R160LC 7 PDF

CONTENTS
SECTION 1 GENERAL
Group 1 Safety Hints 1-1
Group 2 Specifications 1-9
SECTION 2 STRUCTURE AND FUNCTION

Group 1 Pump Device 2-1
Group 2 Main Control Valve 2-20
Group 3 Swing Device 2-43
Group 4 Travel Device 2-54
Group 5 RCV Lever 2-65
Group 6 RCV Pedal 2-72
SECTION 3 HYDRAULIC SYSTEM

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

Group 1 Component Location 4-1
Group 2 Electrical Circuit 4-3
Group 3 Electrical Component Specification 4-20
Group 4 Connectors 4-29
SECTION 5 MECHATRONICS SYSTEM

Group 1 Outline 5-1
Group 2 Mode Selection System 5-3
Group 3 Automatic Deceleration System 5-6
Group 4 Power Boost System 5-7
Group 5 Travel Speed Control System 5-8
Group 6 Automatic Warming Up Function 5-9
Group 7 Engine Overheat Prevention Function 5-10
Group 8 Anti-Restart System 5-11
Group 9 Self-Diagnostic System 5-12
Group 10 Engine Control System 5-14
Group 11 EPPR(Electro Proportional Pressure Reducing) Valve 5-21
Group 12 Prolix Switch 5-24
Group 13 Monitoring System 5-25
SECTION 6 TROUBLESHOOTING
Group 1 Before Trobleshooting 6-1
Group 2 Hydraulic and Mechanical System 6-4
Group 3 Electrical System 6-24
Group 4 Mechatronics System 6-41
SECTION 7 MAINTENANCE STANDARD

Group 1 Operational Performance Test 7-1
Group 2 Major Components 7-21
Group 3 Track and Work Equipment 7-29
SECTION 8 DISASSEMBLY AND ASSEMBLY

Group 1 Precaution 8-1
Group 2 Tightening Torque 8-4
Group 8 Turning Joint 8-125
Group 9 Boom, Arm and Bucket Cylinder 8-130
Group 10 Undercarriage 8-147
Group 11 Work Equipment 8-159
SECTION 9 COMPONENT MOUNTING TORQUE

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

excavator.
OPERATE ONLY FORM OPERATOR'S SEAT

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

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

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

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

Do not incinerate or puncture pressurized
containers.
Make sure machine is clean of trash, grease,
and debris.
Do not store oily rags; They can ignite and burn
spontaneously.
13031GE13
1-4
BEWARE OF EXHAUST FUMES
Prevent asphyxiation. Engine exhaust fumes
can cause sickness or death.
If you must operate in a building, be positive
there is adequate ventilation. Either use an
exhaust pipe extension to remove the exhaust
fumes or open doors and windows to bring
enough outside air into the area.
REMOVE PAINT BEFORE WELDING OR HEATING

Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint
is heated by welding, soldering, or using a torch.
Do all work outside or in a well ventilated area.
Dispose of paint and solvent properly.
Remove paint before welding or heating:
・ If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
・ If you use solvent or paint stripper, remove
stripper with soap and water before welding.
Remove solvent or paint stripper containers
and other flammable material from area.
13031GE14
Allow fumes to disperse at least 15 minutes
before welding or heating.
ILLUMINATE WORK AREA SAFELY

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

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

Escaping fluid under pressure can penetrate the
skin causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
fluids. 13031GE18
If an accident occurs, see a doctor immediately.

Any fluid injected into the skin must be surgically
removed within a few hours or gangrene may
result.
13031GE19
1-6
AVOID HEATING NEAR PRESSURIZED FLUID
LINES
Flammable spray can be generated by heating
near pressurized fluid lines, resulting in severe
burns to yourself and bystanders. Do not heat
by welding, soldering, or using a torch near
pressurized fluid lines or other flammable
materials.
Pressurized lines can be accidentally cut when
13031GE20
heat goes beyond the immediate flame area.
Install fire resisting guards to protect hoses or
other materials.
PREVENT BATTERY EXPLOSIONS

Keep sparks, lighted matches, and flame away
from the top of battery. Battery gas can
explode.
Never check battery charge by placing a metal
object across the posts. Use a volt-meter or
hydrometer.
Do not charge a frozen battery; It may explode.
Warm battery to 16°C(60°F). 13031GE21
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,
13031GE22
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 13031GE23
Parts catalogue.)
DISPOSE OF FLUIDS PROPERLY

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

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

Before returning machine to customer, make
sure machine is functioning properly, especially
the safety systems. Install all guards and
shields.
1-8
GROUP 2 SPECIFICATIONS
1. MAJOR COMPONENT
16072SP01
1-9
2. SPECIFICATIONS
1) 5.1m(16' 9") MONO BOOM, 2.6m(8' 6") ARM
16072SP02
Description Unit Specification
Operating weight kg(lb) 17400(38360)

Bucket capacity(SAE heaped), standard m (yd³)
3
0.70(0.92)
Overall length A 8600(28' 3")
Overall width, with 600mm shoe B 2590( 8' 6")
Overall height C 3050(10' 0")
Superstructure width D 2475( 8' 1")
Overall height of cab E 2915( 9' 7")
Ground clearance of counterweight F 1035( 3' 5")
Engine cover height G 2295( 7' 6")
Minimum ground clearance H mm(ft-in) 460( 1' 6")
Rear-end distance I 2530( 8' 4")
Rear-end swing radius I' 2480( 8' 2")
Distance between tumblers J 3190(10' 6")
Undercarriage length K 3980(13' 1")
Undercarriage width L 2590( 8' 6")
Track gauge M 1990( 6' 6")
Track shoe width, standard N 600(24")
Travel speed(Low/high) km/hr(mph) 3.7/5.6(2.3/3.5)
Swing speed rpm 12.1
Gradeability Degree(%) 30(58)
Ground pressure(600mm shoe) kgf/cm2(psi) 0.42(5.97)
1-10
2) 5.1m(16' 9") HYDRAULIC ADJUSTABLE BOOM, 2.6m(8' 6") ARM
16072SP03
Description Unit Specification
Operating weight kg(lb) 17400(38360)

Bucket capacity(SAE heaped), standard m (yd³)
3
0.70(0.92)
Overall length A 8570(28' 1")
Overall width, with 600mm shoe B 2590( 8' 6")
Overall height C 2820( 9' 3")
Superstructure width D 2475( 8' 1")
Overall height of cab E 2915( 9' 7")
Ground clearance of counterweight F 1035( 3' 5")
Engine cover height G 2295( 7' 6")
Minimum ground clearance H mm(ft-in) 460( 1' 6")
Rear-end distance I 2530( 8' 4")
Rear-end swing radius I' 2480( 8' 2")
Distance between tumblers J 3190(10' 6")
Undercarriage length K 3980(13' 1")
Undercarriage width L 2590( 8' 6")
Track gauge M 1990( 6' 6")
Track shoe width, standard N 600(24")
Travel speed(Low/high) km/hr(mph) 3.7/5.6(2.3/3.5)
Swing speed rpm 12.1
Gradeability Degree(%) 30(58)
Ground pressure(600mm shoe) kgf/cm2(psi) 0.42(5.97)
1-11
3. WORKING RANGE
1) 5.1m(16' 9") MONO BOOM
A
A'
F
D
E
C
B'
B
8ft 18072SP03
Description 2.2m(7' 3") Arm 2.6m(8' 6") Arm 3.1m(10' 2") Arm
Max digging reach A 8690mm (28' 6") 9030mm (29' 8") 9450mm (31' 0")
Max digging reach on ground A' 8530mm (27'12") 8870mm (29' 1") 9300mm (30' 6")
Max digging depth B 5660mm (18' 7") 6060mm (19'11") 6560mm (21' 6")
Max digging depth (8ft level) B' 5440mm (17'10") 5860mm (19' 3") 6370mm (20'11")
Max vertical wall digging depth C 5140mm (16'10") 5440mm (17'10") 5730mm (18'10")
Max digging height D 8740mm (28' 8") 8870mm (29' 1") 8970mm (29' 5")
Max dumping height E 6100mm (20' 0") 6240mm (20' 6") 6380mm (20'11")
Min swing radius F 3180mm (10' 5") 3170mm (10' 5") 3180mm (10' 5")
108.6 [118.4] kN 108.6 [118.4] kN 108.6 [118.4] kN
SAE 11070 [12080] kgf 11070 [12080] kgf 11070 [12080] kgf
24410 [26630] lbf 24410 [26630] lbf 24410 [26630] lbf
Bucket digging force
124.5 [135.9] kN 124.5 [135.9] kN 124.5 [135.9] kN
ISO 12700 [13850] kgf 12700 [13850] kgf 12700 [13850] kgf
28000 [30550] lbf 28000 [30550] lbf 28000 [30550] lbf
85.2 [93.0] kN 75.0 [81.8] kN 67.4 [73.5] kN
SAE 8690 [9480] kgf 7650 [8350] kgf 6870 [7490] kgf
19160 [20900] lbf 16870 [18400] lbf 15150 [16530] lbf
Arm digging force
89.0 [97.1] kN 77.6 [84.6] kN 69.4 [75.7] kN
ISO 9080 [9910] kgf 7910 [8630] kgf 7080 [7720] kgf
20020 [21840] lbf 17440 [19030] lbf 15610 [17030] lbf
[ ] : Power boost
1-12
2) 5.1m(16' 9") HYDRAULIC ADJUSTABLE BOOM
A
A'
F
D
E
C
B'
B
8ft
18072SP04
Description 2.2m(7' 3") Arm 2.6m(8' 6") Arm

Max digging reach A 8750mm (28' 8") 9110mm (29'11")
Max digging reach on ground A' 8600mm (28' 3") 8960mm (29' 5")
Max digging depth B 5460mm (17'11") 5830mm (19' 2")
Max digging depth (8ft level) B' 5350mm (17' 7") 5750mm (18'10")
Max vertical wall digging depth C 4670mm (15' 4") 5030mm (16' 6")
Max digging height D 9390mm (30'10") 9600mm (31' 6")
Max dumping height E 6680mm (21'11") 6900mm (22' 8")
Min swing radius F 3130mm (10' 3") 2970mm ( 9' 9")
108.6 [118.4] kN 108.6 [118.4] kN
SAE 11070 [12080] kgf 11070 [12080] kgf
24410 [26630] lbf 24410 [26630] lbf
Bucket digging force
124.5 [135.9] kN 124.5 [135.9] kN
ISO 12700 [13850] kgf 12700 [13850] kgf
28000 [30550] lbf 28000 [30550] lbf
85.2 [93.0] kN 75.0 [81.8] kN
SAE 8690 [9480] kgf 7650 [8350] kgf
19160 [20900] lbf 16870 [18400] lbf
Arm digging force
89.0 [97.1] kN 77.6 [84.6] kN
ISO 9080 [9910] kgf 7910 [8630] kgf
20020 [21840] lbf 17440 [19030] lbf
[ ] : Power boost
1-13
4. WEIGHT
Item kg lb
Upperstructure assembly 7480 16490

Main frame weld assembly 1400 3090
Engine assembly 350 770
Main pump assembly 90 200
Main control valve assembly 80 180
Swing motor assembly 250 550
Hydraulic oil tank assembly 180 400
Fuel tank assembly 140 310
Counterweight 2950 6500
Cab assembly 310 680
Lower chassis assembly 6900 15210
Track frame weld assembly 2030 4480
Swing bearing 260 570
Travel motor assembly 240 530
Turning joint 50 120
Track recoil spring 140 600
Idler 160 370
Carrier roller 20 45
Track roller 50 120
Track-chain assembly(600mm standard triple grouser shoe) 1180 2600
Front attachment assembly(5.1m boom, 2.6m arm,
3020 6660
0.7m3 SAE heaped bucket)
5.1m boom assembly 1250 2760
2.6m arm assembly 800 1760
0.7m3 SAE heaped bucket 540 1190
Boom cylinder assembly 160 350
Arm cylinder assembly 180 400
Bucket cylinder assembly 140 310
Bucket control link assembly 120 265
1-14
5. LIFTING CAPACITIES
1) R160LC-7
(1) 5.1m(16' 9") boom, 2.2m(7' 3") arm equipped with 0.7m3(SAE heaped) bucket and 600mm(24")
triple grouser shoe.
・ : Rating over-front ・ : Rating over-side or 360 degree
Load radius At max. reach

Load point 1.5m(5ft) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) Capacity Reach
height
m(ft)
7.5m kg *3400 3380 5.81

(25ft) lb *7500 7450 (19.1)
6.0m kg *3340 2300 7.16
(20ft) lb *7360 5070 (23.5)
4.5m kg *4260 *4260 *3820 3030 3120 1860 7.92
(15ft) lb *9390 *9390 *8420 6680 6880 4100 (26.0)
3.0m kg *8470 *8470 *5390 4580 *4280 2890 2830 1660 8.30
(10ft) lb *18670 *18670 *11880 10100 *9440 6370 6240 3660 (27.2)
1.5m kg *6540 4220 4640 2740 2760 1600 8.34
(5ft) lb *14420 9300 10230 6040 6080 3530 (27.4)
Ground kg *6700 *6700 7130 4010 4510 2620 2890 1680 8.06
Line lb *14770 *14770 15720 8840 9940 5780 6370 3700 (26.4)
-1.5m kg *6610 *6610 *10490 7530 7060 3950 4460 2570 3300 1930 7.42
(-5ft) lb *14570 *14570 *23130 16600 15560 8710 9830 5670 7280 4250 (24.3)
-3.0m kg *10560 *10560 *8970 7680 *6210 4010 *3380 2570 6.28
(-10ft) lb *23280 *23280 *19780 16930 *13690 8840 *7450 5670 (20.6)
-4.5m kg *5840 *5840
(-15ft) lb *12870 *12870
Note 1. Lifting capacity are based on SAE J1097 and ISO 10567.
2. Lifting capacity of the ROBEX series does not exceed 75% of tipping load with the machine
on firm, level ground or 87% of full hydraulic capacity.
3. The load point is a hook located on the back of the bucket.
4. *indicates load limited by hydraulic capacity.
1-15
Load point 1.5m(5ft) 3.0m(10ft) 4.5m(15ft) 6.0m(20ft) 7.5m(25ft) Capacity Reach
height
m(ft)
7.5m kg *3080 2940 6.33
(25ft) lb *6790 6480 (20.8)
6.0m kg *2760 *2760 *3070 2090 7.56
(20ft) lb *6080 6080 *6770 4610 (24.8)
4.5m kg *3500 3050 2880 1710 8.28
(15ft) lb *7720 6720 6350 3770 (27.2)
3.0m kg *7360 *7360 *4940 4630 *4000 2900 *2560 1940 2630 1520 8.64
(10ft) lb *16230 *16230 *10890 10210 *8820 6390 *5640 4280 5800 3350 (28.3)
1.5m kg *7670 *7670 *6190 4250 *4570 2720 3220 1870 2560 1470 8.68
(5ft) lb *16910 *16910 *13650 9370 *10080 6000 7100 4120 5640 3240 (28.5)
Ground kg *7420 *7420 *6980 3990 4480 2590 3150 1810 2660 1520 8.42
Line lb *16360 *16360 *15390 8800 9880 5710 6940 3990 5860 3350 (27.6)
-1.5m kg *6300 *6300 *10000 7410 6990 3890 4400 2520 3000 1730 7.81
(-5ft) lb *13890 *13890 *22050 16340 15410 8580 9700 5560 6610 3810 (25.6)
-3.0m kg *9330 *9330 *9580 7530 *6480 3910 4430 2540 *3370 2230 6.75
(-10ft) lb *20570 *20570 *21120 16600 *14290 8620 9770 5600 *7430 4920 (22.1)
-4.5m kg *6950 *6950 *4610 4090
(-15ft) lb *15320 *15320 *10160 9020

height
m(ft)
7.5m kg *2730 2520 6.92
(25ft) lb *6020 5560 (22.7)
6.0m kg *2640 *2640 *2760 1850 8.05
(20ft) lb *5820 *5820 *6080 4080 (26.4)
4.5m kg *3110 3080 *1940 *1940 2630 1530 8.73
(15ft) lb *6860 6790 *4280 *4280 5800 3370 (28.6)
3.0m kg *4380 *4380 *3640 2920 *2840 1940 2410 1370 9.06
(10ft) lb *9660 *9660 *8020 6440 *6260 4280 5310 3020 (29.7)
1.5m kg *9510 8060 *5730 4300 *4290 2720 3200 1850 2340 1310 9.10
(5ft) lb *20970 17770 *12630 9480 *9460 6000 7050 4080 5160 2890 (29.9)
Ground kg *8210 7460 *6710 3900 4460 2560 3120 1770 2420 1350 8.85
Line lb *18100 16450 *14790 8800 9830 5640 6880 3900 5340 2980 (29.0)
-1.5m kg *5960 *5960 *9730 7320 6940 3830 4350 2470 *2970 1730 2680 1510 8.28
(-5ft) lb *13140 *13140 *21450 16140 15300 8440 9590 5450 *6550 3810 5910 3330 (27.2)
-3.0m kg *8420 *8420 *10150 7380 *6700 3820 4340 2450 *3290 1900 7.30
(-10ft) lb *18560 *18560 *22380 16270 *14770 8420 9570 5400 *7250 4190 (24.0)
-4.5m kg *11640 *11640 *8040 7600 *5380 3930
(-15ft) lb *25660 *25660 *17730 16760 *11860 8660
1-16
(4) 5.1m(16' 9") hydraulic adjustable boom, 2.2m(7' 3") arm equipped with 0.7m3(SAE heaped) bucket
and 600mm(24") triple grouser shoe.

height
m(ft)
6.0m kg *3390 2230 7.24
(20ft) lb *7470 4920 (23.8)
4.5m kg *3860 3020 3080 1810 7.99
(15ft) lb *8510 6660 6790 3990 (26.2)
3.0m kg *5440 4570 *4280 2880 2800 1610 8.36
(10ft) lb *11990 10080 *9440 6350 6170 3550 (27.4)
1.5m kg *6500 4190 4660 2710 *3240 1860 2730 1560 8.41
(5ft) lb *14330 9240 10270 5970 *7140 4100 6020 3440 (27.6)
Ground kg *5860 *5860 *7040 3960 4520 2590 2860 1630 8.13
Line lb *12920 *12920 *15520 8730 9960 5710 6310 3590 (24.6)
-1.5m kg *5850 *5850 *9740 7460 *6890 3900 4480 2540 3270 1890 7.50
(-5ft) lb *12900 *12900 *21470 16450 *15190 8600 9880 5600 7210 4170 (24.6)
-3.0m kg *8500 7650 *5940 3980 *2930 2530 6.37
(-10ft) lb *18740 16870 *13100 8770 *6460 5580 (20.9)
(5) 5.1m(16' 9") hydraulic adjustable boom, 2.6m(8' 6") arm equipped with 0.7m3(SAE heaped) bucket
and 600mm(24") triple grouser shoe.

height
m(ft)
6.0m kg *3120 2010 7.66
(20ft) lb *6880 4430 (25.1)
4.5m kg 2850 1640 8.37
(15ft) lb 6280 3620 (27.5)
3.0m kg *4020 2890 *2940 1920 2600 1470 8.72
(10ft) lb *8860 6370 *6480 4230 5730 3240 (28.6)
1.5m kg *6640 *6640 *6170 4220 *4550 2700 3250 1840 2540 1420 8.77
(5ft) lb *14640 *14640 *13600 9300 *10030 5950 7170 4060 5600 3130 (28.8)
Ground kg *6650 *6650 *6880 3940 4510 2550 3180 1780 2650 1480 8.50
Line lb *14660 *14660 *15170 8690 9940 5620 7010 3920 5840 3260 (27.9)
-1.5m kg *5680 *5680 *9340 7340 *6930 3840 4440 2480 2980 1680 7.90
(-5ft) lb *12520 *12520 *20590 16180 *15280 8470 9790 5470 6570 3700 (25.9)
-3.0m kg *8890 *8890 *9150 7480 *6240 3880 *4340 2520 *2970 2180 6.86
(-10ft) lb *19600 *19600 *20170 16490 *13760 8550 *9570 5560 *6550 4810 (22.5)
-4.5m kg *6330 *6330 *4220 4080
(-15ft) lb *13960 *13960 *9300 8990
1-17
6. BUCKET SELECTION GUIDE
1) GENERAL BUCKET
0.39m3 SAE 0.50m3 SAE 0.64m3 SAE ※0.70m3 SAE 0.89m3 SAE ◈0.69m3 SAE
heaped bucket heaped bucket heaped bucket heaped bucket heaped bucket heaped bucket
Recommendation
Capacity Width 5.1m (16' 9") 5.1m (16' 9")
Weight Mono boom Hydraulic adjustable boom
SAE CECE Without With 2.0m arm 2.6m arm 3.1m arm 2.2m arm 2.6m arm
heaped heaped side cutter side cutter (7' 3") (8' 6") (10' 2") (7' 3") (8' 6")
0.39m3 0.34m3 620mm 740mm 410kg

(0.51yd3) (0.44yd3) (24.4") (29.1") (900lb)
0.50m3 0.44m3 760mm 880mm 470kg

(0.65yd3) (0.58yd3) (29.9") (34.6") (1040lb)
0.64m3 0.55m3 920mm 1040mm 510kg

(0.84yd3) (0.72yd3) (36.2") (40.9") (1120lb)
※0.70m3 0.60m3 990mm 1110mm 540kg

(0.92yd3) (0.78yd3) (39.0") (43.7") (1190lb)
0.89m3 0.77m3 1220mm 1340mm 610kg

(1.16yd3) (1.01yd3) (48.0") (52.8") (1340lb)
◈0.69m3 0.62m3 990mm 700kg

(0.9yd3) (0.81yd3) (39.0") - (1540lb)
※ : Standard bucket
◈ : Heavy duty bucket
Applicable for materials with density of 2000kg/m3 (3370lb/yd3) or less
1-18
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) 500(20) 600(24) 700(28)

Operating weight kg(lb) 17150(37810) 17400(38360) 17650(38910)
R160LC-7
Ground pressure kgf/cm2(psi) 0.50(7.11) 0.42(5.97) 0.37(5.26)
Overall width mm(ft-in) 2490(8' 2") 2590(8' 6") 2690(8'10")
3) NUMBER OF ROLLERS AND SHOES ON EACH SIDE
Item Quantity
Carrier rollers 2EA

Track rollers 7EA
Track shoes 49EA
4) SELECTION OF TRACK SHOE

Suitable track shoes should be selected according to operating conditions.
Method of selecting shoes
Confirm the category from the list of applications in table 2, then use table 1 to select the shoe.
Wide shoes(Categories B and C) have limitations on applications. Before using wide shoes, check
the precautions, then investigate and study the operating conditions to confirm if these shoes are
suitable.
Select the narrowest shoe possible to meet the required flotation and ground pressure. Application
of wider shoes than recommendations will cause unexpected problem such as bending of shoes,
crack of link, breakage of pin, loosening of shoe bolts and the other various problems.
※ Table 1
Track shoe Specification Category
500mm triple grouser Option A

600mm triple grouser Standard A
700mm triple grouser Option B
1-19
※ Table 2
Category Applications Precautions
Rocky ground, ・ Travel at low speed on rough ground with large obstacles such as
A river beds, boulders or fallen trees
normal soil
Normal soil, ・ These shoes cannot be used on rough ground with large obstacles such
soft ground as boulders or fallen trees
B ・ Travel at high speed only on flat ground
・ Travel slowly at low speed if it is impossible to avoid going over
obstacles
Extremely soft gound ・ Use the shoes only in the conditions that the machine sinks and it is
(Swampy ground) impossible to use the shoes of category A or B
・ These shoes cannot be used on rough ground with large obstacles such
C as boulders or fallen trees
・ Travel at high speed only on flat ground
・ Travel slowly at low speed if it is impossible to avoid going over
obstacles
1-20
8. SPECIFICATIONS FOR MAJOR COMPONENTS
1) ENGINE
Item Specification
Model Mitsubishi S6S-DT

Type 4-cycle turbocharged diesel engine, low emission
Cooling method Water cooling
Number of cylinders and arrangement 6 cylinders, in-line
Firing order 1-5-3-6-2-4
Combustion chamber type Direct injection type
Cylinder bore×stroke 94×120mm(3.70"×4.72")
Piston displacement 4996cc(305cu in)
Compression ratio 19.5 : 1
Rated gross horse power(SAE J1349) 126Hp at 2100rpm(94kW at 2100rpm)
Maximum torque at 1500rpm 42.5kgf・m(307lbf・ft)
Engine oil quantity 16.5ℓ(4.4U.S. gal)
Dry weight 355kg(783lb)
High idling speed 2200+50rpm
Low idling speed 950±100rpm
Rated fuel consumption 169.3g/Hp・hr at 2100rpm
Starting motor Mitsubishi 24V-5.0kW
Alternator Mitsubishi 24V-5.0A
Battery 2×12V×100Ah
2) MAIN PUMP
Item Specification
Type Variable displacement tandem axis piston pumps

Capacity 2×80cc/rev
Maximum pressure 330kgf/cm2 (4694psi) [360kgf/cm2 (5120psi)]
Rated oil flow 2×168ℓ/min (44.3U.S. gpm/ 40U.K. gpm)
Rated speed 2100rpm
[ ]: Pooer boost
1-21
3) GEAR PUMP
Item Specification
Type Fixed displacement gear pump single stage

Capacity 15cc/rev
Maximum pressure 35kgf/cm2(500psi)
Rated oil flow 31.5ℓ/min(8.3U.S. gpm/7.0U.K. gpm)
4) MAIN CONTROL VALVE
Item Specification
Type 11 spools mono-block

Operating method Hydraulic pilot system
Main relief valve pressure 330kgf/cm2(4695psi)[360kgf/cm2(5120psi)]
Overload relief valve pressure 380kgf/cm2(5550psi)
[ ]: Pooer boost
5) SWING MOTOR
Item Specification
Type Two fixed displacement axial piston motor

Capacity 117.8cc/rev
Relief pressure 240kgf/cm2(3414psi)
Braking system Automatic, spring applied hydraulic released
Braking torque 56kgf・m(405lbf・ft)
Brake release pressure 20kgf/cm2(284psi)
Reduction gear type 2 - stage planetary
Swing speed 12.1rpm
6) TRAVEL MOTOR
Item Specification
Type Variable displacement axial piston motor
Relief pressure 330kgf/cm2(4695psi)
Reduction gear type Planetary & differential type
Braking system Automatic, spring applied hydraulic released
Brake release pressure 6kgf/cm2(85psi)
Braking torque 40.6kgf・m(294lbf・ft)
1-22
7) REMOTE CONTROL VALVE
Item Specification
Type Pressure reducing type

Minimum 6.5kgf/cm2(92psi)
Operating pressure
Maximum 26kgf/cm2(370psi)
Lever 61mm(2.4in)
Single operation stroke
Pedal 123mm(4.84in)
8) CYLINDER
Item Specification
Bore dia×Rod dia×Stroke Ø115×Ø80×1090mm

Boom cylinder
Cushion Extend only
Arm cylinder
Cushion Extend and retract
Bucket cylinder
Cushion Extend only
※ Discoloration of cylinder rod can occur when the friction reduction additive of lubrication oil spreads
on the rod surface.
※ Discoloration does not cause any harmful effect on the cylinder performance.
9) SHOE
Item Width Ground pressure Link quantity Overall width
Option 500mm(20") 0.50kgf/cm2(7.11psi) 49 2490mm( 8' 2")

R160LC-7 Standard 600mm(24") 0.42kgf/cm (5.97psi)
2
49 2590mm( 8' 6")
Option 700mm(28") 0.37kgf/cm2(5.26psi) 49 2690mm( 8' 10")
1-23
10) BUCKET
Capacity Tooth Width
Item
SAE heaped CECE heaped quantity Without side cutter With side cutter
STD 0.70m (0.92yd )

3 3
0.60m3(0.78yd3) 5 990mm(39.0") 1110mm(43.7")
0.39m3(0.51yd3) 0.34m3(0.44yd3) 3 620mm(24.4") 740mm(29.1")
0.50m (0.65yd )
3 3
0.44m (0.58yd )
3 3
4 760mm(29.9") 880mm(34.6")
R160LC-7
OPT 0.64m3(0.84yd3) 0.55m3(0.72yd3) 5 920mm(36.2") 1040mm(40.9")
0.89m (1.16yd )
3 3
0.77m (1.01yd )
3 3
6 1220mm(48.0") 1340mm(52.8")
◈0.69m3(0.90yd3) 0.62m3(0.81yd3) 5 990mm(39.0") -
◈ : Heavy duty bucket
1-24
9. RECOMMENDED OILS
Use only oils listed below or equivalent.
Do not mix different brand oil.
Ambient temperature °
C( °
F)
Capacity
Service point Kind of fluid
ℓ(U.S. gal) -20 -10 0 10 20 30 40
(-4) (14) (32) (50) (68) (86) (104)
SAE 30
SAE 10W
Engine
Engine oil 16.5(4.4)
oil pan SAE 10W-30
SAE 15W-40
Swing drive 5(1.3)

Gear oil SAE 85W-140
Final drive 3×2
(0.8×2)
Tank: ISO VG 32
Hydraulic tank Hydraulic oil 160(42.2) ISO VG 46
System:
240(63.4) ISO VG 68
ASTM D975 NO.1

Fuel tank Diesel fuel 260(68.7)
ASTM D975 NO.2
Fitting NLGI NO.1

Grease As required
(Grease nipple)
NLGI NO.2
Mixture of
Radiator antifreeze 30(7.9) 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
1-25

Group 6 RCV Pedal 2-72
GROUP 1 PUMP DEVICE
1. STRUCTURE
The pump device consists of main pump, regulator and gear pump.
Pm1 Qmax adjusting screw
Pn1 EPPR valve
a4 A3
B3
Dr Pn2
Pm2
Qmin adjusting screw Qmin adjusting screw
Regulator Regulator
Pn1 Pm1 Pm2 Pn2
B3
B1
a3
a1 a2
Front pump Valve block Rear pump Gear pump
16072SF01
A1 A2 Port Port name Port size

a1 a2 A1,2 Delivery port SAE6000psi 3/4"
B1 Suction port SAE2500psi 2 1/2"
Dr Drain port PF 1/2 - 19
Pn1,Pn2 Pilot port PF 1/4 - 15
Pm1 Pm2 Pm1,Pm2 Qmax cut port PF 1/4 - 15
Pn1 Pn2 P1 EPPR port PF 1/4 - 13
a1,2 Gauge port PF 1/4 - 15
a4
a3 Gauge port PF 1/4 - 14
Dr P1 a4 Gauge port PF 1/4 - 13
A3
B1 B3 a3 A3 Gear pump delivery port PF 1/2 - 19
B3 Gear pump suction port PF 3/4 - 20.5
2-1
1) MAIN PUMP(1/2)
The main pump consists of two piston pumps(front & rear) and valve block.
702
789, 732 532 214 548 531 724 792 534 901 954 719 151 152 211 113
535
808
953
886 04
717
406
261
774
111
824
127
710
123
251
212
490 153 156 157 313 124 312 114 466 885 314 467 141 981 271 401
725 728 983
14072SF02
04 Gear pump 271 Pump casing 719 O-ring

111 Drive shaft(F) 312 Valve block 724 O-ring
113 Drive shaft(R) 313 Valve plate(R) 725 O-ring
114 Spline couping 314 Valve plate(L) 728 O-ring
123 Roller bearing 401 Hexagon socket bolt 732 O-ring
124 Needle bearing 406 Hexagon socket bolt 774 Oil seal
127 Bearing spacer 466 VP Plug 789 Back up ring
141 Cylinder block 467 VP Plug 792 Back up ring
151 Piston 490 Plug 808 Hexagon head nut
152 Shoe 531 tilting pin 824 Snap ring
153 Set plate 532 Servo piston 885 Pin
156 Bushing 534 Stopper(L) 886 Spring pin
157 Cylinder spring 535 Stopper(S) 901 Eye bolt
211 Shoe plate 548 Pin 953 Set screw
212 Swash plate 702 O-ring 954 Set screw
214 Bushing 710 O-ring 981 Plate
251 Support 717 O-ring 983 Pin
261 Seal cover(F)
2-2
2) REGULATOR(1/2)
412 876 874

A 755
647
897 B 858
614
612 648
723
642
615 438
613
875 801
A 611
B 801
924
641 730 643 708 644 645 646 728

SECTION B-B
413 438 413 438
656 D
438
735
D
722
496 724 725 436 496 724 725 436
VIEW C(FRONT) VIEW C(REAR)
KR38-9C07(FR) A
KR38-9C05(RR)
735 722 P2
079
16072SF03
Pf
466
Pm
Pn
Port Port name port size
753 496 755
A Delivery port 3/4"
SECTION D-D B Suction port 2 1/2"
B Pn Pilot port PF 1/4-15
Pm Qmax cut port PF 1/4-15
2-3
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
2-5 (140-7TIER)
412 Hexagon socket screw 631 Sleeve, pf 730 O-ring

413 Hexagon socket screw 641 Pilot cover 732 O-ring
436 Hexagon socket screw 642 Pilot cover(QMC) 733 O-ring
438 Hexagon socket screw 643 Pilot piston 734 O-ring
496 Plug 644 Spring seat(Q) 735 O-ring
601 Casing 645 Adjust stem(Q) 755 O-ring
611 Feed back lever 646 Pilot spring 756 O-ring
612 Lever(1) 647 Stopper 763 O-ring
613 Lever(2) 648 Piston(QMC) 801 Nut
614 Fulcrum plug 651 Sleeve 814 Snap ring
615 Adjust plug 652 Spool 836 Snap ring
621 Compensator piston 653 Spring seat 858 Snap ring
622 Piston case 654 Return spring 874 Pin
623 Compensator rod 655 Set spring 875 Pin
624 Spring seat(C) 656 Block cover 876 Pin
625 Outer spring 708 O-ring 887 Pin
626 Inner spring 722 O-ring 897 Pin
627 Adjust stem(C) 723 O-ring 898 Pin
628 Adjust screw(C) 724 O-ring 924 Set screw
629 Cover(C) 725 O-ring 925 Adjust screw(QI)
630 Lock nut 728 O-ring
2-4
3) GEAR PUMP
700 354 351 433
B3
850
355
434
A3
311
312
a3
710 435 361 353 732 309 307 310 308 434 466, 725
2-6 (140-7TIER)
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
2-5
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
bush(156) and cylinder spring(157).
The drive shaft is supported by bearing
(123,124) at its both ends.
The shoe is caulked to the piston to from
a spherical coupling. It has a pocket to
relieve thrust force generated by loading
pressure and the take hydraulic balance
so that it slides lightly over the shoe
plate(211). The sub group composed by
a piston and a shoe is pressed against
the shoe plate by the action of the
cylinder spring via a retainer and a
spherical bush.
Similarly, the cylinder block is pressed 14072SF04
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.
If the servo piston moves to the right and 532 α
left as hydraulic force controlled by the
regulator is admitted to hydraulic
chamber located on both sides of the α
servo piston, the swash plate slides over
the swash plate support via the spherical
part of the tilting pin to change the tilting
angle(α)
2-7 (140-7TIER)
2-6
(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 312
and feeds 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 2-8 (140-7TIER)
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.
2-7
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 Pn, 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 Pn rises.
With this mechanism, when the pilot
pressure corresponding to the flow
required for the work is commanded, the
pump discharges the required flow only,
and so it does not consume the power Pilot pressure, Pn
uselessly.
2-8
① Flow reducing function
643 654 651 652 613 646
P1 CL
B(E)
874
897
C
A
875
611
Servo piston Small diameter

Large diameter D chamber
chamber 548
531
2-10 (140-7TIER)
As the pilot pressure Pn 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.
2-9
② Flow increasing function
643 654 651 652 613 646
P1 CL
B(E)
874
897
C
875
611
Small diameter
Servo piston D chamber
Large diameter 548
chamber
531
2-11 (140-7TIER)
As the pilot pressure Pn 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.
2-10
③ Adjustment 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.
※ Adjusting values are shown in table.
Adjustment of flow control 2-12 (140-7TIER)

characteristic
Speed
Tightening Flow control Flow change
amount of starting amount
Delivery flow, Q
adjusting pressure
screw(924) change
amount
(min -1) (Turn) (kgf/cm2) (ℓ/min)
2100 +1/4 +1.5 +10.0
Pilot pressure, Pn
2-11
(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 simultaneous
Delivery pressure, (P1+P2)
total horsepower type that operates by
the sum of load pressures of the two
pumps in the tandem double-pump
system, the prime mover is automatically
prevented from being overloaded,
irrespective of the load condition of the
two pumps, when horsepower control is
under way.
Since this regulator is of the simultaneous
total horsepower type, it controls the
tilting angles(displacement volumes) of
the two pumps to the same value as
represented by the following equation :
Tin = P1×q/2Л + P2×q/2Л
= (P1+P2)×q/2Л
The horsepower control function is the
same as the flow control function and is
summarized in the following.(For detailed
behaviors of respective parts, refer to the
section of flow control).
2-12
① Overload 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
2-14 (140-7TIER)
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.
2-13
② Flow 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
2-15 (140-7TIER)
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.
2-14
③ Low tilting angle(Low flow) command preferential function
As mentioned above, flow control and horsepower control tilting angle commands are
transmitted to the feedback lever and spool via the large-hole sections(C & F) of levers 1 and 2.
However, since sections C and F have the pins(Ø4) protruding from the large hole(Ø8), only the
lever lessening the tilting angle contacts the pin(897) ; the hole(Ø8) in the lever of a larger tilting
angle command is freed without contacting the pin(897). Such a mechanical selection method
permits preference of the lower tilting angle command of the flow control and horsepower control.
④ Adjustment of input horsepower
Since the regulator is of total cumulative horsepower type, adjust the adjusting screws of both
the front and rear pumps, when changing the horsepower set values. The pressure change
values by adjustment are based on two pumps pressurized at the same time, and the values will
be doubled when only one pump is loaded.
a. Adjustment of outer spring

Adjust it by loosening the hexagon 625 626 630 628
nut(630) and by tightening(or
loosening) the adjusting screw C(628).
Tightening the screw shifts the control 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 N×A turns
at first.(A=1.85)
※ Adjusting values are shown in table
2-16 (140-7TIER)
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) (kgf・m)
2100 +1/4 +17.8 +3.54 Delivery pressure, (P1+P2)
2-15
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.
※ Adjusting valves are shown in table
Adjustment of inner spring

Speed
Tightening Flow Input torque 2-17 (140-7TIER)
amount of change change
adjusting amount amount
screw(QI)
(925)
Delivery flow, Q
(min -1) (Turn) (ℓ/min) (kgf・m)
2100 +1/4 +7.4 +3.14
Delivery pressure, (P1+P2)
2-16
(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
2-18 (140-7TIER)
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 pressure, (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 horsepower control. On the contrary, the
set horsepower rises as the power shift pressure Pf falls.
2-17
(4) Adjustment of maximum and minimum flows
Η Adjust it by loosening the hexagon 808
the set screw(954). 954
The maximum flow only is adjusted
without changing other control
characteristics.
2-19(1) 140-7TIER
Adjustment of max flow
Speed
Tightening Flow change
amount of amount
adjusting screw
Delivery flow, Q
(954)
(min -1) (Turn) (˶/min)
2100 +1/4 -3.4
Delivery pressure, Pn
Θ Adjustment of minimum flow

Adjust it by loosening the hexagon
806
the hexagonal socket head set screw
953
(953). Similarly to the adjustment of the
maximum flow, other characteristics are
not changed.
However, remember that, if tightened too 2-19(2) 140-7TIER
much, the required horsepower during

the maximum delivery pressure(or
during relieving) may increase.
Delivery flow, Q
Adjustment of min flow

Speed
Tightening Flow change
amount of amount
adjusting screw
(953)
(min -1) (Turn) (˶/min)
2100 +1/4 +3.4 Delivery pressure, Pn
2-18
(5) Qmax cut control
647
The regulator regulates 648
the maximum delivery flow
by inputting the pilot 723
pressure Pm. Since this is 642 438
a 2-position control method,
the maximum delivery flow 801
may be switched in two 801
steps by turning on/off the 924
pilot pressure Pm.(The
641 730 643 708 644 645 646 728
maximum control flow
cannot be controlled in
intermediate level.) 2-4 (140-7TIER)
① Functional explanation
As shown in the figure, the pilot pressure
Pm switches the maximum flow in two
steps.
Delivery flow, Q
When the pilot pressure Pm is given, it is Pm
admitted to the lefthand side of the
piston QMC(648). The piston QMC
moves the stopper(647) and pilot
piston(643) to the right, overcoming the
force of the pilot spring(646), thereby
reducing the delivery flow of the pump. Pilot pressure, Pn
Since the adjusting screw QMC(642) is
provided with a flange, the piston QMC
stops upon contact with the flange, and
the position of the pilot piston at this time
determines the maximum flow of the
pump.
② Adjustment of Qmax cut flow

Adjust it by loosening the hexagon
Delivery flow, Q
the adjusting screw QMC(642).

Tightening the screw decreases the
Qmax cut flow as shown in the figure.
Pilot pressure, Pn
2-19
GROUP 2 MAIN CONTROL VALVE
1. STRUCTURE
Mark Port name Port size Tightening torque
Rs Make up for swing motor
Pa1 Travel left pilot port(FW)
Pb1 Travel left pilot port(BW)
Pc1 Travel right pilot port(BW)
Pd1 Travel right pilot port(FW)
Pa20 Boom up pilot port
Pa21 Boom up confluence pilot port
Pb20 Boom down pilot port
Pb21 Lock valve pilot port(Boom)
Pc2 Swing pilot port(RH)
Pd2 Swing pilot port(LH)
Pb3 Arm in confluence pilot port
Pc3 Swing priority pilot port
Pa4 Option A pilot port(Breaker)
Pb4 Arm in regeneration cut port
Pc40 Arm in pilot port
Pc41 Lock valve pilot port(Arm) G1/4 3.5~3.9kgf・m
Pc42 Arm in regen-cut signal selector port (25.3~28.2lbf・ft)
Pd40 Arm out pilot port
Pd41 Arm out confluence pilot port
Pa5 Bucket in pilot port
Pb5 Bucket out pilot port
Pc5 Option B pilot port
Pd5 Option B pilot port
Pc6 Option C pilot port
Pd6 Option C pilot port
PO Pilot pressure port
Pu Main relief pressure up
Ai Auto idle signal port
Dr0 Drain port(Travel straight)
Dr1 Drain port(Boom holding valve)
Dr2 Drain port(Boom2 & swing priority)
Dr3 Drain port(Arm holding valve)
Pn1 Negative control signal port(P1 port side)
Pn2 Negative control signal port(P2 port side)
A1 Travel motor left side port(FW)

B1 Travel motor left side port(BW)
C1 Travel motor right side port(BW)
D1 Travel motor right side port(FW)
B2 Boom rod side port
C2 Swing motor port(LH)
D2 Swing motor port(RH) G3/4 15~18kgf・m
B4 Option A port(Breaker) (109~130lbf・ft)
A5 Bucket head side port
B5 Bucket rod side port
C5 Option B port
D5 Option B port
C6 Option C port
D6 Option C port
P1 Pump port(P1 side)
P2 Pump port(P2 side)
A2 Boom head side port 20~25kgf・m

C4 Arm head side port G1
D4 Arm rod side port (115~180lbf・ft)
SAE3000, 1 1/2 8.5~11.5kgf・m

14072SF10 T1 Return port (61.5~83.1lbf・ft)
(M12)
2-20
1 Body 50 Stopper-regeneration
2 Spool-straight travel 51 Piston-cut off
3 Spool-travel 52 Poppet-signal
4 Spool-swing 53 Spring-signal
5 Spool-boom 54 Plug
6 Spool-swing priority 55 Orifice-signal
7 Spool-boom2 56 Coin type filter
8 Spool-arm2 57 Orifice-plug
9 Spool-arm 58 Plug
10 Spool-arm regeneration 59 Plug
& breaker 60 Plug
11 Spool-option 61 Plug-orifice
12 Spool-bucket 62 Poppet-negative control
13 Cover-pilot A 63 Coin type filter
14 Cover-pilot B1 64 Spring seat
15 Cover-Pilot B2 65 Spring-negative control
16 Block-holding 66 Piston-negative control
17 Block-regeneration 67 Socket-negative control
18 Plug 68 Plug
19 Poppet1-check valve 69 Plug
20 Spring-check valve 70 Plug
21 Plug 71 Plug
22 Poppet2-check valve 72 Plug
23 Spring-check valve 73 Plug
24 Spring seat1 74 O-ring
26 Spacer bolt 76 O-ring
27 Spring-return(L) 77 O-ring
28 Spring-return(S) 78 O-ring
29 Stopper1-TS 79 O-ring
30 Stopper2-priority 80 O-ring
32 Poppet-TS check valve 82 O-ring
33 Spring-TS check valve 83 O-ring
34 Poppet-lock valve 84 O-ring
35 Restrictor-lock valve 85 O-ring
36 Spring-lock valve pilot 86 Back-up ring
37 Guide poppet 87 Back-up ring
38 Poppet-pilot 88 Back-up ring
39 Seat-poppet 89 Back-up ring
40 Piston1 90 O-ring
41 Guide-piston 91 Bolt with washer
42 Spring1-lock valve 92 Socket head bolt
43 Piston2 93 Socket head bolt
44 Socket-lock valve 94 Main relief valve
45 Spool-lock valve 95 Over load relief valve
46 Spring2-lock valve 96 Plug-relief valve
47 Stopper-lock valve 97 Plug-relief valve
48 Spool-regen selector 98 Plug-relief valve
49 Spring-regeneration 99 Over load relief valve
14072SF11
2-21
2. HYDRAULIC CIRCUIT
14072SF05
2-22
3. FUNCTION
1) CONTROL IN NEUTRAL FUNCTION

(1) P1 SIDE
14072SF13
14072SF15
The hydraulic fluid from pump P1 flows into the main control valve through the inlet port "P1", pass the
travel straight spool, into the P1 bypass passage and P1parallel passage.
The hydraulic fluid from the pump P1 is directed to the tank through the bypass passage of spools :
travel left, boom1, arm2, arm regeneration & option A and bucket, the negative relief valve, tank
passage, and the tank port "T1"
2-23
(2) P2 SIDE
14072SF14
14072SF16
The hydraulic fluid from pump P2 flows into the main control valve through the inlet port "P2", pass the
straight travel spool, into the P2 bypass passage and P2 parallel passage.
The hydraulic fluid from the pump P2 is directed to the tank through the bypass passage of spools :
travel right, swing, boom2 & swing priority, arm1, option "B" and option "C", and the negative relief
valve with the tank passage.
2-24
2) EACH SPOOL OPERATION
(1) TRAVEL OPERATION
① Travel forward operation
14072SF17
② Travel backward operation
14072SF18
During the travel operation, the hydraulic fluid of the pump P1 is supplied to the travel motor and the
hydraulic fluid of the pump P2 is supplied to the other travel motor.
The pilot pressure from the pilot control valve is supplied to the spring side of pilot port (pa1, pd1).
And it shifts travel right and left spools in the left direction against springs. Hydraulic fluid from the
pump P1 flow into the travel left spool through the bypass passage and hydraulic fluid from the pump
P2 flow into the travel right spool through the bypass passage.
Then they are directed to the each travel motor through port A1 and D1. As a result, the travel motors
turn and hydraulic fluid returns to the tank passage through the travel spools.
In case of the opposite operation, the operation is similar.
2-25
(2) TRAVEL STRAIGHT FUNCTION
14072SF19
This function keeps straight travel in case of simultaneous operation of other actuators(boom, arm,
bucket, swing) during a straight travel.
① During travel only :
The hydraulic fluid of the pump P1 is supplied to the travel motor and the pump P2 is supplied to
the other motor.
Thus, the machine keep travel straight.
② The other actuator operation during straight travel operation :
When the other actuator spool(s) is selected under straight travel operation, the straight travel
spool is moved.
The hydraulic fluid from pump P1 is supplied actuator through P1 and P2 parallel pass and travel
motors through orifice at side of straight travel spool.
The hydraulic oil fluid from pump P2 is supplied to travel motors(left/right).
Therefore, the other actuator operation with straight travel operation, hydraulic oil fluid from pump
P1 is mainly supplied to actuator, and the hydraulic oil fluid form pump P2 is mainly supplied to
travel motors(left/right).
Then the machine keeps straight travel.
2-26
(3) BOOM OPERATION
① Boom up operation
14072SF24
14072SF25
During boom up operation, the pilot pressure from RCV is supplied into the port Pa20 and shift the
boom1 spool in the left direction. The hydraulic oil fluid from pump P1 is entered P1 parallel passage
and then passes through the load check valve and boom holding valve then flows into the port A2.
Following this it flows into the head side of the boom cylinder.
(In this case, the boom holding valve is free flow condition)
At the same time the pilot pressure through the port Pa21 shifts the boom2 spool. The hydraulic oil
fluid from pump P2 entered boom summation passage via the P2 parallel passage, the swing priority
spool, the boom2 spool, arm1 spool and the check. The flows combine in passage and are directed
to port A2 and head side of boom cylinder.
The flow from rod side of the boom cylinder return to the boom1 spool through the port B2. There
after it is directed to the hydraulic oil tank through the tank passage.
2-27
② Boom down operation
14072SF26
During the boom lowing operation, the pilot pressure from RCV is supplied to the port Pb20 and shift
the boom1 spool in the right direction.
The hydraulic fluid from the pump P1 enters the parallel passage and is directed to the port B2
through the load check valve. Following this, it flows into the rod side of the boom cylinder.
The return flow from the head side of the boom cylinder returns to the boom1 spool through the port
A2 and boom holding valve. Thereafter it is directed to the hydraulic oil tank through tank passage.
For details of the boom holding valve, see page 2-36.
2-28
(4) BUCKET OPERATION
① Bucket roll in operation
14072SF34
② Bucket roll out operation
14072SF35
2-29
① Bucket roll in operation
During the bucket roll in operation, the pilot pressure from RCV is supplied to port Pa5 and shift the
bucket spool in the left direction.
The hydraulic fluid from pump P1 entered P1 parallel passage and is directed to the port A5 through
the check1.
At the same time, the hydraulic fluid from P1 bypass passage is directed to the port A5 through the
check2.
Following this it flows into the head side of the bucket cylinder.
The return flow from the rod side of the bucket cylinder returns to the bucket spool through the port
B5. Thereafter it is directed to the hydraulic oil tank through the tank passage.
② Bucket roll out operation
In case of the bucket roll out operation, the operation is similar
③ Bucket operation with arm or boom operation
When combined operation, mostly same as above but the fluid from bypass passage is empty.
So only the fluid from parallel passage is supplied to the bucket cylinder. Also, parallel passage is
installed the orifice for supplying the fluid from pump to the boom or the arm operation prior to the
bucket operation.
2-30
(5) SWING OPERATION
① Swing left operation
14072SF32
② Swing right operation
14072SF33
The pilot pressure from the RCV is supplied to the Pd2 and shift the swing spool in left direction. The
hydraulic fluid from pump P2 flows into swing spool through the parallel passage. Then it is directed to
swing motor through the port D2. As the result, swing motor turns and flow from the swing motor
returns to the hydraulic oil tank through the port C2, swing spool and the tank passage .
In case of swing right operation, the operation is similar.
2-31
(6) ARM OPERATION
① Arm roll in operation
14072SF21
14072SF20
Arm roll in operation :

