8T 10T
Bolt size
kgfşm lbfşft kgfşm lbfşft
M 8 ź 10 2.2 ~ 3.4 15.9 ~ 24.6 3.0 ~ 4.4 21.7 ~ 31.8
M10 ź 1.2 4.5 ~ 6.7 32.5 ~ 48.5 5.9 ~ 8.9 42.7 ~ 64.4
M12 ź 1.25 7.8 ~ 11.6 56.4 ~ 83.9 10.6 ~ 16.0 76.7 ~ 115.7
M14 ź 1.5 13.3 ~ 18.1 96.2 ~ 130.9 17.9 ~ 21.1 129.5 ~ 174.3
M16 ź 1.5 19.9 ~ 26.9 143.9 ~ 194.6 26.6 ~ 36.0 192.4 ~ 260.4
M18 ź 1.5 28.6 ~ 43.6 206.9 ~ 315.4 38.4 ~ 52.0 277.7 ~ 376.1
M20 ź 1.5 40.0 ~ 54.0 289.3 ~ 390.6 53.4 ~ 72.2 386.2 ~ 522.2
M22 ź 1.5 52.7 ~ 71.3 381.2 ~ 515.7 70.7 ~ 95.7 511.4 ~ 692.2
M24 ź 2.0 67.9 ~ 91.9 491.1 ~ 664.7 90.9 ~ 123.1 657.5 ~ 890.4
M30 ź 2.0 136.9 ~ 185.1 990.2 ~ 1338.8 181.7 ~ 248.3 1314.2 ~ 1796.0
M36 ź 3.0 192.1 ~ 259.9 1389.5 ~ 1879.9 261.8 ~ 354.2 1893.6 ~ 2561.9

8-5
3) PIPE & HOSE

Thread size Width across flat(mm) kgfşm lbfşft

1/4" 19 3 21.7
3/8" 22 4 28.9
1/2" 27 5 36.2
3/4" 36 12 86.8
1" 41 14 101.3

4) FITTING

Thread size Width across flat(mm) kgfşm lbfşft

1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 6 43.4
3/4" 36 13 94.0
1" 41 15 108.5

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) Loosen the breather slowly to release the
pressure inside the hydraulic tank.
Escaping fluid under pressure can
penetrate the skin causing serious in
injury.
(3) Loosen the drain plug under the hydraulic
tank and drain the oil from the hydraulic
tank. 12
ň Hydraulic tank quantity : 275ֻ
1
(4) Remove bolts(12) and disconnect
pipe(1,2)
2
(5) Disconnect pilot line hoses(4,5,6,7,8,9,10)
3 11
(6) Remove bolts(11) and disconnect pump
suction tube (3)
Ɠ When pump suction tube is disconnected,
the oil inside the piping will flow out, so
catch it in oil pan.
4
(7) Sling the pump assembly and remove the 7
pump mounting bolts.
ň Weight : 155 kg (342 lb) 9
Pull out the pump assembly from 6
housing.
5 8
Ɠ When removing the pump assembly,
check that all the hoses have been 10
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 return filter with new.
(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.
‫ ڸ‬Remove the air vent plug(2EA)
‫ ڹ‬Tighten plug lightly
‫ ں‬Start the engine, run at low idling, and
check oil come out from plug.
‫ ڻ‬Tighten 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 leak or not.

8-8
2. MAIN PUMP(1/2)
1) STRUCTURE

A
789 532 548 724 792 954
732 214 531 702 534 901 719
535
808
953
886
717
406
261
824

111
774
127
710

123 251 401 211 156 157 313 312 725 314 468 141 152 113
490 212 153 158 114 124 466 885 728 151 271

111 Drive shaft(F) 313 Valve plate(R) 710 O-ring


113 Drive shaft(R) 314 Valve plate(L) 717 O-ring
114 Spline 325 Valve casing 719 O-ring
123 Roller bearing 401 Hexagon socket bolt 724 O-ring
124 Needle bearing 406 Hexagon socket bolt 725 O-ring
127 Bearing spacer 407 Hexagon socket bolt 728 O-ring
141 Cylinder block 413 Hexagon socket bolt 732 O-ring
151 Piston 466 VP Plug 774 Oil seal
152 Shoe 468 VP Plug 789 Back up ring
153 Push plate 490 VP Plug 792 Back up ring
156 Bushing 531 tilting 808 Hexagon head nut
157 Cylinder spring 532 Servo piston 824 Snap ring
158 Spacer 534 Stopper(L) 885 Pin
211 Shoe plate 535 Stopper(S) 886 Spring pin
212 Swash plate 541 Seat 901 Eye bolt
214 Bushing 542 Spacer 953 Hexagon socket screw
251 Support plate 543 Stopper 1 954 Set screw
261 Seal cover(F) 544 Stopper 2 981 Name plate
263 Seal cover(R) 545 Steel ball 983 Pin
271 Pump casing 548 Pin
312 Valve block 702 O-ring