During arm roll in operation the pilot pressure from the RCV is supplied to the port Pc40 and Pb3
and shifts arm1 spool and arm2 spool in the right direction.
The hydraulic oil from the pump P2 flows into the arm cylinder head side through P2 parallel
passage, the load check valve and the port C4.
At same time, the hydraulic fluid from the pump P1 flows into the arm summation passage through
parallel passage, the check valve, the arm2 spool and the boom2 spool. Then it entered the arm
cylinder head side with hydraulic fluid from arm1 spool.
2-32
Arm regeneration :
The return flow from the arm cylinder rod side is pressurized by self weight of arm and so, returns to
port D4. The pressurized oil returning to port D4 enters the arm regeneration & breaker spool
through the arm holding valve and the arm1 spool. It is suppled the arm cylinder head through
internal passage. This is called the arm regeneration function.
The amount of regeneration fluid are changed by movement of the arm regeneration & breaker
spool.
A few fluid after P2 parallel passage is push piston "C" through the notch of arm regeneration spool
and selector spool. At this time, the selector spool is opened by pilot pressure from RCV.
Then, the arm regeneration spool shift to right side and flow to tank pass increases and
regeneration flow decreases. Therefore, pressure of arm cylinder head increases, then, arm
regeneration flow decreases.
Furthermore, the arm regeneration cut pressure is supplied to port and arm regeneration spool is
move into the right direction fully. The flow from the arm cylinder rod is returned to the hydraulic oil
tank and regeneration function is not activated.
2-33
② Arm roll out operation
14072SF23
14072SF22
During arm roll out operation the pilot pressure from RCV is supplied to the port Pd40 and the
Pd41 and shifts arm1 spool and arm2 spool in the right direction.
The hydraulic fluid from pump P2 flows into arm1 spool through the parallel passage. Then it
enters into the arm cylinder rod side through the load check valve, bridge passage, arm holding
valve and the port D4.
Some of the hydraulic fluid from pump P2 bypassed through bypass notch.
The rest of hydraulic fluid from pump P2 flows into the arm summation passage through P1
parallel passage the check valve arm2 spool and boom2 spool.
Then it enters into the arm cylinder rod side with the fluid from the arm1 spool.
The return flow from the arm cylinder head side returns to the hydraulic tank through the port C4
the arm1 spool and tank passage.
2-34
(7) SWING PRIORITY FUNCTION
14072SF27
During swing priority operation, the pilot pressure is supplied to the port Pc3 and shift swing priority
spool in the right direction.
The hydraulic fluid from P2 parallel passage flows into the parallel passage of arm1 side through
swing priority spool and the passage "A" and also flows into the boom2 spool.
Due to shifting of the swing priority spool, the fluid from pump P2 flows to swing side more then next
spools to make the swing operation most preferential.
2-35
(8) HOLDING VALVE OPERATION
① Holding operation
14072SF30
At neutral condition, the pilot piston chamber is connected to drain port through the pilot port.
And the piston "B" is supported with spring "B" and the pressured fluid from actuator entered to inside
of the holding valve through the periphery hole of check, crevice of the check and the plug and the
periphery hole of plug.
Then, this pressured oil pushed the poppet to the poppet seat and the check to the seat of body.
So the hydraulic fluid from actuator is not escaped and the actuator is not moved.
2-36
② Release holding operation
14072SF31
The pilot pressure is supplied to the pilot port for release holding valve and shifts the piston "B" in the
left direction against the spring "B", and shifts the poppet in the left direction through piston "B" and
piston "A" against spring "B" and shifts the spool in the left side.
At same time, the return fluid from actuator returns to the drain port through the periphery hole of
check, crevice of the check and the plug, the periphery hole of the plug, in side of holding valve,
crevice of the poppet and the poppet seat, the periphery hole of the poppet seat, crevice of the socket
and spool and inside of spool.
When the poppet is opened, pressure of inside of holding valve is decreased and the return fluid from
actuator returns to the tank passage through the notch of spool.
2-37
(9) NEGATIVE CONTROL
14072SF28
When no function is being actuated on P1 side, the hydraulic fluid from the pump P1, flows into the
tank passage through the bypass passage and orifice. The restriction caused by this orifice thereby
pressurizes. This pressure is transferred as the negative control signal pressure Pn1 to the pump P1
regulator.
It controls the pump regulator so as to minimize the discharge of the pump P1.
The bypass passage is shut off when the shifting of one or more spools and the flow through bypass
passage became zero. The pressure of negative control signal become zero and the discharge of the
pump P1 become maximum.
The negative control pressure reaches to the set level, the hydraulic fluid in the passage pushes open
negative control valve and escapes into the return passage.
For the pump P2 the same negative control principle.
2-38
(10) OPERATION OF MAIN RELIEF VALVE
The main relief valve is fitted to the straight travel valve block and functions as follows :
① The pressurized oil passes through the orifice (A) of the plunger is filled up in chamber A of the
inside space, and seats the plunger against the housing securely.
14072SF36
② When the pressure at (P) becomes equal to the set pressure of the spring the hydraulic oil
passes through the piston (A) pushes open the poppet and flows to tank passage (T) through the
hole (E).
14072SF37
2-39
③ Opening the poppet causes the pressure in chamber A to fall and the plunger to open. As the
result the pressurized oil at port P runs into tank passage (T)
14072SF38
④ High pressure setting pilot signal(Pu) : ON

When the power boost switch is ON, the pilot pressure enters through hole A.
It pushes the piston(B) in the left direction to increase the force of the spring and change the relief
set pressure to the high pressure.
14072SF36
2-40
(11) OPERATION OF PORT RELIEF VALVE
① Function as relief valve
ⓐ The pressurized oil passes through the piston A and orifice is filled up in chamber A of the
inside space and seat the plunger against the socket and the socket against the housing
securely.
14072SF39
ⓑ When the pressure at port P becomes equal to the set pressure of the spring, the pressurized
oil pushes open the poppet flows to tank passage (T) through hole E.
14072SF40
2-41
ⓒ Opening of the poppet causes the pressure in chamber A to fall and the plunger to open. As
the result the pressurized oil at port P runs into tank passage (T).
14072SF41
② Make-up function
When negative pressure exists at port P, the oil is supplied through tank passage (T). When
the pressure at tank passage (T) becomes higher than that at port P, the socket moves in the
right direction. Then, sufficient oil passes around the socket from tank passage (T) to port P
and fills up the space.
14072SF42
2-42
GROUP 3 SWING DEVICE
1. STRUCTURE
Swing device consists swing motor, swing reduction gear.
Swing motor include mechanical parking valve, relief valve, make up valve and time delay valve.
Reduction gear Grease port(PT1/4) Swing motor Gear oil filling port(PT1/4) PA A B PB
Gear oil drain port(PT1/2) SH PG Time delay valve Mu Dr Oil gauge port(PT1/4)
17W72SM01
Port Port name Port size

SH
A Main port SAE PF 3/4
PG
B Main port SAE PF 3/4
dr4
Dr Drain port PF 1/2
Mu Make up port PF 1
Mu PG Brake release port PF 1/4
PA PB
SH Brake pilot port PF 1/4
PA,PB Gage port PF 1/4
A B
Hydraulic circuit
2-43
1) SWING MOTOR
117 121 118 114 706 707 702 712 472 106 994 469 488 355 351 052 841
438
432 X X
A 303
106
748
471
A 747
443
444
304
468
487
746
101
433
491
745
437
124 451
301 401 051 993

131
122 123 113 116 111 744 742 031 743 058 060 053 054
464 485
059
057
056
055
SECTION A-A SECTION X-X

17W72SM02
031 Brake valve 123 Retainer 464 Plug

051 Relief valve 124 Shoe plate 468 Plug
052 Reactionless valve assy 131 Valve plate 469 Plug
053 Valve 151 Plug 471 O-ring
054 Block 161 O-ring 472 O-ring
055 Plug 162 O-ring 485 O-ring
056 Back up ring 163 O-ring 487 O-ring
057 O-ring 171 Hexagon screw 488 O-ring
058 Plug 301 Casing 491 Oil seal
059 O-ring 303 Casing 702 Piston
060 O-ring 304 Front cover 706 O-ring
101 Drive shaft 351 Plunger 707 O-ring
106 Spacer 355 Spring 712 Brake spring
111 Cylinder block 401 Hexagon socket bolt 742 Friction plate
113 Bushing 432 Snap ring 743 Separate plate
114 Spring 433 Snap ring 744 Plug
116 Push rod 437 Snap ring 745 Plug
117 Spacer 438 Snap ring 746 Plug
118 Spacer 443 Roller bearing 841 Hexagon socket bolt
121 Piston 444 Roller bearing 993 Plug
122 Shoe 451 Spring pin 994 Plug
2-44
2) REDUCTION GEAR
25 37 36 13 3 35 34 5 2 30 29 6 7 10 9 11 18 19 26 31
28
27
38
33 32 1 8 14 12 23 15 16 21 17 20 24 22 39
17W72SM03
1 Casing 15 Planet gear 2 28 Stop ring

2 Drive shaft 16 Pin 2 29 Plug
3 Spacer 17 Spring pin 30 Plug
5 Roller bearing 18 Sun gear 2 31 Socket bolt
6 Oil seal 19 Carrier 1 32 Gauge pipe
7 Roller bearing 20 Side plate 1 33 Gauge bar
8 Thrust plate 21 Pin 1 34 Cover plate
9 Carrier 2 22 Needle cage 35 Hexagon bolt
10 Stop ring 23 Bush 2 36 Lock plate
11 Ring gear 24 Planet gear 1 37 Hexagon bolt
12 Knock pin 25 Lock washer 38 Stop ring
13 Pinion gear 26 Side plate 3 39 Side plate 2
14 Thrust washer 27 Sun gear 1
2-45
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.
p×q F
T= , q=Z・A・PCD・tanθ, F1 = , F2=F tanθ, S=PCD×tanθ
2Л COSθ
Where p : Effective difference of pressure(kgf/cm2)
q : Displacement(cc/rev)
T : Output torque(kgf・cm)
Z : Piston number(9EA)
A : Piston area(cm2)
θ: Tilting angle of swash plate(degree)
S : Piston stroke(cm)
Low High
pressure oil pressure oil
F1 F2
131
124 123 121 111 R290SM05(2)
2-46
2) MAKE UP VALVE
In the system using this type of motor, there is no counter balance functioning valve and there
happens the case of revolution exceeding hydraulic supply of motor. To prevent the cavitation
caused by insufficient oil flow there is a make up valve to fill up the oil insufficiency.
A make up valve is provided immediately before the port leading to the hydraulic oil tank to secure
feed pressure required when the hydraulic motor makes a pumping action. The boost pressure
acts on the hydraulic motor's feed port via the make up valve.
Pressurized oil into the port B, the motor rotate counterclockwise.
If the plunger of MCV moves neutral position, the oil in the motor is drain via left relief valve, the
drain oil run into motor via right make up valve, which prevent the cavitation of motor.
A B
29072SM09
2-47
3) RELIEF VALVE
3
5
1 Body
2 O-ring
4 3 Plug
15 4 O-ring
11 5 Back up ring
6 Plunger
14
7 Piston
13 7 8 Spring
9 Seat spring
9
12 10 Seat
2 11 Sleeve
12 Adjust plug
1
13 O-ring
14 Back up ring
8
15 Nut
10
29072SM03
(1) Construction of relief valve

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

Figure illustrates how the pressure acting P P=pressure, T=time
on the relief valve is related to its rising PS
process. Here is given the function, 4
referring to the figure following page.
P1 3
T
1
29072SM05
2-48
① Ports (P,R) at tank pressure.
A1 m 6 7
8 A2
29072SM04
② When hydraulic oil pressure(P×A1) reaches the preset force(FSP) of spring(8), the plunger (6)
moves to the right as shown.
P1×A1 = Fsp + P1×A2
Fsp
P1=
A1 - A2
P=P1
8
29072SM06
2-49
③ When the pressure of chamber g reaches the preset force(Fsp) of spring(8), the piston(7) moves
right and stop the piston(7) hits the end of body.
m 6 7 f g
P=P2
P=P1
8
29072SM07
④ When piston(7) hits the end of body, it stops moving to the right any further. As the result, the
pressure in chamber(g) equals(Ps).
Ps×A1 = Fsp + Ps×A2
Fsp
Ps =
A1 - A2
m 6 7 g
P=Ps
P=P1
8
29072SM08
2-50
4) BRAKE SYSTEM
(1) Control valve swing brake system
This is the brake system to stop the swing motion of the excavator during operation.
In this system, the hydraulic circuit is throttled by the swing control valve, and the resistance
created by this throttling works as a brake force to slow down the swing motion.
Work Deceleration Stop
A B A B A B
MCV MCV MCV
MCV A, B opened MCV A, B throttled MCV A, B closed

210-7 2-48(1)
(2) Mechanical swing parking brake system

The mechanical swing parking brake system is installed to prevent the upper structure from
swinging downhill because of its own weight when the excavator is parked on a slope since it
completely eliminates the hydraulic drift of swing motion while the excavator is on a slop, work can
be done more easily and safely.
① Brake assembly
Circumferential rotation of separate
plate(743) is constrained by the groove
located at casing(301). When housing
is pressed down by brake spring(712)
through friction plate(742), separate 712
plate(743) and brake piston(702), friction
force occurs there. 702
Cylinder(111) is constrained by this 743
friction force and brake acts, while brake
742
releases when hydraulic force exceeds Groove
111
spring force.
301
17W72SM04
111 Cylinder 712 Brake spring

301 Casing 742 Friction plate
702 Brake piston 743 Separate plate
2-51
② Operating 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 move
spool(5) to the leftward against the force of the spring(8), so pilot pump charged oil(P3) goes to
the chamber G.
This pressure is applied to move the piston(702) to the upward against the force of the
spring(712). Thus, it releases the brake force.
5
712
G SH
702
8
1 Swing control lever

2 Swing control valve(MCV)
3 Time delay valve 12
4 Shuttle valve
P3
5 Spool
8 Spring
702 Brake piston 2 2
712 Brake spring 4
17W72SM05
2-52
b. When the swing control lever(1) is set the neutral position, the time delay valve(3) shifts the
neutral position and the pilot oil blocked chamber G.
Then, the piston(702) is moved lower by spring(712) force and the return oil from the chamber G
is drain.
5
712
G SH
702
8
1 Swing control lever

2 Swing control valve(MCV)
3 Time delay valve
4 Shuttle valve
702 Brake piston P3
712 Brake spring
2 2
4
17W72SM06
2-53
GROUP 4 TRAVEL DEVICE
1. CONSTRUCTION
Travel device consists travel motor and gear box.
Travel motor includes brake valve, parking brake and high/low speed changeover mechanism.
Port Port name Port size
A Main port SAE 5000psi 1"

B Main port SAE 5000psi 1"
P1, P2 Gauge port PT 1/4
P3 Gauge port PT 1/8
D1, D2 Drain port PF 1/2
P 2 speed control port PF 1/4
14072SF60
2-54
1) BASIC STRUCTURE
14072SF62
2-55
2) STRUCTURE
14072SF61
1 Hub 25 Needle bearing 106 Shoe 151 Rolling 219 O-ring 355 O-ring
2 Spindle 27 Parallel pin 107 Retainer plate 161 Piston(2) 220 Piston seal 357 RO plug
3 Carrier 28 O-ring 108 Thrust ball 162 Shoe(2) 301 Rear flange 358 O-ring
4 Ring gear A 29 O-ring 109 Timing plate 167 Pivot 323 Spool 359 O-ring
5 Ring gear B 30 PT plug 110 Washer 171 Paralell pin 324 Plug 363 Spool(2)
6 Cluster gear 31 Floating seal 111 Collar 193 Spring 325 Stopper 366 Spring
7 Sun gear 32 Socket bolt 112 Piston 201 Valve 326 Plug 368 Steel ball
8 Coupling gear 33 Spring washer 113 Spring 202 Sleeve 327 Valve 379 Filter
9 Shaft(cluster) 34 Parallel pin 114 Spring 203 Spring retainer 328 Spring 380 Plug
12 Distance piece 35 Socket bolt 115 Friction plate 204 Plug 330 Spring 381 Piston
13 Cover 36 Steel ball 116 Mating plate 205 Shim 336 O-ring 382 Plug
14 Thrust collar 40 O-ring 132 Oil seal 206 Spring 337 O-ring 383 O-ring
15 Ring 42 Parallel pin 135 O-ring 208 O-ring 341 Parallel pin 384 O-ring
17 Pin 102 Main shaft 139 O-ring 209 O-ring 343 Socket bolt 385 Steel ball
19 Coupling 103 Swash plate 145 Snap ring 210 O-ring 346 PT plug 397 Orifice
20 Thrust plate 104 Cylinder block 149 Ball bearing 211 Back-up ring 352 RO plug 398 PT plug
23 Seal ring 105 Piston 150 Ball bearing 217 Back-up ring 354 PT plug 399 Name plate
24 Ball bearing
2-56
2. FUNCTION
1) HYDRAULIC MOTOR
(1) Rotary group
Y1
301 104 105 102 F3

F3
ri
F3
Y2 F3
P
F2
F3 A P
F1
α
109 103
25032TM04
The pressurized oil delivered from the hydraulic pump flows to rear flange(301) of the motor,
passes through the brake valve mechanism, and is introduced into cylinder block(104) via timing
plate(109). This oil constructively introduced only to one side of Y1-Y2 connecting the upper and
lower dead points of stroke of piston(105). The pressurized oil fed to one side in cylinder
block(104) pushes each piston(105, four or five) and generates a force(F kg = P kg/cm2×A cm2).
This force acts on swash plate(103), and is resolves into components (F2 and F3) because swash
plate(103) is fixed at an angle(α°) with the axis of drive shaft(102). Redial component(F3)
generates respective torques(T = F3×ri) for Y1-Y2. This residual of torque(T = F3×ri) rotates
cylinder block(104) via piston(105). Cylinder block(104) is spline-coupled with drive shaft(102).
So the drive shaft(102) rotates and the torque is transmitted.
2-57
(2) Brake valve
① Brake released(Starting / Running)
When the pressurized oil supplied from
port Ⓐ, the oil opens valve(327) and
flows into port Ⓒ at the suction side of
hydraulic motor to rotate motor. At the
same time, the pressurized oil passes 112
through pipe line ⓐ from a small hole in
spool(323) and flows into chamber ⓑ. P
The oil acts on the end face of
spool(323) which is put in neutral position 328 323 a b
by the force of spring(328), thus causing
D E C
spool(323) to side to the left. When
spool(323) slides, port Ⓓ on the passage
at the return side of hydraulic motor,
which is closed by the spool groove
during stoppage, connected with port Ⓑ
at the tank side and the return oil from 327
the hydraulic motor runs into the tank. In

consequence, the hydraulic motor
rotates. Moreover, sliding of spool(323)
causes the pressurized oil to flow into
B A Drain
ports Ⓟ.
The pressurized oil admitted into port Ⓟ
activates piston(112) of the parking brake
to release the parking brake force. (For
details, refer to description of the parking 25032TM05
brake.) When the pressurized oil is

supplied from port Ⓑ, spool(323) move
reversely and the hydraulic motor also
rotates reversely.
2-58
② Brake applied(Stopping / Stalling)
When the pressurized oil supplied from
port Ⓐ is stopped during traveling, no
hydraulic pressure is applied and
spool(323) which has slid to the left will
return on the right(Neutral) via stopper D C
(325) by the force of spring(328).
At the same time, the hydraulic motor will g 381
rotate by the inertia even if the
pressurized oil stopped, so the port D of f
201
the motor will become high pressure.
323
This pressurized oil goes from chamber
ⓕ to chamber ⓖ through the left-hand
325
valve(201).
When the oil enters chamber ⓖ, the 328
piston(381) slids to the right so as not to
rise the pressure, as shown in the figure. 327
Meanwhile, the left-hand valve(201) is
pushed open by the pressurized oil in 330
port D. B A
Therefore, the pressurized oil in port D
flows to port C at a relatively low
pressure, controlling the pressure in port 25032TM06
D and preventing cavitation in port C.

When the piston(381) reaches the stroke
end, the pressure in chamber ⓖ and ⓕ
increase and the left-hand valve(201)
closes again, allowing the oil pressure in
port D to increase further. Then, the
right-hand valve(201) opens port C with
pressure higher than that machine relief
set pressure.
In this way, by controlling the pressure in
port D in two steps, the hydraulic motor is
smoothly braked and brought to a stop.
2-59
③ Braking effect on downhill travel
If the machine traveling downhill with a
relatively small supply of high pressure oil
to its travel motors should start coasting,
the same braking effect as the one
described above would automatically 112
occur.
In the coasting condition, the motor is
P
driven, instead of driving the track, from
the ground and sucks high pressure oil 328 323 a b
in.
In other words, the motor tends to draw D E C
more high pressure oil than is being
supplied.
Under this condition, port A goes
negative to pull oil out of chamber ⓑ
through oil way ⓐ, moving back the 327
spool(323) rather rapidly.
The clearance on the left then becomes
smaller to throttle the outgoing oil more
than before, thereby obstructing the
pumping action of the motor. B A Drain
As in stopping the machine, pressure will
build up in port D to make it harder to
drive the motor from the ground: This is
25032TM07
the braking action.
2-60
(3) Parking brake
① Running 113 112 a 116 115 104
When the pressurized oil is supplied from
the brake valve, the spool of brake valve
in the hydraulic motor assembly actuates
to open the passage to the parking brake
and the pressurized oil is introduced into
cylinder chamber ⓐ which is composed
of the spindle of reduction gear assembly
and piston(112). When the hydraulic
pressure reaches 6kgf/cm2(0.59Mpa) or
more, it overcomes the force of spring
(113) and shifts piston(112). With shift of
piston(112), no pressing force is applied
to mating plate(116) and friction plate
(115) and the movement of friction plate
(115) becomes free, whereby the brake
force to the cylinder in the hydraulic motor
assembly is released.
25032TM08
② Stopping
When the pressurized oil from the brake
113 112 a 116 115 104
valve is shut off and the pressure in
cylinder chamber ⓐ drops 6kgf/cm 2
(0.59Mpa) or less, piston(112) will return
by the force of spring(113).
Piston(112) is pushed by this force of
spring(113), and mating plate(116) and
friction plate(115) in free condition are
pressed against the spindle of reduction
gear assembly.
The friction force produced by this
pressing stops rotation of the cylinder
block(104) and gives a braking torque
40.6kgf・m(398N・m) to the hydraulic
motor shaft.
Note that oil control through a proper oil
passage ensures smooth operation.
25032TM08
2-61
(4) High/low speed changeover mechanism
① At low speed - At pilot pressure of less than 20kgf/cm2(1.96Mpa)
Pilot pressure
P
A B
366
363 θ1 Spindle
103 Support
C 161
a
Motor
case
Drain 25032TM09
When the pilot pressure is shut off from port Ⓟ, valve(363) is pressed upward by the force of
spring(366), the pressurized oil supply port Ⓒ is shut off, and oil in chamber ⓐ is released into
the motor case through the valve(363). Consequently, swash plate(103) is tilted at a maximum
angle(θ1) and the piston displacement of hydraulic motor becomes maximum, thus leading to
low-speed operation.
② At high speed - At pilot pressure of 20kgf/cm2(1.96Mpa) or more
Pilot pressure
P
A B
366
b
363 θ2
Spindle
103
Support
C 161
a
Motor
case
Drain
25032TM10
When a pilot pressure supplied from port Ⓟ(At a pressure of 20kgf/cm2(1.96Mpa) or more), the
pressure overcomes the force of spring(366) and valve(363) is pressed downward. The
pressurized oil supply port Ⓒ is then introduced into chamber ⓐ through the valve(363). Piston
(161) pushes up swash plate(103) until it touches side ⓑ of the spindle. At this time, swash
plate(103) is tilted at a minimum angle(θ2) and the piston displacement of hydraulic motor
becomes minimum, thus leading to high-speed operation.
2-62
2) REDUCTION GEAR
(1) Function
The reduction gear unit consists of a Planetary gear mechanism
combination of simple planetary gear
mechanism and differential gear
mechanism. This mechanism reduce the
high speed rotation from the hydraulic
motor and convert it into low speed, high
torque to rotate the hub(or case), which in
turn rotates the sprocket.
(2) Operating principle
① Upon rotation of the sun gear (S) via the
input shaft, the planetary gear (P)
engages with the fixed ring gear (R) while
rotating on its axis.
Rotation around the fixed ring gear (R) is
transmitted to the carrier (K).
R・P2
i1 = 1+
S・P1 14072SF63A
② With rotation of the carrier (K), the Differential gear mechanism

planetary gears (P1) and (P2) rotate
around the fixed ring gear(R).
When a proper difference in number of
teeth is given between (P1) and (R) and
between (P1) and (P2), a difference in
rotation is produced on the gear (D)
because the gears (P1) and (P2) are on
the same axis.
1
i2 =
R・P2
1 -
D・P1
14072SF63B
2-63
③ Upon rotation of the sun gear (S) via the Combination of planetary gear mechanism and
input shaft, planetary motion is given differential gear mechanism
among the gears (S), (P1) and (R) and
rotation of the gear (P1) around another
gear causes the carrier (K) to rotate.
This carrier rotation gives differential
motion among the gears (R), (P1), (P2)
and (D) to rotate the ring gear (D). The
motor then rotates since the ring gear (D)
is connected to the hub (case) of the
motor.
R・P2
1 +
S・P1
i = i1 × i2 =
R・P2
1 -
D・P1
14072SF63C
2-64
GROUP 5 RCV LEVER
1. STRUCTURE
The casing has the oil inlet port P(Primary pressure) and the oil outlet port T(Tank). In addition the
secondary pressure is taken out through ports 1,2,3 and 4 provided at the bottom face.
23.3
19
25
Single
operation Simultaneous
operation
Handle bending direction

(No. push rod direction)
4
P
1
T 3
2
30
30
VIEW A
25032RL01
Port LH RH Port size

P Pilot oil inlet port Pilot oil inlet port
T Pilot oil return port Pilot oil return port
1 Left swing port Bucket out port
PF 1/4
2 Arm in port Boom down port
T
P 3 Right swing port Bucket in port
4 Arm out port Boom up port
1 32 4
Hydraulic circuit
2-65
CROSS SECTION
The construction of the pilot valve is shown in the attached cross section drawing. The casing has
vertical holes in which reducing valves are assembled.
The pressure reducing section is composed of the spool(5), spring(7) for setting secondary pressure,
return spring(10), stopper(9), spring seat(8) and shim(6). The spring for setting the secondary
pressure has been generally so preset that the secondary pressure is 5 to 20.5kgf/cm2(Depending on
the type). The spool is pushed against the push rod(14) by the return spring.
When the push rod is pushed down by tilting the handle, the spring seat comes down simultaneously
and changes setting of the secondary pressure spring.
1 Case 11 Plug 21 O-ring

2 Plug 12 Rod seal 22 Handle connector
3 Plug 13 O-ring 23 Nut
4 O-ring 14 Push rod 24 Insert
5 Spool 15 Plate 25 Boot
6 Shim 16 Bushing 26 Handle
7 Spring 17 Joint assembly 27 Switch assembly
8 Spring seat 18 Swash plate 28 Screw
9 Stopper 19 Adjusting nut 29 Switch assembly
10 Spring 20 Lock nut 30 Switch cover
40 Boot
2-66
CROSS SECTION
14072SF80
2-67
2. FUNCTIONS
1) FUNDAMENTAL FUNCTIONS
The pilot valve is a valve that controls the spool stroke, direction, etc of a main control valve. This
function is carried out by providing the spring at one end of the main control valve spool and
applying the output pressure(Secondary pressure) of the pilot valve to the other end.
For this function to be carried out satisfactorily, the pilot valve is composed of the following
elements.
(1) Inlet port(P) where oil is supplied from hydraulic pump.
(2) Output ports(1, 2, 3 & 4) to apply pressure supplied from inlet port to ends of control valve spools.
(3) Tank port(T) necessary to control the above output pressure.
(4) Spool to connect output port to inlet port or tank port.
(5) Mechanical means to control output pressure, including springs that work on the above spools.
2) FUNCTIONS OF MAJOR SECTIONS
The functions of the spool(5) are to receive the supply oil pressure from the hydraulic pump at its
port P, and to change over oil paths to determine whether the pressure oil of port P is led to output
ports 1, 2, 3 & 4 or the output port pressure oil to tank port T.
The spring(7) works on this spool to determine the output pressure.
The change the deflection of this spring, the push rod(14) is inserted and can slide in the plug(11).
For the purpose of changing the displacement of the push rod through the switch plate(19) and
adjusting nut(20) are provided the handle(27) that can be tilted in any direction around the fulcrum
of the universal joint(18) center.
The spring(10) works on the case(1) and spring seat(8) and tries to return the push rod(14) to the
zero-displacement position irrespective of the output pressure, securing its resetting to the center
position.
This also has the effect of a reaction spring to give appropriate control feeling to the operator.
2-68
3) OPERATION
The operation of the pilot valve will be described on the basis of the hydraulic circuit diagram shown
below and the attached operation explanation drawing.
The diagram shown below is the typical application example of the pilot valve.
5 6
3
1
3
P T
2 4
2-70 (140-7TIER)
1 Pilot valve 3 Main pump 5 Hydraulic motor

2 Pilot pump 4 Main control valve 6 Hydraulic cylinder
2-69
(1) Case where handle is in neutral position
7
10
P 5
1 3
25032RL03
The force of the spring(7) that determines the output pressure of the pilot valve is not applied to
the spool(5). Therefore, the spool is pushed up by the spring(10) to the position of port(1, 3) in the
operation explanation drawing. Then, since the output port is connected to tank port T only, the
output port pressure becomes equal to tank pressure.
2-70
(2) Case where handle is tilted
15
1 3
25032RL04
When the push rod(14) is stroked, the spool(5) moves downwards.

Then port P is connected with port(1) and the oil supplied from the pilot pump flows through
port(1) to generate the pressure.
When the pressure at port(1) increases to the value corresponding to the spring force set by tilting
the handle, the hydraulic pressure force balances with the spring force. If the pressure at port(1)
increases higher than the set pressure, port P is disconnected from port(1) and port T is
connected with port(1). If it decreases lower than the set pressure, port P is connected with
port(1) and port T is disconnected from port 1.
In this manner the secondary pressure is kept at the constant value.
Besides, in some type, when the handle is tilted more than a certain angle, the upper end of the
spool contacts with the inside bottom of the push rod and the output pressure is left to be
connected with port P.
2-71
GROUP 6 RCV PEDAL
1. STRUCTURE
The casing(Spacer) has the oil inlet port P(Primary pressure), and the oil outlet port T(Tank). In
addition the secondary pressure is taken out through ports 1,2, 3 and 4 provided at the bottom face.
° 12.4
12.4 °
1 2
3 4 14072SF73A
Port Port Port size
P Pilot oil inlet port

T Pilot oil return port
1 Travel(LH, Forward)
PF 1/4
T 2 Travel(LH, Backward)
P 3 Travel(RH, Forward)
1 23 4 4 Travel(RH, Backward)
Hydraulic circuit
2-72
CROSS SECTION
The construction of the RCV pedal is shown in the below drawing. The casing has vertical holes in
which reducing valves are assembled.
The pressure reducing section is composed of the spool(8), spring(6) for setting secondary pressure,
return spring(10), stopper(9), and spring seat(7). The spring for setting the secondary pressure has
been generally so preset that the secondary pressure is 5 to 19 kgf/cm2 (depending on the type).
The spool is pushed against the push rod(14) by the return spring.
When the push rod is pushed down by tilting pedal, the spring seat comes down simultaneously and
changes setting of the secondary pressure spring.
27 31 30 29 28 33
32 25,26
24
23 3
22 36
14 15
16
21 17
13 18
12
19
11 20
9
6
5
7
4
10
3 8
37 1 35 34 2
14072SF70
1 Body(1) 13 Snap ring 25 Cover

2 Body(2) 14 Push rod 26 Bolt
3 Plug 15 Spring pin 27 Cam
4 Plug 16 Seal 28 Bushing
5 Spring seat 17 Steel ball 29 Cam shaft
6 Spring 18 Spring 30 Set screw
7 Spring seat 19 Plate 31 Set screw
8 Spool 20 Snap ring 32 Nut
9 Stopper 21 Plug 33 Bellows
10 Spring 22 O-ring 34 Space
11 Rod guide 23 Rod seal 35 O-ring
12 O-ring 24 Dust seal 36 O-ring
37 Bolt
2-73
2. FUNCTION
1) FUNDAMENTAL FUNCTIONS
The pilot valve is a valve controls the spool stroke, direction, etc of a main control valve. This
function is carried out by providing the spring at one end of the main control valve spool and
applying the output pressure(Secondary pressure) of the pilot valve to the other end.
For this function to be carried out satisfactorily, the pilot valve is composed of the following
elements.
(1) Inlet port(P) where oil is supplied from hydraulic pump.
(2) Output port(1, 2, 3 & 4) to apply pressure supplied from inlet port to ends of control valve spools.
(3) Tank port(T) necessary to control the above output pressure.
(4) Spool to connect output port to inlet port tank port.
(5) Mechanical means to control output pressure, including springs that work on the above spools.
2) FUNCTIONS OF MAJOR SECTIONS
The functions of the spool(8) are to receive the supply oil pressure from the hydraulic pump at its
port P, and to change over oil paths to determine whether the pressure oil of port P is led to output
ports 1, 2, 3 & 4 or the output spool to determine the output pressure.
The spring(6) works on this spool to determine the output pressure.
The change the deflection of this spring, the push rod(14) is inserted and can slide in the plug(21).
For the purpose of changing th displacement of the push rod through the cam(27) and adjusting
nut(32) are provided the pedal that can be tilted in any direction around the fulcrum of the cam(27)
center.
The spring(10) works on the casing(1) and spring seat(7) and tries to return the push rod(14) to the
zero-displacement position irrespective of the output pressure, securing its resetting to the center
position.
This also has the effect of a reaction spring to give appropriate control feeling to the operator.
2-74
3) OPERATION
The operation of the pilot valve will be described on the basis of the hydraulic circuit diagram shown
below ant the attached operation explanation drawing.
The diagram shown below is the typical application example of the pilot valve.
5 6
3
1
2
2 4
2-76 (140-7 TIER)
1 Pilot valve 3 Main pump 5 Hydraulic motor

2 Pilot pump 4 Main control valve 6 Hydraulic cylinder
2-75
(1) Case where pedal is in neutral position
T 8
10
P
1 2
14072SF74
The force of the spring(6) that determines the output pressure of the pilot valve is not applied to
the spool(8). Therefore, the spool is pushed up by the spring(10) to the position of port 2 in the
operation explanation drawing. Then, since the output port is connected to tank port T only, the
output port pressure becomes equal to tank pressure.
2-76
(2) Case where pedal is tilted
14
1 2 14072SF75
When the push rod(14) is stroked, the spool(8) moves downwards.

Then port P is connected with port 1, and the oil supplied from the pilot pump flows through port 1
to generate the pressure.
When the pressure at port 1 increases to the value corresponding to the spring force set by tilting
the handle, the hydraulic pressure force balances with the spring force. If the pressure at port 1
increases higher than the set pressure, port P is disconnected from port 1 and port T is connected
with port 1. If it decreases lower than the set pressure, port P is connected with port 1 and port T
is disconnected from port 1.
In this manner the secondary pressure is kept at the constant value.
Besides, in some type, when the handle is tilted more than a certain angle, the upper end of the
spool contacts with inside bottom of the push rod and the output pressure is left to be connected
with port P.
2-77
Group 1 Hydraulic Circuit 3-1

Group 2 Main Circuit 3-2
Group 3 Pilot Circuit 3-5
Group 4 Single Operation 3-13
Group 5 Combined Operation 3-23
GROUP 1 HYDRAULIC CIRCUIT
DR4
10 11 8 9
4 Pn2 Pn1 29
LH RED RED RH
C6
D6 2 28 28
Pc6
E
Pd6
Pi1
DR5
B5 V2
A5
31 30
Pc5 Pb5
dr7
Pd5 Pa5
C4
D4 B4
VA VB VB VA DR3 1 Main pump
Pc40 Pc41 Pb4
Pd40
Pa4 2 Main control valve
12 3 Swing motor
Pc42
Pk
S/Motor "DB" V3 4 Travel motor
3 Pc3 5 RCV lever(LH)
Pb3
DR2
Pa21
Pd41 6 RCV lever(RH)
SH
7 RCV pedal
B2
C2
PG
D2
A2
Pb21
8 Boom cylinder(LH)
DB Pc2
DR1
Pb20
9 Boom cylinder(RH)
R/Pipe "R4" Pd2 Pa20
10 Arm cylinder
11 Bucket cylinder
C1 B1
C D1 Pc1 Pb1 A1
12 Turning joint
Pd1 Pa1
13 Check valve
14 Check valve
25 DR0 25
A B P0
15 Hydraulic tank
Ai
T1 16 Oil cooler
24 P1 P2 Pz
17 Air breather
18 Return filter
SWING ARM 5 BUCKET BOOM 6 7 TRAVEL
19 Strainer
20 Spin filter
21 Line filter
(1) (3) (2) (4) (3) (1) (2)
22 Solenoid valve
(4)
P1 P2
23 Accumulator
SH
(1) (2) (3) (4) 13
Pd1 Pc1 Pa1 Pb1 27 Dr#,T
14 1 24 Pressure switch
B A D E G F H J
16 25 Pressure switch
26 Pc2 Pd2 Pd40 Pc40 Pa5 Pb5 Pa20 Pb20
17 26 Terminal
23 Pn1 Pn2
22 Pb4 Pk Pm1 Pm2 Pz Pm1 Pm2 27 Last guard filter

A1
A5 A4 A3 A2
20 28 Safety lock valve
P4 PG(S/Motor) 15 18
M
29 Safety lock valve
P3 P0(MCV)
P2 19 dr1
30 Pressure switch
T
P1
21 31 Shut off valve
16073HC01
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
Hydraulic oil tank
3-02 (140-7 TIER)
The pumps receive oil from the hydraulic tank through a suction filter. The discharged oil from the
pump flows into the control valve and goes out the tank ports.
The oil discharged from the main pump flows to the actuators through the control valve.
The control valve controls the hydraulic functions.
The return oil from the actuators flows to the hydraulic tank through the control valve and the oil
cooler.
3-2
2. RETURN CIRCUIT
Full flow filter Oil cooler Check valve(2)

1.5kgf/cm2
Main control valve Actuators
Check valve(1)
3.0kgf/cm2
Bypass relief valve

1.5kgf/cm2 3-03 (140-7 TIER)
All oil returned 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 1.5kgf/cm2(21psi) and 3.0kgf/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. When the oil pressure exceeds 3.0kgf/cm2(43psi), the oil returns directly to the
hydraulic tank, resulting in the oil temperature being raised quickly at an appropriate level.
When the oil cooler is clogged, the oil returns directly to the hydraulic tank through bypass check valve(1).
The full-flow filter and bypass relief valve are provided in the hydraulic tank.
The oil returned 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 1.5kgf/cm2(21psi) differential pressure.
3-3
3. DRAIN CIRCUIT
Travel motor Swing motor
Main
Return line pump
Turning
joint
dr2 ~ dr8
Return filter
Hydraulic Spin filter

oil tank
dr1
Check valve
1.5kgf/cm 2
16073CI02
Besides internal leaks from the motors and main pump, the oil for lubrication circulates. The main
pump drain oil have to be fed to the hydraulic tank passing through spin filter.
When the drain oil pressure exceed 1.5kgf/cm2(21psi), the oil returns to the hydraulic tank directly.
1) TRAVEL MOTOR DRAIN CIRCUIT

Oil leaked from the right and left travel motors comes out of the drain ports provided in the
respective motor casing and join with each other. These oils pass through the turning joint and
return to the hydraulic tank after being filtered by spin filter.
2) SWING MOTOR DRAIN CIRCUIT
Oil leaked from the swing motor returns to the hydraulic tank passing through a return filter with oil
drained from the travel circuit .
3) MAIN PUMP DRAIN CIRCUIT
Oil leaked from main pump returns to the hydraulic tank passing through spin filter.
3-4
GROUP 3 PILOT CIRCUIT
Remote control valve Remote control valve

RCV pedal (RH lever)
(LH lever)
Safety lock
solenoid valve Swing parking brake
Control valve
Travel speed solenoid valve
Max flow cut off solenoid valve
Power boost solenoid valve
Swing priority solenoid valve

Line filter
Main pump
Relief valve
35kgf/cm2
Pilot pump
Suction filter
3-05 (140-7 TIER)
The pilot circuit consists of suction circuit, delivery circuit and return circuit.
The pilot pump is provided with relief valve, receives the oil from the hydraulic tank through the
suction filter.
The discharged oil from the pilot pump flows to the remote control valve through line filter, EPPR
valve, solenoid valve assemblies, swing parking brake, main control valve and safety lock solenoid
valve.
3-5
1. SUCTION, DELIVERY AND RETURN CIRCUIT
ARM BUCKET BOOM

CYLINDER CYLINDER CYLINDER
TRAVEL MOTOR
Pn2 Pn1
C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5
Pc5 Pb5
Pd5 Pa5
OPTION
BUCKET
C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
ARM
SWING MOTOR V3 REGENERATION
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
TRAVEL(RH) TRAVEL(LH)
P0
T1
TRAVEL
Pz
FRONT REAR
Dr#,T PUMP PUMP PILOT
(1) (2) (3) (4)
Pd1 Pc1 Pa1 Pb1 PUMP
SW AM BK BM
Pk Pz
Pb4 Pc3 Pm1 Pm2
A5 A4 A3 A2 A1
P4 PG
(1) (3) (2) (4) (3) (1) (2) (4) (S/Motor)
P3 P0(MCV)
HYDRAULIC TANK
sh P2
B A D E G F H J T P1
Pc2 Pd2 Pd40 Pc40 Pa5 Pb5 Pa20 Pb20 LINE FILTER
16073HC02
The pilot pump receive oil from the hydraulic tank. The discharged oil from the pilot pump flows to
the safety solenoid valve through the line filter. The oil is filtered by the line filter. The pilot relief valve
is provided in the pilot pump for limiting the pilot circuit pressure.
The oil filtered by line filter flows remote control valve through safety solenoid valve.
The return oil flow into the hydraulic tank.
3-6
2. SAFETY VALVE(SAFETY LEVER)
DOZER ARM BUCKET BOOM

CYLINDER CYLINDER CYLINDER CYLINDER
TRAVEL MOTOR
Pn2 Pn1
C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5
Pc5 Pb5
Pd5 Pa5
OPTION BUCKET
C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
ARM
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
T1
TRAVEL
Pz
FRONT REAR
(1) (2) (3) (4)
SAFETY
SW AM BK BM SOLENOID
VALVE
Pb4 Pk Pz LEVER
Pm1 Pm2
A5 A4 A3 A2 A1
UP
P4 PG
(1) (3) (2) (4) (3) (1) (2) (4) (S/Motor)
P3 P0(MCV)
HYDRAULIC TANK
sh P2
P1
B A D E G F H J T
Pc2 Pd2 Pd40 Pc40 Pa5 Pb5 Pa20 Pb20 LEVER DOWN LINE FILTER
16073HC03
When the lever of the safety solenoid valve is moved upward, oil flows into the remote control valve
through solenoid valve and line filter.
When the lever of the safety solenoid valve is moved downward, oil does not flow into the remote
control valve, because of the blocked port.
3-7
3. ARM REGENERATION SYSTEM
ARM BUCKET BOOM

TRAVEL MOTOR
Pn2 Pn1
C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5
Pc5 Pb5
Pd5 Pa5
OPTION BUCKET
C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
ARM
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
T1
TRAVEL
Pz
FRONT REAR
Dr#,T PUMP PUMP
(1) (2) (3) (4) PILOT
SW AM BK BM
Pb4 Pk Pz
Pm1 Pm2
A5 A4 A3 A2 A1
P4 PG
(1) (3) (2) (4) (3) (1) (2) (4) (S/Motor)
P3 P0(MCV) HYDRAULIC TANK
sh P2
P1
B A D E G F H J T
16073HC04
Then the heavy duty mode switch on the cluster is pushed ON, the arm regeneration solenoid valve
is deactivated and the arm regeneration spool is returned to neutral position.
Then, the arm regeneration function is activated and arm operation speed is increased.
3-8
4. TRAVEL SPEED CONTROL SYSTEM
ARM BUCKET BOOM

CONTROL PISTON
PILOT VALVE
TRAVEL MOTOR
RED RED
Pn2 Pn1
C6
D6
OPTION
VA VB VB VA
B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET
Pk C4
D4 DR3 B4
dr3
Pc41 Pb4
Pc40
Pa4
Pd40
ARM 1
Pc42
SWING MOTOR ARM
V3 REGENERATION
Pc3
DR2 Pb3
Pa21 Pd41
BOOM 2 ARM 2
B2
C2
D2 Pb21 A2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
TRAVEL T1
Pz
FRONT REAR
(1) (2) (3) (4)
SW AM BK BM
Pk Pz
Pb4 Pc3 Pm1 Pm2
A5 A4 A3 A2 A1
P4 PG
(1) (3) (2) (4) (3) (1) (2) (4) (S/Motor)
P3 P0(MCV)
HYDRAULIC TANK
sh P2
P1
B A D E G F H J T
16073HC05
When the travel speed switch is pushed, the travel speed solenoid valve is actuated and the
discharged oil from the pilot pump flows to the Pk port of pilot valve in the travel motors.
As a result, the control piston is pushed by the main oil flow, thus the displacement is minimized.
When the travel speed switch is pushed once more, the travel speed solenoid valve is return to
original position by the force of spring, the hydraulic oil of Pk port retums to the hydraulic tank.
As a result, the control piston is returned by the main oil flow, thus the displacement is maximized.
3-9
5. MAIN RELIEF PRESSURE CHANGE SYSTEM
ARM BUCKET BOOM

TRAVEL MOTOR
Pn2 Pn1
C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET
C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
ARM
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
T1
TRAVEL
Pz(Pu)
FRONT REAR
(1) (2) (3) (4)
SW AM BK BM
Pb4 Pk Pz
Pm1 Pm2
A5 A4 A3 A2 A1
P4 PG
(1) (3) (2) (4) (3) (1) (2) (4) (S/Motor)
P3 P0(MCV)
HYDRAULIC TANK
sh P2
P1
B A D E G F H J T
16073HC06
When the power boost switch on the left control lever is pushed ON, the power boost solenoid valve
is actuated, the discharged oil from the pilot pump flows into Pz port of the main relief valve of main
control valve; then the setting pressure of the main relief valve is raised from 330kgf/cm2 to 360kgf/cm2
for increasing the digging power. And even when pressed continuously, it is canceled after 8
seconds.
3-10
6. MAX FLOW CUT OFF SYSTEM
ARM BUCKET BOOM

TRAVEL MOTOR
Pn2 Pn1
C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET
SWING MOTOR
C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pa4
Pd40
ARM 1
Pc42
ARM
V3 REGENERATION
Pc3
DR2 Pb3
Pa21 Pd41
BOOM 2 ARM 2
B2
C2
D2 Pb21 A2
DR1
Pc2 Pb20
Pd2 Pa20
TRAVEL SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
(1) (2) (3) (4) P0

Pd1 Pc1 Pa1 Pb1
T1
Pz
SW AM BK BM
P1 P2
Dr#,T
(1) (3) (2) (4) (3) (1) (2) (4)

sh
B A D E G F H J Pn2 Pn1
Pm1 Pm2
Pc2 Pd2 Pd40 Pc40 Pa5 Pb5 Pa20 Pb20
Pk Pz M
Pb4 Pc3 Pm1 Pm2
A5 A4 A3 A2 A1 dr1
P4 PG HYDRAULIC TANK
(S/Motor) P3
P3 P0(MCV)
P2
P1
T
LINE FILTER
16073HC07
When the breaker operation mode is selected on the cluster, max flow cut off solenoid valve actuates
automatically.
Thus pilot pressure(Pm1,2) is sent to the regulator and pump discharge volume is decreased.
3-11
7. SWING PARKING BRAKE RELEASE
ARM BUCKET BOOM

TRAVEL MOTOR
Pn2 Pn1
C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5 Pb5
Pc5
SWING MOTOR Pd5 Pa5
OPTION BUCKET
SH
C4
D4 DR3 B4
PG
Pc41 Pb4
Pc40
Pa4
Pd40
ARM 1
Pc42
ARM
V3 REGENERATION
DR Pc3
DR2 Pb3
Pa21 Pd41
BOOM 2 ARM 2
A Mu B C2 B2
D2 Pb21 A2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
TRAVEL T1
Pz
FRONT REAR
(1) (2) (3) (4)
SW AM BK BM
Pk Pz
Pb4 Pc3 Pm1 Pm2
A5 A4 A3 A2 A1
P4 PG
(1) (3) (2) (4) (3) (1) (2) (4) (S/Motor)
P3 P0(MCV)
HYDRAULIC TANK
SH P2
P1
B A D E G F H J T
16073HC08
When the swing control lever is tilted, the pilot oil flow into SH port of shuttle valve, this pressure
move spool so, discharged oil from pilot valve flow into PG port.
This pressure is applied to swing motor disc, thus the brake is released.
When the swing control lever is set in the neutral position, oil in the swing motor disc cylinder is
drained, thus the brake is applied.
3-12
GROUP 4 SINGLE OPERATION
1. BOOM UP OPERATION
ARM BUCKET BOOM
TRAVEL MOTOR
Pn2 Pn1
C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET
C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
SWING MOTOR ARM
V3 REGENERATION
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
T1
Pz
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
16073HC10
When the right control lever is pulled back, the boom spools in the main control valve are moved to
the up position by the pilot oil pressure from the remote control valve.
The oil from the front and rear pump flows into the main control valve and then goes to the large
chamber of boom cylinders. At the same time, the oil from the small chamber of boom cylinders
returns to the hydraulic oil tank through the boom spool in the main control valve. When this
happens, the boom goes up. The excessive pressure in the boom cylinder bottom end circuit is
prevented by relief valve. When the boom is up and the control lever is returned to neutral position,
the circuit for the holding pressure at the bottom end of the boom cylinder is closed by the boom
holding valve. This prevents the hydraulic drift of boom cylinder.
3-13
2. BOOM DOWN OPERATION
ARM BUCKET BOOM

TRAVEL MOTOR
Pn2 Pn1
C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET
C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
SWING MOTOR ARM
V3 REGENERATION
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
T1
Pz
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
16073HC11
When the right control lever is pushed forward, the boom spools in the main control valve are moved
to the down position by the pilot oil pressure from the remote control valve.
The oil from the rear pump flows into the main control valve and then goes to the small chamber of
boom cylinders. At the same time, the oil from the large chamber of boom cylinders returns to the
hydraulic tank through the boom spool in the main control valve.
When the down speed of boom is faster, the oil returned from the large chamber of boom cylinder
combines with the oil from the rear pump, and flows into the small chamber of the cylinder.
This prevents cylinder cavitation by the negative pressure when the rear pump flow can not match
the boom down speed. And the excessive pressure in the boom cylinder rod end circuit is prevented
by the relief valve.
3-14
3. ARM ROLL IN OPERATION
ARM BUCKET BOOM

TRAVEL MOTOR
Pn2 Pn1
C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET
C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
SWING MOTOR ARM
V3 REGENERATION
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
T1
Pz
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
16073HC12
When the left control lever is pulled back, the arm spools in the main control valve are moved the to
roll in position by the pilot oil pressure from the remote control valve.
The oil from the front and rear pump flows into the main control valve and then goes to the large
chamber of arm cylinder.
At the same time, the oil from small chamber of arm cylinder returns to the hydraulic oil tank through
the arm spool in the main control valve. When this happens, the arm rolls in.
The cavitation which will happen to the bottom of the arm cylinder is also prevented by the make-up
valve in the main control valve.
3-15
4. ARM ROLL OUT OPERATION
ARM BUCKET BOOM

TRAVEL MOTOR
Pn2 Pn1
C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET
C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
SWING MOTOR ARM
V3 REGENERATION
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
T1
Pz
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
16073HC13
When the left control lever is pushed forward, the arm spool in the main control valve are moved to
the roll out position by the pilot oil pressure from the remote control valve.
The oil from the front and rear pump flows into the main control valve and then goes to the small
chamber of arm cylinder.
At the same time, the oil from the large chamber of arm cylinder returns to the hydraulic oil tank
through the arm spool in the main control valve. When this happens, the arm rolls out.
The cavitation which will happen to the rod of the arm cylinder is also prevented by the make-up
3-16
5. BUCKET ROLL IN OPERATION
ARM BUCKET BOOM

TRAVEL MOTOR
Pn2 Pn1
C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET
C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
SWING MOTOR ARM
V3 REGENERATION
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
T1
Pz
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
16073HC14
When the right control lever is pulled left, the bucket spool in the main control valve is moved to the
roll in position by the pilot oil pressure from the remote control valve.
The oil from the rear pump flows into the main control valve and then goes to the large chamber of
bucket cylinder.
At the same time, the oil from the small chamber of bucket cylinder returns to the hydraulic oil tank
through the boom spool in the main control valve. When this happens, the bucket rolls in.
The cavitation which will happen to the bottom of the bucket cylinder is also prevented by the make-
up valve in the main control valve.
3-17
6. BUCKET ROLL OUT OPERATION
ARM BUCKET BOOM

TRAVEL MOTOR
Pn2 Pn1
C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET
C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
SWING MOTOR V3
ARM
REGENERATION
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
T1
Pz
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
16073HC15
When the right control lever is pushed right, the bucket spool in the main control valve is moved to
the roll out position by the pilot oil pressure from the remote control valve.
The oil from the rear pump flows into the main control valve and then goes to the small chamber of
bucket cylinder.
At the same time, the oil from the large chamber of bucket cylinder retums to the hydraulic oil tank
through the bucket spool in the main control valve. When this happens, the bucket rolls out.
The cavitation which will happen to the rod of the bucket cylinder is also prevented by the make-up
3-18
7. SWING OPERATION
BUCKET BOOM
CYLINDER CYLINDER
TRAVEL MOTOR ARM
CYLINDER
Pn2 Pn1
C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
SWING MOTOR OPTION BUCKET
SH
C4
D4 DR3 B4
PG
Pc41 Pb4
Pc40
Pa4
Pd40
ARM 1
ARM Pc42
V3 REGENERATION
DR Pc3
DR2 Pb3
Pa21 Pd41
BOOM 2 ARM 2
A Mu B C2 B2
D2 Pb21 A2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
TRAVEL T1
Pz
FRONT REAR
(1) (2) (3) (4)
SW AM BK BM
Pb4 Pk Pz
Pm1 Pm2
A5 A4 A3 A2 A1
P4 PG
(1) (3) (2) (4) (3) (1) (2) (4) (S/Motor)
P3 P0(MCV)
HYDRAULIC TANK
sh P2
P1
B A D E G F H J T
16073HC16
When the left control lever is pushed left or right, the swing spool in the main control valve is moved
to the left or right swing position by the pilot oil pressure from the remote control valve.
The oil from the front pump flows into the main control valve and then goes to the swing motor.
At the same time, the return oil from the swing motor returns to the hydraulic oil tank through the
swing spool in the main control valve. When this happens, the superstructure swings to the left or
right. The swing parking brake, make up valve and the overload relief valve are provided in the
swing motors. The cavitation which will happen to the swing motor is also prevented by the make up
valve in the swing motor itself.
3-19
SWING CIRCUIT OPERATION
PARKING BRAKE
BRAKE RELEASE VALVE
BRAKE OFF
SH BRAKE ON
PG
dr4
MAKE UP VALVE
C(MAKE UP PORT)
PA PB MOTOR BRAKE VALVE
A B
TO/FROM MAIN CONTROL VALVE
21073HS26
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".
BYPASS VALVE
This bypass valve absorbs shocks produced as swing motion stops and reduced oscillation cause
by swing motion.
3-20
8. TRAVEL FORWARD AND REVERSE OPERATION
ARM BUCKET BOOM

TRAVEL MOTOR
RED RED
Pn2 Pn1
C6
D6
Pc6
VA VB VB VA Pd6
OPTION
B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET
Pk C4
D4 DR3 B4
dr3
Pc41 Pb4
Pc40
Pa4
Pd40
ARM 1
Pc42
SWING MOTOR ARM
V3 REGENERATION
Pc3
DR2 Pb3
Pa21 Pd41
BOOM 2 ARM 2
B2
C2
D2 Pb21 A2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
TRAVEL T1
Pz
FRONT REAR
(1) (2) (3) (4)
SW AM BK BM
Pb4 Pk Pz
Pm1 Pm2
A5 A4 A3 A2 A1
P4 PG
(1) (3) (2) (4) (3) (1) (2) (4) (S/Motor)
P3 P0(MCV)
HYDRAULIC TANK
sh P2
P1
B A D E G F H J T
16073HC17
When the travel levers are pushed forward or reverse position, the travel spools in the main control
valve are moved to the forward or reverse travel position by the pilot oil pressure from the remote
control valve. The oil from the both pumps flows into the main control valve and then goes to the
both travel motors through the turning joint. The return oil from both travel motors returns to the
hydraulic oil tank through the turning joint and the travel spools in the main control valve. When this
happens, the machine moves to the forward or reverse.
3-21
TRAVEL CIRCUIT OPERATION
RED RED
VA VB dr3
VB VA
Pk
OVERLOAD
CHECK VALVE RELIEF VALVE
TURNING JOINT COUNTER

BALANCE VALVE
TO/FROM MAIN CONTROL VALVE
21073HS27
Valves are provided on travel motors to offer the following functions.
1) COUNTER BALANCE VALVE

When stopping the motor of slope descending, this valve to prevent the motor over run.
2) OVERLOAD RELIEF VALVE
Relief valve limit the circuit pressure below 365kgf/cm2 to prevent high pressure generated at at time
of stopping the machine. Stopping the motor, this valve sucks the oil from lower pressure passage
for preventing the negative pressure and the cavitation of the motor.
3-22
GROUP 5 COMBINED OPERATION
1. OUTLINE
ARM
CYLINDER BUCKET
CYLINDER BOOM
CYLINDER
TRAVEL MOTOR
Pn2 Pn1
C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET
C4
D4 B4
DR3
Pc41 Pb4
Pc40
Pa4
Pd40
SWING MOTOR ARM 1
Pc42
ARM
V3 REGENERATION
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
D2 A2
Pb21
DR1
Pc2 Pb20
Pd2 Pa20
BOOM 1
SWING
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
DR0
P0
Ai T1
Pz
HYDRAULIC TANK STRAIGHT

TRAVEL
SPOOL FRONT REAR PILOT
PUMP PUMP PUMP
16073HC20
The oil from the front and rear pump flows through the neutral oil passage, bypass oil passage and
confluence oil passage in the main control valve. Then the oil goes to each actuator and operates
them. Check valves and orifices are located on these oil passage in the main control valve. These
control the oil from the main pumps so as to correspond to the operation of each actuator and
smooth the combined operation.
STRAIGHT TRAVEL SPOOL
This straight travel spool for straight travel is provided in the main control valve.
If any actuator is operated when traveling, the straight travel spool is pushed to the left by the pilot oil
pressure.
Consequently, the left and right travel oil supply passage are connected, and equivalent amount of
oil flows into the left and right travel motors. This keeps the straight travel.
3-23
2. COMBINED SWING AND BOOM OPERATION
ARM BUCKET BOOM

TRAVEL MOTOR
Pn2 Pn1
C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET
C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
SWING MOTOR V3 ARM
REGENERATION
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
T1
Pz
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
16073HC21
When the swing and boom functions are operated, simultaneously the swing spool and boom spools
in the main control valve are moved to the functional position by the pilot oil pressure from the
remote control valve.
The oil from the front pump flows into the swing motor through swing spool and the boom cylinder
through boom 2 spool.
The oil from the rear pump flows into the boom cylinders through the boom 1 spool.
The superstructure swings and the boom is operated.
3-24
3. COMBINED SWING AND ARM OPERATION
ARM BUCKET BOOM

TRAVEL MOTOR
Pn2 Pn1
C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET
C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
SWING MOTOR ARM
V3 REGENERATION
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
T1
Pz
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
16073HC22
When the swing and arm functions are operated, simultaneously the swing spool and arm spools in
the main control valve are moved to the functional position by the pilot oil pressure from the remote
control valve.
The oil from the front pump flows into the swing motor through swing spool and the arm cylinder
through arm 1 spool.
The oil from the rear pump flows into the arm cylinder through the arm 2 spool.
The superstructure swings and the arm is operated.
3-25
4. COMBINED SWING AND BUCKET OPERATION
ARM BUCKET BOOM

TRAVEL MOTOR
Pn2 Pn1
C6
D6
Pc6
Pd6
OPTION
Pd6
B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET
C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
SWING MOTOR ARM
V3 REGENERATION
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
T1
Pz
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
16073HC23
When the swing and bucket functions are operated, simultaneously the swing spool and bucket
spool in the main control valve are moved to the functional position by the pilot oil pressure from the
remote control valve.
The oil from the front pump flows into the swing motor through the swing spool.
The oil from the rear pump flows into the bucket cylinder through the bucket spool.
3-26
5. COMBINED SWING, BOOM, ARM AND BUCKET OPERATION
ARM BUCKET BOOM

TRAVEL MOTOR
Pn2 Pn1
C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET
C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
SWING MOTOR ARM
V3 REGENERATION
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
T1
Pz
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
16073HC24
When the swing, boom, arm and bucket functions are operated, simultaneously each spool in the
main control valve is moved to the functional position by the pilot oil pressure from the remote control
valve.
The oil from the front pump flows into the swing motor, boom cylinders and arm cylinder through the
swing spool, boom 2 spool, arm 1 spool, and the parallel and confluence oil passage.
The oil from the rear pump flows into the boom cylinders, arm cylinder and bucket cylinder through
the boom 1 spool, arm 2 spool, bucket spool and the parallel and confluence oil passage.
The superstructure swings and the boom, arm and bucket are operated.
3-27
6. COMBINED SWING AND TRAVEL OPERATION
ARM BUCKET BOOM

TRAVEL MOTOR
Pn2 Pn1
C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET
C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
SWING MOTOR ARM
V3 REGENERATION
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
T1
Pz
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
16073HC25
When the swing and travel functions are operated, simultaneously the swing spool and travel spools
in the main control valve are moved to the functional position by the pilot oil pressure from the
remote control valve and straight travel spool is pushed to the left by the pilot oil pressure from the
pilot pump.
The oil from the front pump flows into the swing motor through the swing spool. The oil from the rear
pump flows into the travel motor through the RH travel spool and the LH travel spool via the straight
travel spool.
The superstructure swings and the machine travels straight.
3-28
7. COMBINED BOOM AND TRAVEL OPERATION
ARM BUCKET BOOM

TRAVEL MOTOR
Pn2
Pn2 Pn1
C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET
C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
SWING MOTOR ARM
V3 REGENERATION
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
T1
Pz
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
16073HC26
When the boom and travel functions are operated, simultaneously the boom spools and travel
spools in the main control valve are moved to the functional position by the pilot oil pressure from the
remote control valve and the straight travel spool is pushed to the left by the oil pressure from pilot
pump.
The oil from the front pump flows into the boom cylinders through the boom 2 spool and boom 1
spool via the parallel and confluence oil passage in case boom up operation. The oil from the rear
pump flows into the travel motors through the RH travel spool and the LH travel spool via the straight
travel spool.
3-29
8. COMBINED ARM AND TRAVEL OPERATION
ARM BUCKET BOOM

TRAVEL MOTOR
Pn2 Pn1
C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET
C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
SWING MOTOR ARM
V3 REGENERATION
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
T1
Pz
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
16073HC27
When the arm and travel functions are operated, simultaneously the arm spools and travel spools in
the main control valve are moved to the functional position by the pilot oil pressure from the remote
control valve and the straight travel spool is pushed to the left by the oil pressure from pilot pump.
The oil from the front pump flows into the arm cylinders through the arm 1 spool and arm 2 spool via
the parallel and confluence oil passage. The oil from the rear pump flows into the travel motors
through the RH travel spool and the LH travel spool via the straight travel spool.
The arm is operated and the machine travels straight.
3-30
9. COMBINED BUCKET AND TRAVEL OPERATION
ARM BUCKET BOOM

TRAVEL MOTOR
Pn2 Pn1
C6
D6
Pc6
Pd6
OPTION
B5
C5 A5
D5 Pb5
Pc5
Pd5 Pa5
OPTION BUCKET
C4
D4 DR3 B4
Pc41 Pb4
Pc40
Pd40 Pa4
ARM 1
Pc42
SWING MOTOR V3
ARM
REGENERATION
Pc3 Pb3
Pa21 DR2
Pd41
BOOM 2 ARM 2
B2
C2
Pb21 A2
D2
DR1
Pc2 Pb20
Pd2 Pa20
SWING BOOM 1
C1 B1
D1 Pc1 Pb1 A1
Pd1 Pa1
P0
T1
Pz
HYDRAULIC TANK
FRONT REAR PILOT
PUMP PUMP PUMP
16073HC28
When the bucket and travel functions are operated, simultaneously the bucket spool and travel
spools in the main control valve are moved to the functional position by the pilot oil pressure from the
remote control valve, and the straight travel spool is pushed to the left by the oil pressure from pilot
pump. The oil from the front pump flows into the bucket cylinder through the bucket spool via the
confluence oil passage. The oil from the rear pump flows into the travel motors through the RH
travel spool and the LH travel spool via the straight travel spool of the control valve.
The bucket is operated and the machine travels straight.
3-31
Group 1 Component Location 4-1

Group 2 Electrical Circuit 4-3
Group 3 Electrical Component Specification 4-20
Group 4 Connectors 4-29
GROUP 1 COMPONENT LOCATION
1. LOCATION 1
16074EL01
1 Horn switch 11 Travel alarm stop switch 20 RS232 serial port

2 Cluster 12 Preheat switch 21 Fuse box
3 Starting switch 13 Washer switch 22 Master switch
4 Cigar lighter 14 Wiper switch 23 Aircon & heater switch panel
5 Accel dial 15 Main light switch 24 One touch decel switch
6 Breaker switch 16 Speaker 25 Power max switch
7 Beacon switch 17 Cassette & radio 26 Safety lever
8 Service meter 18 Resistor 27 Overload switch
9 Breaker selection switch 19 CPU controller 28 Quick coupling switch
10 Cab light switch
4-1
2. LOCATION 2
1
ON
1
OF
F
5
1
3
6
7
2 8
9
10
1
11
12
13
14
15
16
16074EL02
1 Lamp 6 Heater relay 11 Travel alarm buzzer

2 Fuel sender 7 Speed sensor 12 Battery
3 Fuel filler pump 8 Engine oil pressure switch 13 Battery relay
4 Beacon lamp 9 Temperature sender 14 Fuse box
5 Air cleaner switch 10 Alternator 15 Master switch
16 CPU controller
4-2
GROUP 2 ELECTRICAL CIRCUIT
INLET M/ACT TEMP M/ACT MODE(D/FOOT) MODE(VENT) RESISTOR RELAY(HI) RELAY(M2)

103 3L FUSE BOX 5W 104
2 7 2 7 BLOWER
1 4 1 4 3R 105
3 M M 3 M M
3
7
1
7
Lo 1
4
ML 2
MH 3
5 5 POWER RY
M
Hi
4
2
2
5
6
7
5
6
7
5
6
7
1
2
3
4
5
6
7
1
2
3
4
1
2
3
4
1
2
3
4
10
11
105
1
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
5W 104
53
5W 56
85
AC COMP
86
1
2
3
4
20A
10A
20A
20A
10A
10A
10A
20A
10A
10A
10A
20A
10A
10A
10A
10A
10A
10A
10A
2
1
1
4
4
2
3
2
3
5A
5A
5A
5A
5A
5A
5A
5A
5A
87a 87
GW
WR
30
BW
WB
BG
BG
GB
GB
3R
GL
YB
3R
LR
LB
R/DRYER HORN
YBr
YW
85
LG
86
YW
CR-35
BG
RY
RY
2B
YB
L
L
20A
87a
9A
9B
21
22
17
20
18
19
23
24
25
16
15
CN-60
Pa
87a 87
30
30
86
85
CN-95
87
ETHER(PRE-HEAT)
CASSETTE RADIO
85
86
36A
2
1
26
35
27
FUEL FILLER P/P

33A
2
1
32
36
6B
6A
CIGAR LIGHTER
29
33
36
28
35
SWITCH PANEL
WIPER MOTOR
FUEL CUT-OFF
BEACON LAMP
87a 87
30
CN-29
CR-7
AC& HEATER
CONVERTOR
AC& HEATER
87a
SAFETY SOL
ROOM LAMP
WORK LAMP
CABIN LAMP
AC BLOWER
SOLENOID 1
SOLENOID 3
HEAD LAMP
30
86
85
3L
87
START KEY
W
2
R
1
B
CLUSTER
CR-2
TRAVEL
WIPER+
CPU B+
87a
SPARE
CN-36
START
30
86
85
G11
87
HORN
18A
103
V/W
CPU
93
FUSIBLE LINK
G
G
L
L
60R 60B 60B
BR
BR
106
106
101
R
GY/W
Y
4A
4E
85
L/W
RW
GY
OR
OR
GY
GY
GY
BR
BR
2R
2L
W
BATTERY
G
V
R
Y
Y
L
5A
22
98
5
CR-1 MASTER SW
12V X 2
102
100
109
110
50
52
18
99
49
77
78
90
15
10
88
87
86
97
83
20
19
G21 B
4
5
1
NO. 9 G TO:STARTER "B" TERM.
CN-11 DESTINATION NO. DESTINATION CN-11
1,2 BR B 111
1 1 GND(CONTROLLER) 1 AC CONTROLLER GND 1
32 2B 2B G5 BATT RY
2 2 GND(BLOWER) 2 BLOWER MOTOR GND 2
6 RY 2L 4
3 3 FUSE(IG) 3 AC 24V 3 DO-3
3,4 RW/R 2R 102 9E G
4 4 FUSE(Battery) 4 AC CONTROLLER B+ 4 2
33 2R 2RW 49 G23 B
5 5 FUSE(Battery) 5 AC CONTROLLER B+ 5 1
30 LW G 101
6 6 DPS(COMPRESSOR) 6 AC COMP 6
31 LY DIODE
7 7 CONDENSOR FAN 7 AC CONDENSOR FAN 7
5 G
8 R 6A DO-2
8 ILLUMINATION 8 ILLUMINATION 8 9A G
2
AIR CON 92 V
AIR-CON 1
DIODE
WB 15
BW 16
17
BG 18
GL 19
20
21
22
23
24
25
26
27
28
29
30
31
1
2
RW/R 3
RW/R 4
5
6
8
9
NO. DESTINATION CN-10
V 100 DO-1
GW
BrR
WR
YBr
9
8
LW
9
BG
BG
GB
1 CASSETTE RADIO 24V 1
BR
BR
RY
G
YB
LG
YB
LR
LB
LY
OVERLOAD SW QUICK COUPLING SW

G
Y
R 6E 2
WIPER 2 ILLUMINATION 2 16A W
1.25BrR
2
8
7
9
1.25GB
8
2
7
9
1
1
CUT
3 NC 3
CN-21 I 2B G1
10
11
12
13
14
15
16
17
18
10
11
12
13
14
DIODE
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
4 GND 4 CN-61
3 1
R 10 5 NC 5 G62 B CN-25
G53
CS-53
2 Y 99 1 M B
1
TEMP MOTOR ACT(+)
DUCT SENSOR(GND)
TEMP MOTOR ACT(-)
GY 12 6 CASSETTE&ROOM LAMP B+ 110

BLOWER RELAY(M1)
BLOWER RELAY(M2)
COMPRESSOR(DPS)
6 G
BLOWER RELAY(LO)
1
2
MODE M/ACT(FOOT)
10
5
6
INLET MOTOR(REC)
CS-50
10
BLOWER RELAY(HI)
6
CS-67
INLET MOTOR(FRE)
3 2 22A R
MODE M/ACT(PBR)
MODE M/ACT(DEF)
5
TEMP M/ACT(PBR)
2
MOTOR ACT(REF)
CONDENSER FAN
DUCT SENSOR(+)
MODE M/ACT(M+)
4A 7 NC
MODE M/ACT(M-)
2A B
R
112
10
B
6
4
4
5
8
9
10
3
7
2
6
FUEL PUMP
4
5
8
9
ILLUMINATION
HORN
OR
4 G 8 8 CASSETTE GND 8
BATTERY(+)
BATTERY(+)
5 G52 B
POWER IG
L 9 9 NC 9 1
L/W
OR
OR
1A GY
96 22
11
6 2 6 G R
OR
M
G1 B
10 BEACON LAMP 10 2
2A Y
G2 B
DUCT OR 89
GND
GND
SENSOR 11 CABIN LIGHT 11 CN-20

NC
NC
NC
NC
NC
NC
7
6
4
WIPER MOTOR 12 NC 12 CN-12 CL-5
CN-141 G51 B B 2 2 B
AC&HEATER CONTROLLER
FEED BACK 1
G 8 CABIN HARNESS 91 V
2
V 1 1 V
1
W 1 1 2
MOTOR DRIVE SIG 2 CN-17
L 9 NO. DESTINATION CN-9 WORK LAMP
MOTOR DRIVE- 3 1 B G3 2A B
R 10 1 W W 9 1 HORN SW 1
Y 98 1
MOTOR DRIVE+ 4 2
2 HORN SW 2
CL-4 1A V
B 2 2 B B G3 G61 B 2
GND 5 3 1
GY/W 3 3 GY/W GY/W 3 3 NC 3 6 R
VCC 6 4 BR 81 2 CL-6
R 4 4 R R 29 4 INT. SIG 4
CONTINUE 24V 7 5 B 13 HEAD LAMP
V 5 5 V V 11 5 ACCEL DIAL(-) 5
WASHER P/P 8 6 W 25
L 6 6 L L 13 6 ACCEL DIAL(SIG) 6
WASHER SIG. 9 7 G/OR 11
BR 7 7 BR BR 10 7 ACCEL DIAL(+) 7
INT. SIG 10 8
OR 11 8 SPARE SW 8
WIPER CUT SW 11
N.C 12 CN-6 NO. DESTINATION CN-8
GY 12 4 OR 1 SPARE SW 1
FEED BACK 13 1 1 FUSE
2 Y 2 SPARE SW 2
2 2 QUICK COUPLING SOL Y 97
WIPER MOTOR CONT. 5 L/W 3 BEACON LAMP 24V 3
3 3 OVERLOAD PS G 96
6 G 4 BEACON LAMP SIG 4
4 4 CPU CONTROLLER OR 1A
CL-2 3 GY/W 5 BRAKER SW 24V 5 CN-66
5 5 FUSE GY 95 95 GY
B G5 G1 B 6 BRAKER SIG 6 2
6 6 GND G41 B
GY 1 1 GY 7 SPARE SW 7 1
7 7 FUSE
R 8 8 R 8 SPARE SW 8 BREAKER SOL.
8 8 ILLUMINATION BR 94
9 W 9 START KEY (START SIG) 9
9 9 SWITCH PANEL R 93
CIGARLIGHT 10 BR 10 START KEY (ACC) 10
10 10 SWITCH PANEL V 92
CN-24 11 V 11 START KEY (BR) 11
B/W 12 CN-48 11 11 WASHER PUMP W 18
2 CS-1 OR 16 12 L 12 START KEY (COM) 12
GY 11 8 GY 1 12 12 CPU CONTROLLER
CN-7
1 h 2
W/OR 15 CS-52
GY 1E R 6
10 1 HEAD LIHGT SIG 1
SPEAKER RH 9 10 G 28 V 91
HOUR METER 9 2 WORK LIHGT SIG 2
CN-23 DOOR S.W W 82
8 3 WIPER DRIVE SIG 3
B/OR 10 CN-138 BR 44
2
OR 9 GY 14
8
6 7 RH SIDE HARNESS 4 PRE HEAT SIG 4
L 90
1 24V 24V A 2 B G8
B G6 6 5 SW PANEL 24V 5
CL-1 GND B 7 B G9 OR 89
OR 22 5 5 6 CABIN LIGHT SIG 6
SPEAKER LH 8 GY 12V 12V C 1 GY 88
1 4 7 HEAD LIHGT 24V 7
4 Y Y 87
2 DC/DC CONVERTER 3 8 WORK LIHGT 24V 8
L 12 L 79
CN-27 2 CN-5 9 WASHER SIG 9
ROOM LAMP G 28 13 L B G4
N.C 1 CN-139 1 1 1 SWITCH PANEL 10 GND 10
B/W 12 OR/W 28
S.R- 2 OR 22 2 2 NC 11 TRAVEL ALARM SIG 11
2 SPARE 17 BR R 86 CD-31
N.C 3 B G7 3 3 FUSE 12 CABIN LIGHT 24V 12
B/OR 10 1 29 R 84 L/W
S.L- 4 4 4 FUSE 13 13 2 Pa
14 GY G18 B
N.C 5 CN-10 NO. DESTINATION 5 5 FUSE 14 14 1
1 V 12V SOCKET 15 W/OR
N.C 6 1 1 FUSE 6 6 CPU CONTROLLER 15 15
R 2 2 R CN-56 16 OR OVERLOAD PS
ILL 7 2 2 ILLUMINATION 7 7 FUSE RH CONSOL
GY 11 RR BR 17 21 SH CN-2
S.R+ 8 3 3 POWER IG(24V) 1 8 8 CPU CASE EARTH V 107
3 2B B 18 18 B 1 PRE-HEAT RY 1
N.C 9 4 4 GND GND 2 9 9 GND V/W 85
V 1 Y 19 19 Y 2 AC COMP 2
ACC 10 5 5 RX 3 10 10 CPU CONTROLLER B/W 24
Y 4a 4 Y L 20 20 L 3 FUEL CUT-OFF 3
B+ 11 6 6 FUSE TX 4 11 11 CPU CONTROLLER B G33
OR 9 4 FUEL CUT-OFF 4
S.L+ 12 7 7 12 12 NC OR 57
5 B CLUSTER 5 EPPR 5
S.L+ 13 8 8 GND 13 13 NC BR 75
B 5 6 EPPR 6
GND 14 9 9 14 14 NC
6 G
15 NC 7 NC 7
10 10 BEACON SW 15
CN-143 7 OR 8 NC 8
11 11 SWITCH PANNEL
N.C 1
R 20 12 12 ENG.HARNESS REAR
RADIO ON/OFF 2
G 21
3
BAND
BAND 4
L 22 CABIN HARNESS CS-5
NO. DESTINATION CN-6
OR 1
23 CS-26A 1 QUICK COUPLING SW 24V 1 CN-140
BR B 8 Y 21 21 Y
SEEK 5 GY 5A 1
OR 24 2 Y 9 2 QUICK COUPLING SW SIG 2 2
SEEK 6 L/W 84 G42 B
GY 18A 2 3 OVERLOAD SW 3 1
1
N.C 7 G 46
B 13 HORN 4 OVERLOAD SW 4
GND 8 BRAKER GY/W 10 QUICK COUPLING
Y 14 5 WIPER MOTOR 24V 5
VOL/R OUT 9 CS-26 B G2
V 15 6 GND 6
VOL/L OUT 10 GY 18 GY 83
GY 16 CL-9 1 CN-9 NO. DESTINATION 7 CIGARLIGHTER 24V 7
VOL/R IN 11 7 OR GY 5 8 B R 6F
W 17 2 2 1 1 GND 8 CIGARLIGHTER ILL. 8
VOL/L IN 12 3 B CS-54 9 Y W 82
B 18 1 2 2 HORN RELAY 9 WIPER DRIVE SIG 9 CN-22
B G2 BRAKER BR 81 10A GY/W
GND 13 10 M
R 19 9 10 L 7A 3 3 NC 10 INT. SIG 10 2
N.C 14 9 10 BR V 80 80 V
GY 14 4 4 WIPER CONTROLLER 11 WASHER PUMP 11 1
CABIN LIGHT 8 11 B 12 NC 12
CASSETTE RADIO 8 5 5 CPU CONTROLLER WASHER P/P
6 7 12 W
CN-5
CN-144 2 B 19 6 6 CPU CONTROLLER
B 18 CL-8 6 13 G/OR L 79
EARTH(VOLUME) 1 7 OR 20 7 7 CPU CONTROLLER 1 WASHER SIG 1
W 17 7a OR 5 5 14 GY
VOLUME L/IN 2 2 1 8 8 NC 2 NC 2
GY 16 3a B 4 BR 77
VOLUME R/IN 3 1 3 CLUSTER 24V 3 37A V/W B G13
V 15 3 CN-8 V 50
VOLUME L/OUT 4 G 15 15 G 4 WIPER MOTOR CONT. 4
Y 14 2 1 1 NC GY 78
VOLUME R/OUT 5 L 7 7 L 5 CONVERTOR 24V 5
B 13 1 2 2 NC W/OR 61 CN-92
EARTH(MAIN) 6 CL-7 16 Y 6 HOUR METER SIG 6
R 19 6 G SPARE SW 3 3 FUSE OR 8
N.C 7 6 G 7 HOUR METER 24V 7
R 20 3b B M 4 4 BEACON LAMP SH 70 CR-36
RADIO ON/OFF 8 17 OR 8 SHIELD 8
G 21 CS-23 5 5 FUSE B 113 20 L
BAND 9 B G1 18 GY 9 CLUSTER GND 9 30
L 22 BEACON LAMP 10 6 6 BRAKER SOL Y 68 20A L 87a 87 85
9 10 19 10 CLUSTER SERIAL+ (RX) 10 86
BAND 10 G 6A B
BR 23 9 7 7 NC L 69 107 V
SEEK UP 11 20 OR 11 CLUSTER SERIAL- (TX) 11 87
OR 24 8 8 8 FUSE 62 Y/W
SEEK UP 12 8 21 BR 12 NC 12 85
6 7 9 9 SAFETY RELAY 30 86
2 Y 16 22 R 13 13 87a
REMOCONE 6 10 10 POWER RELAY
7 23 V 14 14 PRE-HEAT
5 5 11 11 DIODE(DO-2)
1 24 W 15 15 CR-43
4 12 12 FUSE 41 L
3 CN-7
RH SIDE 2 R
1 2 1
G 6 2
2 25 R
2A R
1 1 HEAD LAMP NO. CN-4
4 V DESTINATION 3
1 B G6 24 B/W
2 2 WORK LAMP 1 POWER MAX SW 1 4 4 3
BEACON LAMP SW 26 W Y 34
3 3 WIPER CONTROLLER 2 POWER MAX SW 2
27 BR ENG.STOP RY
4 4 CPU CONTROLLER B G7
CS-27 28 L 3 O/T DECEL SW 3
B G3 5 5 FUSE GY 45
10 3 OR 4 O/T DECEL SW 4
9 10 GY 5A 6 6 CABIN LIGHT 5 NC 5
9 29 GY B G8
7 7 FUSE 6 SAFETY SW (Com) 6 CN-68
8 2 Y
23
FROM START MOTOR 8 8 8 FUSE 109 R
6 7 30 L 7 SAFETY SW (NC) 7 2
2 9 9 WIPER CONTROLLER G 76 76 G
8 SAFETY SW (NO) 8 1
B
6 G1 B
CR-24 7 OR 17 10 10 GND
5 31
15R 1
5 OR/W
11 11 CPU CONTROLLER LH CONSOL SAFETY SOL
V 1 4 1 R
CR-5
12 12 FUSE
3 15 L/W
15R 13 13 FUSE NO. DESTINATION CN-3 30
2 B G31 94 BR 87a 87 85
GY 5 14 14 FUSE 1 GND 1 86
1
G4
B/OR 17 17 B/OR
4A
OR 3A
2A
1A
25
26
BR 27
28
GY 29
30
OR/W 31
BR 10
15 FUSE 2 START RY 2
4
OR 3
15 87
11
12
G/OR 13
Pre-heater PRE-HEAT RY CD-14

BR 21
22
23
24
BRAKER SW W 16 37 V/W
1F Y
3 ALT(I) 3 85
2 Pa
W
GY 78A
R
R
R
V
V
Y
Y
B
L
30 86 2F G
W
4 ALT(IG) 4 87a
R
V
W
B
G 32 1
CN-28
RH HARNESS 5 WATER TEMP SENDOR 5
CS-2
V/W 2 SAFETY
CN-116
1
4
5
12E
2
6
3
B CN-55
10
11
12
13
14
15
16
17
1 CD-13
CN-142
6 WATER TEMP SENDOR

5
4
6
6
2
3
C
B
A
Y 67 19A Y Y 1 1E Y
B 7 TACHO SENSOR 7 2 2 Pa
WIPER MOTOR DRIVE
L 65 43 G G 2 2E G
+
-
S
CN-2 NO. DESTINATION

0, I
8 TACHO SENSOR 1 1
1
AC COMP 8
GY/W 30
WORK LIGHT OUT
WORK LIGHT OUT
CABIN LIGHT OUT

CABIN LIGHT OUT
1 V
WORK LIGHT 24V
WORK LIGHT 24V
CABIN LIGHT 24V

HEAD LIGHT OUT
CABIN LIGHT 24V

HEAD LIHGT 24V
1 1 PRE-HEAT RY 9 ENG.OIL PS 9 CN-81 CD-12

TRAVEL ALARM
CN-79 2 V/W 1A Y
WASHER SIG
2 2 AC COMP RY. 10 10 43 G
POWER 24V
B/W 3 3 B/W H0 I 1 2 Pa
PRE-HEAT
11 51 V 2A G
4
3
3 ENG.STOP RY
2
11
6
3
5
BR ACC H
1
ST C
INT. SIG
2
4 4 ACCEL DIAL 12 12
GND
4 OR START KEY SW TRAVEL BZ CD-11

5 5 FUSE ENG HARNESS FRONT 1 Y
FUEL CUT-OFF 5 BR
6 6 CPU CONTROLLER CN-1 2 Pa
R 14 2 G
SWITCH PANEL 1 P1,P2,P3 B+ 1 1
7 7 NC
CN-75 8 8 NC 2 NC 2
OR 4 B 47
2 3 P1,P2,P3 GND 3
BR 5 B/W 38
1 4 PUMP1 PRESS SIG 4
BR 39
5 PUMP2 PRESS SIG 5
EPPR V/V V 40
6 PUMP3 PRESS SIG 6
CN-19B
CN-45 CR-23 HARNESS PUMP PS B G12
CN-3 NO. DESTINATION
ENG.HARNESS REAR M B 1 1 B
CD-10 1
M B/OR 2 2 B/OR
1 1 GND Pa
L
B
36
G32
2
OR 58
2 2 SAFETY RY
3 W CN-19 CN-19A
3 3 CPU,DIODE(DO-1) 75 BR BR 48
B+ START RY. 4 GY AIR CLEANER SW
1 1
FROM BATT.RY 4 4 FUSE OR OR
5 G 57 31
STARTER 5 5 CPU CONTROLLER CD-16 2 2
6 B B G22
TO:PRE-HEAT RY 6 6 CPU CONTROLLER 2
CD-42 CN-1 7 Y G/W 35
R R 1 1 R
CN-74 7 7 CPU CONTROLLER 1
24V 3 1 1 CPU CONTROLLER 8R 8 L
G W 3 U
B+ 8 8 CPU CONTROLLER
WATER LEVEL
SIG 2 2 2 NC 9 GY/W
W B 2 2 9 9 CPU CONTROLLER
GND 1
3
B
W
3 3 CPU CONTROLLER ~ 3 I 1
W 3
10 10 NC
4 4 CPU CONTROLLER G R 10 SH 59
PUMP1 PRESS 4 BR R 2 11 11 NC
5 5 CPU CONTROLLER
5 V 12 12 NC
CD-43 6 6 CPU CONTROLLER ALT. 7 B
R R 1A DO-4 SH 70
24V 3 R 10
58
OR 8E
G BR 4 2
2
SIG
W B 2A HARNESS PUMP PS 1
GY 4
OR
GND 1
DIODE
PUMP2 PRESS ENG. HARNESS FRONT
CN-47
1
2
CD-44
R R 1E CS-29 CD-8
24V 3 B 1 G 5
G V 5 1
G43
1 ˚C
26A
SIG 2 Y 2 B 6
W B 2E 2 2
3E
3A
64
19
55
63
60
GND 1 RESISTER
3
CN-4 NO. DESTINATION 21E7-4000
Y/W
POWER MAX 1 B WATER TEMP SENDOR

27
BR/W
27
PUMP3 PRESS
B
G/W
1 1 GND
12A
L/W
13A
G/OR 11A
CS-19 2
8A
Y
12
B/OR 33
26
34
OR/W 28
GY/W 30
14
47
16
38
39
40
45
35
36
13
G/OR 11
29
25
B/OR 33
65
67
12
32
55
BR/W 60
63
W/OR 61
Y/W 62
41
52
48
42
37
54
64
51
44
46
66
23
68
69
71
72
73
31
W
66
54
29
R
Y
2 CPU CONROLLER
CN-15
2
CD-17
BR/OR
BR/OR
B 3 3 B
G44
2
1
1 3 3 GND rp Y 7
CN-137
26
CN-70
G/W
G/W
1
Y/W
B/W
B/W
V/W
2
L/W
CN-88
CN-133
m 2
OR
OR
4 4
GY
GY
GY GY
BR
BR
BR
W
W
W
W
B
L
W
G
R
R
4 CPU CONROLLER
B
B
Y
B
G
2
L
L
4
V
73
72
71
B/W 42
1
7
Y/W
5 5 NC
CD-1
ONE TOUCH DECEL G

CD-2
B
B
TACHO SENSOR
CN-51
CN-76
1
2
CN-50
6 GND
B
1
2PCS BOOM AUTO-IDLE PS
2
6
5
4
3
2
6
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
1
G
R
B
CN-15
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
CS-4 6 V TRAVEL MAX
7 7 NC POWER
˚C
OR 5
CD-7
7 G FLOW
CN-126
1
2
B C MAX
SIG
A CD-18 BOOM
M+
P+
NC
M-
8 SAFETY SOL
P-
V 6 8
3
4
1
2
PRIORITY1
WATER TEMP SENDOR

GND(PRES.SENSOR)
TRAVEL SPEED SOL.

B
HYD TEMP SENDOR

24V(PRES.SENSOR)
9
TRAVEL ALARM SW
FUEL LEVEL SENSOR

GY/W
1
BOOM PRIORITY SOL

Pa
5
TACHO SENSOR(+)
7 HYD
TACHO SENSOR(-)
G
ANTI-RESTART RY
WATER LEVEL SW
2
POWER MAX SOL.

AIR CLEANER SW
ENG PREHEATER
Pa
PROGRAM DUMP
C FUEL
TRAVEL BUZZER
POWER MAX SW
GND (POT&DIAL)
LH HARNESS TEMP
BATTERY 24V(+)
MAX FLOW SOL.
A CS-20 ACCEL DIAL SIG
OVERLOAD SIG
GND (SENSOR)
LEVEL
P1 PRESS SIG.
P2 PRESS SIG.
P3 PRESS SIG.
O/T DECEL SW
ENG.STOP SIG
PUMP EPPR(+)
5V (POT&DIAL)
PRE-HEAT SW
PUMP EPPR(-)
ACCEL ACT(+)
HOUR-METER
ACCEL ACT(-)
CD-37
WORKING PS
6
SAFETY SW
3
RS232 (GND)
5 OR ENG OIL PRESS RS232
ENG OIL PS
GND (MAIN)
1
2
SERIAL-RX
ALT LEVEL
SERIAL-TX
POWER IG
WORK
RS232 (+)
GOV. MOTOR CN-92
RS232 (-)
CONN.
POT-SIG
PS
GND
Pa
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
SAFETY SW
CPU CONTROLLER 16074EL03
4-3
MEMORANDUM
4-4
1. POWER CIRCUIT
The negative terminal of battery is grounded to the machine chassis.
When the start switch is in the OFF position, the current flows from the positive battery terminal as shown
below.
1) OPERATING FLOW
Battery Battery relay Fusible link (CN-60)
Fuse box [No.1] I/conn [CN-8(12)] Start switch [CS-2(1)]
Power relay [CR-35(30)]
Fuse box [No.2] I/conn [CN-10(6)] Room lamp [CL-1(2)]
Cassette radio [CN-27(11)]
Fuse box [No.3] I/conn [CN-11(4)] AC & Heater controller [Battery(+)]
Fuse box [No.4] I/conn [CN - 5(4)] I/conn [CN -17(5)] Wiper motor Controller
[CN-141(7)]
Wiper motor [CN-21(4)]
Fuse box [No.5] CPU controller [CN-50(7)]
Fuse box [No.6] I/conn [CN-11(5)] Relay(Hi, M2)
Fuse box [No.7] Engine stop relay [CR-43(2,3)]
※ I/conn : Intermediate connector
2) CHECK POINT
Engine Start switch Check point Voltage
- GND (Battery 2 EA) 20~25V

OFF OFF - GND (Battery 2 EA) 20~25V
- GND (Fusible link) 20~25V
※ GND : Ground
4-5
POWER CIRCUIT
1 2 1
2
3
4 4 3
16074EL04
4-6
2. STARTING CIRCUIT
1) OPERATING FLOW
Battery(+) terminal Battery relay[CR-1] Fusible link Fuse box No.1
I/conn [CN-8(12)] Start key [CS-2(1)]
※ Start switch : ON
Start switch ON [CS-2(2)] I/conn [CN-8(11)] Diode[DO-2]
Battery relay [CR-1]:Battery relay operating(All power is supplied with the electric component)
Start switch ON [CS-2(3)] I/conn [CN-8(10)] Power relay [CR-35(86) → (87)]
Fuse box (All power is supplied with electric component)
※ Start switch : START

Start switch START[CS-2(5)] I/conn[CN-8(9)] Safety relay [CR-5(86) → (87)]
I/conn [CN-3(2)] Start relay [CR-23]
2) CHECK POINT
① - GND (Battery)
② - GND (Start key)
③ - GND (Battery relay M4)
Operating Start ④ - GND (Starter B ) 20 ~ 25V
⑤ - GND (Starter M)
⑥ - GND (Start relay)
⑦ - GND (Battery relay M8)
※ GND : Ground
4-7
STARTING CIRCUIT
1 2 1
2
3
3 4 4
1
2
16074EL05
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
(1) Warning flow
Alternator“I”terminal I/conn〔CN-3(3)〕 CPU Controller [CN-51(9)]
Cluster warning lamp (Via serial interface)
(2) Charging flow

Alternator "B+" terminal Battery relay Battery(+) terminal
Fusible link〔CN-60〕 Fuse box
2) CHECK POINT
① - GND (Battery voltage)

② - GND (Battery relay)
ON ON ③ - GND (Alternator B⁺terminal) 20~27V
④ - GND (Alternator I terminal)
⑤ - GND (CPU)
※ GND : Ground
4-9
CHARGINGING CIRCUIT
1
2
16074EL06
4-10
4. HEAD AND WORK LIGHT CIRCUIT
1) OPERATING FLOW
Fuse box (No.15) I/conn〔CN-7(7)〕 Switch panel〔CN-116(9)〕
Fuse box (No.16) I/conn〔CN-7(8)〕 Switch panel〔CN-116(10,11)〕
(1) Main light switch ON
Head light switch ON〔CN-116(1)〕 l/conn〔CN-7(1)〕
Head light ON〔CL-4(2)〕
I/conn〔CN-10(2)〕 Cassette radio illumination ON〔CN-27(7)〕
I/conn〔CN-11(8)〕 AC & Heater controller illumination ON
I/conn〔CN-6(8)〕 Cigarlight〔CL-2〕
(2) Main light switch ON

Work light switch ON〔CN-116(2,3)〕 l/conn〔CN-7(2)〕 l/conn〔CN-12(1)〕
Work light ON〔CL-5(2), CL-6(2)〕
2) CHECK POINT
① - GND(Fuse box)
② - GND(Switch power input)
STOP ON 20~25V
③ - GND(Switch power output)
④ - GND(Head light)
⑤ - GND(Fuse box)
⑥ - GND(Switch power input)
STOP ON 20~25V
⑦- GND(Switch power output)
⑧ - GND(Work light)
※ GND : Ground
4-11
HEAD AND WORK LAMP CIRCUIT
16074EL07
4-12
5. BEACON LAMP AND CAB LIGHT CIRCUIT
1) OPERATING FLOW
Fuse box (No.18) I/conn〔CN-8(3)〕 Beacon lamp switch〔CN-23(6)〕
Fuse box (No.17) I/conn〔CN-7(12)〕 Switch panel〔CN-116(16, 17)〕
(1) Beacon lamp switch ON
Beacon lamp switch ON〔CS-23(2)〕 Switch lndicator lamp ON〔CS-23(9)〕
l/conn〔CN-8(4)〕 l/conn〔CN-10(10)〕
Beacon lamp ON〔CL-7〕
(2) Cab light switch ON
Cab light switch ON〔CN-116(7, 8)〕 I/conn〔CN-7(6)〕 I/conn〔CN-10(11)〕
Cab light ON〔CL-8(2), CL-9(2)〕
2) CHECK POINT
① - GND(Fuse box)
STOP ON 20~25V
④ - GND(Beacon lamp)
⑤ - GND(Fuse box)
⑥ - GND(Switch power input)
STOP ON 20~25V
⑦ - GND(Switch power output)
⑧ - GND(Cab light)
※ GND : Ground
4-13
CN-10
1
2
CL-7
B 3
M
G 4
5
BEACON LAMP
6
7
4
8
CL-9 9
OR
G G
2 10
OR OR
1 11
12
CL-8
8
OR
2
CABIN LIGHT
CN-46
1
START KEY 20A
1
ROOM LAMP 5A
2
AC & HEATER 5A
3
WIPER+ 10A
4
CN-116
CPU B+ 5A
HEAD LIGHT OUT 1 5
AC BLOWER 20A
WORK LIGHT OUT 2 6
WORK LIGHT OUT 3 FUEL CUT-OFF 10A

7
WIPER MOTOR DRIVE 4
7
CN-7 CLUSTER 10A
8
PRE-HEAT 5 1
BEACON LAMP AND CAB LAMP CIRCUIT
CASSETTE RADIO 5A
POWER 24V 6 2 9
OR
CPU 10A
SWITCH PANEL
CABIN LIGHT OUT 7 3
10
CABIN LIGHT OUT 8 4 CONVERTOR 5A

11
HEAD LIHGT 24V 9 5
OR SWITCH PANEL 5A
12
WORK LIGHT 24V 10 6
STARTER 10A
WORK LIGHT 24V 11 7 13
4-14
12 WIPER MOTOR 20A
WASHER SIG 8 14
13 10A
5
GND 9 HEAD LAMP
6
FUSE BOX
15
TRAVEL ALARM 14 10
WORK LAMP 10A
16
INT. SIG 15 11
R R R R CABIN LAMP 10A
CABIN LIGHT 24V 16 12 17
17 Y BEACON LAMP 5A
CABIN LIGHT 24V 18
AC & HEATER 20A

19
HORN 10A
20
1
CIGAR LIGHTER 10A

21
ETHER(PRE-HEAT) 10A
22
TRAVEL 5A
23
SOLENOID 1 10A
24
CN-8 SAFETY SOL 5A
25
1
SOLENOID 3 10A
2 26
Y Y FUEL FILLER P/P 10A
3
27
G G 10A
4 SPARE
CS-23 28
B 5
10
9 10 G
9 6
8 7
8
6 7 8
2 Y
6 9
7
5 5 10
1
4 11
2
3 12
G
2
1
16074EL09
BEACON LAMP SW
6. WIPER AND WASHER CIRCUIT
1) OPERATING FLOW
(1) Key switch ON
Fuse box (No.12) I/conn [CN-7(5)] Switch panel [CN-116(6)]
Fuse box (No.4) I/conn [CN-5(4)] I/conn [CN-17(5)] Wiper motor controller [CN-141(7)]
Wiper motor [CN-21(4)]
Fuse box (No.14) I/conn [CN-6(5)] l/conn [CN-17(4)] Wiper motor controller [CN-141(6)]
Washer pump [CN-22(2)]
(2) Wipe switch ON : 1st step(Intermittent)
Wiper switch ON [CN-116(15)] I/conn[CN-9(4)] I/conn[CN-6(10)] I/conn[CN-17(8)]
Wiper motor controller [CN-141(10) → (3)] Wiper motor intermittently operating [CN-21(6)]
(3) Wiper switch ON : 2nd step(Low speed)
Wiper switch ON [CN-116(4)] I/conn [CN-7(3)] I/conn [CN-6(9)] I/conn[CN-17(2)]
Wiper motor controller [CN-141(2) → (4)] Wiper motor operating [CN-21(2)]
(4) Washer switch ON
Washer switch ON [CN-116(12)] I/conn [CN-7(9)] I/conn [CN-5(1)] I/conn [CN-17(7)]
Wiper motor controller [CN-141(9) → (8)] I/conn [CN-17(6)] I/conn [CN-6(11)]
Washer operating [CN-22(1)]
Wiper switch ON [CN-116(4)] I/conn [CN-7(3)] I/conn [CN-6(9)] I/conn[CN-17(2)]
Wiper motor controller [CN-141(2) → (4)] Wiper motor operating [CN-21(2)]
(5) Auto parking(When switch OFF)
Switch OFF [CN-116(4)] Wiper motor parking position by wiper motor controller
2) CHECK POINT
① - GND(Fuse box)
24V
STOP ON 0~5V
④ - GND(Wiper Power input)
⑤ - GND(Wiper power output) 24V
⑥ - GND(Wiper motor) 0 or 24V
※ GND : Ground
4-15
WASHER CONTROL CIRCUIT
FUSE BOX
10
28
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
10A
10A
20A
10A
10A
10A
20A
10A
10A
10A
10A
10A
10A
10A
20A
10A
20A
10A
10A
5A
5A
5A
5A
5A
5A
5A
5A
5A
ETHER(PRE-HEAT)
CASSETTE RADIO
FUEL FILLER P/P

CIGAR LIGHTER
SWITCH PANEL
WIPER MOTOR
FUEL CUT-OFF
BEACON LAMP
AC & HEATER
AC & HEATER
CONVERTOR
SAFETY SOL
ROOM LAMP
WORK LAMP
CABIN LAMP
AC BLOWER
SOLENOID 1
SOLENOID 3
HEAD LAMP
START KEY
STARTER
CLUSTER
TRAVEL
WIPER+
CPU B+
SPARE
CN-46
HORN
CPU
1 2
CN-9
1
2
3
4
5
6
CN-116 7
HEAD LIGHT OUT 1 8
WORK LIGHT OUT 2
4
WORK LIGHT OUT 3 CN-7
WIPER MOTOR DRIVE 4 1
PRE-HEAT 5 2
POWER 24V 6 3
CABIN LIGHT OUT 7 4
CABIN LIGHT OUT 8 5
HEAD LIHGT 24V 9 6
WORK LIGHT 24V 10 7
WORK LIGHT 24V 11 8
WASHER SIG 12 9
GND 13 10
TRAVEL ALARM 14 11
INT. SIG 15 12
CABIN LIGHT 24V 16
CABIN LIGHT 24V 17
SWITCH PANEL
WIPER
CUT CN-6
CN-21
6 1
3 1 2
CS-53
2 3
5 3 4
4 5
4
5 6
6 M 2 6 7
8
9 CN-22
WIPER MOTOR
10 2 M
CN-141
11 1
FEED BACK 1
12 WASHER TANK
MOTOR DRIVE SIG 2 CN-17
MOTOR DRIVE- 3 1 CN-5
MOTOR DRIVE+ 4 2 1
GND 5 3 2
VCC 6 4 3
CONTINUE 24V 7 5 4
WASHER P/P 8 6 5
WASHER SIG. 9 7 6
INT. SIG 10 8 7
WIPER CUT SW 11 8
N.C 12 9
FEED BACK 13 10
11
WIPER MOTOR CONT. 7 12 16074EL10
4-16
6
3
M
CN-51
1
5
rp
WORKING PS 1
m
CN-75
P-
M-
NC
P+
M+
SIG
2
POWER MAX SW
1
2
-
S
h
GOV MOTOR
CD-17
TRAVEL ALARM SW
1
2
3
BR
OR
ACCEL DIAL
A
B
C
1
2
3
4
5
6
1
2
CN-142
CN-76
CN-48
L
Y
AIR CLEANER SW
B
B
TACHO SENSOR
16
W
W
V
HOUR METER
G/OR
OR
NC 17
W/OR
8
7
5
4
1
6
3
NC 18
CN-9
NC 19
B
B
GND (POT & DIAL) 20
W
BR
BR
OR
OR
Y
Y
L
L
G/OR
5V (POT & DIAL) 21
G/OR
W
POT-SIG 22
9
8
7
5
3
2
4
1
9
8
6
8
7
5
6
5
2
4
1
7
6
3
4
3
12
11
10
W
CN-5
CN-3
CN-2
ACCEL DIAL SIG 23
FUEL LEVEL SENSOR
Y
24
L
G
OR
L
OR
TACHO SENSOR(-) 25
Y
CONTROLLER CIRCUIT
TACHO SENSOR(+) 26
CPU CONTROLLER
NC 27
NC 28
NC 29
NC 30
GND (SENSOR) 31
NC 32
WATER TEMP SENDOR 33
HYD TEMP SENDOR 34
NC 35
NC 36
CN-50
CN-46
BOOM PRIORITY SOL 1
START KEY 20A
MAX FLOW SOL 2 1
ROOM LAMP 5A
POWER MAX SOL 3 2
W/OR
HOUR-METER 4 AC & HEATER 5A
3
ENG PREHEATER 5 WIPER+ 10A
4
NC 6
GY 5A
4-17
GY CPU B+
BATTERY 24V(+) 7 5
BR AC BLOWER 20A
PUMP EPPR(-) 8 6
NC 9 CLUSTER 10A
7
PROGRAM DUMP 10 CASSETTE RADIO 5A
FUSE BOX
8
ANTI-RESTART RY 11
OR CPU 10A
V
ACCEL ACT(+) 12 9
CONVERTOR 5A
TRAVEL SPEED SOL 13 10
NC 14 SWITCH PANEL 5A
11
NC 15 FUEL CUT-OFF 20A
12
TRAVEL BUZZER 16
PRE-HEAT SW 17 SPARE
27
NC 18 SPARE 20A
28
NC 19
OVERLOAD SIG 20
NC 21
NC 22
G
ACCEL ACT(-) 23
OR
POWER IG 24
NC 25
NC 26
NC 27
GND (MAIN) 28
SERIAL-TX 29
SERIAL-RX 30
GND 31
RS232 (+) 32
RS232 (-) 33
RS232 (GND) 34
NC 35
PUMP EPPR(+) 36
16074EL11
DC
2
1
1
2
HYD TEMP
CD-1
CD-2
FUEL LEVEL
CN-51
Pa
B
CLUSTER
CD-18
TX
RX
WORKING PS 1
GND
POWER IG(24V)
POWER MAX SW 2
ENG OIL PRESS