8-9
MAIN PUMP(2/2)

544

542

543

545

541 (079)

725
726

466
725

325

407
VIEW A

325 Valve casing 542 Spacer 725 O-ring


407 Hexagon socket bolt 543 Stopper 1 726 O-ring
466 Plug 544 Stopper 2 079 Proportional reducing valve
541 Seat 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, socket - Hexagon Headed VP plug
wrench, double(single) open bolt Hexagon nut (PF thread)
end spanner
19 M12 M12 VP-1/4
B 24 M16 M16 -
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. 10x8x200
Torque wrench Capable of tightening with the specified torques.

8-11
(2) Tightening torque

Torque Wrench size


Part name Bolt size
kgfňm lbfňft 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
Ɠ Wind a seal tape 1 1/2 to 2
M 8 3.0 21.7 0.24 6
turns round the plug
M10 5.8 42.0 0.31 8
M12 10.0 72.3 0.39 10
M14 16.0 115.7 0.47 12
M16 24.0 173.6 0.55 14
M18 34.0 245.9 0.55 14
M20 44.0 318.3 0.67 17
PT plug(Material : S45C) PT 1/16 0.7 5.1 0.16 4
PT 1/ 8 1.05 7.59 0.20 5
PT 1/ 4 1.75 12.66 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 15.0 108.5 0.55 14
PF 1 19.0 137.4 0.67 17
PF 1 1/4 27.0 195.3 0.67 17
PF 1‫ڰ‬ 28.0 202.5 0.67 17

8-12
3. REGULATOR
1) STRUCTURE(1/2)

412 875 874


755
A
897 858
B
614
612

615
613
A 611
B

A
KR3H - 9N29
P2
438 Pf

801 Pi

924

641 730 643 708 644 645 646 728

413 438

438

656

Pi
735

496 724 725 436

8-19
REGULATOR(2/2)

734 653 654 836 651 652 601 624 629 630 628
655

641 801
C
814 925

898

631 627

732

733
732

622

621 623 625 626 887 763 756


Section A-A

412 Hexagon socket screw 629 Cover(C) 730 O-ring


413 Hexagon socket screw 630 Nut 732 O-ring
436 Hexagon socket screw 631 Sleeve 733 O-ring
438 Hexagon socket screw 641 Pilot cover 734 O-ring
496 Plug 643 Pilot piston 735 O-ring
601 Casing 644 Spring seat(Q) 755 O-ring
611 Feed back lever 645 Adjust stem(Q) 756 O-ring
612 Lever(1) 646 Pilot spring 763 O-ring
613 Lever(2) 651 Sleeve 801 Nut
614 Center plug 652 Spool 814 Snap ring
615 Adjust plug 653 Spring seat 836 Snap ring
621 Compensator Piston 654 Return spring 858 Snap ring
622 Piston case 655 Set spring 874 Pin
623 Compensator rod 656 Block cover 875 Pin
624 Spring seat(C) 708 O-ring 887 Pin
625 Outer spring 722 O-ring 897 Pin
626 Inner spring 724 O-ring 898 Pin
627 Adjust stem(C) 725 O-ring 924 Set screw
628 Adjust screw(C) 728 O-ring 925 Adjust screw(QI)

8-20
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

B 5 M 6 BP-1/ 8 - M10
6 M 8 BP-1/ 4 PO-1/4 M12, M14
socket wrench, Hexagon Headed VP plug
double(single) open end - Hexagon nut
bolt (PF thread)
B
6 M8 M8 -
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 Steel bar of key material approx. 10x8x200
Torque wrench Capable of tightening with the specified torques.
Pincers -
Bolt M4, Length : 50mm

8-21
(2) Tightening torque

Torque Wrench size


Part name Bolt size
kgfňm lbfňft 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
Ɠ Wind a seal taped 1 1/2 to 2
turns round the plug 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 16.0 115.7 0.47 12
PT plug(Material : S45C) PT 1/16 0.7 5.1 0.16 4
PT 1/ 8 1.05 7.59 0.20 5
PT 1/ 4 1.75 12.66 0.24 6
PF plug(Material : S45C) PF 1/ 4 3.0 21.7 0.24 6