TRAVEL ALARM SW 3
DC
SENDOR
GY/W
ENG OIL PS 4
2
1
RR
CD-8
NC 5
WATER TEMP
NC 6
4
3
2
1
7
8
9
11
10
12
CN-56
CN-3
24V(PRES.SENSOR) 7
CN-46
L
Y
B
GND(PRES.SENSOR) 8
BR
START KEY 20A
MONITORING CIRCUIT
ALT LEVEL 9 1
GY/W
P1 PRESS SIG. ROOM LAMP 5A
10
2
1
2
L
Y
B
P2 PRESS SIG. 11 AC & HEATER 5A
SH
WATER LEVEL
CD-16
3
B
G
P3 PRESS SIG. 12
10A
B
WIPER+
4
2
NC
9
8
7
5
4
1
6
3
G/W
15
14
13
12
11
10
13
EARTH 1
CN-5
5A
8
7
5
4
1
6
3
CPU B+
O/T DECEL SW 14 5
CN-3
EARTH 2
L
20A
Y
B
WATER LEVEL SW 15 AC BLOWER
BR
SH
L 6
B
G
AIR CLEANER SW 16 FUEL CUT-OFF 10A
7
NC 17
BR CLUSTER 10A
NC 18 8
CASSETTE RADIO 5A
NC 19 9
GND (POT & DIAL) 20 CPU 10A

10
5V (POT & DIAL) 21 CONVERTOR 5A
11
POT-SIG 22
SWITCH PANEL 5A
ACCEL DIAL SIG 23 12
V STARTER 10A
CPU CONTROLLER
FUEL LEVEL SENSOR 24 13
TACHO SENSOR(-) 25 WIPER MOTOR 20A

14
4-18
TACHO SENSOR(+) 26 HEAD LAMP 10A
FUSE BOX
15
NC 27
WORK LAMP 10A
NC 28 16
CABIN LAMP 10A

NC 29 17
NC 30 BEACON LAMP 5A
B 18
GND (SENSOR) 31 AC & HEATER 20A
19
NC 32
G HORN 10A
WATER TEMP SENDOR 33 20
CIGAR LIGHTER 10A

HYD TEMP SENDOR 34 21
NC 35 ETHER(PRE-HEAT) 10A
22
B
NC 36 TRAVEL 5A
23
CN-50 SOLENOID 1 10A

24
Pa
PUMP EPPR(-) 8 SAFETY SOL 5A
CD-10
25
N.C 9
AIR CLEANER SW
BW SOLENOID 3 10A
PROGRAM DUMP 10 26
FUEL FILLER P/P 10A

11 27
10A
EARTH 1
NC SPARE
28
GND (MAIN) 28
Y
SERIAL-TX 29
L
SERIAL-RX 30
GND 31
R
RS232 (+) 32 CN-126
G BW
4
RS232 (-) 33
B R
3
RS232 (GND) 34
G
2
NC 35
B
1
NC 36
CONN
RS232
16074EL12
OVERLOAD SW QUICK COUPLING SW
1
2
8
7
9
1
2
8
7
9
I
10
5
6
5
6
10
B
3
7
9
2
6
1
4
5
8
10
3
7
9
2
6
1
4
5
8
A
10
CS-50
CS-67
C
B
2
1
2
1
Y
B
OR
OR
POWER MAX
CS-29
CS-19
SAFETY SW
CS-4
A
B
C
Y
B
B
1
2
8
ONE TOUCH DECEL

10
GY
L/W
Y
OR
CS-27
SIG
SIG
G
SIG
24V
24V
24V
OR
GND
GND
GND
5
6
R
R
G
G
R
G
W
W
W
9
BREAKER SW
3
7
9
2
6
1
4
5
8
1
2
3
10
1
2
3
1
2
3
PUMP3 PRESS
PUMP2 PRESS
PUMP1 PRESS
CD-42
CD-44
CD-43
B
V
R
R
R
B
GY
BR
B
GY
ELECTRIC CIRCUIT FOR HYDRAULIC
OR
GND
CD-7
INT. SIG
B
PRE-HEAT
Pa 1
POWER 24V
Y WASHER SIG
BREAKER
TRAVEL ALARM
WORK PS
SWITCH PANEL
1
2
HEAD LIHGT 24V
CABIN LIGHT 24V
OR
HEAD LIGHT OUT
CABIN LIGHT 24V

WORK LIGHT 24V
WORK LIGHT 24V
CABIN LIGHT OUT
CABIN LIGHT OUT
WORK LIGHT OUT
WORK LIGHT OUT
BREAKER
2
1
CS-26A
WIPER MOTOR DRIVE

CS-26
GY
GY
CD-37 CN-15 CN-15

GY
GY
Pa 1 2
B 17
16
15
14
13
12
11
10
Y
9
7
3
6
2
8
5
4
1
2 1
CN-116
CS-20 EARTH 1
B
SAFETY SW
OR/W
2PCS BOOM AUTO-IDLE PS
B
Y
B
Y
B
OR
G
OR
GY
L/W
GY
V
R
OR/W
W
B
BR
2
9
8
7
5
4
1
6
1
2
2
9
8
7
5
5
4
1
4
6
9
8
7
6
3
3
8
7
5
4
1
6
3
5
4
1
12
11
10
6
12
11
10
3
12
11
10
CD-1
CN-6
CN-7
CN-1
CN-4
CN-8
B
C 1
B
B
B
Y
G
2
GY
V
B
B
Y
BR/OR
G
OR
GY
BR
HYD TEMP
B/W
OR/W
OR
L/W
CN-51
WORKING PS 1
Y/W
Y
POWER MAX SW 2
TRAVEL ALARM SW 3
OR/W
ENG OIL PS 4
NC 5
NC 6
R
24V(PRES.SENSOR) 7
B
GND(PRES.SENSOR) 8
ALT LEVEL 9
P1 PRESS SIG. 10
B/W
BR
P2 PRESS SIG. 11
V
P3 PRESS SIG. 12
NC 13
GY
O/T DECEL SW 14
WATER LEVEL SW 15
AIR CLEANER SW 16
NC 17
NC 18
NC 19
GND (POT & DIAL) 20
5V (POT & DIAL) 21
POT-SIG 22
ACCEL DIAL SIG 23
CPU CONTROLLER
FUEL LEVEL SENSOR 24
TACHO SENSOR(-) 25
4-19
TACHO SENSOR(+) 26
NC 27
NC 28
NC 29
NC 30
B
GND (SENSOR) 31
NC 32
HORN 10A
WATER TEMP SENDOR 20
33
CIGAR LIGHTER 10A
HYD TEMP SENDOR 34 21
NC ETHER(PRE-HEAT) 10A
35 BR/OR 22
NC 36 TRAVEL 5A
Y
22
R SOLENOID 1 10A
CN-50 24
BOOM PRIORITY SOL 1 SAFETY SOL 5A
G/W R
25
FUSE BOX
MAX FLOW SOL 2

BR/W OR SOLENOID 3 10A
POWER MAX SOL 26
3
L/W FUEL FILLER P/P 10A
HOUR-METER 4 27
SPARE 10A
ENG PREHEATER 5
28
NC 6
BATTERY 24V(+) 7
PUMP EPPR(-) 8
NC 9
PROGRAM DUMP 10
ANTI-RESTART RY 11
ACCEL ACT(+) 12
W
TRAVEL SPEED SOL 13
NC 14
NC 15
TRAVEL BUZZER 16
V
PRE-HEAT SW 17
NC 18
NC 19
G
OVERLOAD SIG 20
NC 21
NC 22
B
ACCEL ACT(-) 23
L/W
B
Y
B
POWER IG
GY
24
NC 25
V
G
1
2
1
2
NC 26
CN-68
CN-66
Y
G
NC 27
2
1
1
CN-81
2
GND (MAIN) 28
1
2
SAFETY SOL
TRAVEL BZ
BREAKER SOL.
1
2
CN-140
SERIAL-TX 29
CN-55
CD-31
SERIAL-RX 30
QUICK COUPLING
G 2
Y 1
GND 31
Pa
RS232 (+)
OVERLOAD PS
32
RS232 (-) 33
RS232 (GND) 34
NC 35
NC 36
Y
Y
G
G
Y
Y
G
1
1
1
2
2
2
1
2
CN-70
CD-12
CD-13
CD-11
CD-14
W
1
Y
Pa
Pa
Pa
Pa
2
TRAVEL
CN-133
1
G/W
R
BOOM
CN-88
1
L/W
PRIORITY1 MAX
R
2
POWER
CN-137
1
BR/W
MAX
R
FLOW
2
16074EL13
GROUP 3 ELECTRICAL COMPONENT SPECIFICATION
Part name Symbol Specification Check
※ Check specific gravity

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

Rated load : 24V
Normal : About 50Ω
Battery relay 100A(continuity)
1000A(30second) ※ Check contact
Normal : ∞Ω
CR-1
※Check contact
Start key 24V 40A OFF : ∞Ω(For each terminal)
ON : 0Ω(For terminal 1-3 and 1-2)
START : 0Ω(For terminal 1-5)
CS-2
Pressure switch 1
Pa 3 ~ 6kgf/cm2 ※ Check contact
(For overload) 2 (N.O TYPE) Normal : ∞(OPEN)
CD-31
Pa
Pressure switch 0.5 kgf/cm2 ※ Check resistance
(For engine oil)
CD-18
(N.C TYPE) Normal : 0Ω(CLOSE)
4-20
※ Check resistance
1 C
Temperature 50°C : 804Ω
-
sensor 80°C : 310Ω
2
100°C : 180Ω
CD-1, CD-8
Pa Pressure: ※ Check contact

Air cleaner
635mmH2O
pressure switch Normal : ∞Ω
(N.O TYPE)
CD-10
2 ※ Check contact
Coolant level
sensor 24V 0.5A High level : ∞Ω
1
Low level : 0Ω
CD-16
Full : 50Ω 6/12 : 350
2 11/12 : 100Ω 5/12 : 400Ω
10/12 : 150Ω 4/12 : 450Ω
Fuel sender 1 - 9/12 : 200Ω 3/12 : 500Ω
8/12 : 250Ω 2/12 : 550Ω
CD-2 7/12 : 300Ω 1/12 : 600Ω
Empty warning :700Ω
1
m
rp
Tacho sensor 2 -
Normal : 300Ω(For terminal 1,2)
CD-17
1 2 1 ※ Check resistance
2 Normal : About 200Ω
Relay 24V 20A
3 (For terminal 1-3)
4 4 3 : 0Ω(For terminal 2-4)
4-21
30
87a 87 85
86 ※ Check resistance
87
Normal : About 160Ω
85
Relay 87a
30 86 24V 16A (For terminal 85-86)
CR-2 CR-35 : 0Ω(For terminal 30-87a)
CR-5 CR-36 : ∞Ω(For terminal 30-87)
CR-7
M- 6
6 5
M M+ 5
NC 4
2
P- 3 Normal : 1-2Ω(For terminal 5-6)
Accel actuator 3 1 -
SIG 2 0.8-1.2kΩ
P+ 1 (For terminal 1-3)
CN-76
2
Solenoid valve 1 24V 1A Normal : 15~25Ω
(For terminal 1-2)
CN-66 CN-68 CN-70 CN-88
CN-133 CN-137 CN-140
2 ※ Check resistance
EPPR valve 700mA Normal : 18~25Ω
1 (For terminal 1-2)
CN-75
1
Prolix resistor 50Ω 20W± 5%
Normal : 50Ω
2
CN-47
2
1 ※Check resistance
Speaker 4Ω 20W
Normal : 4Ω
CN-23(LH)
CN-24(RH)
4-22
※ Check contact
10 9 8 7 6 5 4 3 2 1
10 6 5
Normal
Switch ON - 0Ω(For terminal 1-5,2-6)
(Looking type) 24V 8A
9 8 2 7 1
- ∞Ω(For terminal 5-7,6-8)
CS-23, CS-27, CS-50, OFF - ∞Ω(For terminal 1-5,2-6)
CS-52, CS-54 - 0Ω(For terminal 5-7,6-8)
8
2
7
9
1 ※ Check contact
I
Normal
ON - 0Ω(For terminal 1-5,2-6)
Switch 24V 8A
- ∞Ω(For terminal 5-7,6-8)
5
10
10 OFF - ∞Ω(For terminal 1-5,2-6)
9
3
7
2
6
1
4
5
CS-67 - 0Ω(For terminal 5-7,6-8)
24V 70W ※ Check disconnection

Lamp 1 (H3 TYPE) Normal : 1.2Ω
CL-4, CL-5, CL-6,
CL-8, CL-9
1
※ Check disconnection
Room lamp 2 24V 10W
Nomal : A few Ω
CL-1
1 M 24V 10A ※ Check resistance

Fuel filler pump 35 ℓ/min
2 Normal : 1.0Ω
CN-61
1 ※ Check operation
h ・Supply powe(24V) to
Hour meter 2
16V ~ 32V
terminal No. 2 and connect
terminal No. 1 and ground.
CN-48
4-23
※ Check operation
DC 22.0 ~ 28.0V
Horn ・Supply powe(24V) to each
2A
terminal and connect ground.
CN-20 CN-25
※ Check contact
B C A Normal : 0Ω(For terminal A-B)
24V 15A
Safety switch 1 B : ∞Ω(For terminal A-C)
(N.C TYPE)
A C Operating : ∞Ω(For terminal A-B)
CS-4 : 0Ω(For terminal A-C)
24V ※ Check contact

Safety switch 2 (N.C TYPE) Normal : 0Ω(one pin to ground)
CS-20
E 3
Fuel cut-off S 2 24V
Normal : 15~25Ω
I 1
CN-79
Pa 2 10bar ※ Check contact

Pressure switch
(N.C type) Normal : 0.1Ω
1
CD-7
※ Check disconnection
Beacon lamp 24V 70W
Normal : 1.1Ω
CL-7
4-24
Switch
(Power max, 1
※Check contact
One touch 24V 6A
decal, Breaker, 2 Normal : ∞Ω
Horn) CS-5 CS-19
CS-26 CS-29
2 M
※Check contact
Washer pump 1 24V 3.8A
Normal : 10.7Ω(For terminal 1-2)
CN-22
※Check coil resistance

Normal : About 1MΩ
Cigar lighter 24V 5A 1.4W ※ Check contact
Normal : ∞Ω
Operating time : 5~15sec
CL-2
※Check resistance
Switch 24V 2W
Normal : About 5MΩ
CS-1, CS-20,
CS-53
3 1
2
5 3
4
4 ※Check contact
Wiper motor 5 24V 2A
Normal : 7Ω(For terminal 2-6)
6 M 2 6
CN-21
N.C 1
S.R- 2
S.R- 3
S.L- 4
S.L-
N.C
5
6
※ Check voltage
Cassette radio ILL+
S.R+
7
8
24V 2A 20 ~ 25V
S.R+ 9
ACC
B+
10
11
(For terminal 10-14,11-14)
S.L+ 12
CN-27 S.L+
GND
13
14
4-25
2 Pa
※ Check contact
Receiver dryer 1 24V 2.5A
Normal : 0Ω
CN-29
Start relay ※ Check contact

24V 300A
Normal : 0.94Ω(For terminal 1-2)
CR-23
M
M
Delco Remy ※ Check contact
Starter 28MT 24V Normal : 0.1Ω
B+
CN-45
G B+
※ Check contact
~ 3
Alternator I 24V 60A Normal : 0Ω(For terminal B⁺-1)
U
GND Normal : 24 ~ 27.5V
CN-74
1 ※ Check contact
Travel alarm 24V 0.5A
2 Normal : 5.2Ω
CN-81
1
※ Check contact
Compressor 24V 79W
Normal : 13.4Ω
CN-28
4-26
Normal : About 5KΩ
(For terminal A-C)
A +
※ Check valtage
Accel dial B S - Normal : About 5V
C - (For terminal A-C)
CN-142 : 2 ~ 4.5V
(For terminal C-B)
3 24V
2 SIG 0bar : 1V(For terminal 1-2)
Transducer 500 bar
1 GND 500bar : 5V(For terminal 1-2)
CD-42, CD-43
3 24V
0bar : 1V(For terminal 1-2)
2 SIG
Transducer 50 bar 50bar : 5V(For terminal 1-2)
1 GND
CD-44
A 24V
24V
DC/DC B GND 24V(A-B)
12V 3A
Converter C 12V 12V 12V(B-C)
CN-138
1 M ※ Check resistance
Blower motor 24V 9.5A
2.5Ω(For terminal 1-2)
2
1 Lo 1 ※ Check resistance
2 MH 3 1.12Ω(For terminal 4-2)
Resistor -
3 ML 2 2.07Ω(For terminal 2-3)
4 Hi 4 3.17Ω(For terminal 3-1)
4-27
Duct sensor 1
1°
C OFF ※ Check resistance
(Switch) 2 4°
C ON : 0Ω(For terminal 1-2,
the atmosphere temp : over 4°
C)
※ Check contact
Preheater 24V 200A Normal : 0.94Ω
relay
(For terminal 1-GND)
CN-24
※ check resistance
Preheater 24V 200A
: 0.25 ~ 0.12Ω
4-28
GROUP 4 CONNECTORS
1. CONNECTOR DESTINATION
Connector No. of Connector part No.
Type Destination
number pin Female Male
CN-1 - 6 Pump pressure harness S816-006002 S816-106002
CN-2 AMP 8 Engine rear harness S816-008002 S816-108002
CN-3 AMP 12 Engine front harness S816-012002 S816-112002
CN-4 AMP 8 Cabin LH wire harness S816-008002 S816-108002
CN-5 - 15 RH side harness - 2-85262-1
CN-6 AMP 12 RH side harness S816-012002 S816-112002
CN-7 - 15 Cabin RH wire harness - 2-85262-1
CN-8 AMP 12 Cabin RH wire harness S816-012002 S816-112002
CN-9 AMP 8 Cabin RH wire harness S816-008002 S816-108002
CN-10 DEUTSCH 12 Frame harness DT06-12S DT06-12P
CN-11 DEUTSCH 8 Cabin LH wire harness DT06-8S -
CN-12 DEUTSCH 2 Work lamp harness DT06-2S-P012 DT04-2P-P012
CN-13 DEUTSCH 2 Quick coupling harness DT06-2S-P012 DT04-2P-P012
CN-15 KET 2 Two way S814-002100 S814-102100
CN-17 DEUTSCH 8 Wipe harness DT06-8S DT04-8P
CN-19 - 2 EPPR control S816-102002 -
CN-19A - 2 Normal control S816-002002 -
CN-19B - 2 Emergency control S816-002002 -
CN-20 MOLEX 2 Horn 36825-0211 -
CN-21 AMP 6 Wiper motor 925276-0 -
CN-22 - 2 Washer tank MG640605 -
CN-23 KET 2 LH speaker MG610070 7322-1520
CN-24 KET 2 RH speaker MG610070 7322-1520
CN-25 MOLEX 2 Horn 36825-0211 -
CN-27 AMP 14 Cassette radio 173852 AMP14P
CN-28 - 1 Air-con comp MWP-01F-B -
CN-29 KET 2 Receiver dryer MG640795 -
CN-45 RING TERM 1 Starter S820-510000 -
CN-47 AMP 2 Emergency resistor S810-002202 -
CN-48 - 2 Hour meter S810-002202 -
CN-50 AMP 36 CPU 3441110 -
CN-51 AMP 36 CPU 3441110 -
CN-56 DEUTSCH 4 Cluster - DT04-4P
CN-60 - 2 Fusible link 7122-4125-50 -
CN-61 DEUTSCH 2 Fuel filler pump DT06-2S-P012 DT01-2P-P012
CN-66 DEUTSCH 2 Breaker solenoid valve DT06-2S-P012 DT01-2P-P012
CN-68 DEUTSCH 2 Safety solenoid valve DT06-2S-P012 -
CN-70 DEUTSCH 2 Travel speed solenoid valve DT06-2S-P012 -
4-29
Type Destination
CN-74 TERM 1 Alternator S820-105000 -
CN-75 - 2 EPPR valve S816-002002 -
CN-76 DEUTSCH 6 Accel actuator DT06-6S -
CN-78 KET 2 Water level S814-002100 -
CN-79 - 3 Fuel cut-off S818-020311 -
CN-81 DEUTSCH 2 Travel buzzer DT06-2S-P012 DP04-2P-P012
CN-88 DEUTSCH 2 Power max solenoid valve DT06-2S-P012 -
CN-91 DEUTSCH 2 Over load harness DT06-2S DT04-2P
CN-92 AMP 1 Safety S814-101100 S814-001100
CN-116 - 17 Switch panel S811-017002 -
CN-126 DEUTSCH 4 RS232C connector DT06-4S DT04-4P-E004
CN-133 DEUTSCH 2 Boom priority solenoid valve DT06-2S-P012 -
CN-137 DEUTSCH 2 Max flow solenoid valve DT06-2S-P012 -
CN-138 DEUTSCH 3 DC/DC converter DT06-3S DT04-3P
CN-139 DEUTSCH 2 12V Socket - DT04-2P
CN-141 AMP 13 Wiper motor control unit 172498-1 -
CN-142 DEUTSCH 3 Accel dial DT06-3S -
CN-143 KET 14 Cassette radio MG610406 -
CN-144 AMP 12 Remocon 174045-2 -
RELAY
CR-1 RING TERM 1 Battery relay S820-104002 -
CR-23 - 2 Start relay S814-102001 -
CR-24 - 1 Pre-heater relay S822-014000 -
CR-43 DEUTSCH 4 Engine stop relay DT06-4S -
SWITCH
CS-1 CB104 1 Door switch S822-014004 -
CS-2 - 6 Start key switch S814-006000 -
CS-4 DEUTSCH 3 Safety switch DT06-3S -
CS-5 DEUTSCH 2 Horn switch DT04-2P
CS-19 DEUTSCH 2 One touch decel DT06-2S DT04-2P
CS-20 AMP 1 Safety switch S822-014002 -
CS-23 SWF 10 Beacon lamp switch SWF593757 -
CS-26 DEUTSCH 2 Breaker switch DT06-2S -
CS-27 SWF 10 Breaker switch SWF593757 -
CS-29 DEUTSCH 2 Power max DT06-2S DT04-2P
CS-50 SWF 10 Quick coupling switch SWF593757 -
CS-52 SWF 10 Spare switch SWF593757 -
CS-53 AMP 1 Wiper cut switch S822-014002 -
CS-54 SWF 10 Spare switch SWF593757 -
CS-67 SWF 10 Overload switch SWF593757 -
4-30
Type Destination
LAMP
CL-1 KET 2 Cabin room lamp MG610392 -
CL-2 - 1 Cigar light S822-014002 -
CL-4 DEUTSCH 2 Head lamp - DT04-2P-P012
CL-5 DEUTSCH 2 Work lamp-LH - DT04-2P
CL-6 DEUTSCH 2 Work lamp-RH - DT04-2P
CL-7 CB104 1 Beacon lamp S822-014004 -
CL-8 DEUTSCH 2 LH cabin light - DT04-2P
CL-9 DEUTSCH 2 RH cabin light - DT04-2P
SENDER
CD-1 AMP 2 Hydraulic Temp sender 85202-1 -
CD-2 DEUTSCH 2 Fuel sender DT06-2S-P012 -
CD-6 KET 3 Travel pressure switch MG640795 -
CD-7 KET 2 Working pressure switch MG640795 -
CD-8 - 2 Water temp sender 85202-1 -
CD-10 RING TERM 1 Air cleaner switch S820-104002 -
CD-17 - 2 Tacho sensor - S818-120221
CD-18 RING TERM 1 Engine oil pressure switch S820-104000 -
CD-31 DEUTSCH 2 Overload pressure switch DT06-2S-P012 -
CD-42 AMP 3 Pump 1 pressure switch S816-003002 -
4-31
2. CONNECTION TABLE FOR CONNECTORS
1) PA TYPE CONNECTOR
No. of
pin Receptacle connector(Female) Plug connector(Male)
2 5 1 3
1 3 2 5
S811-005002 S811-105002
3 7 1 4
1 4 3 7
S811-007002 S811-107002
4 9 1 5
1 5 4 9
S811-009002 3S811-109002
5 11 1 6
11
1 6 5 11
S811-011002 S811-111002
4-32
No. of
Receptacle connector(Female) Plug connector(Male)
pin
6 13 1 7
13
1 7 6 13
S811-013002 S811-113002
8 1 9
17
17
1 9 8 17
S811-017002 S811-117002
10 21
1 11
21
1 11 10 21
S811-021002 S811-121002
4-33
2) J TYPE CONNECTOR
No. of
pin
1 2
1
2 12
S816-002001 S816-102001
2 3 1
3 1 2
S816-003001 S816-103001
3 1 4 2
4 2 3 1
S816-004001 S816-104001
8 5 2
6 3 1
8 5 2 6 3 1
S816-008001 S816-108001
4-34
3) SWP TYPE CONNECTOR
No. of
pin
1 1
S814-001000 S814-101000
2 1
1 2
S814-002000 S814-102000
3 1
2 1 23
S814-003000 S814-103000
2 4 1 3
1 3 2 4
S814-004000 S814-104000
4-35
No. of
pin Receptacle connector(Female) Plug connector(Male)
3 6
1 4
1 4 3 6
S814-006000 S814-106000
4 8
1 5
1 5 4 8
S814-008000 S814-108000
4 12
1 9
12
4 12
1 9
S814-012000 S814-112000
3 14
1 11
14
1 11 3 14
S814-014000 S814-114000
4-36
4) CN TYPE CONNECTOR
No. of
pin
1 1
S810-001202 S810-101202
2 2
1 1
S810-002202 S810-102202
3 2
1 2 1 3
S810-003202 S810-103202
2 4 1 4
1 3 2 3
S810-004202 S810-104202
4-37
No. of
pin
3 6 1 4
1 4 3 6
S810-006202 S810-106202
4 8 1 5
1 5 4 8
S810-008202 S810-108202
4-38
5) 375 FASTEN TYPE CONNECTOR
No. of
pin
1 2 1 2
S810-002402 S810-102402
6) AMP ECONOSEAL CONNECTOR

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

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

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

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

No. of
pin
1
2
MG640605
2 1
MG640795
4-41
13) KET SDL CONNECTOR
No. of
pin
1
14
14 6
MG610406
4-42
14) DEUTSCH DT CONNECTORS
No. of
pin
1 2 2 1
2
DT06-2S DT06-2P
2 1 1 2
3 3
DT06-3S DT06-3P
4 1 1 4
3 2 2 3
DT06-4S DT06-4P
6 1 1 6
4 3 3 4
DT06-6S DT06-6P
4-43
No. of
pin
4 5 5 4
1 8 8 1
DT06-8S DT06-8P
6 7 7 6
12
1 12 12 1
DT06-12S DT06-12P
4-44
15) MOLEX 2CKTS CONNECTOR
No. of
pin
1 2
35215-0200
16) ITT SWF CONNECTOR

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

No. of
pin
1
1
NMWP01F-B
4-45
Group 1 Outline 5-1

Group 2 Mode Selection System 5-3
Group 3 Automatic Deceleration System 5-6
Group 4 Power Boost System 5-7
Group 5 Travel Speed Control System 5-8
Group 6 Automatic Warming Up Function 5-9
Group 7 Engine Overheat Prevention Function 5-10
Group 8 Anti-Restart System 5-11
Group 9 Self-Diagnostic System 5-12
Group 10 Engine Control System 5-14
Group 11 EPPR(Electro Proportional Pressure Reducing) Valve 5-21
Group 12 Prolix Switch 5-24
Group 13 Monitoring System 5-25
GROUP 1 OUTLINE
The NEW CAPO(Computer Aided Power Optimization) system controls engine and pump mutual
power at an optimum and less fuel consuming state for the selected work by mode selection, auto-
deceleration, power boost function, etc. It monitors machine conditions, for instance, engine speed,
coolant temperature, hydraulic oil temperature, and hydraulic oil pressure, etc.
It consists of a CPU controller, a cluster, an accel actuator, an EPPR valve, and other components.
The CPU controller and the cluster protect themselves from over-current and high voltage input, and
diagnose malfunctions caused by short or open circuit in electric system, and display error codes on the
cluster.
Engine control system

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

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

Self-diagnostic system
Open-short diagnosis & error code display
Machine condition monitoring
Machine monitoring system
Electric signal monitoring
One touch deceleration system
Arm regeneration system
5-1
SYSTEM DIAGRAM
16075MS01
5-2
GROUP 2 MODE SELECTION SYSTEM
1. POWER MODE SELECTION SYSTEM

Main control valve
Engine speed
sensor
Engine
Main pump Pilot pump
Accel Max flow

Fuel injection actuator CO valve
pump
P M
EPPR valve
Engine speed sensor signal

Potentiometer signal
Motor drive signal
Work mode switch signal
Power mode switch signal CPU controller
User mode switch signal Accel dial signal
Accel dial
Drive signal
Normal Emergency
Resistor Battery
Option
16075MS02
Mode selection system(Micro computer based electro-hydraulic pump and engine mutual control
system) optimizes the engine and pump performance.
The combination of 2 power modes(H, S) and accel dial position(10 set) makes it possible to use the
engine and pump power more effectively corresponding to the work conditions from a heavy and
great power requesting work to a light and precise work.
Engine rpm Power shift by EPPR valve

Default Other case Default Other case
Mode Application
Current Pressure Current Pressure
Unload Load Unload Load
(mA) (kgf/cm2) (mA) (kgf/cm2)
M Maximum power 2200 2000 2200 2000 219±30 4 130 0
H High power 2000±50 1800 2100 1900 310±30 10 219 4
S Standard power 1900±50 1700 2000 1800 310±30 10 350 12
AUTO DECEL Engine deceleration 1200±100 - 1200±100 - 600±30 30 600±30 30
One touch decel Engine quick deceleration 950±100 - 950±100 - 700±30 35 700±30 35
KEY START Key switch start position 950±100 - 950±100 - 700±30 35 700±30 35
5-3
2. WORK MODE SELECTION SYSTEM
3 work modes can be selected for the optional work speed of the machine operation.
Main control valve
Extra C
Extra B Bucket
(Dozer)
Extra A & Swing priority
Arm 1
Arm regen solenoid valve
Boom 2 Arm 2
S/Priority Power boost
solenoid valve
Swing Boom 1
Max flow CO
Travel(RH) Travel(LH) solenoid valve
Straight
Travel Main relief
valve
Engine speed
sensor
Engine
Coolant
temp sensor
Accel Max flow

Fuel injection Hyd temp
actuator CO valve
pump sensor
P M
EPPR valve
Engine speed sensor signal
Motor drive signal
Hyd temperature signal
Coolant temperature signal Drive signal

CPU controller Drive signal
Drive signal
Accel dial signal
Accel dial
Serial Communication(-)
Drive signal
Serial Communication(+)
Normal Emergency
Resistor
Option
Cluster 16075MS03
1) HEAVY DUTY WORK MODE

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

Heavy duty OFF OFF
General ON OFF
Breaker OFF ON
5-4
3. USER MODE SELECTION SYSTEM
Through 2 memory sets of MI and MII, an operator can change the engine and pump power and
memorize it for his preference.
Mode Operation
U High idle rpm, auto decel rpm

EPPR pressure can be modulated and memorized separately
HOW TO MODULATE THE MEMORY SET

1) Each memory mode has a initial set which are
mid-range of max engine speed, auto decel rpm,
and EPPR valve input current. When you select
MI or MII, cluster LCD displays.
2) To change the engine high idle speed, press the
USER mode switch and SELECT switch at the 21074OP03G
same time and then ACCEL blinks at 0.5 seconds
interval.
- By pressing or switch, will increase or
decrease.
3) To change DECEL rpm, press the USER mode
switch and SELECT switch once more and then
DECEL blinks at 0.5 seconds interval.
decrease.
4) To change EPPR current, press the USER mode
switch and SELECT switch one more and then
EPPR blinks at 0.5 seconds interval.
decrease.
・ LCD segment vs parameter setting
Segment ACCEL DECEL EPPR
( ) (rpm) (rpm) (mA)
1 High idle-750 Low idle(950) 150
2 High idle-700 1000 200
3 High idle-650 1050 250
4 High idle-600 1100 300
5 High idle-500 1150 350
6 High idle-400 Decel rpm(1200) 400
7 High idle-300 1250 450
8 High idle-200 1300 500
9 High idle-100 1350 550
10 High idle 1400 600
5) To memorize the final setting, press the USER
mode switch and SELECT switch one more time. 21074OP03H
5-5
GROUP 3 AUTOMATIC DECELERATION SYSTEM
Work equipment
pressure switch Travel oil pressure switch
Accel
Fuel injection actuator
pump
P M
Main control valve
Motor drive signal
Auto decel switch signal Pressure switch signal

CPU controller
Accel dial signal
Accel dial
21075MS04
1. WHEN AUTO DECEL LAMP ON

If all the work equipment control levers including swing and travel levers are at neutral for at least 4
seconds, CPU controller drives the governor motor to reduce the engine speed to 1200rpm. As the
result of reducing the engine speed, fuel consumption and noise are effectively cut down during non-
operation of the control levers.
When the Auto decel lamp is turned off by pressing the switch or any control lever is operated, the
reduced engine speed rises upto the speed set before deceleration in a second.
Engine rpm
Accel dial set rpm
1200 rpm
Max Max
4sec 1.5sec 1.5sec
Lever Lever Time

neutral operation
21075MS05
2. WHEN AUTO DECEL LAMP OFF

The engine speed can be set as desired using the engine speed switch, and even if the control levers
are neutral, the engine speed is not reduced.
Note : Auto decel function can be activated when accel dial position is over 4.
5-6
GROUP 4 POWER BOOST SYSTEM
21075MS06
・ When the power boost switch on the left control lever knob is pushed ON, the maximum digging
power is increased by 10%.
・ When the power set is at H or S and the power boost function is activated, the power boost solenoid
valve pilot pressure raises the set pressure of the main relief valve to increase the digging power.
Power boost switch

Description
OFF ON
Power set H or S H
Main relief valve set pressure 330kgf/cm2 360kgf/cm2
Even when pressed continuously,
Time of operation -
it is canceled after 8 sec.
※ Default - Power boost solenoid valve : OFF
5-7
GROUP 5 TRAVEL SPEED CONTROL SYSTEM
Travel motor
Main control valve
Extra C
Extra B Bucket
(Dozer) Regulator Regulator
Extra A &
Arm 1
Arm regen
Boom 2 Arm 2
S/Priority
Swing Boom 1
Travel(RH) Travel(LH)
Straight
Travel
Travel spped
solenoid valve
Engine
Max flow
CO valve
EPPR valve
Travel speed switch signal Drive signal

CPU controller
14075MS07
Travel speed can be switched manually by pressing the travel speed switch on the cluster.
Travel speed Lamp
Speed Operation
solenoid valve on cluster
Lo OFF Turtle Low speed, high driving torque in the travel motor
Hi ON Rabbit High speed, low driving torque in the travel motor
※ Default : Turtle(Lo)
5-8
GROUP 6 AUTOMATIC WARMING UP FUNCTION
Engine
Coolant
temp sensor
Accel Max flow

pump
P M
Coolant temperature signal
EPPR valve
Motor drive signal
Drive signal
Warming up lamp signal

CPU controller
140W75MS08
1. CPU controller reads engine coolant temperature through the temperature sensor, and if the coolant
temperature is less than 30°
C, it increases the engine speed from key start rpm to 1200rpm. At this
time the mode does not change.
2. In case of the coolant temperature increases up to 30°
C,the engine speed is decreased to key start
speed. And if an operator changes mode set during the warming up function, the CPU controller
cancels the automatic warming up function.
3. LOGIC TABLE
Description Condition Function

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

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

C - Warming up lamp : OFF
5-9
GROUP 7 ENGINE OVERHEAT PREVENTION FUNCTION
Engine
Coolant
temp sensor
Accel Max flow

pump
P M
EPPR valve
Coolant temperature signal
Motor drive signal
Drive signal
Overheat warming signal

CPU controller
140W76MS09
1. CPU controller reads engine coolant temperature through the temperature sensor and when the
engine coolant boils up to 110°
C, it sends overheat warning signal to the cluster and decrease the
engine speed same as accel dial 7 position.
2. If the coolant temperature drops less than 100°C, the CPU controller returns the mode to the mode
set before. And if mode set is changed during the function, the CPU controller cancels the function.
Even if the overheat prevention function is canceled by mode change, the overheat warning lamp
turns OFF only when the coolant temperature is less than 100° C.
3. LOGIC TABLE
Description Condition Function
- Coolant temperature : Above 110°

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

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

CHECK Er : 0 3
Press Press Press

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

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

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

Select recorded error(TIME Er) display and press engine and select switch at the same time for
2 seconds or more. Cluster display changes to TIME Er : 00, which shows that CPU controller
deleted all the recorded error codes in the memory.
5-12
5. ERROR CODES TABLE
Fault code No. Description
1 Short circuit in governor motor system
2 Potentiometer circuit is shorted to Vcc(5V) or battery +
3 Short circuit in pump EPPR valve system
5 Short circuit in travel speed solenoid system
6 Short circuit in power boost solenoid system
7 Short circuit in max flow solenoid system
10 Short circuit in hour-meter system
11 Accel dial circuit is shorted to Vcc(5V) or battery +
12 P1 pressure sensor circuit is shorted to power supply(24V) line
16 Governor motor circuit is open or shorted to ground
17 Potentiometer circuit is open or shorted to ground
18 Pump EPPR valve circuit is open or shorted to ground
20 Travel speed solenoid circuit is open or shorted to ground
21 Power boost solenoid circuit is open or shorted to ground
22 Max flow solenoid circuit is open or shorted to ground
25 Hour-meter circuit is open or shorted to ground
26 Accel dial circuit is open or shorted to ground
27 P1 pressure sensor circuit is open or shorted to ground
31 Engine preheater circuit is open or shorted to ground
32 Travel alarm buzzer circuit is open or shorted to ground
33 Alternator circuit is open or shorted to ground
34 Controller input voltage is below 18V
35 Controller input voltage is over 38V
36 Communication error with cluster
37 Engine speed sensor circuit is open or shorted to ground
39 Accel actuator does not stop at a target position
40 There is more than 500rpm difference between target speed and actual speed
41 Hydraulic oil temperature sensor circuit is shorted to ground
42 Fuel level sensor circuit is shorted to ground
43 Coolant temperature sensor circuit is shorted to ground
44 Boom up pressure sensor circuit is shorted to power supply(24V) line
45 Hydraulic oil temperature sensor circuit is open or shorted to battery +
46 Fuel level sensor circuit is open or shorted to battery +
47 Coolant temperature sensor circuit is open or shorted to battery +
48 Boom up pressure sensor circuit is open or shorted to ground
49 Engine preheater circuit is shorted to battery +
51 Boom priority solenoid circuit is open or shorted to ground
56 Travel alarm buzzer circuit is shorted to battery +
58 Boom priority solenoid circuit is shorted to battery +
5-13
GROUP 10 ENGINE CONTROL SYSTEM
1. CPU CONTROLLER MOUNTING
1 CPU controller
2 Electric box
3 Bolt(M8)
14075MS11
2. CPU CONTROLLER ASSEMBLY

1) Remove four pieces of bolt(3) of electric box(2).
2) Disconnect 2 connectors from CPU controller.
3) Remove 6 pieces of screw and open the cover of CPU controller.
4) Inspection : Check PCB(Printed Circuit Board)
(1) If any damage is found, replace CPU controller assembly.
(2) If not, but CAPO system does not work please report it to HHI dealer or A/S department.
5-14
3. EXCHANGE METHOD OF THE ROM
1) Disassemble the ash tray(2).
2) Disassemble the wiper motor cover(3).
3) Disassemble the cluster(1).
21075MS12
4) Loosen the screws(6EA) located back of

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

and assmelbe the cluster in the reverse
order to removal).
21075MS14
5-15
4. ENGINE ACCEL ACTUATOR
1 Accel actuator
2 Push-pull cable for manual control
17W75MS08
1) ENGINE THROTTLE LEVER
Throttle lever
SL : Stopper, low idle
SH : Stopper, high idle
SL SH
Accel actuator
5-18(2) 140-7 TIER
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 accel actuator happen.
5-16
3) ACCEL ACTUATOR
2 4
1
5-19(1) 140-7 TIER
5
1 DC motor
2 Cable
3 Nut
4 Ball joint
5 Connector
6 1
Connector 5 2
4 3
Type 6P, female

1 White(Potentiometer 5V)
2 Blue(Potentiometer SIG)
Line color 3 Black(Potentiometer GND)
& description 4 -
5 Green(Motor+)
6 Yellow(Motor -)
Check resistance
Inspection Spec : 1~2Ω(Between No.5-6)
0.8~1.2kΩ(Between No.1-3)
5-17
4) ACCEL ACTUATOR CABLE SETTING PROCEDURE
(1) Key OFF
① Connect the ball joint of cable to engine throttle lever.
② Pull the cable to high stopper and put nut A edge to yoke of the bracket.
※ Make throttle lever not contact to the edge of high stopper.
③ Turn nut A to clockwise until touching to the edge of high stopper.
④ Make 1 turn more to clockwise in condition of the nut A contact to the edge of high stopper.
(2) Key START
⑤ Confirm if the engine speed on cluster is same as each mode specification.
⑥ If the engine speed displayed on cluster is highter than each mode specification, then turn the nut
A to counter clockwise and make the engine speed same to each mode specification.
⑦ If the engine speed displayed on cluster is lower than each mode specification, then turn the nut
A to clockwise and make the engine speed same to each mode specification.
⑧ Turn nut B to clockwise and fix the cable to bracket.
Nut A Nut B Ball joint Throttle lever
Hi Lo
Cable Bracket
130W5MS05
Mode RPM
M 2200±50
H 2000±50
S 1900±50
Auto decel 1200±100
Key start 950±100
5-18
5. ENGINE SPEED SENSOR
1) DETECT ACTUAL ENGINE RPM AND SEND SIGNAL TO TACHOMETER
Speed sensor
Flywheel housing
18075MS20
2) INSTALLATION
(1) Clean contacting point of sensor.
(2) Screw speed sensor into flywheel housing.
(3) Turn it back 180。when it contacts with gear teeth.
3) INSPECTION
(1) Check resistance
·SPEC : 2.3±0.2 kΩ(at 25。
C)
(2) Check voltage while engine run.
·SPEC : 10Vac or over, dependent on the engine speed(rpm)
5-19
6. CPU CONTROLLER
(1) To match the engine torque with the pump absorption torque, CPU
LED controller varies EPPR valve output pressure, which control pump
discharge amount whenever feedbacked engine speed drops under
the reference rpm of each mode set.
YR
G
(2) Three LED lamps on the CPU controller display as below.
MO
PA DEL
RT :R
NO OB
:21 EX
N8 290
-32 LC
LED lamp Trouble Service

10 -7
2
G is turned ON Normal -
29073CD72
R is turned ON Trouble on CPU ・ Change the controller
G and Y are Trouble on serial ・ Check if serial communication

turned ON communication line lines between controller and
cluster are disconnected
Three LED are Trouble on CPU ・ Check if the input power wire
turned OFF controller power (24V, GND) of controller is
disconnected
・ Check the fuse
G : green, R : red, Y : yellow
5-20
GROUP 11 EPPR VALVE
1. COMPOSITION OF EPPR VALVE

EPPR(Electro Proportional Pressure Reducing) valve consists of electro magnet and spool valve
installed at main hydraulic pump.
1) ELECTRO MAGNET VALVE
Receive electric current from CPU controller and move the spool proportionally according to the
specific amount of electric current value.
2) SPOOL VALVE
Is the two way direction control valve for pilot pressure to reduce hydraulic pump flow.
When the electro magnet valve is activated, pilot pressure enters into flow regulator of hydraulic pump.
So, pump flow decreases to prevent engine stall.
3) PRESSURE AND ELECTRIC CURRENT VALUE FOR EACH MODE
Pressure Electric current Engine rpm
Mode
kgf/cm
2
psi (mA) (At accel dial 10)
M 4±3 57 ± 40 219 ± 30 2200 ± 50

Standard
H 10 ± 3 142 ± 40 310 ± 30 2100 ± 50
(Ver : 1.x)
S 10 ± 3 142 ± 40 310 ± 30 2000 ± 50
M 0±3 0 ± 40 130± 30 2200 ± 50
Option
H 4±3 57 ± 40 219 ± 30 2100 ± 50
(Ver : 2.x)
S 12 ± 3 170 ± 40 350 ± 30 2000 ± 50
★ 19 ± 3 275 ± 40 440 ± 30 -
★ Manually operated condition when prolix switch is selected emergency position.
2. HOW TO SWITCH THE VERSION(1.x ↔ 2.x) ON THE CLUSTER

You can switch the EPPR valve pressure set by selecting the version(1.x ↔ 2.x).
Step 1. Turn the key switch ON.
Step 2. Press the SELECT switch 3 times.
Step 3. While 7 segment on the cluster shows the version of the CPU controller program, for example
16C1.1 press the buzzer stop switch( ) + travel speed control switch( ) at the same
time for 2 seconds.
The display changes to 16C1.1, and it indicates that version 2.1(Option) is selected.
※ If you want to get back to ver:1.x, go to step 1~3.
5-21
2. OPERATING PRINCIPLE
1) STRUCTURE
6 7
2 3 4 5
1
5-22(1) 140-7 TIER
1 Sleeve 4 O-ring 6 Solenoid valve

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

P A
T Return to tank
T
A Secondary pressure to flow regulator at hydraulic pump
2) AT H MODE
Pressure line is blocked and A oil returns to tank.
P A
T P T
3) AT S MODE
Secondary pressure enters into A.
P A
T P T
A
5-22(2) 140-7 TIER
5-22
3. EPPR VALVE CHECK PROCEDURE Spec : 200~500mA
1) CHECK ELECTRIC VALUE AT EPPR VALVE
(1) Start engine.
(2) Set S-mode and cancel auto decel mode.
(3) Position the accel dial at 10.
CN-75
(4) If tachometer show approx 2200±50rpm,
disconnect one wire harness from EPPR
valve.
(5) Install multimeter as figure. EPPR VALVE
Multimeter
(6) Check electric current at bucket circuit
relief position.
5-23(1) 140-7 TIER
2) CHECK PRESSURE AT EPPR VALVE Spec : 2~25kgf/cm2(30~350psi)

(1) Remove plug and connect pressure
gauge as figure.
・Gauge capacity : 0 to 40-50kgf/cm2
(0 to 580-725psi)
(2) Start engine.
(3) Set S-mode and cancel auto decel mode. Supply line, pilot press
(4) Position the accel dial at 10. CN-75

Pressure adjusting
(5) If tachometer show approx 2200±50rpm, screw
locknut
check pressure at relief position of bucket
circuit by operating bucket control lever.
(6) If pressure is not correct, adjust it.
(7) After adjust, test the machine. 5-23(2) 140-7 TIER
5-23
GROUP 12 PUMP PROLIX
Its the conversion connector to manual control temporarily when the electronic control system is out
of order, until repair work be done.
Normal Emergency
CN-47 CN-47
CN-19&19A CN-19&19B
CN-19B
CN-19A
CN-96A CN-96A
CN-96B CN-96B
16075MS12
1. OPERATING PRINCIPLE WIRING DIAGRAM
16075MS30
1) NORMAL
・EPPR valve supply specified amount of pilot pressure to the flow regulator of hydraulic pump and
regulate hydraulic pump delivery amount depending upon the signal of CPU controller by selected
mode.
2) EMERGENCY
・If prolix resistor(CN-19) is connected with CN-19B when any abnormality occurs in NEW CAPO
system, constant electric current from battery flows to EPPR valve so that EPPR valve can be
fixed at the predetermined position.
・In this case excavator can be operated at an equivalent performance to S mode.
5-24
GROUP 13 MONITORING SYSTEM
1. OUTLINE
Monitoring system consists of the monitor part and switch part.
The monitor part gives warnings when any abnormality occurs in the machine and informs the
condition of the machine.
Various select switches are built into the monitor panel, which act as the control portion of the machine
control system.
2. CLUSTER
1) MONITOR PANEL
16075MS31
5-25
2) CLUSTER CHECK PROCEDURE
(1) Start key : ON
① Check monitor initial 5 seconds
a. All lamps light up.
b. Buzzer sound.
② Check monitor after 5 seconds : Indicate cluster version and machine condition
a. Cluster program version : CL : 1.5 Indicates program version 1.5 for 2 seconds.
b. Tachometer : 0rpm
c. Fuel gauge : All light up below appropriate level
d. Hydraulic temperature : All light up below appropriate level
e. Engine coolant temperature gauge : All light up below appropriate level
f. Warning lamp
※ During start key ON the engine oil pressure lamp and battery charging lamp go on, but it is not
abnormal.
※ When engine coolant temperature below 30° C, the warming up lamp lights up.
③ Indicating lamp state
a. Work mode selection : General work
b. Power mode selection : S mode
c. User mode selection : No LED ON
d. Auto decel LED : ON
e. Travel speed pilot lamp : Low(Turttle)
(2) Start of engine
① Check machine condition
a. Tachometer indicates at present rpm
b. Gauge and warning lamp : Indicate at present condition.
※ When normal condition : All warning lamp OFF
c. Work mode selection : General work
d. Power mode selection : S mode
e. User mode selection : No LED ON
f. Auto decel LED : ON
g. Travel speed pilot lamp : Low(Turttle)
② When warming up operation
a. Warming up lamp : ON
b. 10 seconds after engine started, engine speed increases to1200rpm(Auto decel LED : ON)
※ Others same as above ①.
③ When abnormal condition
a. The lamp lights up and the buzzer sounds.
b. If BUZZER STOP switch is pressed, buzzer sound is canceled but the lamp light up until normal
condition.
5-26
3. CLUSTER CONNECTOR
No. Signal Input / Output
1 Power IG(24V) Input(20~32V)

Cluster
2 GND Input(0V)
3 Serial-(RX) Input(Vpp=12V)
4 Serial+(TX) Output(Vpp=4V)
21075MS16
5-27
4. CLUSTER FUNCTION
1) MONITORING DISPLAY
① This displays the current time and machine information such as
engine rpm, coolant/hydraulic oil temperature, hydraulic oil
pressure and also error codes.
※ Refer to the page 5-33 for details.
14073CD03
2) FUEL GAUGE
① This gauge indicates the amount of fuel in the fuel tank.
② Fill the fuel when the white range or warning lamp blinks.
※ If the gauge illuminates the white range or warning lamp
White range blinks even though the machine is on the normal condition,
check the electric device as that can be caused by the poor
21073CD04 connection of electricity or sensor.
3) HYDRAULIC OIL TEMPERATURE GAUGE

① This indicates the temperature of coolant.
・White range : 30° C(86°F) below
・Green range : 30-105 ° C(86-221° F)
Red range ・Red range : 105° C(221° F) above
② The green range illuminates when operating.
21073CD05 ③ Keep idling engine at low speed until the green range
illuminates, before operation of machine.
④ When the red range illuminates, reduce the load on the system.
If the gauge stays in the red range, stop the machine and check
the cause of the problem.
4) ENGINE COOLANT TEMPERATURE GAUGE

① This indicates the temperature of coolant.
・White range : 30° C(86° F) below
・Green range : 30-105 ° C(86-221°F)
Red range ・Red range : 105° C(221° F) above
② The green range illuminates when operating.
21073CD05 ③ Keep idling engine at low speed until the green range
illuminates, before operation of machine.
④ When the red range illuminates, turn OFF the engine, check the
radiator and engine.
5-28
5) FUEL LOW LEVEL WARNING LAMP
① This lamp blinks and the buzzer sounds when the level of fuel is
below 38ℓ(10.0U.S. gal).
② Fill the fuel immediately when the lamp blinks.
21073CD04A
6) HYDRAULIC OIL TEMPERATURE WARNING LAMP

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

① This lamp blinks and the buzzer sounds when the temperature
of coolant is over the normal temperature 110°
C( 230°
F) .
② Check the cooling system when the lamp blinks.
21073CD06A
8) ENGINE OIL PRESSURE WARNING LAMP

① This lamp blinks and the buzzer sounds after starting the engine
because of pressure.
② If the lamp blinks during engine operation, shut OFF engine
immediately. Check oil level.
21073CD07
9) AIR CLEANER WARNING LAMP

① This lamp is operated by the vacuum caused inside when the
filter of air cleaner is clogged which supply air to the engine.
② Check the filter and clean or replace it when the lamp blinks.
21073CD08
5-29
10) COOLANT LEVEL WARNING LAMP
① This lamp blinks and the buzzer sounds when the coolant is
below LOW in the reservoir tank of radiator.
② Check the reservoir tank when the lamp blinks.
21073CD09
11) CPU CONTROLLER CHECK WARNING LAMP

① Communication problem with CPU controller makes the lamp
blinks and the buzzer sounds.
② With lamp blinks all of the lamp on the cluster LCD will be OFF.
21073CD10
12) BATTERY CHARGING WARNING LAMP

① This lamp blinks and the buzzer sounds when the starting
switch is ON, it is turned OFF after starting the engine.
② Check the battery charging circuit when this lamp blinks, during
engine operation.
21073CD13
13) OVERLOAD WARNING LAMP

① When the machine is overload, the overload warning lamp
blinks during the overload switch ON.
21073CD15
14) POWER BOOST PILOT LAMP

① The lamp will be ON when pushing power boost switch on the
LH RCV lever.
21073CD11
5-30
15) ONE TOUCH DECEL PILOT LAMP
① Operating auto decel or one touch decel makes the lamp ON.
② The lamp will be ON when pushing one touch decel switch on
the LH RCV lever.
21073CD17
16) WARMING UP PILOT LAMP

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

① This lamp is turned ON when the preheating function is
actuated in cold weather.
② Start the engine as this lamp is OFF.
21073CD12
18) WORK MODE SWITCH

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

① This switch is to select the maximum power or user mode.
・M : Maximum power
・U : Memorizing operators preferable power setting.
18073CD21
5-31
20) AUTO DECELERATION SWITCH
① This switch is used to actuate the auto deceleration function so
the engine speed is lowered automatically when all control
levers and pedals are at neutral position to save the fuel.
・Light ON : Auto deceleration function is selected.
・Light OFF : Auto deceleration function is cancelled so that the
21073CD22 engine speed increased to previous setting value.
② Operating the auto deceleration function makes the decel
indicate lamp on the LCD panel ON.
21) POWER MODE SWITCH

① The lamp of selected mode is turned ON by pressing the
switch( ), when selecting the mode to use.
・H : This is used for high power work.
・S : This is used for standard power work.
21073CD23
22) TRAVEL SPEED CONTROL SWITCH

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

① When the starting switch is turned ON first, normally the alarm
buzzer sounds for 5 seconds during lamp check operation.
② The red lamp lights ON and the buzzer sounds when the
machine has a problem.
In this case, press this switch and buzzer stops, but the red
21073CD25 lamp lights until the problem is cleared.
24) SELECT SWITCH

① This switch is used to select the monitor display function.
② If the switch is pressed for 3 seconds in time display mode, it is
selected time adjusting function, as below.
・Hour by auto decel switch
21073CD25A ・Minute by buzzer stop switch.
③ After time set, the switch is pressed, it is returned clock.
5-32
5. MONITORING DISPLAY
1) OUTLINE
Information of machine performance as monitored by the CPU controller can be displayed on the
cluster when the operator selects a display mode by touching SELECT switch alone or with BUZZER
STOP switch on the cluster as below.
How to select display mode
Display group Name Display on the cluster
Group selection Display mode selection
Initial Engine rpm
Way 1 Touch SELECT 1 time Time

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

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

C)
Touch SELECT switch Default Current error

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

Touch SELECT switch
3 times while pressing Touch SELECT 3 times Travel oil pressure switch or
Group 3 BUZZER STOP.
(Switch input) In this group SELECT
Touch SELECT 4 times One touch decel switch or
LED blinks at 0.5sec
interval
Touch SELECT 5 times Travel alarm switch or
Touch SELECT 6 times Preheat switch or
Touch SELECT 7 times Over load switch or
5- 33
How to select display mode
Display group Name Display on the cluster
Group selection Display mode selection
Default Hourmeter or
Neutral relay
Touch SELECT 1 time (Anti-restart relay) or
Touch SELECT 2 times Travel speed solenoid or

Touch SELECT switch
4 times while pressing Power boost solenoid
Touch SELECT 3 times (2-stage relief solenoid) or
Group 4 BUZZER STOP.
(Output) In this group SELECT
LED blinks at 1sec Touch SELECT 4 times Swing priority solenoid or
interval
Touch SELECT 5 times Travel alarm or
Touch SELECT 6 times Max flow cut off solenoid or
Touch SELECT 7 times Preheat relay or
※By touching SELECT switch once while pressing BUZZER STOP, display group shifts.
Example : Group 0 1 2 3 4 0
5- 34
2) DESCRIPTION OF MONITORING DISPLAY
Group Display Name Description
It displays current engine speed detected by engine speed

2200 rpm Engine speed sensor from 500 to 3000rpm.
Range : 500~3000rpm by 10rpm
It displays current time(12 is hour and 30 is minute)

TIME 12 : 30 Time
Range : Hour(1~12), minute(00~59)
Power shift It shows that pump power shift pressure of EPPR valve being
EP : 10bar pressure of controlled by the CPU controller is 10bar.
EPPR valve Range : 00~50bar by 1bar
It shows that machine model(R160LC-7) and the program

Model and CPU
16 : C1.2 version of the CPU controller is 5.0.
Group 0 program version
Version display range : 0.0~9.9 by 0.1
It displays front pump pressure of 100bar which is detected by

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

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

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

b24 : 8V Battery voltage
Range : 00.0~48.0V by 0.1V
Potentiometer It shows that potentiometer signal voltage is 2.5V.