8-22
GROUP 4 MAIN CONTROL VALVE

1. REMOVAL AND INSTALL


1) REMOVAL

(1) Lower the work equipment to the ground


and stop the engine.
(2) Loosen the breather slowly to release the
pressure inside the hydraulic tank.
Escaping fluid under pressure can
penetrate the skin causing serious injury.
Ɠ When pipes and hoses are disconnected,
the oil inside the piping will flow out, so
catch it in oil pan.
(3) Remove bolts and disconnect pipe.
(4) Disconnect pilot line hoses.
(5) Disconnect pilot piping.
(6) Sling the control valve assembly.and
remove the control valve mounting bolt.
ň weight : 124kg(273 lb)
(7) Remove the control valve assembly.
Ɠ When removing the control valve
assembly, check that all the piping have
been disconnected.

2) INSTALL

(1) Carry out installation in the reverse order


to removal
(2) Bleed the air from below items.
‫ ڸ‬Cylinder (boom, arm, bucket)
‫ ڹ‬Swing motor
‫ ں‬Travel motor
Ɠ See each item removal and install
(3) Confirmed the hydraulic oil level and
recheck the hydraulic oil leak or not.

8-30
2. STRUCTURE(1/3)

42
39

39 80
52
6 53
2 39 41
17 3
7 46 9 57 13
2728 58 14
11 47
26 8 59
4 29
25 11 32
23 4 30
2728 25
33
31
51 30
23
5049
9
10

40
18 39
34
35
14
13
39 54 56
42
79

39
80

2 Back up ring 26 Check 47 Spring washer


3 O-ring 27 Back up ring 49 Cap
4 Spring 28 O-ring 50 O-ring
6 Cap 29 Cover 51 Cap
7 Spring 30 Spring guide 52 Cap
8 Poppet 31 Spring 53 O-ring
9 O-ring 32 Plunger cap 54 Plunger
10 Port relief valve 33 O-ring 56 Housing
11 Nylon chip 34 Retainer 57 Cap
13 Bolt 35 O-ring 58 Spring
14 Spring washer 39 O-ring 59 Spool
17 Cap 40 Cap 79 Plunger
18 Plunger 41 Main relief 80 Port relief
23 Cap 42 Port relief
25 Check 46 Bolt

8-31
STRUCLTURE(2/3)

64
49
50 55 62
60
55
48
47
60 55
50
49
61 55
55 60

75
74 63
73
61
55
78
65
66 47
76
68 48
69 77
67
71
70
39
72

39 O-ring 63 O-ring 72 Cap


47 Spring washer 64 Orifice 73 Plug
48 Bolt 65 Check 74 Spring
49 Cap 66 Spring 75 Check
50 O-ring 67 Spring 76 Back up ring
55 O-ring 68 O-ring 77 Spring
60 O-ring 69 Sleeve 78 Poppet
61 O-ring 70 O-ring
62 Manifold 71 Piston

8-32
STRUCTLURE(3/3)

13
1 29 14
2
3
47 81 32
46 11
30 1615
33 13
30 31 14
12
4 32 29
5 30
33
30 31
9 42 40
39 39
10 8 37 38
7 3 36
2
6
25
18 4 26
19 11
35 28
34 27 17
20 25
14 4 11
13 53 49 28
39 27
50 23 22
52
21 45 3
1516 40 39 44
42 43 2
38
39 24
40 36
37

39
41

1 Cap 19 Plunger 37 Back up ring


2 Back up ring 20 Plunger 38 Plug
3 O-ring 21 Plunger 39 O-ring
4 Spring 22 Plunger 40 Cap
5 Check 23 Cap 41 Main relief
6 Cap 24 Cap 42 Port relief
7 Spring 25 Check 43 Bolt
8 Poppet 26 Check 44 Plunger
9 O-ring 27 Back up ring 45 O-ring
10 Port relief 28 O-ring 46 Bolt
11 Nylon chip 29 Cover 47 Spring washer
12 Housing 30 Spring guide 49 Cap
13 Bolt 31 Spring 50 O-ring
14 Spring washer 32 Plunger cap 52 Cap
15 Cap 33 O-ring 53 O-ring
16 O-ring 34 Retainer 81 Check
17 Cap 35 O-ring
18 Plunger 36 O-ring