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

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

Coolant
°
Ct : 85°
C sensor is 50°C.
temperature
Range : 0~150° C by 1°C
5-35
It shows that current error of 03(Short circuit in pump EPPR valve

system) is diagnosed by self diagnosis system in the CPU controller.
CHECK Er : 03 Current error If more than 2 errors, when pressing or switch, other
error codes show.
Range : 00~58
Group 2 It shows recorded error code of 03 which is diagnosed before.

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

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

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

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

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

PH : on or oFF Preheat switch
PH : oFF Shows that preheat switch is released.
ol : on Shows that over load switch is pressed.

ol : on or oFF Over load switch ol : oFF Shows that over load switch is released.
5-36
Ho : on Shows that hourmeter is activated by CPU controller.

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

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

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

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

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

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

PR : on or oFF Preheat relay PR : oFF Shows that preheat relay is released.
5-37
Group 1 Before Troubleshooting 6-1

Group 2 Hydraulic and Mechanical System 6-4
Group 3 Electrical System 6-24
Group 4 Mechatronics System 6-41
GROUP 1 BEFORE TROUBLESHOOTING
1. INTRODUCTION
When a trouble is occurred in the machine, this section will help an operator to maintain the machine
with easy.
The trouble of machine is parted Hydraulic & Mechanical system, Electrical system and Mechatronics
system. At each system part, an operator can check the machine according to the troubleshooting
process diagram.
Hydraulic &
GROUP 2
Mechanical part
Troubles occur Electrical part GROUP 3
Mechatronics
GROUP 4
part
6-1
2. DIAGNOSING PROCEDURE
To carry out troubleshooting efficiently, the following steps must be observed.
STEP 1. Study the machine system

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

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

Before starting troubleshooting, check the
machine for the daily maintenance points as
shown in the operator's manual.
And also check the electrical system including
batteries, as the troubles in the electrical system ON THE
INSPECTION
such as low battery voltage, loose connections
and blown out fuses will result in malfunction of
6-2(3) 140-7
the controllers causing total operational failures
of the machine.
6-2
STEP 4. Inspect the trouble actually on the
machine
In case that some trouble cannot be confirmed,
obtain the details of the malfunction from the
operator.
Also, check if there are any in complete
connections of the wire harnesses are or not.
6-3(1) 140-7
STEP 5. Perform troubleshooting

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

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

procedure to avoid consequential malfunctions.
6-3(3) 140-7
6-3
GROUP 2 HYDRAULIC AND MECHANICAL SYSTEM
1. INTRODUCTION
1) MACHINE IN GENERAL
(1) If even a minor fault is left intact and operation is continued, a fatal failure may be caused,
entailing a large sum of expenses and long hours of restoration.
Therefore when even a small trouble occurs, do not rely on your intuition and experience, but look
for the cause based on the troubleshooting principle and perform maintenance and adjustment to
prevent major failure from occurring. Keep in mind that a fault results from a combination of
different causes.
(2) The following lists up commonly occurring faults and possible causes with this machine. For the
troubleshooting of the engine, refer to the coming troubleshooting and repair.
(3) When carrying out troubleshooting, do not hurry to disassemble the components.
It will become impossible to find the cause of the problem.
(4) Ask user or operator the following.
① Was there any strange thing about machine before failure occurred?
② Under what conditions did the failure occur?
③ Have any repairs been carried out before the failure?
(5) Check before troubleshooting.
① Check oil and fuel level.
② Check for any external leakage of oil from components.
③ Check for loose or damage of wiring and connections.
6-4
2. DRIVE SYSTEM
1) UNUSUAL NOISE COMES OUT OF PUMP CONNECTION
Cause Remedy
YES
Coupling element Disassemble
is broken. and repair.
Remove dust plug
under engine
flywheel and
YES
check if rubber Replace hub or
pieces or particles retighten
are not present. Coupling hub setscrew.
spline is worn or
NO hub fastening
setscrew is slack.
If hydraulic pump or engine is
suspected as a culprit refer to this
NO
manual "Structure and function".
6-5
2) ENGINE STARTS BUT MACHINE DOES NOT OPERATE AT ALL
Cause Remedy
NO
Replenish
specified oil to
the standard
Is oil level in Abnormal noise level.
hydraulic oil YES comes out of YES
Hydraulic pump is Disassemble
tank within hydraulic pump
standard level? broken. and repair.
Do not hydraulic Abnormal noise
pump and pump YES comes out of YES
connections pump See item 1).
YES make abnormal
connection at page 6-5
noise?
Is primary pilot
pressure within ⓐ
NO standard level?
YES
Clean pilot
Is not pilot piping piping interior or
YES clogged or is not
oil leakage present repair piping.
on pilot piping?
NO
Pilot valve is Disassemble
ⓐ faulty. and repair.
YES
Pilot relief valve is Repair or
Is gear pump faulty. replace.
NO delivering oil?
NO Gear pump is Disassemble

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

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

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

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

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

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

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

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

normal?
Select valve is Repair or

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

NO
broken. and repair.
6-17
6. ATTACHMENT SYSTEM
1) BOOM OR ARM ACTION IS IMPOSSIBLE AT ALL
Cause Remedy
YES
Does the Port relief valve is Disassemble
symptom change faulty. and repair or
YES
when port relief
replace.
valve is replaced
Is MCV pilot with other valve? NO ⓐ
YES
pressure within
standard level?
Inspect if pilot
piping is not
OK
clogged or oil is Pilot valve is Disassemble
Are other NO
YES
not leaking from faulty. and repair.
attachments the piping.
operatable?
YES
Pilot relief valve is Disassemble
Is gear pump pilot YES
Is gear pump faulty. and repair or
pressure within
NO delivering oil? replace.
standard level?
NO
broken. and repair.
Are LH/RH travel
operations OK
possible? Hydraulic pump is Disassemble
Disassemble broken. and repair.
YES main relief valve
Remove dust plug and check if it is
under engine not irregular.
OK flywheel and Faulty
Main relief valve Disassemble
check if coupling is defective. and repair or
element particles replace.
Inspect oil are not present. Particles present Coupling at pump Disassemble
NO
volume in
hydraulic oil tank. connection is and repair.
broken.
Short Replenish
hydraulic oil.
YES
Cylinder interior is Disassemble
Does control
broken. and repair.
ⓐ valve spool move
lightly by hand?
NO Control valve Disassemble
6-18
2) BOOM, ARM OR BUCKET SPEED IS LOW
Cause Remedy
YES
Normal.
YES
Are other ⓐ
YES attachment
Is combination speeds within
Is speed low only of oil streams standard levels? NO ⓑ
in composite YES
normal at boom YES
operation? hoisting and at Flow summation Disassemble and
Does spool of flow
arm extrusion? summation check check valve spool repair.
NO valve move lightly is stuck.
Are LH/RH travel
by hand?
NO speeds within NO
standard levels?
YES
Are both LH/RH faulty. repair.
travel speeds YES ⓒ
NO
low? Is MCV pilot
pressure within
NO
standard? ⓓ
NO
OK
Does the Port relief valve is Disassemble and
symptom change faulty. repair or replace.
YES
when port relief
valve is replaced
Does control with other valve? Cylinder is faulty. Disassemble and
YES NO
valve spool move repair.
lightly by hand?
NO Control valve spool Disassemble and

Is MCV pilot
ⓐ pressure within is stuck. repair.
standard level?
YES
Clean pilot piping
Is not MCV pilot
pressure piping interior or repair
NO clogged or is not piping.
there oil leakage? Pilot valve is Disassemble and
NO
defective. repair.
YES
Pilot relief valve is Disassemble and
Is primary pilot NO Is gear pump faulty. repair or replace.
ⓑ pressure within
delivering oil?
standard level?
NO
Gear pump is Disassemble and
broken. repair.
Is engine NO
ⓒ revolution within Adjust engine
standard level? revolution.
YES
Clean orifice in
control valve.
Is not orifice in
ⓓ control valve YES
clogged? Is pilot piping not Clean pilot piping
clogged or is oil interior or repair
NO not leaking from piping.
the piping? Is pilot valve
Pilot valve is faulty. Disassemble and
NO normal? NO
repair.
6-19
3) BOOM, ARM OR BUCKET CYLINDER EXTENDS OR CONTRACTS ITSELF AND ATTACHMENT FALLS
Cause Remedy
YES
Port relief valve is Disassemble
Does the symptom faulty. and repair or
change when port
Normal replace.
relief valve is YES
replaced with ⓐ
normal valve? Is control valve
return spring
YES
Is not hydraulic NO
normal?
oil temperature Control valve's Disassemble
high? NO
return spring is and replace.
faulty.
Is genuine Abnormally high. Locate the cause
hydraulic oil or of hydraulic oil
equivalent being temperature rise
used?
and lower it to
proper level.
Replace with
NO
genuine
hydraulic oil or
equivalent.
OK
Pressure Disassemble
Disassemble and tightness and repair.
YES inspect check between control
valve in hydraulic
circuit and check valve casing and
for any fault. spool is poor.
Is cylinder internal Abnormal Contact surface Disassemble
ⓐ leakage within between poppet and repair.
standard level?
and seat is poor.
Cylinder is faulty. Disassemble

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

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

faulty. and repair.
6-21
6) BOOM MAKES A SQUEAKING NOISE WHEN BOOM IS OPERATED
Cause Remedy
YES
Frictional noise
occurs between
the sliding faces
of boom
cylinder's oil
Is boom foot pin seal and boom
greased proper.
sufficiently?
※ Frictional
noise will
disappear if
they are kept
used.
Boom foot pin Supply grease

NO
has run out of to it.
grease. ※
If seizure is in
an initial stage,
supply sufficient
grease.
If seizure is in
a grown state,
correct it by
paper lapping
or with an oil
stone.
6-22
※ HOW TO CHECK INTERNAL BOOM CYLINDER LEAKAGE
1. Lower the bucket teeth to the ground with
bucket cylinder fully retracted and arm
cylinder rod retracted almost in full.
14076BY01
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
6-20(2) 140-7
3. Raise bucket OFF the ground by retracting

the arm cylinder rod.
If oil leaks from piping side and boom

cylinder rod is retracted there is an internal
leak in the cylinder.
If no oil leaks from piping side and boom
cylinder rod is retracted, there is an internal
leak in the control valve.
14076BY02
6-23
GROUP 3 ELECTRICAL SYSTEM
1. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR
・Before disconnecting the connector, always turn the starting switch OFF.
・Before carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No.7.
・After checking, insert the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
Defective clucter Replace
YES Check voltage
between CN-56
(1) and chassis Disconnection in Repair or
NO
wiring harness or replace
Check voltage
between CN-5(3) poor contact (After clean)
and chassis between CN-5(3)-
CN-56(1)
Starting switch : ON
Voltage : 20~32V
NO Disconnection in Repair or
wiring harness or replace
poor contact (After clean)
between CN-5(3)-
and fuse No.8
20W76TS03
Check voltage
YES 20 ~ 30V
NO 0V
6-24
2. COMMUNICATION ERROR "Co : Err" FLASHES ON THE CLUSTER
・Before carrying out below procedure, check all the related connectors are properly inserted.
Cause Remedy
YES
Defective controller Replace
YES Check voltage

between CN-56
(3,4) and chassis
Disconnection in Repair or replace
NO wiring harness or (After clean)
Check voltage
between CN-5 poor contact
between CN-56
(10,11)and (3,4) CN-5(10,11)
chassis
KEY ON
NO
wiring harness or (After clean)
poor contact
between CN-5
(10,11)-CN-50
(29,30)
CONTROLLER
Check voltage
YES *4V *12V 29
NO 0V 0V
30
CN-50
CLUSTER
POWER IG(24V)
GND 2 9
RX *12V
3 10
TX *4V 4 11
CN-56 CN-5
R29076ES02
6-25
3. BATTERY CHARGING WARNING LAMP LIGHTS UP(Starting switch : ON)
Cause Remedy
YES
YES Check voltage
between CN-51
(9) and chassis Disconnection in Repair or replace
NO
YES Check voltage poor contact
between CN-3
(3) and chassis between CN-51(9)
-CN3(3)
Check voltage Disconnection in Repair or replace

NO wiring harness or (After clean)
between alternator
poor contact
terminal "I" and between
chassis CN-3(3)-alternator
Voltage : 20~32V terminal "I"
Engine : Running
Defective alternator Replace

NO
Check voltage
YES 20 ~ 32V
NO 0V
ALTERNATOR
CONTROLLER B+
G
3~
9 3 I
U
GND
CN-51 CN-3 CN-74
14076TS21
6-26
4. WHEN COOLANT OVERHEAT WARNING LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
Coolant overheat Check engine
Resistance
YES between CD-8 (110°C ±2°C ) cooling system
(1,2) is in range
of 120~150Ω?
NO
Defective temp Replace
Disconnect CD-8 sensor
Does display go
off when
disconnect CD-8?
YES
Starting switch : ON Short circuit in Repair or replace
Engine : Start Resistance wiring harness (After clean)
between CN-51
NO
(31,33) is 0~1
Defective Controller Replace
Disconnect CN-51 NO
KEY OFF
CONTROLLER WATER TEMPERATURE

SENSOR
33 5 1 C
31 6 2
CN-51 CN-3 CD-8
14076TS22
6-27
5. WHEN AIR CLEANER WARNING LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
Clogged air filter or Check filter or
defective switch replace switch
Does display go
off when
disconnect CD-
10? YES
Short circuit in Repair or replace
Engine : Start Check resistance wiring harness (After clean)
between CN-51
NO
(16) and chassis
Starting switch : OFF Defective controller Replace
NO
Disconnect CN-51
Check resistance
YES MAX 1Ω
NO MIN 1MΩ
CONTROLLER AIR CLEANER SWITCH
Pa
16
20
CD-10
CN-50
51
25036EL05
6-28
6. WHEN ENGINE OIL PRESSURE WARNING LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
Engine oil leakage, Check engine oil
or defective switch level or replace
Does display go off switch
when disconnect
YES
CD-18? Defective controller Replace
Starting switch : ON Check resistance
Engine : Start between CN-51
NO
(4) and chassis
Starting switch : OFF
NO
Disconnect CN-51 wiring harness or (After clean)
poor contact
between
CN-51(4)-CD-18
Check resistance
YES MAX 1Ω
NO MIN 1MΩ
16076ES03
6-29
7. WHEN HYDRAULIC OIL TEMPERATURE WARNING LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
High temperature Check hydraulic
Resistance oil temperature
YES between CD-1
(1,2) is in range (100°C ±2°C ) ,
of 130~150Ω? Replace
Starting switch : ON Defective torque Replace
Does display go NO
Disconnect CD-1 sensor
off when
disconnect CD-1? YES
Short circuit Check and repair
Starting switch : ON Resistance
Engine : Start between CN-51
NO (31,34) is 0~1Ω?
Starting switch : OFF NO Defective controller Replace

Disconnect CN-51
CONTROLLER HYDRAULIC OIL

TEMPERATURE SENDER
34 2
C
31 1
CN-51 CD-1
R29076ES04
6-30
8. WHEN COOLANT LEVEL WARNING LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
Insufficient coolant Refill coolant or
or Defective switch replace switch
Does display go
off when
disconnect CD-
16? YES
Short circuit Check and repair
Starting switch : ON Check resistance
Engine : Start
between CN-51
NO (15) and chassis
Starting switch : OFF NO Defective controller Replace

Disconnect CN-51
Check resistance
YES MAX 1Ω
NO MIN 1MΩ
COOLANT LEVEL SENSOR

CONTROLLER
15
18 2
51
CN-50 CD-16
25036EL08
6-31
9. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE
Cause Remedy
YES
Is resistance poor contact
YES between CN-51 between
(31) and (33) CN-51-CD-8
over 2kΩ?
Starting switch : OFF YES
Disconnect CN-50 Defective controller Replace
Does the gauge
light up and Check resistance
down at lamp NO
between CN-3(5)
check? and (6)
Defective temp Replace
See Table
NO
Starting switch : ON sensor
Defective cluster Replace

NO
Check Table
Green range Red range Temperature White range Green range Red range
Item (~29° C) (30~105° C) (105°C ~)
Unit Resistance(Ω) 1646~ 1645~158 ~139
White range Tolerance(%) ±20 ±20 ±20
CONTROLLER WATER TEMPERATURE

SENSOR
33 5 1 C
31 6 2
CN-51 CN-3 CD-8
14076TS22
6-32
10. WHEN FUEL GAUGE DOES NOT OPERATE(Check warning lamp ON/OFF)
Cause Remedy
YES
Disconnection in Check and repair
wiring harness
Is resistance
YES between CN-51
(24) and (31)
over 1kΩ? YES
Starting switch : OFF
Disconnect CN-51
Check resistance
Does the gauge between CD-2(1)
light up and NO and (2)
down at lamp Defective fuel Replace
NO
check? Disconnect CD-2
sensor
See Table

NO
Green range Red range Check Table

Level White range Green range Red range
Item
Unit Resistance(Ω) 700~601 600~101 ~100
White range Tolerance(%) ±5 ±5 ±5
CONTROLLER
FUEL SENDER
24 1
CD-2
31
CN-51
R29076ES06
6-33
11. WHEN SAFETY SOLENOID DOES NOT OPERATE
short of fuse No.24.
Cause Remedy
YES
Hydraulic Check hydraulic
YES Check operation malfunction system
of solenoid
Defective solenoid Replace
NO
Safety lever : ON-OFF
YES
ⓐ
YES Check voltage
between CS-4
Check voltage (C) and chassis
between CN-68 Disconnect in Repair or replace
(1) - CN-68(2) Check voltage Starting switch : ON NO
YES between CN-4(8) Voltage : 20~30V wiring harness or (After clean)
Starting switch : ON and chassis Disconnect CN-4 poor contact
Voltage : 20~30V between
Safety state Starting switch : ON CN-4(8)-CS-4(C)
Voltage : 20~30V
Disconnect CN-4
Check voltage Disconnect in Repair or replace
between CN-68 NO
NO (1) with chassis
poor contact
Safety lever : OFF between
Starting switch : ON CN-4(8)-CN-68(1)
Voltage : 20~30V
NO Disconnection in Replace
fuse
YES
Defective switch Repair or replace
Check voltage
ⓐ between CS-20 (CS-20)
and chassis
NO
Defective switch Repair or replace
Starting switch : ON (CS-4)
Voltage : 20~30V
CS-20
NO.25
EARTH 1
B C A
B 6 2
A C 8 1
CS-4 CN-68
CN-4
16076TS23
6-34
12. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE
short of fuse No.22 .
Cause Remedy
YES
Defective hydraulic Check hydraulic
system system
YES Check voltage YES Check operation
between CN-50 YES
of solenoid Defective controller Replace
(13) and chassis
Check resistance
Check if travel Starting switch : ON Starting switch : ON between CN-70
Volage : 20~30V : OFF NO
speed lamps( , (1) and (2)
Disconnect CN-50 : ON
) change when Defective solenoid Replace
Starting switch : OFF NO
pressing the travel
speed switch on SPEC : 15~25Ω
Disconnect CN-70
the cluster YES
Check controller
Y R G
NO
NO
16076ES08
6-35
13. WHEN ENGINE DOES NOT START
START SWITCH
・Check supply of the power at engine stop solenoid while starting switch is ON.
II I O H
1
I,O
・Before carrying out below procedure, check all the related connectors are properly inserted. 9
2
・After checking, insert the disconnected connectors again immediately unless otherwise specified. 10 3 4
H
4
ACC BR
1
B
11 2
3
5
12
Cause Remedy 6
C ST
5
YES 6
Defective battery Check engine CN-8
system charge or CS-2
replace(After POWER RY
checking specific 30
30 86
gravity of battery) 86
Check operation YES 87

Check voltage Defective magnet Replace
of start motor YES between starter of start motor
85
87a 87 85
magnet coil and 87a
BATTERY RY
Starting switch : START chassis Defective start relay Replace CR-35
NO
Starting switch : START MASTER SWITCH
CR-1
YES
SPEC : 20~30V ⓐ
Check operation YES
Check voltage FUSE
NO of start relay
between CR-5
(30) and chassis NO.1
NO DO-1 DO-2
CN-60
CN-95
Starting switch : START wiring harness or (After clean) FUSE
2
1
1
Starting switch :START
Check operation poor contact
of start safety between CR-5 NO.7
NO relay
1
2
2
(86) and CN-8(9) FUSIBLE LINK
YES
Check voltage Defective relay Replace CN-51
between CR-
NO 5(87) and ⓑ FUSE 9
NO
Starting switch : ON NO.13
CPU CONTROLLER
YES CN-92
Defective relay Replace 11
Check voltage
ⓐ between CR-23 CN-50
and chassis START SAFETY RY
NO 30
Starting switch : ON wiring harness or (After clean) 86 30 START RY STARTER
poor contact 86
between CR-5(30)- B+ M
87 2
CR-23(2) 85 1
YES 85 87 87a
87a M
Check voltage Defective fuel cut- Replace
CR-5 CR-23
ⓑ between CN-79 off solenoid CN-3 CN-45
and chassis ENGINE STOP RY
NO Disconnection in Repair or replace
1 2 1
Starting switch : ON wiring harness or (After clean)
2 FUEL CUT -OFF
poor contact
between CN-79 3 G
and CR-43(4) 3 4 4 3
CR-43
CN-2 CN-79
CPU CONTROLLER
CN-50 16076TS06
6 - 36
14. WHEN STARTING SWITCH ON DOES NOT OPERATE
START SWITCH
II I O H
1
I,O
master switch ON. 9
2
・After checking, insert the disconnected connectors again immediately unless otherwise specified. 10 3 4
H
4
ACC BR
1
B
11 2
3
5
12
6
C ST
5
Cause Remedy 6
CN-8
YES CS-2
POWER RY
30
30 86
poor contact
YES Check voltage 86
between DO-2 between DO-2(2)- 87
(1) and chassis CR-1 or defective 85
87a 87 85
Voltage : 20~30V
battery relay 87a
BATTERY RY
CR-35
YES Check voltage Disconnection in Replace MASTER SWITCH
CR-1
between CS-2 NO
wiring harness or
(2) and chassis FUSE
poor contact
Voltage : 20~30V between CS-2(2)- NO.1
Check voltage DO-1 DO-2
CN-60
CN-95
YES CN-8(11)- DO-2(1)
between CS-2(1) FUSE
2
1
1
and chassis
NO.7
1
2
2
Defective start Replace FUSIBLE LINK
Voltage : 20~30V NO
switch
CN-51
Check voltage Disconnection in Replace
and specific NO FUSE 9
gravity of battery wiring harness or
poor contact NO.13
CPU CONTROLLER
Specific gravity : MIN 1.28
between CS-2(1)- CN-92
Voltage : MIN 24V
11
CN-8(12)-CR-1-
Battery CN-50
START SAFETY RY
30
Battery capacity too Charge or replace 86 30 START RY STARTER
NO 86
low (After clean) B+ M
87 2
85 1
85 87 87a
87a M
CR-5 CR-23
CN-3 CN-45
ENGINE STOP RY
1 2 1
2 FUEL CUT -OFF
3 G
3 4 4 3
CR-43
CN-2 CN-79
CPU CONTROLLER
CN-50 16076TS06
6-37
15. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE
・Before carrying out below procedure, check all the related connectors are properly inserted and the fuse
No.4,11 and 13 is not blown out.
Cause Remedy
NO
Defective wiper Replace
cut switch
YES
Check operation wiring harness or (After clean)
wiper cut switch poor contact
between CN-141
Front sliding door Check valtage (11)- CS-53
open-close
between CN-141 YES
YES (11) and chassis Defective switch Replace
panel
NO Check voltage
Front sliding door-close between CN-116
Voltage : 0~1V (6) and chassis
Check operation 1)Recheck fuse Replace
Starting switch : ON NO NO.11
of switch panel
NO Vottage : 20~30V
LED ON. 2)Disconnection in Repair or replace
Starting switch : ON ⓐ poor contact
Push wiper switch button YES
between CN-
116(6)-Fuse
between CN-
116(13)-Chassis
Check voltage between NO
Defective switch Replace
CN-116(4) and chassis panel
Intermittent
NO
1) Recheck fuse Replace
Check voltage CN-116 NO.4
ⓐ (12) and chassis 2) Disconnection Repair or replace
Washing
Check operation in wiring harness (After clean)
of wiper motor or poor contact
Check voltage CN-116 and controller between CN-
(15) and chassis check voltage 141(7)-Fuse,
YES CN-141(7) and
Sarting switch : ON CN-21(4)-Fuse
Voltage : 0~1V
chassis, CN-21(4)
and chassis NO
1) Recheck fuse Replace
Starting switch : OFF NO.14
Voltage : 20~30V Check voltage
2) Disconnection Repair or replace
CN-141(6)-and
YES chassis CN-141(6)-Fuse (After clean)
Starting switch : ON ⓑ
Check continuity YES
Voltage : 20~30V
NO
between Disconnection in Repair or replace
CN-141(2)-CN-116(4), wiring harness or (After clean)
CN-141(9)-CN-116(12), poor contact
CN-141(10)-CN-116(15),
ⓑ NO
CN-141(5)-Chassis , Check wiper Defective wiper Replace
CN-141(1)-CN-21(5), motor resistance motor
CN-141(3)-CN-21(6),
YES between CN-21
CN-141(4)-CN-21(2), (2)-CN-21(6) Defective wiper Replace
CN-141(13)-CN-21(3) YES motor controller
Resistance : 3~4Ω 16076TS08
6-38
16. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP
Cause Remedy HEAD LAMP

NO
Defective lamp Replace switch 1
switch 2
CL-4
Check voltage
YES
between CN-116 YES
(1) and (9) Defective bulb Replace
YES
Check voltage
Starting switch : ON between CL-4(2) CN-7
Head lamp switch : ON and chassis CN-116
Voltage : 20~30V Disconnection in Repair or replace 1
NO 1 HEAD LIGHT OUT
Head lamp switch : ON wiring harness or (After clean) 2 WORK LIGHT OUT
Check voltage 3 WORK LIGHT OUT
between CN-7(1)
Voltage : 20~30V poor contact 4 WIPER MOTOR DRIVE
YES and chassis between CN-7(1)- 5 PRE-HEAT
6 POWER 24V
CL-4(2) 7
Starting switch : ON 7 CABIN LIGHT OUT
Head lamp switch : ON 8 CABIN LIGHT OUT
Voltage : 20~30V 9 HEAD LIHGT 24V
Check voltage Disconnection in Repair or replace
NO 10 10 WORK LIGHT 24V
between CN-116 wiring harness or (After clean) 11 WORK LIGHT 24V
(9) and chassis 12
poor contact WASHER SIG
13 GND
Starting switch : ON between 14 TRAVEL ALARM
Head lamp switch :
ON-OFF
CN-116(1)-CN- 15 INT. SIG
16 CABIN LIGHT 24V
7(1) 17 CABIN LIGHT 24V
SWITCH PANEL
YES
Check voltage poor contact FUSE
between CN- between CN-116
NO 7(7) and chassis
(9)-CN-7(7) NO.15
Head lamp switch : ON
Recheck fuse Replace
NO
16076ES12
6-39
17. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP
Cause Remedy WORK LAMP

NO
Defective lamp Replace switch 1
switch 2
CL-5
CN-12 WORK LAMP
Check voltage
YES
between CN-116 YES 1 1
(10,11) and (2,3) Defective bulb Replace 2 2
Check voltage
YES
Starting switch : ON between CL-5(2) CL-6
Work lamp switch : ON and chassis
Voltage : 20~30V Disconnection in Repair or replace
Starting switch : ON NO
Work lamp switch : ON wiring harness or (After clean)
Check voltage Voltage : 20~30V poor contact CN-7
between CN-7(2) CN-116
YES and chassis between CN-7(2) 1 HEAD LIGHT OUT
-CL-5(2) and 2 2 WORK LIGHT OUT
Starting switch : ON 3 WORK LIGHT OUT
Work lamp switch : ON
CL-6 (2)
4 WIPER MOTOR DRIVE
Check voltage Voltage : 20~30V 5 PRE-HEAT
between CN-116 6 POWER 24V
(10,11) and Disconnection in Repair or replace
NO 8 7 CABIN LIGHT OUT
chassis wiring harness or (After clean) 8 CABIN LIGHT OUT
Starting switch : ON poor contact 9 HEAD LIHGT 24V
Work lamp switch : 10 10 WORK LIGHT 24V
ON-OFF
between CN-116 11 WORK LIGHT 24V
Voltage : 20~30V (2,3)-CN-7(2) 12 WASHER SIG
13 GND
14 TRAVEL ALARM
YES 15 INT. SIG
Disconnection in Repair or replace 16 CABIN LIGHT 24V

17 CABIN LIGHT 24V
SWITCH PANEL
Check voltage poor contact
between CN-7(8) between CN-116
NO and chassis
(10,11)-CN-7(8)
Head lamp switch : ON FUSE
Voltage : 20~30V
NO Recheck fuse Replace NO.16
16076ES13
6-40
GROUP 4 MECHATRONICS SYSTEM
1. ALL ACTUATORS SPEED ARE SLOW

※ Boom, Arm, Bucket, Swing and travel speed are slow, but engine speed is good.
※ Spec : M-mode 2200±50rpm H-mode 2000±50rpm S-mode 1900±50rpm
※ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE
Cause Remedy
YES
Defective
YES Check pressure hydraulic system
at EPPR valve
NO
Check electric NO Defective Replace
SPEC : 5~20kgf/cm2
YES current at EPPR See TEST 4 EPPR valve
valve
Check if Err : 03
on the cluster SPEC : 200~550mA Defective CPU Replace
See TEST 3 NO
controller
Check resistance
between CN-2(9)-
YES (10)
YES
Short circuit or Check & repair
SPEC : 17.5±1Ω(20°
C)
See TEST 1
poor connection wire harness or
Check resistance between CN-50 - between CN-50-
NO at EPPR valve CN-75 CN-75
SPEC : 17.5±1Ω(20°
C) Defective EPPR Replace
See TEST 2 NO
valve
Wiring diagram
16075MS30
6-41
2) TEST PROCEDURE SPEC : 17.5±1Ω(20°C )
(1) Test 1 : Check resistance at connector
CN-2(9)-(10).
① Starting key OFF. CN-2
② Disconnect connector CN-2. 12 10 9 1
③ Check resistance between pin and at

connector CN-2(9)-(10).
Multimeter
14076TS32
(2) Test 2 : Check resistance at connector

SPEC : 17.5±1Ω(20°
C)
CN-75.
① Starting key OFF.
② Disconnect connector CN-75 from EPPR
CN-75
valve at main hydraulic pump.
③ Check resistance between 2 lines as
figure.
Multimeter
6-38(2) 140-7
(3) Test 3 : Check electric current at EPPR valve. SPEC : 200~550mA (S mode)
① Install multimeter as figure.
② Start engine.
③ Set the accel dial at "10"(MAX)
④ Set S-mode and cancel auto decel mode.
CN-75
⑤ If tachometer show approx 1900±50rpm,
check electric current.
EPPR VALVE
Multimeter
6-38(3) 140-7
6-42
(2) Test 4 : Check pressure at EPPR valve. SPEC : 5~20kgf/cm2(70~280psi)
① Remove plug and connect pressure
gauge as figure.
・Gauge capacity : 0 to 40~50kgf/cm2
(0 to 570~710psi)
② Start engine. Supply line, pilot press
③ Set the accel dial at "10"(Max)
④ Set S-mode and cancel auto decel mode. CN-75
⑤ If tachometer show approx 1900 50rpm, Pressure adjusting
check pressure. screw locknut
⑥ If pressure is not correct, adjust it.

⑦ After adjust, test the machine.
6-39(1) 140-7
6-43
2. ENGINE SPEED IS SLOW AT ALL MODE
Cause Remedy
Good
If test 7 is good,
Check tachometer check TEST 1~4
YES work properly or
not by changing YES
Misalignment Clean speed
the mode. between speed sensor and
Is resistance
YES Is resistance See TEST 6 sensor and fly adjust
between CN-50 between CN-51
No good wheel See : 5-20page
(12) - (23) (25) - (26)
SPEC : 0.2~0.4kΩ ⓐ
SPEC : 1~2Ω
See TEST 7 NO
See TEST 5
Check cable
between accel Defective accel Replace accel
NO
actuator and actuator or short actuator or
injection pump. circuit or poor harness
connection assembly
between CN-50-
CN-76
Improper operation Adjust or repair

NO
by loosening or
interference of cable
YES
Short circuit or poor Check and repair
connection
Is resistance
ⓐ between CN-51-
between CD-17
CN-2-CD-17
(1) - (2)
SPEC : 0.2~0.4kΩ
NO
Defective Replace
See TEST 8
speed sensor
Wiring diagram
ACCELACTUATOR
ACCEL ACTUATOR
CPU CONTROLLER
1 P+
2
2 SIG
1 3
12 3 P-
4 NC
5
5 M+ M 6
23 6 M-
CN-76 ACCEL DIAL
CN-50
C -
20 5 B S
21 7 A +
22 CN-142
CN-9
TACHO SENSOR
25 12 1
rp
m
26 11 2
CN-51 CN-2 CD-17 R29076MS03
6-44
2) TEST PROCEDURE SPEC : 1~2Ω
(1) Test 5 : Check resistance between CN-50 Y R G
(12)-(23). CPU
① Starting key OFF. CONTROLLER
② Disconnect connector CN-50 from CPU CN-50
CN-51
controller.
③ Check resistance as figure.
CN-50
12 1
23 13
36 25
Multimeter
R29076MS04
Unit : rpm
(2) Test 6 : Check tachometer(Work properly
Spec Remark
or not)
① Start engine. H-mode 2000±50 Check rpm after
② Check tachometer reading. cancel the Auto decel
S-mode 1900±50 mode.
(3) Test 7 : Check resistance between CN-51 SPEC : 0.2~0.4kΩ

(25) and CN-51(26).
Y R G
② Disconnect connector CN-51 from CPU CPU
CONTROLLER
controller. CN-51
③ Check resistance as figure. CN-50
CN-51 12 1
24 13
36 26 25
Multimeter
R29076MS05
6-45
(4) Test 8 : Check resistance at speed
SPEC : 0.2~0.4kΩ
sensor.
Speed sensor
② Disconnect connector CD-17 of speed
sensor at engine flywheel housing.
③ Check resistance as figure.
CD-17 CD-17
1 2
Engine flywheel
Multimeter
6-42(1) 140-7
6-46
3. ENGINE STALL
Cause Remedy
YES
Not enough engine Contact cummins
YES Check pressure power engine dealer
at EPPR Valve
Defective EPPR Replace
SPEC:5~20kgf/cm2 NO
See TEST 10 valve
Check electric
current at EPPR YES
valve Defective CPU Replace
controller
SPEC : 200~550mA
See TEST 9 Check resistance YES
between CN-50 Short circuit or Check and repair
NO (8)-(24) poor connection
SPEC : 17.5±1Ω(20°
C) between
See TEST 1 Check resistance CN-50 - CN-2 or
NO at EPPR valve
CN-50 - CN-75
SPEC : 17.5±1Ω(20°
C)
See TEST 2 Defective EPPR Replace
NO
valve
Wiring diagram
16075MS30
6-47
2) TEST PROCEDURE SPEC : 200~550mA
(1) Test 9 : Check electric current at EPPR
valve at S-mode CN-75
① Install multimeter as figure.
② Start engine.
③ Set the accel dial at "10"(max)
④ Set S-mode with 1900±50rpm.
⑤ Check electric current. EPPR VALVE
Multimeter
6-44(1) 140-7
(2) Test 10 : Check pressure at EPPR valve SPEC : 5~20kgf/cm2(70~280psi)

at S-mode
① Connect pressure gauge at EPPR valve.
② Start engine.
③ Set the accel dial at "10"(max) Supply line, pilot press
④ Set S-mode with 1900±50rpm.
⑤ Operate bucket lever completely push or CN-75
pull. Pressure adjusting
screw locknut
⑥ Hold arm lever at the end of stroke.
⑦ Check pressure at relief position.
6-44(2) 140-7
6-48
4. MALFUNCTION OF CLUSTER OR MODE SELECTION SYSTEM
Cause Remedy
YES
No power supply to Check fuse
See if all lamps the CPU controller
YES
off in the CPU
controller case YES
Y R G CPU failure Replace
Y R G
See if Co : Err
NO
on the cluster
NO Y R G
ⓐ
NO
OK
Check connection Cluster failure Replace
between CN-50
ⓐ (29) - CN-5(10) or
CN-50(30) - CN-
5(11) No connection Check and repair
NO
KEY OFF
Wiring diagram
CPU CONTROLLER
CLUSTER
POWER IG(24V) 24
GND 28
RX 3 10 29
TX 4 11 30
CN-56 CN-5 CN-50
FUSE
NO.10(CPU)
20W76MS03
6-49
5. SLOW ACTION OF ENGINE SPEED CHANGE WHEN CHANGE THE MODE
Cause Remedy
YES
Slow action of Check and repair
engine speed
control due to
interference
Check interference
between YES
connecting rod and Defective CPU Replace
Check voltage
accel actuator between CN-51(20) controller
YES
-(21) and check
resistance between
CN-51(20)-(22)
Check resistance Defective accel Replace
NO
between CN-50 SPEC : (20)-(21) : 5±1V actuator
NO (20)-(22) : 0.1~0.9kΩ
(12)-(23) See TEST 12
SPEC : 1~2Ω
See TEST 11 Defective accel Replace
NO
actuator
Wiring diagram
ACCEL ACTUATOR
ACCEL ACTUATOR
CPU CONTROLLER
1 P+
2
2 SIG
1 3
12 3 P-
4 NC
5
5 M+ M 6
23 6 M-
CN-76 ACCEL DIAL
CN-50
C -
20 5 B S
21 7 A +
22 CN-142
CN-9
TACHO SENSOR
25 12 1
rp
m
26 11 2
CN-51 CN-2 CD-17
R29076MS03
6-50
2) TEST PROCEDURE SPEC : 1~2Ω
(1) Test 11 : Check resistance. Y R G

CPU
② Disconnect connector CN-50 from CPU CONTROLLER
controller. CN-50
③ Check resistance between CN-50(12)- CN-51
(23) as figure.
CN-50
12 1
23 13
36 25
Multimeter
R29076MS04
6-51
(2) Test 12 : Check voltage and resistance. SPEC : 0.1~0.9kΩ
① Check resistance between CN-51(20)- Y R G
(22). CPU
CONTROLLER
- Starting key OFF.
CN-51
- Disconnect connector CN-51 from CPU
CN-50
controller.
- Check resistance value with multimeter
as figure.
CN-51
12 1
24 22 20 13
36 25
Multimeter
R29076MS08
② Check voltage between CN-51(20) and SPEC : 5±1V

CN-51(21). Y R G
- Prepare 2 pieces of thin sharp pin, steel CPU

or copper. CONTROLLER
PIN
- Starting key ON.
CN-50
- Insert prepared pins to rear side of CN-51
connectors : One pin to CN-51(20)

Other pin to CN-51(21)
- Check voltage.
CN-51
12 1
24 21 20 13
36 25
Multimeter
R29076MS09
6-52
6. AUTO DECEL SYSTEM DOES NOT WORK
Cause Remedy
YES
Defective CPU Replace
controller
NO
Check resistance Short circuit or Replace or repair
between CN-51 poor connection
(1)-GND between CN-51(1)
pressure switches
SPEC :
Actuator operating :
4~5V
Actuator stop :0~1V
See TEST 13 Defective auto Replace
NO
decel pressure
switch
Wiring diagram
CONTROLLER
AUTO DECEL
PRESSURE SWITCH
1 Pa
1 2
CD-7
CN-51
14076TS31
6-53
2) TEST PROCEDURE SPEC : Actuator stop : 4~5V
(1) Test 13 : Check voltage at CN-51(1) and Actuator operating : 0~1V
ground. Y R G
① Prepare 1 piece of thin sharp pin, steel or CPU

CONTROLLER
copper. PIN
② Starting key ON. CN-50
CN-51
③ Insert prepared pin to rear side of

connectors : One pin to (1) of CN-51.
④ Check voltage as figure.
CN-51 12 1
24
36 25
Ground
Multimeter R29076MS11
6-54
7. MALFUNCTION OF WARMING UP
Cause Remedy
YES
Defective cluster or Repair or Replace
Check resistance CPU controller or
YES
between CN-51 CD-8(Sensor)
(31) - CD-8(2)
SPEC : Below10Ω NO Poor connection Repair
Check resistance KEY OFF
between CN-
between CN -51
(33) - CD-8(1) 51(31) - CD-8(2)
SPEC : Below 10Ω
KEY OFF
NO
Poor connection Repair
between CN-
51(33) - CD-8(1)
Wiring diagram
CONTROLLER
WATER TEMPERATURE SENSOR

31 6 2 C
33 5 1
CD-8
CN-51 CN-3
14076TS29
6-55
8. MALFUNCTION OF POWER MAX
Cause Remedy
YES Check resistance
between CN-88 Defective power Repair or replace
(1) - (2) max. solenoid valve
YES
Resistance
between CN-51 SPEC: 15-30Ω
(2)-GND normal? See TEST 15
NO Short circuit or poor Repair or replace

SPEC : Power max button pressed ON : 0 connection
Is voltage between Power max button released OFF : between CN-51(2) -
CN-88(1) -GND See Test 16
normal? CS-29 and CN-50
(3) -CN-88(1)
SPEC
KEY ON : 24±1V
KEY OFF : 0V
See TEST 15
NO Short circuit or poor Repair or replace
connection
between CN-88(2)-
battery relay(+)
Wiring diagram
CPU CONTROLLER
POWER MAX SOLENOID
3 1
2
CN-50
1
CN-88
2 2
FUSE
CN-51 CN-4 NO.24
POWER MAX SWITCH
2
1
CS-29
16076MS06
6-56
2) TEST PROCEDURE SPEC : Key ON : 24±1V
Key OFF : 0V
(1) Test 15: Check voltage between connector Resistance : 15~30Ω
CN-88 - GND.
① Start key ON.
② Disconnect connector CN-88 from power Power max. switch
max solenoid valve.
③ Check voltage as figure.
LH RCV-lever
CN-88
CN-88
Power max.
solenoid valve
Multimeter
R29076MS14
(2) Test 16: Check resistance between

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

③ Check resistance as figure. CONTROLLER
CN-51
CN-50
CN-51
12 2
24 13
36 25
Ground
Multimeter
R29076MS15
6-57
Group 1 Operational Performance Test 7-1

Group 2 Major Components 7-21
Group 3 Track and Work Equipment 7-29
GROUP 1 OPERATIONAL PERFORMANCE TEST
1. PURPOSE
Performance tests are used to check:
1) OPERATIONAL PERFORMANCE OF A NEW
MACHINE
Whenever a new machine is delivered in
parts and reassembled at a customer's site,
it must be tested to confirm that the
operational performance of the machine
meets Hyundai spec.
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
performance level.
Before servicing the machine, conduct
performance tests to check the extent of
deterioration, and to decide what kind of 140LC7MS01
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.
7-1
2. TERMINOLOGY
1) STANDARD
Specifications applied to the brand-new
machine, components and parts.
140LC7MS02
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.
140LC7MS03
7-2
3. OPERATION FOR PERFORMANCE TESTS
1) Observe the following rules in order to carry
out performance tests accurately and
safely.
(1) The machine
Repair any defects and damage found,
such as oil or water leaks, loose bolts,
cracks and so on, before starting to test.
(2) Test area
① Select a hard, flat surface.
② Secure enough space to allow the
machine to run straight more than 20m,
and to make a full swing with the front
attachment extended.
③ If required, rope off the test area and
provide signboards to keep unauthorized
personnel away.
(3) Precautions
① Before starting to test, agree upon the
signals to be employed for communication
among coworkers. Once the test is
7-3 (140-7 TIER)
started, be sure to communicate with
each other using these signals, and to
follow them without fail.
② Operate the machine carefully and
always give first priority to safety.
③ While testing, always take care to avoid
accidents due to landslides or contact
with high voltage power lines. Always
confirm that there is sufficient space for
full swings.
④ Avoid polluting the machine and the
ground with leaking oil. Use oil pans to
catch escaping oil. Pay special attention
to this when removing hydraulic pipings.
(4) Make precise measurements
① Accurately calibrate test instruments in
advance to obtain correct data.
② Carry out tests under the exact test
conditions prescribed for each test item.
③ Repeat the same test and confirm that
the test data obtained can be procured
repeatedly. Use mean values of
measurements if necessary.
7-3
2) ENGINE SPEED
(1) Measure the engine speed at each power
mode
※ The engine speed at each power mode
must meet standard RPM; if not, all other
operational performance data will be
unreliable. It is essential to perform this
test first.
(2) Preparation
① Warm up the machine, until the engine
coolant temperature reaches 50° C or
more, and the hydraulic oil is 50±5°
C.
② Set the accel dial at 10(Max) position.
③ Push the M-mode switch and confirm
that the fuel injection pump governor
lever comes into contact with the high-
idle stopper.
④ Measure the engine RPM.
(3) Measurement
① Start the engine. The engine will run at
start idle speed. Measure engine speed
with a tachometer.
② Measure and record the engine speed at
each mode(M, H, S).
③ Select the M-mode.
④ Lightly operate the bucket control lever a
few times, then return the control lever to
neutral; The engine will automatically
enter the auto-idle speed after 4
seconds.
⑤ Measure and record the auto deceleration
speed.
(4) Evaluation
The measured speeds should meet the following specifications.
Unit : rpm
Model Engine speed Standard Remarks
Start idle 950±100

M mode 2200±50
R160LC-7 H mode 2000±50
S mode 1900±50
Auto decel 1200±50
Condition : Set the accel dial at 10(Max) position.
7-4
3) TRAVEL SPEED
(1) Measure the time required for the
excavator to travel a 20m test track.
(2) Preparation
① Adjust the tension of both tracks to be
equal.
② Prepare a flat and solid test track 20m in
length, with extra length of 3 to 5m on
both ends for machine acceleration and 0.3~0.5m
deceleration.
③ Hold the bucket 0.3 to 0.5m above the
ground with the arm and bucket rolled in.
④ Keep the hydraulic oil temperature at 160LC7MS04
50±5° C.
(3) Measurement
① Measure both the low and high speeds
of the machine.
② Before starting either the low or high
speed tests, adjust the travel mode
switch to the speed to be tested, then
select the following switch positions.
・ Mode selector : M mode
③ Start traveling the machine in the
acceleration zone with the travel levers at 3 ~ 5m 20m 3 ~ 5m
full stroke.
④ Measure the time required to travel 20m.
⑤ After measuring the forward travel 160LC7MS05
speed, turn the upperstructure 180°and

measure the reverse travel speed.
⑥ Repeat steps ④ and ⑤ three times in
each direction and calculate the average
values.
(4) Evaluation
The average measured time should meet the following specifications.
Unit : Seconds / 20m
Model Travel speed Standard Maximum allowable Remarks
1 Speed 19.5±1.0 24.3

R160LC-7
2 Speed 12.9±1.0 16.1
7-5
4) TRACK REVOLUTION SPEED
(1) Measure the track revolution cycle time
with the track raised off ground.
(2) Preparation
① Adjust the tension of both side tracks to
be equal.
② On the track to be measured, mark one 90 ~ 110
shoe with chalk.
③ Swing the upperstructure 90°and lower
the bucket to raise the track off ground.
Mark
Keep the boom-arm angle between 90 to
110°as shown. Place blocks under
machine frame.
50±5° C.
(3) Measurement
① Select the following switch positions.
・ Travel mode switch : 1 or 2 speed
・ Auto decel switch : OFF
② Operate the travel control lever of the
raised track in full forward and reverse.
③ Rotate 1 turn, then measure time taken
for next 3 revolutions.
④ Raise the other side of machine and
repeat the procedure.
⑤ Repeat steps ③ and ④ three times and
calculate the average values.
(4) Evaluation
The revolution cycle time of each track should meet the following specifications.
Unit : Seconds / 3 revolutions
Model Travel speed Standard Maximum allowable
1 Speed 25.0±2.0 30.0

R160LC-7
2 Speed 16.0±2.0 19.2
7-6
5) TRAVEL DEVIATION
(1) Measure the deviation by the tracks from
a 20m straight line.
(2) Preparation
① Adjust the tension of both tracks to be
equal.
② Provide a flat, solid test yard 20m in
length, with extra length of 3 to 5m on
0.3~0.5m
both ends for machine acceleration and
deceleration.
③ Hold the bucket 0.3 to 0.5m above the
ground with the arm and bucket rolled in.
160LC7MS04
④ Keep the hydraulic oil temperature at
50±5° C.
(3) Measurement
① Measure the amount of mistracking at
high and low travel speeds.
② Before beginning each test, select the
following switch positions. 3~5m extra length
・ Mode selector : M mode a
M
20
③ Start traveling the machine in the
acceleration zone with the travel levers at
full stroke. 3~5m extra length
④ Measure the distance between a straight
20m line and the track made by the
machine.(Dimension a)
⑤ After measuring the tracking in forward 7-7(2) 140-7
travel, turn the upperstructure 180°and
measure that in reverse travel.
⑥ Repeat steps ④ and ⑤ three times and
(4) Evaluation
Mistrack should be within the following specifications.
Unit : mm / 20m
Model Standard Maximum allowable Remarks
R160LC-7 200 below 240
7-7
6) SWING SPEED
(1) Measure the time required to swing three
complete turns.
(2) Preparation
① Check the lubrication of the swing gear
and swing bearing.
② Place the machine on flat, solid ground
with ample space for swinging. Do not
conduct this test on slopes.
③ With the arm rolled out and bucket rolled
in, hold the bucket so that the height of
the bucket pin is the same as the boom
foot pin. The bucket must be empty.
50±5° C.
(3) Measurement
・ Mode selector : Each mode
② Operate swing control lever fully.
③ Swing 1 turn and measure time taken to
swing next 3 revolutions.
④ Repeat steps ② and ③ three time and
(4) Evaluation
The time required for 3 swings should meet the following specifications.
Unit : Seconds / 3 revolutions
Model Standard Maximum allowable Remark
R160LC-7 14.9±1.5 18.6
7-8
7) SWING FUNCTION DRIFT CHECK
(1) Measure the swing drift on the bearing
outer circumference when stopping after a
360°full speed swing.
(2) Preparation
① Check the lubrication of the swing gear
and swing bearing.
② Place the machine on flat, solid ground
with ample space for swinging. Do not
conduct this test on slopes.
③ With the arm rolled out and bucket rolled
in, hold the bucket so that the height of 160LC7MS07

foot pin. The bucket must be empty.
④ Make two chalk marks: one on the swing
bearing and one directly below it on the
track frame.
⑤ Swing the upperstructure 360°.
⑥ Keep the hydraulic oil temperature at
50±5° C.
(3) Measurement
① Conduct this test in the M mode.
② Select the following switch positions.
③ Operate the swing control lever fully and
return it to the neutral position when the
mark on the upperstructure aligns with
that on track frame after swinging 360°
④ Measure the distance between the two
marks.
⑤ Align the marks again, swing 360°, then
test the opposite direction.
⑥ Repeat steps ④ and ⑤ three times each
and calculate the average values.
140LC7MS08
(4) Evaluation
The measured drift angle should be within the following specifications.
Unit : Degree
Model Mode select switch Standard Maximum allowable Remarks
R160LC-7 M mode 90 below 157.5
7-9
8) SWING BEARING PLAY
(1) Measure the swing bearing play using a
dial gauge to check the wear of bearing
races and balls.
(2) Preparation
① Check swing bearing mounting cap
screws for loosening.
② Check the lubrication of the swing
bearing. Confirm that bearing rotation is
smooth and without noise.
③ Install a dial gauge on the track frame as
shown, using a magnetic base.
④ Position the upperstructure so that the 7-10(1) 140-7
boom aligns with the tracks facing
towards the front idlers.
⑤ Position the dial gauge so that its needle
point comes into contact with the bottom
face of the bearing outer race.
⑥ Bucket should be empty.
(3) Measurement
① With the arm rolled out and bucket rolled Measurement : (h1)
in, hold the bottom face of the bucket to

the same height of the boom foot pin.
Record the dial gauge reading(h1).
② Lower the bucket to the ground and use
it to raise the front idler 50cm. Measurement : (h2)
Record the dial gauge reading(h2).
③ Calculate bearing play(H) from this
data(h1 and h2) as follows.
H=h2-h1
(4) Evaluation 160LC7MS09
The measured drift should be within the following specifications.