8-33
3. DISASSEMBLY AND ASSEMBLY
1) PRECAUTION
(1) Disassembly
‫ ڸ‬Handle the components carefully not to
drop them or bump them with each other
as they are made with precision.
‫ ڹ‬Do not force the work by hitting or
twisting as burred or damaged
component may not be assembled or
result in oil leakaged or low performance.
‫ ں‬When disassembled, tag the
components for identification so that they
can be re-assembled correctly.
‫ ڻ‬Once disassembled, O-rings and backup
rings are usually not to be used again.
(Remove them using a wire with its end
made like a shoehorn. Be careful not to
damaged the slot.)
‫ ڼ‬If the components are left disassembled
or half-disassembled, they may get rust
from moisture or dust. If the work has to
be interrupted, take measures to prevent
rust and dust.

(2) Assembly
‫ ڸ‬Take the same precautions as for
disassembly.
‫ ڹ‬When assembling the components,
remove any metal chips or foreign
objects and check them for any burrs
or dents. Remove burrs and dents with
oil-stone, if any.
‫ ں‬O-rings and backup rings are to be
replaced with new ones, as a rule.
‫ ڻ‬When installing O-rings and backup
rings, be careful not to damage them.
(Apply a little amount of grease for
smoothness.)
‫ ڼ‬Tighten the bolts and caps with specified
torque.

8-34
2) MOUNTING AND DISMOUNTING VALVES
1 2 4 3
(1) Disassembly
‫ ڸ‬Remove socket bolts (1, 2) and separate
3-spool valve(ѓ) from block(є)
‫ ڹ‬Remove socket bolts (3, 4) and separate
4-spool valve(ѕ) from block(є)

(2) Assembly
‫ ڸ‬In the reverse manner of disassembly,
reassemble 4-spool valve(ѕ).
‫ ڹ‬reassemble 3-spool valve(ѓ).
‫ ں‬Tighten the bolts to the torque of 10kgfň
m (72.3lbfňft)
Ɠ Before reassembly, see if the O-Rings ѓ є ѕ
are fitted in between the blocks.
Tools
ňHexagon socket : 10mm
ňTorque wrench

8-35
3) OPERATING SECTION OF HYDRAULIC PACK
(1) Disassembling
‫ ڸ‬Loosen socket bolt (1) to remove cover
(2). 2 1

‫ ڹ‬Pull the plunger out while holding the


spring.
Ɠ Do not pull it out violently, but draw it out
gently while making sure of its contact
with HG hole. 3 4 5

‫ ں‬Place the plunger between holders and


loosen plunger cap (3) by using a vise.
Tools
‫ ڻ‬Remove plunger cap (3), guide (4) and ňHexagon socket : 8mm
ňTorque wrench
spring (5) in this order.

(2) Assembling
‫ ڸ‬Place the plunger between holders and
clamp the holders with the vise.
‫ ڹ‬Mount guide (4), spring (5) and plunger
cap (3) to the plunger.
‫ ں‬Tighten plunger cap (3) at the specified
torque.
‫ ڻ‬Tightening torque : 6kgfňm (43.4lbfňft)
Restore the plunger to the valve while
holding the spring section.
Ɠ Insert the plunger into the valve hole
while turning it slowly so that it is well
aligned with the HG hole. In particular,
be careful not to hit it against the first
round corner.
‫ ڼ‬Install cover (2) after making sure that O-
ring is placed on the edge of the valve
hole and tighten socket bolt (1) with the
specified torque.
Tightening torque : 5kgfňm (36.2lbfňft)

8-36
4) LOGIC ASSEMBLY(Boom, Arm)
(1) Disassembling
1
‫ ڸ‬Remove cap (1)
‫ ڹ‬Remove spring (3) and poppet (2).
3

(2) Assembling
2
‫ ڸ‬Mount poppet (2) and spring (3) to the
valve housing.
‫ ڹ‬Tighten cap (1) at the specified torque.
Ɠ Be careful for the backup ring not
to protrude.
Tightening torque : 8kgfňm (57.9lbfňft)
Tools
ňHexagon socket : 30mm
ňTorque wrench

8-37
5) LOGIC CHECK ASSEMBLY(Boom Operation)
(1) Disassembling 11 10 9

‫ ڸ‬Remove the cap(1).