Unit : mm
Model Standard Maximum allowable Remarks
R160LC-7 0.5 ~ 1.5 3.0
7-10
9) HYDRAULIC CYLINDER CYCLE TIME
(1) Measure the cycle time of the boom,
standard arm, and standard bucket
cylinders.
(2) Preparation
Boom cylinder
① To measure the cycle time of the boom
Raise
cylinders:
With the arm rolled out and the empty
bucket rolled out, lower the bucket to the
ground, as shown. Lower
② To measure the cycle time of the arm
cylinder.
With the empty bucket rolled in, position
the arm so that it is vertical to the ground. Arm cylinder
Lower the boom until the bucket is 0.5m
above the ground.
Roll out Roll in
③ To measure the cycle time of the bucket
cylinder.
90
The empty bucket should be positioned
0.5m
at midstroke between roll-in and roll-out,
so that the sideplate edges are vertical to
the ground.
Bucket cylinder
④ Keep the hydraulic oil temperature at
50±5° C.
(3) Measurement
・ Mode selector : M mode Roll out Roll in
Heavy duty work mode
② To measure cylinder cycle times. 0.5m
- Boom cylinders.
160LC7MS10
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.
7-11
- Bucket cylinders
Measure the time it takes to roll in the
bucket, and the time it takes to roll out
the bucket. To do so, position the
bucket at one stroke end, then move the
control lever to the other stroke end as
quickly as possible.
- Repeat each measurement 3 times and
(4) Evaluation
The average measured time should meet the following specifications.
Unit : Seconds
Model Function Standard Maximum allowable Remarks
Boom raise 3.0±0.4 3.6

Boom lower 2.6±0.4 3.2
Arm in 2.9±0.4 3.5
R160LC-7
Arm out 2.8±0.3 3.4
Bucket load 3.5±0.4 4.2
Bucket dump 2.0±0.3 2.5
7-12
10) DIG FUNCTION DRIFT CHECK
(1) Measure dig function drift, which can be
caused by oil leakage in the control valve
and boom, standard arm, and standard
bucket cylinders, with the loaded bucket.
When testing the dig function drift just
after cylinder replacement, slowly operate
each cylinder to its stroke end to purge air.
(2) Preparation
① Load bucket fully. Instead of loading the
bucket, weight(W) of the following
specification can be used.
・ W=M3×1.5
Where :
M3 = Bucket heaped capacity(m3)
1.5= Soil specific gravity
② Position the arm cylinder with the rod 20
to 30mm extended from the fully retracted
position. 160LC7MS11
③ Position the bucket cylinder with the rod

20 to 30mm retracted from the fully
extended position.
④ With the arm rolled out and bucket rolled
in, hold the bucket so that the height of
foot pin.
⑤ Keep the hydraulic oil temperature at
50±5° C.
(3) Measurement
① Stop the engine.
② Five minutes after the engine has been
stopped, measure the changes in the
positions of the boom, arm and bucket
cylinders.
③ Repeat step ② three times and calculate
the average values.
(4) The measured drift should be within the following specifications.
Unit : mm / 5min
Model Drift to be measured Standard Maximum allowable Remarks
Boom cylinder 10 below 20

R160LC-7 Arm cylinder 10 below 20
Bucket cylinder 40 below 50
7-13
11) CONTROL LEVER OPERATING FORCE
(1) Use a spring scale to measure the
maximum resistance of each control lever
at the middle of the grip.
(2) Preparation
① Keep the hydraulic oil temperature at
50±5°C.
(3) Measurement
① Start the engine.
② Select the following switch positions.
③ Operate each boom, arm, bucket and
swing lever at full stroke and measure
the maximum operating force for each.
④ Lower the bucket to the ground to raise
one track off the ground. Operate the
travel lever at full stroke and measure the
maximum operating force required.
When finished, lower the track and then
jack-up the other track.
⑤ Repeat steps ③ and ④ three times and
(4) Evaluation
The measured operating force should be within the following specifications.
Unit : kgf
Model Kind of lever Standard Maximum allowable Remarks
Boom lever 1.6 or below 2.0

Arm lever 1.6 or below 2.0
R160LC-7 Bucket lever 1.6 or below 2.0
Swing lever 1.6 or below 2.0
Travel lever 2.1 or below 3.15
7-14
12) CONTROL LEVER STROKE
(1) Measure each lever stroke at the lever top
using a ruler.
※ When the lever has play, take a half of this
value and add it to the measured stroke.
(2) Preparation
Keep the hydraulic oil temperature at
50±5° C.
(3) Measurement
② Measure each lever stroke at the lever
top from neutral to the stroke end using a
ruler.
③ Repeat step ② three times and calculate
the average values.
(4) Evaluation
The measured drift should be within the following specifications.
Unit : mm
Model Kind of lever Standard Maximum allowable Remarks
Boom lever 87±10 109

Arm lever 87±10 109
R160LC-7 Bucket lever 87±10 109
Swing lever 87±10 109
Travel lever 142±10 178
7-15
13) PILOT PRIMARY PRESSURE
(1) Preparation
② Push the pressure release button to
bleed air.
③ Loosen and remove plug on the pilot
pump delivery port and connect pressure
gauge.
④ Start the engine and check for oil
leakage from the port.
50±5° C.
(2) Measurement
・ Auto decel switch : OFF
140LC7MS12
② Measure the primary pilot pressure in the
H mode.
(3) Evaluation
The average measured pressure should meet the following specifications:
Unit : kgf / cm2
Model Engine speed Standard Allowable limits Remarks
R160LC-7 M mode 33 + 07 -
7-16
14) FOR TRAVEL SPEED SELECTING PRESSURE:
(1) Preparation
bleed air.
③ To measure the speed selecting pressure:
Install a connector and pressure gauge
④ assembly to turning joint P port as shown.
Start the engine and check for on
P
leakage from the adapter. B
A
⑤ Keep the hydraulic oil temperature at D
C
50±5° C.
Dr
(2) Measurement
Travel mode switch : 1 speed
2 speed 21077MS13

② Measure the travel speed selecting
pressure in the Hi or Lo mode.
③ Lower the bucket to the ground to raise
the track off the ground. Operate the
travel lever at full stroke and measure the
fast speed pressure.
④ Repeat steps ② and ③ three times and
(3) Evaluation
The average measured pressure should be within the following specifications.
Unit : kgf / cm2
Model Travel speed mode Standard Maximum allowable Remarks
1 Speed 0 -
R160LC-7
2 Speed 35±5 -
7-17
15) SWING PARKING BRAKE RELEASING PRESSURE
(1) Preparation
bleed air.
③ Install a connector and pressure gauge SH
assembly to swing motor SH port, as

shown.
leakage from the adapter.
50±5° C.
(2) Measurement
② Operate the swing function or arm roll in 21077MS14
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
Unit : kgf / cm2
Model Description Standard Allowable limits Remarks
Brake disengaged 35 15~44

R160LC-7
Brake applied 0 -
7-18
16) MAIN PUMP DELIVERY PRESSURE
(1) Preparation
bleed air.
③ To measure the main pump pressure.
assembly main pump gauge port as
shown.
leakage from the port.
50±5° C.
(2) Measurement
① Select the following switch positions. 140LC7MS13

② Measure the main pump delivery
pressure in the M mode(High idle).
(3) Evaluation
The average measured pressure should meet the following specifications.
Unit : kgf / cm2
Model Engine speed Standard Allowable limits Remarks
R160LC-7 High ilde 35 + 02 -
7-19
17) SYSTEM PRESSURE REGULATOR RELIEF SETTING
(1) Preparation
bleed air.
③ To measure the system relief pressure.
A
assembly main pump gauge port, as
3
shown.
④ Start the engine and check for oil a4
P
m
1
leakage from the port. Ps
v
D
r
⑤ Keep the hydraulic oil temperature at a2
a1
50±5° C.
(2) Measurement
P
m
2
② Slowly operate each control lever of
boom, arm and bucket functions at full 21077MS15
stroke over relief and measure the
pressure.
③ In the swing function, place bucket
against an immovable object and
measure the relief pressure.
④ In the travel function, lock undercarriage
with an immovable object and measure
the relief pressure.
(3) Evaluation
Unit : kgf / cm2
Model Function to be tested Standard Port relief pressure
Boom, Arm, Bucket 330(360)±10 380 +100

R160LC-7
Travel 330±10 -
( ) : Power boost
7-20
GROUP 2 MAJOR COMPONENT
1. MAIN PUMP
3 1 2
9 5 6 4 7 8 7-21 (140-7)
Standard Recommended
Part name & inspection item replacement Counter measures
dimension value
Clearance
between piston(1) & cylinder Replace piston
d D 0.028 0.056
bore(2) or cylinder.
(D-d)
Play between
piston(1) & shoe caulking
0-0.1 0.3
section(3)
(δ) Replace
assembly of
Thickness of shoe piston & shoe.
δ
(t) t 3.9 3.7
Free height of cylinder

spring(4) Replace cylinder
31.3 30.5
(L) spring.
L
Combined height of set

plate(5) & spherical h H
19.0 18.3 Replace retainer
bushing(6) or set plate.
(H-h)
Surface roughness for valve Surface roughness

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

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

incomplete.
・Insert poppet into casing and function it. ・Normal when it can function lightly without
being caught.
Around spring ・Rusting, corrosion, deformation or breaking ・Replacement for significant damage.
of spring, spring seat, plug or cover.
Around seal ・External oil leakage. ・Correction or replacement.

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

port relief valve &
・Contacting face of valve seat. ・Replacement when damaged.
negative control
relief valve ・Contacting face of poppet. ・Replacement when damaged.
・Abnormal spring. ・Replacement.
・O-rings, back up rings and seals. ・100% replacement in general.
Balance plate ・Worn less than 0.03mm ・Lapping

・Worn more than 0.03mm ・Replace
・Sliding surface has a seizure(Even through ・Replace
small).
7-22
3. SWING DEVICE
1) WEARING PARTS
Standard Recommended
Inspection item replacement Counter measures
dimension value
Replace piston or
Clearance between piston and cylinder block bore 0.028 0.058
cylinder block
Replace assembly
Play between piston and shoe caulking section(δ) 0 0.3
of piston and shoe
Replace assembly
Thickness of shoe(t) 5.5 5.3
of piston and shoe
Replace set of
Combined height of retainer plate and spherical retainer plate and
6.5 6.0
bushing (H-h) sperical bushing
Thickness of friction plate 4.0 3.6 Replace
H
h
δ
2) SLIDING PARTS
Part name Standard roughness Allowable roughness Remark
Shoe 0.8-Z(Ra=0.2) 3-Z(Ra=0.8)

(LAPPING)
Shoe plate 0.4-Z(Ra=0.1) 3-Z(Ra=0.8)

(LAPPING)
Cylinder 1.6-Z(Ra=0.4) 12.5-Z(Ra=3.2)

(LAPPING)
Valve plate 0.8-Z(Ra=0.2) 6.3-Z(Ra=1.6)

(LAPPING)
7-23
4. TRAVEL DEVICE
Disassembling and inspection of the motor must be done in strict accordance with the servicing
standards described here. During servicing, handle each part very carefully not to damage them,
especially for their movable or sliding sections.
1) SEALS
Once the seals(O-rings, oil seals, and floating seals) have been disassembled, they must be
replaced with new ones even if no damage is observed.
2) TABLE OF MAINTENANCE STANDARD
(1) Replace all parts having a seriously damaged appearance.
(2) Replace the part if any one of the states(Symptoms) listed in the table below is observed.
Item Maximum allowable
No. Part name Situation Standard dimension value(Criteria)
Spindle kit
2 ・Spindle assembly ・Seriously damaged in
8 ・・Spindle appearance.
- -
17 ・・Coupling gear
・Pin ・Galling or other forms of
excessive wear are observed.
Carrier assembly
3 Carrier ・The tooth surface of the cluster
6 Cluster gear gear(6) is nonuniformly worn out
9 Shaft and damaged. - -
14 Thrust collar
・The cluster gear(6) does not
25 Needle bearing
move smoothly.
34 Dowel pin
4 Ring gear A ・The tooth surface is

nonuniformly worn out and - -
damaged.
5 Ring gear B ・The tooth surface is

nonuniformly worn out and - -
damaged.
7 Sun gear ・The tooth surface is

nonuniformly worn out and
- -
damaged.
・The spline section is worn.
8 Coupling gear ・Excessive wear or pitching is

- -
observed on the tooth surface.
19 Coupling ・The spline section is worn. - -
20 Thrust bearing ・Worn out. Axial clearance Clearance : 0.8mm

between coupling
gear(8) and cover(13)
: 0.3 to 0.6mm
7-24
22 Distance piece ・The sliding surface is damaged.

・The sliding surface is excessively - -
worn out.
24 Ball bearing ・Dents are present.

・Flaking develops. - -
・Nonuniform wear is present.
Rear flange kit ・The movable section contacting Linear clearance : Linear clearance :
101 Rear flange the spool(123) is damaged. 10 to 20 μ 25 μ
・The clearance against the spool
(123) is too large.
・The surface contacting the valve
(127) is damaged.
・The depth to the surface
contacting the valve (127) is too
large.
123 Spool ・The outer surface is damaged.
・The outer surface is
nonuniformly worn out.
102 Shaft ・The surface contacting the oil

seal(132) is worn out. - -
・The spline section is worn out.
103 Swash plate ・Seizure is observed. - -
104 Cylinder block ・The spline section is worn out.

・The bore inner surface is worn
out too much. - -
・The sliding surface that contacts
the timing plate(109) is damaged
or nonuniformly worn out.
Piston assembly ・An axial clearance is present Clearance : 0.05mm Clearance : 0.15mm
105 Piston between the piston(105) and the
106 shoe shoe(106).
・The shoe is excessively worn out.
・The shoe is nonuniformly worn
out.
107 Retainer plate ・The peripheral edge is

- -
nonuniformly worn out.
7-25
108 Thrust ball ・The spherical sliding section that

contacts the retainer plate(107)
is nonuniformly worn out. - -
109 Timing plate ・The sliding surface has the traces
of seizure or nonuniformly wear.
115 Friction plate ・Both edges are nonuniformly Braking torque Braking torque
worn out. 40.6kgf・m or more 40.6kgf・m or less
116 Mating plate ・The required torque cannot be
achieved.
・The traces of seizure are present.
118 Valve seat ・The seat surface is damaged. - -
119 Valve ・The outer surface is damaged.

- -
・The seat surface is damaged.
Body kit
136 Body ・The sliding section that contacts Linear clearance : Linear clearance :
the spool(137) is damaged. 7 to 15 μ 20 μ
・The clearance against the
spool(137) is too large.
137 Spool ・The outer surface is damaged.
・The outer surface is nonuniformly
worn out.
149 Roller bearing ・Dents are present.

150 Ball bearing
・Flaking develops. - -
・Nonuniform wear is observed.

- -
164 Stopper ・The seat surface is damaged. - -

- -
172 Valve seat ・The seat surface is damaged. - -
7-26
5. TURNING JOINT
Part name Maintenance standards Remedy
Sliding surface with Plating worn or peeled due to seizure or contamination. Replace
sealing sections.
Sliding surface ・Worn abnormality or damaged more than 0.1mm Replace

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

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

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

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

(0.059in)
7-27
6. CYLINDER
Part name Inspecting section Inspection item Remedy
Piston rod ・Neck of rod pin ・Presence of crack ・Replace

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

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

than coating
7-28
GROUP 3 TRACK AND WORK EQUIPMENT
1. TRACK
1) TRACK ROLLER
32077MS01
Unit : mm
No. Check item Criteria Remedy
Standard size Repair limit

1 Outside diameter of flange
Ø200 Ø188
Rebuild or
2 Outside diameter of tread Ø160 Ø148 replace
3 Width of tread 48 54
4 Width of flange 21.5 -
Standard size & Tolerance Standard Clearance
Clearance between shaft Shaft Hole clearance limit Replace
5
and bushing -0.29 +0.46 0.39 bushing
Ø70 -0.33 Ø70.1 0 to 0.476 2.0
Side clearance of roller Standard clearance Clearance limit

6 Replace
(Both side) 0.2 to 1.2 2.0
7 - 29
2) CARRIER ROLLER
5
1
4 3
16077MS02
Unit : mm

1 Outside diameter of flange
Ø169 Ø155
Rebuild or
2 Outside diameter of tread Ø144 Ø130 replace
4 Width of flange 17 -
Clearance between shaft Shaft Hole clearance limit
5 Replace
and support
Ø55 -0.05 Ø55 +0.3 0.15 to 0.4 1.2
-0.1 +0.1
7-30
3) IDLER
8
1
2
7
3 5
4
21037MS03
Unit : mm

1 Outside diameter of protrusion
Ø560 Ø550
2 Outside diameter of tread Ø520 Ø510 Rebuild or
3 Width of protrusion 84 74 replace
4 Total width 160 -

Clearance between shaft Shaft Hole clearance limit Replace
6
and bushing 0 +0.05 bushing
Ø75 -0.03 Ø75.35 0 0.35 to 0.43 2.0
Clearance between shaft 0 +0.07
7 and support Ø75 -0.03 Ø75 +0.03 0.03 to 0.1 1.2 Replace
Side clearance of idler Standard clearance Clearance limit

8 Replace
(Both side) 0.4 to 1.2 2.0
7 - 31
4) TRACK
2 1
4
3
5
32077MS04
Unit : mm
Standard size Repair limit Turn or

1 Link pitch replace
171.45 175.65
2 Outside diameter of bushing ͚54 ͚46
Rebuild or
3 Height of grouser 25 16 replace
4 Height of link 101.6 93.6
Tightening torgue
5 Initial tightening torque : 40Ü4kgfÂm Retighten
(Tightening angle method)
7 - 32
5) TRACK FRAME AND RECOIL SPRING
2
3
1
21037MS05
Unit : mm
Standard size Tolerance Repair limit

+2
1 Vertical width of idler guide Track frame 113 0
117
- 0.5 Rebuild or
Idler support 110 - 1.0 106
replace
+2
Track frame 272 0 277
2 Horizontal width of idler guide
+0.5
Idler support 270 -0.5
267

3 Recoil spring Free Installation Installation Free Installation
length length load length load Replace
Ø225×525 420 11,908kg - 9,527kg
7 - 33
2. WORK EQUIPMENT
A C D E F
B K J I H G
160LC7MS20
Unit : mm
Pin Bushing
Remedy
Measuring point Normal Recomm. Recomm.
Mark Limit Limit &
(Pin and Bushing) value service service
of use of use Remark
limit limit
A Boom Rear 75 74 73.5 75.5 76 Replace

B Boom Cylinder Head 70 69 68.5 70.5 71 〃
C Boom Cylinder Rod 75 74 73.5 75.5 76 〃
D Arm Cylinder Head 70 69 68.5 70.5 71 〃
E Boom Front 75 74 73.5 75.5 76 〃
F Arm Cylinder Rod 70 69 68.5 70.5 71 〃
G Bucket Cylinder Head 70 69 68.5 70.5 71 〃
H Arm Link 70 69 68.5 70.5 71 〃
I Bucket and Arm Link 70 69 68.5 70.5 71 〃
J Bucket Cylinder Rod 70 69 68.5 70.5 71 〃
K Bucket Link 70 69 68.5 70.5 71 〃
7 - 34
Group 1 Precaution 8-1

Group 2 Tightening Torque 8-4
Group 8 Turning Joint 8-125
Group 9 Boom, Arm and Bucket Cylinder 8-130
GROUP 1 PRECAUTIONS
1. REMOVAL WORK
1) Lower the work equipment completely to the ground.
If the coolant contains antifreeze, dispose of it correctly.
2) After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
3) When draining oil, prepare a container of adequate size to catch the oil.
4) Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
5) To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors.
6) Fit wires and hoses with tags to show their installation position to prevent any mistake when
installing.
7) Check the number and thickness of the shims, and keep in a safe place.
8) When raising components, be sure to use lifting equipment of ample strength.
9) When using forcing screws to remove any components, tighten the forcing screws alternately.
10) Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
11) When removing hydraulic equipment, first release the remaining pressure inside the hydraulic tank
and the hydraulic piping.
12) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
number D d L
06 6 5 8
08 8 6.5 11
10 10 8.5 12
12 12 10 15
14 14 11.5 18 Taper 1/8
øD ød
16 16 13.5 20
18 18 15 22
20 20 17 25
L
22 22 18.5 28
24 24 20 30
27 27 22.5 34
8-1
2. INSTALL WORK
1) Tighten all bolts and nuts(Sleeve nuts) to the specified torque.
2) Install the hoses without twisting or interference.
3) Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
4) Bend the cotter pin or lock plate securely.
5) When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded
portion with 2-3 drops of adhesive.
6) When coating with gasket sealant, clean the surface and remove all oil and grease, check that there
is no dirt or damage, then coat uniformly with gasket sealant.
7) Clean all parts, and correct any damage, dents, burrs, or rust.
8) Coat rotating parts and sliding parts with engine oil.
9) When press fitting parts, coat the surface with antifriction compound(LM-P).
10) After installing snap rings, check that the snap ring is fitted securely in the ring groove(Check that
the snap ring moves in the direction of rotation).
11) When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then
connect securely.
12) When using eyebolts, check that there is no deformation or deterioration, and screw them in fully.
13) When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
14) When operating the hydraulic cylinders for the first time after repairing and reassembling the
hydraulic cylinders, pumps, or other hydraulic equipment or piping, always bleed the air from the
hydraulic cylinders as follows:
(1) Start the engine and run at low idling.
(2) Operate the control lever and actuate the hydraulic cylinder 4-5 times, stopping 100mm before the
end of the stroke.
(3) Next, operate the piston rod to the end of its stroke to relieve the circuit. (The air bleed valve is
actuated to bleed the air.)
(4) After completing this operation, raise the engine speed to the normal operating condition.
※ If the hydraulic cylinder has been replaced, carry out this procedure before assembling the rod to
the work equipment.
※ Carry out the same operation on machines that have been in storage for a long time after
completion of repairs.
8-2
3. COMPLETING WORK
1) If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run
the engine to circulate the water through the system. Then check the water level again.
2) If the hydraulic equipment has been removed and installed again, add engine oil to the specified
level. Run the engine to circulate the oil through the system. Then check the oil level again.
3) If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been
removed for repair, always bleed the air from the system after reassembling the parts.
4) Add the specified amount of grease(Molybdenum disulphied grease) to the work equipment related
parts.
8-3
GROUP 2 TIGHTENING TORQUE
1. MAJOR COMPONENTS
Torque
No. Descriptions Bolt size
kgf・m lbf・ft
1 Engine mounting bolt(Engine-Bracket) M12 × 1.75 10.0±0.5 72.3±3.6
2 Engine mounting bolt(Bracket-Frame) M20 × 2.5 30±3.5 253±25.3
Engine
3 Radiator mounting bolt, nut M12 × 1.75 12.2±1.3 88.2±9.4
4 Coupling mounting bolt M16 × 2.0 22.1±2.4 159±17.3
5 Main pump mounting bolt M16 × 2.0 22.1±2.4 159±17.3
6 Main control valve mounting bolt M12 × 1.75 12.2±1.3 88.2±9.4
Hydraulic
7 system Fuel tank mounting bolt M20 × 2.5 45±5.1 325±36.9
8 Hydraulic oil tank mounting bolt M20 × 2.5 45±5.1 325±36.9
9 Turning joint mounting bolt, nut M12 × 1.75 12.2±1.3 88.2±9.4
10 Swing motor mounting bolt M20 × 2.5 57.9±8.7 419±62.9
11 Swing bearing upper mounting bolt M20 × 2.5 57.8±6.4 418±46.3
12 Power Swing bearing lower mounting bolt M20 × 2.5 57.8±6.4 418±46.3
train
13 Travel motor mounting bolt M16 × 2.5 23±2.5 166±18.1
system
14 Sprocket mounting bolt M16 × 2.0 23±2.5 166±18.1
15 Carrier roller mounting bolt, nut M20 × 2.5 54.7±6.0 396±43.4
16 Track roller mounting bolt M20 × 2.5 54.7±6.0 396±43.4
17 Under Track tension cylinder mounting bolt M16 × 2.0 29.7±4.5 215±32.5
18 carriage Track shoe mounting bolt, nut 5/8-18UNF 40±4 289±28.9
19 Track guard mounting bolt M20 × 2.5 57.9±8.7 419±62.9
20 Counter weight mounting bolt M30 × 3.9 199±30 1439±217
21 Others Cab mounting bolt, nut M12 × 1.75 12.2±1.3 88.2±9.4
22 Operator's seat mounting bolt M 8 × 1.25 1.17±0.1 8.5±0.7
※ For tightening torque of engine and hydraulic components, see each component disassembly and
assembly.
8-4
2. TORQUE CHART
Use following table for unspecified torque.
1) BOLT AND NUT - Coarse thread
8T 10T
Bolt size
kgf・m lbf・ft kgf・m lbf・ft
M 6 × 1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6
M 8 × 1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.73 ~ 4.12 19.7 ~ 29.8
M10 × 1.5 4.0 ~ 6.0 28.9 ~ 43.4 5.5 ~ 8.3 39.8 ~ 60
M12 × 1.75 7.4 ~ 11.2 53.5 ~ 79.5 9.8 ~ 15.8 71 ~ 114
M14 × 2.0 12.2 ~ 16.6 88.2 ~ 120 16.7 ~ 22.5 121 ~ 167
M16 × 2.0 18.6 ~ 25.2 135 ~ 182 25.2 ~ 34.2 182 ~ 247
M18 × 2.5 25.8 ~ 35.0 187 ~ 253 35.1 ~ 47.5 254 ~ 343
M20 × 2.5 36.2 ~ 49.0 262 ~ 354 49.2 ~ 66.6 356 ~ 482
M22 × 2.5 48.3 ~ 63.3 350 ~ 457 65.8 ~ 98.0 476 ~ 709
M24 × 3.0 62.5 ~ 84.5 452 ~ 611 85.0 ~ 115 615 ~ 832
M30 × 3.5 124 ~ 168 898 ~ 1214 169 ~ 229 1223 ~ 1655
M36 × 4.0 174 ~ 236 1261 ~ 1703 250 ~ 310 1808 ~ 2242
2) BOLT AND NUT - Fine thread

8T 10T
Bolt size
kgf・m lbf・ft kgf・m lbf・ft
M 8 × 1.0 2.17 ~ 3.37 15.7 ~ 24.3 3.04 ~ 4.44 22.0 ~ 32.0
M10 × 1.25 4.46 ~ 6.66 32.3 ~ 48.2 5.93 ~ 8.93 42.9 ~ 64.6
M12 × 1.25 7.78 ~ 11.58 76.3 ~ 83.7 10.6 ~ 16.0 76.6 ~ 115
M14 × 1.5 13.3 ~ 18.1 96.2 ~ 130 17.9 ~ 24.1 130 ~ 174
M16 × 1.5 19.9 ~ 26.9 144 ~ 194 26.6 ~ 36.0 193 ~ 260
M18 × 1.5 28.6 ~ 43.6 207 ~ 315 38.4 ~ 52.0 278 ~ 376
M20 × 1.5 40.0 ~ 54.0 289 ~ 390 53.4 ~ 72.2 386 ~ 522
M22 × 1.5 52.7 ~ 71.3 381 ~ 515 70.7 ~ 95.7 512 ~ 692
M24 × 2.0 67.9 ~ 91.9 491 ~ 664 90.9 ~ 123 658 ~ 890
M30 × 2.0 137 ~ 185 990 ~ 1338 182 ~ 248 1314 ~ 1795
M36 × 3.0 192 ~ 260 1389 ~ 1879 262 ~ 354 1893 ~ 2561
8-5
3) PIPE AND HOSE
Thread size Width across flat(mm) kgf・m lbf・ft

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
4) FITTING
Thread size Width across flat(mm) kgf・m lbf・ft

1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 6 43.4
3/4" 36 13 94.0
1" 41 15 109
8-6
GROUP 3 PUMP DEVICE
1. REMOVAL AND INSTALL

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

Escaping fluid under pressure can
penetrate the skin causing serious injury. 9
74
(4) Loosen the drain plug under the hydraulic
tank and drain the oil from the hydraulic
tank.
A
2
・ Hydraulic tank quantity : 160ℓ
A
1
(42.2 U.S.gal)
(5) Remove socket bolts(74) and disconnect
pipe(9). 72
3
21078DA01
(6) Disconnect pilot line hoses(48, 49, 55, 58,

64, 69, 71, 78).
(7) Remove socket bolts(72) and disconnect
pump suction tube(3).
※ When pump suction tube is disconnected,
the oil inside the piping will flow out, so
catch it in oil pan.
(8) Sling the pump assembly and remove the
pump mounting bolts.
・ Weight : 90kg(200lb)
※ Pull out the pump assembly from housing.
When removing the pump assembly,
1408DA02
check that all the hoses have been
disconnected.
8-7
2) INSTALL
(1) Carry out installation in the reverse order
to removal.
(2) Remove the suction strainer and clean it.
(3) Replace return filter with new one.
(4) Remove breather and clean it.
(5) After adding oil to the hydraulic tank to the
specified level.
(6) Bleed the air from the hydraulic pump.
① Remove the air vent plug(2EA).
② Tighten plug lightly.
③ Start the engine, run at low idling, and
check oil come out from plug.
④ Tighten plug.
(7) Start the engine, run at low idling(3~5
minutes) to circulate the oil through the
system.
(8) Confirm the hydraulic oil level and check
the hydraulic oil leak or not.
8-8
2. MAIN PUMP(1/2)
1) STRUCTURE
702
789, 732 532 214 548 531 724 792 534 901 954 719 151 152 211 113
535
808
953
886 04
717
406
261
774
111
824
127
710
123
251
212
490 153 156 157 313 124 312 114 466 885 314 467 141 981 271 401
725 728 983
14072SF02
04 Gear pump 271 Pump casing 719 O-ring

111 Drive shaft(F) 312 Valve block 724 O-ring
113 Drive shaft(R) 313 Valve plate(R) 725 O-ring
114 Spline couping 314 Valve plate(L) 728 O-ring
123 Roller bearing 401 Hexagon socket bolt 732 O-ring
124 Needle bearing 406 Hexagon socket bolt 774 Oil seal
127 Bearing spacer 466 VP Plug 789 Back up ring
141 Cylinder block 467 VP Plug 792 Back up ring
151 Piston 490 Plug 808 Hexagon head nut
152 Shoe 531 tilting pin 824 Snap ring
153 Set plate 532 Servo piston 885 Pin
156 Bushing 534 Stopper(L) 886 Spring pin
157 Cylinder spring 535 Stopper(S) 901 Eye bolt
211 Shoe plate 548 Pin 953 Set screw
212 Swash plate 702 O-ring 954 Set screw
214 Bushing 710 O-ring 981 Plate
251 Support 717 O-ring 983 Pin
261 Seal cover(F)
8-9
2) TOOLS AND TIGHTENING TORQUE
(1) Tools
The tools necessary to disassemble/reassemble the pump are shown in the follow list.
Tool name & size Part name
Hexagon socket PT plug PO plug Hexagon socket

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

413) and remove regulator.
MP01 (140-7)
(5) Loosen hexagon socket head bolts(401)

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

with its regulator-fitting surface down and
separate pump casing(271) from valve
block(312).
※ Before bringing this surface down, spread
rubber sheet on workbench without fail to
prevent this surface from being damaged.
MP02 (140-7)
8-12
(7) Pull cylinder block(141) out of pump
casing(271) straightly over drive
shaft(111). Pull out also pistons(151), set
plate(153), spherical bush(156) and
cylinder springs(157) simultaneously.
※ Take care not to damage sliding surfaces
of cylinder, spherical bushing, shoes,
swash plate, etc.
MP03 (140-7)
(8) Remove hexagon socket head bolts(406)

and then seal cover(F, 261).
※ Fit bolt into pulling out tapped hole of seal
cover(F), and cover can be removed
easily.
※ Since oil seal is fitted on seal cover(F),
take care not to damage it in removing
cover.
(9) Remove hexagon socket head bolts(408) MP04 (140-7)
and then seal cover(R, 262).
In case fitting a gear pump, first, remove
gear pump.
(10) Tapping lightly fitting flange section of
swash plate support(251) on its pump
casing side, separate swash plate support
from pump casing.
MP05 (140-7)
(11) Remove shoe plate(211)and swash

plate(212) from pump casing(271).
MP06 (140-7)
8-13
(12) Tapping lightly shaft ends of drive shafts
(111, 113) with plastic hammer, take out
drive shafts from swash plate supports.
MP07 (140-7)
(13) Remove valve plates(313, 314) from valve

block(312).
※ These may be removed in work(6).
MP08 (140-7)
(14) If necessary, remove stopper(L, 534),

stopper(S, 535), servo piston(532) and
tilting pin(531) from pump casing(271),
and needle bearing(124) and splined
coupling(114) from valve block(312).
※ In removing tilting pin, use a protector to
prevent pin head from being damaged.
※ Since loctite is applied to fitting areas of
tilting pin and servo piston, take care not
to damage servo piston.
※ Do not remove needle bearing as far as
possible, except when it is considered to
be out of its life span.
※ Do not loosen hexagon nuts of valve
block and swash plate support.
If loosened, flow setting will be changed.
8-14
4) ASSEMBLY
(1) For reassembling reverse the
disassembling procedures, paying
attention to the following items.
① Do not fail to repair the parts damaged
during disassembling, and prepare
replacement parts in advance.
② Clean each part fully with cleaning oil and
dry it with compressed air.
③ Do not fail to apply clean working oil to
sliding sections, bearings, etc. before
assembling them.
④ In principle, replace seal parts, such as
O-rings, oil seals, etc.
⑤ For fitting bolts, plug, etc., prepare a
torque wrench or so on, and tighten them
with torques shown in page 8-11, 12.
⑥ For the double-pump, take care not to
mix up parts of the front pump with those
of the rear pump.
(2) Fit swash plate support(251) to pump

casing(271), tapping the former lightly
with a hammer.
※ After servo piston, tilting pin, stopper(L)
and stopper(S) are removed, fit them
soon to pump casing in advance for
reassembling.
※ In tightening servo piston and tilting pin,
use a protector to prevent tilting pin head
MP09 (140-7)
and feedback pin from being damaged.
In addition, apply loctite(Medium strength)
to their threaded sections.
8-15
(3) Place pump casing with its regulator fitting
surface down, fit tilting bush of swash
plate to tilting pin(531) and fit swash plate
(212) to swash plate support(251)
correctly.
※ Confirm with fingers of both hands that
swash plate can be removed smoothly.
※ Apply grease to sliding sections of swash
plate and swash plate support, and drive
MP10 (140-7)
shaft can be fitted easily.
(4) To swash plate support(251), fit drive

shaft(111) set with bearing(123), bearing
spacer(127) and snap ring(824).
※ Do not tap drive shaft with hammer or so
on.
※ Assemble them into support, tapping
outer race of bearing lightly with plastic
hammer.
Fit them fully, using steel bar or so on.
MP11 (140-7)
(5) Assemble seal cover(F, 261) to pump

casing(271) and fix it with hexagon socket
head bolts(406).
※ Apply grease lightly to oil seal in seal
cover(F).
※ Assemble oil seal, taking full care not to
damage it.
※ For tandem type pump, fit rear cover(263)
and seal cover(262) similarly.
MP12 (140-7)
(6) Assemble piston cylinder subassembly

〔cylinder block(141), piston subassembly
(151, 152), set plate(153), spherical bush
(156), spacer(158) and cylinder spring
(157)〕.
Fit spline phases of retainer and cylinder.
Then, insert piston cylinder subassembly
into pump casing.
MP13 (140-7)
8-16
(7) Fit valve plate(313) to valve block(312),
entering pin into pin hole.
※ Take care not to mistake suction / delivery
directions of valve plate.
MP14 (140-7)
(8) Fit valve block(312) to pump casing(271)

and tighten hexagon socket head bolts
(401).
※ At first assemble this at rear pump side,
and this work will be easy.
※ Take care not to mistake direction of valve
block.
※ Clockwise rotation(Viewed from input
shaft side) - Fit block with regulator up
MP16 (140-7)
and with delivery flange left, viewed from
front side.
※ Counter clockwise rotation(Viewed from
input shaft side) - Fit block with delivery
flange right, viewed from front side.
(9) Putting feedback pin of tilting pin into

feedback lever of regulator, fit regulator
and tighten hexagon socket head bolts
(412, 413).
※ Take care not to mistake regulator of front
pump for that of rear pump.
MP17 (140-7)
(10) Fit drain port plug(468).

This is the end of reassembling procedures.
8-17
3. REGULATOR
1) STRUCTURE(1/2)
412 876 874

A 755
647
897 B 858
614
612 648
723
642
615 438
613
875 801
A 611
B 801
924
641 730 643 708 644 645 646 728

SECTION B-B
413 438 413 438
656 D
438
735
D
722
496 724 725 436 496 724 725 436
VIEW C(FRONT) VIEW C(REAR)
KR38-9C07(FRT) A
KR38-9C05(RR)
735 722 P2
079
Pf
466
Pm
Pi
753 496 755
SECTION D-D
B
16072SF03
8-18
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
2-5 (140-7)
412 Hexagon socket screw 631 Sleeve, pf 730 O-ring

413 Hexagon socket screw 641 Pilot cover 732 O-ring
436 Hexagon socket screw 642 Pilot cover(QMC) 733 O-ring
438 Hexagon socket screw 643 Pilot piston 734 O-ring
496 Plug 644 Spring seat(Q) 735 O-ring
601 Casing 645 Adjust stem(Q) 755 O-ring
611 Feed back lever 646 Pilot spring 756 O-ring
612 Lever(1) 647 Stopper 763 O-ring
613 Lever(2) 648 Piston(QMC) 801 Nut
614 Fulcrum plug 651 Sleeve 814 Snap ring
615 Adjust plug 652 Spool 836 Snap ring
621 Compensator piston 653 Spring seat 858 Snap ring
622 Piston case 654 Return spring 874 Pin
623 Compensator rod 655 Set spring 875 Pin
624 Spring seat(C) 656 Block cover 876 Pin
625 Outer spring 708 O-ring 887 Pin
626 Inner spring 722 O-ring 897 Pin
627 Adjust stem(C) 723 O-ring 898 Pin
628 Adjust screw(C) 724 O-ring 924 Set screw
629 Cover(C) 725 O-ring 925 Adjust screw(QI)
630 Lock nut 728 O-ring
8-19
(1) Tools
The tools necessary to disassemble/reassemble the pump are shown in the follow list.
Tool name & size Part name

Hexagon socket PT plug PO plug Hexagon socket
Name B
head bolt (PT thread) (PF thread) head setscrew
Allen wrench 4 M 5 BP-1/16 - M 8
B
5 M 6 BP-1/8 - M10
6 M 8 BP-1/4 PO-1/4 M12, M14
Double ring spanner,
socket wrench, double(Single) Hexagon head VP plug
open end spanner - Hexagon nut
bolt (PF thread)
B
6 M 8 M 8 -
Adjustable angle wrench Small size, Max 36mm
Screw driver Minus type screw driver, Medium size, 2 sets
Hammer Plastic hammer, 1 set
Pliers For snap ring, TSR-160
Steel bar 4×100mm
Pincers -
Bolt M4, Length : 50mm
8-20
Torque Wrench size
Part name Bolt size
kgf・m lbf・ft in mm
Hexagon socket head bolt M 5 0.7 5.1 0.16 4
Material : SCM435) M 6 1.2 8.7 0.20 5
M 8 3.0 21.7 0.24 6
M10 5.8 42.0 0.31 8
M12 10.0 72.3 0.39 10
M14 16.0 116 0.47 12
M16 24.0 174 0.55 14
M18 34.0 246 0.55 14
M20 44.0 318 0.67 17
PT Plut(Materal : S45C) PT1/16 0.7 5.1 0.16 4
※Wind a seal tape 1 1/2 to 2 PT 1/8 1.05 7.59 0.20 5
turns round the plug
PT 1/4 1.75 12.7 0.24 6
PT 3/8 3.5 25.3 0.31 8
PT 1/2 5.0 36.2 0.39 10
PF Plut(Materal : S35C) PF 1/4 3.0 21.7 0.24 6
PF 1/2 10.0 72.3 0.39 10
PF 3/4 15.0 109 0.55 14
PF 1 19.0 137 0.67 17
PF 1 1/4 27.0 195 0.67 17
PF 1 1/2 28.0 203 0.67 17
8-21
3) DISASSEMBLY
Since the regulator consists of small
precision finished parts, disassembly and
assembly are rather complicated.
For this reason, replacement of a regulator
assembly is recommended, unless there is
a special reason, but in case disassembly is
necessary for an unavoidable reason, read
through this manual to the end before
starting disassembly.
(1) Choose a place for disassembly.
※ Choose a clean place.
※ Spread rubber sheet, cloth, or so on top of
work-bench to prevent parts from being
damaged.
(2) Remove dust, rust, etc. from surfaces of
regulator with clean oil.
(3) Remove hexagon socket head screw

(412, 413) and remove regulator main
body from pump main body.
※ Take care not to lose O-ring.
REG01 (140-7)
(4) Remove hexagon socket head screw

(438) and remove cover(C,629)
※ Cover(C) is fitted with adjusting screw
(C,QI) (628, 925), adjusting ring(C, 627),
lock nut(630), hexagon nut(801) and
adjusting screw(924).
Do not loosen these screws and nuts.
If they are loosened, adjusted pressure-
flow setting will vary.
REG02 (140-7)
8-22
(5) After removing cover(C, 629) subassembly,
take out outer spring(625), inner spring
(626) and spring seat(C, 624) from
compensating section.
Then draw out adjusting ring(Q, 645), pilot
spring(646) and spring seat(644) from
pilot section.
※ Adjusting ring(Q,645) can easily be drawn
out with M4 bolt.
REG03 (140-7)
(6) Remove hexagon socket head screws

(436, 438) and remove pilot cover(641).
After removing pilot cover, take out set
spring(655) from pilot section.
REG04 (140-7)
(7) Remove snap ring(814) and take out

spring seat(653), return spring(654) and
sleeve(651).
※ Sleeve(651) is fitted with snap ring(836).
※ When removing snap ring(814), return
spring(654) may pop out.
Take care not to lose it.
REG05 (140-7)
(8) Remove locking ring(858) and take out

fulcrum plug(614) and adjusting plug
(615).
※ Fulcrum plug(614) and adjusting plug
(615) can easily be taken out with M6 bolt.
REG06 (140-7)
8-23
REG07 (140-7)
(9) Remove lever(2, 613). Do not draw out

pin(875).
※ Work will be promoted by using pincers or
so on.
REG08 (140-7)
(10) Draw out pin(874) and remove feedback

lever(611).
Push out pin(874, 4mm in dia.) from above
with slender steel bar so that it may not
interfere with lever(1, 612).
REG09 (140-7)
REG10 (140-7)
8-24
(11) Remove lever(1, 612). Do not draw out
pin(875).
(12) Draw out pilot piston(643) and spool(652).
(13) Draw out piston case(622), compensating
piston(621) and compensating rod(623).
※ Piston case(622) can be taken out by
pushing compensating rod(623) at
opposite side of piston case.
This completes disassembly.
8-25
4) ASSEMBLY
(1) For assembly, reverse disassembly
procedures, but pay attention to the
following items.
① Always repair parts that were scored at
disassembly.
② Get replacement parts ready beforehand.
Mixing of foreign matter will cause
malfunction.
Therefore, wash parts well with cleaning
oil, let them dry with jet air and handle
them in clean place.
③ Always tighten bolts, plugs, etc. to their
specified torques.
④ Do not fail to coat sliding surfaces with
clean hydraulic oil before assembly.
⑤ Replace seals such as O-ring with new
ones as a rule.
(2) Put compensating rod(623) into

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

spool of casing.
※ Confirm that spool and sleeve slide
smoothly in casing without binding.
※ Pay attention to orientation of spool.
Spool
Feedback lever
8-27 (140-7)
8-26
(5) Fit feedback lever(611), matching its pin
hole with pin hole in spool.
Then insert pin(874).
※ Insert pin in feedback lever a little to ease
Lever (1) side Lever (2) side
operation.
※ Take care not to mistake direction of (Fulcrum plug of
adjusting plug side)
feedback lever.
8-28 (140-7)
(6) Put pilot piston(643) into pilot hole of

casing.
※ Confirm that pilot piston slides smoothly
without binding.
(7) Put pin force-fitted in lever(2, 613) into
groove of pilot piston.
Then fix lever(2).
REG11 (140-7)
(8) Fit fulcrum plug(614) so that pin force-

fitted in fulcrum plug(614) can be put into
pin hole of lever(2).
Then fix locking ring(858).
(9) Insert adjusting plug(615) and fit locking
ring.
※ Take care not to mistake inserting holes
for fulcrum plug and adjusting plug.
At this point in time move feedback lever
to confirm that it has no large play and is
free from binding. REG12 (140-7)
(10) Fit return spring(654) and spring seat

(653) into spool hole and attach snap ring
(814).
REG13 (140-7)
8-27
(11) Fit set spring(655) to spool hole and put
compensating piston(621) and piston
case(622) into compensating hole.
Fit pilot cover(641) and tighten it with
hexagonal socket head screws(436, 438).
REG14 (140-7)
(12) Put spring seat(644), pilot spring(646) and

adjusting ring(Q, 645) into pilot hole.
Then fix spring seat(624), inner spring
(626) and outer spring(625) into
compensating hole.
※ When fitting spring seat, take care not to
mistake direction of spring seat.
REG15 (140-7)
(13) Install cover(C, 629) fitted with adjusting

screws(628, 925), adjusting ring(C, 627),
lock nut(630), hexagon nut(801) and
adjusting screw(924).
Then tighten them with hexagonal socket
head screws(438).
This completes assembly. REG16 (140-7)
8-28
GROUP 4 MAIN CONTROL VALVE
1. REMOVAL AND INSTALL OF MOTOR

1) REMOVAL
pressure in the hydraulic piping.

penetrate the skin causing serious injury.
※ When pipes and hoses are disconnected,
(4) Remove bolts and disconnect pipe.
(5) Disconnect pilot line hoses.
(6) Disconnect pilot piping.
1408DA10
(7) Sling the control valve assembly and
remove the control valve mounting bolt.
・Weight : 80kg(180lb)
(8) Remove the control valve assembly.
When removing the control valve
assembly, check that all the piping have
been disconnected.
2) INSTALL
to removal.
(2) Bleed the air from below items.
1408DA11
① Cylinder(Boom, arm, bucket)
② Swing motor
③ Travel motor
※ See each item removal and install.
(3) Confirm the hydraulic oil level and

recheck the hydraulic oil leak or not.
1408DA12
8-29
2. STRUCTURE(1/4)
1408DA13
1 Body 14 Pilot cover 31 Spring holder