‫ ڹ‬Remove the spool (2) and the spring (3).
‫ ں‬Remove the sleeve (4). Be careful not to
damage the sleeve surface.
‫ ڻ‬Remove the springs (5, 6), check
valve(7) and poppet (8).
‫ ڼ‬Remove the plug(9), spring(10) and
check valve(11). 8 7 6 5 4 3 2 1

Tools
ňHexagon socket : 32mm
ňTorque wrench

(2) Assembling
‫ ڸ‬Reassemble the check valve(11) and the
spring(10).
‫ ڹ‬Tighten the plug(9) to the specified
torque of 2kgfňm(14.5lbňft)
‫ ں‬Reassemble sleeve(4) with cap(1) after
inserting spring(3) and piston(2) to the
sleeve(4)
‫ ڻ‬Reassemble poppet(8), check valve(7)
and spring(6)
‫ ڼ‬Reassemble the cap assembly(1) and
tighten it to specified torque of
6kgf.m(43.4lbfňft)

8-38
6) FOOT RELIEF ASSEMBLY
1 2
(1) Disassembling
‫ ڸ‬Remove valve(1) from valve block.
Ɠ Do not disassemble internal part of valve
assembly because it is not easy to adjust
them.
(2) Assembling
Reassemble valve(1) and tighten the
cap(2) to the specified torque of
6kgf.m(43.4lbňft) Tools
ňHexagon socket : 30mm
ňTorque wrench

7) SELECTOR ASSEMBLY(traveling straight)


(1) Disassembling 1 2 3
‫ ڸ‬Remove the cap(1).
‫ ڹ‬Remove the spring(2) and the spool(3).
(2) Assembling
‫ ڸ‬Reassemble the spool(3) and the
spring(2).
‫ ڹ‬Tighten the cap(1) to the specified torque
of 6kgf.m(43.4lbňft)
Tools
ňSocket : 30mm
ňTorque wrench

8-39
GROUP 5 SWING DEVICE

1. REMOVAL AND INSTALL OF MOTOR


1) REMOVAL
(1) Lower the work equipment to the ground
and stop the engine.
(2) Loosen the breather slowly to release the
pressure inside the hydraulic tank.
Escaping fluid under pressure can
penetrate the skin causing serious in
injury.
Ɠ When pipes and hoses are disconnected,
the oil inside the piping will flow out, so
catch it in oil pan.
(3) Disconnect pipe assy(2, 3)
(4) Disconnect pilot line hoses(4, 5, 6, 7) 5

(5) Sling the swing motor assembly(1)and 2


remove the swing motor mounting bolts(8) 4
ň Motor device weight : 319kg(703lb)
ň Tightening torque : 58.4kgfňm
1 3
(422.4lbfňft)
(6) Remove the swing motor assembly.
Ɠ When removing the swing motor
assembly, check that all the piping have
been disconnected.

2) INSTALL
(1) Carry out installation in the reverse order 6
to removal
(2) Bleed the air from the swing motor. 8
‫ ڸ‬Remove the air vent plug. 7
‫ ڹ‬Pour in hydraulic oil until it over flows
from the port.
‫ ں‬Tighten plug lightly.
‫ ڻ‬Start the engine, run at low idling, and
check oil come out from plug.
‫ ڼ‬Tighten plug fully.
(3) Confirmed the hydraulic oil level and
check the hydraulic oil leak or not.

8-40
2. SWING MOTOR
1) STRUCTURE

993 117 121 118 114 706 707 702 712 472 488 355 351 469 051

106
438
432 444
106 303
443
471
304

101
491
437
124
468
487
433
401
301 994 122 123 113 116 111 742 743 031 131 451

464 485

Section A-A

101 Drive shaft 304 Front cover 485 O-ring


106 Spacer 351 Plunger 487 O-ring
111 Cylinder block 355 Spring 488 O-ring
113 Retainer 401 Hex socket screw 491 Oil seal
114 Cylinder spring 432 Snap ring 702 Brake piston
116 Push rod 433 Snap ring 706 O-ring
117 Spacer F 437 Snap ring 707 O-ring
118 Spacer R 438 Snap ring 712 Brake piston
121 Piston 443 Roller bearing 742 Friction plate
122 Shoe 444 Roller bearing 743 Separator plate
123 Return plate 451 Pin 993 Plug
124 Swash plate 468 VP plug 994 Plug
131 Balance plate 469 RO plug 051 Relief valve
301 Casing A 471 O-ring 031 Time delay valve
303 Valve casing A 472 O-ring