2 Spool 15 Pilot cover 32 Check valve
3 Spool 24 Spring holder 33 Check valve spring
4 Spool 25 Spring holder 73 Plug
6 Spool 26 Spool end 74 O-ring
7 Spool 27 Spring 78 O-ring
11 Spool 29 Stopper 91 Socket head bolt
13 Pilot cover 30 Stopper 93 Socket head bolt
101 Lock valve
8-30
STRUCTURE(2/4)
1408DA14
3 Spool 27 Spring 72 Plug

8 Spool 48 Selector spool 78 O-ring
12 Spool 50 Stopper 81 O-ring
13 Pilot cover 51 Piston 86 Back-up ring
14 Pilot cover 57 Restrictor 88 Back-up ring
17 Pilot cover 59 Plug 90 O-ring
24 Spring holder 60 Plug 91 Socket head bolt
25 Spring holder 61 Restrictor 92 Socket head bolt
26 Spool end 68 Socket head plug 93 Socket head bolt
69 Socket head plug 101 Lock valve
8-31
STRUCTURE(3/4)
1408DA15
18 Plug 58 Plug 80 O-ring

19 Check valve 70 Plug 81 O-ring
20 Check valve spring 72 Plug 82 O-ring
21 Plug 73 Plug 83 O-ring
22 Check valve 77 O-ring 84 O-ring
23 Check valve spring 78 O-ring 87 Back-up ring
8-32
STRUCTURE(4/4)
1408DA16
16 Pilot cover 53 Check valve spring 76 O-ring

34 Lock valve 54 Plug 77 O-ring
35 Lock valve restrictor 55 Restrictor 78 O-ring
36 Lock valve spring 56 Coin type filter 79 O-ring
37 Spring holder 62 Negative poppet 82 O-ring
38 Poppet 63 Coin type filter 84 O-ring
39 Poppet seat 64 Spring holder 85 O-ring
40 Piston 65 Negative spring 87 Back-up ring
41 Piston guide 66 Negative piston 89 Back-up ring
42 Lock valve spring 67 Negative socket 94 Main relief valve
43 Piston 68 Plug 95 Socket head bolt
44 Lock valve socket 69 Plug 96 Overload relief valve
45 Lock valve spool 71 Plug 97 Elief valve plug
46 Lock valve spring 73 Plug 98 Relief valve plug
47 Lock valve plug 75 O-ring 99 Overload relief valve
52 Check valve
8-33
3. DISASSEMBLY AND ASSEMBLY
1) GENERAL PRECAUTIONS
(1) All hydraulic components are manufactured to a high precision. Consequently, before
disassembling and assembling them, it is essential to select an especially clean place.
(2) In handling a control valve, pay full attention to prevent dust, sand, etc. from entering into it.
(3) When a control valve is to be remove from the machine, apply caps and masking seals to all
ports. Before disassembling the valve, recheck that these caps and masking seals are fitted
completely, and then clean the outside of the assembly. Use a proper bench for working. Spread
paper or a rubber mat on the bench, and disassemble the valve on it.
(4) Support the body section carefully when carrying or transferring the control valve. Do not lift by
the exposed spool, end cover section etc.
(5) After disassembling and assembling of the component it is desired to carry out various tests(For
the relief characteristics, leakage, flow resistance, etc.), but hydraulic test equipment is necessary
for these tests. Therefore, even when its disassembling can be carried out technically, do not
disassemble such components that cannot be tested, adjusted, and so on. Additionally one
should always prepare clean cleaning oil, hydraulic oil, grease, etc. beforehand.
2) TOOLS
Before disassembling the control valve, prepare the following tools beforehand.
Name of tool Quantity Size(mm)

Vice mounted on bench(Soft jaws) 1 unit
Hexagon wrench Each 1 piece 5, 6, 10, 12 and 14
Socket wrench Each 1 piece 27 and 32
Spanner Each 1 piece 32(Main relief valve)
8-34
3) DISASSEMBLY
(1) Disassembly of spools without holding valve
① Loosen hexagon socket head bolts with washer
(Hexagon wrench : 5mm)
② Remove the pilot cover.
※ Pay attention not to lose the O-ring under the pilot cover.
③ Remove the spool assembly from the body by hand slightly.
※ When extracting each spool from its body, pay attention not to damage the body.
※ When extracting each spool assembly, it must be extracted from spring side only.
※ When any abnormal parts are found, replace it with completly new spool assembly.
※ When disassembled, tag the components for identification so that they can be reassembled
correctly.
1408DA17
8-35
(2) Disassembly of spools with holding valve(Boom 1, Arm 1 spool)
① Loosen hexagon socket head bolts with washer
(Hexagon wrench : 5mm)
② Remove the pilot cover with internal parts.
※ Pay attention not to lose the O-ring and the poppet under the pilot cover.
※ Pay attention not to damage the "piston A" under pilot cover.
③ Remove the spool assembly from the body by hand slightly.
※ When extracting each spool from its body, pay attention not to damage the body.
※ When extracting each spool assembly, it must be extracted from spring side only.
※ When any abnormal parts are found, replace it with completly new spool assembly.
※ When disassembled, tag the components for identification so that they can be reassembled
correctly.
1408DA22
8-36
(3) Disassembly of the holding valve
① Remove the pilot cover with the holding valve as discribed on previous page.
※ Do not disassembled internal parts of the pilot cover.
② Loosen the poppet seat and remove the poppet, the spring seat, the spring and the check.
(Spanner : 32mm)
※ Pay attention not to lose the poppet.
※ Do not disassembled internal parts of the check.
1408DA23
8-37
(4) Disassembly of the load check valve and the negative relief valve
① The load check valve
a. Fix the body to suitable work bench.
※ Pay attention not to damage the body.
b. Loosen the plug (Hexagon wrench : 10mm).
c. Remove the spring and the load check valve with pincers or magnet.
② The negative relief valve
a. Loosen the socket (Hexagon wrench : 12mm).
b. Remove the spring, the spring holder, the piston and the negative control poppet.
1408DA21
8-38
(5) Disassembly of the main and overload relief valve
① Fix the body to suitable work bench.
② Remove the main relief valve.
(Spanner : 32mm)
③ Remove the overload relief valve.
(Spanner : 32mm)
※ When disassembled, tag the relief valve for identification so that they can be reassembled
correctly.
※ Pay attention not to damage seat face.
※ When any abnormal parts are found, replace it with completly new relief valve assembly.
1408DA19
1408DA20
8-39
(6) Inspection after disassembly
Clean all disassembled parts with clean mineral oil fully, and dry them with compressed air.
Then, place them on clean papers or cloths for inspection.
① Control valve
a. Check whole surfaces of all parts for burrs, scratches, notches and other defects.
b. Confirm that seal groove faces of body and block are smooth and free of dust, dent, rust etc.
c. Correct dents and damages and check seat faces within the body, if any, by lapping.
※ Pay careful attention not to leave any lapping agent within the body.
d. Confirm that all sliding and fitting parts can be moved manually and that all grooves and path's
are free foreign matter.
e. If any spring is broken or deformed, replace it with new one.
f. When a relief valve does not function properly, repair it, following it's the prescribed disassembly
and assembly procedures.
g. Replace all seals and O-rings with new ones.
② Relief valve
a. Confirm that all seat faces at ends of all poppets and seats are free of defects and show uniform
and consistent contact faces.
b. Confirm manually that main poppet and seat can slide lightly and smoothly.
c. Confirm that outside face of main poppet and inside face of seat are free from scratches and so
on.
d. Confirm that springs are free from breakage, deformation, and wear.
e. Confirm that orifices of main poppet and seat section are not clogged with foreign matter.
f. Replace all O-rings with new ones.
g. When any light damage is found in above inspections, correct it by lapping.
h. When any abnormal part is found, replace it with a completely new relief valve assembly.
8-40
4) ASSEMBLY
(1) General precaution
① In this assembly section, explanation only is shown.
For further understanding, please refer to the figures shown in the previous structure &
disassembly section.
② Pay close attention to keeping all seals free from handling damage and inspect carefully for
damage before using them.
③ Apply clean grease or hydraulic oil to the seal so as to ensure it is fully lubricated before
assembly.
④ Do not stretch seals so much as to deform them permanently.
⑤ In fitting O-rings, pay close attention not to roll them into their final position in addition, a twisted
O-ring cannot easily untwist itself naturally and could thereby cause inadequate sealing and
thereby both internal and external oil leakage.
⑥ Tighten fitting bolts for all sections with a torque wrench adjusted to the respective tightening
torque.
⑦ Do not reuse removed O-rings and seals.
(2) Load check valve
① Assemble the load check valve and spring.
② Put O-rings on to plug.
③ Tighten plug to the specified torque.
・Hexagon wrench : 10mm
・Tightening torque : 6~7kgf・m(43.4~50.6lbf・ft)
(3) Negative control relief valve
① Assemble the nega-con poppet, piston, spring holder and spring together into body.
② Put O-ring on to plug and tighten the latter to its specified torque.
(4) Main relief, port relief valves
Install main relief valve, overload relief valve into the body and tighten to the specified torque.
Tightening torque
Component Tools
kgf・m lbf・ft
Main relief valve Spanner 32mm 8~9 57.8~65.1
Overload relief valve Spanner 32mm 8~9 57.8~65.1
(5) Main spools

① Carefully insert the previously assembled spool assemblies into their respective bores within of
body.
※ Fit spool assemblies into body carefully and slowly. Do not under any circumstances push them
forcibly in.
8-41
(6) Covers
① Fit spool covers to the non-spring assembly end of the spool, and tighten the hexagonal socket
head bolts to the specified torque.
・Tightening torque : 1~1.1kgf・m(7.2~7.9lbf・ft)
※ Confirm that O-rings have been fitted.
② Fit spring covers to the spring end for the spools, and tighten hexagon socket head bolts to the
specified torque.
※ Confirm that O-rings have been fitted.
(7) Holding valves
① Assemble the check, spring seat and poppet together into body.
② Tighten the poppet seat to the specified torque.
・Spanner : 26mm
③ Fit the "piston A" under pilot cover with internal parts into hole on the poppet seat.
④ Tighten hexagon socket head bolt to specified torque.
8-42
GROUP 5 SWING DEVICE
1. REMOVAL AND INSTALL OF MOTOR

1) REMOVAL

※ When pipes and hoses are disconnected, 2
the oil inside the piping will flow out, so B

catch it in oil pan. A
(4) Disconnect hose assembly(2).

1
(5) Disconnect pilot line hoses(3,4,5,6,7,8,9).
(6) Sling the swing motor assembly(1) and
remove the swing motor mounting bolts
(10). 17W78SM01
※ Motor device weight : 250kg(550lb)

(7) Remove the swing motor assembly.
※ When removing the swing motor 3
assembly, check that all the piping have 7
been disconnected. 4
2) INSTALL 5
10 8
to removal.
(2) Bleed the air from the swing motor. 6 9
① Remove the air vent plug.
② Pour in hydraulic oil until it overflows from 17W78SM02
the port.
③ Tighten plug lightly.
④ Start the engine, run at low idling and
⑤ Tighten plug fully.
8-43
2. DISASSEMBLY AND ASSEMBLY OF SWING MOTOR
1) STRUCTURE
117 121 118 114 706 707 702 712 472 106 994 469 488 355 351 052 841
438
432 X X
A 303
106
748
471
A 747
443
444
304
468
487
746
101
433
491
745
437
124 451
301 401 051 993

131
122 123 113 116 111 744 742 031 743 058 060 053 054
464 485
059
057
056
055
SECTION A-A SECTION X-X 17W72SM02

8-44
2) DISASSEMBLY
(1) Lift the motor out. Clean the motor in
kerosene and dry with compressed air.
※ To avoid dust inside the motor, mask all
the ports of the motor with tapes.
32038SM01
(2) Loosen the drain plug to discharge oil in

the casing(301).
32038SM02
(3) Fix the drive shaft(101) on the workbench

with the end of output shaft down. Put
matching marks on casing (301) and valve
casing(303) for easy reassembly.
32038SM03
(4) Remove the valve(052).
32038SM04
8-45
(5) Remove the relief valve(051) from valve
casing(303).
32038SM05
(6) Remove plug(469) from valve casing

(303) and spring(355), plunger(351).
※ Be careful not to damage the plunger seat
assembly.
32038SM06
(7) Remove valve casing(303) from casing

(301). Then, remove the valve plate(131)
from valve casing(303) with care.
32038SM07
(8) Remove the brake spring(712) from brake

piston(702).
32038SM08
8-46
(9) Remove brake piston(702) from casing
(301).
32038SM09
(10) Remove the cylinder(111) from the output

shaft (101) with the motor positioned
horizontally. Remove piston(121), retainer
(123), bushing(113), spacer (117) and
shoe plate(124).
※ If shoe plate would not removed easily, try
again after procedure(14).
32038SM10
(11) Remove friction plate(742) and separate

plate(743) from casing(301).
32038SM11
(12) Remove snap ring(437) with plier and

remove the front cover(304) from casing
(301).
※ Front cover could be removed with sliding
shaft if necessary.
32038SM12
8-47
(13) Remove drive shaft(101) from casing (301).
32038SM13
(14) Remove the shoe plate(124) from casing

(301).
32038SM14
(15) Proceed with following job only when

necessary.
① Remove the snap ring(432), spacer(106)
from drive shaft(101) and remove the
cone of roller bearing(443) by press.
※ Do not reuse bearings.
Press
Output shaft 32038SM15
Roller bearing
② Remove oil seal(491) from front cover

(304).
32038SM16
8-48
③ Remove the roller bearing(444) from the
valve casing(303) by using slide hammer
bearing puller.
32038SM17
④ When disassembling the relief valve,

release the plug(3). 3
Remove the piston(7), spring seat(9), 5
spring(8) and plunger(6) with the body(1) 4
downwards. 15
※ Do not release the lock nut(15). 11
14
7
13
9
12
2
1
10
29078SM04
This completes disassembly.
8-49
3) ASSEMBLY
Do the reassembly in the reverse procedure
of the disassembly.
(1) Place the casing(301) on the workbench
with the valve casing(303) downward.
32038SM20
(2) When reassembling the roller bearing,

install the snap ring(432), and spacer(106)
to the drive shaft(101). Insert the collar
and cone of the roller bearing(443).
Install the spacer(106) and stop ring(432).
Install stop ring(433) to the output shaft
(101) by heating the cone of the roller
bearing(444).
32038SM21
Out put
Roundring parts of
the collar toward
spacer
Spacer
32038SM22
(3) Insert the drive shaft(101) into the casing

(301) with the end of output shaft upward
and tap the outer race of roller bearing
with the hammer.
32038SM23
8-50
(4) Tack O-ring(471) to the casing(301).
32038SM25
(5) Reassemble the front cover(304) to the

casing(301).
※ Apply grease to the rib of oil seal to avoid
damage to the rib.
32038SM26
(6) Install the snap ring(437) to the casing

(301).
32038SM27
(7) Insert the shoe plate(124) with the casing

(301) position horizontally.
32038SM28
8-51
(8) Insert the push rod(116) into the cylinder
(111). Place the bushing(113) assembled
with spacer(117) onto the cylinder.
※ Insert two push rods in each hole.
32038SM29
(9) Install the piston sub-assembly(121, 122)

to the retainer(123).
32038SM30
(10) Reassemble the piston assembly(121,

122) to the cylinder(111).
32038SM31
(11) Place the casing(301) under the front

cover(304) and reassemble 3 sheets of
separate plate(743) and then 2 sheets of
friction plate(742) to the casing(301).
32038SM32
8-52
(12) Insert O-ring(706, 707) inside the casing
(301).
32038SM33
(13) Reassemble brake piston(702) to the

casing(301).
32038SM34
(14) Reassemble brake spring(712) to the

brake piston(702).
32038SM35
(15) When assembling the roller bearing(444),

insert the roller bearing(444) into valve
casing(303) by hammering.
32038SM36
8-53
(16) Reassemble valve plate(131) to the valve
casing(303) and reassemble O-ring(472).
32038SM37
(17) Connect the valve casing(303) with the

casing(301) and tighten the hexagon
screw(401).
32038SM38
(18) Insert plunger(351) and spring(355) in the

valve casing and install O-ring(488).
Tighten plug(469) to the valve casing.
32038SM39
(19) Insert O-rings(051-1) to the relief valve

(051) and reassemble them to valve
casing(303).
32038SM42
8-54
(20) Tighten the plug(468) to valve casing(303)
with O-ring(487) and tighten the plug(464)
to casing(301) with O-ring(485).
32038SM43
(21) Connect the valve casing(303) with the

casing(301).
This completes assembly.
8-55
3. REMOVAL AND INSTALL OF REDUCTION GEAR
1) REMOVAL
(1) Remove the swing motor assembly.
For details, see removal of swing motor
assembly.
(2) Sling reduction gear assembly(1) and
remove mounting bolts(2).
(3) Remove the reduction gear assembly.
・Reduction gear device weight : 180kg
(396lb)
13031GE18
2) INSTALL
to removal.
・Tightening torque : 49.2±66.6kgf・m
(356±481lbf・ft)
21078DA05
8-56
4. DISASSEMBLY AND ASSEMBLY OF REDUCTION GEAR
1) STRUCTURE
25 37 36 13 3 35 34 5 2 30 29 6 7 10 9 11 18 19 26 31
28
27
38
33 32 1 8 14 12 23 15 16 21 17 20 24 22 39
17W72SM03

8-57
2) DISASSEMBLY
2 25 37 36
(1) Spread off the 4 corners of lock washer 13
(25) with a tool.
※ Do not reuse lock washer(25). 3
Loosen the hexagon bolts(37) and then 1
remove lock washer(25) and lock plate 35
(36) from the pinion gear(13). 34
Remove pinion gear(13) and spacer(3)
from the drive shaft(2). 21078SR001
Remove cover plate(34) from the casing

(1) by loosening the hexagon bolts (35).
(2) Remove gauge bar(33) and gauge pipe

(32) from the swing motor casing.
※ Pour the gear oil out of reduction gear into 33
the clean bowl to check out the friction 32
decrease.
21078SR002
(3) Loosen the socket bolts(31) to separate

swing motor from reduction gear.
31
21078SR003
(4) Tighten 3 M16 eye bolts to the ring gear

(11) and then lift the ring gear(11) out of
the casing(1).
11
1
21078SR004
8-58
(5) Remove stop ring(28) and then sun gear1 28
(27).
27
19
21078SR005
(6) Tighten two M10 eye bolts to carrier1(19)

and lift up and remove carrier1(19) as
subassembly.
19
21078SR006
(7) Disassembling carrier1(19) assembly.

① Remove stop ring(38).
② Remove side plate2(39), planet gear1 39
(24), needle cage(22), side plate1(20) 26 38
22
and side plate3(26) from the carrier.
24
③ Using M8 solid drill, crush spring pin(17) 19
20
so that the pin1(21) can be removed by 17
21
hammering.
④ Remove side plate3(26) from carrier1(19).
21078SR007
※ Do not reuse spring pin(17).
※ Do not remove pin1(21), carrier1(19) and
spring pin(17) but in case of replacement.
※ Put matching marks on the planet gear1
(24) and the pin1(21) for easy reassembly.
8-59
(8) Remove sun gear2(18) and thrust washer
(14).
18
14
21078SR008
(9) Remove carrier2(9) assembly from casing

(1).
9
21078SR009
(10) Disassembling carrier2(9) assembly

① Using M8 solid drill, crush spring pin(17)
so that the pin2(16) can be removed.
※ Do not reuse spring pin(17).
17
② Remove pin2(16), planet gear2(15) and
9 16
bush2(23) from the carrier2(9).
15
※ Put matching marks on the planet gear2 23
(15) and the pin2(16) for easy reassembly.
※ Do not disassemble pin2(16), carrier2(9)
21078SR010
and spring pin(17) but in case of
replacement.
(11) Remove thrust plate(8) and stop ring (10)

from the drive shaft(2).
8
10 2
21078SR011
8-60
(12) Remove drive shaft(2) with roller bearing
(7) and oil seal(6) assembled. 2
Remove knock pin(12) from the casing(1). 7
6
12
21078SR012
(13) Remove roller bearing(7) and oil seal(6)

from the drive shaft(2).
※ Do not reuse oil seal(6) once removed.
6
7
21078SR013
(14) Using the bearing disassembly tool,

remove roller bearing(5).
5
21078SR014
(15) Remove plugs(29, 30) from the casing(1).

30
29
30
21078SR015
8-61
3) ASSEMBLY
(1) Assemble roller bearing(5) inside the
casing(1). 5
21078SR016
(2) Assemble the drive shaft(2) into the

casing(1) and then install oil seal(6) and 7
roller bearing(7).
6
21078SR017
(3) Install stop ring(10) and thrust plate(8) on

top of drive shaft(2).
8
10 2
21078SR018
(4) Assembling carrier2(9) assembly.

① Install thrust washer(14) inside the
carrier2 (9).
② Install bush2(23) inside the planet gear2 17
(15) and then assemble them to the
9 16
carrier2(9). 15
③ Assemble the pin2(16) to the carrier2(9) 23
and then press the spring pin(17) by
hammering.
21078SR019
④ Punch 2 points of the spring pin(17) lip.
※ Take care not to mistake the matching
marks of each part.
8-62
(5) Assemble carrier2(9) assembly correctly
to the drive shaft(2).
9
21078SR020
(6) Assemble sun gear2(18) and thrust

washer(14) to the center of the carrier2(9)
assembly. 18
14
9
21078SR021
(7) Assembling carrier1(19) assembly.

① Assemble the pin1(21) to the carrier1(19)
and then press the spring pin(17) by
39
hammering. 26 38
22
② Punch 2 points of the spring pin's(17) lip.
24
③ Install side plate3(26) onto the center of 19
20
carrier1(19). 17
④ Install needle cage(22) into the planet 21
gear1(24).
21078SR022
⑤ Assemble side plate(20), planet gear1
(24), side plate2(39) and then stop ring
(38) to the pin1(21).
※ Take care not to mistake the matching
marks of each part.
8-63
(8) Install sun gear1(27) onto the side plate3
(26).
27
26
19
21078SR023
(9) Assemble carrier1(19) assembly onto the

carrier2 assembly.
19
21078SR024
(10) Apply loctite to the tapped holes of casing

(1).
(11) Tighten 3 M16 eye bolts to the ring
gear(11) and lift up and then assemble it
onto the casing(1).
※ Don't fail to coincide the knock pin(12) 11
holes.
1
21078SR025
(12) Hammer 4 knock pins(12) around the ring

gear(11). 28
(13) Assemble stop ring(28) to the drive shaft 12
of the swing motor.
11
1
21078SR026
8-64
(14) Apply loctite to the tapped holes of the
ring gear(11) and then mount swing motor
onto the ring gear(11).
※ Don't fail to coincide the gauge bar(33)
hole.
(15) Tighten socket bolts(31) around the swing
motor assembly. 31
・Tightening torque : 24kgf・m(173lbf・ft)
21078SR027
(16) Assemble plugs(29, 30), gauge bar(33)

and gauge pipe(32).
33
32
30
1
29
30 21078SR028
(17) Turn the swing motor assembly upside

down and assemble cover plate(34) by 25 37 36
2 13
tightening the hexagon bolts(35).
Install spacer(3) and pinion gear(13) to
the drive shaft(2). 3
Assemble lock plate(36) on the pinion
35
gear(13). 34
Assemble 2 lock washers(25) on the lock
plate(36) with their 2 hole coincided
21078SR029
individually to the tapped holes of drive
shaft(2).
Tighten hexagon bolts(37) to the drive
shaft(2) and then fold all the lock
washer(25) corners over the hexagon
bolts(37).
・Tightening torque : 24kgf・m(173lbf・ft)
(18) Inject oil into the reduction gear.
8-65
GROUP 6 TRAVEL DEVICE

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

※ When pipes and hoses are disconnected, 1
(4) Remove the track shoe assembly.
Dr P
For details, see removal of track shoe 2
B
assembly. A
(5) Remove the cover.

(6) Remove the hose.
※ Fit blind plugs to the disconnected hoses. 21078DA47
(7) Remove the bolts and the sprocket.

(8) Sling travel device assembly(1).
(9) Remove the mounting bolts(2), then
remove the travel device assembly.
2) INSTALL
to removal.
(2) Bleed the air from the travel motor.
① Remove the air vent plug.
② Pour in hydraulic oil until it overflows from
the port.
③ Tighten plug lightly.
④ Start the engine, run at low idling, and
⑤ Tighten plug fully.
8-66
2) STRUCTURE
14072SF61
1 Hub 25 Needle bearing 106 Shoe 151 Rolling 219 O-ring 355 O-ring
2 Spindle 27 Parallel pin 107 Retainer plate 161 Piston(2) 220 Piston seal 357 RO plug
3 Carrier 28 O-ring 108 Thrust ball 162 Shoe(2) 301 Rear flange 358 O-ring
4 Ring gear A 29 O-ring 109 Timing plate 167 Pivot 323 Spool 359 O-ring
5 Ring gear B 30 PT plug 110 Washer 171 Paralell pin 324 Plug 363 Spool(2)
6 Cluster gear 31 Floating seal 111 Collar 193 Spring 325 Stopper 366 Spring
7 Sun gear 32 Socket bolt 112 Piston 201 Valve 326 Plug 368 Steel ball
8 Coupling gear 33 Spring washer 113 Spring 202 Sleeve 327 Valve 379 Filter
9 Shaft(cluster) 34 Parallel pin 114 Spring 203 Spring retainer 328 Spring 380 Plug
12 Distance piece 35 Socket bolt 115 Friction plate 204 Plug 330 Spring 381 Piston
13 Cover 36 Steel ball 116 Mating plate 205 Shim 336 O-ring 382 Plug
14 Thrust collar 40 O-ring 132 Oil seal 206 Spring 337 O-ring 383 O-ring
15 Ring 42 Parallel pin 135 O-ring 208 O-ring 341 Parallel pin 384 O-ring
17 Pin 102 Main shaft 139 O-ring 209 O-ring 343 Socket bolt 385 Steel ball
19 Coupling 103 Swash plate 145 Snap ring 210 O-ring 346 PT plug 397 Orifice
20 Thrust plate 104 Cylinder block 149 Ball bearing 211 Back-up ring 352 RO plug 398 PT plug
23 Seal ring 105 Piston 150 Ball bearing 217 Back-up ring 354 PT plug 399 Name plate
24 Ball bearing
8-67
(1) Tools
Tool name Remark
Allen wrench 5, 6, 8, 10, 14 B
Socket 22, 30, 32, 41

Socket for socket wrench, spanner
Rod 5, 6, 8, 10, 14, 19
Pliers -
(-) Driver 150mm
Plastic and iron hammer Wooden hammer allowed. Normal 1 or so
Steel rod approx 7×7×200mm
Monkey wrench -
Oil seal inserting jig -
Bearing pliers -
Seal tape -
Eye bolt M12, M16
Press(0.5 ton) -
Oil stone -
Bearing assembling jig -
Liquid packing Loctite #577
Screw lock Loctite #243

Torque
Part name Item Size
kgf・m lbf・ft
Hexagon socket plug 30 PT 1/2 6.0±2.0 43.4±14.5
Hexagon socket bolt 32 M12×1.75×50 10.4±1.6 75.2±11.6
Hexagon socket bolt 35 M16×2.0×30 25.7±4.0 186±28.9
Sleeve 202 PF 1 25.0±5.0 181±36.2
Plug 204 PF 1/2 10.0±2.0 72.3±14.5
Plug 324 M36×1.5 45.0±9.0 326±65.1
Plug 326 M36×1.5 26.0±4.0 188±28.9
Hexagon socket bolt 343 M16×2.0×40 25.7±4.0 186±28.9
Plug 346 PT 1/4 3.0±0.5 21.7±3.6
Plug 352 PF 1/4 3.0±0.5 21.7±3.6
Hexagon socket plug 354 NTPF 1/16 0.6±0.25 4.3±1.8
Plug 357 PF 1/2 10.0±2.0 72.3±14.5
Plug 380 PF 3/8 6.0±1.0 43.4±7.2
Plug 382 PF 1/8 1.5±0.25 10.8±1.8
Hexagon socket plug 398 PT 1/8 1.25±0.25 9.0±1.8
8-68
3. DISASSEMBLY
(1) Before disassembling the motor, check the items to be inspected and, for remedy against trouble,
closely examine the nature of the trouble, so that the motor can be disassembled effectively.
(2) To disassemble the motor, use the disassembling procedures described in section 2) and select a
clean place.
(3) Place a rubber or vinyl sheet or other such protective materials on your working bench to protect
the surface of the motor to be serviced.
(4) During disassembly, give a match mark to the mating surfaces of each part.
(5) Arrange removed parts in order so that they will not become damaged or missing during
disassembly.
(6) Once seals have been disassembled, they should be replaced even if damage is not observed.
Have replacement seals ready on hand before starting your disassembling job.
8-69
2) DISASSEMBLING PROCEDURE
(1) Disassembling the brake valve section
and the hydraulic motor section
※ When inspecting or repairing the motor,
use the disassembling procedures
described below.
※ Numbers in parentheses ( ) following the
part name denote the item numbers
shown in the attached assembly
drawings.
※ Prior to disassembly, install the motor on 25038TM02(1)
an inversion working bench.
① Remove valve kit from the rear flange

(301).
② Remove the O-rings(208, 209, 210) and
back up rings(211, 217) from the valve
kit.
※ Do not reuse the O-ring after removal.
25038TM02(2)
③ Remove the twelve hexagon socket

head bolts(343).
25038TM02(3)
④ Remove the rear flange kit(301) from the

spindle(2).
※ Pay attention, shaft(102) may pulled up
with the rear flange kit.
※ Proceed to pages 8-80 through 8-84 to
see the brake valve disassembling
procedure.
25038TM02(4)
8-70
⑤ Remove the timing plate(109), the two
pins(341) and the ball bearing(150) from
the rear flange kit(301).
⑥ Remove the two O-ring(27) and O-ring
(29) from spindle(2).
※ Do not reuse the O-rings(27, 29) after
removal.
※ Proceed to pages 8-85 through 8-87 to
see the description of the hydraulic motor
25038TM03(1)
disassembling procedure.
(2) Disassembling the reduction gear/

Hydraulic motor shafts and oil seals
① Turn the motor and cover(8) over.
② Remove three plugs(33).
③ Remove twelve hexagon socket head
bolts(35).
25038TM03(2)
④ Install two eye bolt(PF 1/2) to the threads

for plugs(33).
⑤ Fasten hook to the eye bolts then lift up
cover(8).
※ When cover(8) do not come up easily
due to friction of O-ring(30), bang cover
(8) evenly using a plastic hammer.
⑥ Remove O-ring(30) from cover(8).
※ Do not reuse the removed O-ring.
25038TM03(3)
⑦ Drain lubricating oil from the reduction
gear.
※ Proceed to page 8-88 through 8-92 to
see the reduction gear disassembling
procedure.
8-71
3) DISASSEMBLY OF BRAKE VALVE
(1) Disassembly of the spool(323)
① Remove the two plugs(324) from the rear
flange(301).
Remove the two O-ring(336) from the
plug(324).
※ Removal of the two plugs(324) from the
rear flange(301) is facilitated by
loosening plugs(324) with rear flange
(301) attached to the spindle(2).
※ Do not reuse the O-ring(336) after 25038TM03(4)
removal.
② Remove the two springs(328), the two

stoppers(325), and the spool(323) from
the rear flange(301).
※ Be careful not to damage the outer
surface of the spool(323) and the sliding
surface of the rear flange(301).
※ Spool is selectively fitted to the rear
flange(301). When replacing either or
them, therefore, the rear flange kit should
25038TM04(1)
be replaced.
(2) Disassembly of the check valves

① Remove the two plugs(326) from the rear
flange(301).
※ Removal of the two plug(326) from the
rear flange(301) is facilitated by
loosening plug(326) with the rear flange
(301) attached to the spindle(2).
25038TM04(2)
8-72
② Remove the two springs(330) and the
two valves(327) from the rear flange(301).
※ Be careful not to damage the seat
sections of the valves(327) or rear flange
(301).
25038TM04(3)
③ Remove the O-ring(337) from the plug

(326).
※ Do not reuse the O-ring(337) after
removal.
(3) Disassembly of the spool(363) from

the rear flange(301)
① Remove plug(357) from rear flange(301).
※ Removal of plug(357) from rear
flange(301) is facilitated by loosening
plugs(324) with rear flange(301) attached
to spindle(2).
25038TM04(4)
② Take out spool(363) from rear flange

(301).
③ Remove O-ring(355) from plug(357).
※ Do not reuse removed O-ring(355).
25038TM05(1)
8-73
(4) Removal inner parts of the rear flange
assembly
① Remove the two plugs(380) from rear
flange(301).
25038TM05(2)
② Remove the two O-rings(359) from each

plug(380).
③ Take out piston(381) from rear flange
(301).
※ Do not reuse removed the O-rings(359).
※ Be careful not to scratch the outer
surface of the piston(381) and the sliding
surface of the rear flange(301).
※ Piston(381) is selectively fitted to rear
25038TM05(3)
flange(301). When replacing either of
them, therefore, the rear flange kit should
be replaced.
④ Removed the two plugs(382) from rear

flange(301).
25038TM05(4)
⑤ Take out each two O-rings(383, 384)

from each plug(382).
※ Do not reuse removed O-rings(383, 384).
8-74
⑥ 3Take out two steel balls(385) from the
rear flange.
25038TM06(1)
(5) Removal of the valve kit

① Remove the plug(204) from sleeve(202).
※ The valve kit is pressure adjusted by
shim(205), when replacing of inner parts,
therefore, the valve kit should be
replaced.
25038TM06(2)
② Remove the O-ring(210) from plug(204).

③ Take out shim(205) from plug(204).
※ Do not reuse removed the O-ring(210).
25038TM06(3)
8-75
④ Take out spring retainer(203), spring
(206) and valve(201) in that order.
25038TM06(4)
25038TM07(1)
25038TM07(2)
⑤ Remove piston seal(220) from valve

Piston seal
(201).
Valve
25038TM14
8-76
4) DISASSEMBLY OF HYDRAULIC MOTOR
(1) Disassembly of the parking brake parts
① Remove the piston(112) by injecting
compressed air from the parking brake
access hole in the spindle(2).
※ Take care that abrupt injection of
compressed air(3~5kgf/cm2) may cause
the piston(112) to pop out.
To ensure your safety, apply a protective
cover to the piston.
25038TM07(3)
② Remove the two O-rings(135, 139) from

the piston(112).
※ Do not reuse O-rings(135, 139) after
removal.
25038TM07(4)
(2) Disassembly of the internal parts of

the motor
① Lay the motor body on the side.
② Drain out the oil from the motor.
③ Hold the cylinder block(104) with both
hands, and remove it from the spindle(2).
※ When laying the motor on its side, place
a receptacle under it to receive spilling
hydraulic oil.
25038TM08(1)
※ Before pull out cylinder block(104), turn it
alternately clockwise & counterclockwise
two or three times to separate the piston
kit from swash plate(103). This means
that the parts attached to the cylinder
block(104) come out of it and fall in the
spindle.
8-77
④ 3Detach the two friction plates(115) and
two mating plates(116) from cylinder
block(104) which has been taken out in
step ③.
⑤ Separate the piston assembly(105, 106),
retainer plate(107), thrust ball(108),
washer(111) and five needle rollers(151)
from cylinder block(104) which has been
taken out in step ③.
25038TM08(2)
※ Cylinder block(104), piston assembly,
retainer plate, etc. which are included in
cylinder & piston kit and are not supplied
one by one, therefore, cylinder & piston
kit should be replaced.(Refer to class
shown in parts list.)
⑥ Take out swash plate(103) from spindle

(2).
25038TM08(3)
⑦ Take out shaft(102) from spindle(2). At

this time, ball bearing(149) is also taken
out together with shaft(102).
※ Oil seal(132) cannot be taken out.
※ Lightly shaft(102) end on the reduction
gear side with a plastic hammer to make
the removal easier.
Take notice when removing the shaft
(102) rap strongly and swiftly, the shaft
25038TM08(4)
will come quickly free from the spindle.
⑧ Take out two pivots(167) and two pins
(171) from spindle(2).
8-78
⑨ Remove the piston assembly and spring
(193) by compressed air(3~5kgf/cm 2)
trough the passage for the piston
assembly in spindle(2).
※ Piston(161) and shoe(162) are included
in the piston assembly and are not
supplied one by one, therefore, the piston
assembly should be replaced.
※ Abrupt compressed air causes the piston
25038TM09(1)
assembly to spring out which dangerous.
The piston assembly can be taken out
safely by putting a protective cover or the
lie on it.
(3) Disassembly of the cylinder block

① Place the cylinder block on the work
bench and take out snap ring(145) with
the snap ring pliers while pressing the
retainer against washer(110).
※ Before compressing spring(114), make
sure that cylinder block(104), retainer and
press arbor are in good alignment: This is
for galling or denting cylinder block(104).
25038TM09(2)
※ Put a vinyl cover on the sliding surface of
cylinder block(104) for protection.
② Slacking the press force slowly, until free
of the spring force.
※ Do not remove spring(114) if it not to be
replaced.
※ When disassembling there is a possibility
that the spring may be injured.
Slacking very slowly in order to prevent
injury to the spring.
③ Remove the snap ring(145), washer(110),

spring(114) and washer(110).
25038TM09(3)
8-79
5) DISASSEMBLY OF REDUCTION GEAR
(1) Disassembly of Input gear A(4)
① Before removing ring gear A, give an
alignment match mark to both the ring
gear and hub(1).
② Remove the ring gear A(4) using a
crowbar or any other suitable tool.
※ After ring gear A(4) has been removed,
remove any adhesive residue from the
mating surfaces of the ring gear and the
TM27 (140-7)
hub.
③ Remove the ten dowel pins(27) from the
hub(1).
Ring gear A(4)
Crowbar
R210TDD1(7)
(2) Disassembly of the hub(1), ring gear

B(5), and the coupling gear(8)
① Remove the ten hexagon socket head
bolts(35).
※ Since the hexagon socket head bolts(35)
have their threaded sections coated with
an adhesive, a loosening torque larger
than the tightening one is needed to
remove the bolts.
※ Tightening torque : 35.5±5.5 kgf・m TM-SPARE07
(256.8±39.8 lbf・ft)
※ Be extra careful during removal not to let
the threaded sections of the hexagonal
socket head bolts(35) seize.
② Before removing the coupling gear(8)
from the spindle(2), mark the mating
surfaces of the coupling gear(8) and the
spindle(2) using a paint marker.
8-80
② Mount ring bolts in the M12 tapped holes
of the hub(1),and then lift the hub(1) Lift up Hub(1)
Spindle(2)
using lifter and separtate the hub(1) and
the spindle(2).
This also disconnects the two ball
bearings(24), the seal ring(23), the O-
ring(40), the coupling gear(8), ring gear
B(5), the ring(15), and the distance
piece(12).
R210TDD1(8)
※ Proceed as follows if disassembly is not
possible with the method mentioned
above :
・ Rotate the motor through 180 degress to
let the spindle side of the motor face
upward.
・ As shown in the photo, lightly tap the
edge of the hub(1) equally with an
aluminum rod and a hammer until the
hub(1) has become disconnected from
the spindle(2).
This will also disconnect the following TM29 (140-7)
parts :
Two ball bearing(24), seal ring(23), O-
ring(40), coupling gear(8), ring gear B(5),
ring(15), distance piece(12).
※ Lay a rubber mat under the working
bench to the prevent damage to hub(1)
and other parts due to possible fall from
the working bench.
8-81
(3) Disassembly of the inside of the
spindle(2) Hammer
① Remove the O-ring(29) from the spindle(2).
Screwdriver
② Rotate the spindle(2) through 180 degrees.
③ Remove the oil seal(132) from the
spindle(2). Spindle(2)
(To remove the oil seal, set a (-) Oil seal(132)
screwdriver at the cylindrical edge of the oil
seal and lightly tap with a hammer.)
R210TDD2(1)
※ Do not reuse the O-ring(29) after

removal.
※ Remove the oil seal(132) only if it is to
be replaced.
Do not reuse the oil seal(132) once it
has been removed.
④ Remove the floating seal(31) from the
spindle(2).
TM30 (140-7)
8-82
(4) Disassembly of the inside of the hub(1)
① Place the hub(1) on the working bench
so that the cover side of the hub faces
upward.
② Remove one of the two ball bearings(24)

from the hub(1) as shown in the figure. Hub(1) Hammer
This also lets the seal ring(23) come
loose.
※ In principle, the ball bearings(24) should
not be removed from the hub(1) since
Steel bar
the former is shrinkage-fitted into the
latter. Ball bearing(24)
※ Do not reuse the ball bearings(24) after Seal ring(23)
R210TDD2(2)
removal.
③ Place the hub(1) on the working bench
so that the hub end facing the spindle
points upward. Hammer
④ Remove the other ball bearing(24) from Hub(1)
the hub(1) as shown in the figure.
⑤ Remove the O-ring(40) from the hub(1).

※ Do not reuse the O-ring(40) after Steel bar
removal.
Ball bearing(24)
R210TDD2(3)
8-83
(5) Disassembly of the coupling gear(8)
① Remove the ring(15) from ring gear B(5).
※ Do not reuse the ring(15) after removal.
TM31 (140-7)
② Remove the coupling gear(8) from ring

※ gear B(5).
Except for their replacement, do not
disassemble the coupling gear(8) or ring
gear B(5).
(6) Disassembly of the carrier assembly
① Do not disassemble the carrier assembly
any further.
If a component of the carrier assembly is
irrecoverably damaged, replace the
entire carrier assembly with a new one.
※ Components of the carrier assembly
・Carrier(3)
・Cluster gear(6)
・Shaft(9)
・Thrust collar(14)
・Needle bearing(25)
・Dowel pin(34)
TM32 (140-7)
8-84
4. ASSEMBLY
(1) Reassemble in work area that is clean and free from dust and grit.
(2) Handle parts with bare hands to keep them free of linty contaminates.
(3) Repair or replace the damaged parts.
Each parts must be free of burrs its corners.
(4) Do not reuse O-rings, oil seal and floating seal that were removed in disassembly.
Provide the new parts.
(5) Wash all parts thoroughly in a suitable solvent.
Dry thoroughly with compressed air.
Do not use the cloths.
(6) When reassembling oil motor components of motor, be sure to coat the sliding parts of the motor
and valve with fresh hydraulic oil.(NAS class 9 or above)
(7) Use a torque wrench to tighten bolts and plugs, to the torque specified as follows.
8-85
2) ASSEMBLY OF BRAKE VALVE
(1) Assembly of the check valve
① Fit the O-ring(337) on the plug(326).
② Insert the spring(330) and the valve(327)
into the plug(326), and then grease the
spring(330) and the valve(327) and
hand-lock the former.
③ Insert the plug(326) in conjunction with
the spring(330) and the valve(327) into
the rear flange(301), and tighten the plug
25038TM04(2)
to the required torque.
※ Apply grease to the O-ring(337).
※ Tighten the plug(326) to a torque of
26±4kgf・m(188±29lbf・ft).
(2) Assembly of the spool

① Insert the spool(323) into the rear flange
(301).
※ Apply a working fluid to the spool(323)
and insert it into the rear flange(301).
※ Align the center of the hole in the rear
flange with the axial center of the spool to
prevent damage to the inner surface of
the rear flange and the outer surface of
25038TM04(1)
the spool due to contact.
※ Above mentioned damage causes
internal leakage after reassembly, thus
degrading the motor performance.
② Attach the O-ring(336) to the plug(324).
※ Apply grease to O-ring(336).
③ Install stopper(325) and the spring(328)

into both plugs(324) and tighten the
plugs(324) into the rear flange(301) at the
required torque.
※ Apply grease to the O-ring(355).
※ Required torque : 45±9kgf・m
(325±65lbf・ft)
※ Even if either the rear flange(301) or the
spool(323) is to be replaced, their entire
25038TM03(4)
assembly(kit) must be replaced.
8-86
(3) Assembly of the two-speed control
valve
① Fit O-ring(355) on plug(357).
② Insert spring(366) in spool(363) and insert
spool(363) to rear flange(301).
※ Apply hydraulic oil to spool(363).
25038TM05(1)
the spool due to contact.
Above mentioned damage causes
internal leakage after reassembly, thus
degrading the motor performance.
③ Tighten plug(357) to rear flange(301) with

specified torque.
※ Tightening torque : 10±2kgf・m
(72.3±14.5lbf・ft)
25038TM04(4)
8-87
(4) Assembly the inner parts of the rear
flange assembly
① Insert steel ball(385) to rear flange(301).
25038TM06(1)
② Fit O-rings(383, 385) on plug(382).

③ Tighten plug(382) to rear flange(301) with
specified torque.
※ Tightening torque : 1.5±0.25kgf・m
(10.8±1.8lbf・ft)
※ Apply grease to O-rings(383, 384).
※ Apply sealant to threaded section of
plug(382).
25038TM05(4)
④ Insert piston(381) to rear flange(301).

※ Apply hydraulic oil to piston(381) and
then insert it into rear flange(301).
the piston due to contact. The above
mentioned damage causes internal
25038TM05(3)
leakage after reassembly, thus degrading
the motor performance.
※ Rear flange(301) and piston(381)
constitutes a rear flange kit. When
replacing either of them, therefore,
replace the rear flange kit.
8-88
⑤ Fit O-ring(359) on plug(380).
⑥ Install plug(380) to rear flange(301), and
tighten plug(380) to rear flange(301) with
the specified torque.
※ Tightening torque : 6±1kgf・m
(43.4±7.2lbf・ft)
25038TM05(2)
⑦ After fitted O-ring(358) on plug(352),

install steel ball(368) and plug(352) to
rear flange(301).
※ Apply grease to O-ring(358),
※ Do not disassemble and assemble any
further.
1408DA50
⑧ Install orifice(397) and filter(379) to rear

flange(301).
※ Do not disassemble and assemble any
further.
1408DA51
1408DA52
8-89
(5) Assembly of the relief valve
① Fit O-rings(208, 209, 219) and back up
rings(211, 217) on sleeve(202).
② Fit O-ring(210) on plug(204).
※ Apply grease to the O-ring.
③ Insert shim(205) into plug(204).
※ Use the disassembled shim, because the
pressure adjustment made by shim.
When replacing the inner parts of relief
25038TM06(3)
valve, therefore, the valve kit should be
replaced.
④ Fit piston seal(220) to valve(201).

Piston seal
※ Piston seal(220) consist of O-ring and
Valve
polyester ring, apply grease to them and
then fit the O-ring and after fit the
polyester ring to valve(201).
25038TM14
8-90
⑤ Insert valve(201), spring(206) and spring
retainer(203) to sleeve(202) and tighten
plug(204) fitted with shim(205) to the
specified torque.
※ Apply hydraulic oil to valve(201) and then
insert it to sleeve(202).
※ Align the center of hole in sleeve(202)
with the axial center of valve(201) to
25038TM07(2)
the sleeve and outer surface of the valve
due to contact.
・Tightening torque : 10±2kgf・m
(72.3±14.5lbf・ft)
※ Use the disassembled parts, because the
relief valve is pressure adjusted. When
replacing the inner parts of the relief
valve, therefore, the valve kit should be
replaced.
※ Apply grease to mating surface of the
shim and then fit into the plug. The
above mentioned will keep the two faces 25038TM07(1)
practically glued together, the shim will

not drop down when install the plug to the
sleeve.
25038TM06(4)
25038TM06(2)
8-91
3) ASSEMBLY OF REDUCTION GEAR AND HYDRAULIC MOTOR
※ Before reassembling the reduction gear and the hydraulic motor following completion of parts
replacement, one of the following two operations must be carried out:
・Selecting a distance piece(12) of the appropriate thickness.
・Selecting a thrust bearing(20) of the appropriate thickness.
※ Reassembling must be down only after clearance adjustment of these parts.
※ Prior to the start of reassembling, check for parts that require replacement.
No A : Reassembling
(See page 8-94 through 8-106)
Parts
replacement
Parts to be replaced
B : Thickness selection of a distance
・Hub kit
piece(12)
・Spindle kit
(See page 8-107)
・Ball bearing(24)
Yes
Parts to be replaced C : Thickness selection of a thrust

・Carrier assembly bearing(20)
・Cover(13) (See page 8-108 through 8-110)
※ If all of the above-name parts can be reused in reassembly, be sure to make these adjustments.
Disregard of these adjustments will result in malfunction or premature failure of the motor.
8-92
A : REASSEMBLING
Hammer
(1) Assembly of the hub section Force-fitting jig
① Mount the hub(1) on a working bench so
that the mounting side of the cover(13) Ball bearing
faces upward.
Hub
② Insert the ball bearing(24) into the hub(1)
using a force-fitting jig.
※ Heat the hub(1) to a temperature of
90±5° C. R210TDD2(6)
※ Shrinkage-fit the ball bearing(24).

※ If a force-fitting jig is not available, insert
the ball bearing(24) into the hub(1) and
then hammer the former.
③ Rotate the hub(1) through 180 degress
to make the mounting side of the
spindle(2) face upward.
④ Insert th ball bearing(24) into the hub(1)
using a force-fitting jig.
※ Shrinkage-fit the ball bearing(24).
⑤ Assemble the O-ring(40) into the hub(1).
※ Apply a thin coat of grease to the O-
ring(40).
⑥ Assemble the seal ring(23) into the
hub(1).
The seal ring can better be assembled
into the hub by tapping the edge of the
seal ring lightly with a plastic hammer.
※ When assembling the seal ring(23) into
the hub(1).
※ Be extra careful not to damage the O-
ring(40).
8-93
(2) Assembly of the spindle(2) section
① Mount the two floating seals(26) in the
spindle(2).
※ Apply a thin coat of grease to the O-ring
in the floating seal(26).
※ Be extra careful to ensure that dust does
not stick to the seal surface.
TM-SPARE04
(3) Assembly of the hub(1) and the spindle(2)

① Mount the spindle(2) on a working bench
so that the cover side of the spindle
faces upward.
② Fit eye-bolts to the hub(1), and then lift it
with a crane and gently insert it into the
spindle(2).
※ If the hub(1) or the spindle(2) does not
snugly fit because of the presence of the
TM-SPARE03
ball bearing(24) evenly tap the top of the
hub(1) with a plastic hammer during
fitting.
(4) Assembly of the coupling gear(8) in

ring gear B(5) and ring gear B(5)
① Mount the coupling grar(8) in ring gear
B(5).
② Fit the ring(15) into the ring groove of
ring gear B(5).
※ Do not reuse the ring(15) after removal.
Use a new one during reassembling.
8-94
(5) Assembly of the coupling gear(8)
① Attach a distance piece(12) to the
coupling gear(8) using grease.
※ During attachment, apply a thin coat of
grease to the mounting surface of the
coupling gear(8) to prevent possible fall
of the distance piece(12).
Parts to be replaced
・Hub kit B : Proceed to thickness
・Spindle kit section of a distance piece(12)
・Ball bearing(24) (see page 8-107)
No parts to Proceed directly to

be replaced the next step.
② Mount the coupling gear(8)

(fitted with ring gear B(5)) on a coupling
gear lifter, and then lift it with the crane
and mount it in the spindle.
③ Match the match marks on the coupling
gear(8) and the spindle(2).
④ Insert the ten pins(17), and caulk the pin
hole edges of the coupling gear(8).
※ Do not reuse the pins(17) after removal.
TM42 (140-7)
Use new ones during reassembling.
⑤ Tighten the ten hexagonal socket
bolts(35) to the required torque using a
torqur wrench.
※ Tightening torque : 25.7±4 kgf・m
(185.9±28.9 lbf・ft)
※ Apply an adhesive to the threaded
section of the spindle(2) and the pin
holes after degreasing both.
※ After completely degreasing the
hexagonal socket bolts(35), apply
TM-SPARE05
molycoat to the bottom of each such bolt
neck.
⑥ Rotate the motor through 180 degrees to
make the spindle side face upward.
8-95
(6) Assembly of the oil seal(132)
① Fit the oil seal(132) into the oil seal
mounting hole of the spindle(2).
※ Apply white petrolatum or lithium grease
to the lip section of the oil seal(132).
※ Use a new oil seal during reassembling.
TM44 (140-7)
(7) Assembly of the roller bearing(149)

① Shrinkage-fit the roller bearing(149) onto
the shaft(102).
※ If the roller bearing(149) has been
removed from the shaft(102) during
disassembling, replace the former with a
new one and then shrinkage-fit it onto the
shaft(102).
※ Shrinkage-fitting temperature :
TM45 (140-7)
100±10° C.
※ Apply molybdenum disulfide grease to
the outer contact surface of the roller
bearing(149).
※ When inserting the poller bearing(149),
use leather gloves and take care not to
get burned.
8-96
(8) Assembly of the piston assembly (161,
162)
① Mount spring(193) to piston assembly
(161,162).
※ Apply grease to spring(193).
② Mount the piston assembly(161, 162) in
the piston hole of the spindle(2).
※ Apply grease to piston assembly
(161,162). TM46 (140-7)
Piston kit
Spindle
R210TDD2(7)
(9) Assembly of the pivot(167)

① Mount two pins(171) to the spindle(2)
and two pivots(171).
※ Apply grease on half round section of
pivot(167).
(10) Assembly of cylinder block sestion

① Insert washer(110), spring(114),
washer(110) and snap ring(145) in that
order, into the shaft bore of cylinder
block(104).
TM47 (140-7)
8-97
② Set cylinder block in the press in order to
compress the spring(114).
Place retainer on the washer(110) and
push down this tool with the press arbor
until the snap ring groove becomes
cleared.
Fit snap ring(145) into the groove.
※ When working on the cylinder block,
protect its sliding face by covering it with
TM48 (140-7)
a vinyl sheet.
※ A push of about 200kgf(440.9lbf) will be
needed to compress the spring.
(11) Assembly of piston motor sub assembly

① Fit 5-rollers(151) into the pin holes of
cylinder block(104), and then, put
collor(111) and thrust ball(108) on it.
※ Immerse piston assembly in hydraulic oil.
TM49 (140-7)
② Insert piston assembly into retainer

plate(107).
③ Mount the piston assembly in the cylinder
block(104).
After mounting, immerse the entire them
in a working fluid.
TM50 (140-7)
8-98
④ As shown in the figure, mount the swash
plate(103), the thrust plate(153), the
thrust ball(108), collor(111) the retainer
plate(107), the roller(151), the cylinder
block(104), and the piston assembly
(105,106) in the shaft(102).
Then, mount a lifter(Ⅱ) and make the
shaft(102) upright.
※ The outer lacing of the roller bearing
TM51 (140-7)
(149) must be mounted in the spindle(2)
beforehand.
※ Accurately align and assemble the
retainer plate(107) and the spherical
section of the thrust ball(108).
⑤ Lift the motor assembly using a lifter, and
mount it in the spindle(2). Lifter
※ Mounting must be done so that the steel-
ball hole in the swash plate(103) and the
steel ball(167) come into a fit. Mounting
must also be done gently so that no
parts come into contact with the
spindle(2) or other sections.
Spindle(2)
Contact may damage parts.
※ After the motor assembly has been
mounted, turn the cylinder block by hand
to check for backlash. Perform
inspections if back-lash is present.
R210TDD2(8)
8-99
(12) Assembly of the parking brake section
① Fit the mating plate(116) first and then the
friction plate(115), one by one, into the
grooves of the outer surface of the
cylinder block(104).
※ This order of fitting must be strictly
observed.
※ Immerse the friction plates(115) in a
working fluid before fitting them into the
TM52 (140-7)
grooves.
② Fit the O-rings(139,178) in the O-ring

grooves of the piston(112).
※ Apply a thin coat of grease to the O-
rings(139,178).
TM53 (140-7)
③ Mount the piston(112) in the spindle(2).