8-41
3. REMOVAL AND INSTALL OF REDUCTION GEAR
1) REMOVAL
(1) Remove the swing motor assembly.
For details, see removal of swing motor
assembly
(2) Slide reduction gear assembly(1) and
remove mounting bolts(2)
(3) Remove the reduction gear assembly
ş Reduction gear device weight :
260kg(573lb)

2) INSTALL
(1) Carry out installation in the reverse order
to removal.
şMounting bolt : 58.4kgfşm(422.4lbşft)
1
2

8-53
4. REDUCTION GEAR
1) STRUCTURE

351 202 103 402 915 209 802

102

401
231 312 311
801
911

201
288
211

287
912
286

204 285

403
284
210
282

283 901 910 702

902 203 701

102 Front casing 283 Thrust washer 403 Needle gauge


103 Middle casing 284 Thrust button 701 Hex socket bolt
201 Shaft 285 Pin1 702 Hex socket bolt
202 Ring gear 2 286 Side plate 801 Oil seal
203 Planetary gear 2 287 Side plate 802 O - ring
204 Sun gear 2 288 Side plate 901 Spring pin
209 Ring gear 1 311 Level bar 902 plug
210 Planetary gear 1 312 Pipe 910 Spring pin
211 Sun gear 1 351 Lock pin 911 Stop ring
231 Carrier 401 Roller bearing 912 Stop ring
282 Pin 402 Roller bearing 915 Stop ring

8-54
2) Inspections
(1) Precautions
This assembly is designed to balance the life time of each part. Therefore, when replacing the
parts, some parts could require another part's replacement at the same time because of their
structural or functional correlations.
(2) Inspections replacement
‫ ڸ‬When the pitting happens on a tooth of sun gear, planetary gear or ring gear, replace the
gear.(When a pit size is bigger than ܵ1mm(0.04") or the pits are more than 5 percent of the
tooth.)
‫ ڹ‬Replace the lock pin when loosely installed in the pin groove because of the wearing.
‫ ں‬Replace the oil seal when damaged or weared. Replace the oil seal when reassembling the
reduction gear assembly.
‫ ڻ‬Replace the No.1 carrier assembly when flaking happens on the sliding surfaces of the No.1
planetary gear.
‫ ڼ‬Replace the No.2 planetary gear assembly when radial clearance of bearing is more than
0.6mm(0.02").
Replace the No.2 planetary gear assembly when removing the output shaft.
‫ ڽ‬Replace the thrust button when the sliding surface of the sun gear is badly damaged.
‫ ھ‬Replace the thrust washer only when it was damaged.
‫ ڿ‬Replace the shaft support bearing when it was damaged. Do not reuse the disassemble shaft
support bearing.
Ɠ Inspect the No.2 planetary gear, thrust button, thrust washer, and shaft support bearing as
in assembly.
3) Disassembly.
(1) Remove the level bar(311) and pipe(312) installed in the swing motor.
(2) Loosen the drain plug in the swing gear box to discharge the gear oil.
Ɠ Check the gear oil for contamination.
(3) Release the bolt(702) and remove the swing motor from is reduction gear assembly.
(4) Release the No.1 sun gear(211).
(5) Release the No.1 carrier assembly including No.1 planetary gear.
(6) Disassemble the No.1 carrier assembly, if necessary.
(7) Release the No.2 sun gear(204) and if necessary, remove the stop ring(915).
(8) Remove the No.1 ring gear(209).
(9) Remove the middle, casing(103).
(10) Remove the output shaft(201) assembly.
(11) Remove the No.2 ring gear(202) front the casing(102).
(12) Remove the oil seal(801) from the front casing(102).
(13) Remove the self-aligning roller bearing(402).
(14) Remove the pin(282).
(15) Remove the spring pin from the output shaft.
(16) Remove the No.2 planetary gear(203) and thrust washer(283).
Ɠ Remove that the above articles(13~16) are applied for only special inspections or
maintenance.

8-55
4) Assembly
(1) Reassemble the output shaft assembly.
‫ ڸ‬Install the self-aligning roller bearing(4010 in the output shaft(201) after warming it up for about
10 minutes in the oil can at 80Ƅ ~ 100Ƅ(176Ȫ ~ 212Ȫ).
‫ ڹ‬Insert the thrust button(284) in the groove of the output shaft.
‫ ں‬Insert the thrust plate(283) of No.2 planetary gear(203) in the output shaft(201).
‫ ڻ‬Insert