※ If the piston(112) does not fit into the
spindle(2) because of the resistance of
the O-ring, tap the edge of the
piston(112) lightly and equally with a
plastic hammer.
Be careful not to damage the O-ring at
this time.
TM54 (140-7)
④ Arrange the twelve springs(113) correctly

in the spring mounting hole of the
piston(112).
TM55 (140-7)
8-100
⑤ Fit the two O-rings(39) and the O-
ring(29) in the O-ring grooves of the
spindle(2).
※ Apply a thin coat of grease to the two O-
rings(39).
※ Remount the O-ring(29) without
greaseing it.
If this O-ring is greased and remounted,
possible oozing of the grease from the
TM56 (140-7)
contact surfaces of the rear flange(101)
and the spindle(2) during motor
operation may be mistaken for oil
leakage.
⑥ Fill the spindle(2) with a working fluid.
Quantity required : 1.7 liters.
(13) Assembly of the rear flange(101) back
in the spindle(2)
① Mount the ball bearing(150) in the rear
flange(101).
※ Apply molybdenum disulfide grease to
the outer contact surface of the ball
bearing(150).
② Fit the two dowel pins(341) into the pin

holes of the rear flange(301).
③ Using the dowel pins(341) as a guide,
mount the timing plate(109) in the rear
flange(301).
At this time, apply grease to the contact
surfaces of the timing plate(109) and the
rear flange(301).
④ Fit the two dowel pins(42) into the
TM57 (140-7)
spindle(2).
※ Mount the timing plate(109) firmly in the
rear flange(301) to prevent the former
from falling out of the latter.
8-101
⑤ Mount the rear flange(301) on the
spindle(2).
At this time, the two dowel pins(42) that
have been fitted into the spindle(2) must
be aligned with the pin holes.
25038TM02(4)
⑥ Tighten the nine hexagon socket head

bolts into the spindle(2) at the required
torque.
Tightening torque :
25.7±4 kgf・m(185.9±28.9 lbf・ft)
※ If, in step (12)-③ above, the piston(112)
does not fit into the spindle(2) because of
the resistances of the O-rings, proceed
as follows to mount the rear flange(101)
25038TM02(3)
on the spindle(2) : mount four hexagon
socket bolts(182) in diagonal form, and
tighten them equally so that the rear
flange(101) is kept horizontal.
⑦ Assemble the relief valve to rear
flange(301), then tighten at requried
torque.
Tightening torque :
25±5kgf m(185±36 lbf・ft)
25038TM02(2)
8-102
(15) Assembly of the carrier assembly
① Attach one of the two thrust bearing(20)
to the coupling gear(8) using grease.
※ Apply a thin coat of molybdenum
disulfide grease to the thrust bearing(20).
Parts to be replaced if C : Thickness selection of a

required : thrust bearing(20)
Hub kit and spindle kit carrier (see pages 8-108
assembly cover(13) through 8-110)
No parts to Proceed directly to

be replaced the next step.
② Mount the coupling(19) on the shaft

(102).
disulfide grease to the spline section of
the coupling(19).
③ Place the steel ball(36) in the sun

gear(7), and place the sun gear in the
coupling(19).
UNTITLED
8-103
④ Insert the carrier assembly into the
hub(1), and correctly engage the teeth of
ring gear B(5) and teeth B of the cluster
gear(6).
※ This must be done only after determining
the timing point of carrier assembly
reassembling
(see next for further details).
TM62 (140-7)
※ Determining the timing point of carrier

Teeth A Sun gear installer
assembly reassembling
Match marking position (pre-installing jig)
To insert the carrier assembly into the procedure
hub(1) and correctly engage teeth B of
the cluster gear(6) and the teeth of ring Carrier(3)
gearB(5), carry out the operating
procedure described after this figure :
Cluster gear(6)
※ Procedure " "
Align the match marks of the three cluster R210TDD3(1)
gears(6) at the positions shown.

At those positions, engage the sun gear
installer correctly with the cluster gears(6)
and fix the sun gear installer.
Insert the carrier assembly into the
hub(1). This dismounts the sun gear
installer automatically.
(16) Assembly of ring gear A(4)
① Mount ring gear A(4) on the hub(1).
Insert
Check at this time that the teeth of ring
Match mark Ring gear A(4)
gear A and teeth A of the cluster gear are
in correct engagement.
② Rotate the hub(1) to fit the match marks Hub(1)
on ring gear A and the hub.

③ Fit the ten dowel pins(27) into the hub(1).
※ After completely degreasing that surface
R210TDD3(2)
of ring A(4) that contacts the hub(1),
apply a thin coat #SS60F hermetic
sealant to that contact surface.
④ Fill the reducer section with a lubricating
oil.
Quantity required : Approx. 3.3 liters
8-104
(17) Assembly of the cover(13)
① Attach the thrust bearing(20) to the
carrier(3) using grease.
disulfide grease to the surface of the
thrust bearing(20).
② Install cover(8) to hub(1).

※ Apply slightly loctite No. 24 to that
matching face of cover which is to mate
with the surface of hub(1).
TM63 (140-7)
③ Fasten cover(13) to hub(1) with 20

hexagonal bolts(32) and 20 supper lock
washers(33), applying to the specified
torque.
※ Tightening torque :
10.4±1.6 kgf・m(75.2±11.6 lbf・ft)
Before tighting bolts, apply loctite 242 to
the hexagon bolts(32).
④ Tighten 3-plugs(30) to cover(13) to the
TM64 (140-7)
specified torque.
※ Tightening torque :
6±2 kgf・m(45±14 lbf・ft)
※ Before tighting plugs, wrap the threaded
portion of each plug with two lagers of
the seal tape.
※ Tighten each plug until the last thread
becomes nearly flush with the cover
surface within an extent equal to plus or
minus one thread relative to the surface.
8-105
B : THICKNESS SELECTION OF A DISTANCE
PIECE(12)
(1) If the parts listed below have been
replaced, select a distance piece(12) of
the appropriate thickness.
After selection, return to the original
reassembling procedure [procedure (5) of
subsection 3] and carry out the next step
of that procedure.
Hub kit
Parts replacement Spindle kit
Ball bearing(24)
(2) Steps(1) through(4) of the original

reassembling procedure must be carried
out as directed.
① Mount a measure plate on the spindle(2)
without inserting a distance piece(12).
② Lightly tighten a few hexagon socket
bolts(35).
③ As shown in the figure at right, measure
dimension A using a depth micrometer. TM65( 140-7)
※ Tighten the hexagon socket head bolts

equally.
④ Measure dimension C of the coupling
gear(8) to be mounted see the figure at
right.
⑤ Using the clearance measurements, Measure plate for distance Depth micrometer
piece thickness
calculate the appropriate distance piece
Spindle(2)
thickness as follows.
・ Measure the clearance between the
A
B
edge of the spindle(2) and that of the ball

X
bearing(24).
Take this clearance as X.
X=A-B Coupling gear(8)
Ball bearing(24)
・ Next, determine the distance piece of the
appropriate thickness.
c
Take this thickness as T.
T = (C + X) ±0.1
⑥ Using the results of steps (1) through (5)
above, select the appropriate thickness. A : Dimension required
B : Jig dimension
Then, proceed with the original
R210TDD3(3)
reassembling operation.
8-106
C : THICKNESS SELECTION OF A THRUST
BEARING(20)
(1) If the parts listed below have been

replaced, select a thrust bearing(20) of
the appropriate thickness.
After selection, return to the original
reassembling procedure [procedure (15)
at page 8-104] and carry out the next
step of that procedure.
Hub kit
Spindle kit
Parts replacement
Carrier assembly
Cover(13)
(2) Steps(1) through(4) of the original

reassembling procedure must be carried
out as directed.
① Attach one of the two thrust bearings(20)
to the coupling gear(8).
At this time, use the thinnest distance
piece.
② Mount the coupling(19) on the shaft
(102). TM66 (140-7)
③ Place the sun gear(7) in the coupling

(19).
④ Insert the carrier assembly into the
hub(1), and correctly engage the teeth B
of the cluster gear(6).
※ This must be done only after determining
the timing point of carrier assembly
reassembling (see page 8-105 for further
details.)
※ Do not apply molybdenum disulfide
grease to the thrust bearing(20).
8-107
⑤ Fit the match marks on ring gear A(4)
and the hub(1), and mount the ring gear Insert
on the hub. Check at this time that teeth
Match mark Ring gear A(4)
A of the cluster gear(6) and the teeth of
ring gear A(4) are in correct engagement.
Hub(1)
R210TDD3(2)
⑥ Mount a thrust-bearing adjusting plate on

the hub(1), and lightly tighten the former
using two M12 hexagon socket bolts.
Don not mount the thrust bearing(20) at
this time.
TM67 (140-7)
⑦ As shown in the figure at right, measure

Depth micrometer
dimension A using a depth micrometer. Thrust bearing
adjusting plate
A
B
X
Carrier
Ring gear A(4)

R210TDD3(4)
⑧ Measure dimension C of the cover(13) to

be mounted.
See the figure at right.
Cover (13)
R210TDD3(5)
8-108
⑨ Using the clearance measurements,
calculate the appropriate thrust bearing
thickness as follows.
・ Measure the clearance between the
edge of the carrier(3) and that of ring
gear A(4).
Take this clearance as X
X=B-A
A : Dimension required
B : Jig dimension
・ Next, determine the thrust bearing of the
appropriate thickness.
Take this thickness as T.
T = (C - X) - (0.3 to 0.6)
⑩ Using the results of steps(7) through(9)
above,select the appropriate thickness
from three types.
Then, proceed with the original
reassembling operation.
8-109
GROUP 7 RCV LEVER

1) REMOVAL


penetrate the skin causing serious injury. 1
(4) Loosen the socket bolt(2).

2
(5) Remove the cover of the console box.
(6) Disconnect pilot line hoses(3).
3
(7) Remove the pilot valve assembly(1).
※ When removing the pilot valve assembly,
check that all the hoses have been
21078DA06
disconnected.
2) INSTALL
to removal.
8-110
1) STRUCTURE
14072SF80
8-111
1 Case 11 Plug 21 O-ring
2 Plug 12 Rod seal 22 Handle connector
3 Plug 13 O-ring 23 Nut
4 O-ring 14 Push rod 24 Insert
5 Spool 15 Plate 25 Boot
6 Shim 16 Bushing 26 Handle
7 Spring 17 Joint assembly 27 Switch assembly
8 Spring seat 18 Swash plate 28 Screw
9 Stopper 19 Adjusting nut 29 Switch assembly
10 Spring 20 Lock nut 30 Switch cover
40 Boot
8-112
(1) Tools
Tool name Remark
Allen wrench 6 B
22
Spanner
27
(+) Driver Length 150
(-) Driver Width 4~5
Torque
Part name Item Size
kgf・m lbf・ft
Plug 2 PT 1/8 3.0 21.7
Joint 18 M14 3.5 25.3
Swash plate 19 M14 5.0±0.35 36.2±2.5
Adjusting nut 20 M14 5.0±0.35 36.2±2.5
Lock nut 21 M14 5.0±0.35 36.2±2.5
Screw 29 M 3 0.05 0.36
8-113
3) DISASSEMBLY
(1) Clean pilot valve with kerosene.
※ Put blind plugs into all ports
(2) Fix pilot valve in a vise with copper(or
lead) sheets.
(3) Remove end of boot(26) from case(1)
and take it out upwards.
1408DA62
※ For valve with switch, remove cord also

through hole of casing.
1408DA63
(4) Loosen lock nut(21) and adjusting nut(20)

with spanners on them respectively, and
take out handle section as one body.
1408DA64
(5) Remove the boot(40)
1408DA61
8-114
(6) Loosen adjusting nut(20) and plate(19)
with spanners on them respectively, and
remove them.
RE04 (140-7)
RE05 (140-7)
(7) Turn joint anticlockwise to loosen it,

utilizing jig(Special tool).
※ When return spring(10) is strong in force,
plate(16), plug(11) and push rod(14, 15)
will come up on loosening joint.
Pay attention to this.
RE06 (140-7)
RE07 (140-7)
8-115
(8) Remove plate(16).
RE08 (140-7)
(9) When return spring(10) is weak in force,

plug(11) stays in casing because of
sliding resistance of O-ring.
※ Take it out with minus screwdriver.
Take it out, utilizing external periphery
groove of plug and paying attention not to
damage it by partial loading.
※ During taking out, plug may jump up due
to return spring(10) force.
RE09 (140-7)
Pay attention to this.
(10) Remove reducing valve subassembly

and return spring(10) out of casing.
※ Record relative position of reducing valve
subassembly and return springs.
RE10 (140-7)
(11) Loosen hexagon socket head plug(2) with

hexagon socket screw key.
RE11 (140-7)
8-116
(12) For disassembling reducing valve section,
stand it vertically with spool(5) bottom
placed on flat workbench. Push down
spring seat(8, 31) and remove two pieces
of semicircular stopper(9) with tip of small
minus screwdriver.
※ Pay attention not to damage spool
surface.
※ Record original position of spring seat(8,
RE14 (140-7)
31).
※ Do not push down spring seat more than
6mm.
(13) Separate spool(5), spring seat(8, 31),

spring(7, 30) and shim(6) individually.
※ Until being assembled, they should be
handled as one subassembly group.
RE15 (140-7)
(14) Take push rod(14, 15) out of plug(11).
RE16 (140-7)
(15) Remove O-ring(13) and seal(12) from

plug(11).
Use small minus screwdriver or so on to
remove this seal.
RE17 (140-7)
8-117
RE18 (140-7)
(16) Remove lock nut(21) and then boot(26).
RE19 (140-7)
25038RL02(4)
8-118
(17) Cleaning of parts
① Put all parts in rough cleaning vessel
filled with kerosene and clean them
(Rough cleaning).
※ If dirty part is cleaned with kerosene just
after putting it in vessel, it may be
damaged. Leave it in kerosene for a
while to loosen dust and dirty oil.
※ If this kerosene is polluted, parts will be
damaged and functions of reassembled
valve will be degraded.
Therefore, control cleanliness of
kerosene fully.
② Put parts in final cleaning vessel filled
with kerosene, turning it slowly to clean
them even to their insides (Finish
cleaning).
※ Do not dry parts with compressed air,
since they will be damaged and/or rusted
by dust and moisture in air.
(18) Rust prevention of parts.
Apply rust-preventives to all parts.
※ If left as they after being cleaned, they will
be rusted and will not display their
functions fully after being reassembled.
8-119
4) ASSEMBLY
(1) Tighten hexagon socket head plug(2) to
the specified torque.
※ Tighten two bolts alternately and slowly.
RE29 (140-7)
(2) Put shim(6), springs(7, 30) and spring

seat(8, 31) onto spool(5) in this order.
RE30 (140-7)
(3) Stand spool vertically with its bottom

placed on flat workbench, and with spring
seat pushed down, put two pieces of
semicircular stopper(9) on spring seat
without piling them on.
※ Assemble stopper(9) so that its sharp
edge side will be caught by head of spool.
Do not push down spring seat more than
6mm.
RE31 (140-7)
(4) Assemble spring(10) into casing.

Assemble reducing valve subassembly
into casing.
※ Assemble them to their original positions.
RE32 (140-7)
8-120
(5) Assemble O-ring(13) onto plug(11).
RE33 (140-7)
(6) Assemble seal(12) to plug(11).

※ Assemble seal in such lip direction as
shown below.
RE34 (140-7)
(7) Assemble push rod(14, 15) to plug(11).

※ Apply working oil on push-rod surface.
RE35 (140-7)
(8) Assemble plug subassembly to casing.

※ When return spring is weak in force,
subassembly stops due to resistance of
O-ring.
RE36 (140-7)
8-121
(9) When return spring is strong in force,
assemble 4 sets at the same time,
utilizing plate(16), and tighten joint(18)
temporarily.
RE37 (140-7)
(10) Fit plate(16).
(11) Tighten joint(18) with the specified torque

to casing, utilizing jig.
RE38 (140-7)
(12) Assemble plate(19) to joint(18).

※ Screw it to position that it contacts with 4
push rods evenly.
※ Do not screw it over.
RE39 (140-7)
(13) Assemble adjusting nut(20), apply

spanner to width across flat of plate(19) to
fix it, and tighten adjusting nut to the
specified torque.
※ During tightening, do not change position
of disk.
RE40 (140-7)
8-122
(14) Fit boot(40) to plate.
1408DA61
(15) Fit boot(26) and lock nut(21), and handle

subassembly is assembled completely.
25038RL02(4)
RE48 (140-7)
(16) Pull out cord and tube through adjusting

nut hole provided in direction 60°to 120°
from casing hole.
1408DA66
8-123
(17) Assemble bushing(17) to plate and pass
cord and tube through it.
※ Provide margin necessary to operation.
1408DA67
(18) Determine handle direction, tighten lock

nut(21) to specified torque to fix handle.
1408DA68
(19) Apply grease to rotating section of joint

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

(21) Inject volatile rust-preventives through all
ports and then put blind plugs in ports.
25038RL04
8-124
GROUP 8 TURNING JOINT

1) REMOVAL

※ When pipes and hoses are disconnected,
(4) Disconnect all hoses.
(5) Sling the turning joint assembly (1) and
1
remove the mounting bolt(2).
21078DA07
・Tightening torque : 12.3± 1.3kgf・m
(88.9± 9.4lbf・ft)
(6) Remove the turning joint assembly.
※ When removing the turning joint, check
that all the hoses have been disconnected.
2) INSTALL
to removal. 1
※ Take care of turning joint direction.
※ Assemble hoses to their original positions.
※ Confirm the hydraulic oil level and check
2
21078DA08
8-125
1) STRUCTURE
14 3
15
10 6
12 4
5
11
11
9
8
21078DA09
1 Hub 6 Shim 11 Wear ring

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

6
(3) Remove retainer ring(12), spacer(4) and 10
shim(5). 12
4
5
21078DA11
(4) Place hub(1) on a V-block and by using a

wood buffer at the shaft end, hit out Secure with hand
Wooden block
shaft(2) to about 1/2 from the body with a
hammer.
※ Take care not to damage the shaft(2)
when remove hub(1) or rest it sideway.
※ Put a fitting mark on hub(1) and shaft(2). V block
Work bench
8-141(3)
(5) Remove six slipper seals(7) and O-ring(9),

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

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

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

6
(12) to shaft(2). 10
(5) Fit O-ring(10) to hub(1). 12
(6) Fit shim(6) to shaft(2). 4

5
21078DA14
8-128
(7) Install cover(3) to body(1) and tighten
bolts(14). 14
・Torque : 10~12.5kgf・m(72.3~90.4lbf・ft) 15
21078DA10
8-129
GROUP 09 BOOM, ARM AND BUCKET CYLINDERS

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

※ Escaping fluid under pressure can
Fit blind plugs in the hoses after
disconnecting them, to prevent dirt or dust
from entering.
① Set block between bucket cylinder and
arm.
1408DA80
② Remove bolt(2), nut(3) and pull out pin

(1).
※ Tie the rod with wire to prevent it from
coming out.
1408DA81
③ Disconnect bucket cylinder hoses(4) and

put plugs(5) on cylinder pipe.
1408DA82
8-130
④ Sling bucket cylinder assembly(8) and
remove bolt(6) then pull out pin (5).
⑤ Remove bucket cylinder assembly(8).
1408DA83
(2) Install
① Carry out installation in the reverse order
to removal.
When aligning the mounting position of
the pin, do not insert your fingers in the
pin hole.
※ Bleed the air from the bucket cylinder.
8-131
2) ARM CYLINDER
(1) Removal
※ Expand the arm and bucket fully, lower
the work equipment to the ground and
stop the engine.
Loosen the breather slowly to release the 13031GE18
from entering.
① Set block between arm cylinder and
boom.
1408DA84
② Remove bolt(2) and pull out pin(1).

coming out.
1408DA85
③ Disconnect arm cylinder hoses(4) and

put plugs on cylinder pipe.
④ Disconnect greasing pipings(5).
1408DA86
8-132
⑤ Sling arm assembly(8) and remove bolt
(7) then pull out pin(6).
⑥ Remove arm cylinder assembly(8).
1408DA87
(2) Install
to removal.
pin hole.
※ Bleed the air from the arm cylinder.
8-133
3) BOOM CYLINDER
(1) Removal
※ Expand the arm and bucket fully, lower the
work equipment to the ground and stop
the engine.
Loosen the breather slowly to release the 13031GE18
from entering.
① Disconnect greasing hoses(1).
② Sling boom cylinder assembly.
1408DA88
③ Remove bolt(4), stop plate(5) and pull out 4

pin(2). 5
2
coming out.
5
4
21078DA23
④ Lower the boom cylinder assembly(6) on

a stand.
1408DA89
8-134
⑤ Disconnect boom cylinder hoses(7) and
put plugs on cylinder pipe.
1408DA90
⑥ Remove bolt(9) and pull out pin(8).

⑦ Remove boom cylinder assembly(6).
6
8
9
1408DA91
(2) Install
to removal.
pin hole.
※ Bleed the air from the boom cylinder.
※ Conformed the hydraulic oil level and
check the hydraulic oil leak or not.
8-135
1) STRUCTURE
(1) Bucket cylinder
9,10 6,7 22 8 4 3 11,12 5 27 26 11,13 1 2 14 16,17 15 18 19 20 21
Internal detail
28,29 24 23 25 28,29
17W78CY01
1 Tube assembly 11 O-ring 21 Lock nut

2 Rod assembly 12 Back-up ring 22 Socket head bolt
3 Gland 13 Back-up ring 23 Band assembly
4 DD2 bushing 14 Cushion ring 24 Pipe assembly(R)
5 Snap ring 15 Piston 25 Pipe assembly(B)
6 Rod seal 16 O-ring 26 O-ring
7 Back-up ring 17 Back-up ring 27 Socket head bolt
8 Buffer ring 18 Piston seal 28 Pin bush
9 Dust wiper 19 Wear ring 29 Dust seal
10 Snap ring 20 Dust ring
8-136
(2) Arm cylinder
9,10 6,7 8 4 24 30 5 29 3 11,12 1 2 13 15,16 14 17 18 19 23
Internal detail
31,32 27 25,26 28 31,32
17W78CY02
1 Tube assembly 11 O-ring 24 Socket head bolt

2 Rod assembly 12 Back-up ring 25 Band assembly(R)
3 Gland 13 Cushion ring 26 Band assembly(B)
4 DD2 bushing 14 Piston 27 Pipe assembly(R)
5 Snap ring 15 O-ring 28 Pipe assembly(B)
6 Rod seal 16 Back-up ring 29 O-ring
7 Back-up ring 17 Piston seal 30 Socket head bolt
8 Buffer ring 18 Wear ring 31 Pin bush
9 Dust wiper 19 Dust ring 32 Dust seal
10 Snap ring 23 Lock nut
8-137
(3) Boom cylinder
9,10 6,7 22 8 4 3 11,12 27 5 26 11,13 1 2 14 16,17 15 18 19 20 21
Internal detail
28,30 24 23 25 29,31
17W78CY03
1 Tube assembly 12 Buck-up ring 22 Socket head bolt

2 Rod assembly 13 Buck-up ring 23 Band assembly
3 Gland 14 Cushion ring 24 Pipe assembly(R, LH/RH)
4 DD2 bush 15 Piston 25 Pipe assembly(B, LH/RH)
5 Snap ring 16 O-ring 26 O-ring
6 Rod seal 17 Buck-up ring 27 Socket head bolt
7 Buck-up ring 18 Piston seal 28 Pin bush
8 Buffer ring 19 Wear ring 29 Pin bush
9 Dust wiper 20 Dust ring 30 Dust seal
10 Snap ring 21 Lock nut 31 Dust seal
11 O-ring
8-138
(1) Tools
6
8 B
Allen wrench
14
17
7
Spanner
8
(-) Driver Small and large sizes

Torque
Part name Item Size
kgf・m lbf・ft
Bucket cylinder
22 M18 23±3.0 232±21.7
Boom cylinder
Arm cylinder 24 M16 23±3.0 166±14.5
Socket head bolt
Bucket cylinder
27
Boom cylinder M10 5.4±0.5 39.1±3.6
Arm cylinder 30
Bucket cylinder 21 M55
Lock nut Boom cylinder 21 M55 100±10.0 723±72.3
Arm cylinder 23 M60
Bucket cylinder
15
Piston Boom cylinder - 150±15.0 1085±109
Arm cylinder 14
8-139
3) DISASSEMBLY
(1) Remove cylinder head and piston rod
① Hold the clevis section of the tube in a
vise.
※ Use mouth pieces so as not to damage
the machined surface of the cylinder
tube. Do not make use of the outside
piping as a locking means.
② Pull out rod assembly(2) about 200mm

(7.1in). Because the rod assembly is
rather heavy, finish extending it with air
pressure after the oil draining operation.
m
0m
20 2
21078DA30
③ Loosen and remove socket bolts(22) of

the gland in sequence. Hexagon
socket wrench 22
※ Cover the extracted rod assembly(2) with
rag to prevent it from being accidentally
damaged during operation. Turn counter
clockwise
Cover here
with rag
2
21078DA31
④ Draw out cylinder head and rod assembly

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

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

① Remove lock nut(21). 13 16 15 14 22 21
※ Since lock nut(21) and lock washer(22)
is tightened to a high torque, use a
hydraulic and power wrench that utilizers
a hydraulic cylinder, to remove the lock
nut(21) and lock washer (22).
② Remove piston assembly(14), back up
ring(16), and O-ring(15).
21078DA34
③ Remove the cylinder head assembly Plastic

from rod assembly(2). hammer
※ If it is too heavy to move, move it by Lift with a crane
striking the flanged part of cylinder head
with a plastic hammer. Pull straight
※ Pull it straight with cylinder head
assembly lifted with a crane.
Exercise care so as not to damage the
lip of rod bushing(4) and packing
21078DA35
(5,6,7,8,9,10) by the threads of rod
assembly(2).
8-141
(3) Disassemble the piston assembly
① Remove wear ring(18). 19 18 17 18 19
② Remove dust ring(19) and piston seal
(17).
※ Exercise care in this operation not to
damage the grooves.
8-156(1) 210-7
(4) Disassemble cylinder head assembly

10 9 6 7 8 4 5 12 11
① Remove back up ring(12) and O-ring
(11).
② Remove snap ring(10), dust wiper(9).
③ Remove back up ring(7), rod seal(6) and
buffer ring(8).
※ Exercise care in this operation not to
damage the grooves.
※ Do not remove seal and ring, if does not
21078DA36
damaged.
8-142
4) ASSEMBLY
(1) Assemble cylinder head assembly
※ Check for scratches or rough surfaces if
found smooth with an oil stone.
① Coat the inner face of gland(3) with
hydraulic oil.
21078DA37
② Coat dust wiper(9) with grease and fit Press here

dust wiper(9) to the bottom of the hole of (Straight down)
dust seal. Metal
At this time, press a pad metal to the 9
metal ring of dust seal.
③ Fit snap ring(10) to the stop face.
8-157(2) 210-7
④ Fit back up ring(7), rod seal(6) and buffer

ring(8) to corresponding grooves, in that
order.
※ Coat each packing with hydraulic oil Wrong Right
before fitting it.
※ Insert the backup ring until one side of it
is inserted into groove.
8-157(3) 210-7
※ Rod seal(6) has its own fitting direction.

Push bar
Therefore, confirm it before fitting them.
※ Fitting rod seal(6) upside down may
damage its lip. Therefore check the
correct direction that is shown in fig.
21078DA38
8-143
⑤ Fit back up ring(12) to gland(3).
※ Put the backup ring in the warm water of 11
30~50° C.
12
⑥ Fit O-ring(11) to gland(3).
21078DA39
(2) Assemble piston assembly

※ Check for scratches or rough surfaces.
If found smooth with an oil stone.
① Coat the outer face of piston(14) with
hydraulic oil.
8-158(2) 210-7
② Fit piston seal(17) to piston.

※ Put the piston seal in the warm water of 17
60~100° C for more than 5 minutes.
※ After assembling the piston seal, press its
outer diameter to fit in.
8-158(3) 210-7
③ Fit wear ring(18) and dust ring(19) to

piston(14). 19 18 17 18 19
14
8-158(4) 210-7
8-144
(3) Install piston and cylinder head
① Fix the rod assembly to the work bench. Cylinder head assembly
② Apply hydraulic oil to the outer surface of Rod assembly
rod assembly(2), the inner surface of
piston and cylinder head.
③ Insert cylinder head assembly to rod
assembly.
21078DA40
④ Insert cushion ring(13) to rod assembly.

※ Note that cushion ring(13) has a direction 13
in which it should be fitted. Insert
8-159(2) 210-7
⑤ Fit piston assembly to rod assembly.

Piston assembly
・Tightening torque : 150±15.0kgf・m
(1085±109lbf・ft)
8-159(3) 210-7
⑥ Fit lock nut to piston.

・Tightening torque : 20
Item kgf・m lbf・ft
Bucket 21 100±10 723±72.3

Boom 21 100±10 723±72.3
Arm 23 100±10 723±72.3
8-159(4) 210-7
8-145
(3) Overall assemble Fix with a bar
① Place a V-block on a rigid work bench.
Mount the tube assembly(1) on it and fix Lift
the assembly by passing a bar through
the clevis pin hole to lock the assembly.
② Insert the rod assembly in to the tube Straight
assembly, while lifting and moving the
rod assembly with a crane.
※ Be careful not to damage piston seal by Appply liquid packing
21078DA41
thread of tube assembly.
③ Match the bolt holes in the cylinder head
flange to the tapped holes in the tube
assembly and tighten socket bolts to a Turn clockwise
specified torque. Apply loctite
※ Refer to the table of tightening torque.
Place rag
21078DA42
8-146
GROUP 10 UNDERCARRIAGE
1. TRACK LINK
1) REMOVAL
(1) Move track link until master pin is over
front idler in the position put wooden block
Master pin
as shown.
(2) Loosen tension of the track link.
※ If track tension is not relieved when the
grease valve is loosened, move the
machine backwards and forwards.
(3) Push out master pin by using a suitable
tool.
Block
8-161(1) 140-7
(4) Move the machine slowly in reverse, and

lay out track link assembly (1).
※ Jack up the machine and put wooden
block under the machine.
※ Don't get close to the sprocket side as the
track shoe plate may fall down on your
feet. 1
1408DA100
2) INSTALL
to removal.
※ Adjust the tension of the track link.
90 ~ 110
16078MS06
8-147
2. CARRIER ROLLER Frame
1) REMOVAL
(1) Loosen tension of the track link. Grease
valve
8-162(1) 140-7
(2) Jack up the track link height enough to

permit carrier roller removal.
Jack Carrier roller

8-162(2) 140-7
(3) Loosen the lock nut (1).

1 Carrier
(4) Open bracket(2) with a screwdriver, push roller
out from inside, and remove carrier roller 2
assembly.
8-162(3) 140-7
2) INSTALL
to removal.
8-148
3. TRACK ROLLER Frame
1) REMOVAL
(1) Loosen tension of the track link. Grease
valve
8-163(1) 140-7
(2) Using the work equipment, push up track

frame on side which is to be removed.
※ After jack up the machine, set a block
under the unit.
90 ~ 110
16078MS06
(3) Remove the mounting bolt(1) and draw

out the track roller(2). 1 2
8-163(3) 140-7
2) INSTALL
to removal.
8-149
4. IDLER AND RECOIL SPRING
1) REMOVAL
(1) Remove the track link.
For detail, see removal of track link.
8-164(1) 140-7
(2) Sling the recoil spring(1) and pull out idler

and recoil spring assembly from track
frame, using a pry. 1
8-164(2) 140-7
(3) Remove the bolts(2), washers(3) and

separate ilder from recoil spring.
2, 3
8-164(3) 140-7
2) INSTALL
to removal.
※ Make sure that the boss on the end face
of the recoil cylinder rod is in the hole of
the track frame.
8-164(4) 140-7
8-150
3) DISASSEMBLY AND ASSEMBLY OF IDLER
(1) Structure
6 5
8
3
1 2
4
4
3
5 21078DA43
1 Shell 4 Bushing 7 Spring pin

2 Shaft 5 Bracket 8 Plug
3 Seal assembly 6 O-ring
8-151
(2) Disassembly Press
① Remove plug and drain oil.
② Draw out the spring pin(7), using a press.
7 8-166(1) 140-7
③ Pull out the shaft(2) with a press.

Press
④ Remove seal(3) from idler(1) and bracket
(5).
⑤ Remove O-ring(6) from shaft.
2
8-166(2) 140-7
⑥ Remove the bushing(4) from idler, using

a special tool.
※ Only remove bushing if replacement is
necessity.
4
8-166(3) 140-7
8-152
(3) Assembly
※ Before assembly, clean the parts.
※ Coat the sliding surfaces of all parts with 1 4 Press
oil.
① Cool up bushing(4) fully by some dry ice
and press it into shell(1).
Do not press it at the normal temperature,
or not knock in with a hammer even after
the cooling.
8-167(1) 140-7
② Coat O-ring(6) with grease thinly, and

install it to shaft(2).
6
③ Insert shaft(2) into bracket(5) and drive in
the spring pin(7). 2
8-167(2) 140-7
④ Install seal(3) to shell(1) and bracket(5).

3
8-167(3) 140-7
⑤ Install shaft(2) to shell(1).

2 1
8-167(4) 140-7
8-153
⑥ Install bracket(5) attached with seal(3).
8-168(1) 140-7
⑦ Knock in the spring pin(7) with a

5 7 1
hammer.
8-168(2) 140-7
⑧ Lay bracket(5) on its side.

5
Supply engine oil to the specified level,
and tighten plug.
8-168(3) 140-7
8-154
4) DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING
(1) Structure
4 7, 8 3 6 5 2 1 9 10 11 12
13
R210UCG1
1 Body 6 Lock plate 10 Back up ring

2 Tie bar 7 Bolt 11 Dust seal
3 Spring 8 Spring washer 12 Rod assembly
4 Bracket 9 Rod seal 13 Grease valve
5 Lock nut
8-155
(2) Disassembly
① Apply pressure on spring(3) with a press.
※ The spring is under a large installed load.
This is dangerous, so be sure to set
properly.
・Spring set load : 11908kg(26253lb) 4
② Remove bolt(7), spring washer(8) and
7, 8
lock plate(6).
3
③ Remove lock nut(5).
6
Take enough notice so that the press 5
which pushes down the spring, should
not be slipped out in its operation.
④ Lighten the press load slowly and
remove bracket(4) and spring(3).
R210UCG2(1)
⑤ Remove rod(12) from body(1).

1 12
⑥ Remove grease valve(13) from rod(12).
13
R210UCG2(2)
⑦ Remove rod seal(9), back up ring(10)

and dust seal(11). 1 9 10 11
R210UCG2(3)
8-156
(3) Assembly
① Install dust seal(11), back up ring(10) and 1 9 10 11
rod seal(9) to body(1).
※ When installing dust seal(11) and rod
seal(9), take full care so as not to
damage the lip.
R210UCG2(3)
② Pour grease into body(1), then push in

1 12
rod(12) by hand.
After take grease out of grease valve
mounting hole, let air out.
※ If air letting is not sufficient, it may be
difficult to adjust the tension of crawler.
③ Fit grease valve(13) to rod(12).
・Tightening torque : 10±0.5kg・m
(72.4±3.6lb・ft) 13
R210UCG2(4)
④ Install spring(3) and bracket(4) to body

(1). Press
⑤ Apply pressure to spring(3) with a press
and tighten lock nut(5).
※ Apply sealant before assembling.
※ During the operation, pay attention
specially to prevent the press from 4
slipping out.
3
R210UCG2(5)
8-157
⑥ Lighten the press load and confirm the
set length of spring(3).
⑦ After the setting of spring(3), install lock
plate(6), spring washer(8) and bolt(7).
16078UC08
8-158
GROUP 11 WORK EQUIPMENT
1. STRUCTURE
A
A
SECTION A SECTION B SECTION C
21078DA44
8-159
1) BUCKET ASSEMBLY
(1) Removal
① Lower the work equipment completely to
A
ground with back of bucket facing down.
B
36078AT04
② Remove nut(1), bolt(2) and draw out the

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

pin(B) then remove the bucket assembly.
36078AT02
(2) Install
to removal.
pin hole.
※ Adjust the bucket clearance.
For detail, see operation manual.
36078AT05
8-160
2) ARM ASSEMBLY
(1) Removal
※ Loosen the breather slowly to release the
penetrated the skin causing serious
injury.
① Remove bucket assembly.
For details, see removal of bucket 8-175(1) 210-7
assembly.
② Disconnect bucket cylinder hose(1).
Fit blind plugs(5) in the piping at the
chassis end securely to prevent oil from 5
spurting out when the engine is started.
③ Sling arm cylinder assembly, remove 1
spring, pin stopper and pull out pin.
coming out.
1
④ For details, see removal of arm cylinder
assembly.
14W78AS10
Place a wooden block under the cylinder
and bring the cylinder down to it.
⑤ Remove bolt(2), plate(3) and pull out the
pin(4) then remove the arm assembly.
※ When lifting the arm assembly, always lift Crane
the center of gravity.
2, 3, 4
8-175(3) 210-7
(2) Install
to removal.
When lifting the arm assembly, always lift
※ Bleed the air from the cylinder.
8-161
3) BOOM CYLINDER
(1) Removal
① Remove arm and bucket assembly.
For details, see removal of arm and
bucket assembly.
② Remove boom cylinder assembly from
boom.
For details, see removal of arm cylinder
assembly. 8-176(1) 210-7
③ Disconnect head lamp wiring.

④ Disconnect bucket cylinder hose(2) and
arm cylinder hose(1).
※ When the hose are disconnected, oil
may spurt out.
⑤ Sling boom assembly(3).
1408DA101
⑥ Remove bolt(4), plate(5) and pull out the

Crane
pin(6) then remove boom assembly.
※ When lifting the boom assembly always
lift the center of gravity.
4, 5, 6
3
8-176(3) 210-7
(2) Install
to removal.
When lifting the arm assembly, always lift
※ Bleed the air from the cylinder.
21078DA46
8-162
Group 1 Introduction guide 9-1

Group 2 Engine system 9-2
Group 3 Electric system 9-4
Group 4 Hydraulic system 9-6
Group 6 Structure 9-9
Group 7 Work equipment 9-13
GROUP 1 INTRODUCTION GUIDE
1. This section shows bolt specifications and

standard torque values needed when
mounting components to the machine.
2. Use genuine Hyundai spare parts.
We expressly point out that Hyundai will not
accept any responsibility for defects resulted
from non-genuine parts.
In such cases Hyundai cannot assume
liability for any damage.
※ Only metric fasteners can be used and
incorrect fasteners may result in machine
damage or malfunction.
※ Before installation, clean all the components
with a non-corrosive cleaner. Bolts and
threads must not be worn or damaged. 16079MS14
9-1
GROUP 2 ENGINE SYSTEM
1. ENGINE AND ACCESSORIES MOUNTING
Muffler
A
B
Throttle lever
3
1
5
2
6
Fan
3
4
4
5 Fan spacer
2
A
2 B
4
3
Engine Air cleaner
Accel
actuator
B
CA
TO
17W79CM01
・Tightening torque
Item Size kgf・m lbf・ft Item Size kgf・m lbf・ft

1 M 6×1.0 1.05±0.2 7.6±1.4 4 M12×1.75 10.0±2.0 72.3±14.5
2 M 8×1.25 2.5±0.5 18.1±3.6 5 M12×1.75 30.0±3.5 217±25.3
3 M10×1.5 6.9±1.4 49.9±10.1 6 M12×1.75 55±3.5 398±25.3
9-2
2. COOLING SYSTEM AND FUEL TANK MOUNTING
Air compressor
2 Air con
Water idle pulley
separator
Cooler & radiator
Hyd tank
2
Fuel tank
3
A
Air con pulley

4 2
DISCHARGE
Receiver drier -A
1
UID
LIQ
Condenser
6
3 VIEW A
7 Needle valve
Reservoir Radiator
HY
UN
tank FU
DA
I
Oil cooler
LL
LO
W
5
3
Fan guard
Shroud
5
17W79CM02

1 M 6×1.0 1.05±0.2 7.6±1.45 5 M12×1.75 12.8±3.0 92.6±21.7
2 M 8×1.25 2.5±0.5 18.1±3.6 6 M20×2.5 46±5.1 333±36.9
3 M10×1.5 6.9±1.4 49.9±10.1 7 - 2.3±0.6 16.6±4.3
4 M10×1.5 8.27±1.7 59.8±12.3 - - - -
9-3
GROUP 3 ELECTRIC SYSTEM
1. ELECTRIC COMPONENTS MOUNTING 1
Fuel filler pump Work lamp
ON
2
OFF
3
3
1
Travel alarm buzzer
3
2 2
1 3
Battery relay
Horn
1
Washer
tank
Fuse box
16079CM03

1 M 6×1.0 1.05±0.2 7.6±1.45 3 M10×1.5 6.9±1.4 49.9±10.1
2 M 8×1.25 2.5±0.5 18.1±3.6 4 M12×1.75 12.8±3.0 92.6±21.7
9-4
2. ELECTRIC COMPONENTS MOUNTING 2
Beacon lamp
3
Wiper motor
1 2 VIEW A
1 Prolix
Electric box resistor
CPU
Cluster controller
2 1
1 YR
G
2
Wiper motor cover
14079CM04

1 M 6×1.0 1.05±0.2 7.6±1.45 3 M10×1.5 6.9±1.4 49.9±10.1
2 M 8×1.25 2.5±0.5 18.1±3.6 - - - -
9-5
GROUP 4 HYDRAULIC SYSTEM
1. HYDRAULIC COMPONENTS MOUNTING 1
4
Solenoid
A valve
Air breather
2
4 4
Main pump
3
4
Hydraulic tank
5
Level gauge 6
Spin filter
4
Main control valve
4 Turning joint
5
10
5
9
Swing motor 5
RCV-LH VIEW A
4 7 Main pump
1 housing
RCV-RH Terminal 7
1 8
Coupling
2 4
RCV-pedal
4
Cross
4
4
16079CM05

1 M 6×1.0 1.05±0.2 7.6±1.45 6 M14×2.0 19.6±2.9 142±21
2 M 6×1.0 1.44±0.3 10.4±2.2 7 M16×2.0 22.0±1.0 159±7.2
3 M 8×1.25 2.5±0.5 18.1±3.6 8 M16×2.0 22.1±2.4 160±17.4
4 M10×1.5 6.9±1.4 49.9±10.1 9 M20×2.5 57.9±8.7 419±62.9
5 M12×1.75 12.2±1.3 88.2±9.4 10 M20×2.5 45±5.1 325±36.9
9-6
2. HYDRAULIC COMPONENTS MOUNTING 2
1
2
1
1
2
2
1
5 BOOM CYLINDER ARM CYLINDER
Boom safety lock system Arm safety lock system

Boom safety
lock valve
2
2
2 Arm safety
lock valve
2
Boom cylinder 2
2
Arm cylinder
3
4
3 4
BUCKET CYLINDER 16079CM07

1 M10×1.5 3.2±0.3 23.1±2.2 4 M16×2.0 23±2.0 166±14.5
2 M10×1.5 5.4±0.5 39.1±3.6 5 M18×2.5 32±3.0 232±21.7
3 M12×1.75 5.5±0.6 39.8±4.3 - - - -
9-7
GROUP 5 UNDERCARRIAGE
ADJUST COMPONENT
Rod
4
Swing bearing
Idler
6
6
6
Idler
5
Carrier roller
7 Track chain
Cover
5
1
2
Adjust
component
Track roller
3
5
Travel motor Track guard
Sprocket 3
16079CM08

1 M10×1.5 6.9±1.4 49.9±10.1 5 M20×2.5 54.7±6.0 396±43.4
2 M12×1.75 12.8±3.0 92.6±21.7 6 M20×2.5 57.8±6.4 418±46.3
3 M16×2.0 23±2.5 166±18.1 7 5/8" 40±4.0 289±43.4
4 M16×2.0 29.7±4.5 215±32.5 - - - -
9-8
GROUP 6 STRUCTURE
1. CAB AND ACCESSORIES MOUNTING
2
Sun roof
4
Sun visor 1
Latch
Cab
A Air vent cover

4
4 4
VIEW A 5
3
2
5
Door latch
6 Striker
29079CM09

1 M 6×1.0 0.49±0.1 3.5±0.7 4 M10×1.5 6.9±1.4 49.9±10.1
2 M 8×1.25 2.5±0.5 18.1±3.6 5 M12×1.75 12.8±3.0 92.6±21.7
3 M10×1.5 4.7±0.9 34±6.5 6 M16×2.0 29.7±4.5 215±32.5
9-9
2. CAB INTERIOR MOUNTING
Seat
1
1
Storage
4 box cover
Aircon upper
cover
Console 1
box(RH) 5
Storage
Wiper motor box
cover
1 1 5
Defroster 5
hose cover Aircon lower
cover
1 Console box(LH)
6 3
Travel
lever 5 Safety lever
Slide rail 2
Seat base 7
Pedal bracket
5
Viscous
mount
5
Foot rest
Bottom plate
5
14079CM10

1 M 6×1.0 0.49±0.1 3.5±0.7 5 M10×1.5 6.9±1.4 49.9±10.1
2 M 6×1.0 1.05±0.2 7.6±1.4 6 M10×1.5 8.27±1.7 59.8±12.3
3 M 8×1.25 3.43±0.7 24.8±5.1 7 M16×2.0 29.7±4.5 215±32.5
4 M 8×1.25 4.05±0.8 29.3±5.8 - - - -
9-10
3. COWLING MOUNTING
3
3 Engine hood
Side cover(RH)
Catch
3
Tank cover 2
3
3
2
3
3
3 3
3 Support(RH)
3
3
MCV hood
HY
UN
DA
I
FU
LL
LO
W
Air cleaner hood 2
Support(LH)
17W79CM11

1 M 6×1.0 0.49±0.1 3.5±0.7 3 M12×1.75 12.8±3.0 92.6±21.7
2 M 8×1.25 2.5±0.5 18.1±3.6 - - - -
9-11
4. COUNTERWEIGHT AND COVERS MOUNTING
Upper frame
Pump under cover
Engine under cover
Hyd tank under cover Radiator under cover
1
Fuel tank
under cover
MCV under cover

Cab under cover(B) 1 Cab
under cover(C)
Swing bearing grease

drain cover 1
1
Cab under cover(A)
16079CM12

1 M10×1.5 6.9±1.4 49.9±10.1 3 M30×3.9 119±30 1439±217
2 M12×1.75 12.8±3.0 92.6±21.7 - - - -
9-12
GROUP 7 WORK EQUIPMENT
Arm cylinder
rod pin
1 Arm cylinder
Bucket cylinder 1
head pin
Bucket 1 1
cylinder
Arm pin 1 Boom
Bucket cylinder Arm cylinder

rod pin head pin Boom cylinder head pin
Bucket control link Boom pin 1

1 Boom cylinder
Bucket 1
2
1
Side cutter(RH)
Bucket control
rod pin
Side cutter(LH)
16079CM13

1 M16×2.0 29.7±4.5 215±32.5 2 M20×2.5 57.9±8.7 419±62.9
9-13

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CONTENTS

SECTION 2 STRUCTURE AND FUNCTION

SECTION 3 HYDRAULIC SYSTEM

SECTION 4 ELECTRICAL SYSTEM

SECTION 5 MECHATRONICS SYSTEM

SECTION 7 MAINTENANCE STANDARD

SECTION 8 DISASSEMBLY AND ASSEMBLY

SECTION 9 COMPONENT MOUNTING TORQUE

2. Convert 550mm into inches.

Millimeters to inches ⓑ 1mm = 0.03937 in

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

Kilogram to Pound 1kg = 2.2046lb

0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

Liter to U.K. Gallon 1ℓ = 0.21997 U.K.Gal

0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

Group 1 Safety Hints 1-1

FOLLOW SAFE PROCEDURE

WEAR PROTECTIVE CLOTHING

WARN OTHERS OF SERVICE WORK

USE HANDHOLDS AND STEPS

steps, and handrails when leaving the machine.

PROTECT AGAINST FLYING DEBRIS

PROTECT AGAINST NOISE

AVOID POWER LINES

MOVE AND OPERATE MACHINE SAFELY

Coordinate hand signals before starting the

OPERATE ONLY FORM OPERATOR'S SEAT

PARK MACHINE SAFELY

SERVICE COOLING SYSTEM SAFELY

HANDLE FLUIDS SAFELY-AVOID FIRES

Store flammable fluids away from fire hazards.

REMOVE PAINT BEFORE WELDING OR HEATING

ILLUMINATE WORK AREA SAFELY

STAY CLEAR OF MOVING PARTS

AVOID HIGH PRESSURE FLUIDS

If an accident occurs, see a doctor immediately.

PREVENT BATTERY EXPLOSIONS

PREVENT ACID BURNS

DISPOSE OF FLUIDS PROPERLY

REPLACE SAFETY SIGNS

LIVE WITH SAFETY

Description Unit Specification

Operating weight kg(lb) 17400(38360)

Description Unit Specification

Operating weight kg(lb) 17400(38360)

Description 2.2m(7' 3") Arm 2.6m(8' 6") Arm

Upperstructure assembly 7480 16490

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

Load radius At max. reach

7.5m kg *3400 3380 5.81

Load radius At max. reach

Load radius At max. reach